dsca00275925 --1

Engine Operation and Maintenance
Manual Attachments
Document ID DSCA00275925-
Classification Confidential
Date of issue 19.01.2021
Status Approved
Product type W16V32
Product number XAAB614715, XAAB614722, XAAB614725

© Copyright by Wärtsilä Finland Oy
All rights reserved. No part of this booklet may be reproduced or copied in any form or by any means (electronic,
mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written
permission of the copyright owner.
THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVE INFORMATION WITH
REGARD TO THE SUBJECT-MATTER COVERED AS WAS AVAILABLE AT THE TIME OF PRINTING. HOWEVER,
THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS SUITED ONLY FOR SPECIALISTS IN THE
AREA, AND THE DESIGN OF THE SUBJECT-PRODUCTS IS SUBJECT TO REGULAR IMPROVEMENTS,
MODIFICATIONS AND CHANGES. CONSEQUENTLY, THE PUBLISHER AND COPYRIGHT OWNER OF THIS
PUBLICATION CAN NOT ACCEPT ANY RESPONSIBILITY OR LIABILITY FOR ANY EVENTUAL ERRORS OR
OMISSIONS IN THIS BOOKLET OR FOR DISCREPANCIES ARISING FROM THE FEATURES OF ANY ACTUAL ITEM
IN THE RESPECTIVE PRODUCT BEING DIFFERENT FROM THOSE SHOWN IN THIS PUBLICATION. THE PUBLISHER
AND COPYRIGHT OWNER SHALL UNDER NO CIRCUMSTANCES BE HELD LIABLE FOR ANY FINANCIAL
CONSEQUENTIAL DAMAGES OR OTHER LOSS, OR ANY OTHER DAMAGE OR INJURY, SUFFERED BY ANY
PARTY MAKING USE OF THIS PUBLICATION OR THE INFORMATION CONTAINED HEREIN.
Wärtsilä 32 Engine O&MM 0. Table of Contents
0. Table of Contents
Installation specific drawings 1
Damper 2
Governor 3
Oil mist detector 4
Valves 5
DSCA00275925- 0-1
0. Table of Contents Wärtsilä 32 Engine O&MM
This page intentionally left blank
0-2 DSCA00275925-
18.07.2019 dkl004 Klemets
18.07.2019 tve001 Vesterbacka
Device definition Wire definition
IOM = Input output module WA1, WA2, WA3, WB1, WB2, WB3
LDU = Local display unit WDE-1, WFE, WTC
MCM = Main controller module WOMD-1, WDE-2 2 x 120 Ω + 2 x 2 x 1,5 mm²
PDM = Power distribution module
ESM = Engine safety module WOMD-2 5 x 0,75 mm²
WCS = Wärtsilä CAN switch W1-W10 7 x 0,75 mm²
WIP = Wärtsila instrument panel a
WBEB-A-1, WBEB-B-1 Single CAN 120 Ωx 0,75 mm²
WCP = Wärtsila control panel WBEB-A-2, WBEB-B-2 2 x 120 Ω + 2 x 2 x 1,5 mm²
a BEB = Big end bearing
Created by Checked by Approved by ENG. no

M.M. J.A. J.R. XAAB614715
Memo no. Project number XAAB614722
XAAB614725
CN-A142452 SP/04599
Responsible department Based Document type
DAAF299495 h Wiring diagram
Wärtsilä Finland Product Document status
W16V32 UNIC C2 Released
WDG - Confidential
Title Document ID Rev.
a L.F J.R CN-A150556 04 05 2020 BEB added (1,2,3,4,6,23,24,25) SHI 2303 DAAF484518 a
Engine wiring diagram Size Date of issue Sheet
Rev. Rev by Appr. by CN-note Rev. Date Changed: A3 21 01 2020 1 / 25
This document is the property of Wärtsilä which retains all rights, including copyrights, relating to the information contained herein. This document or any part hereof shall not be copied, reproduced, published, distributed or disclosed to a third party without the consent of the owner.
IOM-TC
WTC
WOMD-2 WOMD-1
QU700
PRELUBE PUMP
CV615A
M201 M
TE511
LS103A
TE517
TE521
SE518
PT312
CV519
CV312
TE471
PT281
PT271
PT471
TE527
TE600
TE282
TE272
SE528
TE403
TE402
TE472
CV643
PT101
IOM-FE
PT401
TE101
TE401
TEZ402-1
TEZ403-1
WFE
TE5071A
TE5081A TE5071B
TE7071A TE5081B
IOM-B3
IOM-A3
TE7072A TE7071B
TE7081A TE7072B
TE7082A TE7081B
TE708 TE7076B TE7076A TE7082B
TE709
TE7066B TE7066A
WB3
WA3
TE5041A LS103B
TE5051A TE7056B TE7056A TE5041B
TE5061A TE5051B
IOM-B2
IOM-A2
TE7041A TE5061B
TE7042A TE7041B
TE7051A TE7042B
TE7052A TE7051B
TE7061A TE7052B
TE7062A TE7061B
TE704 TE7046B TE7046A TE7062B
TE705
TE706
TE707
TE7036B TE7036A
WB2
WA2
TE5011A CV656
TE5021A LS108B
TE5031A TE5011B
IOM-B1
IOM-A1
TE7011A TE5021B
TE7012A TE7026B TE7026A TE5031B
TE7021A TE7011B
TE7022A TE7012B
TE7031A TE7021B
TE7032A TE7022B
TE702 TE7031B
TE703 TE7032B
TE700
TE7016B TE7016A TE701
WA1
WB1
a
a
BEB-B
BEB-A
CV381
LS108A
LS204
IOM-DE
GS792
GS171
PT301
PT311
PT201
PT241
TE201
WBEB-B-1
WBEB-A-1
WBEB-B-2
WBEB-A-2
TE482
TE601
PT291A
WIP
LDU
PT601
ESM
PDM
WCS
TURNING DEVICE
MCM-1
MCM-2
M792 M
WDE-2
WDE-1
Engine external
CV161
CV613
GT165
ST173
CV331
CV321
ST174
ST196S
ST196P
PTZ201
TEZ403
TEZ402
CV153-1
CV153-2
PDM-1
2,5 mm² Black 1,5 mm² Black 1,5 mm² Black 1,5 mm² Black
PDM:F1 24 VDC BUS1 X21-5 X2-11 MCM-1-X24-1 MCM-2-X24-1 ESM-X11-1
1,5 mm² Black 1,5 mm² Black
LDU-X21-8 WIP-X11-1
2,5 mm² Black 1,5 mm² Brown (WDE-1)
X2-12 24 VDC BUS1 DE, page 11/1B
1,5 mm² Brown 8 (WB1)
24 VDC BUS1 B-bank, page 12/1B
+ F1 2,5 mm² Black 1,5 mm² Black
X2-13 WCS-X11-1
1,5 mm² Brown (WBEB-A-1)
X2-14 24 VDC SUPPLY TO BEB-A page 23/1A a
1,5 mm² Brown (WBEB-B-1)
24 VDC SUPPLY TO BEB-B page 23/1D
2,5 mm² Black 1,5 mm² Black 1,5 mm² Black 1,5 mm² Black
PDM:F2 24 VDC BUS2 X21-13 X2-21 MCM-1-X34-1 MCM-2-X34-1 ESM-X12-1
MAIN SWITCH 1,5 mm² Black 1,5 mm² Black
HS801 LDU-X22-8 WIP-X12-1
Primary 2,5 mm² Black 1,5 mm² Grey (WDE-1)
2,5 mm² Black X2-22 24 VDC BUS2 DE, page 11/1B
Engine external 24 VDC 1 2 X11-1 24 VDC PRIMARY 1,5 mm² Grey 8 (WB1)
max 10 mm² 2,5 mm² Blue 24 VDC BUS2 B-bank, page 12/1B
0 VDC 3 4 X11-3 0 VDC PRIMARY + F2 2,5 mm² Black 1,5 mm² Black
X2-23 WCS-X12-1
Secondary 2,5 mm² Black 1,5 mm² Grey (WBEB-A-1) 24 VDC SUPPLY TO BEB-A page 23/1A
24 VDC 5 6 X12-1 24 VDC SECONDARY X2-24
2,5 mm² Blue 1,5 mm² Grey (WBEB-B-1) 24 VDC SUPPLY TO BEB-B page 23/1D a
0 VDC 7 8 X12-3 0 VDC SECONDARY
2,5 mm² Black F3 1,5 mm² Black
24 VDC AUX X21-9 X2-31 24 VDC SUPPLY TO GT165 page 7/2F
2,5 mm² Green/Yellow X2-32 24 VDC SUPPLY TO IS7602, page 6/2C
PE X11-2 PE 1 X2-33 24 VDC SUPPLY TO QU700, page 6/5E
Ground cable 2.5 mm² Green/Yellow
PE X12-2 PE 2 X2-34 24 VDC SUPPLY TO MCM SIGNALS, page 9/5B
X2-35 24 VDC SUPPLY TO MCM SIGNALS, page 4/2C
+ F4 1,5 mm² Black
X2-36 24 VDC SUPPLY TO BUTTONS, page 5/4C
X2-37 24 VDC SUPPLY TO MCM SIGNALS, page 4/2E
X2-38 24 VDC SPARE
On engine Gnd strap 24 VDC SUPPLY MCM SIGNALS page 27/5C

X2-39 24 VDC SUPPLY TO ESM SPEED PULSE, page 6/3E
Gn/Ye 24 VDC SPARE
2,5 mm² Blue 1,5 mm² Blue 1,5 mm² Blue 1,5 mm² Blue
0 VDC BUS1 X21-7 X2-51 MCM-1-X24-2 MCM-2-X24-2 ESM-X11-2
GROUND GROUND
(Engine block) 1,5 mm² Blue 1,5 mm² Blue
LDU-X21-7 WIP-X11-2
1,5 mm² Blue (WDE-1)

1,5 mm² Blue 8 (WB1)
0 VDC BUS1 B-bank, page 12/1B
1,5 mm² Blue
X2-53 WCS-X11-2
1,5 mm² Blue (WBEB-A-1)
X2-54 0 VDC SUPPLY TO BEB-A page 23/1A a
1,5 mm² Blue (WBEB-B-1)
0 VDC SUPPLY TO BEB-B page 23/1D
2,5 mm² Blue 1,5 mm² Blue 1,5 mm² Blue 1,5 mm² Blue
0 VDC BUS2 X21-11 X2-61 MCM-1-X34-2 MCM-2-X34-2 ESM
ESM-X12-2
1,5 mm² Blue 1,5 mm² Blue
LDU-X22-7 WIP-X12-2
1,5 mm² Violet (WDE-1)

1,5 mm² Violet 8 (WB1)
Fuses: 0 VDC BUS2 B-bank, page 12/1B
1,5 mm² Blue
PDM:F1 20 A 24 VDC BUS1 X2-63 WCS-X12-2
PDM:F2 20 A 24 VDC BUS2 1,5 mm² Violet (WBEB-A-1)
PDM:F3 20 A (not in use) X2-64 O VDC SUPPLY TO BEB-A-1 page 23/1B a
PDM:F4 20 A (not in use) 1,5 mm² Violet (WBEB-B-1)
O VDC SUPPLY TO BEB-B-1 page 23/1D
F1 3A 2,5 mm² Blue
F2 3 A 0 VDC AUX X21-10 X2-71 0 VDC SUPPLY TO GT165 page 7/2F
F3 1A X2-72 0 VDC SUPPLY TO BUTTONS page 5/4C
X2-73 0 VDC SUPPLY TO QU700 page 6/5D
F4 1A X2-74 0 VDC SUPPLY TO K1 page 9/6A
X2-75 0 VDC SUPPLY TO MCM SIGNALS page 4/1C
X2-76 0 VDC SUPPLY TO MCM SIGNALS page 4/1D
X2-77 0 VDC SPARE
CHASSIS
CANbus
On engine Main cabinet Main cabinet On engine
MCM-1 WCS MCM-2 LDU

WDE-1 W1 White W2 White W3 White W4 White W5 White White WB1
White
X4-1 X24-3 X11-3 X24-3 X21-6 X4-7 CAN1
CAN1 Blue Blue Blue Blue Blue Blue Blue
X4-2 X24-4 X11-4 X24-4 X21-5 X4-8
WDE-1 WB1
page 11/1C White W6 White W7 White W8 White W9 White White page 12/1C
X4-3 X34-3 X34-3 X22-6 X4-9 CAN2
CAN2 Black Blue Blue Blue Blue Black
X4-4 X34-4 X34-4 X22-5 X4-10
CAN4 D-SUB9
Connector for
service tool outlet
GROUND X13-2 CAN L
X13-3 PWR OUT-
X13-7 CAN H
X13-9 PWR OUT+
CAN1, -2, -3 inner shields grounded
a W10 Single CAN cable ESM a
CAN3 White WBEB-A-1 CAN3 White WBEB-B-1
page 23/1B X24-5 X11-3
CAN3 Blue CAN3 Blue page 23/1D
X24-6 X11-4
Set ESM CAN termination resistor

DIP switch (J920) to "off" position
Maximum lenght between shielding (120 CAN termination resistor DISCONNECTED)
and grounding point 150 mm
Turbo speed indication
MCM-1
24 VDC AUX
from X2-35 page 3/6C X42-1 AO5 (SI518)
X42-2
0 VDC AUX
from X2-75 page 3/6F XM7-21
page 10/6A
XM7-22 Module ID
ESM MCM-2 LDU
WIP
ESM alarm X26-9 X25-5 (ID =1) X12-8
Blue X12-3 X26-10 X25-6 DI19 (NS718) X12-4
X12-4 TC A speed
PDM-1
MCM-1
PDM system X31-4 X21-1
supply failure X31-3 X21-2 DI25 (NS7800-1) X21-8
(ID =1) X21-7
PDM system
supply earth X31-6 X22-5
failure X31-5 X22-6 DI23 (NS7799-1)
MCM-2 MCM-2
24 VDC AUX X21-8
from X2-37 page 3/6C X42-1 AO5 (SI528) (ID =2) X21-6
X42-2
WIP
0 VDC AUX Failure 1 X11-8
from X2-76 page 3/6F XM7-23 24 VDC X11-7
page 10/6A Failure 2 X12-8
XM7-24 24 VDC X12-7
Failure 3
WIP 24 VDC X13-8
MCM-1
X13-7
Blue X13-3 TC B speed X13-5 X14-7
X13-4 Failure out X13-6 X14-8 DI12 (NS869) WIP failure
WCP
X31-19 to XM7-9 COMMON page 9/8E
X31-20 to XM7-10 IB724 Local control indication page 9/8E
X31-21 to XM7-11 IB726 Remote indication page 9/8E

MCM-1
OS7302
START X31-5 X12-4 DI2 Remote start
STOP
OS7304
X31-9 X12-6 DI3 Remote stop
X31-26 X12-8 DI4 OS7343

Engine blow
X31-27 X13-2 DI5 OS7344

Engine blocked
X31-28 X13-4 DI6 IB724

Local control indication
X31-11 to XM7-8 OS7308 Remote shutdown reset

RESET page 8/3B
X31-13 X33-7 IB725
Blue 0,75 mm² DO4 Waiting for reset
X33-8
0 VDC AUX
from X2-72 page 3/6E
X33-5 IS872
DO3
X31-17 X4-26 X33-6 Engine ready for start
24 VDC AUX
X31-18 from X2-36 page 3/6C
OS7308 Remote shutdown reset
X31-12 X12-1 DI1 (+)
OS7304 Remote stop
X12-5 DI3 (+)
X31-10 OS7302 Remote start
X12-3 DI2 (+)
X31-25
X31-4
IS872 Engine ready for start
X31-3 to K1:A1 page 9/6A
X31-2
Remote stop
X31-1 to XM7-4 page 8/3C
Remote start to XM7-2 page 8/3C
ESM Main cabinet On engine
3 x 0,5 mm²
Black ST173
X13-1 X4-30 +
Brown Engine speed 1
X13-2 X4-31 s
Blue
X13-3 X4-32 -
3 x 0,5 mm²
Black ST174
X14-1 X4-33 +
Brown Engine speed 2
X14-2 X4-34 s
Blue
X14-3 X4-35 -
3 x 0,75 mm²
Black TEZ402
X13-6 X4-36
Brown HT water temp, engine outlet A
X13-5 X4-37
Blue
X13-4 X4-38
3 x 0,75 mm²
Black TEZ403
X14-6 X4-39
Brown HT water temp, engine outlet B
X14-5 X4-40
Blue
X14-4 X4-41
2 x 0,75 mm²
Black PTZ201
X14-7
X14-8
X4-42
X4-43
Blue
+
-
I LO press, engine inlet
WIP-11 P
MCM-1 LO pressure
to HS723:23 page 8/1B X12-5
to HS723:24 X12-6
24 VDC AUX HT temp
+ X13-7 from X2-32 page 3/6C X24-1 X28-1 X11-5
DI8 IS7602 Stop/shutdown status 1 X28-2 X11-6
s X13-8 X24-2
page 9/6B to K2:A1 Engine speed
+ X22-7 X15-7 X28-7 X11-3
DI24 IS7306 Stop/shutdown override status X28-8 X11-4
s X22-8 X15-8
a
X33-1 X13-7 CHASSIS
DO1 OS7342 Engine stop (s)
X33-2 X13-8 Brown
22 kΩ WBEB-A-2
X33-3 X14-11 from Sentry SHD Alarm
DO2 Grey page 23/1B
OS820 Main controller shutdown (s)
X33-4 X14-12
Brown
X14-9 X4-48 WBEB-B-2
from Sentry SHD Alarm
EngSd2 Grey page 23/1D
X14-10 X4-49
QU700 oil mist detector

24/0 VDC AUX WOMD-1 Black
MCM-2
from X2-33 page 3/6C X1-1
Light Blue
X44-3 X11-8 from X2-73 page 3/6E X1-2
DO10 OS7345 Stop 2
X44-4 X12-8 X1-4
X1-5 OMD shutdown
DO12 X44-7 XM7-33 page 9/3B Brown
XS7323 Shutdown prewarning
X44-8 XM7-34 page 9/3B X13-9 X4-46 X5-7
EngSd1 R=22 kΩ
page 3/6C X2-39 X27-1 Grey
5 x 0,75 mm² X13-10 X4-47 X5-8
WDE-2 Black Engine speed, ESM to IOM
X4-6 X27-2 X1-3
page 14/3D
page 9/5C Engine speed pulse
On engine Main cabinet X13-11 GROUND
EngSd3 22 kΩ
X12-3 X13-12
GROUND
GROUND
Main cabinet On engine
ESM 2 x 1,5 mm²

Black CV153-1
SS1
X22-1
Blue + Stop/shutdown valve solenoid 1
X22-2 -
2 x 1,5 mm²
Black CV153-2
SS2
X22-3
Blue + Stop/shutdown valve solenoid 2
X22-4 -
MCM-1 3 x 0,5 mm²

Brown ST196P
X23-2 s
Freq1 Blue Engine speed, primary
X23-3 -
Black
Black wire not connected to speed sensor
3 x 0,5 mm²
Brown ST196S
X22-2 s
Freq2 Blue Engine speed, secondary
X22-3 -
Black
Black wire not connected to speed sensor
2 x 1,5 mm²
Black CV321
HSD1
X35-1
Blue + Start solenoid valve
X35-2 -
2 x 1,5 mm²
Black CV331
HSD2
X35-3
Blue + Slowturning solenoid valve
X35-4 -
W161 2 x 1,5 mm²

Black CV161
X42-3 A Fuel rack control
AO6 Blue
X42-4 B
PG-EG 58
MCM-2 2 x 1,5 mm²

Black CV613
HSD1
X35-1
Blue + Air assist valve
X35-2 -
3 x 0,75 mm²
Black GT165
24 VDC from X2-31 page 3/6C X4-27
Brown 1+ I Fuel rack position
AI1 MCM-1-X31-1 X4-28 3s
Blue
MCM-1-X31-2 X4-29 2-
0 VDC from X2-71 page 3/6F
ESM
Cabinet Engine external
External shutdown 1 +
X16-1 XM7-13 OS7309 22 kΩ
s External shutdown 1
X16-2 XM7-14
External shutdown 2 "Not used"
+ OS7310
X16-3 XM7-37 22 kΩ
HS723 s External shutdown 2
Emergency stop button X16-4 XM7-38 "From switchboard shutdown"
External shutdown 3 +
X16-5 XM7-39 OS7311
s External shutdown 3 22 kΩ
X16-6 XM7-40 "Not used"
page 6/2C 23 13 21 External shutdown 4 + OS7305
to MCM-1-X13-7 22 kΩ X16-7 XM7-5 22 kΩ
s External shutdown 4
to MCM-1-X13-8 2414 22 X16-8 XM7-6 "Ext Sd4 from Emg. Stop PB"
Stop/shutdown override +
X16-9 XM7-27 OS7306
s Stop/shutdown override
Shutdown reset X16-10 XM7-28
"Not used"
X16-12
MCM-1 MCM-2
+ OS7308 +
X12-1 XM7-7 X14-3 OS7317
DI1 s Remote shutdown reset DI10 s Remote stand-by request
X12-2 XM7-8 X14-4
page 5/3B from WCP 31-11 + +
X12-3 XM7-1 OS7302 X14-5 OS7313
DI2 s Remote start DI11 s Engine external start block 2
X12-4 page 5/6D from WCP 31-2 XM7-2 X14-6 "Not used"
+ OS7304 + OS7314
X12-5 XM7-3 X14-7
DI3 s Remote stop DI12 s Engine external start block 3
X12-6 page 5/6D from WCP 31-4 XM7-4 X14-8 "Not used"
+ + XS7318
X14-3 GS7600 X33-7
DI10 s Clutch status DO4 - Slowturning pre-warning
X14-4 X33-8
+ GS772
X14-5
DI11 s Busbar breaker status, after
X14-6
+ OS7312
X15-1
DI13 s Engine external start block 1
X15-2 "From switchboard"
+
X15-3 OS7320
DI14 s Blackout start mode
X15-4
+ OS7329
X15-7
DI16 s Isochronous load sharing enable
X15-8
+ GS798
X25-1
DI17 s Generator breaker status NO
X25-2
+ OS7321
DI18 X25-3
s Engine unload
X25-4
+ OS163
DI19 X25-5
s Speed/load increase
X25-6
+ OS164
X25-7
DI20 s Speed/load decrease
X25-8
+ OS7326
X22-5
DI23 s Fixed speed select
X22-6
+ GS771
X21-1
DI25 s Busbar breaker status,before
X21-2
+ OS5270
X21-3
DI26 s Enable exh. gas temp. ctrl for SCR
X21-4
K1
AC/DC +
from X4-26 page 5/6D A1+ 13 IS872
ESM Blue
Engine ready for start
+ 0 VDC AUX from X2-74 page 3/6E A2- -
X21-1 XM7-15 14
Speed switch 1 - IS181
Speed switch 1 (Engine running)
Blue
X21-2 XM7-16
+ K2
Speed switch 2 X21-3 XM7-41 IS182
- Speed switch 2 AC/DC +
X21-4 XM7-42 from ESM-X24-2 page 6/3C A1+ 13 IS7602 Stop/shutdown status 1
+ IS184 -
Speed switch 4 X23-1 XM7-43 A2- 14
- Speed switch 4 24 VDC SUPPLY
X23-2 XM7-44
+ from X2-34 page 3/6C
Blue
Speed window 1 X23-3 XM7-29 IS7601-1 K3
- Speed window 1 MCM-1-X45-7
X23-4 XM7-30 DO8 AC/DC +
+ MCM-1-X45-8 A1+ 13 CV223
Speed window 2 X23-5 XM7-31 IS7601-2 Prelubrication pump control
- Speed window 2 -
X23-6 XM7-32 A2- 14
+ IB7324
Shutdown status X25-9 XM7-17
Blue
- Shutdown status K4
X25-10 XM7-18
+ AC/DC +
Shutdown pre-warning X26-11 XM7-33 XS7323 A1+ 13 OS441
page 6/3E MCM-2 X44-7 Shutdown pre-warning Preheater control
- -
X26-12 XM7-34 24 VDC SUPPLY A2- 14
page 6/3E MCM-2 X44-8 +
Stop/Shutdown status 2 X24-3 XM7-25 IS7603 from X2-38 page 3/6C
- Stop/shutdown status 2 K5
Blue
X24-4 XM7-26 MCM-2-X43-7
Engine speed output 1 + DO16 AC/DC +
mA(+) X27-7 XM7-19 SI196 MCM-2-X43-8 A1+ 13 CV119
mA(-) - Engine speed Fuel oil pump control
X27-8 XM7-20 -
A2- 14
Blue
K8
AC/DC +
page 6/3E ESM X27-2 A1+ 13 XM7-35 SI173/SI174
MCM-1 Engine speed pulse
+ -
X45-1 IS875 A2- 14 XM7-36
DO5 s Start failure indication
X45-2
+ IS7331
X45-3
DO6 s Tripped to speed droop control
X45-4
+ CV224
X45-5
DO7 s Generator jack pump control
X45-6 Max. allowed voltage 48V for engine external signals
+ NS886
X44-1
DO9 s Engine control system, major failure
X44-2
+ OS7315
X44-3
DO10 s Load reduction request/indication
X44-4
+ + COMMON
X44-5 OS7602 XM7-9
DO11 s Gen. breaker open command s IB724 Local indication
X44-6 page 5/4A XM7-10
s IB726 Remote indication
+ XM7-11
X44-7 IS190
DO12 s Ready to clutch
X44-8
+ OS7603
X43-1
DO13 s Clutch open command
X43-2
+ GSY101
X43-3
DO14 s MDF selected, calculated
X43-4
+ NS885
X43-5
DO15 s Common engine alarm
X43-6
+ NS881
X43-7
DO16 s Engine control system, minor alarm
X43-8
Cabinet Engine external Cabinet Engine external
MCM-1 LDU
+ OT190 TX+
X41-3 Ethernet 1 X31-1
AI6 s Analogue speed reference TX-
X41-4 X31-2 Modbus TCP 1
+ RX+
X41-5 UT793 X31-3
AI7 s Engine load feedback RX-
X41-6 X31-4
+ TX+
X32-5 CT7001 Ethernet 2 X32-1
AO3 s Engine load for propulsion control TX- Modbus TCP 2
X32-6 X32-2
RX+
+ X32-3
X24-7 Modbus serial (add 120 Ω resistor if end of bus line) RX-
RS 485 - X32-4
X24-8 TX
Ethernet 1 X41-1
RX Modbus TCP 1 optical
CAN4 120 Ω X41-2
+ CAN bus 4 TX
X34-5 X42-1
- Load sharing CAN Ethernet 2 RX
X34-6 X42-2 Modbus TCP 2 optical
X11 RS-232 (Not in use)

Use termination resistor in both ends of the CAN bus D-sub 9-pin male
*
XM7-21 SI518 TC A speed
page 4/2D XM7-22
*Remove jumpers at site if signals are in use
*
page 4/2E XM7-23 SI528 TC B speed
XM7-24
Cabinet Engine cabling
IOM-DE IOM-A1 IOM-A2 IOM-A3 IOM-FE IOM-TC
WDE-1 WA1 WA2 WA3 WFE WTC

Brown Brown Brown Brown Brown Brown
page 3/6A 24 VDC BUS1 X2-12 X11-1 X11-1 X11-1 X11-1 X11-1 X11-1
Blue Blue Blue Blue Blue Blue
page 3/6C 0 VDC BUS1 X2-52 X11-2 X11-2 X11-2 X11-2 X11-2 X11-2
Grey Grey Grey Grey Grey Grey
page 3/6B 24 VDC BUS2 X2-22 X21-8 X21-8 X21-8 X21-8 X21-8 X21-8
Violet Violet Violet Violet Violet Violet
page 3/6E 0 VDC BUS2 X2-62 X21-7 X21-7 X21-7 X21-7 X21-7 X21-7
White White White White White White 120 Ω

X4-1 H X11-3 X11-3 X11-3 X11-3 X11-3 X11-3
CAN 1 Blue Blue Blue Blue Blue Blue
X4-2 L X11-4 X11-4 X11-4 X11-4 X11-4 X11-4
page 4/1B White
X21-6
White
X21-6
White
X21-6
White
X21-6
White
X21-6
White * X21-6
120 Ω
CAN 2 X4-3 H Black Black Black Black Black Black
X4-4 L X21-5 X21-5 X21-5 X21-5 X21-5 X21-5
*
CHASSIS CHASSIS CHASSIS CHASSIS CHASSIS CHASSIS
* Leave inner shielding unconnected at this end

Cabinet Engine cabling
IOM-B1 IOM-B2 IOM-B3
WB1 WB2 WB3

Brown Brown Brown
page 3/6A24 VDC BUS1 X2-12 X11-1 X11-1 X11-1
Blue Blue Blue
page 3/6C 0 VDC BUS1 X2-52 X11-2 X11-2 X11-2
Grey Grey Grey
page 3/6B 24 VDC BUS2 X2-22 X21-8 X21-8 X21-8
Violet Violet Violet
page 3/6C 0 VDC BUS2 X2-62 X21-7 X21-7 X21-7
White White White 120 Ω

X4-7 H X11-3 X11-3 X11-3
CAN 1 Blue Blue Blue
X4-8 L X11-4 X11-4 X11-4
page 4/8B
White
X21-6
White
X21-6
White * X21-6
120 Ω
CAN 2 X4-9 H Black Black Black
X4-10 L X21-5 X21-5 X21-5
*
CHASSIS CHASSIS CHASSIS
* Leave inner shielding unconnected at this end

IOM-DE IOM-DE
2 x 1,5 mm² CV381
Black VIC Control valve 2 x 0,75 mm² PT201
X11-5 +
HSD 1 Blue Black LO press, engine inlet
X11-6 - AI 3 X42-1
Blue
+ I
X42-2 -
X42-3
P
3 x 0,75 mm²
X42-4
Black LS108A
DIO 5 (24 V+) X41-7 + FO leakage, dirty fuel, DE A-bank 2 x 0,75 mm²
Blue PT241
REF (0 V) X41-5 - Black LO press, filter inlet
DIO 1 X41-1
Brown
S AI 4 X42-5
Blue
+ I
X42-6 -
X42-7
P
3 x 0,75 mm²
X42-8
Black GS171
DIO 5 (24 V+) X41-7 + Stop lever in stop position
Blue 3 x 0,75 mm²
REF (0 V) X41-5 - X33-1
Brown AI 5 Black
DIO 2 X41-2 S TE201
X33-2
Blue LO temp, engine inlet
X33-3
3 x 0,75 m² Brown
X33-4
Black GS792
DIO 6 (24 V+) X41-8 + Turning gear engaged
Blue
REF (0 V) X41-6 - 3 x 0,75 mm²
Brown AI 6 X33-5
DIO 3 X41-3 S Black TE482
X33-6
Blue LT water temp, LOC outlet
X33-7
3 x 0,75 m² Brown
X33-8
Black LS204
DIO 6 (24 V+) X41-8 + Lube oil low level, wet sump
Blue
REF (0 V) X41-6 - 3 x 0,75 mm²
Brown AI 9 X23-1
DIO 4 X41-4 S Black TE601
X23-2
Blue CA temp, engine inlet
X23-3
Brown
X23-4
Engine wiring Cabinet
5 x 0,75 mm²
WDE-2 Black 2 x 0,75 mm² PT291A
FI 1 X31-1 X4-6 page 6/3E Black Ctrl oil press, aft. VIC valve A-bank
AI 14 X22-5
Blue
+ I
X22-6 -
X22-7
P
2 x 0,75 mm² X22-8
PT301
Black Start air pressure, engine inlet
AI 1 X32-1
Blue
+ I 2 x 0,75 mm²
Black
PT601
CA press,engine inlet
X32-2 -
X32-3
P AI 16 X12-5
Blue
+ I
X12-6 -
X32-4 X12-7
P
2 x 0,75 mm² X12-8
PT311
Black Control air press
AI 2 X32-5
Blue
+ I
X32-6 -
X32-7
P ID=1 X31-3
X31-5
X32-8
CHASSIS
CHASSIS
IOM-FE IOM-FE
2 x 1,5 mm² CV615A
Black TC impeller cooling, TC A 3 x 0,75 mm²
X11-5 + AI 8 X43-5
HSD 1 Blue Black TEZ402-1
X11-6 - X43-6
Blue HT water temp, jacket outlet A-bank
X43-7
Brown
X43-8
3 x 0,75 mm²
DIO 5 (24 V+) Black LS103A 3 x 0,75 mm²
X41-7 + FO leakage, clean primary, A-bank AI 9 X23-1
REF (0 V) Blue Black TEZ403-1
X41-5 - X23-2
DIO 1 Brown Blue HT water temp, jacket outlet B-bank
X41-1 S X23-3
Brown
X23-4
WOMD-2 QU700 ID=2 X31-3

Black X31-6
DIO 5 (24 V+) X41-7 X5-1 NS700 Detector
Light blue
DIO 2 X41-2 X5-2 failure alarm
Brown
DIO 6 (24 V+) X41-8 X5-3 QS700 Oil mist CHASSIS
Orange
DIO 3 X41-3 X5-4 alarm
Grey
X42-2 X4-3 4-20mA PT700
White
X42-4 X4-4 4-20mA Crankcase pressure
GROUND
2 x 0,75mm² PT101
Black FO press, engine inlet
AI1 X32-1
Blue
+ I
X32-2 -
X32-3
P
X32-4
2 x 0,75mm² PT401
AI 2 Black HT water press, jacket inlet
X32-5
Blue
+ I
X32-6 -
X32-7
P
X32-8
3 x 0,75 mm²
AI 5 X33-1
Black TE101
X33-2
Blue FO temp, engine inlet
X33-3
Brown
X33-4
3 x 0,75 mm²
AI 6 X33-5
Black TE401
X33-6
Blue HT water temp, jacket inlet
X33-7
Brown
X33-8
CHASSIS
IOM-TC IOM-TC
2 x 1,5 mm² CV312
Black Instrument air valve control
HSD 2 X11-7 + 2 x 0,75mm² PT271
Blue
X11-8 - Black LO press, TC A inlet
AI 1 X32-1
Blue
+ I
X32-2 -
X32-3
P
2 x 0,75mm² CV519 X32-4
Black Exh WG contol
DIO 6 (24 V+) X41-8
Blue
+ I 2 x 0,75mm² PT471
X21-4 -
AO1+
AO1- X21-3
P AI 2 X32-5
Black
Blue
+ I
LT water press, LT CAC inlet
X32-6 -
REF (0 V) X41-6
X32-7
P
2 x 0,75mm² X32-8
CV643
Black CA by-pass valve control 2 x 0,75mm²
DO6 (24 V+) X41-8
Blue
+ I Black
PT281
LO press, TC B inlet
AO2+ X21-2
X21-1
-
P AI 3 X42-1
Blue
+ I
AO2- X42-2 -
REF (0 V) X41-6 X42-3
P
X42-4
3 x 0,75 mm² Amplifier

Black SE518 3 x 0,75 mm²
DIO5 (24 V+) X41-7 A A TC A speed AI 4 X42-5
Black
REF (0 V) X41-5
Blue
Brown
D D f X42-6
Blue
TE600
Air temp, TC inlet
X42-7
FI 1 X31-1 B B n X42-8
Brown
DAAF075204
3 x 0,75 mm² Amplifier 3 x 0,75 mm²
Black SE528 AI 5 X33-1
Black TE272
DIO5 (24 V+) X41-7 A A TC B speed X33-2
REF (0 V) X41-5
Blue
Brown
D D f X33-3
Blue LO temp, TC A outlet
Brown
FI 2 X31-2 B B n X33-4
DAAF075204 3 x 0,75 mm²

AI 6 X33-5
Black TE472
X33-6
Blue LT water temp, LT CAC outlet
X33-7
Brown
CHASSIS X33-8
3 x 0,75 mm²
AI 7 X43-1
Black TE471
X43-2
Blue LT water temp, LT CAC inlet
X43-3
Brown
X43-4
3 x 0,75 mm²
AI 8 X43-5
Black TE282
X43-6
Blue LO temp, TC B outlet
X43-7
Brown
X43-8
CHASSIS
IOM-TC
3 x 0,75 mm²
AI 9 X23-1
Black TE402
X23-2
Blue HT water temp, jacket outlet A-bank
X23-3
Brown
X23-4
2 x 0,5 mm²
AI 10 X23-5
Green TE527
X23-6 +
White Exh gas temp, B outlet
X23-7
X23-8 -
2 x 0,75mm² PT312
Black Instrument air press
AI 11 X13-1
Blue
+ I
X13-2 -
X13-3
P
X13-4
3 x 0,75 mm²
AI 12 X13-5
Black TE403
X13-6
Blue HT water temp, jacket outlet B-bank
X13-7
Brown
X13-8
2 x 0,5 mm²
AI 13 X22-1
Green TE521
X22-2 +
White Exh gas temp, TC B inlet
X22-3
X22-4 -
2 x 0,5 mm²
X22-5
AI 14 Green TE511
X22-6 +
White Exh gas temp, TC A inlet
X22-7
X22-8 -
2 x 0,5 mm²
AI 15 X12-1
Green TE517
X12-2 +
White Exh gas temp, TC A outlet
X12-3
X12-4 -
ID=3 X31-3
X31-5
X31-6
CHASSIS
IOM-A1 IOM-A1
AI1 2 x 0,5 mm²
X32-1 AI9 2 x 0,5 mm²
Green TE5011A X23-1
X32-2 Green TE7031A
White + Exh gas temp, cyl A01 X23-2
White + Liner temp 1, cyl A03
X32-3
X23-3
X32-4 -
X23-4 -
AI2 2 x 0,5 mm²

X32-5 AI10 2 x 0,5 mm²
Green TE5021A X23-5
X32-6 Green TE7032A
White + Liner temp 2, cyl A03
X32-7
X23-7
X32-8 -
X23-8 -
AI3 2 x 0,5 mm²

X42-1 AI13 2 x 0,5 mm²
Green TE5031A X22-1
X42-2 Green TE702
White + Main bearing 02 temp
X42-3 X22-3
X42-4 -
X22-4 -
AI5 2 x 0,5 mm²

X33-1 AI14 2 x 0,5 mm²
Green TE7011A X22-5
X33-2 Green TE703
White + Liner temp 1, cyl A01 X22-6
White + Main bearing 03 temp
X33-3 X22-7
X33-4 -
X22-8 -
AI6 2 x 0,5 mm²

X33-5
Green TE7012A ID=4 X31-3
X33-6 +
White Liner temp 2, cyl A01 X31-7
X33-7
X33-8 -
2 x 0,5 mm² CHASSIS

AI7 X43-1
Green TE7021A
X43-2 +
White Liner temp 1, cyl A02
X43-3
X43-4 -
AI8 2 x 0,5 mm²

X43-5
Green TE7022A
X43-6 +
X43-7
X43-8 -
CHASSIS
IOM-A2 IOM-A2
AI1 2 x 0,5 mm²
X32-1
Green TE5041A AI9 2 x 0,5 mm²
X32-2 + X23-1
White Exh gas temp, cyl A04 Green TE7061A
X32-3 X23-2 +
X32-4 - X23-3
X23-4 -
AI2 2 x 0,5 mm²

X32-5
X32-6 + X23-5
White Exh gas temp, cyl A05 Green TE7062A
X32-7 X23-6 +
X32-8 - X23-7
X23-8 -
AI3 2 x 0,5 mm²

X42-1
X42-2 + X13-1
White Exh gas temp, cyl A06 Green TE704
X42-3 X13-2 +
White Main bearing 04 temp
X42-4 - X13-3
X13-4 -
AI5 2 x 0,5 mm²

X33-1
X33-2 + X13-5
White Liner temp 1, cyl A04 Green TE705
X33-3 X13-6 +
X33-4 - X13-7
X13-8 -
AI6 2 x 0,5 mm²

X33-5
X33-6 + X22-1
X33-7 X22-2 +
X33-8 - X22-3
X22-4 -
AI7 2 x 0,5 mm²

X43-1
X43-2 + X22-5
X43-3 X22-6 +
X43-4 - X22-7
X22-8 -
AI8 2 x 0,5 mm²

X43-5
Green TE7052A
X43-6 + X31-3
X43-7 X31-5
X43-8 -
ID=5 X31-4
X31-7
CHASSIS
CHASSIS
IOM-A3 IOM-A3
AI1 2 x 0,5 mm²
X32-1
Green TE5071A 2 x 0,5 mm²
X32-2 + AI11 X13-1
White Exh gas temp, cyl A07 Green
X32-3 TE708
X13-2 +
- White Main bearing 08 temp
X32-4 X13-3
X13-4 -
AI2 2 x 0,5 mm²

X32-5
Green TE5081A 2 x 0,5 mm²
X32-6 + AI12 X13-5
White Exh gas temp, cyl A08 Green
X32-7 TE709
X13-6 +
- White Main bearing 09 temp
X32-8 X13-7
X13-8 -
AI5 2 x 0,5 mm²

X33-1
Green TE7071A
X33-2 +
White Liner temp 1, cyl A07 X31-3
X33-3
- X31-6
X33-4
ID=6 X31-4
X31-7
AI6 2 x 0,5 mm²
X33-5
Green TE7072A
X33-6 +
X33-7
- CHASSIS
X33-8
AI7 2 x 0,5 mm²

X43-1
Green TE7081A
X43-2 +
X43-3
X43-4 -
2 x 0,5 mm²
AI8 X43-5
Green TE7082A
X43-6 +
X43-7
X43-8 -
CHASSIS
IOM-B1 IOM-B1
2 x 0,75 mm² CV656
Black Air wastegate AI7 2 x 0,5 mm²
DIO 6+ X41-8
Blue
+ I X43-1
Green TE7021B
A01+ X21-4 - X43-2
A01- X21-3
P X43-3
White + Liner temp 1, cyl B02
Ref (0V) X41-6 X43-4 -
3 x 0,75 mm² 2 x 0,5 mm²

AI8 X43-5
Black LS108B Green
DIO 5+ X41-7 + FO leakage, dirty fuel DE, B-bank TE7022B
Blue X43-6 +
Ref (0V) X41-5 - White Liner temp 2, cyl B02
Brown X43-7
DIO 1 X41-1 S X43-8 -
AI1 2 x 0,5 mm² AI9 2 x 0,5 mm²

X32-1 X23-1
Green TE5011B Green TE7031B
X32-2 + X23-2 +
White Exh gas temp, cyl B01 White Liner temp 1, cyl B03
X32-3 X23-3
X32-4 - X23-4 -
AI2 2 x 0,5 mm² AI10 2 x 0,5 mm²

X32-5 X23-5
Green TE5021B Green TE7032B
X32-6 + X23-6 +
White Exh gas temp, cyl B02 White Liner temp 2, cyl B03
X32-7 X23-7
X32-8 - X23-8 -
AI3 2 x 0,5 mm² AI11 2 x 0,5 mm²

X42-1 X13-1
Green TE5031B Green TE700
X42-2 + X13-2 +
White Exh gas temp, cyl B03 White Main bearing 00 temp
X42-3 X13-3
X42-4 - X13-4 -
AI5 2 x 0,5 mm² AI12 2 x 0,5 mm²

X33-1 X13-5
Green TE7011B Green TE701
X33-2 + X13-6 +
White Liner temp 1, cyl B01 White Main bearing 01 temp
X33-3 X13-7
X33-4 - X13-8 -
AI6 2 x 0,5 mm²

X33-5 ID=8 X31-3
Green TE7012B
X33-6 + X31-8
White Liner temp 2, cyl B01
X33-7
X33-8 -
CHASSIS
CHASSIS
IOM-B2 IOM-B2
3 x 0,75 mm²
Black LS103B AI7 2 x 0,5 mm²
DIO 5+ X41-7 + X43-1
Blue FO leakage, clean primary, B-bank Green TE7051B
Ref (0V) X41-5 - X43-2 +
Brown White Liner temp 1, cyl B05
DIO 1 X41-1 X43-3
S
X43-4 -
2 x 0,5 mm² AI8 2 x 0,5 mm²

AI1 X32-1 X43-5
Green Green TE7052B
TE5041B X43-6 +
X32-2 + White Liner temp 2, cyl B05
White Exh gas temp, cyl B04 X43-7
X32-3
- X43-8 -
X32-4
2 x 0,5 mm² AI9 2 x 0,5 mm²

AI2 X32-5 X23-1
Green Green TE7061B
TE5051B X23-2 +
X32-7
- X23-4 -
X32-8
2 x 0,5 mm² AI10 2 x 0,5 mm²

AI3 X42-1 X23-5
Green Green TE7062B
TE5061B X23-6 +
X42-3
- X23-8 -
X42-4
AI5 2 x 0,5 mm² X31-3

X33-1
Green TE7041B X31-5
X33-2 +
White Liner temp 1, cyl B04 ID=9 X31-4
X33-3
X33-4 - X31-8
AI6 2 x 0,5 mm²

X33-5
Green TE7042B CHASSIS
X33-6 +
X33-7
X33-8 -
CHASSIS
IOM-B3 IOM-B3
AI1 2 x 0,5 mm²
X32-1
Green TE5071B AI7 2 x 0,5 mm²
X32-2 + X43-1
White Exh gas temp, cyl B07 Green TE7081B
X32-3 X43-2 +
X32-4 - X43-3
X43-4 -
AI2 2 x 0,5 mm²

X32-5
Green TE5081B AI8 2 x 0,5 mm²
X32-6 + X43-5
White Exh gas temp, cyl B08 Green TE7082B
X32-7 X43-6 +
X32-8 - X43-7
X43-8 -
AI5 2 x 0,5 mm²

X33-1
Green TE7071B
X33-2 + X31-3
X33-3 X31-6
X33-4 - ID=10 X31-4
X31-8
AI6 2 x 0,5 mm²

X33-5
Green TE7072B
X33-6 +
White Liner temp 2, cyl B07 CHASSIS
X33-7
X33-8 -
CHASSIS
a
Cabinet Engine wiring BEB-A
WBEB-A-1 1,5 mm² Brown
page 3/6B 24 VDC BUS1 X2-14 X1-1
1,5 mm² Blue
1,5 mm² Grey
1,5 mm² Violet
page 3/6D 0 VDC BUS2 X2-64 X1-4
CAN White
MCM-1-X24-5 H X4-1
page 4/6C CAN 3 CAN Blue
MCM-1-X24-6 L X4-3
S2
Set CAN termination DIP switch (S2)
Termination 120 Ω CAN to "Term" position
DIP switch S2 (120 Ω CAN termination resistor connected)
S3=9
S4=1
Node 25
WBEB-A-2 Brown 100 kΩ
X3-3 HIGH-HIGH ALARM (SHD ALARM)
page 6/1C Engine Shd 2 Grey
X3-4
GROUND
BEB-B
WBEB-B-1 1,5 mm² Brown
1,5 mm² Blue
1,5 mm² Grey
1,5 mm² Violet
page 3/6D 0 VDC BUS2 X2-64 X1-4
ESM X11-3 CAN White

X4-1
page 4/6C
CAN Blue
ESM X11-4 X4-3
S2
Set CAN termination DIP switch (S2)
Termination 120 Ω CAN to "Term" position
DIP switch S2 (120 Ω CAN termination resistor connected)
S3=A
S4=1
Node 26
WBEB-B-2 Brown 100 kΩ

X3-3 HIGH-HIGH ALARM (SHD ALARM)
page 6/5B Engine Shd 2 Grey
X3-4
Leave inner shielding unconnected at this end

GROUND
a
BEB-A
TE7016A
Big end bearing cyl 1 temp
Ch. 1 X5-1
TE7026A
Ch. 2 X5-2
TE7036A
Ch. 3 X5-3
TE7046A
Ch. 4 X5-4
TE7056A
Ch. 5 X6-1
TE7066A
Ch. 6 X6-2
TE7076A
Ch. 7 X6-3
TE7086A
Ch. 8 X6-4
a
BEB-B
TE7016B
Ch. 1 X5-1
TE7026B
Ch. 2 X5-2
TE7036B
Ch. 3 X5-3
TE7046B
Ch. 4 X5-4
TE7056B
Ch. 5 X6-1
TE7066B
Ch. 6 X6-2
TE7076B
Ch. 7 X6-3
TE7086B
Ch. 8 X6-4
Modbus communication link
Communication speed: 19200 bits/s
Communication mode: RTU
Data bits: 8
Parity: NONE
Stop bits: 1
Commands in use: 02 (Input status), 03 (Holding register)
Polling delay: 200 ms (recommended)
Physical interface: RS-485, 2-wire
Title Explanation
Code Sensor code
Name Signal name
BL Alarm is blocked in stop mode
Type Signal type
Range / Unit Signal range and unit
Set point - Alarm Set point for alarm condition
Set point - L.red. Set point for load reduction request condition
Set point - Stop Set point for stop / shutdown condition
Alarm cond. Condition for alarm / stop / load reduction activation
Modbus addresses - Anal. On analog addresses (40xxx) integer value multiplied by Scale is shown
Modbus addresses - Alarm On alarm addresses (10xxx) 0 = normal and 1 = alarm ON
Modbus addresses - L.red. On load reduction addresses (12xxx) 0 = normal and 1 = load reduction request ON
Modbus addresses - Stop On stop addresses (11xxx) 0 = normal and 1= stop ON
Scale Division factor
Error values -32767 = value not update (not configured) and -32765 = sensor failure
PT101 alarm updated to 6 bar, PT271 and PT281 alarm updated to 2,1 bar, PT601 alarm and load reduction set points updated,
Comments 10 and 11 added for TE601 alarm and load reduction setpoints, 1 bar corrected to 0,8 bar in comment number 3,
a 20.05.2020 A.G J.R
TE600 alarm setpoint removed, IS4011 HT water temp shutdown removed from modbus list, IS7337 OMD shutdown status code
changed to QS701
Rev Date Made Checked Description
MODBUS SLAVE ID ENGINE NUMBER Wärtsilä Finland OY MODBUS CODE LIST FOR UNIC C2
1 XAAB614715,XAAB614722,XAAB614725 Marine Solutions MAIN ENGINE
SHI 2303
This drawing is property of Wärtsilä Finland Oy and shall not be copied, shown nor communicated to a third party without the consent of the owner.
Proj.no Product Made: Mattus 7.8.2019 Pages Document No Rev.

SP/04599 W16V32 Approved: Remsu 7.8.2019 1/7 DMCA00018291 a
1(7) DMCA00018291_a.xlsx
SP/04599, SHI 2303 , W16V32, DMCA00018291 rev. a
B Type Range / Set point Alarm Modbus Addresses
Code Name L Unit Alarm Delay L.red. Delay Stop Delay cond Anal. Alarm L.red. Stop Scale
Fuel oil
PT101 Fuel oil pressure, inlet X 4-20 mA 0 - 16 bar 6,0 3s low 40001 10001 100
TE101 Fuel oil temp, inlet Pt100 0 - 160 °C 9) High 40002 9) 10
LS103A Fuel oil leakage, injection pipes A-bank NC-switch 0-1 1 5s open 10004 1
LS103B Fuel oil leakage, injection pipes B-bank NC-switch 0-1 1 5s open 10005 1
LS108A Fuel oil leakage, dirty fuel DE A-bank NC-switch 0-1 1 5s open 10010 1
LS108B Fuel oil leakage, dirty fuel DE B-bank NC-switch 0-1 1 5s open 10011 1
Lub. oil
PT201 Lub. oil pressure, inlet X 4-20 mA 0 - 10 bar 3 5s 2,5 5s low 40015 10015 12015 100
TE201 Lub. oil temp., inlet Pt100 0 - 160 °C 70 5s 80 5s high 40016 10016 12016 10
LS204 Lub. oil level, wet sump NC-switch 0-1 1 20s closed 10017 1
PDY243 Lub. oil filter differential pressure Calculated 0 - 2 bar 1,2 5s high 40018 10018 100
PT271 Lub. oil pressure at turbocharger A X 4-20 mA 0 - 10 bar 2,1 10s low 40019 10019 100
PT281 Lub. oil pressure at turbocharger B X 4-20 mA 0 - 10 bar 2,1 10s low 40020 10020 100
TE272 Lub. oil temp. at turbo charger A outlet Pt100 0 - 160 °C 115 10s high 40021 10021 10
TE282 Lub. oil temp. at turbo charger B outlet Pt100 0 - 160 °C 115 10s high 40022 10022 10
PT291A Ctrl oil press, aft. VIC valve A-bank X 4-20 mA 0 - 10 bar 5) 0,8 4) 0,8 high/low 10025 12025 100
Starting air
PT301 Starting air pressure 4-20 mA 0 - 40 bar 16 5s low 40029 10029 100
PT311 Control air pressure 4-20 mA 0 - 40 bar 16 5s low 40030 10030 100
PT312 Instrument air press 4-20 mA 0 - 10 bar 5 3s low 40031 10031 100
Cooling water
PT401 HT-water pressure, inlet X 4-20 mA 0 - 6 bar 2) 2,0 5s 3) 1,6 5s low 40034 10034 12034 100
TE401 HT-water temp.inlet X Pt100 0 - 160 °C 60 5s low 40035 10035 10
TE402 HT-water temp. A-bank outlet X Pt100 0 - 160 °C 105 5s high 40036 10036 10
TE403 HT-water temp. B-bank outlet X Pt100 0 - 160 °C 105 5s high 40037 10037 10
PT471 LT-water pressure, inlet X 4-20 mA 0 - 6 bar 2) 2,0 5s low 40039 10039 100
TE471 LT-water temp. inlet Pt100 0 - 160 °C 55 30s high 40040 10040 10
TE482 LT Water temperature, LOC outlet Pt100 0 - 160 °C 40041 10
TE472 LT water temp, LT CAC outlet Pt100 0 - 160 °C 40042 10
TEZ402-1 HT-water temp, outlet LR A-bank X Pt100 0 - 160 °C 108 5s 40043 12043 10
TEZ403-1 HT-water temp, outlet LR B-bank X Pt100 0 - 160 °C 108 5s 40044 12044 10
2(7) DMCA00018291_a.xlsx
Exhaust gas
TE511 Exhaust gas temp. TC A inlet 1 NiCr/Ni 0 - 750 °C 590 10s 640 20s high 40047 10047 12047 10
TE521 Exhaust gas temp. TC B inlet 1 NiCr/Ni 0 - 750 °C 590 10s 640 20s high 40048 10048 12048 10
TE517 Exhaust gas temp. TC A outlet NiCr/Ni 0 - 750 °C 450 30s high 40049 10049 10
TE527 Exhaust gas temp. TC B outlet NiCr/Ni 0 - 750 °C 450 30s high 40050 10050 10
TE5011A Exhaust gas temp. cylinder A1 NiCr/Ni 0 - 750 °C 530 10s 570 10s high 40051 10051 12051 10
TE5011B Exhaust gas temp. cylinder B1 NiCr/Ni 0 - 750 °C 530 10s 570 10s high 40060 10060 12060 10
TY500 Exhaust gas temperature average calculated 0 - 750 °C 40069 10
TY5017A Exhaust gas temp. deviation 01A X calculated -200 - 200 °C ±90/±50 10s ±110/±60 20s high 40070 10070 12070 10
TY5017B Exhaust gas temp. deviation 01B X calculated -200 - 200 °C ±90/±50 10s ±110/±60 20s high 40079 10079 12079 10
3(7) DMCA00018291_a.xlsx
Charge air
PT601 Charge air pressure, inlet 4-20 mA 0-6 bar 4,2 5s 7) 4,4 5s high 40091 10091 12091 100
TE601 Charge air temperature, inlet X Pt100 0-160 °C 10) 70 5s 11) 75 5s high 40092 10092 12092 10
TE601 Charge air temperature, inlet X Pt100 0-160 °C 25 5s low 10093 10
TE600 Air temp, TC inlet Pt100 -50 - 100°C 40095 10
Crankcase
TE700 Main bearing temp. 0 NiCr/Ni 0-160 °C 110 5s 120 1s 130 1s high 40101 10101 12101 11101 10
PT700 Crankcase pressure X 4-20 mA -30...30mbar 4 3s high 40112 10112 100
NS700 Oil mist detector failure NC-switch 0-1 1 3s closed 10113 1
QS700 Oil mist detector alarm & load reduction X NO-switch 0-1 1 1s 1 5s open 10114 12114 1
Miscellaneous
GS792 Turning gear position X NC-switch 0-1 1 0,1s active 10118 1
GS171 Stop lever in stop position X NO-switch 0-1 1 0,1s closed 11119 1
GT165-2 Fuel rack position 4-20 mA 0 - 50 mm 40120 10
SE518 Turbo charger speed A Mg 0-1000Hz 0 - 50000 rpm 31200 5s 31512 0,1s high 40121 10121 12121 0
SE528 Turbo charger speed B Mg 0-1000Hz 0 - 50000 rpm 31200 5s 31512 0,1s high 40122 10122 12122 0
KY870 Modbus counter calculated 1 - 1000 40125 1
STY196 Engine speed 0 - 1000 rpm 40126 1
ST196P Engine speed sensor failure primary X 0-1 1 3s active 10127 1
ST196S Engine speed sensor failure secondary X 0-1 1 3s active 10128 1
WY196-2 Torsional vibration level, peak X calculated 0 - 2 deg 1,0 10s high 40129 10129 100
GTY1624 Engine load, relative BMEP calculated -10 - 120% 102 10s 111 10s high 40130 10130 12130 10
4(7) DMCA00018291_a.xlsx
Engine status
IS872 1) Engine ready for start SW-function 0-1 1 active 10135 1
IS880 1) Engine start block active SW-function 0-1 1 active 10136 1
IB724 1) Local control mode switch 0-1 1 active 10137 1
IS875 Start failure SW-function 0-1 1 0s active 10138 1
OS7315 1) Load reduction request SW-function 0-1 1 active 10139 1
IS7602 1) Stop/shutdown switch 0-1 1 0s active 10140 1
OS7320 1) Blackout start mode switch 0-1 1 active 10142 1
OS7343 1) Engine blow switch 0-1 1 active 10143 1
Status of start blockings
OS223 / PT201 1) Engine not pre-lubricated switch 0-1 1(< 0,3 bar) 0s active 10146 1
GS792 1) Turning gear engaged switch 0-1 1 0s active 10147 1
GS171 1) Stop lever in stop position switch 0-1 1 0s active 10148 1
OS7344 1) Local selector in blocked position switch 0-1 1 0s active 10149 1
OS7312 1) Ext Sb1 from switchboard switch 0-1 1 0s active 10151 1
Status of shutdowns
STY196 Engine speed sensor failure emergency switch 0-1 1 0,1s active 10159 11159 1
IS1741/IS1742 Overspeed shutdown status from ESM switch 0-1 1 (> 115%) 0,1s active 11161 1
IS2011 Lube oil press shutdown status switch 0-1 1 0,1s 1 (< 2,0 bar) 6) active 10162 11162 1
QS701 OMD shutdown status switch 0-1 1 0,1s 1 6) active 10163 11163 1
IS7338 Big end bearing shd switch 0-1 1 0,1s 1 (> 130 °C) 6) active 10164 11164 1
IS7310 Ext Sd2 from Switchboard shutdown switch 0-1 1 0,1s 1 6) active 10167 11167 1
IS7305 Ext Sd 4 from Emg. Stop PB switch 0-1 1 0s closed 11169 1
NZ331 Slowturning failure SW-function 0-1 1 0,1s active 11170 1
NY1604 Engine speed low, run mode switch 0-1 1 1s active 11171 1
Others
NS869 WIP failure SW-function 0-1 1 3s active 10173 1
NS718 ESM alarm SW-function 0-1 1 0s active 10178 1
NS7799-1 PDM system supply earth fault SW-function 0-1 1 0,1s active 10181 1
NS7800-1 PDM system supply failure SW-function 0-1 1 0,1s active 10182 1
NB7801 System control supply failure SW-function 0-1 1 0,1s active 10183 1
NS803 Control system high temperature calculated 0-1 1 0,1s active 10184 1
NS8100 CAN failure in system SW-function 0-1 1 3s active 10185 1
5(7) DMCA00018291_a.xlsx
Liners
TE7011A Cylinder A1 liner temperature 1 NiCr/NiAl 0 - 300 °C 150 5s 160 1s 170 1s high 40186 10186 12186 11186 10
TE7011B Cylinder B1 liner temperature 1 NiCr/NiAl 0 - 300 °C 150 5s 160 1s 170 1s high 40204 10204 12204 11204 10
6(7) DMCA00018291_a.xlsx
Big End Bearings
TE7016A Big end bearing temp, cyl 01A NiCr/Ni 0 - 160 °C 110 5s 120 1s high 40224 10224 12224 10
TE7016B Big end bearing temp, cyl 01B NiCr/Ni 0 - 160 °C 110 5s 120 1s high 40233 10233 12233 10
Notes:
1) Status information, not to be treated as an alarm
2) Variable set point: 2 bar at nominal speed, 1 bar at 50% speed and below.
Linear between speeds 50% to 100%. Assumed static pressure 1 bar. Exhaust gas temp. deviation diagram (TY50*7A)
3) Variable set point: 1,6 bar at nominal speed, 0,8 bar at 50% speed and below.
Linear between speeds 50% to 100%. Assumed static pressure 1 bar. 150
4) LR activated if CV381 is off and PT291A > 0,8 bar 125
5) Alarm activated if CV381 is on and PT291A < 0,8 bar
6) Shutdown is actuated after shutdown pre-warning delay has been elapsed. 100 High -150 150 500 500
Temperature deviation [ºC]

Pre-warning delay is defined in ESM-settings. LR low A2/A7 -150 -150 -120 -120
75
7) Also activates on sensor failure LR high A2/A7 150 150 120 120
8) Only active if engine speed >= rated speed - 100 rpm 50 Alarm low A2/A7
-150 -120 -70 -70
9) TE101 low and high temp alarms to be generated in external alarm system Normal areaAlarm high A2/A7
for exhaust 150
gas 120 70 70
10) Variable set point: 100°C below 50%load, 80°C below 80% load, 25
70°C below and equal to 100% load. temperature deviation
0
11) Variable set point: 105°C below 50%load, 85°C below 80% load, 150 200 250 300 350 400 450 500 550 600
75°C below and equal to 100% load. -25 245 250 500 600
LR low -150 -110 -60 -60
-50
LR high 150 110 60 60
-75 Alarm low -150 -90 -50 -50
Alarm high 150 90 50 50
-100
Low -110 110 250 250
Alarm
-125 High -50 50 500 500
Load Red
-150 Load Reduction cyl. 2
250 ºC 500 ºC alarm Cyl. 2
Average Exhaust Gas Temperature. [ºC]
7(7) DMCA00018291_a.xlsx
GEISLINGER
DAMPER
LONG
SERVICE LIFE
Manual for GD4-Damper
1 INTRODUCTION ............................................................................................... 3
2 SAFETY INSTRUCTIONS ................................................................................... 4
3 APPLICATION OF THE PRODUCT ..................................................................... 6
4 TECHNICAL DATA ............................................................................................ 6
5 DAMPER DESCRIPTION .................................................................................... 7
6 TRANSPORT AND LIFTING INSTRUCTIONS ..................................................... 8

6.1 Transport instructions ......................................................................................... 8
6.2 Lifting tackle ...................................................................................................... 9
6.3 Tapped holes for lifting purposes...................................................................... 11
6.4 Lifting instructions ............................................................................................ 12
7 PACKAGING AND STORAGE ......................................................................... 13
8 UNPACKING ................................................................................................... 14
9 DAMPER INSTALLATION INSTRUCTIONS...................................................... 15
10 STARTING UP THE DAMPER .......................................................................... 17
11 REMOVING THE PRODUCT ............................................................................ 18
12 DISMANTLING AND ASSEMBLING THE PRODUCT ....................................... 19
13 SERVICING ...................................................................................................... 20
14 REPAIR INFORMATION .................................................................................. 22
15 OPERATING CONDITIONS.............................................................................. 23
15.1 Oil pressure ...................................................................................................... 23
15.1.1 Maximum permissible oil pressure .................................................................... 24
15.2 Oil discharge .................................................................................................... 24
15.3 Oil viscosity ...................................................................................................... 26
15.4 Permissible temperature range for VITON-seals ................................................. 26
16 DISPOSING OF USED PARTS .......................................................................... 27
17 ORDERING REPLACEMENT PARTS ................................................................ 28
18 WARRANTY.................................................................................................... 29
19 APPENDIX....................................................................................................... 29
20 GENERAL MOUNTING INSTRUCTION FOR BOLTS ........................................ 30

20.1 Cleaning the threaded parts ............................................................................. 30
20.2 Use of auxiliary materials for assembly .............................................................. 32
20.2.1 Note on Loctite products .................................................................................. 32
20.2.2 Application on threaded parts .......................................................................... 32
20.2.3 Application on washers .................................................................................... 33
20.3 Assembly ......................................................................................................... 34
20.3.1 Note on washers .............................................................................................. 34
20.3.2 Tightening process ........................................................................................... 34
20.4 After assembly ................................................................................................. 36
20.5 Re-use.............................................................................................................. 36
CONTACT INFORMATION............................................................................................. 37
1 INTRODUCTION
General information on the operating instructions
These operating instructions contain important information about the proper use of the
product and its safety. Follow these instructions carefully and precisely. This helps to reduce
the risk of damage to the product or personal injury caused by failure to follow correct
installation procedures, downtime and repair costs whilst also increasing the reliability and
service life of the product. The target group for these instructions is technicians. All jobs
described in this manual must be performed only by technically trained and qualified
personnel with the appropriate equipment.
The assembly drawings located in appendix are an important part of these

instructions. Refer to the assembly drawings whenever instructed in this manual.
All numbers in these operating instructions in brackets () refer to item numbers
which are given on the assembly drawing or on figures in this manual.
 These operating instructions are part of the product.
 Keep these instructions in a safe place for the entire life of the product.
 If the product is transferred to a new owner, these instructions and all

associated documents must be passed on to the new owner.
The meaning and appearance of safety symbols used in these operating instructions are as
follows:
The text after the signal word “WARNING!” contains

important information, which must be followed to avoid
serious personal injury or death.
WARNING!
The text after the signal word “NOTICE!” contains

NOTICE! information, which must be followed to avoid damage to the
product and systems.
2 SAFETY INSTRUCTIONS
WARNING!
 Ensure that the work area is properly ventilated or appropriate life

supporting breathing apparatus is available.
 Do not smoke or maintain open flames from torches, matches, lighters

etc. in the work area.
 Secure all loose fitting clothing, hair and jewelry before working on
rotating equipment.
 Do not attempt to install, assemble, align, or service a product on

equipment which is rotating or otherwise in operation.
 Do not attempt to install a product component which is damaged.
 Do not attempt to operate a product which has been damaged or contains

damaged components or contains parts obtained from other than
Geislinger.
 Do not heat an oil bath above the flash point of the oil.
Failure to follow these instructions may result in serious personal injury, damage
to the product and system or both.
WARNING!
ANY WORK CARRIED OUT ON AND IN CLOSE PROXIMITY TO THE SYSTEM SHALL
ONLY BE UNDERTAKEN
 by trained personnel who are familiar with the product and its use on the
product in which it is installed.
 with the system shut down and the supply of power switched off.
 in compliance with federal, state and local regulations related to

workplace safety.
 in compliance with the safety information and data provided in these

operation instructions.
 in compliance with national safety regulations and state of engineering

practice.
Failure to follow these instructions may result in serious personal injury, damage
to the product and system or both.
The following personal protective equipment is to be used for all work on and in the
immediate vicinity of the product.
Safety helmet Safety footwear Protective gloves Protective goggles

3 APPLICATION OF THE PRODUCT
This product is specifically designed for use in the designated system. Make sure that the
system into which the product will be installed is specifically approved.
The product will only function properly if it has been installed in this system according to
the instructions contained in this manual.
Installation of the product in equipment other than the

designated system may cause damage to the system and to
NOTICE! the product.
4 TECHNICAL DATA
Technical data, dimensions of the components and weights: See attached assembly
drawings and the arrangement drawings (if available).
5 DAMPER DESCRIPTION
Geislinger's vibration damper is a spring-coupled torsional vibration damper with hydraulic

damping. Radially arranged spring blades transmit the elastic torque. Torsional vibrations
are damped by oil displacement from one chamber to the adjoining one.
The spring packs (1) and intermediate pieces (2) are clamped together using a clamping
ring (3). The inner ends of the spring packs (1) reach into the axial grooves of the inner star
(9). The chambers (A, B), which are formed by the intermediate pieces (2) and the spring
packs (1), are filled with oil. If torque is applied to the damper, the outer part (1, 2, 3, 5, 7)
and the inner part (9) of the damper will be twisted against each other. The spring blades
(1) will be deflected during this process. This changes the volume of the oil in chambers A
and B. The oil will be displaced from one chamber into the adjoining one through a narrow
gap. The resultant oil flow resistance delays the relative movement of both parts of the
damper (outer and inner) and dampens the torsional vibrations.
The main bolts (750) connect the middle piece of the damper (1, 2, 3) to the flange (5) and
the side plate (7) by means of friction locking. The two plates (5,7) of the outer part of the
damper and the seals fitted in these hold the oil in the damper so that the required
working pressure can be built up. See Figure 5.1.
3
5 7
750
2
A, B Oil chambers
Figure 5.1
6 TRANSPORT AND LIFTING INSTRUCTIONS
Improper transport and lifting of the product may cause it to

fall.
The product may only be lifted and handled by personnel who

have the required licence to
WARNING!
 work with cranes
 drive industrial trucks
and are also familiar with transport and lifting instructions in
 the operating instructions

 and the assembly drawing
Supports must always be provided for overhanging

components. Failure to follow these instructions may result in
serious personal injury, property damage or both.
6.1 Transport instructions
 Only transport the product with the transport lock (if present) mounted
 Only move the product in a horizontal position.
 Do not tilt the shipping crate or pallet.
 Avoid hard impacts during transportation.
 Max. lifting speed 50 m/min.
 Do not damage the packaging and preserving agents.
6.2 Lifting tackle
Lifting tackle can break or otherwise fail when lifting the

product, particularly when it is attached to an engine, causing
it to fall.
ONLY USE HIGH-STRENGTH LIFTING TACKLE for lifting.

WARNING!
The nominal carrying capacity of a SINGLE lifting device must
be greater than the total weight of the product or the
component to be carried!
Failure to do so can result in serious personal injury, damage

to the product or both.
LIFTING TACKLE SUPPLIED WITH THE ORDER
These are loadable from all sides and have to be mounted and used in accordance with the
instructions in:
 the lifting tackle manufacturer's operating instructions

 the assembly drawing
 and the lifting examples (see Figure 6.4).
LIFTING TACKLE PROVIDED BY THE CUSTOMER

(Lifting tackle not in the scope of delivery)
Geislinger takes no warranty on lifting tackles provided by

the customer.
Lifting tackle can break or otherwise fail when lifting the

product, particularly when it is attached to an engine, causing
WARNING! it to fall.
ONLY HIGH-STRENGTH LIFTING TACKLE is permitted to lift the

product.
The nominal carrying capacity of a SINGLE lifting device must

be greater than the total weight of the product or the
component to be carried!
Failure to do so can result in serious personal injury, damage

to the product or both.
In addition, the following regulations must be observed:
 It is only permissible to use lifting tackle approved in the country where it will be
used.
 The lifting tackle must comply with the all applicable national and international
safety specifications.
 The lifting tackle must not be damaged or corroded.
 The lifting tackle must be 100% crack-tested.
 The lifting tackle must be completely screwed in the tapped lifting holes on the
product.
 The tapped lifting holes on the product must not be damaged during the screwing.
 The lifting tackle must be mounted and used in accordance with the instructions in:
 the lifting tackle manufacturer's operating instructions

 the assembly drawing
 and the lifting examples (see Figure 6.4)
For all lifting tackle: Check the lifting tackle is tight before
lifting!
If the lifting tackle is not tightened correctly the product may

WARNING! fall causing serious personal injury, property damage or both.
6.3 Tapped holes for lifting purposes
On the assembly drawing these are indicated with this symbol.
The product should only be lifted using the tapped holes

marked in this way for lifting. Lifting the product without
using the tapped holes may cause the product to fall causing
serious personal injury, property damage or both.
WARNING!
CHECKING THE TAPPED LIFTING HOLES BEFORE ASSEMBLING THE LIFTING TACKLE
Before assembling the lifting tackle check the applicable tapped lifting hole to make sure
that it is suitable to use.
The tapped lifting hole cannot be used if
 the thread is damaged, chipped, crossed or distorted

 the thread is corroded
 if there are signs of reworking such as Helicoil screw
WARNING! thread inserts
If the lifting tackle is used with any of these conditions

present the lifting tackle may fail and the product may fall
causing serious personal injury, property damage or both.
MULTI-PURPOSE TAPPED HOLES
These are tapped holes for screws used for tapped lifting holes and for other purposes.
Use:
 Remove bolt from multi-purpose tapped hole

 Fit lifting tackle as specified on the assembly drawing in appendix
 After the lifting operation has been completed, remove the lifting tackle and refit
bolt complying with the
 tightening torque
 sealing specifications
 and safety measures
as given on the assembly drawing in appendix.
6.4 Lifting instructions
Only lift the product
 Using the lifting tackle provided. See Chapter “Lifting tackle”

 With suitable carrying straps such as ropes, chains or belts.
 After lifting tackle and carrying straps have been fitted in accordance with the
regulations. See Chapter “Lifting tackle”
 Using the tapped lifting holes indicated on the assembly drawing. See Chapter
“Tapped holes for lifting purposes”
 At least two lifting points simultaneously.
 With the load distributed as equally as possible.
Never lift the product using only one connection point for the
lifting tackle. Using only one connection point can result in
NOTICE! the product breaking loose and falling resulting in property
damage.
Lifting examples
>30°
max. 30°
Figure 6.4 maximum = 45°
STANDING UNDER A SUSPENDED LOAD IS PROHIBITED!
A suspended load may suddenly break loose and fall resulting

WARNING! in serious personal injury, property damage or both.
7 PACKAGING AND STORAGE
STANDARD PACKAGING
The product parts are sealed in polythene film and all metal parts are protected against
corrosion. They are packed in crates made of soft wood or are placed on wooden pallets.
Special packaging can also be used for the products in line with the customer's
requirements.
If the packaging is damaged, the product must be
 installed in the system within 100 hours

NOTICE! or
 the preservatives must be reapplied and the packaging
restored to its original condition.
Failure to do so reduce the service life of the product.
DISPOSAL OF STANDARD PACKAGING
The PE film can be recycled.

Contact Geislinger or a Geislinger service location to request for data sheets on
packaging/special packaging. Contact data can be found on www.geislinger.com.
STORAGE INSTRUCTIONS
 Do not damage the packaging and preserving agents. See “NOTICE” above.
 Do not stack the products or place heavy parts on top of them.
 Store the product in dry conditions: max. permissible relative humidity 85%.
 Avoid variations in temperature of more than 25° Celsius.
 Make sure that the permissible temperature range for seals is adhered to during
storage. See chapter “Operating conditions” for permissible temperature range for
O-rings and seals.
If the temperature rises above or falls below the permissible

temperature range for seals during storage, it may damage
NOTICE! the seals and then subsequently reduce the service life of the
product.
8 UNPACKING
The product, product components and connecting parts may be delivered separately or
packed individually. Each package may contain separately packed tools or small
components (e.g. screws, sealing rings, lifting tackle, etc.). Do not throw these away with
the packaging.
Take the product out of the wooden crate.
Remove the packing film and rust-inhibiting paper (if provided) from the product.
Check the product for possible damage and corrosion that may have occurred during
transportation.
Fit the lifting tackle (730) (if supplied), as appropriate. Clean the surfaces underneath prior
to mounting.
 First bring the product into an upright position.


Before installation, the product may become unbalanced and

fall or roll over. Secure the product to prevent it from moving.
If the product falls or rolls over, it may cause serious personal
injury, damage to the product or both.
WARNING!
Bolts which are indicated with this symbol are only hand
tightened by Geislinger or delivered in loose condition. Bolts finally tightened by
customer according to the “Mounting instructions for bolts” given on the
assembly drawing.
9 DAMPER INSTALLATION INSTRUCTIONS
GENERAL
See Chapter “Operating conditions” for information on requirements for problem-free

operation of the damper and information on the permissible operating position of the
damper.
PREPARATION
The damper must be fully assembled.
Check the oil feed and return bores marked in the assembly drawing to make sure that
they are clean and oil can flow through. Remove any masking tape.
Remove the rust inhibitor (e.g. Anticorit) from all flange-mounting surfaces and centring
shoulders.
Do not scratch or damage the surfaces during cleaning.
NOTICE! Scratched or damaged surfaces may result that the damper

does not operate properly and subsequently reduce the
service life.
O-rings on the flanges (for oil supply and venting) must be well greased and undamaged.
INSTALLATION
Install the damper in the system in accordance with the
 installation instructions in the assembly drawing and the
 safety regulations and transport and lifting instructions contained in Chapters

“Safety instructions” and “Transport and lifting instructions” of this manual.
Do not damage the centring shoulders, seals and sealing

surfaces during the mounting operation.
NOTICE! Damaged centring shoulders, seals and sealing surfaces may

result that the damper does not operate properly and
subsequently reduce the service life.
CHECKS AFTER INSTALLATION
Remove lifting tackle and ancillary installation tools (if

present) from the damper and keep them for use later.
Failure to do so, it may cause serious personal injury, damage

WARNING! to the damper or both.
10 STARTING UP THE DAMPER
INSPECTION BEFORE STARTING UP (If possible)
Supply oil to the damper with the pre-lubrication pump until oil escapes from the oil
circulation bores. (Visual inspection)
See the assembly drawing for the position and number of oil circulation bores.
If no oil escapes from one or several oil circulation bores,

follow the troubleshooting procedures indicated in Chapter
“Repair Information”.
NOTICE!
Failure to do so may result that the damper does not operate
properly and subsequently reduce the service life.
An additional thread for connecting a pressure gauge is provided on the majority of

dampers at flange (5) or side plate (7). As a result, the oil pressure in the damper can also
be measured when the engine is not running by connecting a pressure gauge.
11 REMOVING THE PRODUCT
PRODUCT MAY BE HOT! RISK OF BURNING!
Do not switch on the pre-lubrication pump for the engine

when the product is being dismantled! (Danger: sprayed oil!)
Allow the product to cool off to room temperature before

WARNING!
removing it.
 Use a suitable container for hot oil to catch the oil remaining in the product.
Dispose of the oil in accordance with state and local regulations where the product
is serviced.
 Remove the product from the system, following the “Safety instructions” (see
Chapter 2) as well as “The transport and lifting instructions” (see Chapter 6)
indicated in the operating instructions and the assembly drawing.
 Loosen fastening screws (but do not remove).
 Attach the lifting device to the product and secure the product with the crane. (*)
 Remove the fastening screws.
 Fit the ejector screws in the jack threads of the product inner star (9) and push the
product off the crankshaft slowly, exerting even pressure.
*… If it is not possible to mount the lifting devices immediately, mount auxiliary steel rods
to pull out the product from the engine until the lifting devices can be mounted (mount
auxiliary steel rods -> remove fastening screws -> pull out product -> mount lifting devices)
Do not damage the centring shoulders, seals and sealing

surfaces during removal.
NOTICE! Damaged centring shoulders, seals and sealing surfaces may

result that the product does not operate properly and
subsequently reduce the lifetime.
 Place the product on the flange plate (5).
The product may become unbalanced and fall or roll over.

Secure the product to prevent it from moving. If the product
falls or rolls over, it may cause serious personal injury,
damage to the product or both.
WARNING!
12 DISMANTLING AND ASSEMBLING THE PRODUCT
 Position product on the flange (5)
 Contact Geislinger or a Geislinger service location for a service date. See list
www.geislinger.com or appendix.
Do not loosen the main bolts (750) of the product, because

thereby the concentricity setting of the outer part will be lost.
NOTICE! Disassembly of the product requires the use of special

apparatus and the associated knowledge. A further
disassembly and assembly is permitted only by Geislinger or a
Geislinger service location. See list www.geislinger.com or
appendix.
Failure to do so may result that the product does not operate

13 SERVICING
The damper is to be given a comprehensive service in accordance with the stated servicing
frequencies and servicing instructions.
SERVICING INTERVALS AND INSTRUCTIONS

Intervals in hours worked during normal operation
SPEED RANGE OF THE DAMPER

300 – 999 rpm ≥ 1000 rpm
SERVICE TIME SERVICE TIME
SMALL LARGE SMALL LARGE
all all all all
WORK TO BE PERFORMED
15-18,000 30-36,000 10-12,000 20-24,000
Remove the damper from the system X X X X
* Separate the inner part of the damper
from the outer part. Don´t dismantle the X X
damper middle piece 1,2,3.
* Separate the inner part of the damper
from the outer part. Dismantle the damper X X
middle piece 1,2,3.
* Clean all parts, especially the oil supply
X X X X
and oil circulation bores with acetone.
* Replace all rubber seals that can be
X X X X
accessed #
* Replace disc springs and/or lock washers X X X X
* Replace all removed bolts, screws and nuts
X X X X
with thread size up to and including M20
* Check all removed bolts, screws and nuts
X X X X
with thread size larger than M20.
* Check permissible wear. Repair worn parts
X X X X
or replace them, if necessary
* Service or replace all spring packs (1). If
X X
wear is over the limit.
* Service or replace inner star (9). If wear is
X X
over the limit.
Dispose of worn parts. See Chapter
“Disposing of used parts” X X X X
*... The product may only be dismantled by Geislinger or a Geislinger service location. See list
www.geislinger.com or appendix.
#... All rubber seals have to be replaced at least 6 years after the start of operation.
If permissible wear between servicing intervals has been
exceeded by more than 50%, subsequent servicing intervals
are to be shortened accordingly. For this, it is assumed that
NOTICE! wear is at a linear rate.
Servicing frequencies also depend on the specific conditions of

use in each case.
LUBRICATING OIL QUALITY
 The quality of the lubricating oil should be checked at regular intervals
If the quality of the lubricating oil does not match the

specification by the engine manufacturer or if it contains too
NOTICE! much water, it may damage the product.
14 REPAIR INFORMATION
INSPECTED CONDITION CORRECTIVE MEASURE
No oil is escaping from the oil circulation Contact Geislinger or Geislinger service
bores when hydraulic oil is supplied by the location. See list www.geislinger.com or
pre-lubrication pump. appendix.
Seals “sweat” (oil loss less than 0.5 litre of oil
No effect on the function of the damper;
per day) during operation; no repair required.
Seals leaking (oil loss more than 0.5 litre of Damper within crankcase:
oil per day); No effect on the function of as long as
minimum required oil pressure is kept
within the damper
Damper outside crankcase:
Contact Geislinger or Geislinger service
location. See list www.geislinger.com or
appendix.
Traces of oil in a radial position on the flange Contact Geislinger or Geislinger service
or side plate; main bolts (750) leaking. location. See list www.geislinger.com or
appendix.
Bronze particles in oil detected No influence on the function of the
damper;
If the quality of the oil does not match the Drain product completely (for products
specification by the engine manufacturer or without permanent oil flushing). Fill
higher water content in the engine oil than product with fresh oil and drain it again;
permitted by the engine manufacturer. repeat flushing process several times.
No damage to engine bearings.
If the quality of the oil does not match the Contact Geislinger or Geislinger service
specification by the engine manufacturer or location. See list www.geislinger.com or
higher water content in the engine oil than appendix.
permitted by the engine manufacturer.
Bearing positions in engine already damaged
as a result of this.
If other damage or wear to the product is identified but not described in this table, contact
Geislinger or a Geislinger service location to identify the appropriate corrective measure.
See list www.geislinger.com or appendix.
15 OPERATING CONDITIONS
Everything specified in the operating instructions applies to standard applications. If in

doubt, discuss with Geislinger or a Geislinger service location. See list www.geislinger.com
All values given for the damper's oil supply apply to the position before the oil enters the
damper. (Connection of damper to the customer's unit.)
If the operating conditions listed below do not appear in either the assembly
drawing or the operating instructions, please discuss with Geislinger. See list
www.geislinger.com
OPERATING POSITION OR ALIGNMENT OF THE DAMPER
The damper must be installed so, that in its normal operating position, the rotating shaft of
the damper is in a horizontal axis position.
Operation of the damper in a certain tilted position for a

longer period is not permissible. Short-term displacements (for
example due to ship or vehicle movements) are permissible.
NOTICE!
Failure to do so may result that the damper does not operate
15.1 Oil pressure
To ensure the hydrodynamic oil damping, the damper must be supplied with the correct
and specified minimum required oil pressure. The minimum required oil pressure is given in
the torsional vibration calculation of the damper.
Responsibility of engine manufacturer:
 Design of oil supply to produce at least the minimum required oil pressure in the
damper
 To supply the maximum oil discharge
 To provide a constant pressure

Neither the engine oil pumps nor the oil supply system is
designed and delivered by Geislinger. It is therefore in the
responsibility of the engine manufacturer to ensure that the oil
NOTICE! supply system is designed in a way that the minimum required
oil pressure is available in the damper.
If the minimum required oil pressure is not obtained, please

contact Geislinger or a Geislinger service location. See list
www.geislinger.com.
Failure to do so may affect the performance of the damper.
15.1.1 Maximum permissible oil pressure
The maximum permissible oil supply pressure is 6 bar absolute. If the supply pressure is
higher than specified, please contact Geislinger. See list www.geislinger.com
15.2 Oil discharge
The mean value of the expected amount of oil discharge through the damper (liter/min) is
specified on the assembly drawing.
The quantity of oil discharge is dependent on:
 oil viscosity (if the oil flows through bearing gaps)

 pressure difference
 flow cross-sections
Due to tolerances and other effects, deviations of up to ±50% from the mean value can
occur.
If the estimated values have to be defined more exactly, oil discharge

measurements have to be made under dynamic conditions. Please contact
Geislinger. See list www.geislinger.com
In case the oil flows through drillings for converting the oil quantity for values other than
those specified on the assembly drawing, the following formula applies:
P2
Q2 = Q1 x
P1
Q1 = amount of oil according to specification on the assembly drawing

Q2 = newly calculated amount of oil at changed pressure and viscosity values.
P1 = pressure difference (specification on the assembly drawing minus 1 bar).
P2 = new pressure difference value.
In case the oil flows through bearing gaps the following formula applies:
P2 V1
Q2 = Q1 x x
P1 V2
Q1 = amount of oil according to specification on the assembly drawing

Q2 = newly calculated amount of oil at changed pressure and viscosity values.
P1 = pressure difference (specification on the assembly drawing minus 1 bar).
P2 = new pressure difference value.
V1 = viscosity according to specification on the assembly drawing.
V2 = new viscosity value.
15.3 Oil viscosity
The specified value applies to the position of the damper oil inlet. For the value specified,
see the assembly drawing (technical data field: viscosity) or obtain it from Geislinger. If
Geislinger has not been provided with any data at the time of design, the calculation is
based on usual figures for the industry.
If the oil viscosity falls below or raises above the specified

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

transport and storage:
from (minimum) to (maximum)
- 20° C (- 4° F) + 120° C (+ 248° F)
Permissible temperature range before start-up and

during operation:
from (minimum) to (maximum)
- 10° C (+ 14° F) + 120° C (+ 248° F)
The exceeding respectively the dropping below of the

NOTICE! permissible temperature ranges may damage the seals and
then subsequently damage the product and the system.
16 DISPOSING OF USED PARTS
After withdrawing the product from service or after replacing individual components:
 All metal parts can be recycled (scrap metal).
 Oil still in the product or remaining oil must be disposed of as used oil.
 All old seals (O-rings, etc.) must be disposed of as oily consumables (special waste).
National and local regulations must always be observed when disposing of the
product or parts thereof.
17 ORDERING REPLACEMENT PARTS
Use only original Geislinger replacement parts.
NOTICE! Failure to do so may cause serious damage of the product and

void the warranty.
Please provide the following information so that the product can be accurately identified if
enquiries are sent:
 Type designation of product ( See the stamped designation on the outer part or
type plate which is mounted on the product)
 Product serial number ( See type plate)
 Part number of the replacement part ( See assembly drawing/parts list)
 Quantity of the parts required
 Designation of the part
Example
Designation: C 80/17.5/62H/10 or D 280/26/V/M
Serial number: 10106273/2/10
Part number of the replacement part: 850
Quantity of the parts: 2
Designation of the part: O-ring

18 WARRANTY
See:
 Geislinger document GS 442 (AGB) (will be send by Geislinger on request)
 or customer-contract
 or order confirmation
19 APPENDIX
These operating instructions contain the following supplements:
 General assembly instructions for screws and screw/nut connection
 Installation declaration (inside European Union)
 Assembly drawing(s) with parts list
 List of Geislinger service locations
 Code book number coding (optional)
 Operating instructions for bought-in parts (optional)

20 GENERAL MOUNTING INSTRUCTION FOR BOLTS
These instructions are intended to supplement the “Mounting instruction for

bolts” given on the assembly drawing.
20.1 Cleaning the threaded parts
Before handling the threaded parts using the assembly tools, the contact surfaces must be
cleaned carefully and thoroughly.
These include the contact surfaces:
 the bolts on the head contact surface and on the thread (see Figure 1.1)
 the nuts (if present) on both contact surfaces and on the thread (see Figure 1.2)
 both sides of the washers (see Figure 1.3)
 the threaded holes (if present) of the counter piece (see Figure 1.4)
 and the contact surfaces on the parts being connected (see Figure 1.5)
Figure 1.1 Figure 1.2 Figure 1.3
Figure 1.4 Figure 1.5

Oxide layers
If the contact surfaces have oxidised, first carefully remove the oxide layers mechanically,
for example using a wire brush.
Dirt and grease
After removing the oxide layers (if present), all contact surfaces must be cleaned and
degreased thoroughly. Isoparaffin or acetone can be used as agents for cleaning and
degreasing.
Do not touch decreased and cleaned contact surfaces

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

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

must be dried thoroughly!
NOTICE!
20.2.1 Note on Loctite products
Loctite products must always be used within the processing time specified by Loctite. These
processing times can be found in the instructions for the used Loctite products. Do not
exceed the maximum processing times permitted! Try and keep the processing times as
short as possible.
Read first! Relevant Loctite manual!
20.2.2 Application on threaded parts
Before applying the auxiliary materials, the load-bearing thread length "X" (see figure 1.6)
must be calculated for the parts being connected together. This thread length must then
be wetted with the auxiliary material across the entire area. In terms of the quantity, use
only so much that only small quantities of excess auxiliary material overflow after assembly.
A test assembly is recommended to be able to estimate the amount required.
Figure 1.6
With sealing unions in particular, ensure that the threaded gap is completely filled with
sealant. For thread size M16 and over (see Figure 1.7), the threaded hole or the nut thread
must also be coated with the auxiliary material.
up to M14 over M16

X X X
X
+ or
X = load-bearing thread length
Figure 1.7
20.2.3 Application on washers
When using washers, apply to both the front and the back (see green triangles on figures
1.8). In terms of quantity, use only so much that the contact surface is completely covered
and only small quantities of excess auxiliary material overflow after assembly. A test
assembly is recommended to be able to estimate the amount required.
Example of a single-bolt connection
Example of a bolt/nut connection
Figures 1.8
20.3 Assembly
The bolts must be tightened according to the “Mounting instruction for bolts” given on
the assembly drawing.
20.3.1 Note on washers
Disc springs and sometimes wedge lock washers are normally only used as washers for bolt
locking. These must be assembled as follows (see figures 1.9 and 1.10.)
Disc spring usage Wedge lock washer usage
Figure 1.9 Figure 1.10
20.3.2 Tightening process
The bolts must be tightened crosswise, i.e. opposite pairs of bolts must be tightened
immediately after one another. The assembly must always be carried out according to the
same procedure, as described in the example below for a twelve-point division.
The torque values, the tightening of the bolt and the application area for the auxiliary
materials are described in the “Mounting instruction for bolts” on the assembly drawing.
TWELVE DIVISION EXAMPLE
 Mark bolts 1-4

 Pre-assemble bolts 1-4 without Loctite but apply grease on the threads (as
stated on the assembly drawing) to approx. 30% of the torque value given on the
assembly drawing and in the order given in figure 1.11.
Given torque values on assembly drawing:
Case A: Only tightening torque: Tighten the bolts 1-4 to approx. 30% of the given
tightening torque value.
Case B: Initial tightening torque + twist angle: Tighten the bolts 1-4 with the given
initial tightening torque plus approx. 30% of the given twist angle.
1
12 5
8 9
4 3
10 7
6 11
2
Figure 1.11
 Final assembly of bolts 5-12 according to the “Mounting instructions for bolts” on
the assembly drawing and in the order given in figure 1.12.
1
12 5
8 9
4 3
10 7
6 11
2
Figure 1.12
 Remove bolts 1-4
 Final assembly of bolts 1-4 according to the “Mounting instructions for bolts” on
the assembly drawing and in the order given in figure 1.13.
1
12 5
8 9
4 3
10 7
6 11
2
Figure 1.13
20.4 After assembly
Immediately after the bolt assembly is complete, the excess residue of the auxiliary
materials (especially Loctite residue) must be removed.
20.5 Re-use
If bolt connections secured or sealed using Loctite are unfastened, any old Loctite reside
remaining on the bolts must be completely removed mechanically, for example using a
wire brush. With threaded connections and internal threads (e.g. with nuts), old Loctite
residue must also be removed completely.
All washers from unfastened bolt connections must be

replaced by new washers.
NOTICE!
Afterwards, all parts must be prepared for re-assembly (see chapter “General mounting
instruction for bolts”).
CONTACT INFORMATION
Geislinger Coupling Geislinger Silenco®
Geislinger Carbotorq® Geislinger Damper
Geislinger Monitoring
Geislinger Flexlink Geislinger Vdamp®
Geislinger Gesilco® Geislinger Gesilco® Shaft
Geislinger GmbH, Hallwanger Landesstrasse 3, 5300 Hallwang/Salzburg, Austria, Tel. +43 662 669 99-0, Fax +43 662 669 99-40, info@geislinger.com
geislinger.com
Status: Approved Confidential Document id: DBAE990763 - Page 1 (1)
Status: Approved Confidential Document id: WDAAA160525 l Page 1 (42)
Product Manual 36637

(Revision J, 7/2016)
Original Instructions
PG-EG
Integral EG Actuator for PG Governors
Installation and Operation Manual

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.
General
Precautions Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
Revisions the publications page of the Woodward website:
www.woodward.com/publications
The latest version of most publications is available on the publications page. If

your publication is not there, please contact your customer service representative
to get the latest copy.
Any unauthorized modifications to or use of this equipment outside its specified

mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
Proper Use modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
If the cover of this publication states "Translation of the Original Instructions"

please note:
The original source of this publication may have been updated since this
Translated translation was made. Be sure to check manual 26455, Customer Publication
Publications Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 36637
Copyright © Woodward, Inc. 1995–2016
All Rights Reserved
Manual 36637 PG-EG Integral EG Actuator for PG Governors
Contents
REGULATORY COMPLIANCE ........................................................................III

WARNINGS AND NOTICES ............................................................................III
ELECTROSTATIC DISCHARGE AWARENESS .................................................. V
CHAPTER 1. GENERAL INFORMATION ........................................................... 1
Introduction .............................................................................................................1
Description ..............................................................................................................1
Reverse or Direct Acting.........................................................................................1
Vibration Resistance...............................................................................................1
CHAPTER 2. INSTALLATION.......................................................................... 7
Introduction .............................................................................................................7
Initial Operation ......................................................................................................7
Receiving ................................................................................................................7
Storage ...................................................................................................................8
Mounting Requirements .........................................................................................8
Linkage ...................................................................................................................8
Electrical and Hydraulic Connections .....................................................................9
Clearances ...........................................................................................................10
Governor Oil .........................................................................................................11
Oil Problems .........................................................................................................11
Governor Oil Service ............................................................................................12
Cleaning the PG-EG Actuator Oil Filter ................................................................13
CHAPTER 3. PRINCIPLES OF OPERATION ................................................... 14
Flapper Nozzle System ........................................................................................14
Torque-motor System ...........................................................................................14
Direct and Reverse Acting ....................................................................................15
CHAPTER 4. OPERATION AND ADJUSTMENTS ............................................. 19
Introduction ...........................................................................................................19
Centering Adjustment ...........................................................................................19
Adjustment of the Anti-rotation Device .................................................................20
Mode Select Valve and Mode Indicating Switch ..................................................20
Parts List for Figure 4-1 ........................................................................................21
Maintenance .........................................................................................................25
Applications ..........................................................................................................25
CHAPTER 5. PRODUCT SUPPORT AND SERVICE OPTIONS ........................... 27
Product Support Options ......................................................................................27
Product Service Options .......................................................................................27
Returning Equipment for Repair ...........................................................................28
Replacement Parts ...............................................................................................28
Engineering Services............................................................................................29
Contacting Woodward’s Support Organization ....................................................29
Technical Assistance ............................................................................................30
REVISION HISTORY .................................................................................... 31
DECLARATIONS ......................................................................................... 32
Woodward i
PG-EG Integral EG Actuator for PG Governors Manual 36637
Illustrations and Tables
Figure 1-1. PG-EG Actuator Connections ..............................................................2

Figure 1-2. PGA/PGG-EG Governor Connections (Without Mode Select Block) ..3
Figure 1-3. PGA/PGG-EG Governor Connections (With Mode Select Block) .......4
Figure 1-4. PG-EG 200 Actuator Connections .......................................................5
Figure 1-5. PGA-EG/PGG-EG 200 With and Without Mode Select Block .............6
Figure 2-1. Governor Travel ...................................................................................9
Figure 3-1. Schematic of Pilot Valve and Pressure Regulator Section ................13
Figure 3-2. PG-EG Schematic, without Mode Select Valve .................................15
Figure 3-3. PG-EG Schematic, with Mode Select Valve, Controlling on PG .......16
Figure 3-4. PG-EG Schematic, with Mode Select Valve, Controlling on EG .......17
Figure 3-5. EG Actuator Schematic, No Ballhead Backup ...................................18
Figure 4-1. Torque Motor Exploded View .............................................................21
Figure 4-2. Mode Select Block Exploded View ....................................................22
Figure 4-3. Assembly and Tubing Exploded View................................................26
ii Woodward
Regulatory Compliance
Other European Compliance:
Compliance with the following European Directives or standards does not qualify
this product for application of the CE Marking:
Machinery Directive: Compliant as partly completed machinery with

Directive 2006/42/EC of the European Parliament
and the Council of 17 May 2006 on machinery.
Special Conditions for Safe Use:

Field wiring must be suitable for at least 95 °C.
Compliance with the Machinery Directive 2006/42/EC noise measurement and

mitigation requirements is the responsibility of the manufacturer of the machinery
into which this product is incorporated.
Warnings and Notices

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

equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
Overspeed / loss of life, or property damage.
Overtemperature / The overspeed shutdown device must be totally independent of the
Overpressure prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
Woodward iii
The products described in this publication may present risks that

could lead to personal injury, loss of life, or property damage. Always
wear the appropriate personal protective equipment (PPE) for the job
Personal Protective at hand. Equipment that should be considered includes but is not
limited to:
Equipment
 Eye Protection
 Hearing Protection
 Hard Hat
 Gloves
 Safety Boots
 Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
Start-up property damage.
On- and off-highway Mobile Applications: Unless Woodward's control

functions as the supervisory control, customer should install a
system totally independent of the prime mover control system that
Automotive monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
Applications
control with possible personal injury, loss of life, or property damage.
To prevent damage to a control system that uses an alternator or

battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Battery Charging
Device
iv Woodward
Electrostatic Discharge Awareness

Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
 Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
Electrostatic contact while handling the control).
Precautions  Avoid all plastic, vinyl, and Styrofoam (except antistatic versions)
around printed circuit boards.
 Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
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.
Follow these precautions when working with or near the control.

1. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
 Do not touch any part of the PCB except the edges.
 Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
 When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
Woodward v
Chapter 1.
General Information
Introduction
This manual contains information about the Woodward Integral EG Actuator for
PG governors as an add-on unit:
 to form the PG-EG actuator (no ballhead) or
 to create a ballhead backup governor (PGA-EG or PGG-EG) from the PGA
or PGG governor.
In this manual, PG-EG refers to any of these three governor types.
This manual covers the EG, governor components affected by the EG, and
information pertaining to the PG-EG. For more general governor information,
refer to the PGA governor manual (36604) or the PGG governor manual (36627).
Description
The EG is an electro-hydraulically controlled actuator that accepts a (0 to 200)
mA signal, and outputs on a standard PG servo proportional to the mA signal.
Reverse or Direct Acting

The actuator is available for use with either direct- or reverse-acting electronic
controls. Direct-acting units assume an increasing fuel as the current level
increases. Reverse-acting units assume a decreasing fuel position as the current
level increases.
Reverse-acting EG actuators are normally used on ballhead governors to provide

an automatic ballhead back-up in case the electrical control signal is lost or
interrupted.
Direct-acting EG actuators will cause shutdown if the electrical current to the

actuator is lost or interrupted.
Direct-Acting Reverse-Acting
Fuel Rack Position (0.050 to 0.950) inches TR (0.050 to 0.950) inches TR
Control Current (20 to 160) mA (160 to 20) mA
Vibration Resistance
The EG actuator is in itself resistant against vibration due to the torque motor
beam being mass-stabilized in all three axes. As a consequence, vibrations have
minimal influence on the position of the beam.
Woodward 1
Figure 1-1. PG-EG Actuator Connections
2 Woodward
Figure 1-2. PGA/PGG-EG Governor Connections (Without Mode Select Block)
Woodward 3
Figure 1-3. PGA/PGG-EG Governor Connections (With Mode Select Block)
4 Woodward
Figure 1-4. PG-EG 200 Actuator Connections
Woodward 5
Figure 1-5. PGA-EG/PGG-EG 200 With and Without Mode Select Block
6 Woodward
Chapter 2.
Installation
Introduction
This chapter describes receiving, storage, and installation requirements for the
actuator.
Due to typical noise levels in turbine or engine environments,

hearing protection should be worn when working on or around the
actuator.
The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
Use of a predicted minimum fuel shutdown procedure is highly

recommended. Failure to comply with this recommendation can
cause personal injury and/or property damage.
Use care while handling and installing the actuator. Be particularly

careful to avoid striking the drive shaft, terminal shaft, or the
electrical connector. Abuse can damage seals, internal parts, and
factory adjustments. Do not set the actuator on its drive shaft.
External fire protection is not provided in the scope of this product. It

is the responsibility of the user to satisfy any applicable
requirements for their system.
Initial Operation
Before initial operation of the engine equipped with this actuator, read
all of this installation chapter. Make sure that all installation steps have
been correctly accomplished and all linkages are secured and properly
attached. Carefully review the direction of rotation for the actuator oil
pump.
Receiving
Your PG governor is shipped from the factory bolted to a wooden platform in a
vertical position. After being tested at the factory, the governor is drained of oil.
This leaves a light film of oil covering the internal parts, preventing rust. No
internal cleaning is required.
Use care in handling the governor. Be particularly careful to avoid

striking the drive shaft. Do not drop or rest the governor on its drive
shaft. Such treatment could damage the gears and bearings in the
governor oil pump.
Woodward 7

Most PG governors lift from an eye-bolt threaded into a 0.375-16 (inch) hole in
the center of the cover. PG-200, PG-300, and PG-500 governors must be lifted
with a sling. Some PG governors have split covers which need to be lifted with a
sling as well.
Storage
The governor may be stored for up to a year as received from the factory. Store
the governor in a vertical position. Fill completely with oil if extended storage is
necessary.
Mounting Requirements
A gasket must be used between the governor and the accessory mounting pad.
A 0.81 mm (0.032 inch) thick gasket is recommended for this purpose. The
gasket is used to absorb imperfections between the governor base and the
mounting pad, and to avoid oil leakage between the governor and the drive
portion of the engine.
Install the governor square on the accessory pad, using the correct length of
coupling between the governor and the drive. Make sure the driveshaft does not
bind, and that there is no excessive side load on the driveshaft assembly. Make
sure the coupling is tight, and do not use force when installing the drive shaft into
the coupling. The governor must be installed in a vertical position.
A rough or non-concentric drive can prevent smooth governor operation and

shorten governor life. The drive should be as smooth as possible. Poor drive
dynamics can damage governor seals and bearings.
Rotation direction is factory set for some governors. Damage will

result if the governor is installed on a drive which rotates in the
wrong direction. Specifications for individual governors indicate if
the unit has been plugged to limit rotation to one direction only.
Many PG governors are equipped with check valves in the pump,
allowing rotation in both clockwise and counterclockwise directions.
Linkage
Align the linkage from the governor to the fuel pumps or valves to eliminate
binding and excessive backlash. The relationship of governor/terminal shaft
angular position to the fuel control position must be adjusted in accordance with
the engine manufacturer's specifications. The linkage must not limit the
governor's ability to call for maximum fuel or to shut down the engine.
Linkage must not give during major transients and must not be so heavy that it
hinders accurate governor response. Linkage must be designed to resist wear.
Linkage is responsible for many apparent “governor problems”, and proper

design and installation of the linkage between the governor output and the
engine is extremely important.
8 Woodward

The fuel-control linkage must be adjusted so at least 15 % of the governor travel
(output) from minimum position has been used when the fuel control is at idle no-
load (A and D; see Figure 2-1). This minimum setting is required due to the
location of the compensation cut-off port (if so equipped).
Use as much of the governor output travel as possible. Stability is greatly

improved with the use of maximum governor travel. Design linkage so governor
output and resultant power output of the engine are nearly linear.
Figure 2-1. Governor Travel
Electrical and Hydraulic Connections

Make the pneumatic (if applicable), hydraulic, and electrical connections required
for the particular governor. Refer to Figures 1-1 through 1-3 for the PG-EG 58
governor and Figures 1-4 and 1-5 for the PG-EG 200 governor.
Most governors are equipped with an oil spray to reduce or prevent vibration-
induced damage to the torque-motor assembly.
All governors have hydraulic connections for a booster. For information regarding
selecting the correct booster type, refer to Manual 36684.
When connecting a start booster to the governor, at least two lines are required:
 Oil to booster inlet, which takes oil from the governor sump to the
booster inlet
 Oil from booster outlet #1, which takes oil from the booster outlet #1 to
the accumulator system of the governor. By supplying oil under pressure
during starting from the booster into the accumulator, the governor
should distribute the oil internally without any delay.
In most cases there should be no need to connect other lines between the
booster and the actuator or governor.
On a PG-EG 58 actuator no other connections are possible. On the PG-EG 200

actuator and PGA-EG/PGG-EG 200 governors, it is possible to connect a second
Woodward 9

line (oil from booster outlet #3) to the first stage relay piston to assist opening up
the output servo of the governor.
On PGA-EG/PGG-EG 58 governors and PGA-EG/PGG-EG 200 governors, there

is also an option to connect a line (oil from booster outlet #2) to the speed setting
servo. Again, under most conditions, the speed setting will be receiving oil under
pressure directly from the accumulators. Under some conditions a better starting
performance may be obtained by connecting this line.
Table 1-1. Overview of Available Connections
OIL TO OIL FROM OIL FROM OIL FROM

MODEL FIGURE BOOSTER BOOSTER BOOSTER BOOSTER
INLET OUTLET #1 OUTLET #2 OUTLET #3
PG-EG 58 1-1 Always Always Not present Not present

PGA-EG 58 no MSB
1-2 Always Always Optional Not present
PGG-EG 58 no MSB
PGA-EG 58 w/MSB
1-3 Always Always Optional Not present
PGG-EG 58 w/MSB
PG-EG 200 1-4 Always Always Not present Optional
PGA-EG 200 no MSB
PGG-EG 200 no MSB
1-5 Always Always Optional Optional
PGA-EG 200 w/MSB
PGG-EG 200 w/MSB
All governors have hydraulic connections for a heat exchanger which allows oil to
be circulated to an external cooler to ensure that the governor oil temperature
remains between 71 °C and 93 °C (160 °F and 200 °F) under all operating
conditions. In case a heat exchanger is used on a governor also equipped with
an oil spray, extra attention is required. Since the spray tube is located at the
same height as the oil-to-cooler connection on the governor’s power case, these
two connections are hydraulically linked. This means that the oil spray will no
longer function when combined with a cooler, since the oil will follow the path
with the least resistance. In order to prevent this, we recommend adding an
orifice to the oil-to-cooler line exactly where it leaves the power case to ensure
enough flow of oil is going to the oil spray.
Standard electrical connections are made to the four-pin connector on the side of
the column (see figures). Optionally, the EG actuator may be wired to the
connector on the receiver bracket through an internal mounting bracket.
Instead of a connector, the governor may be equipped with a flying lead, leaving
the governor on the side of the column. This option is used mostly on governors
in a high-vibration environment.
Clearances
Leave adequate clearance to connect the linkage, to fill the governor with oil, and
to remove the cover (if necessary).
10 Woodward
Governor Oil
Governor oil must have lubricating and hydraulic properties. The oil must have a
viscosity index that allows it to perform over the operating temperature range of
the governor. The oil must have additives that allow it to remain stable and
predictable over the operating temperature range of the governor. The oil used in
the governor must be compatible with the nitrile, polyacrylic, and fluorocarbon
seals used in the governor.
Many oils and synthetic lubricating fluids used in the engines controlled by PG
governors meet these specifications. When possible use the same grade and
weight of oil used in the engine. Information in this manual is intended to be used
only in the selection of the governor lubricating oil, not for selecting engine lube
oil. USE ONLY NEW, CLEAN OIL. DO NOT USE USED ENGINE OIL IN THE
GOVERNOR.
Woodward governors and actuators are designed to give stable operation with
oils which provide 50 to 3000 SUS (Saybolt Universal Seconds) of viscosity
throughout the operating temperature range. Ideally the viscosity at the normal
operating temperature should be between 100 and 300 SUS. Poor governor
response or instability is often an indication that the oil being used is too thick or
too thin.
For more detailed information on the choice of governor oil, refer to manual
25071, Oils for Hydraulic Controls.
The recommended oil temperature for continuous governor operation is

(60 to 93) °C / (140 to 200) °F. Measure the oil temperature of the governor or
actuator on the outside lower part of the power case. The actual oil temperature
will be about 6 °C (10 °F) higher. The governor is designed to operate in ambient
temperatures of (29 to 93) °C / (20 to 200) °F.
Oil Problems
A filter is located between the oil pump and the control pilot valve of the EG
actuator. Should this filter become clogged, it can seriously hinder the ability of
the actuator to control, even on the mechanical ballhead side. Take extra care
with the PG to be sure that oil is clean and that it does not deteriorate due to
heat.
Excessive component wear or seizure in a governor indicates the possibility of

insufficient lubrication caused by:
 An oil that flows slowly when it's cold or at start-up;
 High or low governor oil level;
 Restrictions in oil lines to boosters or heat exchangers;
 Contaminated oil (usually caused by dirty oil containers used when
transferring oil to the governor);
 A governor exposed to heating and cooling cycles, creating condensation of
water in the oil;
 Oil not suitable for the operating conditions.
Operating a governor continuously beyond the high-limit temperature of the oil

will result in oil oxidation. This is identified by varnish or sludge deposits on
governor parts. To reduce oil oxidation, lower the oil operating temperature with a
heat exchanger or other means, or change to an oil more oxidation resistant at
the operating temperature.
Woodward 11

PG-governors operating with internal oil-pressures in excess of 1655 kPa
(240 psi) often require a heat exchanger to protect the oil from damage.
Many governor problems are the result of improper selection or

improper maintenance of governor oil. The governor should be
serviced on a routine schedule. Develop the schedule with
consideration to the governor operating temperature and the
cleanliness of the atmosphere in which the governor operates.
A loss of stable governor control and possible engine overspeed

may result if oil viscosity exceeds the 50 to 3000 SUS range.
Governor Oil Service

Replace the governor oil if it is contaminated or if it is suspected of causing
governor problems. Drain the oil while it is still hot and agitated. Flush the
governor with kerosene or an equivalent solvent. If drain time is insufficient for
the solvent to completely drain or evaporate, flush with the same grade and
weight of oil which will be used to refill the governor. Discard the oil used to flush
out the solvent.
To avoid contamination of the governor, the replacement oil must be free of dirt,
water, or other foreign material. Use clean containers to store and transfer oil.
Refer persistent or recurring oil problems to an oil specialist.
After the oil is selected, fill the governor with new, clean oil, in the volumes listed
here: Type 12/29/58 (1.4 L / 1.5 qt), Type 200/300 (6.2 L / 6.5 qt), Type 500
(6.6 L / 7.0 qt).
While the engine is not running, fill the governor to the maximum level indication.
During normal operation, this level should not drop below the minimum level. Do
not add oil when operating the governor.
PG-EG 200, 300, and 500 cases must be filled in two stages. Fill with about
4 liters/quarts before starting, then add the amount needed to bring the oil up to
operating levels after start-up. On these governors, there is an oil level dipstick
inside the fill port cap. On newer types, a small sight gauge glass has been
added onto the terminal shaft housing. Always use the dipstick for accurate oil
level readings. All other PG-EGs have an oil filler cup in the cover and a special
long oil gauge glass on the power case.
To prevent contamination of the flapper nozzle system, an oil filter has been fitted
to the oil feed line going to the EG actuator. Check this filter every time the oil is
changed, and clean if necessary.
12 Woodward
Figure 3-1. Schematic of Pilot Valve and Pressure Regulator Section
Cleaning the PG-EG Actuator Oil Filter

Clean the filter after it has been dis-assembled from the manifold block on the
side of the actuator.
Use white spirit or another oil-based cleaning fluid to wash backward, against the
normal flow direction onto a filter cloth or similar. Do not use sharp tools to probe
into the filter. Debris content should come out leading a flow of cleaning fluid thru
the filter. Use a soft brush to help the particles get loose from the mesh surface.
Inspect the content of the filter. Normal wear of the PG-EG actuator should
produce very few particles, so if you find a lot of debris you should investigate its
origin. Make sure the cans used to add oil are clean (no dust, no water, no other
oil remains).
If a filter is very dirty and cannot be cleaned it should be replaced by a new filter:
Woodward number 3005-533.
If, over time, filters continue to be very dirty, consider reducing the time between
cleaning. Clogged filter can seriously reduce the flow of oil to the EG-actuator,
thus making it very difficult to maintain its dynamic behavior.
Woodward 13
Chapter 3.
Principles of Operation
Flapper Nozzle System

The flapper nozzle system is basically a hydraulic amplifier which converts the
torque motor beam position through the pilot valve into a servo position. Pump
pressure oil is supplied to the interior of the pilot valve and lowered by the
pressure regulating valve into the regulated pressure at 690 kPa (100 psi). This
flow of 690 kPa oil is then directed onto the bottom of the control land and
through a dropping orifice (giving the pilot valve control pressure) to the top of the
same control land but with a larger surface. At the same time, pilot valve control
pressure oil is directed through a nozzle and sprays onto the bottom of the torque
motor beam (acting as the flapper).
The balance of these hydraulic pressures and forces positions the pilot valve in
the bushing and causes the pilot valve to follow the position of the torque motor
beam. To center the pilot valve in the bushing in steady state, the gap between
the flapper (the torque motor beam) and the nozzle is adjustable by means of the
center adjustment.
The control land of the pilot valve, balanced between the regulated pressure
below and the pilot valve control pressure above, provides a hydraulic
amplification of the position of the torque-motor beam. This permits accurate
positioning of the plunger in the bushing without having the bushing rotate to
eliminate static friction as is necessary in the mechanical pilot valve system.
Torque-motor System
The torque-motor system consists of an electromagnetic coil and a beam. On top
of the beam, an armature is mounted which is placed into the electromagnetic
field of the coil. The beam itself is suspended by a torsion spring, allowing a
small degree of rotation of the beam around the center of the torsion spring but
no translations.
The torque-motor beam is balanced between the restoring spring, the level-
adjust spring, and the torque from the torque-motor. With the system in steady
state, the pilot valve of the flapper nozzle system is centered and the servo is
stationary.
By changing the current to the coil, the amount of torque on the armature
changes, and thus the torque on the torque-motor beam. This will change the
gap between the beam and the pilot valve, cause the pilot valve to follow the
movement of the beam, and allow oil to flow to or from the servo. The resultant
change in servo position causes the restoring lever to load or unload the
restoring spring, and thus restores the equilibrium of the torque-motor beam at
the new current level. The torque motor beam resumes its original position, and
the gap between the beam and the pilot valve will be restored to its original size
with the pilot valve centered.
14 Woodward
Direct and Reverse Acting

The same set of springs may be set for either a direct- or reverse-acting actuator.
The only difference is the level to which the level-adjust spring is set, and the
wires to the torque-motor which are reversed.
Figure 3-2. PG-EG Schematic, without Mode Select Valve
Woodward 15
Figure 3-3. PG-EG Schematic, with Mode Select Valve, Controlling on PG
16 Woodward
Figure 3-4. PG-EG Schematic, with Mode Select Valve, Controlling on EG
Woodward 17
Figure 3-5. EG Actuator Schematic, No Ballhead Backup
18 Woodward
Chapter 4.
Operation and Adjustments
Introduction
Because the PGA-EG and PGG-EG are each a combination of an electric
actuator and a ballhead governor, routine start-up adjustments can be more
complex than on other governors.
When installing or adjusting a PGA-EG/PGG-EG which has been taken off an

engine or has been repaired, make sure to understand if the governor is running
under control of the electronics or on the ballhead. Be sure of electronic control
when setting the dynamics of the electronic control system.
Centering Adjustment
The torque-motor/pilot valve relationship in the electric actuator is

calibrated at the factory and should not need readjustment unless
the torque motor, the pilot valve plunger, or the pilot valve bushing is
replaced. The adjustment is extremely sensitive and will change all
other adjustments.
DO NOT TOUCH any of the calibration adjustments unless

thoroughly familiar with the electrical portions of the control.
Complete calibration of the actuator should not be attempted on the
engine as overspeeding or other dangers may occur during the
calibration process.
It is absolutely vital that the armature/torque motor beam combination is correctly

centered between the magnets of the torque motor. If the tools to assist this
action are not available, do not attempt to do this.
If a torque motor has been disassembled, it may be necessary to re-magnetize

the magnets to ensure the torque motor will have enough power to allow all
settings to be made. Since measuring the amount of magnetism present is very
difficult, do not disassemble the magnet unless you are able to re-magnetize it
afterwards.
Use of the proper tools for the centering adjustment is essential to

proper control operation. These tools are available only in specially-
equipped workshops.
DO NOT DISASSEMBLE any part of the torque motor outside a

Woodward plant.
Woodward 19
Adjustment of the Anti-rotation Device

On the PG-EG actuator with no ballhead, to prevent the feedback lever between
the tailrod and the actuator from becoming dislodged by vibration, an anti-rotation
device has been added. It consists of a steel plate mounted on the cover of the
torque motor which guides a pin protruding from the tailrod. Because of the
tolerance of the slot in which the pin moves up and down, and the thickness of
the plate, it is important that pin and plate are perpendicular to each other. To
adjust this, the mounting screws of the plate run through two slots, allowing the
plate to be positioned correctly.
If the guiding plate has been removed, assemble as follows.
1. Install the guiding plate and mount the screws by hand. Do not tighten the
screws but allow small adjustments.
2. First check visually if the plate is set perpendicular to the pin. Adjust this by
moving the plate in its slots until it is.
3. Now run the tailrod up and down. This will set the plate in the correct
position and ensure the slot and the tailrod are exactly parallel. Now tighten
the screws to a torque of (0.7 to 0.8) N·m / (6 to 7) lb-in.
Mode Select Valve and Mode Indicating Switch

Mode Indicating Pressure Switch
To show the mode the governor is working in, a mode indicating pressure switch
is available.
Two switches are available:

 one for use with (690 to 896) kPa / (100 to 130) psi pump pressure
governors, with a switch point of 586 kPa / 85 psi;
 one for use with 1379 kPa / 200 psi pump pressure governors, with a switch
point of 1276 kPa / 185 psi.
The switch is mounted in one of two locations, depending on whether or not the
governor is equipped with a mode select valve.
No Mode Select Block

When the governor is not equipped with a mode select block, use the switch
mounting position available on the mode select block. For both 690 kPa / 100 psi
and 1379 kPa / 200 psi pump pressures, the resultant signals are:
 pins A-C closed = pins A-B open = EG-mode;
 pins A-B closed = pins A-C open = PG-mode.
20 Woodward
Figure 4-1. Torque Motor Exploded View
Parts List for Figure 4-1

Ref. No. Part Name ............................. Quantity Ref. No. Part Name ..............................Quantity
36637-1 internal retaining ring ...........................1 36637-20 flapper spacer ..................................... 1
36637-2 bi-metal washer ...................................1 36637-21 torque motor beam ............................. 1
36637-3 internal retaining ring ...........................1 36637-22 not used
internal retaining ring ...........................1 36637-23 not used
36637-5 flat washer ...........................................1 36637-24 not used
36637-6 regulator spring ...................................1 36637-25 not used
36637-7 regulator ..............................................1 36637-26 screw 8-32 x .750 ............................... 1
36637-8 bushing................................................1 36637-27 control adjuster ................................... 1
36637-9 actuator plunger ..................................1 36637-28 torque motor house ............................ 1
36637-10 grommet ..............................................1 36637-29 screw 6-32 x 1.000 ............................. 4
36637-11 screw 6-32 x .750 ................................2 36637-30 washer ................................................ 4
36637-12 torque motor cover ..............................1 36637-31 buffer spring ....................................... 1
36637-13 armature stop ......................................1 36637-32 primary feedback lever ....................... 1
36637-14 torque motor magnet ...........................1 36637-33 screw 10-32 x .375 ............................. 1
36637-15 reduced nut .........................................2 36637-34 range adjustment strap ....................... 1
36637-16 spring adjuster.....................................1 36637-35 screw 10-32 x 1.000 ........................... 1
36637-17 trim spring ...........................................2 36637-36 tailrod clamp ....................................... 1
36637-18 armature ..............................................1 36637-37 secondary feedback lever ................... 1
36637-19 torsion spring.......................................1 36637-38 pivot pin .............................................. 2
Woodward 21
Figure 4-2. Mode Select Block Exploded View
22 Woodward

Ref. No. Part Name ............................. Quantity
36637-101 O-ring ..................................................1
36637-102 O-ring ..................................................2
36637-103 block- PG-200 .....................................1
36637-104 screw- .250-20 x 1.50 .........................4
36637-105 washer ................................................4
36637-106 O-ring ..................................................2
36637-107 O-ring ..................................................1
36637-108 block- PG-58 .......................................1
36637-109 screw- .312-18 x 2.50 ..........................4
36637-110 washer ................................................4
36637-111 O-ring ..................................................1
36637-112 O-ring ..................................................2
36637-113 O-ring ..................................................1
36637-114 pilot valve ............................................1
36637-115 spring ..................................................1
36637-116 O-ring ..................................................1
36637-117 plug .....................................................1
36637-118 retaining ring .......................................1
36637-119 pressure switch ...................................1
36637-120 elbow ...................................................1
numbers 121 to 129 not used
36637-130 screw- .250-20 x 3.00 ..........................3
36637-131 washer ................................................3
36637-132 plate- cover .........................................1
36637-133 O-ring ..................................................1
36637-134 seal .....................................................1
36637-135 plunger- driver .....................................1
36637-136 connector ............................................1
36637-137 block- pneumatic mode select .............1
36637-138 decal—PG-EG mode select ................1
36637-150 screw- .250-20 x 1.75 ..........................3
36637-151 washer ................................................3
36637-152 knob ....................................................1
36637-153 O-ring ..................................................1
36637-154 block- manual mode select..................1
36637-155 retaining ring .......................................1
36637-156 decal- manual mode select .................1
36637-170 screw- .250-20 x 2.00 ..........................3
36637-171 washer ................................................3
36637-172 block- electric mode select ..................1
36637-173 valve 3 way-solenoid ...........................1
36637-174 decal- electric mode select ..................1
Mode Select Block

When the governor is equipped with a mode select block, use only the position
available on the mode select block. Do not use the switch mounting position on
the connecting block in this case. For both 690 kPa / 100 psi and 1379 kPa /
200 psi pump pressures, the resultant signals are:
 pins A-C closed = pins A-B open = EG-mode;
 pins A-B closed = pins A-C open = PG-mode.
Woodward 23
Mode Select Valve

A mode select valve allows the operator to choose and influence the mode the
governor is controlling in. This can be done by means of either a manual,
electrical, or pneumatic signal to the mode select valve.
The valve has two modes:

 Mechanical Control (or PG mode): The oil from the accumulator is routed
through the mode select valve to the ballhead pilot valve/compensation
system and into the servo.
 Electrical Control (or EG mode): The oil from the accumulator is routed
through the mode select valve to the actuator pilot valve, back to the mode
select valve, and through the ballhead pilot valve/compensation system into
the servo.
In electrical mode, the actuator pilot valve and the ballhead pilot
valve are placed in series. In order for the governor to operate in this
mode, it is necessary to raise the mechanical speed setting over the
electrical speed setting, since this offset will open the ballhead pilot
valve and keep it “out of the way.” This speed difference should
amount to 5 % to 10 % of the maximum speed.
Under EG mode, the ballhead will still control if the PG speed setting
is lower than the EG.
The mode select valve consists of a pilot valve located in a block which is
mounted onto the side of the governor power case. Internal governor hydraulics
are routed through the block. When the pilot valve is driven against a return
spring, the valve will switch. When the driving force is removed, the spring
returns the pilot valve and the valve switches back. Two pilot valves are
available: a direct-acting one and a reverse-acting one.
Five different methods are available to drive the mode select valve:
Manual—Turning a knob clockwise directs pressure oil against the end of the
valve plunger and forces the plunger against the return spring to switch into PG
mode. Turning the manual knob counterclockwise connects the operating end of
the mode select valve plunger to drain, allowing the return spring to move the
plunger and switch to EG mode.
Direct Electrical—A 24 V (dc) signal moves a solenoid valve to direct pressure

oil against the end of the direct-acting valve plunger and forces it against the
return spring to switch into PG mode. Removal of the electrical signal connects
the operating end of the valve plunger to drain, allowing the return spring to move
the plunger and switch to EG mode.
Reverse Electrical—A 24 V (dc) signal moves a solenoid valve to direct

pressure oil against the end of the reverse-acting valve plunger and forces it
against the return spring to switch into EG mode. Loss or removal of the signal
connects the operating end of the valve plunger to drain, allowing the return
spring to move the plunger and switch to PG mode.
24 Woodward

Direct Pneumatic—Air pressure drives a plunger which shuttles the direct-acting
mode select valve plunger against the return spring to switch into PG mode.
Removal or loss of air pressure will cause the return spring to move the plunger
back and switch to EG mode.
Reverse Pneumatic—Air pressure drives a plunger which shuttles the reverse-

acting mode select valve plunger against the return spring to switch into EG
mode. Removal or loss of air pressure will cause the return spring to move the
plunger back and switch to PG mode.
Maintenance
The mode select valve should require minimal or no maintenance. O-rings should
be replaced to eliminate possible oil leaks. The pneumatic, electric, or manual
actuator which sets the position of the pilot valve may be removed from the
housing for cleaning or repair.
Do not attempt to disassemble any portion of the mode select valve

with the governor running. Pressure oil circulates in all parts of the
valve, and the governor will quit operating, and oil will be pumped
out of the governor should any part of the valve be loosened or
removed while the governor is running.
Applications
The ballhead governor and the electric-input actuator operate continually, with
each having its own desired fuel-output position. PGA-EG hydraulics select the
lesser of the two fuel outputs for the actual fuel output.
Setting up for reverse-acting means that the electronics in the control are
programmed for reverse-acting; the actuator must be calibrated to accept this
reverse signal. Loss of electrical signal to the actuator causes the actuator to call
for increased fuel, moving the output to increase until the ballhead takes over
control (remember that for correct actuator use, the mechanical speed setting
must be raised by 5 % to 10 %). This means that the reverse-acting setup of
control and governor results in automatic switching from electrical control to
ballhead control should electronic failure occur, although at a higher speed.
When control and actuator are set up for direct-acting, loss of electronic signal to
the actuator means that the actuator goes to minimum fuel. Since the ballhead is
set to a speed 5 % to 10 % above the electronic maximum speed, it cannot take
over control.
Woodward 25
Figure 4-3. Assembly and Tubing Exploded View

Ref. No. Part Name ............................. Quantity Ref. No. Part Name ............................. Quantity
36637-201 O-ring .................................................. 3 36637-208 manifold block .....................................1
36637-202 connector- elbow................................. 1 36637-209 plug .125 NPTF ...................................2
36637-203 connector- straight .............................. 2 36637-210 O-ring ..................................................2
36637-204 tubing .375 OD ................................. AR 36637-211 gasket .................................................1
36637-205 washer ................................................ 2 36637-212 washer ................................................1
36637-206 screw .250-28 x 2.50........................... 2 36637-213 screw .250-28 x 1.25 ...........................1
36637-207 filter ..................................................... 1
26 Woodward
Chapter 5.
Product Support and Service Options
Product Support Options

If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
1. Consult the troubleshooting guide in the manual.
2. Contact the OE Manufacturer or Packager of your system.
3. Contact the Woodward Business Partner serving your area.
4. Contact Woodward technical assistance via email
(EngineHelpDesk@Woodward.com) with detailed information on the
product, application, and symptoms. Your email will be forwarded to an
appropriate expert on the product and application to respond by telephone
or return email.
5. If the issue cannot be resolved, you can select a further course of action to
pursue based on the available services listed in this chapter.
OEM or Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a

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

www.woodward.com/directory.
Product Service Options

Depending on the type of product, the following options for servicing Woodward
products may be available through your local Full-Service Distributor or the OEM
or Packager of the equipment system.
 Replacement/Exchange (24-hour service)
 Flat Rate Repair
 Flat Rate Remanufacture
Woodward 27

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 option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard
mechanical products and some of the electronic 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.
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. This option is applicable to mechanical products only.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
 return number;
 name and location where the control is installed;
 name and phone number of contact person;
 complete Woodward part number(s) and serial number(s);
 description of the problem;
 instructions describing the desired type of repair.
Packing a Control
Use the following materials when returning a complete control:
 protective caps on any connectors;
 antistatic protective bags on all electronic modules;
 packing materials that will not damage the surface of the unit;
 at least 100 mm (4 inches) of tightly packed, industry-approved packing material;
 a packing carton with double walls;
 a strong tape around the outside of the carton for increased strength.

Replacement Parts
When ordering replacement parts for controls, include the following information:
 the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
 the unit serial number, which is also on the nameplate.
28 Woodward
Engineering Services
Woodward’s Full-Service Distributors offer various Engineering Services for our
products. For these services, you can contact the Distributor by telephone or by
email.
 Technical Support
 Product Training
 Field Service
Technical Support is available from your equipment system supplier, your local
Full-Service Distributor, or from many of Woodward’s worldwide locations,
depending upon the product and application. This service can assist you with
technical questions or problem solving during the normal business hours of the
Woodward location you contact.
Product Training is available as standard classes at many Distributor locations.

Customized classes are also available, which can be tailored to your needs and
held at one of our Distributor locations or at your site. This training, conducted by
experienced personnel, will assure that you will be able to maintain system
reliability and availability.
Field Service engineering on-site support is available, depending on the product

and location, from one of our Full-Service Distributors. The field engineers are
experienced both on Woodward products as well as on much of the non-
Woodward equipment with which our products interface.
For information on these services, please contact one of the Full-Service

Distributors listed at www.woodward.com/directory.
Contacting Woodward’s Support Organization

For the name of your nearest Woodward Full-Service Distributor or service facility,
please consult our worldwide directory at www.woodward.com/directory, which
also contains the most current product support and contact information.
You can also contact the Woodward Customer Service Department at one of the
following Woodward facilities to obtain the address and phone number of the
nearest facility at which you can obtain information and service.
Products Used in Products Used in Products Used in Industrial

Electrical Power Systems Engine Systems Turbomachinery Systems
Facility --------------- Phone Number Facility --------------- Phone Number Facility --------------- Phone Number
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727
Germany: Germany ------ +49 (711) 78954-510 India --------------- +91 (124) 4399500
Kempen---- +49 (0) 21 52 14 51 India --------------- +91 (124) 4399500 Japan---------------+81 (43) 213-2191
Stuttgart - +49 (711) 78954-510 Japan---------------+81 (43) 213-2191 Korea ---------------+82 (51) 636-7080
India --------------- +91 (124) 4399500 Korea ---------------+82 (51) 636-7080 The Netherlands--+31 (23) 5661111
Japan---------------+81 (43) 213-2191 The Netherlands--+31 (23) 5661111 Poland -------------- +48 12 295 13 00
Korea ---------------+82 (51) 636-7080 United States -----+1 (970) 482-5811 United States -----+1 (970) 482-5811
Poland -------------- +48 12 295 13 00
United States -----+1 (970) 482-5811
Woodward 29
Technical Assistance
If you need to contact technical assistance, you will need to provide the following information.
Please write it down here before contacting the Engine OEM, the Packager, a Woodward
Business Partner, or the Woodward factory:
General
Your Name
Site Location
Phone Number
Fax Number
Prime Mover Information

Manufacturer
Engine Model Number
Number of Cylinders
Type of Fuel (gas, gaseous, diesel,
dual-fuel, etc.)
Power Output Rating
Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #2
Serial Number
Control/Governor #3
Serial Number
Symptoms
Description
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.
30 Woodward
Revision History
Changes in Revision J—
 Updated Figures 1-1 through 1-5
Changes in Revision H—
 Added filter cleaning instructions
Changes in Revision G—
 Updated Declaration of Incorporation
Changes in Revision F—
 Added Regulatory Compliance information
 Added installation information and warnings to Chapter 2
 Added Declarations
Changes in Revision E—
 Chapter 2—Added paragraph advising how to use an external cooler with
actuators that have oil spray
Woodward 31
Declarations
32 Woodward
THIS PAGE INTENTIONALLY LEFT BLANK
Woodward 33
We appreciate your comments about the content of our publications.

Send comments to: icinfo@woodward.com
Please reference publication 36637J.
PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811  Fax +1 (970) 498-3058
Email and Website—www.woodward.com
Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.
Status: Approved Confidential Document id: WDAAA160523 i Page 1 (36)

(Revision M, 5/2002)
Booster Servomotor
Single Cylinder (8901-037, -043, -051)

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

General
To verify that you have the latest revision, check manual 26311 , Revision Status &
Distribution Restrictions of Woodward Technical Publications, on the publications
Revisions page of the Woodward website:



please note:
Translated translation was made. Be sure to check manual 26311 , Revision Status &
Publications Distribution Restrictions of Woodward Technical Publications, to verify whether
Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.
undertaken.
Manual 36684
Copyright © Woodward 1974–2002
All Rights Reserved
Manual 36684 Booster Servomotor
Contents
WARNINGS AND NOTICES ............................................................................III

ELECTROSTATIC DISCHARGE AWARENESS ................................................. IV
REGULATORY COMPLIANCE ........................................................................ V
Introduction .............................................................................................................1
Description ..............................................................................................................1
Types of Boosters...................................................................................................1
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
How Single-Cylinder and Tandem Boosters Operate ..........................................15
How a Two-Stage Booster Operates....................................................................16
CHAPTER 4. REPLACEMENT PARTS ........................................................... 18
Ordering Replacement Parts ................................................................................18
CHAPTER 5. PRODUCT SUPPORT AND SERVICE OPTIONS ........................... 23
Engineering Services............................................................................................25
DECLARATIONS ......................................................................................... 27
Woodward i
Booster Servomotor Manual 36684
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 4-1. Exploded View of Single Boosters .....................................................19
Figure 4-2. Exploded View of Tandem Boosters ..................................................20
Figure 4-3. Exploded View of Two-Stage Boosters..............................................22
ii Woodward



limited to:
Equipment
 Eye Protection
 Hard Hat
 Gloves
 Safety Boots
 Respirator


Applications
Woodward iii

Battery Charging
Device


synthetics.
iv Woodward
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.
Woodward v
vi Woodward
Chapter 1.
General Information
Introduction
This manual covers the three types of Woodward booster servomotor:
 Low-volume, single-cylinder booster
 Medium-volume, double-cylinder (tandem) booster
 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

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.
2 Woodward
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
Figure 1-3. Outline Drawing of Single Booster
4 Woodward
Figure 1-4. Outline Drawing of Tandem Booster
Woodward 5
Figure 1-5. Outline Drawing of Two-Stage Booster
6 Woodward
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).
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

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.
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

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.
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.
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

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:
 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.
 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.
 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
Figure 2-1. Governors Used with Single-Cylinder Boosters
Woodward 11
Figure 2-2. Governors Used with Single-Cylinder Boosters
12 Woodward
Figure 2-3. Governors Used with Tandem Boosters
Woodward 13
Figure 2-4. Governors Used with Two-Stage Boosters
14 Woodward
Chapter 3.
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
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.
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

Third Phase of Operation
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
Chapter 4.
Replacement Parts
Ordering Replacement Parts

When ordering replacement parts, include the following information:
 The booster servomotor part number shown on the nameplate.
 The manual number printed on the cover of the manual (this is manual
36684).
 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.

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
18 Woodward
Figure 4-1. Exploded View of Single Boosters
Woodward 19

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

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
Woodward 21
Figure 4-3. Exploded View of Two-Stage Boosters
22 Woodward
Chapter 5.

or return email.

and market segment.
service that includes repairs, repair parts, and warranty service on
Woodward's behalf. Service (not new unit sales) is an AISF's primary
mission.


Woodward 23


 return number;
Packing a Control
 at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;

Replacement Parts
24 Woodward
email.
 Field Service




For the name of your nearest Woodward Full-Service Distributor or service
facility, please consult our worldwide directory published at
Products Used In Products Used In Products Used In

Electrical Power Systems Engine Systems Industrial Turbomachinery
Systems
Facility---------------- Phone Number Facility---------------- Phone Number Facility---------------- Phone Number
Germany: Germany------- +49 (711) 78954-510 India --------------- +91 (129) 4097100
Kempen ---- +49 (0) 21 52 14 51 India --------------- +91 (129) 4097100 Japan -------------- +81 (43) 213-2191
Stuttgart-- +49 (711) 78954-510 Japan -------------- +81 (43) 213-2191 Korea -------------- +82 (51) 636-7080
India --------------- +91 (129) 4097100 Korea -------------- +82 (51) 636-7080 The Netherlands - +31 (23) 5661111
Japan -------------- +81 (43) 213-2191 The Netherlands - +31 (23) 5661111 Poland--------------- +48 12 295 13 00
Korea -------------- +82 (51) 636-7080 United States ---- +1 (970) 482-5811 United States ---- +1 (970) 482-5811
Poland--------------- +48 12 295 13 00
United States ---- +1 (970) 482-5811
For the most current product support and contact information, please visit our
website directory at www.woodward.com/directory.
Woodward 25
General
Your Name
Site Location
Phone Number
Fax Number

Manufacturer
Engine Model Number
Number of Cylinders
dual-fuel, etc.)
Power Output Rating
etc.)
Control/Governor #1
Serial Number
Control/Governor #2
Serial Number
Control/Governor #3
Serial Number
Symptoms
Description
26 Woodward
Declarations
Woodward 27

Please reference publication 36684M.

Phone +1 (970) 482-5811  Fax +1 (970) 498-3058

Wärtsilä id: WDAAA273494 c
Manual 25071
(Revision J)
Oils for
Hydraulic Controls
Reference Manual
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
 DANGER—Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
DEFINITIONS  WARNING—Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
 CAUTION—Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
 NOTICE—Indicates a hazard that could result in property damage only (including
damage to the control).
The engine, turbine, or other type of prime mover should be equipped with an
overspeed shutdown device to protect against runaway or damage to the prime
mover with possible personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover
control system. An overtemperature or overpressure shutdown device may also
be needed for safety, as appropriate.
Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property damage.
This publication may have been revised or updated since this copy was produced. To verify that
you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:
If your publication is not there, please contact your customer service representative to get the
latest copy.
Any unauthorized modifications to or use of this equipment outside its specified mechanical,
electrical, or other operating limits may cause personal injury and/or property damage, including
damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or
"negligence" within the meaning of the product warranty thereby excluding warranty coverage
for any resulting damage, and (ii) invalidate product certifications or listings.
To prevent damage to a control system that uses an alternator or battery-charging

device, make sure the charging device is turned off before disconnecting the battery
from the system.
To prevent damage to electronic components caused by improper handling, read

and observe the precautions in Woodward manual 82715, Guide for Handling and
Protection of Electronic Controls, Printed Circuit Boards, and Modules.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed
by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1986
All Rights Reserved
Manual 25071 Oils for Hydraulic Controls
Contents

Introduction .............................................................................................................1
Oil Characteristics ..................................................................................................1
Oil Lubrication Properties .......................................................................................2
Performance Additives ...........................................................................................3
Lubrication Protective Additives .............................................................................3
CHAPTER 2. HOW TO SELECT AN OIL........................................................... 5
General Information ................................................................................................5
Proper Oil Selection................................................................................................7
Automatic Transmission Fluids ..............................................................................8
Synthetic Oils ..........................................................................................................8
Remarks ...............................................................................................................11
CHAPTER 3. OIL MAINTENANCE ................................................................. 12
General Information ..............................................................................................12
Oil Change Intervals .............................................................................................12
When to Change Governor Oil .............................................................................14
Contaminated Governor Oil ..................................................................................14
Oil Filters...............................................................................................................14
Oil Lacquering ......................................................................................................16
Figure 2-1. Oil Chart ...............................................................................................9

Figure 2-2. Viscosity Comparisons .........................................................................9
Woodward i
Oils for Hydraulic Controls Manual 25071
ii Woodward
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:
 protect the lubricated surface
 improve lubricant performance
 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.
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.
Woodward 1
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.
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.
2 Woodward
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.

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).
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.

Woodward 3
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.
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.
4 Woodward
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
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.
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.
Woodward 5

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.
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.
6 Woodward
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”.
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).
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.
Woodward 7
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.
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.
8 Woodward
Figure 2-1. Oil Chart
Figure 2-2. Viscosity Comparisons
Woodward 9

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.
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.
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.
10 Woodward

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.
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:
 MIL-L-2104A
 MIL-L-2104B
 MIL-L-2104C
 MIL-L-46152
 MIL-L-46152A
 MIL-L46152B
 MIL-L-45199B
Woodward 11
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.
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.
12 Woodward

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.
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
Woodward 13
When to Change Governor Oil

Oil should be changed if:
 Appearance is different than when new.
 Oil feels gritty when rubbed between fingers.
 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.
 Any water, antifreeze, or other incompatible material contaminates the oil.
 Viscosity has changed; increased or decreased.
 Excessive wear of parts occurs.
 If governor has been run at temperatures exceeding the recommended limit
for the type of oil use.
 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.
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.
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.
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.
14 Woodward
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).
βx = __N(up)__, where x = particle size (in µm)

N(down)
Thus β10 = 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,
β10 = __10 000__ = 2

5000
Some filter literature may show a rating as:

βx = 2/20/75, x = 6/11/15
which means: β6 = 2, β11 = 20, β15 = 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/β) x 100%
So, if β10 = 2
Efficiency at 10 µm = (1–1/2) x 100% = 50%
Woodward 15

Here is an efficiency table for “x” size particles:
βx = 1.01 is 1% efficient
βx = 2.0 is 50% efficient (nominal)*
βx = 75.0 is 98.7% efficient (absolute)*
βx = 1000.0 is 99.9% efficient
βx = 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.
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.
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:
 too high an oil temperature;
 too long an interval between oil changes;
 water condensing inside the governor during cooldown periods (water in oil
can cause hydrolysis which is a known failure mode for oils).
16 Woodward

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:
 Oil Temperature—Woodward recommends that the oil temperature for
continuous operation be between 60 and 93 °C (140 and 200 °F).
 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.
 Oil Selection—Woodward specifies two essential factors that need to be
considered in the selection of an oil for proper governor operation:
 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).
 operating temperature—recommended is an oil temperature for
continuous operation between 60 and 93 °C (140 and 200 °F).
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.
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 17

Please reference publication 25071J.

Phone +1 (970) 482-5811  Fax +1 (970) 498-3058

2010/3/Fort Collins
(Revision M, 4/2004)
PGA Governor

General
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
Revisions the publications page of the Woodward website:



please note:
Translated translation was made. Be sure to check manual 26455, Customer Publication
Publications Cross Reference and Revision Status & Distribution Restrictions, to verify whether
undertaken.
Manual 36604
Copyright © Woodward 1975–2004
All Rights Reserved
Manual 36604 PGA Governor
Contents
WARNINGS AND NOTICES ........................................................................... IV

ELECTROSTATIC DISCHARGE AWARENESS .................................................. V
Introduction .............................................................................................................1
Description ..............................................................................................................1
References .............................................................................................................2
CHAPTER 2. INSTALLATION.......................................................................... 9
Introduction .............................................................................................................9
Receiving ................................................................................................................9
Storage ...................................................................................................................9
Mounting Requirements .........................................................................................9
Oils for Hydraulic Controls ....................................................................................10
Clearances ...........................................................................................................11
CHAPTER 3. ADJUSTMENTS ....................................................................... 13
Introduction ...........................................................................................................13
Compensation Needle Valve Adjustment .............................................................13
Speed Setting Adjustment ....................................................................................14
Direct Speed Setting Mechanism .........................................................................14
Speed Droop Adjustment .....................................................................................18
Oil or Water Pressure Failure Shutdown Devices ................................................18
Overspeed-Trip Test Device ................................................................................18
Solenoid Operated Shutdown ..............................................................................19
Field Adjustment of Angle Fuel Limiter Linkage ...................................................19
CHAPTER 4. TROUBLESHOOTING ............................................................... 22
Introduction ...........................................................................................................22
Oil .........................................................................................................................22
Compensating Needle Valve ................................................................................22
Definitions .............................................................................................................22
Preliminary Inspection ..........................................................................................23
Introduction ...........................................................................................................27
Basic Governor .....................................................................................................27
Speed Setting Section ..........................................................................................30
Speed Droop Linkage ...........................................................................................35
Power Cylinders ...................................................................................................35
Compensation Cutoff ............................................................................................36
CHAPTER 6. REPLACEMENT PARTS ........................................................... 39
Replacement Parts Information ............................................................................39
CHAPTER 7. AUXILIARY FEATURES AND DEVICES ...................................... 54
Introduction ...........................................................................................................54
Commonly Used Auxiliary Devices ......................................................................54
Additional Accessories .........................................................................................84
Woodward i
PGA Governor Manual 36604
Contents
CHAPTER 8. PRODUCT SUPPORT AND SERVICE OPTIONS ...........................89

Engineering Services ............................................................................................91
Figure 1-1. PGA Governor with 12 ft-lb Linear Output Power Cylinder..................3
Figure 1-2. PGA Governor with 12 ft-lb Rotary Output Power Cylinder .................3
Figure 1-3. Outline Drawing of PGA with 12 ft-lb Rotary Servo and UG-40 Base .4
Figure 1-4. Outline Drawing of PGA with 12 ft-lb Linear Output, PG Standard
Base, and Vane Servo with Shaft Extension .....................................5
Figure 1-5. Outline Drawing of PGA with 58 ft-lb Rotary Output and UG-40 Base 6
Figure 1-6. Outline Drawing of PGA with 58 ft-lb Rotary Output, UG-40 Base, and
Load Control ......................................................................................7
Figure 1-7. Outline Drawing of Base Assemblies ...................................................8
Figure 3-1. Exploded View of High Speed Adjustment ........................................14
Figure 3-2. Left Side View of Governor with Cover Removed .............................15
Figure 3-3. Exploded View of Speed Setting Cylinder .........................................15
Figure 3-4. Exploded View of Low Speed Adjustment .........................................18
Figure 3-5. Schematic Diagram of the Speed Droop Linkage ..............................19
Figure 3-6. PGA Governor Fuel Limiter Linkage Adjustment ...............................20
Figure 3-7. Graphic Effects of Fuel Limiter Adjustments ......................................21
Figure 5-1. Schematic Diagram of PGA with Direct Bellows ................................37
Figure 5-2. Schematic Diagram of 12 ft-lb Spring Loaded Power Cylinder..........38
Figure 5-3. Schematic Diagram of 29 ft-lb Differential Power Cylinder (Linear or
Rotary Output) .................................................................................38
Figure 6-1. Exploded View of PGA Long Column ................................................41
Figure 6-2. Exploded View of PGA Receiver Assembly .......................................43
Figure 6-3. Exploded View of PGA Power Case ..................................................45
Figure 6-4. Exploded View, Standard PG Base Assembly ..................................46
Figure 6-5. Exploded View of PG/UG-8, PG/UG-8-90°, PG/UG-40, and PG
Extended Square Bases ..................................................................47
Figure 6-6. Exploded View of 12 ft-lb Spring Loaded Power Cylinder (Linear
Output) .............................................................................................49
Figure 6-7. Exploded View of 12 ft-lb Spring Loaded Power Cylinder (Rotary
Output) .............................................................................................51
Figure 6-8. Exploded View of 29/58 ft-lb Differential Cylinder (Rotary Output with
Tailrod) .............................................................................................53
Figure 7-1. PGA with Shutdown Solenoid ............................................................54
Figure 7-2. Cutaway of Solenoid Operated Shutdown .........................................55
Figure 7-3. Schematic Diagram, Basic PG and Solenoid Shutdown ...................56
ii Woodward
Figure 7-4. Exploded View, Solenoid Shutdown ..................................................57

Figure 7-5. Overspeed-Trip Test Device ..............................................................58
Figure 7-6. Exploded View of the Overspeed Trip Test Device ...........................59
Figure 7-7. Load Indicating Switches ...................................................................60
Figure 7-8. Exploded View of Load Indicating Switches ......................................61
Figure 7-9. Manifold Pressure Versus Fuel Flow .................................................63
Figure 7-10. Exploded View of Angle Type Manifold Gauge Pressure Fuel
Limiter ..............................................................................................65
Figure 7-11. Schematic Diagram of PGA Governor with Manifold Pressure Fuel
Limiter and Speed Setting Fuel Limiter ...........................................66
Figure 7-12. Schematic Diagram of PGA with Speed Setting Fuel Limiter ..........67
Figure 7-13. Fuel Limit Speed Setting Schedule ..................................................68
Figure 7-14. PGA with Vane Servo ......................................................................69
Figure 7-15. Timing Valves for Integral Vane Servo ............................................70
Figure 7-16. Timing Valves for Externally Mounted Vane Servo .........................70
Figure 7-17. Exploded View of Vane Servo Timing Valve Assembly (External
Type) ................................................................................................71
Figure 7-18. Schematic Diagram, Fuel Limiter and Optional Load Control
Override Linkage, and Vane Servo .................................................72
Figure 7-19. Exploded View of Adjustable Load Control Linkage ........................79
Figure 7-20. Exploded View of Load Control Pilot Valve .....................................81
Figure 7-21. Exploded View of Fuel Limiter .........................................................83
Figure 7-22. Exploded View of Integral Vane Servo ............................................87
Figure 7-23. Exploded View of Fuel Limiter Oil Filter ...........................................88
Table 1-1. Governor Oil Pressure Versus Power Cylinder Work Capacities
(Typical) .............................................................................................1
Table 2-1. Viscosity and Operating Temperature of Oils .....................................12
Table 4-1. Troubleshooting...................................................................................24
Table 7-1. Troubleshooting the Manifold Pressure Fuel Limiter ..........................74
Woodward iii



limited to:
Equipment
 Eye Protection
 Hard Hat
 Gloves
 Safety Boots
 Respirator


Applications
iv Woodward

Battery Charging
Device


synthetics.
Woodward v
vi Woodward
Chapter 1.
General Information
Introduction
This manual covers the Woodward model PGA (pressure compensated–air
speed setting) marine governor. The PGA marine governor with a long column
consists of a basic PG hydraulic governor for automatic regulation of prime
mover speed and pneumatic speed changing mechanism for remote control of
speed. Two types of power cylinders are available, a single-acting spring-return,
or double-acting differential-piston-type power cylinder with tailrod (see Table
1-1). For the 12 ft-lb (16 J) type, a spring return power cylinder is available for
either pull or rotary output. For the 29 ft-lb (39 J) type, a differential power
cylinder is available with rotary output.
Table 1-1. Governor Oil Pressure Versus Power Cylinder Work Capacities
(Typical)
Power Cylinder Work Capacity

Governor Operating 12 ft-lb (16 J) 29 ft-lb (39 J)
Oil Pressure spring return differential
100 psi (690 kPa) 12 ft-lb (16 J) 29 ft-lb (39 J)
200 psi (1379 kPa) —— 58 ft-lb (79 J)
All PGA marine governors have the same basic components regardless of how
simple or complex the complete control may be. The following components,
found in each PGA marine governor, are sufficient to enable the governor to
maintain a constant engine speed as long as the load does not exceed engine
capacity:
 An oil pump oil accumulator, and a relief valve maintains a uniform oil
pressure
 A centrifugal flyweight head-pilot valve assembly controls the flow of oil to
and from the governor power cylinder assembly
 A power cylinder assembly—sometimes referred to as a servomotor—
positions the fuel racks, fuel valve, or steam valve of the prime mover
 A compensation system stabilizes the governor system
 A pneumatic speed setting mechanism is used to adjust the governor speed
setting remotely
Description
Governor
The governor controls engine or turbine speed by regulating the amount of fuel or
steam supplied to the prime mover. Speed control can be isochronous (the
governor maintains a constant steady state speed, within the capacity of the unit,
regardless of load), or with droop (speed decreases as load increases).
Woodward 1
An air pressure signal from a pneumatic air transmitter or controller supplies air
to the governor speed-setting mechanism. The governor controls the engine at a
definite speed for each air pressure. The most common air pressure range for
the governor is 7 to 71 psi (48 to 490 kPa). Normal minimum control air pressure
is 3 psi (21 kPa); maximum is 100 psi (690 kPa). We recommend a governor
operating speed of between 250 to 1000 rpm.
The pneumatic speed setting mechanism is a bellows-type mechanism. Bellows

speed setting permits load division of paralleled units, and also provides a
definite, accurate relationship between speed and speed signal. The speed
setting mechanism is available for use with air input signals of varying range and
magnitude. Depending upon the exact configuration installed in the governor,
speeds may be adjusted up to 5-to-1 range. A manual speed setting knob is
incorporated in the unit to permit manual operation when the air pressure signal
is not available.
Base Assemblies
Various base assemblies are available for use on PGA governors. Five types of
bases are mentioned in this manual, along with appropriate outline drawings, and
exploded views:
 PG standard
 PG/UG-8 standard
 PG/UG-8-90° (base rotated 90° with respect to PG/UG-8 standard)
 PG/UG-40
 PG extended square
These base assemblies have essentially the same basic components. The
difference between units is the base configuration and the type of drive shaft
used (see Figures 1-3 through 1-7). The PG standard base uses a serrated or a
special drive shaft: the PG/UG-8, PG/UG-8-90°, and PG/UG-40 base may use
either a serrated or keyed drive shaft; and the PG extended square base uses
only a keyed drive shaft.
The drive shaft, driven by a mechanical connection to the engine or turbine,

rotates the governor oil pump drive gear, flyweight heads, and pilot valve
bushing.
References
36652 PG Automatic Safety Shutdowns and Alarms
36695 PG Manifold Air Pressure Bias Fuel Limiter
36701 PGA Governor product specification
2 Woodward
Figure 1-1. PGA Governor with 12 ft-lb Linear Output Power Cylinder
Figure 1-2. PGA Governor with 12 ft-lb Rotary Output Power Cylinder
Woodward 3
Figure 1-3. Outline Drawing of PGA with 12 ft-lb Rotary Servo and UG-40 Base
(Do not use for construction.)
4 Woodward
Figure 1-4. Outline Drawing of PGA with 12 ft-lb Linear Output, PG Standard
Base, and Vane Servo with Shaft Extension
Woodward 5
Figure 1-5. Outline Drawing of PGA with 58 ft-lb Rotary Output and UG-40 Base
6 Woodward
Figure 1-6. Outline Drawing of PGA with 58 ft-lb Rotary Output, UG-40 Base, and
Load Control
Woodward 7
Figure 1-7. Outline Drawing of Base Assemblies

8 Woodward
Chapter 2.
Installation
Introduction
Refer to Figures 1-3 through 1-7 for physical dimensions of a PGA governor.
Use care in handling the governor and be particularly careful to avoid striking the
drive shaft. Do not drop or rest the governor on its drive shaft. Such treatment
could damage the governor oil pump gears.

loss of life, or property damage.
The overspeed shutdown device must be totally independent of the

prime mover control system. An overtemperature or overpressure
Receiving
Your PGA governor is received from our factory bolted to a wooden platform in a
vertical position. After testing the governor at the factory, it is drained of oil. This
leaves a light film of oil covering the internal parts. preventing rust. No internal
cleaning is required.
Storage
Store the governor in a vertical position and full of oil. To hold the governor in a
vertical position, bolt it to a platform or leave it in the shipping crate. Before
storing the governor, fill it with oil since it is shipped empty.
Mounting Requirements
A gasket must be used between the governor and accessory mounting pad.
Mount the governor square on its mounting pad using the correct length of
coupling between the governor and the drive. Be sure there is no binding, or
excessive side load in the drive shaft assembly, or excessive looseness in the
coupling. There should be no forces pushing the drive shaft into the governor.
Mount the governor in a vertical position.
If the governor being installed has been designed for rotation in one
direction only, be sure the engine or turbine drive to governor drive
rotation is the same, otherwise the governor could be damaged.
Specifications for individual governors indicate if the unit has been
plugged to limit rotation to one direction only and is not equipped
with check valves.
Woodward 9
Align the linkage from the governor to the fuel pumps properly to eliminate
binding and/or excessive backlash. The relationship of governor terminal shaft
angular position to fuel control position must be adjusted in accordance with the
engine manufacturer’s specifications. Many governors include a feature
commonly referred to as compensation “cutoff”. Due to the location of the
compensation cutoff port in the power cylinder wail, it is necessary that the
governor to fuel control linkage be adjusted so that at idle no-load the output of
the governor is at least 15% of its travel from minimum position.
Make the hydraulic and electrical connections (if any) required for the particular
model governor being installed.
Oils for Hydraulic Controls

Use this manual as a guide in the selection of a suitable lubricating/hydraulic oil
for governor use. Oil grade selection is based on viscosity change over the
operating temperature range of the governor. Also, use this manual to aid in
recognizing and correcting common problems associated with oil used in
governors. This manual is not intended to be used in the selection of the
lubricating oil for the engine, turbine, or other type prime mover.
For applications where the Woodward governor shares the oil supply with the
prime mover, use the oil recommended by the prime mover manufacturer.
Governor oil is both a lubricating oil and a hydraulic oil. It must have a viscosity
index that allows it to perform over the operating temperature range and it must
have the proper blending of additives that cause it to remain stable and
predictable over this range. Governor fluid must be compatible with seal
materials (nitrile, polyacrylic, and fluorocarbon). Many automotive and gas engine
oils, industrial lubricating oils, and other oils of mineral or synthetic origin meet
these requirements. Woodward governors are designed to give stable operation
with most oils, if the fluid viscosity at the operating temperature span is within a
50 to 3000 SUS (Saybolt Universal Seconds) range. Ideally, at the normal
operating temperature the viscosity should be between 100 to 300 SUS. Poor
governor response or instability usually is an indication that the oil is too thick or
too thin.
Excessive component wear or seizure in a governor indicates the possibility of:

1. Insufficient lubrication caused by:
A. An oil that flows slowly either when it is cold or during start-up.
B. No oil in the governor.
2. Contaminated oil caused by:

A. Dirty oil containers.
B. A governor exposed to heating up and cooling down cycles, which
creates condensation of water in the oil.
3. Oil not suitable for the operating conditions caused by:

A. Changes in ambient temperature.
B. An improper oil level which creates foamy, aerated oil.
Operating a governor continuously beyond the high limit temperature of the oil
will result in oil oxidation. This is identified by varnish or sludge deposits on the
governor parts. To reduce oil oxidation, lower the governor operating
temperature with a heat exchanger or other means, or change to an oil more
oxidation resistant at the operating temperature.
10 Woodward
A loss of stable governor control and possible prime mover

overspeed, capable of causing physical injury or death, may result if
the viscosity exceeds the 50 to 3000 SUS range.
Specific oil viscosity recommendations are given in the chart (Table 2-1). Select
a readily available good brand of oil, either mineral or synthetic, and continue
using it. Do not mix the different classes of oils. Oil that meets the API (American
Petroleum Institute) engine service classification in either the “5” group or the “C”
group, starting with “SA” and “CA” through “SF” and “CD” is suitable for governor
service. Oils meeting performance requirements of the following specifications
are also suitable. MIL-L-2104A, MIL-L-2104B, MIL-L-2104C, MIL-L-46152, MIL-
L-46152A, MIL-L-46152B, MIL-L-45199B.
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 clean solvent having some lubricity (kerosene), before
refilling with new oil. If drain time is insufficient for the solvent to completely drain
or evaporate. flush governor with 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.
Oil that has been carefully selected to match the operating conditions and is
compatible with governor components should give long service between oil
changes. For governors operating under ideal conditions (minimum exposure to
dust and water and 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.
Any persistent or recurring oil problems should be referred to a qualified oil

specialist for solution.
The recommended oil temperature for continuous governor operation is 140 to

200 °F (60 to 93 °C). Measure the temperature of the governor or actuator on the
outside lower part of the case. The actual oil temperature will be slightly warmer,
by approximately 10 °F (6 °C). The ambient temperature range is –20 to +200 °F
(–29 to +93 °C).
The primary concern is for the hydraulic fluid properties in the

governor.
Clearances
Leave adequate clearance for connecting the control linkage, filling the governor
with oil, and removing the cover.
Woodward 11
Table 2-1. Viscosity and Operating Temperature of Oils
12 Woodward
Chapter 3.
Adjustments
Introduction

property damage.
These adjustments may be made in the field for optimum performance or after
repairs. Always note the starting point before making any adjustments.
Normally, the only requirements for putting a new or overhauled governor into
service are filling the governor with oil and adjusting the compensation needle
valve to obtain maximum stability. All other operating adjustments are made
during factory testing according to engine manufacturer’s specifications and
should not require further adjustment. Do not attempt internal adjustment of the
governor unless thoroughly familiar with the proper procedures.
Compensation Needle Valve Adjustment

The compensation needle valve is an adjustable part of the compensation
system. its setting, which directly affects governor stability, depends on the
individual characteristics of the prime mover.
1. With the prime mover operating at IDLE, open the compensation needle
valve several turns to cause the engine to hunt. In some cases, opening of
the needle valve alone may not cause the engine to hunt, but manually
disturbing the governor speed setting will. Allow several minutes of hunting
to remove trapped air in the hydraulic circuits.
2. Close the compensation needle valve gradually until hunting is just

eliminated. Keep the needle valve open as far as possible to prevent
sluggishness in the governor response. The needle valve setting varies from
1/16 to 2 turns open. Never close it tight, the governor cannot operate
satisfactorily when this condition exists.
3. Check the governor stability by manually disturbing the governor speed

setting. The compensation adjustment is satisfactory when the governor
returns to speed with only a slight over-or undershoot. Once the needle
valve adjustment is correct, it is not necessary to change the setting except
for large, permanent changes in temperature which affect governor oil
viscosity.
If after a disturbance the engine does not return to a stable condition

and the needle valve is almost closed, replace the existing buffer
springs with springs having the next higher scale.
Woodward 13
Speed Setting Adjustment

The pneumatic speed setting mechanism is a direct type which increases the
governor speed setting as the control air pressure signal increases. Perform the
following procedures as applicable to set the maximum and minimum operating
speed of the governor.
The recommended speed range for the PG governor is 250 to 1000 rpm with a
maximum speed range of 200 to 1600 rpm.
Direct Speed Setting Mechanism

(Figure 3-2)
The governor speed setting adjustments, particularly those which

establish the governor speed range versus the control air pressure
range, are mutually interactive and a change cannot be made to one
end of the range without also affecting the other end. For this reason,
the entire adjustment procedure should be performed in sequence
whenever any change in the low or high speed setting is necessary.
It is preferable that speed adjustments be made on a test stand,
however, they may be made on the prime mover if care is taken to
avoid any possibility of overspeeding the prime mover.
1. If governor is equipped with an optional solenoid or pressure actuated

shutdown device:
a. Solenoid type—must be energized if adjusted to shut down when de-
energized.
b. Pressure type—must be pressurized above shutdown point if adjusted
to shut down upon low pressure.
2. Turn the manual speed adjusting knob fully ccw (until clutch slips) to the
minimum speed position.
3. Initially position the high speed adjusting set screw (125, Figure 3-1) so that
upper end is flush with top of the T-shaped speed setting screw (123).
Figure 3-1. Exploded View of High Speed Adjustment
14 Woodward
Figure 3-2. Left Side View of Governor with Cover Removed

(Governor Shown has Load Control and Single Barrel Limiter)
4. Initially position the speed setting piston stop setscrew (48, Figure 3-3) so
that it projects 1/2 inch above top of the speed setting cylinder.
Figure 3-3. Exploded View of Speed Setting Cylinder
5. Adjust governor low speed setting as follows:

a. Turn on control air to the governor and adjust to the required minimum
pressure corresponding to the required low (idle) speed.
b. Turn speed adjusting nut (Figure 3-2) on speed setting screw as
required (ccw to increase) until the required low speed is reached at
minimum control air pressure.
Woodward 15
Make certain the pneumatic low speed adjusting screw (109) is not
contacting stop pin (106) in the restoring lever and that the piston
stop setscrew (48) is not interfering with upward movement of the
speed setting piston.
6 Calibrate the governor speed range to the control air pressure range as follows:
a. Slowly increase control air pressure toward the required maximum
value. Exercise care not to overspeed the prime mover.
Make certain the maximum speed limiting valve adjusting screw (44,
Figure 3-3) on speed setting piston rod is not contacting and’
prematurely unseating the limiting check valve (43) in top of the
speed setting cylinder.
b. If the required high speed is reached before control air pressure is

adjusted to the required maximum value, move the ball bearing pivot
bracket (fulcrum) (134, Figure 3-1) toward the speed setting cylinder to
decrease the governor speed range in relation to the control air
pressure range.
c. If control air pressure is adjusted to the required maximum value before
the required high speed is reached, move the ball bearing pivot away
from the speed setting cylinder to increase the governor speed range in
relation to the control air pressure range.
d. To adjust the ball bearing pivot, loosen uppermost screw in pivot
bracket on arm of the speed setting screw. Adjust position of bracket
(and ball bearing pivot) on arm by loosening the knurled nut on
appropriate side of bracket and tightening the opposite nut.
7. After every adjustment of the pivot bracket, the low speed setting must be
readjusted. Repeat steps 5 and 6 until the required low speed exactly
corresponds with the required minimum control air pressure and both high
speed and maximum control air pressure are reached simultaneously.
Speed must begin to increase instantly with any increase in control air
pressure above the minimum value.
8. Adjust control air pressure to the maximum value. Allow prime mover speed
to stabilize. Turn the limiting valve adjusting screw (44, Figure 3-3) cw until
prime mover speed just begins to drop, then back out 1/4 to 1/2 turn and
lock in position. This will prevent or limit accidental overspeeding of the
prime mover should the speed setting piston be moved past its high speed
position for any reason.
9. Reduce control air pressure to the minimum value.
10. Turn the piston stop setscrew (48, Figure 3-3) cw until it just contacts top of
the speed setting piston and then back out three full turns (3/32 inch/2.4
mm) and lock in position.
16 Woodward
The piston stop setscrew is normally used to limit upward movement

of the speed setting piston during shutdown periods to 3/32 inch (2.4
mm) above the low speed position of the piston. This allows the
governor to open the fuel control more quickly on start-up and
therefore, minimize cranking time.
Some governor applications may require a low or minimum speed

stop, in which case the piston stop setscrew is used to limit upward
movement of the piston at the low or minimum speed point. Where
this is done, the governor cannot then be used to shut down the
prime mover and some means external to the governor must be
provided for this purpose.
11. Lift the shutdown rod upward far enough to remove any end play (lost
motion) but not so far as to cause prime mover speed to drop below the low
speed setting. While holding the shutdown rod up, position shutdown nut on
the rod so that it is 0.050 inch (1.27 mm) above upper end of the fulcrum
block on the speed setting piston rod and lock in place with upper nut.
The shutdown nuts are usually omitted where the governor

application does not require a shutdown capability. If the nuts have
been included but shutdown is not a requirement, make certain the
nuts are positioned at top of shutdown rod at maximum distance
from the fulcrum block.
12. If the governor is to shut down the prime mover when control air is turned off
or accidentally interrupted, adjust the pneumatic low speed stop screw so
that it is 0.040 to 0.050 inch (1.02 to 1.27 mm) below stop pin in the
restoring lever at low speed. Turn off control air to the governor and allow
the prime mover to shut down. Readjust stop screw for 0.002 to 0.005 inch
(0.05 to 0.13 mm) clearance between head of screw and stop pin in the
restoring lever.
13. If the governor is to go to low speed when control air is turned off or
interrupted, adjust the pneumatic low speed stop screw so that the desired
speed is reached with no control air pressure. Speed should be at least 20
rpm below idle.
Loosen and tighten lock nut (108, Figure 3-4), to adjust the low speed
stop screw (109), only when the governor is stopped. Governor
rotation, while making this adjustment, causes the pilot valve
plunger to bind in the pilot valve bushing.
14. Adjust maximum speed setting for the manual speed setting knob as
follows:
a. Turn off control air to the governor. If the governor is adjusted to
shutdown upon interruption of control air, turn the manual speed
adjusting knob cw until prime mover speed increases slightly before
turning off control air.
b. Turn the manual speed knob cw until prime mover is running at high
speed.
c. Turn the high speed adjusting setscrew 125, Figure 3-1) in the speed
adjusting screw 123 cw until it just contacts the high speed stop pin. If
the setscrew is turned too far, prime mover speed will decrease.
Woodward 17
Figure 3-4. Exploded View of Low Speed Adjustment
15. Make certain to turn the manual speed adjusting knob fully ccw to the
minimum speed position before resuming normal operation under pneumatic
control.
Speed Droop Adjustment

Normally, the governor is adjusted at the factory for the speed droop specified by
the prime mover manufacturer. Prime mover characteristics or system
requirements may necessitate minor readjustment. To adjust, loosen the lock
screw and slide cam along slot in fulcrum pin (see Figure 3-5). Move the cam
lobe away from the fulcrum pin centerline toward power piston tailrod to increase
speed droop or toward the centerline to decrease the speed droop. When the
centerlines of the cam lobe and fulcrum pin coincide (“0” droop), the governor will
operate isochronously.
Do not move the cam past the “0” droop position as ‘negative’ droop
will occur (prime mover speed increases as the governor power
piston moves toward the maximum fuel or steam position). This will
result in very unstable governing action.
With the prime movers operating in parallel, the droop unit(s) must have sufficient
droop to prevent load interchanges between prime movers.
Oil or Water Pressure Failure Shutdown Devices

Refer to manual 36652, PG Automatic Safety Shutdowns and Alarms.
Overspeed-Trip Test Device

Refer to Chapter 7, Auxiliary Features and Devices.
18 Woodward
Figure 3-5. Schematic Diagram of the Speed Droop Linkage
Solenoid Operated Shutdown

Refer to Chapter 7, Auxiliary Features and Devices.
Field Adjustment of Angle Fuel Limiter Linkage

The following information applies only to the manifold pressure fuel limiter of the
type illustrated in Figure 3-6.
Some governors are equipped with a fuel limiter of the type illustrated in Figure
7-21. Since adjustment of this type of limiter is only possible on a test stand, no
instructions are provided in this manual. Complete Test stand adjustment
procedures are available in manual 36695, PG Manifold Air Pressure Bias Fuel
Limiter.
Figures 3-6 and 3-7 show various adjustments, and indicate the effect of each
adjustment.
It should be clearly understood that these are approximate since variations

inevitably exist between governors. Adjustment (C) is likely to show this variation
more than others due to its proximity to a linkage pivot pin. The graphs are
plotted as increments of tailrod travel, at point of fuel limit, per unit of adjustment
above and below the datum settings given for the particular governor.
Woodward 19
Figure 3-6. PGA Governor Fuel Limiter Linkage Adjustment

(Shown with Angle Fuel Limiter with Speed Setting Fuel Limiter)
Adjustment (A)
Adjusting this screw varies the angle of the charge pressure fuel limiter cam and
the slope of the fuel limiter characteristic.
After making use of this adjustment it is necessary to trim the base of the limiter
curve, by means of adjustment (C), in order to restore it to its original value. The
graph shows the relationship between increments of governor tailrod travel at
fuel limit against units of adjustment after both adjustments have been made.
20 Woodward
Adjustment (B)
This is the bellows datum adjusting screw. Its setting determines the manifold
charge pressure at which the fuel limiter piston begins to move downwards,
increasing the governor tailrod travel at which fuel limit occurs. Its effect is to
move the limiting characteristic sideways parallel with the charge pressure axis.
Adjustment (C)
Adjustment of this screw raises or lowers the entire manifold charge pressure
fuel limiting characteristic.
Adjustment (D)
This is the speed setting fuel limiter datum setting nut. Its adjustment raises or
lowers the entire limiting characteristic.
Adjustment (E)
Adjustment of the position of this linkage pivot pin in the slotted lever changes the
linkage ratio such that for a fixed advance in speed setting piston position, the
corresponding movement of governor power piston tailrod, at the point of fuel limit, may
be increased or decreased (the slope of the fuel limiting characteristic may be altered).
After making use of this adjustment it is necessary to trim the base of the limiter
curve, by means of adjustment (D), in order to restore it to its original level. The
graph shows the relationship between increments of governor tailrod travel at
fuel limit against units of adjustment, after both adjustments have been made.
Adjustment (F)
A constant fuel limit is held for all speeds below the speed setting at which this
screw contacts the lower limiter lever.
Adjustment of the screw varies the speed setting at which the sloping portion of
the limiting characteristic is reached. Its effect is to move the characteristic
sideways, parallel with the speed setting axis.
Adjustment (G)
This adjustment varies the level of the constant “fuel limit” at low speed settings referred
to under adjustment (F). It influences only this lower portion of the characteristic.
Figure 3-7. Graphic Effects of Fuel Limiter Adjustments

Woodward 21
Chapter 4.
Troubleshooting
Introduction
It is impossible to anticipate every kind of trouble that is encountered in the field.
This covers the most common troubles experienced. Poor governing may be due
to faulty governor performance, or it may be due to the governor attempting to
correct for faulty operation of the engine or turbine auxiliary equipment. The
effect of any auxiliary equipment on the overall control required of the governor
must also be considered.

property damage.
Oil
Governor oil level must be kept between the lines on the oil level gauge glass
with the unit operating. The correct level is at the joint line of the power case and
column—the upper line on the gauge glass—and no higher. Instructions given on
decals near the oil gauge should be strictly adhered to. Dirty oil causes
approximately 50% of all governor troubles. Use clean new or filtered oil.
Containers used to fill governors from bulk containers should be perfectly clean.
Oil contaminated with water breaks down rapidly, causes foaming and corrodes
internal governor parts.
Compensating Needle Valve

The compensating needle valve must be correctly adjusted with the governor
controlling the engine or turbine, even though the compensation may have been
previously adjusted at the factory or on governor test equipment. Although the
governor may appear to be operating satisfactorily because the unit runs at
constant speed without load, the governor still may not be correctly adjusted.
High overspeeds and low underspeeds, or slow return to speed, after a load
change or speed setting change, are some of the results of an incorrect setting of
the compensating needle valve.
Definitions
Use the chart on the following pages to determine the probable causes of faulty
operation, and to correct these troubles. Terms used in the chart are defined as
follows:
Hunt
A rhythmic variation of speed which can be eliminated by blocking governor
operation manually, but which will recur when returned to governor control.
22 Woodward
Surge
A rhythmic variation of speed, always of large magnitude, which can be
eliminated by blocking governor action manually and which will not recur when
returned to governor control, unless speed adjustment is changed or the load
changes.
Jiggle
A high frequency vibration of the governor fuel rod end (or terminal shaft) and
fuel linkage. Do not confuse this with normal controlling action of the governor.
Preliminary Inspection
Governor troubles are usually revealed in speed variations of the prime mover,
but it does not necessarily follow that such variations are caused by the
governor. When improper speed variations appear, the following procedure
should be performed.
1. Check the load to be sure the speed changes are not the result of load
changes beyond the capacity of the prime mover.
2. Check engine operation to be sure all cylinders are firing properly and that
the fuel injectors are in good operating condition and properly calibrated.
3. Check linkage between governor and fuel or steam control to be sure there
is no binding or excessive backlash.
4. Check setting of governor compensation needle valve.
5. Check operation of control air pressure transmitter.
6. Check governor oil pressure. A test port is provided in two sides of the
governor power case for this purpose.
7. The source of most troubles in any hydraulic governor stems from dirty oil.
Grit and other impurities can be introduced into the governor with the oil, or
form when the oil begins to breakdown (oxidize) or become sludgy. The
internal moving parts are continually lubricated by the oil within the unit.
Valves, pistons and plungers will stick and even “freeze” in their bores, due
to excessive wear caused by grit and impurities in the oil. If this is the case
erratic operation and poor response can be corrected by flushing the unit
with fuel oil or kerosene. The use of commercial solvents is not
recommended as they may damage seals or gaskets.
Change the oil and flush the governor twice a year if possible. Remove the
cover, open the drain cock and drain out the old oil. Flush the governor by
filling it with fuel oil, and with the engine running at low speed, cycle the
governor. Cycle the governor by opening the needle valve two or three
turns. Let the governor hunt for a minute or two and then stop the engine
and drain the governor. Flush the governor once again. Fill the governor
with oil, pouring it over all the internal parts that are visible. Start the engine
and reset the compensation needle valve.
8. Check drive to governor for any evidence of misalignment, roughness,

excessive backlash, etc.
Woodward 23
Table 4-1. Troubleshooting
Trouble Cause Correction

1. Engine hunts A. Needle valve adjustment incorrect. Adjust needle valve as described in governor
or surges. manual.
B. Buffer springs too light. This may Install heavier buffer springs (consult
occur on a new Installation—or on an old Woodward).
installation as a result of a radical
change in load conditions.
C. Lost motion in engine linkage, fuel Repair linkage, fuel pumps, or gas valve.
pumps, or gas valve.
D. Binding in engine linkage, fuel Repair and re-align linkage, fuel pumps or
pumps, or gas valve. gas valve.
E. Governor stroke too short. This Redesign or rework the fuel linkage to require
may occur on a new installation. Should more governor stroke. (Consult manufacturer
be at least 50% of total governor travel of engine and Woodward).
between idle and full load.
F. Low oil level. No harm will be done Add oil slowly to the correct level in gauge.
if top of oil is still visible in gauge glass.
G. Dirty oil or foaming oil in governor. Drain governor oil, flush governor to clean,
and refill with proper clean oil. Bleed air and
adjust the needle valve as described in
governor manual.
H. Governor worn or not correctly Try spare governor or repair and adjust
adjusted. governor.
a. Check flyweight pins and bearings for
wear.
b. Check flyweight toes for wear and/or flat
spots.
c. Check flyweight head thrust bearing,
also centering bearing.
d. Pilot valve plunger may be sticking.
Clean and polish if necessary.
Do not break corners of control land.

e. Check vertical adjustment of pilot valve
plunger and correct if necessary.
f. Clean and polish all moving parts to
ensure smooth and free operation.
I. Spring too weak in telescopic link. Install heavier spring so that link stays solid at
all times.
J. Governor not suitable for engine. Consult Woodward.
2. Fuel pump A. Low oil pressure in governor. a. Check governor pump gears and gear
racks do not open pockets for excessive wear. No correction
quickly when except to replace worn parts.
cranking engine. b. Flush governor and refill with clean oil to
remove dirt in pump check valves.
c. Examine pump check valves. If not
seating tight, install new ones.
B. Cranking speed too low. Install a booster servomotor (consult
Woodward).
C. Booster servomotor (if used) not a. Check action of automatic air starting
functioning properly. valve.
b. Check air and oil connections.
D. Solenoid shutdown not wired Check wiring for the de-energize to shutdown
properly. type. A small voltage must be applied for
starting.
E. Shutdown nuts not adjusted Loosen nuts and start engine. Readjust nuts
correctly. for proper clearance at idle.
F. Speed setting or manifold pressure Increase maximum starting fuel. Consult
fuel limiter set too low. engine manufacturer for correct settings.
24 Woodward

3. Jiggle at A. Rough engine drive. Inspect drive mechanism:
governor rod end or a. Check alignment of gears.
terminal shaft. b. Inspect for rough gear teeth, eccentric
gears, or excessive backlash in gear train.
c. Check gear keys and nuts or set screws
holding drive gears to shafts.
d. Tighten chain between crankshaft and
camshaft (if used).
e. Check engine vibration dampener (if
used).
f. If governor has serrated drive shaft
check for wear of shaft and serrated coupling.
B. Failure of flexible drive in flyweight Remove, disassemble and clean flyweight
head. head parts.
Check spring and install new spring coupling

assembly if necessary. Center the coupling
for equal travel in opposite directions.
C. Governor not bolted down evenly Loosen screws, disconnect fuel linkage and
on engine mounting pad. turn governor 45° cw and ccw on its mounting
pad a few times. Tighten screws.
4. Load does not A. Droop setting too low on one or a. Check if governor travel is at least 50%
divide properly more units. of total travel. If necessary increase governor
between connect- travel by shortening terminal shaft lever.
ed units for ship b. Adjust droop on each unit until desired
propulsion or division of load is obtained.
similar type c. Increasing droop results in the unit
installation. All units taking a smaller share of load changes.
on droop. d. Decreasing droop results in the unit
taking a larger share of load changes.
B. Speed settings of the governors are a. Check control air pressures at both
not the same. governors with accurate pressure gauges.
b. Check if both manual speed setting
knobs are at minimum.
c. If the load unbalance between the
engines is a constant value correct by
resetting base speed setting nut (125). Turn
cw to decrease and vice versa.
d. If load unbalance moves from one
engine to the other when changing speed
from minimum to maximum readjust pivot
bracket (134).
5. Engine is slow to A. Incorrect buffer springs in governor. Install correct buffer springs (consult
recover from a Woodward).
speed deviation B. Governor oil pressure is low. See item 2A of this table.
resulting from a C. Fuel supply restricted. Clean fuel filters and fuel supply lines.
change in load or D. Engine may be overloaded. Reduce the load.
slow to respond to E. Type PG governors with Consult Woodward. Changes in field may
a change in speed pneumatic-hydraulic speed control are require services of a governor engineering
setting. designed to increase speed setting specialist.
slowly. If this is objectionable, special
parts can be supplied to obtain faster
action.
F. Supercharger does not come to new No simple field correction. Consult engine
speed quickly to supply sufficient air to manufacturer and Woodward or overhaul the
burn the added fuel. supercharger.
Woodward 25

6. Engine does A. Fuel racks do not open far enough. a. Check fuel pump stops and adjust as
not pick up rated necessary.
full load. b. Check linkage between governor and
fuel pumps and adjust if necessary.
c. Certain special PG governors are
equipped with a load limiting device, and the
governor may be against the load limit.
Adjustment may be made, if considered
advisable.
d. Oil pressure may be too low, see item
2A of this table.
B. Fuel supply restricted. See item 7C of this table.
C. Supercharger does not supply Overhaul supercharger.
sufficient air.
D. Slipping clutch (if used) between See clutch instruction manual.
engine and driven load.
7. Engine does A. Low control air pressure. Check pneumatic transmitter and air lines.
not reach full speed B. Maximum speed stop too low. At maximum control air pressure stop screw
and full load. (46) should not touch ball check (52).
C. Minimum and maximum speed too Raise level by readjusting base speed setting
low. nut (125) ccw.
D. Maximum speed too low only. Readjust pivot bracket (134).
E. Leaking bellows. Install new bellows (118).
F. Governor at end of travel (position a. Check fuel linkage adjustment.
10). b. Check fuel supply and filters.
G. Speed setting or manifold pressure Readjust settings A–G. (Consult engine
fuel limiter set too low. manufacturer).
H. Propeller too large. Consult shipyard.
8. Load Resonant condition between natural Consult engine manufacturer. Changing
oscillates between frequency of system and 0.5 order governor characteristics may attenuate the
geared engines. engine torsional. oscillations. It may be necessary to install
Both governors are stiffer couplings or couplings with more
hunting. damping.
9. Engine A. Governor too slow. Adjust needle valve for highest opening.
overspeeds on Install lighter buffer springs, if possible.
starting. B. Speed setting too high. Decrease starting speed setting.
C. Governor admits too much fuel for a. Limit travel of booster servomotor.
starting. b. Readjust speed setting or manifold
pressure torque limiter (consult engine
manufacturer).
D. Compensation bypass retarded. Install short buffer piston.
10. Engine stalls A. Governor too slow. Adjust needle valve for maximum opening.
on deceleration to Install lighter buffer spring. Try shorter buffer
minimum speed. piston.
B. Minimum speed too low. Raise minimum speed.
C. Compensation not being cut-off at Consult Woodward to check how governor is
idle. built.
26 Woodward
Chapter 5.
Introduction
For purposes of description, the PGA governor consists of three major sections;
a basic governor section, a speed setting section, and a speed droop linkage. A
schematic diagram (Figure 5-1) provides a visual means of understanding the
operation of the governor.
Basic Governor
The basic governor consists of an oil pump, two accumulators, a speeder spring,
a flyweight head assembly, a thrust bearing, a pilot valve plunger, a rotating
bushing, a buffer compensation system, and a power cylinder.
The governor drive shaft passes through the governor base and engages the
rotating bushing. The oil pump drive gear is an integral part of the bushing. The
pump supplies pressure oil for operation of the basic governor section, the speed
setting section, and all other auxiliary features or devices except applications
using a remote load regulator where engine oil is supplied to the load control
system. The accumulators provide a reservoir of pressurized oil and the relief
valve bypasses excess oil to the governor sump.
Where accumulator pressure exceeds 100 psi (690 kPa), a pressure reducing
valve is fitted to the main power case. This reduces pressure of the oil supplied
to the speed setting mechanism and auxiliary devices. Duplicate suction and
discharge check valves at the pump permit either cw or ccw rotation of the
governor without modification or change to the governor.
Some governors are plugged to limit rotation to one direction only

and are not equipped with check valves.
Operation of Basic PGA

Ballhead and Bushing
The upper end of the rotating bushing engages the flyweight head assembly and
provides a direct drive from the prime mover to the flyweights. The thrust bearing
translates the in-out movement of the flyweights to an up-down movement of the
pilot valve plunger while allowing the plunger to remain stationary with respect to
the rotating flyweights. The relative motion between the bushing and plunger also
minimizes static friction. Two styles of flyweight head assemblies are available.
The exact style used depends on the type of drive train to the governor. A solid
head is used when the drive is relatively free of torsion vibrations. A spring-driven
oil-damped ballhead assembly is used to attenuate objectionable levels of
torsional vibration which may be imparted to the governor from the prime mover.
These vibrations may originate from a source other than the drive itself but reach
the governor through the drive connection. Unless minimized or eliminated, these
vibrations are sensed as speed changes and the governor continually adjusts the
fuel control in an attempt to maintain a constant speed.
Woodward 27
Pilot Valve Plunger
Flyweight centrifugal force tends to lift the plunger while speeder spring force
tends to lower the plunger. The greater of two opposing forces moves the pilot
valve plunger up or down. When the prime mover is on-speed at any speed
setting, these forces are equal and the flyweights assume a vertical position. In
this position, the control land on the pilot valve plunger is centered over the
regulating port in the rotating bushing. No oil, other than leakage make-up, flows
to or from the buffer compensation system or power cylinder. A change in either
of these two forces moves the plunger from its centered position.
The plunger is lowered:
1. When the governor speed setting is unchanged but an additional load slows
the prime mover and governor (thereby decreasing flyweight centrifugal
force).
2. When the prime mover speed is unchanged but speeder spring force is
increased to raise the governor speed setting.
Similarly, the pilot valve plunger is raised when:
1. The governor speed setting is unchanged but load is removed from the
prime mover causing an increase in prime mover and governor speed (and
hence, an increase in flyweight centrifugal force).
2. The prime mover speed is unchanged but speeder spring force is reduced
to lower the governor speed setting.
When the plunger is lowered (an underspeed condition), pressure oil is directed
into the buffer compensation system and power cylinder to raise the power piston
and increase fuel or steam. When lifted (an overspeed condition), oil is permitted
to drain from these areas to sump and the power piston moves downward to
decrease fuel or steam.
Buffer Compensation System

The buffer piston, springs, and needle valve in the hydraulic circuits between the
pilot valve plunger and power cylinder make up the buffer compensation system.
This system stabilizes the governing action by minimizing over or undershoot
following a change in governor speed setting, or a change in load on the prime
mover. It establishes a temporary negative feedback signal (temporary droop) in
the form of a pressure differential which is applied across the compensation land
of the pilot valve plunger. The flow of oil into or out of the buffer system displaces
the buffer piston in the direction of flow. This movement increases the loading on
one spring while decreasing the other and creates a slight difference in the
pressures on either side of the piston with the higher pressure on the side
opposite the spring being compressed. These pressures are transmitted to
opposite sides of the plunger compensation land and produce a net force,
upward or downward, which assists in re-centering the plunger whenever a fuel
or steam correction is made.
28 Woodward
Speed Setting or Load Increase
Increasing the speed setting or increasing load on the prime mover at a given
speed setting have an identical effect. In either case, the flyweights move inward
(underspeed) due to either the increase in speeder spring force or to the
decrease in centrifugal force caused by the decrease in prime mover speed as
load is added. The movement of the flyweights is translated into a downward
movement of the pilot valve plunger. This directs pressure oil into the buffer
system, causing the buffer piston to move toward the power cylinder. The oil
displaced by the movement of the buffer piston forces the power piston to move
upward in the increase direction.
The oil pressures on either side of the buffer piston are simultaneously
transmitted to opposite sides of the plunger compensation land with the higher
pressure on the lower side. This pressure differential is proportional to buffer
piston displacement which, in turn, is determined by the buffer spring rate, rate of
power piston travel, and needle valve setting. The new upward force produced is
added to flyweight force and assists in restoring the balance of forces and re-
centering the pilot valve plunger slightly before the prime mover has fully
accelerated. In effect, this enables the governor to cut off the additional fuel
needed for acceleration by stopping the power piston when it has reached a point
corresponding to that amount of fuel or steam required for steady state operation
at the new higher speed or load. As the prime mover continues to accelerate
toward the set speed, the compensation force is gradually dissipated to offset the
continuing increase in flyweight force. This is done by equalizing the pressures
on each side of the compensation land through the needle valve at a rate
proportional to the continued rate of acceleration. If the rate of dissipation is the
same as the rate of increase in flyweight force, the pressure differential is
reduced to zero at the instant flyweight force becomes exactly equal to speeder
spring force. This minimizes speed overshoot and permits the governor to quickly
re-establish stable operation. The needle valve setting determines the rate at
which the differential pressure is dissipated and allows the governor to be
“matched” to the characteristics of the prime mover and its load. The compressed
buffer spring returns the buffer piston to its centered position as the pressure
differential is dissipated.
Whenever large changes in speed setting or load are made, the buffer piston
moves far enough to uncover a bypass port in the buffer cylinder. The pressure
differential across the buffer piston is restricted to some maximum value, and oil
is to flow directly to the power cylinder. The power piston responds quickly to
large changes in speed setting or load. Since the pressure differential across the
compensating land is restricted, the prime mover may overshoot or undershoot
slightly more than normal.
Speed Setting or Load Decrease

Decreasing the speed setting or decreasing load on the prime mover at a given
speed setting are also identical in effect and cause a reverse action to that
described above. The flyweights move outward (overspeed), lifting the pilot valve
plunger and allowing oil to drain from the buffer compensation system. The buffer
piston moves away from the power cylinder, permitting oil to drain from the area
under the power piston which then moves downward in the decrease direction.
The differential pressures acting across the compensation land produce a net
downward force tending to assist the speeder spring in re-centering the pilot
valve plunger slightly before the prime mover has fully decelerated. Power piston
movement is stopped when it has reached a point corresponding to that amount
of fuel or steam required for steady state operation at the new lower speed or
load. Dissipation of the compensation force occurs in the same manner as
previously described and, in this instance, minimizes speed undershoot.
Woodward 29
With large decreases in speed or load, the power piston moves to the “no fuel”
position and blocks the compensation oil passage between the power cylinder
and needle valve. This prevents normal equalization of the compensation
pressures. The buffer piston is held off center and the level of the pressure
transmitted to the upper side of the plunger compensation land is increased. The
increased pressure differential, added to the effect of the speeder spring,
temporarily increases the governor speed setting. The governor begins corrective
action as soon as prime mover speed drops below the temporary speed setting.
This starts the power piston upward to restore the fuel or steam supply in
sufficient time to prevent a large underspeed transient. The above action is
sometimes referred to as “compensation cutoff”. When the upward movement of
the power piston again uncovers the compensation oil passage, normal
compensating action resumes and stabilizes prime mover speed at the actual
speed setting of the governor.
Speed Setting Section

The speed setting section (Figure 5-1) consists of a bellows housed within a
pressure chamber, a hydraulic speed setting pilot valve (pilot valve plunger and
rotating bushing), a single-acting spring-return speed setting hydraulic cylinder, a
restoring linkage for re-centering the pilot valve plunger, and a manual speed
setting mechanism.
The governor speed setting is directly proportional to control air pressure (speed
setting increases as air pressure increases). An increase in control air pressure
causes the bellows to contract and move the pilot valve plunger downward
(increase speed).
The speed at which the governor controls is determined by the force exerted on
the toes of the flyweights by the speeder spring in the basic governor section.
Speeder spring force is determined by the position of the piston in the speed
setting cylinder. The position of the piston, in turn, is determined by the volume of
oil trapped in the area above the piston. The direction and rate of oil flow into or
out of this area is controlled by the speed setting pilot valve plunger which is
mechanically linked to the bellows. If the plunger is moved downward,
uncovering the upper edge of a metering port in the bushing, pressure oil is
allowed to flow into the speed setting cylinder. This displaces the piston
downward, further increasing speeder spring tension and increasing the speed
setting. If the plunger is moved upward, uncovering the lower edge of the
metering port, oil is permitted to drain from the cylinder. This allows the piston
spring to raise the piston, decreasing speeder spring force and lowering the
speed setting.
30 Woodward
The rate of movement of the speed setting piston over its full downward stroke
(idle to maximum speed) is retarded to occur over some specific time interval.
This is done by admitting governor pressure oil into the rotating bushing through
an orifice which registers with the main supply port once in every revolution of the
bushing. This reduces the rate at which oil is supplied to the control port in the
bushing and therefore, the rate of oil flow to the speed setting cylinder. The
diameter of the orifice determines the specific time interval which may be
anywhere within a nominal range of 1 to 50 seconds. Therefore, the rate at which
the speed setting may be increased is restricted under all conditions of operation.
The longer rates are generally used with turbo-supercharged units to permit the
supercharger to accelerate with the engine. The rate of movement of the power
piston over its full upward stroke (maximum to idle speed) is also restricted on
turbo-supercharged units to prevent compressor surge during decelerations. This
timing may be anywhere within a nominal range of 1 to 15 seconds. In these
cases, the speed setting pilot valve plunger has an additional land (not
illustrated) which covers the drain port in the bushing. A vertical slot in the drain
land registers with a second orifice in the rotating bushing once each revolution.
This restricts the rate at which the oil is allowed to drain from the speed setting
cylinder. The width of the slot in the drain land determines the length of time the
drain port (orifice) is open during each revolution and therefore the specific
deceleration time interval.
Direct Pneumatic Operation
The manual speed setting knob must be turned fully ccw to raise the
manual speed setting screw to its uppermost (minimum or low
speed) position during pneumatic operation, If the speed setting
screw (knob) is in any position other than minimum speed, it will, in
effect, raise the pneumatic low speed setting of the governor and
prevent normal pneumatic operation at speed below this setting.
The bellows and restoring spring comprise a force-balance system which is

mechanically connected to the speed setting pilot valve plunger through a
C-shaped link. Control air pressure acting externally on the bellows exerts a
downward force on the lower leg of the C-shaped link. The restoring spring
connected to the upper leg of the link exerts an opposing upward force. Except
during a speed setting change, the downward force of the air pressure acting
upon the bellows exactly counterbalances the upward force of the restoring
spring. With these forces in ‘balance’, the control land on the pilot valve plunger
covers the metering port in the bushing and no oil, other than leakage, can flow
into or out of the speed setting cylinder. A change in control air pressure disturbs
this balance and results in a speed setting change.
Woodward 31
With an increase in control air pressure (increase speed setting), the force acting
on the bellows becomes greater than the restoring spring force and the bellows
contracts in a downward direction. This pushes the C-shaped link downward and
lowers the pilot valve plunger. Intermittent pressure oil then flows into the speed
setting cylinder, forcing the piston downward to further compress the speeder
spring and thereby increase the governor speed setting. As the piston moves
downward, the restoring lever attached at the right end to the upper end of the
piston rod pivots cw about an adjustable ball bearing fulcrum on the extended
arm of the manual speed setting screw. The left end of the lever is connected to
the restoring spring and a loading spring. The cw movement of the lever causes
a proportional increase in restoring spring force which, acting through the link,
gradually expands the bellows to its original length while simultaneously lifting
the plunger. When the net increase in restoring spring upward force equals the
increase in downward force resulting from the increase in control air pressure,
the bellows and plunger is re-centered (restored) with the plunger control land
covering the metering port in the bushing. This stops the flow of oil into the speed
setting cylinder, halting downward movement of the piston at the instant speeder
spring force reaches its new higher value corresponding to that higher control air
pressure. The loading spring ‘loads’ the restoring lever to maintain positive
contact between the lever and ball bearing fulcrum at all times.
With a decrease in control air pressure (decrease speed setting), the force acting
on the bellows becomes less than the restoring spring force and the bellows
expands in an upward direction. This allows the restoring spring to lift the C-
shaped link and pilot valve plunger. As oil drains from the speed setting cylinder
the piston rises, decreasing speeder spring force and the governor speed setting.
As the piston rises, the restoring lever pivots in a ccw direction, proportionally
reducing restoring spring force. The bellows gradually contracts to its original
length and simultaneously lowers the plunger. A decrease in control air pressure
decreases the downward pressure of the bellows. When the upward force of the
restoring spring equals the downward force of the bellows, the control land of the
speed setting pilot valve plunger centers the metering port in the bushing. This
stops oil drainage from the speed setting cylinder, halting upward movement of
the piston at the instant the speeder spring force reaches its new lower value
corresponding to the lower control air pressure.
The ratio of change in restoring spring force for a given movement of the speed
setting piston is determined by the distance between the ball bearing fulcrum and
the point at which the restoring lever is attached to the piston rod. Shortening this
distance decreases the governor speed range for a given control air pressure
range; lengthening this distance increases the speed range for a given air
pressure range.
Some applications may require that the governor be adjusted to go to low speed
upon intentional or accidental interruption of control air pressure or when control
air pressure drops below the required minimum value. In these instances, the
pneumatic low speed adjusting screw is set to contact a stop pin projecting from
the restoring lever when control air pressure and prime mover speed are at their
normal minimum values. If control air pressure is lost or reduced below the
minimum value, the restoring spring raises the speed setting pilot valve plunger
until the low speed adjusting screw contacts the stop pin in the restoring lever. As
the speed setting piston moves upward, the stop pin in the restoring lever
simultaneously pushes downward on the pneumatic low speed adjusting screw
re-centering the speed setting pilot valve plunger at the moment the piston
reaches its low speed position. Governors set to go to low speed upon loss of
control air pressure are usually equipped with an auxiliary shutdown device.
32 Woodward
If the governor is adjusted to go to shutdown upon loss of control air pressure,
the pneumatic low speed adjusting screw is set so that a definite clearance exists
between it and the stop pin in the restoring lever when the control air pressure is
reduced to zero and the governor is shut down. In this case, should control air
pressure be interrupted or reduced below the minimum value, the movement of
the restoring lever as the speed setting piston moves upward does not tend to re-
center the speed setting pilot valve plunger. Therefore, the piston continues to
move upward past the low speed position to the shutdown position.
Normal Shutdown
The shutdown device consists of a shutdown rod which projects upward through
the center of the speed setting piston rod and is attached to the top of the main
pilot valve plunger in the basic governor section. Two nuts on the upper end of
the shutdown rod complete the device. When control air pressure is turned off
the speed setting piston moves upward past its normal low speed position. After
a movement of 1/16-inch, the fulcrum block on the end of the piston rod contacts
the lower (shutdown) nut, lifting the shutdown rod and pilot valve plunger. Oil
drains from the power cylinder, and the power piston moves downward to the
zero fuel or steam position. Some governor applications may require that the
speed setting piston stop be used as a positive low speed stop. In such cases,
the shutdown nuts are usually omitted since the governor cannot be used or
adapted to shutdown the prime mover and some shutdown method external to
the governor must be provided.
Manual Speed Setting Mechanism

The manual speed setting mechanism consists of a knob and friction clutch, a
leadscrew and nut linked to a sliding collar, a speed adjusting nut, high speed
adjusting setscrew and stop pin, and a T-shaped manual speed setting screw
with a ball bearing fulcrum. The knob can be used to adjust the speed setting to
any point within the normal speed range when control air pressure is not
available or its use is not desired.
Manual Operation
With no control air pressure, the pneumatic low speed adjusting screw is held
against the stop pin in the restoring lever by the restoring spring. The restoring
lever is directly connected, through the C-shaped link, to the speed setting pilot
valve plunger. Turning the knob cw (increase speed setting) causes the
leadscrew nut to move outward and lower the sliding collar under the speed
adjusting nut on the vertical shaft of the speed setting screw. This allows the
loading spring to move the speed setting screw (and ball bearing fulcrum)
downward with the collar until the high speed adjusting setscrew contacts the
high speed stop pin.
Woodward 33
As the speed setting screw moves downward to a new position, the left end of
the restoring lever, pulled downward by the loading spring, pushes downward on
the pneumatic low speed adjusting screw and link, uncentering the speed setting
pilot valve plunger. Pressurized oil flows into the speed setting cylinder and
forces the piston downward, increasing the speed setting. The movement of the
piston causes a cw rotation of the restoring lever. Since the pneumatic low speed
adjusting screw is held against the stop pin in the restoring lever by the restoring
spring, the speed setting pilot valve plunger is lifted upward as the lever rotates
until the plunger is again re-centered at the instant the new higher speed position
is attained by the piston.
Turning the knob ccw (decrease speed setting) causes the leadscrew nut to
move inward and raise the sliding collar under the speed adjusting nut. This lifts
the speed setting screw (and ball bearing fulcrum) upward, raising the left end of
the restoring lever and thereby lifting the speed setting pilot valve plunger above
its centered position. As oil drains from the speed setting cylinder, the piston
moves upward, decreasing the speed setting. The ccw movement of the
restoring lever re-centers the plunger at the instant the new lower speed position
is attained by the piston.
Maximum Speed Limiting Valve

The maximum speed limiting valve is a check valve located in the top of the
speed setting cylinder. A limiting valve adjusting screw in a lug on the rod of the
speed setting piston unseats the valve whenever the piston reaches the
maximum speed position (approximately 5 rpm above the normal high speed
rpm). With the valve unseated, excess oil tending to increase the speed setting
beyond the maximum speed set point is released to sump. The valve is effective
whether the speed setting is changed pneumatically or manually.
Piston Stop Setscrew

The piston stop setscrew limits upward travel of the speed setting piston at
shutdown to 3/32 inch (2.4 mm) above the low speed position of the piston. The
cranking time required when the prime mover is restarted is minimized since a
lesser volume of oil is required to move the piston downward to the low speed
position.
Temperature Compensation
In early model governors, a bi-metal strip incorporated in the restoring lever
compensated for differential expansion and changes in spring rates due to
temperature variations. In late model governors, a temperature compensated
(reverse modulus) speeder spring is used in place of the bimetal strip. The
governor speed settings are better stabilized and drifting, due to changes in
ambient and/or operating temperatures are minimized.
34 Woodward
Speed Droop Linkage

Description
Speed droop is a governor feature which allows the prime mover to run at a
proportionally lower speed as load is increased while at the same time it
increases fuel, compensating for the additional load. Speed droop increases
initial stability of the governor and permits division and balancing of loads
between prime movers operated in tandem to drive a common shaft. Speed
droop is defined as the proportional decrease in speed which occurs as the
governor power piston moves from the minimum to the maximum fuel or steam
position. It is normally expressed as the difference in rpm from no-load to full-
load as a percentage of maximum rated speed.
Operation
The linkage automatically changes the governor speed setting by reducing
speeder spring force a slight amount as a function of power piston travel in the
increase direction. Conversely, it increases speeder spring force as the piston
moves in the decrease direction. It consists of a fulcrum block attached to the
upper end of the speed setting piston rod, a lever and fulcrum pin assembly
connected between the fulcrum block and power piston tailrod, an adjustable
cam attached to the fulcrum pin, and a moveable plunger housed within the
speed setting piston rod. The movement of the power piston, transmitted through
the lever assembly causes a rotational movement of the cam which contacts the
top of the plunger. This, in turn, causes an upward (or downward) movement of
the plunger which rests on top of the speeder spring.
The position of the cam lobe with respect to the centerline of the fulcrum pin
determines the proportion of lever movement transmitted to the plunger. When
the centerline is common to both pin and cam lobe, no movement is transmitted
to the plunger. With such a setting (0 droop), the governor attempts to maintain
the set speed regardless of load (isochronous operation). If the lobe of the cam is
positioned at increasing distances from the centerline of the fulcrum pin, an
increasing proportion of lever movement is transmitted to the plunger (droop
operation). The exact position of the cam is determined by the prime mover
characteristics and the share of the load to be carried by that prime mover. The
cam must never be positioned on the opposite side of the fulcrum pin centerline
(toward the pneumatic receiver) as “negative” droop (speed increases with
movement of the power piston in the increase direction) occurs and results in
unstable operation.
Power Cylinders
12 ft-lb (16 J)
All power cylinder assemblies operate under the same basic principle, with a
reciprocating (push-pull) motion. Power cylinder assemblies with a rotary terminal
shaft are available as an alternate, depending upon the installation requirements.
In the arrangement shown in Figure 5-2, the oil needed to move the power piston
in the increase fuel direction is obtained when the governor pilot valve plunger is
lowered below its centered or balanced position. The opened port admits
pressure oil to the buffer piston area, moving the buffer piston, transferring an
equal volume of oil to the power cylinder, and forcing the power piston to move in
the direction to increase fuel to the prime mover.
Woodward 35
To move the power piston in the decrease fuel direction, the governor pilot valve
plunger is raised above its centered position. The trapped oil in the power
cylinder is released to the sump and the power spring forces the power piston in
the decrease fuel direction.
29 ft-lb (39 J) (Rotary Output)

With rotary output power cylinders, the linear motion is converted to a rotary
motion. This power servo (Figure 5-3) “pulls” to increase fuel to the prime mover.
The oil needed to move the power piston is obtained when the governor pilot
valve plunger is lowered below its centered or balanced position. The open port
admits pressure oil to the buffer piston area, moving the buffer piston,
transferring an equal volume of oil to the power cylinder and forcing the power
piston to move in the direction to increase fuel to the prime mover.
To move the power piston in the decrease fuel direction, the pilot valve plunger is
raised above its centered position. When the trapped oil below the power piston
is released to the sump, the pump pressure forces the piston in the decrease
direction.
Compensation Cutoff
With large decreases in speed setting, or large load decrease, the power piston
moves to the “no fuel” position and blocks the compensation oil passage
between the power cylinder and needle valve to prevent normal equalization of
the compensation pressures. This holds the buffer piston off center and
increases the level of the pressure transmitted to the upper side of the plunger
compensation land. The increased pressure differential,- added to the effect of
the speeder spring, temporarily increases the governor speed setting. The
governor begins corrective action as soon as engine speed drops below the
temporary speed setting and starts the power piston upward to restore the fuel
supply in sufficient time to prevent a large underspeed transient. The above
action is referred to as “compensation cutoff”. When the upward movement of the
power piston again uncovers the compensation oil passage, normal
compensating action is resumed and engine speed is stabilized at the actual
speed setting of the governor.
Due to the location of the compensation cutoff port in the power

cylinder wall, the governor/fuel rack linkage must be adjusted so that
the power piston “gap” does not exceed 1-1/32 inches (26.2 mm) at
idle-speed no-load, or less than 4° from minimum fuel.
36 Woodward
Figure 5-1. Schematic Diagram of PGA with Direct Bellows
Woodward 37
Figure 5-2. Schematic Diagram of 12 ft-lb Spring Loaded Power Cylinder
Figure 5-3. Schematic Diagram of 29 ft-lb Differential Power Cylinder (Linear or

Rotary Output)
38 Woodward
Chapter 6.
Replacement Parts
Replacement Parts Information

This chapter provides replacement parts information for the PGA marine
governor. When ordering replacement parts, include the following information:
 Governor serial number and part number shown on nameplate
 Manual number (this is manual 36604)
 Parts reference number in parts list and description of part or part name

property damage.
Woodward 39

Ref. No. Part Name .................................Quantity Ref. No. Part Name ................................. Quantity
36604-1 Screw, hex. hd., drilled, 5/16-24 x 6-1/4 . 2 36604-51 Speed setting piston ...............................1
36604-2 Plain washer, 5/16 x 1/2 x 1/32 .............. 2 36604-52 Speed droop plunger ..............................1
36604-3 Oil filler cup (press-fit) ............................ 1 36604-53 Speed setting piston return spring ..........1
36604-4 Cover dowel bushing (press-fit).............. 2 36604-54 Power piston fulcrum (used
36604-5 Drive screw, #2 x 3/16 ............................ 4 without speed droop) ..............................1
36604-6 Nameplate .............................................. 1 36604-55 Indicator plate .........................................1
36604-7 Cover ..................................................... 1 36604-56 Washer ...................................................1
36604-8 Cover gasket .......................................... 1 36604-57 Screw ......................................................1
36604-9 Screw, soc. hd., 5-40 x 1/2 ..................... 1 36604-58 Hex hd. screw, 0.3 125-24 x 4.9688 .......4
36604-10 Lockwasher, split, #5 .............................. 1 36604-59 Split Iockwasher, 0.3125 .........................4
36604-11 Screw, soc. hd., 1/4-28 x 2 ..................... 1 36604-60 Plain washer, 0.3125 ..............................4
36604-12 Screw, soc. hd., 1/4-28 x 1-1/4............... 1 36604-61 Column sub-assy. (includes item 94) ......1
36604-13 Lock washer, split, 1/4 ............................ 2 36604-62 O-ring, 0.375 ...........................................1
36604-14 Pneumatic receiver assembly 36604-63 By-pass hole plug ...................................1
(see Figure 6-2) ...................................... 1 36604-64 O-ring, 0.375 ...........................................1
36604-15 Cap screw, 0.250-28 x 0-.750 ................ 1 36604-65 Plug ........................................................1
36604-16 Regulating bushing retainer spring ......... 1 36604-66 Inner plug ................................................1
36604-17 Retainer spring collar ............................. 1 36604-67 Soc. hd. pipe plug 0.125 ....................A.R.
36604-18 Washer, 0.328 x 0.562 x 0.064 thick ...... 1 36604-68 Standard power case assy. illustrated
36604-19 Regulating bushing retainer ................... 1 (see Figure 6-3) ......................................1
36604-20 Retainer screw ....................................... 1 36604-69 O-ring ......................................................1
36604-21 Washer. 0.265 x 0.500 x 0.032 thick ...... 1 36604-70 Gasket (column to power case) ..............1
36604-22 Regulating bushing ................................ 1 36604-71 Drive gear bearing stud (press-fit) ..........1
36604-23 Spacer .................................................... 1 36604-72 Speed setting bushing drive gear ...........1
36604-24 Thrust bearing ........................................ 1 36604-73 Spring check plug ...................................1
36604-25 Pilot valve plunger (speed setting) ......... 1 36604-74 Gasket ....................................................1
36604-26 Rotating bushing (SS PV plunger) ......... 1 36604-75 Column side plate ...................................1
36604-27 Plug (press-fit) ........................................ 1 36604-76 Screw ....................................................10
36604-28 Loading spring (SS bushing) .................. 1 36604-77 Lockwasher...........................................10
36604-29 Nut ......................................................... 1 36604-78 Base .......................................................1
36604-30 Nut ......................................................... 1 36604-79 Hex hd. screw, 0.3125-18 x 1 .................4
36604-31 Droop plunger cap .................................. 1 36604-80 Lockwasher, 0.3125 ................................4
36604-32 Power piston fulcrum assembly.............. 1 36604-81 Oil seal ....................................................1
36604-33 Speed droop cam ................................... 1 36604-82 Gasket (power cylinder to power case) ...1
36604-34 Nut ......................................................... 1 36604-83 Soc. hd. screw 0375-16 x 1 ....................4
36604-35 Screw ..................................................... 1 36604-84 Lockwasher, 0375 ...................................4
36604-36 Washer ................................................... 1 36604-85 12 ft-lb., spring-return, linear output,
36604-37 Droop lever assembly ............................ 1 power cylinder (see Figure 6-6) ..............1
36604-37A Droop lever............................................. 1 36604-86 Bushing gasket .......................................1
36604-38 Droop pivot lever assembly .................... 1 36604-87 Bushing ...................................................1
36604-38A Pivot pin ................................................. 1 36604-88 Washer, .250 lD x .031 thick, max.
36604-39 Pin spacer .............................................. 1 OD .490 ..................................................1
36604-39A Pin spacer .............................................. 1 36604-89 Soc. hd. cap screw, .250-28 x .375.........1
36604-40 Washer ................................................... 1 36604-90 Spring .....................................................1
36604-40A Washer ................................................... 1 36604-91 Spring .....................................................1
36604-41 Cotter pin................................................ 1 36604-92 O-ring ......................................................1
36604-41A Cotter pin................................................ 1 36604-93 12 ft-lb., spring return, rotary output,
36604-42 Speed setting cylinder ............................ 1 power cylinder.........................................1
36604-43 Limiting valve assy. (max. speed) .......... 1 36604-94 Thread insert (included in column assy) .1
36604-44 Adjusting screw (max. speed) ................ 1 36604-95 Plug ........................................................1
36604-45 Nut, 10-32 .............................................. 1 36604-96 Plug ........................................................1
36604-46 Guide stud .............................................. 1 36604-97 Plug ........................................................1
36604-47 Nut, 10-32 .............................................. 1 36604-98 Pin ..........................................................1
36604-48 Oval point soc. hd. set screw ................. 1 36604-99 Bracket ...................................................1
36604-49 Split lockwasher, 0.250 .......................... 2 36604-100 Screw ......................................................1
36604-50 Hex hd. screw, 0.250-28 x 1.375............ 2
40 Woodward
Figure 6-1. Exploded View of PGA Long Column
Woodward 41

36604-101 Loading spring (restoring lever).............. 1 36604-136 through 148 Not used
36604-102 Restoring spring ..................................... 1 36604-149 Shutdown solenoid .................................1
36604-103 Restoring lever ....................................... 1 36604-150 Gasket ....................................................1
36604-104 Cotter pin, 1/16 x 3/8 ......................... A.R. 36604-151 Electrical connector ................................1
36604-105 Loading spring pin .................................. 1 36604-152 Washer ...................................................4
36604-106 Stop pin (pneumatic low speed) ............. 1 36604-153 Screw ......................................................4
36604-107 Pilot valve C-link ..................................... 1 36604-154 Friction spring .........................................1
36604-108 Nut, 10-32 .............................................. 1 36604-155 Dial plate .................................................1
36604-109 Stop screw (pneu. low speed adj.) ......... 1 36604-156 Receiver bracket gasket .........................1
36604-110 Headed pin ............................................. 1 36604-157 Philips rd. hd. screw, 6-32 x 3/8 ..............4
36604-111 Bellows coupling .................................... 1 36604-158 Washer, 25/64 x 5/8 x 1/16 .....................1
36604-112 Setscrew, soc. hd, cone pt., 8-32 x 5/16 1 36604-159 Soc. hd. setscrew, 8-32 x 3/8..................1
36604-113 Passage screw ....................................... 1 36604-160 Mid-grip thread insert, 8-32 x 1/4 ............1
36604-114 Washer, soft copper ............................... 1 36604-161 Pivot pin ..................................................4
36604-115 Receiver cup gasket ............................... 1 36604-162 Lead screw nut .......................................1
36604-116 Setscrew, soc. hd., cone pt., 5-40 x 1/4 . 1 36604-163 Spring washer .........................................1
36604-117 Retaining ring, int., 1 .650 OD ................ 1 36604-164 Shoulder washer .....................................1
36604-118 Bellows assy .......................................... 1 36604-165 Speed setting link ...................................1
36604-119 Preformed packing, 1-1/2 OD................. 1 36604-166 Lead screw .............................................1
36604-120 Pneumatic receiver cup .......................... 1 36604-167 Spring roll pin, 3/32 x 5/8 ........................1
36604-121 Speed setting collar ................................ 1 36604-168 Clutch spring ...........................................1
36604-122 Stop pin (high speed) ............................. 1 36604-169 Manual speed adjusting knob .................1
36604-123 Speed setting screw ............................... 1 36604-170 Belleville washer .....................................2
36604-124 Thread insert, 10-32 x 3/8, mid-grip ....... 1 36604-171 Self-locking nut, 1/4-28 ...........................1
36604-125 Setscrew. soc. hd., oval pt., 10-32 x 1 ... 1 36604-172 Mid-grip thread insert 8-32 x 1/4 .............1
36604-126 Speed adjusting nut (manual low speed) 1 36604-173 Friction spring seat .................................1
36604-127 Thread insert, 7/16-20 x 7/16, mid-grip .. 1 36604-174 Dowel pin ................................................2
36604-128 Knurled nut ............................................. 2 36604-175 Spacer ....................................................4
36604-129 Screw, soc. hd., 10-32 x 1-1/8................ 1 36604-176 Receiver bracket .....................................1
36604-130 Lockwasher, hi-collar, #10...................... 2 36604-177 Cotter pin ................................................1
36604-131 Screw, soc. button hd., 10-32 x 1 ........... 1 36604-178 Diode ......................................................1
36604-132 Spacer .................................................... 1 36604-179 Screw ......................................................1
36604-133 Ball bearing ............................................ 1 36604-18 Set Screw, 10-32 x .250 .........................1
36604-134 Pivot bracket .......................................... 1 36604-181 through 200 Not used
36604-135 Lockwasher, #10 hi-collar....................... 1
42 Woodward
Figure 6-2. Exploded View of PGA Receiver Assembly
Woodward 43

36604-201 Pipe plug, 1/8 ......................................... 4 36604-235 Compensating bushing ...........................1
36604-202 Pipe plug, 1/16 ....................................... 2 36604-236 Retainer ring ...........................................1
36604-203 Dowel pin ............................................... 2 36604-237 Flyweight pin ...........................................4
36604-204 Instruction plate ...................................... 1 36604-238 Cotter pin ................................................8
36604-205 Drive screw ............................................ 3 36604-239 Flyweight head........................................1
36604-206 Power case ............................................ 1 36604-240 Lockwasher, #5.......................................8
36604-207 Small accumulator spring ....................... 2 36604-241 Fil. hd. screw, 5-40 x 9/32 .......................8
36604-208 Large accumulator spring ....................... 2 36604-242 Spring coupling assembly .......................1
36604-209 Retaining ring ......................................... 2 36604-243 Splitlock washer, #8 ................................1
36604-210 Spring seat ............................................. 2 36604-244 Rd. hd. screw, 8-32 x 5/16 ......................1
36604-211 Spring seat ............................................. 1 36604-245 Flyweight ................................................2
36604-212 Buffer spring ........................................... 2 36604-246 Bearing ...................................................4
36604-213 Buffer piston ........................................... 1 36604-247 Spring .....................................................1
36604-214 Plug ........................................................ 1 36604-248 Spring washer .........................................1
36604-215 O-ring ..................................................... 1 36604-249 Thrust bearing.........................................1
36604-216 Snap ring ................................................ 1 36604-250 Speeder spring seat ................................1
36604-217 Oil level gauge ....................................... 1 36604-251 Cotter pin ................................................1
36604-218 Oil gauge elbow ..................................... 1 36604-252 Pilot valve plunger nut ............................1
36604-219 Drain cock .............................................. 1 36604-253 Speeder spring .......................................1
36604-220 Accumulator piston ................................. 2 36604-254 Speeder spring check plug .....................1
36604-221 Retainer ring........................................... 2 36604-255 Not used
36604-222 Idler gear stud ........................................ 1 36604-256 Shutdown rod..........................................1
36604-223 Idler gear ................................................ 1 36604-257 Shutdown nut ..........................................1
36604-224 Drive gear............................................... 1 36604-258 Pilot valve bushing assy (optional)..........1
36604-225 Check valve assy (plain) ........................ 2 36604-259 Solid flyweight head assy (optional) ........1
36604-226 Check valve assy (spring loaded) .......... 2 36604-260 Pressure spacer......................................1
36604-227 Retainer ring........................................... 1 36604-261 Pressure reducing valve sleeve ..............1
36604-228 Plug ........................................................ 1 36604-262 Plunger ...................................................1
36604-229 Spring seat ............................................. 1 36604-263 Retaining ring, 0.103 ID ..........................1
36604-230 Spring ..................................................... 1 36604-264 Spring .....................................................1
36604-231 Pilot valve bushing & flyweight 36604-265 Roll pin 0.062 dia. x 0.438 ......................1
head gear assembly ............................... 1 36604-266 Plug ........................................................1
36604-232 Oil seal ring ............................................ 1 36604-267 Spring .....................................................1
36604-233 Bearing ................................................... 1 36604-268 to 280 Not used
36604-234 Pilot valve plunger .................................. 1
44 Woodward
Figure 6-3. Exploded View of PGA Power Case
Woodward 45

Ref. No. Part Name .................................Quantity
36604-281 Lockwire ............................................ A.R.
36604-282 Screw, dr. hd. cap, 1/4-28 x 5/8 ............. 3
36604-283 Bearing retainer ...................................... 1
36604-284 Gasket .................................................... 1
36604-285 Oil seal retainer ...................................... 1
36604-286 Oil seal ................................................... 1
36604-287 Retaining ring ......................................... 1
36604-288 Bearing ................................................... 1
36604-289 Drive shaft .............................................. 1
36604-290 Pin .......................................................... 2
36604-291 Base ....................................................... 1
36604-292 Washer ................................................... 4
36604-293 Screw ..................................................... 4
36604-294 to -300 Not used

Ref. No. Part Name .................................Quantity
36604-301 Lockwire (MS9226-3) ........................ A.R.
36604-302 Screw, dr. hd. cap, 1/4-28 x 5/8
(MS5109-5) ............................................ 3
36604-303 Bearing retainer ...................................... 1
36604-304 Cotter pin (MS24665-372) ...................... 1
36604-305 Castle nut, 5/8-18 (AN310-10) ............... 1
36604-306 Spacer .................................................... 1
36604-307 Bearing ................................................... 1
36604-308 Key ......................................................... 1
36604-309 Drive shaft (keyed) ................................. 1
36604-310 Retaining ring ......................................... 1
36604-311 Drive shaft (serrated or splined) ............. 1
36604-312 Oil seal retainer ...................................... 1
36604-313 Oil seal ................................................... 1
36604-314 Gasket .................................................... 1
36604-315 Plug ........................................................ 2
36604-316 Pin .......................................................... 2
36604-317 Base, PG/UG-8 standard ....................... 1
36604-318 Base, PG/UG-8-90° ................................ 1
36604-319 Base, PG/UG-40 .................................... 1
36604-320 Base, PG-Extended Square ................... 1
36604-321 Washer ................................................... 4
36604-322 Screw ..................................................... 4
36604-323 Washer ................................................... 4
36604-324 Screw ..................................................... 4
36604-325 Washer ................................................... 4
36604-326 Screw ..................................................... 4
36604-327 Washer ................................................... 4
36604-328 Screw ..................................................... 4
36604-329 & -330 Not used Figure 6-4. Exploded View, Standard PG Base
Assembly
46 Woodward
Figure 6-5. Exploded View of PG/UG-8, PG/UG-8-90°, PG/UG-40, and PG

Extended Square Bases
Woodward 47

Ref. No. Part Name ................................ Quantity
36604-331 Screw, cap, soc. hd., 1/4-28 x 3/4 ............ 4
36604-332 Washer ................................................... 4
36604-333 Spring guard ........................................... 1
36604-334 Spring, power cylinder ............................ 1
36604-335 Gasket .................................................... 1
36604-336 Pin .......................................................... 1
36604-337 Tailrod .................................................... 1
36604-338 Tailrod locknut ........................................ 1
36604-339 Tailrod lift nut .......................................... 1
36604-340 Shakeproof washer ................................ 1
36604-341 Piston & rod assembly ............................ 1
36604-342 Power cylinder assy (linear) ................... 1
36604-343 Oil seal ................................................... 1
36604-344 Oil seal ................................................... 1
36604-345 Not used
36604-346 Rod end .................................................. 1
36604-347 Not used
36604-348 Taper pin ................................................ 1
36604-349 Not used
36604-350 Screw ..................................................... 1
36604-351 Nut.......................................................... 1
36604-352 Indicator plate ......................................... 1
36604-353 Washer ................................................... 2
36604-354 Screw ..................................................... 2
36604-355 Spring ..................................................... 1
36604-356 Spring guard seal ring ............................ 1
36604-357 O-ring ..................................................... 1
36604-358 Gasket .................................................... 1
36604-359 Washer ................................................... 4
36604-360 Screw ..................................................... 4
36604-361 O-ring ..................................................... 1
36604-362 Needle valve........................................... 1
36604-363 to -470 Not used
48 Woodward
Figure 6-6. Exploded View of 12 ft-lb Spring Loaded Power Cylinder (Linear
Output)
Woodward 49

36604-471 O-ring ..................................................... 1 36604-498 Pointer ....................................................1
36604-472 Spring guard seal ring ............................ 1 36604-499 Screw ......................................................1
36604-473 Spring ..................................................... 1 36604-500 Washer ...................................................2
36604-474 Washer ................................................... 2 36604-501 Screw ......................................................2
36604-475 Screw ..................................................... 2 36604-502 Power rod pin..........................................1
36604-476 Indicator plate......................................... 1 36604-503 Nut, 7/16-20 ............................................1
36604-477 Spring guard........................................... 1 36604-504 Power piston link.....................................2
36604-478 Screw ..................................................... 4 36604-505 Retaining ring..........................................2
36604-479 Lockwasher ............................................ 4 36604-506 Power lever pin .......................................1
36604-480 Gasket .................................................... 1 36604-507 Retaining ring..........................................2
36604-481 Spring ..................................................... 1 36604-508 Power lever .............................................1
36604-482 Pin .......................................................... 1 36604-509 Screw ......................................................2
36604-483 Tailrod .................................................... 1 36604-510 Lockwasher.............................................2
36604-484 Tailrod locknut ........................................ 1 36604-511 Gasket ....................................................1
36604-485 Tailrod lift nut.......................................... 1 36604-512 Sub-cap ..................................................1
36604-486 Shakeproof washer ................................ 1 36604-513 Plug ........................................................1
36604-487 Power piston .......................................... 1 36604-514 Screw ......................................................8
36604-488 Power cylinder assy (rotary) ................... 1 36604-515 Lockwasher.............................................8
36604-489 Needle bearing (large) ........................... 1 36604-516 Gasket ....................................................1
36604-490 Oil seal (large) ........................................ 1 36604-517 Needle bearing (small) ............................1
36604-491 Terminal shaft ........................................ 1 36604-518 Oil seal (small) ........................................1
36604-492 Rack dial segment .................................. 1 36604-519 Needle valve ...........................................1
36604-493 Terminal shaft scale ............................... 1 36604-520 O-ring ......................................................1
36604-494 Drive screw ............................................ 1 36604-521 Screw ......................................................4
36604-495 Screw ..................................................... 1 36604-522 Lockwasher.............................................4
36604-496 Washer ................................................... 1 36604-523 to -600 Not used
36604-497 Pointer rack ............................................ 1
50 Woodward
Figure 6-7. Exploded View of 12 ft-lb Spring Loaded Power Cylinder (Rotary
Output)
Woodward 51

36604-601 Screw, soc. hd. 5/16-24 inch .................. 6 36604-628 Oil Seal ...................................................2
36604-602 Washer, 5/16 split lock ......................... 10 36604-629 Needle Bearings .....................................2
36604-603 Power cylinder head ............................... 1 36604-630 DO NOT USE
36604-604 Screw, soc. hd., 1/4-28 x 1/2 .................. 1 36604-631 DO NOT USE
36604-605 Washer, 17/64 x 9/16, flat ...................... 1 36604-632 DO NOT USE
36604-606 Tail rod end ............................................ 1 36604-633 DO NOT USE
36604-607 Tallrod, power piston .............................. 1 36604-634 DO NOT USE
36604-608 Screw, soc. hd, 1/4-28 x 7/8 ................... 8 36604-635 Needle Valve ..........................................1
36604-609 Washer, 14 In. split lock ......................... 8 36604-636 O-ring, 438 OD .......................................1
36604-610 Cover, power cylinder ............................ 1 36604-637 Power Cylinder .......................................1
36604-611 Plug, pipe, 1/8-27 NPT ........................... 1 36604-638 Gasket ....................................................1
36604-612 Gasket .................................................... 1 36604-639 Screw ......................................................4
36604-613 Screw, soc. lid., 5/16-18 x 1 ................... 2 36604-640 Lock Washer ...........................................4
36604-614 DO NOT USE 36604-641 Terminal Shaft ........................................2
36604-615 DO NOT USE 36604-642 Pointer Bracket .......................................1
36604-616 DO NOT USE 36604-643 Screw, 8-32 x .625 ..................................1
36604-617 DO NOT USE 36604-644 Lock Washer, No. 8 ................................1
36604-618 DO NOT USE 36604-644A Flat Washer, No. 8 ..................................1
36604-619 Ring, retaining ........................................ 2 36604-645 Pointer ....................................................1
36604-620 Pin, power lever ..................................... 1 36604-646 Screw, .250-28 x 1.000 ...........................2
36604-621 DO NOT USE 36604-647 Lock Washer, .250 ..................................2
36604-622 Power Lever ........................................... 1 36604-648 Screw, .250-28 x 1 ..................................1
36604-623 Nut, 7/16-20 ........................................... 1 36604-649 Lock Washer, .250 ..................................1
36604-624 Link, power piston .................................. 2 36604-650 Lever .......................................................1
36604-625 Pin, piston rod ........................................ 1 36604-651 Drive Screw ............................................2
36604-626 Packing, preformed ................................ 1 36604-652 Scale .......................................................1
36604-627 Power Piston .......................................... 1
52 Woodward
Figure 6-8. Exploded View of 29/58 ft-lb Differential Cylinder (Rotary Output with
Tailrod)
Woodward 53
Chapter 7.
Auxiliary Features and Devices
Introduction
A number of optional auxiliary features and devices are available for use, either
singly or in combination, with the PGA governors. These devices permit the
governor to perform other secondary functions such as limiting engine load,
controlling engine load to maintain a constant power output for each speed
setting, minimizing the tendency to overfuel when starting, permitting temporary
overloads, emergency shutdown, loss of lubricating oil pressure, etc. Auxiliary
equipment should be supplied as original equipment in the governor. It is
recommended that the customer contact Woodward if field installations are
desired.
The following paragraphs give a brief description of the auxiliary equipment

available and list the manuals where detail information may be obtained. This
chapter is divided into two parts; commonly used auxiliary devices, and additional
accessories.
Commonly Used Auxiliary Devices

Solenoid Operated Shutdown
This device may be set up to automatically effect shutdown either when
energized or when de-energized. Coils are available to accommodate most
common dc voltages. For ac operation, an internal rectifier is used to provide the
required dc voltage.
Figure 7-1. PGA with Shutdown Solenoid
Description
The solenoid operated shutdown assembly shown in Figure 7-2 can be
incorporated in almost all PG governors having speed setting arrangements
which use hydraulically operated speed setting servo assemblies (direct bellows
speed setting, current controlled speed setting, etc.). The solenoid is actuated by
switches in the protective circuit being monitored. When actuated, the shutdown
solenoid initiates a sequence of actions within the governor which results in the
fuel or steam valve linkage being moved to the shutdown or off position.
54 Woodward
Figure 7-2. Cutaway of Solenoid Operated Shutdown
Operation
Figure 7-3 shows the shutdown device which consists of a check valve and a
solenoid. The check valve is inserted in the hydraulic circuit between the speed
setting servo assembly and the speed setting pilot valve plunger and bushing.
When the ball in the check valve in unseated, oil1 above the speed setting servo
piston escapes to sump. This allows the servo piston spring to push the speed
setting servo piston up. When the servo piston moves up sufficiently, the piston
rod lifts the shutdown nuts and shutdown rod which is connected to the governor
pilot valve plunger. Therefore, lifting the shutdown rod lifts the pilot valve plunger.
With the pilot valve above center, oil is released through the control port to sump
and the governor power piston moves the fuel linkage in the decrease fuel
direction.
The check ball (Figure 7-3) seats against two valve seats. In units adjusted to
shutdown when the solenoid coil is energized, the spring holds the check ball
against the upper seat during normal operation. When the coil is energized, the
plunger rod moves down, unseating the check ball. In units adjusted to shut
down when the solenoid is de-energized, the plunger rod is adjusted to hold the
check ball on the lower seat during normal operation when the solenoid is
energized. When the, solenoid coil is de-energized, the spring pushes the check
ball upward, unseating it.
Woodward 55
Adjustments
Refer to Figure 7-2 and adjust the ENERGIZE-TO-SHUTDOWN arrangement in
the following manner, Remove the locknut and the plunger stop plug; then
energize the solenoid. Turn the adjusting screw down (clockwise) until oil starts
to seep from the slot in the shutdown valve body. Turn the adjusting screw down
1-1/4 turns further. De-energize the solenoid; insert the plunger stop plug, and
screw the plug down until it touches the solenoid plunger. Back off the plunger
stop plug 2 turns, and lock it in place with the lock nut.
Adjust DE-ENERGIZE-TO-SHUTDOWN in the following manner. Remove the

locknut and the plunger stop plug; then energize the solenoid. Turn the adjusting
screw down until the ball contacts the lower valve seat. Screw down 1/4 turn
farther (forcing the solenoid plunger up). Insert the plunger stop plug, and screw
the plug down until it touches the solenoid plunger. Back off the plunger stop plug
2 turns and lock it in place with the lock nut.
Figure 7-3. Schematic Diagram, Basic PG and Solenoid Shutdown
56 Woodward
Ref. No. Part Name ................................. Quantity Ref. No. Part Name .................................Quantity
36604-701 Solenoid locknut ..................................... 1 36604-720 Valve seat .............................................. 1
36604-702 Plunger stop plug .................................... 1 36604-721 Valve seat .............................................. 1
36604-703 Solenoid plunger lock pin........................ 1 36604-722 Roll pin ................................................... 1
36604-704 Solenoid case ......................................... 1 36604-723 Spring ..................................................... 1
36604-705 Load spring ............................................. 1 36604-724 Bearing plug ........................................... 1
36604-706 Insulating paper ...................................... 1 36604-725 Manual shutdown plunger ...................... 1
36604-707 Solenoid coil ........................................... 1 36604-726 Plunger stop plug ................................... 1
36604-708 Soldering shield washer.......................... 2 36604-727 Headed pin ............................................. 1
36604-709 O-ring...................................................... 2 36604-728 Receptacle ............................................. 1
36604-710 Adjusting screw ...................................... 1 36604-729 Connector (optional) ............................... 1
36604-711 Solenoid plunger assembly..................... 1 36604-730 Coupling (optional) ................................. 1
36604-712 Solenoid plunger washer ........................ 1 36604-731 Spacer .................................................... 1
36604-713 Solenoid plunger rod .............................. 1 36604-732 Dial plate ................................................ 1
36604-714 Solenoid plunger bushing ....................... 2 36604-733 Screw, 6-32 x 3/8” .................................. 1
36604-715 Shutdown valve body ............................. 1 36604-734 Gasket .................................................... 1
36604-716 Varnished tubing ..................................... 2 36604-735 Screw, 4-40 x 1/4” .................................. 1
36604-717 Plunger guide locating pin ...................... 1 36604-736 O-ring ..................................................... 1
36604-718 Steel ball, 1/4” dia. .................................. 1 36604-737 Diode assembly...................................... 1
36604-719 Unloading spring ..................................... 1 36604-738 to 740 Not used
Figure 7-4. Exploded View, Solenoid Shutdown
Woodward 57
Overspeed Trip Test Device

(Figures 7-5 & 7-6)
Figure 7-5. Overspeed-Trip Test Device
Parts List For Figure 7-6

Ref. No. Part Name ................................ Quantity
36604-741 Governor cover....................................... 1
36604-742 Nut.......................................................... 1
36604-743 Guide pin ................................................ 1
36604-744 Quite bushing, 0.314 OD ........................ 1
36604-745 Spring ..................................................... 1
36604-746 Retaining ring ......................................... 1
36604-747 OST spring ............................................. 1
36604-748 Guide sleeve .......................................... 1
36604-749 Adjusting sleeve ..................................... 1
36604-750 Cam ........................................................ 1
36604-751 Roll pin, 0.125 dia. x .625 ....................... 1
36604-752 Roll pin, 0.135 OD x 0.500 ..................... 1
36604-753 O.S.T.D. cap assembly .......................... 1
36604-754 to –820 Not used
58 Woodward
Figure 7-6. Exploded View of the Overspeed Trip Test Device
Woodward 59
The overspeed test device shown in Figure 7-5 offers a means of temporarily
increasing the governor speed setting to check the operation of the engine
overspeed trip mechanism. It can be installed on any PG governor which has a
shutdown rod, including one already in service.
Return your governor to Woodward for addition of the overspeed trip test device.
Operation
To test the overspeed-trip mechanism remove the test device cap (753) and slide the
pin in the top of the cap (754) into the socket in the cam face. Move the cam slowly to
the overspeed position. The guide pin (743) is pushed against the shutdown rod, which
causes the control port in the pilot valve bushing to open. The governor power piston is
forced in the “increase fuel” direction, accelerating the engine to the speed level at
which the engine mounted overspeed trip shuts down the engine.

property damage.
Load Indicating (Tailrod) Switches

(Figures 7-7 & 7-8)
The load indicating switch is used to indicate tailrod position. These switches are
a function of tailrod or fuel rack position.
The load indicator switch is mechanically operated by set screw (825) attached to
the power piston tailrod. The load indicator switch is energized when the tailrod
moves past the preset position while increasing fuel to the engine. This switch
may be connected to an alarm signal or an indicator light. Refer to the engine
manufacturer’s instruction manual for the particular connections. if load is
increased past the preset position the switch is energized.
A load control indicator switch is also available to connect to the load control
linkage. This indicator switch is then a function of speed setting and fuel rack
position and not just tailrod position.
Figure 7-7. Load Indicating Switches

60 Woodward
Ref. No. Part Name ................................. Quantity Ref. No. Part Name .................................Quantity
36604-821 Screw, hex. hd., 10-32 x 7/8 ................... 1 36604-836 Spacer .................................................... 1
36604-822 Lockwasher, int. tooth, #10 ..................... 1 36604-837 Actuator shaft ......................................... 1
36604-823 Tailrod arm ............................................. 1 36604-838 Switch actuator lever (overload) ............. 1
36604-824 Nut, 10-32 ............................................... 1 36604-839 Nut, 10-32 .............................................. 1
36604-825 Knurled adjustment screw ...................... 1 36604-840 Setscrew, soc. hd., oval pt., 10-32 x 5/8 1
36604-826 Nut, self-locking, 6-32 ............................. 2 36604-841 Switch actuator (regulator) ..................... 1
36604-827 Screw, rd. hd., 6-32 x 1-7/8 .................... 2 36604-842 Shaft spring ............................................ 1
36604-828 Plunger switch (microswitch) .................. 2 36604-843 Stop pin, 1/4 x 7/16 ................................ 1
36604-829 Nut, 10-32 ............................................... 2 36604-844 Bushing, 1/4 x 3/8 x 1/4 .......................... 2
36604-830 Lockwasher, int. tooth, #10 ..................... 2 36604-845 Switch bracket ........................................ 1
36604-831 Screw, hex. hd, 10-32 x 3/4 .................... 2 36604-846 Screw, rd. hd., 8-32 x 3/8 ....................... 1
36604-832 Screw, hex. hd., 10-32 x 1/2 ................... 2 36604-847 Lockwasher, int. tooth, #8 ...................... 1
36604-833 Lockwasher, int. tooth, #10 ..................... 2 36604-848 Cable clamp ........................................... 1
36604-834 Retaining ring ......................................... 1 36604-849 and -850 Not used
36604-835 Actuating lever ........................................ 1
Figure 7-8. Exploded View of Load Indicating Switches
Adjustment
Refer to Figure 7-8 and the following.
1. Adjust screw (825) until its threads are centered in tailrod arm (823).
2. Position the tailrod to obtain the correct rack length per engine
specifications.
Woodward 61
3. Adjust switch actuator (841) to just actuate the load regulator switch (828).
Secure switch actuator (841) with screw (832).
4. Adjust switch actuator (838) to actuate overload switch (828) when screw
(832) in switch actuator (841) has moved approximately an additional 1/4”
from actuating the load regulator switch. This setting is also per engine
specifications.
Manifold Gauge Pressure Angle Type Fuel Limiter

Two types of fuel limiters are described in this manual. The Angle Fuel Limiter is
found on many older PGA governors and on some current governors which also
have a speed setting fuel limiter or other options which prevent the use of the
Single Barrel Fuel Limiter.
The Single Barrel Limiter is preferred because it contains a hydraulic amplifier

section which converts the low-force sensor output into a high-force output for
biasing the pilot valve-speeder spring system. A description of this limiter can be
found later in this chapter.
The Angle Type Fuel Limiter biases the limit curve as the manifold charging air
gauge pressure varies.
The normal lag of the turbo-supercharger speed to the engine speed makes it
possible during periods of acceleration with a large increase in load, to supply
more fuel to the engine than can be burned with the air available from the
supercharger. The resulting imbalance of fuel and air leads to poor combustion
and excessive smoke, and often retards the ability of the engine to return to
normal speed after a load change. The governor power piston is restricted in the
opening direction to limit engine fuel as a function of manifold charging air
pressure. This insures that sufficient air is maintained for proper combustion.
The fuel limiter consists essentially of a pressure sensor, a cam, and a

connecting beam (see Figure 7-11).
One end of the connecting beam is attached to the tailrod of the governor power
piston. The other end is positioned as a function of the cam position. The beam
passes under the shutdown block. Raising the beam sufficiently raises the
shutdown block, and with it, the shutdown rod. Lifting the shutdown rod lifts the
pilot valve plunger, since the shutdown rod is an extension of the governor pilot
valve plunger.
The governor power piston moves up, increasing fuel when the pilot valve
plunger is below its centered position. Fuel is increased only until the upward
movement of the power piston causes the connection beam to return the pilot
valve plunger to its centered position. The cam position establishes the height
the power piston may rise before the connecting beam lifts the pilot valve
plunger. Therefore, the cam position determines the maximum fuel allowed to the
engine at any instant.
The cam is mounted on a hydraulically operated sensor piston which is

connected to a force-balance system and takes a position proportional to
manifold charging air gauge pressure. The slope of the cam is adjustable.
Manifold charging air is brought into the bellows and tends to push the cone
valve off its seat. This force is opposed at the cone valve by the force of the
spring between the cone valve and sensor piston.
62 Woodward
The unrestricted flow of pressure oil applies constant pressure to the upper-side
of the sensor piston. A series of orifices restricts the flow of pressure oil to the
underside of the piston. Except while changes are occurring in the manifold
charging air pressure, the bellows force tending to push the cone valve up is
balanced or equaled by the spring force from the opposite direction. The cone
valve normally “floats” just off its seat and continually releases the oil admitted
through the orifice stack to sump. If the bellows force is greater than the
opposing spring force, the cone valve is forced upward, allowing oil to flow from
under the piston at an increased rate. The pressure oil above the piston forces it
down, compressing the spring until the spring force again equals the bellows
force. If the manifold charging air pressure is decreased, the bellows output force
is reduced, and the spring pushes the cone valve onto its seat. The oil pressure
under the piston moves the piston up and reduces the spring load on the cone
valve until the opposing forces are again equal.
The preload on the spring within the bellows assembly determines the charging
air pressure below which a constant maximum fuel limit is held (line RS in Figure
7-9). Preload is adjusted by means of the adjusting screw in the end of the
bellows case and is factory set. The contour of the cam determines the slope of
line ST (Figure 7-9).
Since the fuel limiter is effective at idle speed, the fuel limit must be set high
enough to give sufficient fuel for starting. See Figure 7-10 for exploded view of
the manifold gauge pressure fuel limiter.
Figure 7-9. Manifold Pressure Versus Fuel Flow
Pressure Override Switch

A pressure override switch is used with the microswitch. The pressure switch
automatically cancels the false signal when the engine and governor are stopped
normally.
Fuel Limiter Microswitch

(Figure 7-10)
A speed setting fuel limiter microswitch (1457) is used with a manifold pressure
fuel limiter. It indicates when the governor is limiting fuel as a function of either
engine speed or manifold charging pressure.
When boost beam (1416) reaches its limiting position (horizontal) it activates the
microswitch and in turn either an audio or visual alarm.
To adjust the microswitch loosen nut (1460) and position microswitch (1457) until
the correct set point is attained.
Woodward 63
Ref. No. Part Name................................Quantity Ref. No. Part Name ............................... Quantity
36604-1001 Body ..................................................... 1 36604-1413 Elastic hex nut, .250-20 ........................2
36604-1002 Poppet valve bushing ........................... 1 36604-1414 Cotter pin ..............................................1
36604-1003 Valve plunger ....................................... 1 36604-1415 Boost beam stop ...................................1
36604-1004 Lower spring seat ................................. 1 36604-1416 Boost beam assembly ...........................1
36604-1005 Piston spring......................................... 1 36604-1417 Pivot pin ................................................1
36604-1006 Spring seat ........................................... 1 36604-1418 Fuel limit beam assembly......................1
36604-1007 Fuel limiter piston ................................. 1 36604-1419 Screw, 6-32 x 1 .....................................1
36604-1008 DO NOT USE 36604-1420 Hex nut, 10-32 NF 28 R.H.....................5
36604-1009 Lever fulcrum pin .................................. 1 36604-1421 Pivot screw............................................1
36604-1010 Piston sleeve ........................................ 1 36604-1422 Speed setting fuel limiter spring ............1
36604-1011 Cam guide bracket ............................... 1 36604-1423 Screw ....................................................1
36604-1012 Screw ................................................... 1 36604-1424 Pin guide, 10-32 UNF 2A ......................1
36604-1013 Spring washer ...................................... 1 36604-1425 Clamp ...................................................1
36604-1014 Orifice case .......................................... 1 36604-1426 Spring anchor........................................1
36604-1015 Washer ................................................. 2 36604-1427 Hex hd. cap screw ................................1
36604-1016 Washer ............................................... 33 36604-1428 Power piston fulcrum assembly ............1
36604-1017 Orifice plate ........................................ 32 36604-1429 Bracket ..................................................1
36604-1018 Orifice pack spring ................................ 1 36604-1430 Self locking nut, 1/4-28 UNF-3B............1
36604-1019 Washer ................................................. 1 36604-1431 Spacer ..................................................1
36604-1020 Internal retaining ring ............................ 1 36604-1432 Lock washer .250 lD .............................2
36604-1021 Check valve .......................................... 1 36604-1433 Socket head cap screw,
36604-1022 O-ring ................................................... 2 .250-28 x 1.000 .....................................1
36604-1023 Plug & screen assembly ....................... 1 36604-1434 Washer .................................................1
36604-1024 Bellows assembly ................................. 1 36604-1435 Hex nut, 10-32 NF-2B R.H. thread ........1
36604-1025 O-ring ................................................... 1 36604-1436 Lock washer, #10 ..................................1
36604-1026 Retaining ring ....................................... 2 36604-1437 Cotter pin ..............................................1
36604-1027 Speeder spring power cylinder ............. 1 36604-1438 Soc. hd. screw. .250-28 x 1.750............1
36604-1028 Cam follower arm ................................. 1 36604-1439 Elastic hex nut, 10-32 ...........................1
36604-1029 Pin ........................................................ 1 36604-1440 Spherical washer ..................................1
36604-1030 Set screw.............................................. 1 36604-1441 Bracket pin ............................................1
36604-1031 Soc. hd. screw ...................................... 1 36604-1442 Cut-off valve spring ...............................1
36604-1031a Nut ........................................................ 1 36604-1443 Spring ...................................................1
36604-1032 Lockwasher .......................................... 1 36604-1444 Headed pin............................................1
36604-1033 Ball bearing .......................................... 2 36604-1445 Adj. fulcrum screw.................................1
36604-1034 Nut ........................................................ 1 36604-1446 Speed spring cylinder spacer ................1
36604-1035 Screw ................................................... 1 36604-1447 O-ring ....................................................1
36604-1036 through 1056 DO NOT USE 36604-1448 Power system fulcrum ...........................1
36604-1057 Shutdown rod ....................................... 1 36604-1449 DO NOT USE
36604-1058 through 1067 DO NOT USE 36604-1450 Screw ....................................................1
36604-1068 Hex hd. cap screw ................................ 1 36604-1451 Set screw, 8-32 x .375 ..........................1
36604-1069 Nut ........................................................ 1 36604-1452 Torsion spring .......................................1
36604-1070 Clamp ................................................... 1 36604-1453 Fuel limit cam ........................................1
36604-1071 Splitlock washer, 0.250......................... 2 36604-1454 Fuel limit cam ........................................1
36604-1072 Cap screw ............................................ 2 36604-1455 Screw, 4-40 x 0.562 ..............................2
36604-1073 Hex hd. screw, 0.250-28....................... 1 36604-1456 Actuator ................................................1
36604-1074 Retaining ring ....................................... 1 36604-1457 Microswitch ...........................................1
36604-1076 Ball bearing .......................................... 1 36604-1458 Switch mounting plate ...........................1
36604-1077 Headed pin ........................................... 1 36604-1459 Washer, 0.203 x 0.438 x 0.064 thick .....1
36604-1078 Tube assembly ..................................... 1 36604-1460 Nut, 10-32 .............................................1
36604-1079 through 1100 DO NOT USE 36604-1461 Pressure switch.....................................1
36604-1401 Connecting beam ................................. 1 36604-1462 Pressure switch adapter .......................1
36604-1402 Headed pin .185 x 1.094 ...................... 1 36604-1463 O-ring, 0.239 ID x 0.070 ........................1
36604-1403 Cotter pin, 1/18 x 3/8 ............................ 5 36604-1464 Wire, 20 ga. Red ...................................1
36604-1404 Washer, .203 x .438 x .032 thick .......... 5 36604-1465 Wire, 20 ga. Green ................................1
36604-1405 Pin spacer ............................................ 1 36604-1466 Wire, 20 ga. Orange ..............................1
36604-1406 Set screw, 10-32 x 1.000 ...................... 1 36604-1467 Set screw, 10-32 x 0.250 ......................1
36604-1407 Slotted link ............................................ 1 36604-1468 Crimp terminal.......................................3
36604-1408 Nut ........................................................ 2 36604-1469 Tubing (shrink) 0.125 x 0.625 ...............3
36604-1409 Pivot pin................................................ 1 36604-1470 Pin .........................................................1
36604-1410 Beam .................................................... 1 36604-1471 Check valve ..........................................1
36604-1411 Washer ................................................. 1 36604-1472 through 1500 Not used
36604-1412 Washer, .265 x .500 x .032 thick ............ 2
64 Woodward
Figure 7-10. Exploded View of Angle Type Manifold Gauge Pressure Fuel Limiter
(Shown with fuel limiter microswitch, pressure override switch, and speed setting
fuel limiter)
Woodward 65
Figure 7-11. Schematic Diagram of PGA Governor with Manifold Pressure Fuel
Limiter and Speed Setting Fuel Limiter
66 Woodward
Speed Setting Fuel Limiter

This fuel limiter is dependent only on the governor speed setting. Figure 7-12
shows a schematic arrangement of linkage as related to a basic PG governor.
Figure 7-12. Schematic Diagram of PGA with Speed Setting Fuel Limiter
The speed setting servo piston positions the left end of limiter beam (1). As the
speed setting servo piston moves down, screw (6) forces beam (1) to pivot about
(7). The right hand end of beam (1) moves upward raising the lower limiter link
(2), thereby positioning the slot at the upper end of beam (2) relative to the slope
adjustment pivot locknut (7).
Since the right hand end of limiter beam (3) is attached to the power piston
tailrod its position is a function of fuel setting. The left end of beam (3) is
supported by the upper limiter link (4), the length of which is adjustable. As the
tailrod moves upward, it also moves the slope adjustment pivot (8) until it
reaches the top of the lower limiter link slot. Limiter beam (3) then pivots about
the end of the slot, lowering the left hand end of beam (3). The upper limiter link
(4) moves down, forcing the right end of limiter beam (5) downward. This results
in the left end of limiter beam (5) raising the shutdown rod which is connected to
the main pilot valve. Oil is dumped from under the main servo piston to drain.
Therefore, fuel is limited as a function of the speed setting piston position.
A typical speed setting fuel-limit schedule is shown in Figure 7-13.
Woodward 67
Figure 7-13. Fuel Limit Speed Setting Schedule
The constant fuel portion M-N of the curve is maintained when a gap exists
between the limit advance adjustment screw and the left end of limiter beam (1).
The slope of N-P is set by the position of the slope adjustment pivot (8 on Figure
7-12) in limiter beam (2, Figure 7-12).
Load Control
Introduction
A governor’s function is, primarily, to schedule fuel to the engine in sufficient
quantities to maintain a constant engine speed under varying load conditions. In
some marine governors driving controllable pitch propellers, a secondary
objective is to maintain or limit a definite horsepower output of the engine for
each specific speed setting of the governor.
In order to achieve this, the governor can be provided with a load control valve or
load control vane servomotor. The load control adjusts the load on the engine to
a predetermined value for each specific speed setting of the governor.
Operation
Refer to Figure 7-18. The load control pilot valve plunger is suspended from the
load control floating lever. The lever is connected to the power piston tailrod at
one end and to the speed setting piston rod at the other end. Any movement of
either or both pistons causes a corresponding movement of the plunger which is
housed within a non-rotating bushing.
Pressure oil is supplied to the plunger either externally from the propeller pitch
setting mechanism or from the governor oil pump through a pressure reducing
valve. The pilot valve has two control lands to give signals in the increase and
decrease load direction. Most propeller manufacturers use only the signal from
the upper land to decrease pitch, if the engine load exceeds a predetermined
maximum. On these governors the lower or increase pitch oil line is plugged.
A few propeller manufacturers specify our integral vane servo as shown in

Figures 7-14 and 7-18. They mount a cam on the keyed shaft which operates a
pneumatic transmitter to obtain a varying air pressure depending on the position
of the vane servo. This pressure is used to decrease pitch gradually. Through a
pressure reducing valve oil from the governor pump is used to operate the servo.
On starting the engine the valve is closed to use all of the oil from the pump to
move the main governor servomotor to open the fuel racks.
68 Woodward
Figure 7-14. PGA with Vane Servo
Since the load-control valve is mainly used to control pitch and load, governor
operation for this condition is described. From the schematic it can be seen that
there is a fixed and linear relationship keeping the load control valve centered. If
for a given speed setting the engine needs more fuel than allowed by the
adjustment of the load control valve the power piston will lift it up to uncover the
upper port. The propeller manufacturer uses the hydraulic pressure in the oil line
coming from the governor to decrease pitch, so that equilibrium is being restored
by decreasing load.
If the vane servo is used, it rotates a cam and operates a pneumatic transmitter
installed by the propeller manufacturer to send a modulated pneumatic signal to
the propeller pitch setting mechanism to decrease pitch. At the same time the
other side of the vane is drained and oil flows back to governor sump.
It is possible to obtain non-linear load control curves by incorporating cams and

yield links in the load control floating levers and links. Please consult Woodward.
Adjustment
Adjust the load (pitch) control line in two ways, by the range screw (1111) and
the eccentric (1103). The range screw affects the slope of the curve. Moving the
point from where the load control valve is suspended toward the power piston
tailrod flattens the curve. This means that the governor allows higher load at
lower speeds. Readjusting the eccentric moves the curve up or down affecting
engine loading at all speeds. If the slope is changed it is usually necessary to
also readjust the eccentric.
Woodward 69
Timing Valves
Timing valves (Figure 7-17) may be located internally in the governor for an
integrally mounted vane servo or they may be mounted on the external part of
the governor column for an externally mounted vane servo. In either case their
function is the same, to control the rate of movement of the vane servo in either
the increase or decrease direction. These valves are adjustable to increase or
decrease flow as required.
Figure 7-15. Timing Valves for Integral Figure 7-16. Timing Valves for
Vane Servo Externally Mounted Vane Servo
Single Barrel Fuel Limiter

Description
The fuel limiter (Figure 7-18) is essentially a floating lever, a bellcrank, a
pressure sensor and cam, and a hydraulic amplifier together with a feedback
lever and a fuel limit floating lever. The right end of the floating lever is connected
to the tailrod of the governor power piston and pivots about one leg of the
bellcrank. The left end of the floating lever rests on the right end of the hydraulic
amplifier feedback lever. The position of the bellcrank, and therefore the position
of the floating lever pivot point, is determined by the position of the fuel limit cam.
Raising the floating lever pivot as manifold air pressure increases, allows the
governor power piston to move upward a proportionally greater distance before
fuel limiting occurs.
The pressure sensor is a force-balance device consisting of an inlet check valve,

an orifice pack restriction, a piston and cam assembly, a restoring spring, a bleed
valve, and either a gauge pressure or an absolute pressure bellows
arrangement. The sensor establishes a corresponding piston (and cam) position
for each different manifold air pressure. The relationship between manifold air
pressure and governor power piston position (fuel flow) where limiting occurs is
determined by the profile and angular tilt of the cam. Cam profiles are either
linear or non-linear depending on engine and turbo-supercharger characteristics.
70 Woodward
Figure 7-17. Exploded View of Vane Servo Timing Valve Assembly (External
Type)

Ref. No. Part Name ............................... Quantity
36604-1151 Tube assembly, 3/8 ...............................1
36604-1152 Soc. hd. screw, 1/4-28 x 1.....................2
36604-1153 Splitlock washer, 1/4 .............................2
36604-1154 Fil.hd.screw,8-32x 1/4 ...........................2
36604-1155 Valve cover ...........................................1
36604-1156 Needle screw ........................................2
36604-1157 O-ring, 0.338 OD...................................4
36604-1158 Retaining ring ........................................2
36604-1159 Plug .......................................................2
36604-1160 Ball spring .............................................2
36604-1161 Check ball, 1/4dia. ................................2
36604-1162 Elbow, 90°, 1/4 NPTF-to-3/8 tube .........1
36604-1163 Elbow, 90° 1/4 NPTF-to-3/8 tube ..........1
36604-1164 Pipe plug, 1/16-27 NPTF ......................1
36604-1165 Drive screw, #2 x 3/16 ..........................4
36604-1166 Instruction plate .....................................1
36604-1167 Valve case ............................................1
36604-1168 to -1180 Not used
The hydraulic amplifier is a pilot-operated, single-acting hydraulic cylinder. The

amplifier provides the force necessary to overcome the resistance of the speeder
spring, lift the shutdown rod, and re-center the governor pilot valve plunger when
the fuel limit is reached for a given manifold air pressure.
Woodward 71
Figure 7-18. Schematic Diagram, Fuel Limiter and Optional Load Control
Override Linkage, and Vane Servo
Operation
Pressured oil enters the fuel limiter through the inlet check valve. Oil is directed
to the upper side of the sensor piston and through the orifice pack restriction to
the underside of the sensor piston. The inlet check valve prevents siphoning of
the oil from the limiter housing during shutdown periods and omits the time lag to
refill the orifice pack and piston cylinder. This prevents the sensor piston from
going to maximum fuel position during start-up.
72 Woodward
The bleed valve regulates the rate of oil flow from the area under the sensor
piston to sump as a function of manifold air pressure. When the bleed valve
bypasses a greater flow of oil from this area than is admitted through the orifice
pack, the sensor piston moves downward. Conversely, reducing the bypass oil
flow to less than that admitted causes the sensor piston to rise. When the inflow
and outflow of oil are equal, the piston remains stationary.
The sensing element of the gage-pressure-type fuel limiter consists of a single,

flexible, metallic bellows. Movement of the gauge pressure bellows is transmitted
directly to the bleed valve pin. The bellows force tends to open the bleed valve
while the restoring spring force tends to close the valve. When these opposing
forces balance, the bleed valve diaphragm floats just off of its seat bypassing oil
to sump. This rate of oil flow maintains a constant volume of oil in the area under
the sensor piston.
Assume that the governor speed setting is advanced to a higher speed setting
and a higher manifold air pressure. The governor power piston moves upward
supplying the additional fuel required for engine acceleration. Since manifold air
pressure lags engine acceleration, the fuel limiter cam and bellcrank initially
remain stationary until manifold air pressure rises. As the governor power piston
moves upward increasing fuel, the fuel limit floating lever pivots about the upper
leg of the bellcrank and depresses the right end of the feedback lever on the
hydraulic amplifier. This pushes the amplifier pilot valve plunger below center,
allowing pressured oil to flow into the area under the amplifier piston, causing the
piston to rise. As the piston rises, it simultaneously lifts the left ends of both the
fuel limiter lever and the feedback lever. When the fuel limit lever contacts the
fuel limit nut on the shutdown bushing it begins lifting the shutdown rod to re-
center the governor pilot valve plunger. The upward movements of the fuel limit
and feedback levers continue until the left end of the feedback lever raises far
enough to re-center the amplifier pilot valve plunger and stop the flow of oil to the
amplifier piston. At this point, the fuel limit lever re-centers the governor pilot
valve plunger, stopping the upward movement of the governor power piston. This
limits the amount of fuel to provide a proper fuel/air ratio for efficient burning.
Although the governor flyweights are in an underspeed condition at this time, the
power piston remains stationary until manifold air pressure rises.
As engine speed and load increases, manifold air pressure begins to rise after a
short time lag. The increase in manifold air pressure produces a proportionate
increase in the sensing bellows force. The bellows force, now greater than the
restoring spring force, causes the bleed valve diaphragm to move further off its
seat. This allows a greater flow of oil to sump than is admitted through the orifice
pack. Governor oil pressure acting on the upper side of the sensor piston forces
the piston (and cam) downward and, in the process, further compresses the
restoring spring. The piston continues its downward movement until the net
increase in restoring spring force equals the net increase in bellows force. This
restores the bellows and bleed valve diaphragm to their original positions. At this
point, the outflow of oil is again equal to the inflow and movement of the piston is
halted.
As the sensor piston and cam move downward in response to a rise in manifold
air pressure, the bellcrank rotates in a cw direction. This allows the floating lever
pivot point, the left end of the lever, and in turn the hydraulic amplifier pilot valve
plunger to rise.
Woodward 73
The loading spring under the pilot valve plunger maintains a positive contact
between the plunger, levers, bellcrank, and cam. When the pilot valve plunger
rises above center, the oil under the amplifier piston bleeds to sump through a
drilled passage in the center of the plunger. The passage in the plunger restricts
the rate of oil flow to sump and decreases the rate of movement of the amplifier
piston to minimize hunting. As the amplifier piston moves downward, the left end
of the fuel limit lever also moves downward. This lowers the shutdown rod which
in turn lowers the governor pilot valve plunger and increases engine fuel.
The sequence of events described above occurs in a continuous and rapid

sequence. Normal governor operation is overridden during an acceleration
transient and engine fuel is scheduled as a function of manifold air pressure,
regardless of governor speed setting. To prevent interference with normal
governing action during steady state operation, the sensor piston and cam
continue their downward movement until sufficiently below the effective limiting
point.
Table 7-1. Troubleshooting the Manifold Pressure Fuel Limiter
Trouble Probable Cause Correction

Hard starting and/or excessive Anti-siphoning check valve leaking— Replace check valve.
smoke for short duration sensor piston goes to maximum fuel
during starting after a position at start-up and then returns to
relatively long shutdown minimum fuel position as housing
period. refills with oil.
Excessive smoke during Orifice pack clogged—sensor piston Drain governor oil, flush with fuel oil or
accelerations. goes to and remains at maximum fuel kerosene. Refill with clean oil, operate
position. for a short time, drain and refill. If
necessary, remove fuel limiter orifice
pack, disassemble and clean.
Fuel limiter not adjusted correctly. Fuel limiter must be adjusted on a test
stand.
Governor/engine linkage not adjusted Adjust linkage to manufacturer’s

correctly. specifications.
Restoring spring fatigued or broken. Replace restoring spring.

Engine bogs during Fuel Limiter not adjusted correctly. Adjust Fuel Limiter.
accelerations. Governor/engine linkage not adjusted Adjust linkage to manufacturer’s
correctly. specification.
Erratic operation. Contaminated or foamy oil. Sludge Drain governor oil, flush with fuel oil or
formation. kerosene. Refill with clean oil, operate
for a short time, drain and refill. If
necessary. remove fuel limiter,
disassemble and clean.
Low governor oil level—air Add oil to correct level as indicated on

entrainment. sight gauge glass. Check for leakage,
particularly at governor drive shaft oil
seal. Check manifold air pressure line
for presence of oil which would indicate
leakage at fuel limiter bellows.
Leakage in manifold air pressure lines Repair leaks.

or fittings.
Fuel limiter bellows leaking. Replace bellows.

Dead band at low or high end Sensor piston travel not properly Readjust on test stand.
of fuel limiting schedule. calibrated with manifold air pressure
range.
74 Woodward
Conversely, a drop in manifold air pressure rotates the bellcrank in a ccw
direction. This lowers the fuel limit lever, depressing the pilot valve plunger, and
releases pressured oil to the underside of the amplifier piston. The shutdown rod
and governor pilot valve plunger are raised, releasing oil from the power piston
cylinder to sump and decreasing fuel to the engine. The left end of the fuel limit
floating lever pivots upwards, releasing the hydraulic amplifier pilot valve plunger
upward. As the control land of the pilot valve plunger opens the port from the
piston cylinder, oil is bled to sump through a hole in the pilot valve plunger shaft.
The shutdown rod is lowered, allowing the governor pilot valve plunger to re-
center.
Disassembly
The removal and disassembly procedure for the fuel limiter varies depending on
the optional features it is equipped with and the extent of maintenance required.
Complete removal and disassembly involves partial disassembly of the basic
governor and should be performed in the sequence given below as well as in the
order of reference numbers assigned to the exploded view (Figure 7-21). Discard
o-rings, gaskets, copper sealing washers, retaining rings, cotter pins, etc.,
removed during disassembly.
Omit those steps which do not apply to the particular fuel limiter
being serviced. Do not disassemble the unit any more than
absolutely necessary.
1. Remove component parts of governor load control valve from sensor

housing (1280).
2. Remove governor speed setting mechanism and bracket assembly.
3. Remove fuel limit lever and attaching parts (1218 through 1221).
4. Remove fuel limit floating lever and attaching parts (1222, 1223 and 1224).
Hold pivot (1225) stationary while removing lever and then remove pivot
together with adjusting screw (1226). Remove feedback lever (1227).
5. Disconnect coupling nut (1228) and then back fitting (1231) out of governor
column far enough to clear end of connecting tube from sensor bellows
(1267). Do not bend or place any strain on tube during removal of the
sensor assembly.
6. Remove screws (1232 and 1233) and washers (1234). Lift sensor assembly
(1235 through 1280) off governor column. Remove o-ring (1282) from seat
in governor column.
7. Disassemble sensor assembly in the order of the reference numbers

assigned to Figure 7-21.
8. Cylinder head (1278) is press-fit with housing (1280).
Calibration of a governor after disassembly of the fuel limiter can be

extremely difficult if the governor cannot be removed from the
engine and adjusted on a test stand.
Cleaning
Immerse all parts in solvent and wash ultrasonically or by agitation. Use a
nonmetallic brush or jet of compressed air to clean slots and holes. Dry parts
after cleaning with a jet of clean, dry air.
Woodward 75
Flush orifice pack with a pressurized stream of filtered solvent. Disassemble
orifice pack for more thorough cleaning if clogging or sludge buildup is evident.
Apply a light film of lubricating oil to all finely machined surfaces. Store parts in
dust-free, moisture-proof containers until reassembled.
Inspection
Visually inspect all parts for damage or wear. Pay particular attention to the
following.
1. Mating surfaces must be free of nicks, burrs, cracks or other damage.
2. Screws, plugs, and internal threads must be free of corrosion, cracks,

burred slots, rounded corners, or damaged threads.
3. All threaded areas, apertures and passages must be free of foreign matter.
4. All linkages must be free of corrosion and must move freely without
excessive play.
5. Inspect sensor piston (1251, Figure 7-21) amplifier piston (1246) and
amplifier pilot valve plunger (1244) for scuffing, scoring, or wear. If scuffing
or scoring is evident, inspect the respective piston or plunger bores for
similar damage. Replace all parts which are scuffed or scored. Wear on
highly polished areas is generally acceptable if less than one-third the length
of the piston or plunger land is affected. If excessive wear is suspected,
check the worn area for an out-of-round condition. Replace the pistons if the
worn area is more than 0.001 inch out-of-round. Replace the plunger if the
worn areas on the lands are more than 0.005 inch out-of-round.
6. Corners of plunger lands must be sharp. Replace plunger if corners of lands

are nicked or rounded off to any extent.
7. Piston and plungers must move freely in their respective bores.
8. Bleed valve diaphragms (1254) must be flat within 0.040 inch (1.02 mm).
Any damage such as nicks, creases or other deformities, scratches in
excess of 0.001 inch (0.03 mm) in depth, etc., in necked area of diaphragm
center section is cause for replacement of the part.
9. Examine sensor bellows (1267) for evidence of distortion, cracks or other

damage. The longitudinal length of the bellows assembly, as measured on
the bellows centerline without strap (1270), and barometric pressure at time
of factory assembly are marked on the upper end of the bellows. If this
length has increased more than 0.015 inch (0.38 mm) at the specified
barometric pressure, the evacuated bellows is leaking and the assembly
must be replaced. Plug the tube and immerse the bellows assembly in hot
water (200 °F/93 °C). If bubbles are observed, the sensing bellows is
leaking and the assembly must be replaced.
10. Check needle bearing (1242) for freedom of rotation. Replace bearing if
there is any detectable roughness.
76 Woodward
Repair or Replacement
Limit repair of parts to removal of minor nicks, burrs or corrosion from mating
surfaces. Polish slightly corroded areas in mating surfaces using a fine (600 grit)
abrasive cloth or paper and oil. Repair or rework to any other extent is impractical
and the part should be replaced.
Handle critical parts with extreme care to prevent damage to mating

edges and surfaces. Maintain sharp edges of plunger lands, piston
grooves, metering ports, etc. Rounded edges, nicks, ,or other
damage to such edges results in excessive internal leakage and
decreased control sensitivity.
Lubrication
Lubricate metal parts liberally with lubricating oil at time of reassembly. Lubricate
O-rings with petrolatum before installation.
Reassembly
Use a dust-free work area for reassembly. Reassemble and install the fuel limiter
and load control override linkage in reverse order of the disassembly instructions.
Pay particular attention to the following:
1. Obtain new O-rings, gaskets, sealing washers, retaining rings, cotter pins,
etc., to replace those removed during disassembly.
2. Install retaining rings with sharp edge in the direction of the applied force.
3. If orifice pack was disassembled for any reason, alternately install gaskets
(1262), and orifice plates (1263). Be sure to install a gasket between orifice
plate and washer at each end of stack. Plates must be alternated so
adjacent orifice holes are diametrically opposite.
Woodward 77
36604-1101 Adjusting block ..................................... 1
36604-1102 Soc. hd. screw. 8-32 x .875 .................. 1
36604-1103 Wide link eccentric................................ 1
36604-1104 Cotter pin, 0.060 x 0.375 ...................... 2
36604-1105 Pivot valve link R.H............................... 1
36604-1105a Pivot valve link L.H. .............................. 1
36604-1106 Movable fulcrum pin ............................. 1
36604-1107 Headed pin ........................................... 1
36604-1108 Cotter pin. 0.060 x 0.375 ...................... 1
36604-1109 Floating lever adj. screw ....................... 1
36604-1110 Link adjusting spring ............................. 1
36604-1111 Adjusting screw knob ............................ 1
36604-1112 Roll Pin ................................................. 1
38604-1113 Cotter pin, 1/16 x 5/8 ............................ 1
36604-1114 DO NOT USE
36604-1115 DO NOT USE
36604-1116 Floating lever assembly ........................ 1
36604-1117 through 1135 DO NOT USE
36604-1136 Washer ................................................. 2
36604-1137 Floating lever stop pin .......................... 1
36604-1138 Lock nut ................................................ 1
36604-1139 Slotted set screw, .250-20 x 2.375 ....... 1
38604-1140 Speeder servo lever pin ........................ 1
36604-1141 Speed spring power cylinder ................ 1
36604-1142 Hex nut, 10-32 UNF-2B ........................ 2
36604-1143 Set screw. 10-32 x 1.750 ...................... 1
36604-1144 Guide pin ................................................ 1
36604-1145 Shutdown rod & speeder spring
power piston ......................................... 1
36604-1146 Power piston fulcrum ............................ 1
36604-1147 Droop plunger cap ................................ 1
36604-1148 Droop lever assembly ........................... 1
36604-1149 Shutdown lock nut ................................ 1
36604-1150 Shutdown nut........................................ 1
36604-1151 through 1180 See Figure7-17
36604-1177 Pivot pin link (optional) ......................... 1
36604-1178 Grooved link pin (optional) .................... 1
36604-1179 Retaining ring, (optional) ...................... 4
36604-1180 Grooved adj. floating lever pin
(optional) .............................................. 1
36604-1181 Screw ................................................... 1
36604-1182 Lockwasher .......................................... 1
36604-1183 Load control link ................................... 1
36604-1184 Droop cam ............................................ 1
36604-1165 Nut ........................................................ 1
36604-1186 Load control link ................................... 1
36604-1187 Stop screw, 8-32................................... 1
36604-1188 Check valve .......................................... 1
36604-1189 Pivot pin link (optional) ......................... 1
36604-1190 Grooved linkage pin (optional) .............. 1
36604-1191 Retaining ring, .145 ID (optional) .......... 4
36604-1192 Grooved adj. floating lever pin
(optional) .............................................. 1
36604-1193 through 1200 Not used
78 Woodward
Figure 7-19. Exploded View of Adjustable Load Control Linkage
Woodward 79
36604-1501 Overriding cylinder ................................ 1
36604-1502 Load control indicator scale and
pointer assembly .................................. 1
36604-1503 Washer, 13/64 x 7/16 x 1/32 ................. 1
36604-1504 Screw, phillips head, 10-32 x 1/4 .......... 1
36604-1505 Taper screw, 1/4-28.............................. 2
36604-1506 Split lock washer, 17/64 ........................ 2
36604-1507 Cap screw, hex head, 1/4-28 x 1 .......... 2
36604-1508 Overriding piston .................................. 1
36604-1509 Load control valve spring collar ............ 1
36604-1510 Lock nut, 5/16-24 .................................. 1
36604-1511 Inner load control valve spring .............. 1
36604-1512 Outer load control valve spring ............. 1
36604-1513 Load control spring retainer .................. 1
36604-1514 Spring retainer snap ring ...................... 1
36604-1515 Load control indicator washer ............... 1
36604-1516 Overriding cylinder head ....................... 1
36604-1517 Load control plunger oil seal ................. 1
36604-1518 Load control oil seal gasket .................. 1
36604-1519 Spacer (if no oil seal) ............................ 1
36604-1520 Load control pilot valve plunger ............ 1
36604-1521 Load control pilot valve bushing spring . 1
36604-1522 Load control pilot valve bushing ........... 1
36604-1523 Internal snap ring .................................. 1
36604-1524 Straight half union, 3/8 NPT-1/2 tube ... 2
36604-1525 Column and insert assembly ................ 1
36604-1526 90° elbow, 3/8 NPT-1/2 tube ................ 2
36604-1527 through 1600 Not used
80 Woodward
Figure 7-20. Exploded View of Load Control Pilot Valve
Woodward 81
Ref. No. Part Name................................Quantity Ref. No. Part Name ............................... Quantity
36604-1214 Nut, hex., 8-32 ...................................... 1 36604-1253 Restoring spring seat ............................1
36604-1215 Nut, hex., 5/16-24 ................................. 1 36604-1254 Bleed valve diaphragm .........................1
36604-1216 Nut, hex., 5/16-24 (fuel limit) ................ 1 36604-1255 Filter screen ..........................................1
36604-1217 Shutdown bushing ................................ 1 36604-1256 O-ring, 1/2 OD.......................................2
36604-1218 Cotter pin, 1/16 x 5/B ............................ 1 36604-1257 Check valve assembly ..........................1
36604-1219 Pivot pin (fuel limit lever) ...................... 1 36604-1258 Retaining ring ........................................1
36604-1220 Loading spring ...................................... 1 36604-1259 Washer, 9/64 ID x 3/8 (max.) OD
36604-1221 Fuel limit lever ...................................... 1 x 1/32 ....................................................1
36604-1222 Cotter pin, 1/16 x 3/8 ............................ 1 36604-1260 Orifice pack spring ................................1
36604-1223 Retaining ring, E-type ........................... 1 36604-1261 Washer, 3/16 ID x 3/8 (max.) OD
36604-1224 Fuel limit floating lever .......................... 1 x 1/16 ....................................................2
36604-1225 Pivot ..................................................... 1 36604-1262 Gasket ................................................33
36604-1226 Adjusting screw (fuel limit) .................... 1 36604-1263 Orifice plate .........................................32
36604-1227 Feedback lever ..................................... 1 36604-1264 Orifice case ...........................................1
36604-1228 Coupling nut, 1/2-20 ............................. 1 36604-1265 Not used................................................1
36604-1229 Ferrule, 1/4 tube ................................... 1 36604-1266 Nyloc button soc. hd. screw, 8-32
36604-1230 Hex, nut, 1/2-20 .................................... 1 x 3/8 ......................................................2
36604-1231 Ballhead union, 1/4 tube ....................... 1 36604-1267 Sensor bellows (gauge pressure) .........1
36604-1232 Soc. hd. screw 1/4-28 x 1-1/8 ............... 1 36604-1268 O-ring 1-1/4 OD ....................................1
36604-1233 Soc. hd. screw 1/4-28 x 1-3/4 ............... 1 36604-1269 Bellows spacer ......................................1
36604-1234 Lockwasher 1/4 .................................... 2 36604-1270 Bellows output strap ..............................1
36604-1235 Soc. hd. screw 10-32 x 1/2 ................... 2 36604-1271 Pin, .059 x .082 dia. x 0.782 OAL .........1
36604-1236 Soc. hd. screw 10-32 x 1-1/2 ................ 1 36604-1272 Retaining ring, internal ..........................1
36604-1237 Lockwasher #10 ................................... 3 36604-1273 Hex. hd. screw, 1/4-28 x 3/4 .................1
36604-1238 Cotter pin, 1/16 x 5/8 ............................ 2 36604-1274 Soft copper washer 1/4 ID x 1/2 OD
36604-1239 Pivot pin (bellcrank) .............................. 1 x 1/32 ....................................................1
36604-1240 Bellcrank............................................... 1 36604-1275 Eccentric ...............................................1
36604-1241 Drilled straight pin ................................. 1 36604-1276 Copper gasket.......................................1
36604-1242 Needle bearing ..................................... 1 36604-1277 Valve seat .............................................1
36604-1243 Linkage bracket .................................... 1 36604-1278 Cylinder head (overriding) .....................1
36604-1244 Amplifier pilot valve plunger.................. 1 36604-1279 Taper screw ..........................................9
36604-1245 Pilot valve loading spring ...................... 1 36604-1280 Housing .................................................1
36604-1246 Amplifier piston ..................................... 1 36604-1281 Straight pin (tailrod) ...............................1
36604-1247 Sensor piston sleeve ............................ 1 36604-1282 O-ring, 0.338 OD...................................1
36604-1248 Nyloc button soc. hd. screw 8-32 x 3/8 . 1 36604-1283 Pilot valve plunger nut ...........................1
36604-1249 Roll pin, 1/8 x 3/8 .................................. 1 36604-1284 Loading spring ......................................1
36604-1250 Fuel limit cam ....................................... 1 36604-1285 Spring seat ............................................1
36604-1251 Sensor piston ....................................... 1 36604-1286 to -1300 Not used
36604-1252 Restoring spring ..................................... 1
82 Woodward
Figure 7-21. Exploded View of Fuel Limiter

Woodward 83
Additional Accessories
Introduction
A number of other optional auxiliary features and devices are available for use,
either singly or in combination, with the PGA governors. These devices permit
the governor to perform other secondary functions such as limiting engine load,
controlling engine load to maintain a constant power output for each speed
setting, minimizing the tendency to overfuel when starting, permitting temporary
overloads, emergency shutdown in the event of ancillary equipment failure or
loss of lubricating oil pressure, etc. Auxiliary equipment should be supplied as
original equipment in the governor. It is recommended that the customer contact
Woodward Governor Company if field installations are desired.
The following paragraphs give a brief description of some of the additional

auxiliary equipment available and list the manuals where detail information may
be obtained.
Booster Servomotor
The booster servomotor is used in conjunction with the governor to assist the
prime mover in starting quickly. This device supplies oil under pressure to the
governor at the instant starting air is supplied to the prime mover and enables the
governor to move the linkage to the fuel-on position immediately. See manual
36684.
Extensible Power Cylinder Tailrod

This device may be used in governors equipped with any type of fuel (or load)
limit mechanism to permit the prime mover to temporarily carry overloads. See
manual 36640.
Governor Heat Exchanger

A heat exchanger may be necessary in applications where the governor is
mounted near heat producing equipment or where high drive speeds generate so
much heat that the governor oil becomes too hot. The heat exchanger may be
integral with the governor, externally mounted on the governor, or remotely
located. See manual 36641.
Shutdown Devices
Various devices can be incorporated in the governor to shutdown the prime
mover or provide an alarm signal in the event of equipment failure. These
devices are used in a variety of applications including installations where
automatic safety devices are a necessity. Shutdown devices are available in the
following arrangements to suit the particular operating conditions:
Pressure Actuated Shutdown

The pressure actuated shutdown (air, oil, water) provides the same protective
function as the solenoid operated shutdown. It may be set up to effect shutdown
with either loss of or excessive signal pressure. See manual 36651.
84 Woodward
Lubricating Oil Pressure Failure Shutdown
This is an automatic shutdown device which protects the prime mover in the
event of a partial or complete failure of the prime mover lubricating oil system. It
monitors lubricating oil pressure and is so designed that the shutdown pressure
level becomes progressively higher as prime mover speed increases. This allows
a relatively low minimum oil pressure level for safe operation at idle speed while
requiring increasingly higher levels for safe operation at higher speeds. Some of
these devices also include a capability to monitor prime mover oil pump inlet
pressure and effect shutdown if excessive vacuum (suction) occurs. A time delay
feature (adjustable within a range of 15–40 seconds) allows the prime mover to
be started without lubricating oil pressure yet prevents prolonged operation if a
safe pressure level is not reached within the preset time. At operating speeds
above idle, the time delay is normally bypassed so that shutdown is immediate.
See manual 36652.
Load Balance System

Pneumatic Load Balance
A pneumatic load balance system is available for PGA governors. This unit is
desirable when two or more engines are driving a common load, such as a
propeller shaft of a ship. The engines can be controlled in unison so the loads on
all engines are proportionally shared. This is necessary if the speed and load is
to be varied over a wide range. See manual 36686.
Transfer Valve
A transfer valve is available for use with the pneumatic load balance system. It
facilitates the remote control of the transfer functions for the pneumatic load
balance system. See manual 36686.
Woodward 85

36604-1301 Hex, nut, .250-28 .................................. 2
36604-1302 Shakeproof washer, .250 ...................... 2
36604-1303 Stud ...................................................... 2
36604-1304 Rotary servo end plate ......................... 1
36604-1305 Pin ........................................................ 2
36604-1306 Plug ...................................................... 1
36604-1307 Soc. cap screw ..................................... 2
36604-1308 Plain washer ......................................... 2
36604-1309 Lockwasher, .250 ................................. 2
36604-1310 Needle bearing ..................................... 1
36604-1311 Oil seal ring, 2.664 OD ......................... 1
36604-1312 Rotary servo housing ............................ 1
36604-1313 Dowel pin .............................................. 2
36604-1314 Soc. hd. screw, 8-32 x .500 .................. 2
36604-1315 Lockwasher, .281 OD ........................... 2
36604-1316 Rotary servo ......................................... 1
36604-1317 Vane insert leaf spring .......................... 2
36604-1318 Vane insert ........................................... 2
36604-1319 Rotary servo shaft assy. ....................... 1
36604-1320 Needle bearing ..................................... 1
36604-1321 Oil seal ring, 2.664 OD ........................... 1
36604-1322 Pin ........................................................ 1
36604-1323 Rotary servo back plate ........................ 1
36604-1324 Plain washer ......................................... 2
36604-1325 Lockwasher, .250 ................................. 2
36604-1326 Soc. hd. cap screw ............................... 2
36604-1327 Straight pin ........................................... 1
36604-1328 O-ring ................................................... 1
36604-1329 Straight pin, 0.0638 OD ........................ 1
36604-1330 Woodruff key ........................................ 1
36604-1331 Shaft assembly ..................................... 1
36604-1332 O-ring ................................................... 2
36604-1333 Side panel gasket ................................. 1
36604-1334 Side plate ............................................. 1
36604-1335 Soc. hd. cap screw ............................... 8
36604-1336 Ball bearing........................................... 1
36604-1337 Side plate gasket .................................. 1
36604-1338 Side plate cover .................................... 1
36604-1339 Soc. cap screw, .250-28 x 1.50 ............ 4
36604-1340 Oil seal, 1.125 OD ................................ 1
36604-1341 Soc. hd. cap screw, .250-20 x .625 ...... 8
36604-1342 High collar lockwasher, .250 ID ............ 22
86 Woodward
Figure 7-22. Exploded View of Integral Vane Servo
Woodward 87

36604-1381 Screw, soc. hd., 1/4-28 x 2 3/4 ........ A.R.
36604-1382 Lockwasher, split, 1/4 ...................... A.R.
36604-1383 Preformed packing, 7/16 OD ................ 1
36604-1383a Preformed packing ............................... 1
36604-1384 Plug and filter assembly ....................... 1
36604-1385 Preformed packing, 11/4 OD ................ 1
36604-1386 Preformed packing, 11/16 OD .............. 1
36604-1387 Plug ...................................................... 1
36604-1388 Gasket, soft copper .............................. 1
36604-1389 Case, 3-hole .................................... A.R.
36604-1390 Case, 4-hole .................................... A.R.
Figure 7-23. Exploded View of Fuel Limiter Oil Filter
88 Woodward
Chapter 8.

or return email.

and market segment.
service that includes repairs, repair parts, and warranty service on Woodward's
behalf. Service (not new unit sales) is an AISF's primary mission.


Woodward 89

 return number;
Packing a Control
 at least 100 mm (4 inches) of tightly packed, industry-approved packing material;

Replacement Parts
90 Woodward
email.
 Field Service




For the name of your nearest Woodward Full-Service Distributor or service facility,
please consult our worldwide directory at www.woodward.com/directory, which
also contains the most current product support and contact information.
Products Used in Products Used in Products Used in Industrial

Electrical Power Systems Engine Systems Turbomachinery Systems
Facility --------------- Phone Number Facility --------------- Phone Number Facility --------------- Phone Number
Germany: Germany ------ +49 (711) 78954-510 India --------------- +91 (129) 4097100
Kempen---- +49 (0) 21 52 14 51 India --------------- +91 (129) 4097100 Japan---------------+81 (43) 213-2191
Stuttgart - +49 (711) 78954-510 Japan---------------+81 (43) 213-2191 Korea ---------------+82 (51) 636-7080
India --------------- +91 (129) 4097100 Korea ---------------+82 (51) 636-7080 The Netherlands--+31 (23) 5661111
Japan---------------+81 (43) 213-2191 The Netherlands--+31 (23) 5661111 Poland -------------- +48 12 295 13 00
Korea ---------------+82 (51) 636-7080 United States -----+1 (970) 482-5811 United States -----+1 (970) 482-5811
Poland -------------- +48 12 295 13 00
United States -----+1 (970) 482-5811
Woodward 91
General
Your Name
Site Location
Phone Number
Fax Number

Manufacturer
Engine Model Number
Number of Cylinders
dual-fuel, etc.)
Power Output Rating
etc.)
Control/Governor #1
Serial Number
Control/Governor #2
Serial Number
Control/Governor #3
Serial Number
Symptoms
Description
92 Woodward
Please reference publication 36604M.

Phone +1 (970) 482-5811  Fax +1 (970) 498-3058

Operating instructions
Oil mist detector
MEV283
Read the instructions prior to performing any task!

Dr. E. Horn GmbH & Co. KG
Max-Planck-Straße 34
71116 Gärtringen
GERMANY
Telephone: +49 7034 27024-0
Email: info@dr-horn.org
Internet: www.dr-horn.org
Original instructions for use
MEV283, 1, en_GB
© 2019 Dr. E. Horn GmbH & Co. KG
2 Oil mist detector MEV283 19.11.2019

Supplemental directives
Supplemental directives
Contents of these instructions
These instructions contain specifications for transport, installation, operation,
maintenance and troubleshooting of the MEV283 oil mist detector (subse-
quently referred to as “device”).
Prior to beginning any work, personnel must have carefully read through and
understood these instructions. These instructions are an integral part of the
device and must be stored in the immediate vicinity of the device so that they
are accessible to personnel at all times.
A prerequisite for safe working is the observance of all safety instructions and
handling instructions stated here.
Furthermore, the local accident prevention provisions and general safety
regulations also apply for the area of application of the device.
Figures in these instructions serve to provide a basic understanding and may
differ from the actual version.
Copyright The contents of these instructions are protected by copyright. Their use is
permitted within the scope of use of the device. Any use beyond this without
the written consent of Horn GmbH & Co. KG is not allowed.
Additional applicable documents Documents of Horn GmbH & Co KG
 Drawing of the MEV283
 Motor-specific OMD drawing
 Parameter list
Documents of other manufacturers
In addition to these instructions, the instructions included in the delivery for
the installed components also apply. The instructions they contain – especial-
ly the safety instructions – must be observed.
Customer service For technical information, the respective motor manufacturer or our customer
service is available to you.
Address: Dr. E. Horn GmbH & Co. KG

Max-Planck-Strasse 34
71116 Gärtringen
GERMANY
Email: info@dr-horn.org
Phone: +49 7034 27024-0
Furthermore, we are always interested in information and experience arising

from use and which can be valuable for the improvement of our products.
19.11.2019 Oil mist detector MEV283 3

Table of contents
Table of contents
1 Overview ...................................................................................................... 9
1.1 Device view .......................................................................................... 9
1.2 Brief description .................................................................................. 11
1.3 Scope of delivery ................................................................................ 11
2 Safety ......................................................................................................... 13
2.1 Explanation of symbols ....................................................................... 13
2.2 Intended use....................................................................................... 15
2.3 Safety devices .................................................................................... 15
2.3.1 Signal LEDs ................................................................................... 16
2.3.2 Housing cover ................................................................................ 18
2.3.3 Steel plate ...................................................................................... 18
2.3.4 Earth connector .............................................................................. 18
2.4 Conduct in the event of fire outbreak or accidents ............................... 19
2.5 Signage .............................................................................................. 20
2.6 Residual risks ..................................................................................... 21
2.6.1 Basic hazards at the workplace ...................................................... 21
2.6.2 Dangers posed by electricity ........................................................... 23
2.6.3 Dangers posed by heat .................................................................. 23
2.6.4 Dangers posed by chemicals .......................................................... 24
2.7 Replacement parts.............................................................................. 25
2.8 Responsibility of the operator .............................................................. 26
2.9 Personnel qualifications ...................................................................... 28
2.10 Personal protective equipment ............................................................ 30
2.11 Environmental protection .................................................................... 31
3 Technical data ........................................................................................... 33

3.1 Dimensions and weights ..................................................................... 33
3.2 Connected load .................................................................................. 33
3.3 EMC standard .................................................................................... 33
3.4 Output signal ...................................................................................... 34
3.5 Relay .................................................................................................. 34
3.6 Communication interface .................................................................... 35
3.7 Motor .................................................................................................. 35
3.8 Ambient conditions ............................................................................. 35
3.9 Software version ................................................................................. 35
3.10 Certificates ......................................................................................... 36
3.11 Name plate ......................................................................................... 36
4 Device description..................................................................................... 37
4.1 Overview ............................................................................................ 37
4.2 Functional and process description ..................................................... 39
4.3 Component description ....................................................................... 39

Table of contents
4.3.1 Oil mist ventilation pipe................................................................... 39

4.3.2 Optical measuring track .................................................................. 40
4.3.3 Pressure sensor ............................................................................. 40
4.3.4 Base plate with damping system..................................................... 41
4.3.5 Housing.......................................................................................... 41
4.4 Display and operating elements .......................................................... 42
4.4.1 Signal LEDs ................................................................................... 42
4.4.2 [Oil mist test] button........................................................................ 42
4.4.3 Web interface ................................................................................. 43
4.4.4 Reset button................................................................................... 45
4.5 Connections and ports ........................................................................ 46
4.5.1 Circuit board................................................................................... 46
4.5.2 Connector X1 ................................................................................. 47
4.5.3 Connector X2 (X42 red).................................................................. 47
4.5.4 Connector X3 (X43 green) .............................................................. 48
4.5.5 Connector X4 ................................................................................. 48
4.5.6 Connector X5 ................................................................................. 50
4.5.7 Connector X6 ................................................................................. 51
4.5.8 Connector X284 ............................................................................. 51
4.5.9 Connector J3.................................................................................. 52
4.6 Operating states ................................................................................. 53
4.6.1 Normal status ................................................................................. 53
4.6.2 Error status .................................................................................... 53
4.6.3 Alarm status ................................................................................... 53
5 Materials and tools .................................................................................... 55
6 Transport, packaging and storage............................................................ 57

6.1 Symbols on the packaging .................................................................. 57
6.2 Delivery .............................................................................................. 57
6.3 Transport ............................................................................................ 58
6.4 Packaging .......................................................................................... 59
6.5 Storage .............................................................................................. 59
7 Installation and start-up ............................................................................ 61

7.1 Safety during installation ..................................................................... 61
7.2 Installing the device ............................................................................ 61
7.3 Connecting the device to the mains supply.......................................... 62
7.4 Earthing the device ............................................................................. 62
7.5 Connecting the network ...................................................................... 64
7.6 Testing relays ..................................................................................... 65
8 Operating concept..................................................................................... 67
8.1 Password protection and user role ...................................................... 67
8.2 Structure of the web interface ............................................................. 67
9 Operation ................................................................................................... 69
9.1 Safety during operation ....................................................................... 69
9.2 Switching on ....................................................................................... 69
9.3 Logging into the web interface ............................................................ 70

Table of contents
9.4 Setting the date and time .................................................................... 70

9.5 Setting parameters ............................................................................. 72
9.6 Changing the IP address..................................................................... 77
9.7 Saving the error and event list............................................................. 78
9.8 Calibrating the pressure sensor........................................................... 79
9.9 Logging out from the web interface ..................................................... 80
9.10 Switch off............................................................................................ 81
10 Maintenance .............................................................................................. 83
10.1 Safety during maintenance ................................................................. 83
10.2 Maintenance schedule ........................................................................ 84
10.3 Maintenance work............................................................................... 85
10.3.1 Performing oil mist test on the web interface ................................... 85
10.3.2 Performing the oil mist test manually .............................................. 87
10.3.3 Checking pressure ......................................................................... 89
10.3.4 Replacing the pressure sensor ....................................................... 89
10.3.5 Checking the optical measuring track ............................................. 91
10.3.6 Replace the transmitter and receiver .............................................. 93
10.3.7 Cleaning the optical measuring track .............................................. 97
10.4 After maintenance............................................................................... 98
11 Troubleshooting ........................................................................................ 99
11.1 Safety during troubleshooting.............................................................. 99
11.2 Procedure in the event of faults ........................................................... 99
11.3 Fault indications.................................................................................. 99
11.3.1 Signal LEDs ................................................................................. 100
11.3.2 Information on the web interface ................................................... 100
11.4 Troubleshooting ................................................................................ 101
12 Disassembly ............................................................................................ 103
13 Disposal ................................................................................................... 107
14 Index ........................................................................................................ 109

Overview
1 Overview
1.1 Device view

Complete view
Fig. 1: Complete view

1 Transmitter X42 ( Chapter 4.3.2 “Optical meas- 2 Oil mist ventilation pipe ( Chapter 4.3.1 “Oil mist
uring track” on page 40) ventilation pipe” on page 39)
3 Receiver X43 ( Chapter 4.3.2 “Optical measuring 4 Base plate with damping system ( Chapter 4.3.4
track” on page 40) “Base plate with damping system” on page 41)
5 Housing ( Chapter 4.3.5 “Housing” on page 41) 6 Hose for pressure measurement ( Chapter 4.3.3
“Pressure sensor” on page 40)
7 Connection for the pressure hose 8 Cable for EMC earthing ( Chapter 2.3.4 “Earth
( Chapter 4.3.3 “Pressure sensor” on page 40) connector” on page 18)
9 EMC connection on the oil mist ventilation pipe
(rear side;  Chapter 2.3.4 “Earth connector” on
page 18)

Overview
Detailed view
Fig. 2: Detailed view

1 Connection for the earthing cable ( Chapter 2.3.4 2 M12 connector for Ethernet
“Earth connector” on page 18; to be connected to
11)
3 “Oil mist test” button ( Chapter 4.4.2 “[Oil mist 4 Cable gland for relay
test] button” on page 42)
5 Cable gland for receiver cable 6 Cable gland for cables 4 – 20 mA ( Chapter 3.4
“Output signal” on page 34)
7 Pressure sensor ( Chapter 4.3.3 “Pressure sen- 8 Cable gland for transmitter cable
sor” on page 40)
9 Cable gland for power cable 10 Connection for the pressure hose
( Chapter 4.3.3 “Pressure sensor” on page 40)
11 Earth cable ( Chapter 2.3.4 “Earth connector” on 12 Cable gland for CAN
page 18; to be connected to 1)

Overview
1.2 Brief description

The MEV283 is an oil mist detector that was developed for monitoring 4-
stroke diesel engines.
The device monitors the oil mist concentration and crankcase pressure within
the oil mist ventilation pipe.
The device has a self-calibrating optical measuring track for oil mist detection,
and a temperature-stabilised pressure sensor.
A galvanically isolated analogue output signal is available for each of the two
measured values. The values are also displayed on the web interface.
The device is operated with 24 V DC in order to be able to run it with a back-
up power supply as well as the main supply. It has two 24 V supply connec-
tions.
To start the device, a motor run signal can be used as input from the motor
side.
For connection to an alarm monitoring system, the device has relays for the
operating states “SystemReady”, “PreAlarm”, “PressureAlarm” and “Alarm”.
To exchange of operational data, parameters and operating information, the
device has an Ethernet and a CAN bus interface, both of which can be con-
figured.
1.3 Scope of delivery

 Oil mist detector
 Drawing of the MEV283
 Operating instructions (provided by motor builder)
 Motor-specific OMD drawing
 Parameter list

Safety
2 Safety
2.1 Explanation of symbols

Safety instructions Safety instructions in these instructions are indicated by symbols. The safety
instructions are introduced by signal words, which express the scale of the
hazard.
DANGER!
This combination of symbol and signal word indicates an imme-
diately dangerous situation that could lead to death or serious
injury if it is not avoided.
WARNING!
This combination of symbol and signal word indicates a poten-
tially dangerous situation that could lead to death or serious
injury if it is not avoided.
CAUTION!
This combination of symbol and signal word indicates a poten-
tially dangerous situation that could lead to minor injury if it is not
avoided.
NOTICE!
This combination of symbol and signal word indicates a situation
that could lead to property damage or harm to the environment if
it is not avoided.
Safety instructions within handling Safety instructions can refer to certain individual handling instructions. Such
instructions safety instructions are embedded in the handling instruction so that readability
is not impaired when carrying out the activity. The signal words described
above are used.
Example:
1. Release screw.
CAUTION!
Pinching hazard in the cover!
2. Close the cover carefully.

Do not damage fibre optics.
3. Tighten screw.

Safety
Tips and recommendations

This symbol indicates useful tips and recommendations as well
as information for efficient and trouble-free operation.
Additional markings To highlight handling instructions, results, lists, references and other ele-
ments, these instructions employ the following markings:
Marking Explanation
Step-by-step handling instructions
 Results of action steps
References to sections in these instructions and

other applicable documents
Lists without a specified sequence
“Menu” Web interface menus

Safety
2.2 Intended use

Use This device is designed and constructed exclusively for the intended use
described here.
The oil mist detector is intended exclusively for installation in 4-stroke

diesel motors.
The device is used for measuring and monitoring the oil mist concentration
and the pressure within the drive chamber of diesel engines.
The device is designed for installation and operation in potentially explo-
sive atmospheres (Zone 2).
 Chapter 3 “Technical data” on page 33
Measurement of the drive chamber pressure and atmospheric clouding is
a system for ensuring personnel safety.
Proper use also includes the observance of all information within

these instructions.
Foreseeable misuse Any use of the device that is other than or beyond the intended use is consid-
ered misuse and can lead to dangerous situations.
Foreseeable misuse includes:
 Use of the device with connected loads that do not match the specifica-
tions ( Chapter 3.2 “Connected load” on page 33).
 Use of the device with motors that do not match the specifications.
 Use of the device with incorrectly positioned or damaged lenses.
 Use of the equipment in a zone other than the approved zone (Zone 2).
 Unauthorised modifications, extensions or conversions of the device.
WARNING!
Danger posed by misuse!

Misuse of the device can lead to dangerous situations.
− Do not undertake any unauthorised modifications, exten-
sions, or conversions on the device.
2.3 Safety devices

Non-functioning safety devices
WARNING!
Non-functioning safety devices!

If safety devices are damaged, not functioning or disabled, this
poses the danger of severe injury or death.
− Prior to starting work, check whether all safety devices are
undamaged, functional, and correctly installed.
− Only operate the device with fully installed safety devices.
− Only disable or bypass safety devices in the exceptional
cases that have been described in these instructions.

Safety
2.3.1 Signal LEDs
The LEDs show the operating, error, and alarm status of the device. The red
“Alarm” LED (Fig. 3/1) is on the left; the green “Ready/Failure” LED (Fig. 3/2)
is on the right.
Under normal circumstances, the “Ready/Failure” LED flashes

continuously in an on/off rhythm of 2 seconds and the “Alarm”
LED is off.
Fig. 3: Signal LEDs

Fault indicator When a fault is detected, the “SystemReady” relay ( “Relay” on page 50) is
activated and the “Ready/Failure” LED starts to flash in one of the following
patterns:
Fault description Code3 2s Each column represents 0.5 s
Normal operation 2s
Watchdog error1 E01
Error on the pressure sensor1 E03
Oil mist control inactive2 E05
Measuring track error: oil mist

E06
measurement not possible1
Cleaning of the optical measuring

E08
track required1
Setting of the clock required1 E10
The LED is lit.

The LED is off.
1 The flashing repeats until the error is eliminated.
2When switching on/restarting, approx. 90 s are required for the self-test and
calibration of the optical sensors.
3 For information on the error codes  “Error codes” on page 100.

Safety
Alarm indicator If the oil mist alarm is activated, the alarm relay ( “Relay” on page 50) is acti-
vated and the “Alarm” LED starts to flash in one of the following sequences:
Alarm description Code5 2s Each column represents 0.5 s
Pressure higher than P261 H04
Pressure higher than P271 H05
Oil mist pre-warning2 H09
Oil mist alarm – load reduction

H10
reached3
Oil mist alarm – Autostop level

H11
reached4
The LED is lit.

The LED is off.
1  “Setting the crankcase pressure monitoring/Selecting the pressure range”
on page 74
2 The flashing repeats until the oil mist value falls below the value of parame-
ter P12 ( “Adjusting the oil mist sensor/Activating the motor run signal” on
page 74).
page 74).
page 74).
5 For information on the alarm codes  “Alarm codes” on page 100.

Safety
2.3.2 Housing cover
The housing cover protects the electronics installed in the housing from dirt
and damage due to moisture.
Fig. 4: Housing cover
2.3.3 Steel plate
The steel plate is permanently welded to the oil mist ventilation pipe and
serves as a kick protector for the housing.
Fig. 5: Steel plate
2.3.4 Earth connector
Contact voltages and ignition

sparks WARNING!
Danger of death due to contact voltages and sparks!

Missing or defective potential equalisation can result in contact
voltages and sparks. This poses the danger of severe injury or
death.
− Prior to initial commissioning, connect device to the local
potential equalisation and check that this functions properly.

Safety
The earth connector of the device serves in conducting electrical currents into
the earth (potential equalisation) in order to prevent sparks and contact volt-
ages if an error occurs.
Fig. 6: Earth connector
2.4 Conduct in the event of fire outbreak or accidents

Preventive measures  Always be prepared for fires and accidents.
 Store first-aid equipment (first-aid kit, blankets, etc.) and fire extinguish-
ers, ensuring that these are functional and within reach.
 Ensure that personnel are familiar with the accident signalling devices,
first-aid kit and rescue equipment.
 Keep access routes for rescue vehicles clear.
Measures in the event of fire out-  Immediately trigger an emergency stop using the emergency stop device.
break or accidents  If your own safety is not endangered, bring the person(s) in question out
of the danger zone.
 If necessary, initiate first-aid measures.
 Alert the fire brigade and/or rescue service.
 In the event of a fire outbreak: If your own safety is not endangered,
attempt to put out the fire with extinguishers until firefighters arrive.
 Inform on-site supervisors.
 Keep access routes for rescue vehicles clear.
 Provide information to rescue vehicles.

Safety
2.5 Signage
Illegible signage
WARNING!
Danger of death due to illegible signage!

Over time, stickers and signs can become soiled or otherwise
illegible, so that hazards are not detected and the required oper-
ating instructions cannot be followed. This poses a risk of death.
− Always maintain stickers and signs in legible condition.
− Replace damaged stickers and signs immediately.
Earthing
This symbol indicates that the product must be earthed prior to being put into
operation.
Connection/installation diagram
Fig. 7: Connection/installation diagram

This sign indicates the possible connections and connection plugs in the
housing of the oil mist detector ( Chapter 4.5 “Connections and ports” on
page 46).
The sign is located in the housing cover.

Safety
ATEX marking
Fig. 8: ATEX marking
2.6 Residual risks

The device has been designed according to the latest technological standards
and safety requirements.
Nevertheless, residual risks remain, which require cautious handling. Residu-
al risks and the appropriate conduct and measures required are listed below.
2.6.1 Basic hazards at the workplace
Running motor
WARNING!
Danger of death due to running motor!

Starting the motor while working on or inside the motor may lead
to serious or fatal injuries.
− Prior to all work, switch off the motor and secure it against
being switched on again.
Opened housing
WARNING!
Danger of explosion with housing opened in explosive at-

mospheres!
If a potentially explosive atmosphere is present (regardless of
zone), the housing may not be opened when the device is
switched on, since this would pose an explosion hazard.
Any zone other than the correct one (Zone 2) is already danger-
ous.
− Do not open the housing in an explosive atmosphere if the
device is switched on.
Infrared light beam

WARNING!
Risk of eye injury from infrared light beam!

When maintenance work is performed on the optical measuring
track, there is a risk of eye injury from the infrared light beam.
− Never look directly into the infrared light beam.

Safety
Working at greater heights

WARNING!
Risk of falls and injury when working at greater heights!

Working at greater heights and while standing on climbing aids
poses a risk of falls and injury.
− Use suitable fall protection equipment.
− Only use climbing aids that have a solid stand and provide
sufficient support.
Strong vibrations
WARNING!
Risk of injury from strong vibrations!

Exposure to strong vibrations for extended periods can lead to
considerable injuries and chronic health damage.
− Do not disable vibration dampers.
− Avoid entering the area of the vibrations during operation.
Noise
WARNING!
Hearing impairment due to excessive noise!

The noise level occurring in the work area can cause severe
hearing impairment.
− Wear hearing protection.
− Only remain in the danger zone as long as necessary.
Sharp corners or edges

CAUTION!
Risk of injury on sharp corners or edges!

Sharp corners and edges can lead to skin cuts and abrasions.
− Wear the prescribed personal protective equipment when
working.
Dirt and objects left lying around

CAUTION!
Risk of injury due to dirt and objects left lying around!

Dirt and objects left lying around pose a slipping and tripping
hazard. A fall could cause injuries.
− Always keep the work area clean.
− Remove no longer required objects from the work area,
especially near the floor.
− Mark unavoidable tripping hazards with yellow/black mark-
ing tape.

Safety
2.6.2 Dangers posed by electricity
Electrical current
DANGER!
Danger of death due to electrical current!

Contact with live parts poses an immediate danger of death from
electric shock. Damaged insulation or individual components can
be life-threatening.
− Have work on the electrical system performed only by elec-
tricians.
− If the insulation is damaged, immediately switch off the volt-
age supply and have this repaired.
− Prior to starting work on energised parts of electrical sys-
tems and equipment, establish a voltage-free state and en-
sure this state is maintained for the duration of the work.
Observe the 5 safety rules:
− Switch off.
− Secure against reactivation.
− Verify a voltage-free state.
− Carry out earthing and short-circuiting.
− Provide protection from adjacent live parts.
− Never bypass or disable fuses. When replacing fuses, ob-
serve the correct amperage.
− Keep moisture away from voltage-conducting parts. This
could lead to a short circuit.
2.6.3 Dangers posed by heat
Hot surfaces
WARNING!
Risk of injury due to hot surfaces!

Contact with hot components can lead to severe burns.
− Allow components to cool down to the ambient temperature
before touching them.
− Wear protective gloves.
Hot operating materials

WARNING!
Risk of injury due to hot operating materials!

Operating materials can reach high temperatures during opera-
tion. Skin contact with hot operating materials can cause severe
scalding.
− When performing any work with operating materials, always
wear heat-resistant work clothing and protective gloves.
− Prior to any work with operating materials, check whether
they are hot. If necessary, allow them to cool down.

Safety
2.6.4 Dangers posed by chemicals
Motor oil and fuel

WARNING!
Risk of fire due to motor oil and fuel!

Fumes from oil and fuel can ignite if they come into contact with
the ignition source.
− Do not light any open flames when working on the motor.
− Do not smoke.
− Remove oil and fuel residues from the motor and floor.
Highly flammable materials

WARNING!
Risk of fire due to highly flammable materials!

Highly flammable materials, liquids and gases can ignite and
cause severe or fatal injuries.
Dangerous fumes can be released when chemical substances
are burned.
Dust deposits can swirl up and form an explosive mixture with
the ambient air.
− Do not smoke in the area of the device. Refrain from contact
with exposed lights, flames or sources of ignition of any
type.
− Have a suitable fire-extinguishing agent ready.
− Immediately report any suspicious materials, liquids or gas-
es to your supervisor.
− In the event of a fire, stop work at once. Leave the scene of
the fire and alert the fire brigade.
Flammable mixtures in the sur-

roundings WARNING!
Danger of explosion in the case of flammable mixtures in

the surroundings!
When flammable mixtures are present in the atmosphere, explo-
sions can occur.
Oil under pressure

WARNING!
Risk of injury due to oil under pressure!

If lines or machine components are defective, oil under pressure
can escape. This can lead to serious injuries.
− Never open pressurised pipelines.
− Prior to starting work, completely depressurise pipelines.
− Have defective parts repaired.

Safety
2.7 Replacement parts

Incorrect replacement parts
WARNING!
Risk of injury due to incorrect replacement parts!

The use of incorrect or defective replacement parts can pose
dangers as well as cause damage, malfunctions or total failure.
− Use only original replacement parts made by Horn GmbH &
Co. KG, or replacement parts that have been approved by
Horn GmbH & Co. KG.
− Order replacement parts only through the customer service
of Horn GmbH & Co KG ( “Customer service” on page 3).

Safety
2.8 Responsibility of the operator

Operator The operator is defined as the person operating the device for business or
commercial purposes, or who allows others to use/employ the device, and
who during operation bears the legal product responsibility for the protection
of the user, of personnel or of third parties.
Obligations of the operator The device is used in the commercial sector. The operator of the device is
therefore subject to legal obligations regarding occupational safety.
In addition to the safety instructions detailed here, the regulations for safety,
accident prevention and environmental protection valid for the device’s area
of application must be observed.
In particular, the following applies:
 The operator must familiarise himself with the applicable occupational
health and safety regulations and, by means of a risk assessment, also
determine any hazards arising from the special operating conditions at
the location where the device is used. The operator must implement this
in the form of operating instructions for the operation of the device.
 During the entire lifetime of the device, the operator must check whether
the operating instructions created conform to the latest technical stand-
ards, and if necessary, revise them.
 The operator must ensure that all persons working with the device have
read and understood these instructions, and that they possess the re-
quired qualifications for the individual tasks. Furthermore, the operator
must train personnel at regular intervals and inform them of the dangers
and how to act in an emergency.
 The operator must clearly regulate and define the responsibilities for
installation, operation, troubleshooting, maintenance and cleaning.
 The operator must provide personnel with the required protective equip-
ment and advise them that it is mandatory to wear the required protective
equipment.
 The operator must observe the locally applicable fire protection ordinances.
 The operator must ensure that the area of the device and its surround-
ings have sufficient illumination.
 The operator is responsible for maintaining the device in a technically
flawless condition.
Therefore, the following applies:
 The operator must ensure that the maintenance intervals described in
these instructions are adhered to.
 The operator must have all safety devices regularly checked for proper
function and completeness.

Safety
Duties of the owner in relation to The owner must comply with further obligations from directive 99/92/EC relat-
fire and explosion protection ing to the improvement of health protection and safety of employees who
could be endangered by a potentially explosive atmosphere.
This includes compliance with further organisational measures such as:
 Indication of the Ex-areas
 Creation of an explosion protection document for each zone
 Creation of an access ban for unauthorised persons
 The clear display of all bans
The owner must inform the personnel at regular intervals about:
 Local fire and explosion protection measures.
 Location and function of the safety devices.
 Necessity of a smoking ban.
 Necessity to avoid open flame.
 Procedures for cleaning and maintenance work, plus repairs, including
the tools, auxiliaries, and cleaning agents to be used.
 Necessity of wearing personal protective equipment suitable for the po-
tentially explosive area.
The owner must provide and locate suitable fire extinguishers for fire fighting.
The owner must appropriately indicate the potentially explosive areas and the
zones where flames, naked light, and smoking are banned, by the use of
meaningful signs.

Safety
2.9 Personnel qualifications

Inadequate qualifications
WARNING!
Inadequate qualifications can result in fatalities.

Allowing an inadequately qualified person to perform work on the
device poses a life-threatening danger. Considerable property
damage could occur as well.
− Have all activities carried out only by persons who possess
the qualifications stated in the individual chapters.
− In case of doubt, address the individuals in question and
direct them to exit the danger zone and work area.
− Halt the work as long as inadequately qualified persons are
present at the device.
Requirements of personnel Staff should be made up exclusively of persons who can be expected to carry
out their work reliably. Persons whose responsiveness is affected, e.g. by
drugs, alcohol or medicines, are not authorised.
Observe the locally applicable regulations relating to age and

profession.

Safety
List of qualifications The various tasks described in these instructions have different requirements
regarding the personnel qualifications for those assigned to perform them.
Electrician with additional qualification in explosion protection
Electricians with additional qualification in explosion protection have been
specially trained for their duties and are familiar with the relevant standards
and regulations.
Electricians with additional qualification in explosion protection can carry out
work on electrical systems on the basis of their technical training and experi-
ence and can recognise and avoid potential hazards independently.
Installation specialist
Installation specialists with additional qualification in explosion protection have
been specially trained for their duties and are familiar with the relevant stand-
ards and regulations.
Installation specialists with additional qualification in explosion protection are
specially trained by the manufacturer in working with the product. Their tech-
nical training and experience enable them to carry out tasks on systems and
components and independently recognise and avoid potential hazards.
Instructed person
Instructed persons have been verifiably instructed by the operating company
in a briefing about the tasks assigned to them and the potential hazards
posed by improper conduct.
Instructed persons are able to perform this work professionally and safely.
Instructed persons are authorised for the following activities:
 Switching on the device
 Switching off the device
 Performing a manual oil mist test
 Cleaning work
Maintenance personnel with additional qualification in explosion protec-
tion
Maintenance personnel with additional qualification in explosion protection
have been specially trained for their duties and are familiar with the relevant
standards and regulations.
Maintenance personnel with additional qualification in explosion protection
can carry out work on hydraulic systems on the basis of their technical train-
ing and experience and can recognise and avoid potential hazards inde-
pendently.
Transport specialist
The transport specialist has been trained in the use of cranes or industrial lift
trucks. This specialist is able to select appropriate load handling and lifting
tackle and apply it properly. Based on this knowledge, the specialist can inde-
pendently recognise and avoid potential hazards when moving transport
components.

Safety
2.10 Personal protective equipment

Personal protective equipment serves to protect persons from safety and
health risks during work.
While performing various work on the device, personnel must wear their per-
sonal protective equipment as specifically indicated in the individual sections
of these instructions. Explanation:
Hearing protection
Hearing protection serves to protect against hearing damage due to exposure
to noise.
Industrial safety helmet

Industrial safety helmets protect the head from falling objects, swinging loads
and impacts on fixed stationary objects.
Protective clothing
Protective clothing is close-fitting work attire with a low tear strength, narrow
sleeves and no protrusions.
Protective gloves
Protective gloves serve to protect hands from chafing, abrasions, punctures
or deeper wounds as well as from contact with hot surfaces.
Puncture-resistant safety shoes

Safety shoes protect the feet from crushing, falling parts and slipping on slip-
pery surfaces.
Safety goggles
Safety goggles serve to protect the eyes from flying parts and spurting liquids.
Safety harness
The safety harness serves as protection against falls in the case of increased
danger of falling. This situation occurs when certain height differences are
exceeded and the worksite is not secured by a railing.
Attach the safety harness so that the safety rope is connected to the harness
as well as to a fixed attachment point. If necessary, provide fall-impact ab-
sorbers.
Safety harnesses may only be used by persons specially instructed in their
use.

Safety
2.11 Environmental protection

Environmentally hazardous materi-
als NOTICE!
Danger to the environment due to incorrect handling of

environmentally hazardous materials!
If environmentally hazardous materials are incorrectly handled,
in particular through improper disposal, this could result in con-
siderable environmental damage.
− Always observe the instructions stated below for handling
and disposing of environmentally hazardous materials.
− In case of doubt, request information from local authorities
or specialist disposal companies.
− Observe safety data sheets and instructions.
Observe the following instructions for environmental protection when perform-

ing maintenance work:
Electrical and electronic compo- Electrical and electronic components may contain toxic substances. These
nents components must be collected separately and handed over to municipal col-
lection points or disposed of by a specialist company.
Lubricants Lubricants such as grease and oil contain toxic substances that should not be
allowed to enter the environment. Their disposal must be carried out by a
specialist disposal company.

Technical data
3 Technical data
3.1 Dimensions and weights

Dimensions See drawing (additional applicable documents)
Weights
Data Value Unit
Motor-specific oil mist detector with pipe, approx. 25 kg
Housing, approx. 5 kg
3.2 Connected load
Data Value Unit
Voltage supply 24 V DC
-25 to +30%, %
Max. allowed residual ripple ≤5 %
Fuse 3.15 A
Power consumption, max. 35 W
Safety class acc. to DIN 60529 IP65
Safety class acc. to DIN 60529, optical sensors IP67
Conductor cross-section 0.14 – 1.5 mm
3.3 EMC standard
Specification Value
Generic no. EN 55016 and EN 55022
Safety regulations acc. to EN 61000-4, -6
Rules for type checking acc. to DNV GL

Technical data
3.4 Output signal
Data Value Unit
Output signal of current output 4 – 20 mA
Isolation Galvanically isolated
Pressure ± 25 mbar
Pressure outlet, load max. 500 Ω
Oil mist outlet, load max. 500 Ω
Resolution of pulse width modulation 10,000 steps
Linearity ± 0.25% of final value
Reaction time, approx. 300 ms
3.5 Relay
Specification Value
Type PhotoMOS
Error relay Self-monitoring, short circuit-

protected, freely configurable
Limit value relay Self-monitoring, short circuit-

protected, freely configurable
Data Value Unit
Max. switching current 500 mA
Switching voltage 7 – 60 V AC

Technical data
3.6 Communication interface

Ethernet for parameter settings and process data display (galvanically isolat-
ed).
Data Value Unit
Transmission rate 100 Mbit/s
CAN Galvanically isolated
Protocol CANopen, J1939
Addressing (node ID), adjustable 1 – 127
Transmission rate, adjustable 10k – 1M Baud
3.7 Motor
Specification Value
Motor Wärtsilä engines
Motor types W20, W20DF, W26, W31, W32,

W34DF L+V TYPE
3.8 Ambient conditions
Data Value Unit
Operating temperature -20 – +85 °C
Relative humidity, non-condensing < 90 %
3.9 Software version
Specification Value
Version 2.26 and higher

Technical data
3.10 Certificates
 DNV GL
 ABS
 LR
Other certificates available on request.
3.11 Name plate
1 Lettering of the “Alarm” LED
2 Product type
3 Lettering of the “Ready/Failure” LED
4 Manufacturer
5 Product name
Fig. 9: Name plate
6 Logo
7 Head office of manufacturer

Device description
4 Device description
4.1 Overview
Complete view
Fig. 10: Complete view

1 Transmitter X42 ( Chapter 4.3.2 “Optical meas- 2 Oil mist ventilation pipe ( Chapter 4.3.1 “Oil mist
uring track” on page 40) ventilation pipe” on page 39)
3 Receiver X43 ( Chapter 4.3.2 “Optical measuring 4 Base plate with damping system ( Chapter 4.3.4
track” on page 40) “Base plate with damping system” on page 41)
5 Housing ( Chapter 4.3.5 “Housing” on page 41) 6 Hose for pressure measurement ( Chapter 4.3.3
“Pressure sensor” on page 40)
7 Connection for the pressure hose 8 Cable for EMC earthing ( Chapter 2.3.4 “Earth
( Chapter 4.3.3 “Pressure sensor” on page 40) connector” on page 18)
9 EMC connection on the oil mist ventilation pipe
(rear side;  Chapter 2.3.4 “Earth connector” on
page 18)

Device description
Detailed view
Fig. 11: Detailed view

1 Connection for the earthing cable ( Chapter 2.3.4 2 M12 connector for Ethernet
“Earth connector” on page 18; to be connected to
11)
3 “Oil mist test” button ( Chapter 4.4.2 “[Oil mist 4 Cable gland for relay
test] button” on page 42)
5 Cable gland for receiver cable 6 Cable gland for cables 4 – 20 mA ( Chapter 3.4
“Output signal” on page 34)
7 Pressure sensor ( Chapter 4.3.3 “Pressure sen- 8 Cable gland for transmitter cable
sor” on page 40)
9 Cable gland for power cable 10 Connection for the pressure hose
( Chapter 4.3.3 “Pressure sensor” on page 40)
11 Earth cable ( Chapter 2.3.4 “Earth connector” on 12 Cable gland for CAN
page 18; to be connected to 1)

Device description
4.2 Functional and process description

The oil mist detector measures the oil mist concentration in the air inside the
oil mist ventilation pipe.
Two lenses are used as well.
The first lens emits a light beam, which is registered by the second lens.
If the same amount of light was not received as was transmitted, the opacity
of the drive chamber atmosphere has changed.
The degree of light transmittance depends on the oil mist concentration.
Warnings and alarms are issued if the oil mist concentration exceeds the set
limit values.
The device also measures the pressure within the oil mist ventilation pipe.
Warnings and alarms are issued if the pressure exceeds the set limit values.
4.3 Component description
4.3.1 Oil mist ventilation pipe
The version of the oil mist ventilation pipe depends on the motor
type. An example version is shown here.
The oil mist ventilation pipe is a part of the device and conveys the oil mist to
the on-site ventilation system.
The oil mist ventilation pipe is made of steel.
Inside the oil mist ventilation pipe are the lenses of the optical measuring
track (Fig. 12/1, 3;  Chapter 4.3.2 “Optical measuring track” on page 40)
and the hose for the pressure measurement (Fig. 12/2).
The housing ( Chapter 4.3.5 “Housing” on page 41) is located on the oil mist
ventilation pipe.
Fig. 12: Oil mist ventilation pipe

Device description
4.3.2 Optical measuring track
The optical measuring track delivers the oil mist measurements.

The optical measuring track consists of 2 aluminium lenses, a transmitter X42
(Fig. 13/1) and a receiver X43 (Fig. 13/2).
The transmitter and receiver operate in the non-visible infrared light spectrum.
The transmitter and receiver have internal temperature-controlled heating sys-
tems in order to prevent condensation from forming on the optical surfaces.
A too-high water content in the oil can lead to water vapour in

the oil mist. The heating system prevents condensation of the
water vapour on the optical measuring track.
Fig. 13: Lenses
The transmitter emits light, which is registered by the receiver. When oil mist
streams through the optical measuring track, parts of the light are absorbed.
The signal of the optical measuring track is constantly monitored so that the
current value can always be displayed on the web interface.
If the signal does not lie within the normal range, the alarm or autostop is
activated. The information is also displayed on the web interface.
The soiling of the optical measuring track (at the transmitter

and/or the receiver) is regularly measured.
If the maximum allowed degree of soiling is reached, error code
E08 is displayed and the optical measuring track must be
cleaned ( Chapter 10.3.7 “Cleaning the optical measuring
track” on page 97).
4.3.3 Pressure sensor
The pressure sensor is located in the housing ( Chapter 4.3.5 “Housing” on

page 41).
The pressure sensor is temperature-stabilised and connected to the oil mist
ventilation pipe ( Chapter 4.3.1 “Oil mist ventilation pipe” on page 39) by a
hose.
The pressure is monitored in order to activate the PressureAlarm relay, if
necessary.
The measured pressure is forwarded to the higher-level system by means of
an output signal ( “Output signal” on page 49).
Fig. 14: Pressure sensor

Device description
4.3.4 Base plate with damping system
The base plate with damping system connects the housing ( Chapter 4.3.5
“Housing” on page 41) to the oil mist ventilation pipe ( Chapter 4.3.1 “Oil
mist ventilation pipe” on page 39).
The damping system of the base plate consists of springs (Fig. 15/1), which
are attached above and below.
The damping system reduces vibrations arising from the motor.
Also on the base plate (Fig. 15/2) is a weight (Fig. 15/3), which is used to
minimise or eliminate vibration frequencies.
Fig. 15: Base plate
4.3.5 Housing
The housing is installed over a base plate with damping system

( Chapter 4.3.4 “Base plate with damping system” on page 41) on the oil
mist ventilation pipe ( Chapter 4.3.1 “Oil mist ventilation pipe” on page 39).
The housing is made of die-cast aluminium and serves to protect the electron-
ics from damage due to dirt and moisture.
The relays ( “Relay” on page 50) and pressure sensor ( Chapter 4.3.3
“Pressure sensor” on page 40) are located inside the housing.
On the exterior of the housing are the cable connections and the button for
the manual oil mist test ( Chapter 4.4.2 “[Oil mist test] button” on page 42).
Fig. 16: Housing

Device description
4.4 Display and operating elements
4.4.1 Signal LEDs
For information on the signal LEDs  Chapter 2.3.1 “Signal

LEDs” on page 16.
4.4.2 [Oil mist test] button
The [Oil mist test] button is located on the left-hand side of the housing.
This button is used to initiate the oil mist test ( Chapter 10.3.2 “Performing
the oil mist test manually” on page 87). After 8 seconds, the LED ring lights up
red and the test starts.
The test will not start if the button is pressed for less than 8 or
more than 12 seconds.
Fig. 17: [Oil mist test] button

Device description
4.4.3 Web interface
On the web interface, maintenance staff can view warnings and error mes-
sages, carry out maintenance work, set parameters and change the date.
The manufacturer can also carry out password-protected settings.
Home page
Fig. 18: Home page

The home page of the web interface shows process data, error messages
and events, which are updated each second.
The events history is collected in an internal memory under “Errors and
Events”.

Device description
Info page
Fig. 19: Info page

This page contains important and necessary information on the device and
contact data for support.

Device description
Help page
Fig. 20: Help page

The help page of the web interface contains information regarding use.
4.4.4 Reset button
The reset button (Fig. 21/1) is located at the top left on the circuit board.
If the DHCP server was deactivated via the parameters and the device is no
longer displayed, the reset button can be pressed for approx. 10 seconds.
This reactivates the DHCP server and the device is restarted.
Fig. 21: Reset button

Device description
4.5 Connections and ports

Unplugged connector
WARNING!
Danger due to unplugged connector in potentially explosive

atmospheres!
Unplugging the connector in a potentially explosive atmosphere
(regardless of zone) poses a risk of explosions.
ous.
− Do not unplug connectors in explosive atmospheres.
4.5.1 Circuit board
Fig. 22: Circuit board
1 Reset button ( Chapter 4.4.4 “Reset button” on page 45)
2 Connector X2 ( Chapter 4.5.3 “Connector X2 (X42 red)” on page 47)
3 Connector X6 ( Chapter 4.5.7 “Connector X6” on page 51)
6 Connector X3 ( Chapter 4.5.4 “Connector X3 (X43 green)” on page 48)
8 Connector J3 ( Chapter 4.5.9 “Connector J3” on page 52)

Device description
The circuit board is located in the housing and holds the connector.
The reset button is also located on the circuit board.
4.5.2 Connector X1
Connector X1 (Fig. 22/4) is used for the power supply (clamping area up to
2.5 mm²).
Pin no. Description
X1/1 Main supply 24 V DC
X1/2 Main supply 0 V
X1/3 Earthing
X1/4 Redundant supply 24 V DC
X1/5 Redundant supply 0 V
X1/6 Earthing
Fig. 23: Connector X1

If no emergency power supply is available, connect pins X1/1
and X1/4.
4.5.3 Connector X2 (X42 red)
Connector X2 (Fig. 22/2) connects the transmitter of the optical measuring

track to the oil mist detector.
The colours shown indicate the colour of the cable to be connected.
Pin no. Cable colour Description
X2/1 White Temperature sensor, transmitter +
X2/2 Blue Temperature sensor, transmitter -
X2/3 Green Heating coil, transmitter +
X2/4 Red Heating coil, transmitter -
X2/5 Black Transmitter current +
Fig. 24: Connector X2 X2/6 Brown Transmitter current -

Device description
4.5.4 Connector X3 (X43 green)
Connector X3 (Fig. 22/6) connects the receiver of the optical measuring track
to the oil mist detector.
X3/1 White Temperature sensor, receiver +
X3/2 Blue Temperature sensor, receiver -
X3/3 Red Heating coil, receiver +
X3/4 Green Heating coil, receiver -
X3/5 Brown Receiver current +
X3/6 Black Receiver current -

4.5.5 Connector X4
Connector X4 (Fig. 22/7) transmits the output signal ( “Output signal” on

page 49) and the motor run signal ( “Motor run signal” on page 49) (clamp-
ing area 1.5 mm²).
Pin no. Description
X4/1 Oil mist analogue output 4 – 20 mA
X4/2 Oil mist analogue output 4 – 20 mA
X4/3 Pressure analogue output 4 – 20 mA
X4/4 Pressure analogue output 4 – 20 mA
X4/5 Motor run signal +
X4/6 Motor run signal -

Device description
Output signal
The output signal is transmitted via connector X4 ( Chapter 4.5.5
“Connector X4” on page 48) to the 2 LEDs in the housing cover
( Chapter 2.3.1 “Signal LEDs” on page 16).
The output signal is transmitted with 4 – 20 mA.
The output signal can transfer the following values:
 Oil mist level (Fig. 27/1)
 Drive chamber pressure (Fig. 27/2)
Fig. 27: Output signal, connector X4

Motor run signal The motor run signal of connector X4 ( Chapter 4.5.5 “Connector X4” on
page 48) is used to signal the device that the motor is running.
The signal can be activated by parameter P21 in the parameter list
( “Adjusting the oil mist sensor/Activating the motor run signal” on page 74).
An input signal can be provided in two ways:
 potential-free contact or switch
 analogue voltage signal between 6 V and 24 V
The device must be earthed ( Chapter 7.4 “Earthing the de-

vice” on page 62).
If no input signal can be provided, either the control can be car-

ried out using CAN or the parameter can be set to the “Alway-
sOn” value.

Device description
4.5.6 Connector X5
Connector X5 (Fig. 22/5) transfers the relay signals ( “Relay” on page 50).
Pin no. Description Relay no. Config. value
X5/1 SystemReady relay + 1 2
X5/2 SystemReady relay -
X5/3 PreAlarm relay + 2 4
X5/4 PreAlarm relay -
X5/5 PressureAlarm relay + 3 8
X5/6 PressureAlarm relay -
Fig. 28: Connector X5 X5/7 Alarm relay + (optional) 4 16
X5/8 Alarm relay - (optional)
Relay PhotoMOS relays are used.

Relays 1 – 4 may be set in the configuration as “normally open” or “normally
closed”. This influences the behaviour during the relay test ( Chapter 7.6
“Testing relays” on page 65).
The maximum switching current of the PhotoMOS relay is 500 mA.
The relays are activated in the following situations:
 A failure detected in the system or a power loss activates the Sys-
temReady relay (Relay1, Fig. 29/1)1.
 The “Oil mist pre-warning” or “Load reduction level reached” messages
activate the PreAlarm relay (Relay2, Fig. 29/4).
 A pressure exceeding or falling below the set limit value activates the
PressureAlarm relay (Relay3, Fig. 29/2).
 The “Oil mist autostop value reached” message activates the Alarm
relay (Relay4, Fig. 29/3).
1 The SystemReady relay is activated by an oscillating voltage, which is gen-
erated by the processor. If the processor stops, the voltage is no longer gen-
Fig. 29: Relay erated and the relay changes its status. In the event of a power failure, the
relay reverts to its initial status, independent of the setting (“normally
open/closed”).
It is recommended to leave the SystemReady relay in “normally

open” status.
If a relay is activated, this is displayed on the web interface by error messag-

es and warnings.
The relays are automatically reset once the error has been recti-
fied.

Device description
4.5.7 Connector X6
Connector X6 (Fig. 22/3) transfers the CAN bus signals (clamping area up to
2.5 mm²).
The device has a galvanically isolated CAN bus interface for external data
exchange.
Parameters P70 – P78 ( “Setting the CAN bus” on page 77) are relevant for
the configuration of the CAN bus.
Pin no. Description
X6/1 CAN earthing
X6/2 CAN “low”
X6/3 Earthing
X6/4 CAN “high”
The “CANopen” protocol is supported on the CAN bus.
If the device is the last CAN node on the network, the termina-
tion switch for 120 Ohm must be set to “On” to use the resistor.
4.5.8 Connector X284
Connector X284 establishes the Ethernet connection.

The connection is located on the left-hand side of the housing.
Pin no. Description
X284/1 Transmitter TX+
X284/2 Receiver RX+
X284/3 Transmitter TX-
X284/4 Receiver RX-

Device description
4.5.9 Connector J3
Connector J3 (Fig. 22/8) connects the pressure sensor.
Connector J3 is only intended for internal use by the manufac-

turer.
Fig. 32: Connector J3 J3/1 Black –
J3/2 – –
J3/3 Red –

Device description
4.6 Operating states
4.6.1 Normal status
In normal status, there are no errors or alarms present. In normal status, data
regarding pressure, oil mist concentration and IR power are available.
All these data are process data and are visible on the home page of the web
interface.
If no action is taken on the web interface, the flashing of the

green “Ready/Failure” LED in the 2-second on/off rhythm indi-
cates normal operation.
4.6.2 Error status
Error status indicates that error messages are present. Error and alarm sta-
tuses can be active simultaneously.
All error messages are visible as error codes on the home page of the web
interface.
The type of error can be determined through the flashing of the

“Ready/Failure” LED ( “Fault indicator” on page 16) and is
shown on the web interface.
4.6.3 Alarm status
In alarm status, alarm messages are present. Error and alarm statuses can
be active simultaneously.
All alarm messages are visible as alarm codes on the home page of the web
interface.
The type of alarm can be determined through the flashing of the

“Alarm” LED ( “Alarm indicator” on page 17) and is shown on
the web interface.

Materials and tools
5 Materials and tools

Materials The described activities require the following materials:
 Cleaning agent
 Cleaning rags
Tools The described activities require the following standard tools:
 Combination spanner set
 Allen key set
 Screwdriver set

Transport, packaging and storage
6 Transport, packaging and storage
6.1 Symbols on the packaging

IPPC symbol International symbol for the handling status of packaging materials made of
wood:
 DE Country code (e.g. Germany)
 NW Region code (e.g. NW for North Rhine-Westphalia)
 49XXX Registration no. of the wood supplier
 HT Heat treatment
 DB Debarked
Top The arrow tips on the sign mark the top of the package. They must always
point upwards; otherwise the content could be damaged.
Protect against moisture Protect packages against moisture and keep dry.
Additional symbols and instructions may be present on the

packaging materials. Always observe these.
6.2 Delivery
Transport inspection Upon receipt, check the delivery immediately for completeness and transport
damage.
If there is any visible exterior transport damage, proceed as follows:
1. Do not accept the delivery, or accept it only with reservations.
2. Make a note of the scope of the damage on the transport documents or
on the delivery note of the carrier.
3. Submit a complaint.
Submit a complaint for every defect as soon as it is detected.

Compensation claims will only be accepted within the applicable
reclamation periods.

6.3 Transport
Eccentric centre of gravity
CAUTION!
Risk of injury due to packages tipping over or falling!

Lifting packages with an eccentric centre of gravity can cause
them to swing out, tip over and fall down. This poses a risk of
injury.
− Only use the intended attachment points.
− Note the position of the centre of gravity.
− Always lift packages carefully and ensure that they cannot
tip over or fall.
− When transporting packages with the forklift, lash them
down if there is no other way to ensure that the transport
item is securely fixed.
Pallets with the forklift

A maximum of 4 devices can be stacked and transported with
the forklift.
Personnel:  Transport specialist
Protective equipment:  Protective clothing
 Puncture-resistant safety shoes
 Industrial safety helmet
Packages that are fastened on pallets may be transported with a forklift under
the following conditions:
 The forklift operator must be authorised to drive the forklift.
Fig. 33: Transport of pallets with the

forklift
1. Drive the forklift so that the forks are between or under the beams of the
pallet (Fig. 33).
2. Insert the forks far enough so that they protrude on the opposite side.
3. If the centre of gravity is off-centre, ensure that the pallet cannot tip over.
4. Lift the package and begin transport.

6.4 Packaging
The individual packages are packed according to the expected transport con-
ditions. Only environmentally sound materials are used for the packaging. The
packaging is designed to protect the individual components from transport
damage, corrosion and other damage until they are installed. For this reason,
do not destroy the packaging and only remove it shortly prior to the installa-
tion.
Incorrect disposal
NOTICE!
Harm to the environment due to incorrect disposal!

In many cases, packaging materials can be processed and re-
used. Incorrect disposal of packaging materials can pose haz-
ards to the environment.
− Dispose of packaging materials in an environmentally sound
manner that is in conformance with locally applicable waste
disposal regulations.
− If applicable, contract a specialist company to handle the
disposal.
6.5 Storage
Store packages under the following conditions:
 Do not store outdoors.
 Store in a dry and dust-free area.
 Do not expose to aggressive media.
 Avoid salt-laden atmospheres.
 Avoid mechanical vibrations.
 Storage temperature: -20 to 90 °C
 Relative air humidity: max. 90%
When storing for periods longer than 3 months, regularly check the general
condition of all parts of the packaging. If necessary, renew or replace the
preservation.
In certain cases, there are instructions on the packages regard-

ing their storage that go beyond the requirements mentioned
above. Observe these accordingly.

Installation and start-up
7 Installation and start-up
7.1 Safety during installation

Opened housing
WARNING!

mospheres!
If a potentially explosive atmosphere is present (regardless of
zone), the housing may not be opened when the device is
switched on, since this would pose an explosion hazard.
ous.
− Do not open the housing in an explosive atmosphere if the
device is switched on.
7.2 Installing the device
Personnel:  Installation specialist
 Protective gloves
 Industrial safety helmet
 Safety harness
To install the device, proceed as follows:

1. Establish a suitable connection in the on-site pipeline.
2. Insert operator-supplied seals.
3. Insert the device in the recess.
4. Fasten the device with operator-supplied screws.
 The device is installed.

7.3 Connecting the device to the mains supply
NOTICE!
Risk of property damage due to incorrect electrical connec-

tion!
The device can be damaged if it is incorrectly connected.
− Connect the device to an external power supply (18 – 32 V
DC, nominal 24 V DC) in conformance with
DIN EN IEC 60900 VDE 0682-201:2019-04 and/or
IEC61558.
Personnel:  Electrician with additional qualification in ex-

plosion protection
 Safety harness
Prerequisite:
 The device is installed ( Chapter 7.2 “Installing the device” on page 61).
To connect the device to the operator’s mains supply, proceed as follows:
 Connect the power cable of the operator’s mains supply to connector X1
( Chapter 4.5.2 “Connector X1” on page 47).
For this, use an external power supply in conformance with
DIN EN IEC 60900 VDE 0682-201:2019-04 and/or IEC61558.
 The device is connected to the mains supply.
7.4 Earthing the device

Contact voltages and ignition
sparks WARNING!
Danger of death due to contact voltages and sparks!

Missing or defective potential equalisation can result in contact
voltages and sparks. This poses the danger of severe injury or
death.
− Prior to initial commissioning, connect device to the local
potential equalisation and check that this functions properly.


plosion protection
Prerequisite:
To guarantee proper EMC protection, the housing is connected

by means of a flexible copper mesh strap (Fig. 34/2) to the motor
earth.
To earth the device, proceed as follows:
1. To avoid EMC interference, ensure good conductance through short

earthing straps from the oil mist ventilation pipe to the motor block
(Fig. 34/1).
Each pipe has an M8 thread connection near its flange.
2. Make sure that the shielding is connected to the cable gland and that the
connection is tight.
 The device is earthed.
Fig. 34: Earthing the device

7.5 Connecting the network

Connecting the device to the net-
work
plosion protection
Prerequisites:
 The device is connected to the mains supply ( Chapter 7.3 “Connecting
the device to the mains supply” on page 62).
 The device is earthed ( Chapter 7.4 “Earthing the device” on page 62).
To connect the device to the network, proceed as follows:
 Connect the device to the operator’s network using an Ethernet cable
(M12 connector, code D) at connector X284 ( Chapter 4.5.8 “Connector
X284” on page 51).
 The device is connected to the network.
Connecting the device directly to
the PC
plosion protection
Prerequisites:
 The device is connected to the network ( “Connecting the device to the
network” on page 64).
To connect the device directly to a PC (with the Windows operating system),
proceed as follows:
1. Set up the Ethernet connection so that an IP address is automatically
assigned.
2. Wait approx. one minute.
The wait time depends on the computer network.
3. Enter the name of the device “horn-mev283-0” or the device’s link local
address in the browser.
If the network ID has already been changed, change the network

ID to “horn-mev283-<ID>”.
 Access to the web interface of the device is established.

The device is connected directly to the PC.

Connecting the device to the net-

work with DHCP server
plosion protection
Prerequisites:
 The device is connected to the network ( “Connecting the device to the
network” on page 64).
To connect the device to a network that is running with a DHCP server, pro-
ceed as follows:
1. Use a direct connection ( “Connecting the device directly to the PC” on
page 64).
2. Reboot the PC/system.
3. Check the DHCP server for the IP address to which the device is as-
signed.
Alternatively, use the hostname of the device (“horn-mev283-0”) to dis-
play the web interface.
If the current IP address is unknown and the device is not in

DHCP mode, press the reset button ( Chapter 4.4.4 “Reset
button” on page 45) on the circuit board until the green LED is
no longer lit.
4. Then restart the device with active DHCP.

 The device is connected to the network with DHCP server.
7.6 Testing relays
Personnel:  Installation specialist
 Hearing protection
Prerequisite:
 A user is logged into the web interface ( Chapter 9.3 “Logging into the
web interface” on page 70).
To test the relays, proceed as follows:

Fig. 35: Menu bar

1. Click on “Relay test” (Fig. 35/5) in the menu bar.
Fig. 36: “Relay test” page

 The “Relay test” page (Fig. 36) opens.
Five relays are displayed on the page, although only four relays
are implemented.
Relay 5 is a dummy relay.
2. Compare the values of the relay actions with the basic parameters
( “Setting relay functions” on page 75).
The relays can either be defined as “NO” (normally open) or

“NC” (normally closed).
3. For all relays, press “Relay x on”.
The relay test switches the relays according to the correspond-

ing parameters. Switching is independent of the external status
of the device.
When performing the test, note the connected alarms in the
higher-level alarm management system.
If the relay type is set to “normally open”, the relay ON/OFF

switching is opposite: in other words, “Relay on” sets the status
to “OFF” and “Relay off” sets the status to “ON”.
After exiting this page, the selected relays revert back to the
normal status according to the setting.
 The relays have been tested.

Operating concept
8 Operating concept
8.1 Password protection and user role

The web interface is password-protected to prevent unauthorised persons
from making entries and changes. For this, various user roles are distin-
guished. The respective access rights are linked to the user roles. The access
rights are linked to each user role by means of a password level. The higher
the password level, the more far-reaching the settings that can be undertaken
with the corresponding user role.
Not all pages are accessible for every user or role.
After a password has been entered, access rights of the corresponding user
role are enabled.
Access to the web interface is dependent on the following access levels:
 User (no user name, no password)
 Service (user name: Service, special password)
 Admin (manufacturer; user name: Admin, special password)
Passwords are set up in the course of commissioning and are

disclosed as required.
8.2 Structure of the web interface
Fig. 37: Structure of the web interface
1 Name of device
2 Menu bar
3 Name of menu
4 Logo of manufacturer

Operation
9 Operation
9.1 Safety during operation

Improper operation
WARNING!
Risk of injury due to improper operation!

Improper operation can lead to serious injury or property dam-
age.
− Perform all operating steps according to the information in
these instructions.
− Prior to starting work, check that all covers and safety de-
vices are installed and functioning correctly.
− Never disable safety devices during operation.
− Keep the work area clean and tidy. Components and tools
that are loosely stacked on one another or left lying round
can cause accidents.
9.2 Switching on
Personnel: Instructed person
Protective equipment: Protective clothing
Protective gloves
Hearing protection
Prerequisite:
 Installation and start-up have been completed ( Chapter 7 “Installation
and start-up” on page 61).
To switch on the device, proceed as follows:
1. Switch on the motor control (voltage supply).
2. Configure the motor run signal (parameter P21  “Adjusting the oil mist
sensor/Activating the motor run signal” on page 74).
 The motor run signal is active.
The device is active.

Operation
9.3 Logging into the web interface
Personnel: Maintenance personnel with additional qualification

in explosion protection
Prerequisite:
 The device is switched on ( Chapter 9.2 “Switching on” on page 69).
To log into the web interface, proceed as follows:
1. Call up the web interface with Windows Internet Explorer.
Alternatively, use any other browser. This could, however, cause

problems such as interpretation of commas and decimal points
(i.e. values with commas could not be entered).
2. Enter the user name and password, and confirm by pressing “Enter”.
 The user is logged in.
9.4 Setting the date and time

After the installation or following a lengthier period without power (approx. 2
days), the clock must be checked.
If error E10 appears on the home page, the clock must be reset.
Prerequisite:
 The user is logged into the web interface ( Chapter 9.3 “Logging into
the web interface” on page 70).
To set the date and time, proceed as follows:
Fig. 38: Menu bar

1. Click on “Clock” (Fig. 38/10) in the menu bar.
 The “Clock Setting” view appears.

Operation
Fig. 39: “Clock Setting” page

2. Enter the date and time in the corresponding fields.
3. Confirm the input with “Set”.
The date is always adjusted to the entered value, even if the

entered value lies in the future. Therefore, check whether the
inputs are correct.
 The date and time are set.

If error E10 was displayed on the home page, it disappears.

Operation
9.5 Setting parameters

Incorrect parameter values
WARNING!
Danger due to incorrect parameter values!

The device cannot check the entered values. Incorrect values
can lead to destruction of the motor and endanger human lives.
− After entering parameter values, always check that they are
correct.

Prerequisite:
The actual values can be entered in the “Customer-specific

setting” column.
To set the parameters, proceed as follows:
Fig. 40: Menu bar

1. Click on “Application parameters” (Fig. 40/13) or “Basic parameters”
(Fig. 40/12) in the menu bar.
 The corresponding page opens.

Operation
Fig. 41: “Application parameters” page

2. Enter the parameter values in the respective lines.
3. Click on “Set” to save the inputs.
 The parameters are adjusted.
After the input of parameters in the web interface, the device

performs a restart, which is essentially handled as a “switching
on”.
For motor-specific settings for the device with motor types W20,
W20DF, W26, W31, W32 and W34DF, parameter list in the
additional applicable documents.

Operation
Adjusting the oil mist sen-

sor/Activating the motor run signal
Pxx no. Possible set- Explanation Customer-

ting range specific Value
P11 1 – 20 Delay in seconds for oil mist alarm H09 – H11
P12 0.1 – 10 Oil mist increase in % before warning H09 (oil mist pre-warning)
P14 0.1 – 15 Oil mist increase in % before warning H10 (oil mist alarm – load
reduction reached)
P15 0.1 – 15 Oil mist increase in % before warning H11 (oil mist alarm – autostop
level reached)
P16 0.1 – 8000 Tolerable oil mist increase for 0.8 s (in %)
P20 1 – 16 Digital low pass filter coefficient for oil mist
P21 0–3 Check of motor run signal
0 = high active 2 = CAN
1 = low active 3 = always on
P22 0 – 250 IR power regulation factor
Setting the crankcase pressure

monitoring/Selecting the pressure
range

P23 0/1/2 Pressure sensor range 1 = -25.0/+25.0 mbar
0 = no sensor 2 = 0 – 250 mbar
P24 -25 – 25 Pressure value in mbar for the 4 mA output
P25 -25 – 25 Pressure value in mbar for the 20 mA output
P26 -25 – 25 Limit value for pressure increase in mbar for alarm H04
P27 -25 – 25 Limit value for pressure increase in mbar for alarm H05
P28 1 – 255 Digital low pass filter coefficient for the pressure output

Operation
Setting relay functions

P32 0–1 Relay 1 action (SystemReady relay)
0 = normally opened 1 = normally closed
P33 0–1 Relay 2 action (PreAlarm relay)
P34 0–1 Relay 3 action (PressureAlarm relay)
P35 0–1 Relay 4 action (Alarm relay)
Setting real-time clock

P39 0–1 Clock power fail signalling (E10)
0 = Off 1 = On

Operation
Selecting relays The parameters P47 – P64 control which relay is activated by which event.
The table in  Chapter 4.5.6 “Connector X5” on page 50 con-

tains a configuration value for each relay.

To determine one of the parameters P47 – P64, proceed as follows:

1. Take the configuration value from the table in  Chapter 4.5.6
“Connector X5” on page 50 and enter it in the “Basic parameters” list.
Example: P47 is to activate relay 4 → The setting for P47 is 16

(relay 4).
2. If the operator’s alarm system needs more than one relay to be activated
in the event of an alarm, add configuration values accordingly.
Example: P48 is to activate relays 2 and 3 → The setting for

P48 is 4 (relay 2) + 8 (relay 3) = 12.
 The relays are selected and the parameters are determined in P47 –
P64.

P47 0 – 63 Relay for H04 (pressure higher than P26;  “Setting the crankcase
pressure monitoring/Selecting the pressure range” on page 74)
P48 0 – 63 Relay for H05 (pressure higher than P27;  “Setting the crankcase
pressure monitoring/Selecting the pressure range” on page 74)
P52 0 – 63 Relay for H09 (oil mist pre-warning)
P53 0 – 63 Relay for H10 (oil mist alarm – load reduction reached)
P54 0 – 63 Relay for H11 (oil mist alarm – autostop level reached)
P61 0 – 63 Relay for E05 (oil mist control inactive)
P62 0 – 63 Relay for E03 (error in pressure sensor)
P63 0 – 63 Relay for E06 (error in optical measuring track, oil mist measure-
ment not possible)
P64 0 – 63 Relays for Exx (all errors not mentioned: E01, E08 and E10)

Operation
Setting the CAN bus

P70 0–2 CAN mode
0 = Off 1 = CANopen 2 = J1939
P71 1 – 127 CAN node ID
P72 1–8 CAN bit rate
1 = 20k 4 = 125k 7 = 800k
2 = 50k 5 = 250k 8 = 1M
3 = 100k 6 = 500k
P73 0–1 CANslave auto operating mode – Object 1F80
P74 0 – 65535 Cycle time for TPDO1 [ms]
P78 0 – 65535 Heartbeat time [ms]
9.6 Changing the IP address

Prerequisite:
To change the IP address, proceed as follows:
Fig. 42: Menu bar

1. Click on “Network Settings” (Fig. 42/6) in the menu bar.
 The “Network Settings” page opens.

Operation
Fig. 43: “Network Settings” page

2. Changing the IP address
3. To connect the device again, change the host ID address in the browser.
Carefully double-check the changes; otherwise the connection

could be lost.
4. Multiple devices in the network: Edit the network ID so that the device
can be called up with “horn-mev283-<ID>”.
5. Confirm changes with “Change”.
 The IP address has been changed.
9.7 Saving the error and event list

Prerequisite:
To save errors and events, proceed as follows:
1. Right-click on the errors and events list.
 A context menu opens.
2. Click on “Save as”.
Or, instead of steps 1 and 2, press the key combination “Ctrl S”.
 The “Save as” window opens.

3. Enter name, select storage location and confirm with “Save”.
 The errors and events list is saved.

Operation
9.8 Calibrating the pressure sensor

This function recalibrates the pressure sensor to the external air pressure
(0 mbar).
The pressure must be readjusted if the ambient atmospheric pressure chang-
es.
An error of the pressure sensor or of the wiring is displayed as error message
E03 (“Error pressure sensor”).

Hearing protection
Prerequisites:
 The motor is switched off.
The housing must be aligned vertically for the calibration.
To calibrate the pressure sensor, proceed as follows:
Fig. 44: MEV283 menu bar

1. Click on “Pressure adjustment” (Fig. 44/4) in the menu bar.
 The “Pressure adjustment” page opens.

Operation
Fig. 45: “Pressure adjustment” page

2. Check that the correct sensor for P23 ( “Setting the crankcase pressure
monitoring/Selecting the pressure range” on page 74) is entered in the
parameter list.
A corresponding error signal at a relay output is possible, provid-

ing this is set in the basic parameters.
Fig. 46: Starting the “Pressure adjustment”

3. On the web interface on the “Pressure adjustment” page, click on “Start”.
 The sensor is calibrated.
9.9 Logging out from the web interface

Prerequisite:

Operation
To log the user out of the web interface, proceed as follows:
Fig. 47: Menu bar

1. Click on “Logout” (Fig. 47/8) in the menu bar.
 The “Logout” page (Fig. 48) opens.
Fig. 48: “Logout” page

2. Close your browser.
 The user is logged out.
9.10 Switch off.
Only switch off the device if it is to be taken out of operation for

a lengthier period.
Prerequisite:
 The motor is at a standstill.
To switch off the device, proceed as follows:
 Disconnect device from the voltage supply.
 The device is switched off.

Maintenance
10 Maintenance
10.1 Safety during maintenance

Unauthorised reactivation
DANGER!
Danger of death due to unauthorised reactivation!

If switched-off energy supplies are switched back on without
authorisation, this poses a fatal hazard to persons working on
the device.
− Always secure switched-off energy supplies against reacti-
vation.
Infrared light beam

WARNING!
Risk of eye injury from infrared light beam!

When maintenance work is performed on the optical measuring
track, there is a risk of eye injury from the infrared light beam.
− Never look directly into the infrared light beam.
Improperly performed maintenance

work WARNING!
Risk of injury due to improperly performed maintenance

work!
Improper maintenance can lead to serious injury or property
damage.
− Prior to starting work, ensure that adequate freedom of
movement for assembly is available.
− Ensure that the assembly area is clean and tidy. Compo-
nents and tools that are loosely stacked on one another or
left lying round can cause accidents.
− If components were removed, install all fastening elements
again while paying attention to proper assembly and observ-
ing the specified screw tightening torques.
Incorrect replacement parts

WARNING!
Danger due to use of incorrect replacement parts!

Use of incorrect replacement parts or parts not approved by the
manufacturer can lead to substantial property damage or com-
plete failure of the device. This could also endanger human
lives.
− Only use original replacement parts.

Maintenance
10.2 Maintenance schedule

Maintenance work The sections below describe the maintenance tasks that must be carried out
for optimal and trouble-free operation of the device. The prescribed time inter-
vals must be observed.
The stated time intervals are based on single-shift operation with 8 hours
of operation on 5 days in the week and represent the minimum intervals. If the
device is used more than 8 hours daily or on more than 5 days in the week, it
is the operator’s responsibility to shorten the intervals accordingly to the actu-
al operation time.
Should increased wear be detected at regular inspections, shorten the re-
quired maintenance intervals accordingly for the actual signs of wear. For
questions regarding maintenance work and maintenance intervals, contact
customer service ( “Customer service” on page 3).
Interval Maintenance work Personnel
approx. every Perform oil mist test. Maintenance

1,000 opera-  Chapter 10.3.1 “Performing oil mist test on the web interface” on page 85 or personnel
ting hours  Chapter 10.3.2 “Performing the oil mist test manually” on page 87 with addi-
tional qualifi-
cation in
explosion
protection
As needed Check pressure. Maintenance

 Chapter 10.3.3 “Checking pressure” on page 89 personnel
with addi-
tional qualifi-
cation in
explosion
protection
Clean optical measuring track (error E08). Instructed

 Chapter 10.3.7 “Cleaning the optical measuring track” on page 97 person

Maintenance
10.3 Maintenance work

10.3.1 Performing oil mist test on the web interface

Prerequisite:
To perform the oil mist test on the web interface, proceed as follows:
Fig. 49: Menu bar

1. Click on “Oil mist test” (Fig. 49/3) in the menu bar.
 The “Oil mist test” page (Fig. 50) opens.
Fig. 50: “Oil mist test” page

2. Press “Start” to start the oil mist test.
 The text “Oil mist test triggered” appears on the web interface
(Fig. 51).

Maintenance
Fig. 51: “Oil mist test” page

3. Click on “Home” (Fig. 49/1) in the menu bar.
 The home page opens.
Fig. 52: Home page: example

H09 – H11 are displayed as “Active”. An event is saved in the event list.
When the oil mist test is completed, H09 – H11 are displayed
again as “Not active”.

Maintenance
10.3.2 Performing the oil mist test manually
Hearing protection
Protective gloves
Prerequisite:
 The device is switched on ( Chapter 9.2 “Switching on” on page 69).
To trigger the oil mist test manually, proceed as follows:
1. After switching on the device, wait 5 minutes to ensure that the device
functions properly.
This time is required to calibrate the optical measuring track with

the device. The system activates the pre-warning relay and the
alarm relay (depending on the relay setting in the parameter list).
2. Hold the “Oil mist test” button pressed for 8 seconds until the LED ring of
the button lights up red.
If the button is pressed too long, the red indicator light of the
LED ring switches off and the test does not start.
 The test is performed ( Chapter 10.3.1 “Performing oil mist test on

The “Alarm” LED flashes successively in the rhythm of errors H09 –
H11.
Fig. 53: Oil mist test button
When the oil mist test ends, the “Alarm” LED no longer flashes.
This test can also be started via CAN ( “Starting the oil mist
test via CAN” on page 88).
The following time sequences of the manufacturer serve as an aid and show
how the flow for introducing the test functions.

Maintenance
Fig. 54: Time sequence of manual oil mist test

Starting the oil mist test via CAN
To start the oil mist test via CAN, proceed as follows:

 Set the command “CAN oil mist test start” via the motor control to “1” and
then to “0”.
If the CAN signal is activated for too long, the red indicator light
of the LED ring switches off and the test does not start.
 The test is performed.

The “Alarm” LED flashes successively in the rhythm of errors H09 –
H11.
When the oil mist test ends, the “Alarm” LED no longer flashes.

Maintenance
10.3.3 Checking pressure

Protective gloves
To check the pressure (for error E03), proceed as follows:

1. Check whether the pressure sensor is correctly mounted on the pipe.
2. Check for damaged wiring:
Wiring damaged: Replace the wiring.
Wiring OK: Check connection at X4/3 and X4/4 ( Chapter 4.5.5
“Connector X4” on page 48).
3. Measure signal:
< 2 mA: Replace damaged sensor ( Chapter 10.3.4 “Replacing the
pressure sensor” on page 89).
> 2 mA – < 22 mA: Sensor is OK.
> 22 mA: Replace damaged sensor ( Chapter 10.3.4 “Replacing the
pressure sensor” on page 89).
 The pressure is checked.
10.3.4 Replacing the pressure sensor

Protective gloves
Safety goggles
To replace the pressure sensor, proceed as follows:

1. Disconnect device from the power supply.

Maintenance
2. Remove the screws of the housing cover (Fig. 55).
Fig. 55: Removing screws
3. Remove the housing cover (Fig. 56).
Fig. 56: Removing the housing cover

Removing the pressure sensor 4. Undo screws (Fig. 57/1) and set them aside where they cannot be lost.
5. Remove connecting hose (Fig. 57/2).
6. Remove connector J3.
 The pressure sensor is removed.
Fig. 57: Removing the screws on the

pressure sensor
Installing the pressure sensor 7. Connect connector J3.
8. Attach connecting hose (Fig. 58/2).
9. Tighten screws (Fig. 58/1).
 The pressure sensor is installed.
Fig. 58: Inserting the screws on the

Maintenance
pressure sensor
10. Attach the housing cover (Fig. 59).
Fig. 59: Attaching the housing cover
11. Tighten the screws of the housing cover (Fig. 60).
Fig. 60: Inserting screws
10.3.5 Checking the optical measuring track

Protective gloves
Safety goggles
To check the optical measuring track (error E06), proceed as follows:

Maintenance
Fig. 61: MEV283 home page

1. Check the optical measuring track.
To do this, check the light intensity (“IR power)” on the home page.
Light intensity between 20% and 70%: The optical measuring track is
in order. The optical measuring track is checked.
Light intensity < 20% or > 70%: The optical measuring track is not in
order. Continue with step 3.
2. Check the wiring of the optical sensors on the housing.
Connections damaged: Replace connections ( “Disconnecting the
transmitter and receiver” on page 93 and  “Connecting the transmit-
ter and receiver” on page 97).
Cable break: Replace the transmitter and receiver ( Chapter 10.3.6
“Replace the transmitter and receiver” on page 93).
Connections OK; no cable break: transmitter and receiver are dam-
aged.
Replace the transmitter and receiver ( Chapter 10.3.6 “Replace the
transmitter and receiver” on page 93).
 The optical measuring track is checked.

Maintenance
10.3.6 Replace the transmitter and receiver

Safety goggles
Protective gloves
To remove the transmitter and receiver, proceed as follows:
Disconnecting the transmitter and 1. Disconnect device from the power supply.
receiver

3. Remove the housing cover.
4. Unplug the connections in the housing (connectors X2 and X3).
 The transmitter and receiver are disconnected.

Maintenance
Removing the cable from the hous-

ing
If there is a cable break, the cable must be replaced.
5. Remove the transmitter cable from the cable gland.

6. On the other side, remove the receiver cable from the cable gland.
 The cables are removed from the housing.
Fig. 64: Removing the cable from the

screw connection
Removing the transmitter and re- 7. Disconnect device from the power supply.
ceiver
8. Place a 20 mm open-ended spanner (Fig. 65/1) on the transmitter in front
of the nut to hold the transmitter in position.
Release the fixing nut with a 46 mm open-ended spanner (Fig. 65/2) in
the direction of the arrow.
9. Carefully turn the transmitter with the 20 mm open-ended spanner ap-
prox. 30° in both directions to release the transmitter.
10. Manually undo the fixing nut far enough until the thread no longer engag-
es.
Fig. 65: Releasing the nut of the

transmitter
NOTICE!
Risk of property damage from pulling on cables!
11. Do not pull on the cable to remove the transmitter.

Pull out the cable gland of the transmitter (Fig. 66/arrow) to remove the
transmitter.
Fig. 66: Removing the transmitter  The transmitter of the optical measuring track is removed.

Maintenance
12. Set the O-rings (Fig. 67/3) aside where they cannot be lost.
13. Clean the assembly opening of the oil mist ventilation pipe (Fig. 67/2) on
the inside.
14. Repeat steps 8 – 13 on the other side for the receiver.
 The transmitter and receiver of the optical measuring track are re-
moved.
Fig. 67: Removing transmitter and O-

rings

Protective gloves
To install the transmitter and receiver of the optical measuring track, proceed
as follows:

Maintenance
Installing the transmitter and re-

ceiver
1. If the O-ring (Fig. 68/1) was removed with the transmitter (Fig. 68/5) from
the assembly opening of the oil mist ventilation pipe (Fig. 68/3), grease
the O-ring with acid-free grease or motor oil.
2. Place the O-ring (Fig. 68/1) in the assembly opening of the oil mist venti-
lation pipe (Fig. 68/3).
The O-ring must lie flat at the end of the opening.
3. Insert the O-rings (Fig. 68/2, 4) into the grooves located in the assembly
opening of the oil mist ventilation pipe.
4. Grease the exterior surface of the transmitter (Fig. 68/5).
Fig. 68: Attaching O-rings
5. Manually insert the transmitter (Fig. 68/5) into the assembly opening of
the oil mist ventilation pipe.
NOTICE!
Risk of damaging the cable by turning the sensor during

installation!
6. Attach the fixing nut with the 46 mm open-ended spanner (Fig. 69/2)
while holding the transmitter in position with the 20 mm open-ended
spanner (Fig. 69/1).
7. Tighten the fixing nut with a torque of 25 Nm.
Fig. 69: Tightening the nut of the
transmitter 8. Repeat steps 1 – 7 on the other side for the receiver.
 The transmitter and receiver of the optical measuring track are in-
stalled.
Inserting cables in the housing
9. Insert the transmitter cable into the cable gland.
10. On the other side, insert the receiver cable into the cable gland.
 The cables are inserted in the housing.
Fig. 70: Inserting cable in screw con-

nection

Maintenance
Connecting the transmitter and 11. Plug the connections into the housing (connectors X2 and X3).
receiver
12. Attach the housing cover (Fig. 71).
Fig. 71: Attaching the housing cover
13. Tighten the screws of the housing cover (Fig. 72).

14. Connect device to the power supply.
 The transmitter and receiver are connected.
Fig. 72: Inserting screws
10.3.7 Cleaning the optical measuring track

Protective gloves
To clean the optical measuring track (error E08), proceed as follows:

1. Remove the transmitter and receiver ( “Removing the transmitter and
receiver” on page 94).
2. Clean the surfaces of the optical elements on the front of the sensors with
a cotton bud dipped in industrial-grade alcohol (ethanol).
3. Install the transmitter and receiver ( “Installing the transmitter and re-
ceiver” on page 96, up to step 8).
 The optical measuring track is cleaned. The error codes disappear
from the home page.

Maintenance
10.4 After maintenance

1. Remove any dirt from the work area of the device.
2. Check that disassembled components are properly mounted again, that
removed covers have been reattached and that all safety devices are
functional again.
3. Gather any tools and operating materials that were required and remove
them from the work area of the device.

Troubleshooting
11 Troubleshooting
11.1 Safety during troubleshooting

Unauthorised reactivation
DANGER!
Danger of death due to unauthorised reactivation!

If switched-off energy supplies are switched back on without
authorisation, this poses a fatal hazard to persons working on
the device.
− Always secure switched-off energy supplies against reacti-
vation.
Incorrect troubleshooting
WARNING!
Risk of injury due to incorrect troubleshooting!

If troubleshooting measures are performed improperly, serious
injury and considerable property damage could result.
− Have work in regard to troubleshooting carried out only by
qualified personnel.
− Only carry out the troubleshooting measures described in
these instructions.
− Prior to starting work, ensure that adequate freedom of
movement for assembly is available and that the assembly
area is tidy.
11.2 Procedure in the event of faults

Faults leading to dangerous situa- If a fault presents a recognisable danger for persons or could result in proper-
tions ty damage, proceed as follows:
1. Shut down the device.
2. Inform your supervisor of the fault.
Faults that do not lead to dangerous If a fault is present that prevents further operation of the device without prior
situations intervention, proceed as follows:
1. Check whether the fault can be remedied based on the fault message
that was issued.
2. Check whether the fault table provides any additional helpful information.
3. Remedy the fault or assign suitably qualified personnel do so.
11.3 Fault indications

The warnings and error codes are output for the following components:
 CAN
 Ethernet
 Signal LEDs ( Chapter 2.3.1 “Signal LEDs” on page 16)
 Information on the web interface

Troubleshooting
11.3.1 Signal LEDs
For information on the signal LEDs  Chapter 2.3.1 “Signal

LEDs” on page 16.
11.3.2 Information on the web interface
Alarm codes
H04 - Pressure over P26
H05 - Pressure over P27
H09 - Oil mist pre-warning
H10 - Increase in oil mist
H11 - Oil mist autostop
Error codes
E01 - The watchdog function detected a problem in the software or
in the EPROM checksum.
This could arise if a power failure occurs during switching on
and the operator cannot end the process in the correct
mode.
E03 - The crankcase pressure is not correct.

 Chapter 10.3.3 “Checking pressure” on page 89
E05 - The device is inactive. This is the case if the motor run sig-
nal is not active and after each switching on of the system.
E06 - The optical measuring track is disabled and oil mist detec-
tion is no longer possible.
 Chapter 10.3.5 “Checking the optical measuring track” on
page 91
E08 - The transmission power of the measuring track exceeds a

defined value (85%) of its maximum value and cleaning of
the optics is requested.
 Chapter 10.3.7 “Cleaning the optical measuring track” on
page 97
E10 - If this error code is present, read out the error code via the
Ethernet or CAN connection and set the current time.
 Chapter 9.4 “Setting the date and time” on page 70

Troubleshooting
11.4 Troubleshooting
Fault description Cause Remedy Personnel
The device does not The device does not run because Switch on the device. Instructed person
measure any values. the motor is not running (E05).  Chapter 9.2 “Switching on” on
page 69
The transmitter and receiver are Clean the transmitter and receiver. Maintenance per-
dirty (E08).  Chapter 10.3.7 “Cleaning the sonnel with addi-
optical measuring track” on page tional qualification in
97 explosion protection
The transmitter is faulty (E06). Replace transmitter. Maintenance per-

 Chapter 10.3.6 “Replace the sonnel with addi-
transmitter and receiver” on page tional qualification in
The receiver is faulty (E06). Replace receiver. Maintenance per-

 Chapter 10.3.6 “Replace the sonnel with addi-
transmitter and receiver” on page tional qualification in
The status LEDs do not The device is off. Switch on the device. Instructed person
light up.  Chapter 9.2 “Switching on” on
page 69
The connection to the LEDs is Send the device in for repair

faulty. ( “Customer service” on page 3).
The LEDs are faulty. Send the device in for repair

( “Customer service” on page 3).
The date and time are Error E10 is displayed on the web Set the date and time
incorrect. interface. ( Chapter 9.4 “Setting the date
and time” on page 70).
The device does not The pressure sensor is not Plug in the pressure sensor.
measure any pressure. plugged in.
The amperage at the analogue Check analogue output. If neces-

output is not 4 – 20 mA. sary, send the device in for repair
( “Customer service” on page 3).

Disassembly
12 Disassembly
After use Once the device has reached the end of its useful life, it must be disassem-
bled and disposed of in an environmentally sound manner.
Prior to disassembly  Switch off the device and secure it against being switched on again.
 Physically disconnect the entire electricity supply from the device.
Disassembly of the housing
Personnel: Installation specialist
Protective gloves
Safety harness
WARNING!

mospheres!
An explosive atmosphere must not/must no longer be present
when the housing is opened, as otherwise there is a danger of
explosion.
− Only open the housing if an explosive atmosphere is not or
is no longer present.
Prerequisite:
 The device is switched off ( Chapter 9.10 “Switch off.” on page 81).
To disassemble only the housing, proceed as follows:

Disassembly
2. Remove the housing cover (Fig. 74).
3. Remove the clip (Fig. 75/1) below on the pressure hose.

4. Remove the pressure hose (Fig. 75/2).
5. Remove the transmitter and receiver ( “Removing the transmitter and
receiver” on page 94).
Fig. 75: Removing clip on pressure

hose
6. Remove the screws (Fig. 76).

7. Take off the housing.
 The housing is disassembled.
Fig. 76: Removing the housing

Disassembly of the device

Disassembly
Personnel: Electrician with additional qualification in explosion

protection
Installation specialist
Protective gloves
Safety harness
Prerequisite:
 The device is switched off ( Chapter 9.10 “Switch off.” on page 81).
To remove the device, proceed as follows:
Disconnecting from the network 1. Disconnect the Ethernet connection. To do this, remove the cable in con-
nector X284.
2. Disconnect the power connection. To do this, remove the cable in con-
nector X1.
Removing device 3. Remove the operator-supplied screws from the device.
4. Remove the device from the recess of the on-site pipeline.
5. Remove the operator-supplied seals.
6. Seal the connection in the on-site pipeline with a pipe end.
 The device is removed.

Disposal
13 Disposal
Incorrect disposal
NOTICE!
Harm to the environment due to incorrect disposal!

Incorrect disposal can pose hazards to the environment.
− Have electrical scrap, electronic components, lubricants,
and other auxiliary materials disposed of only by authorised
specialist companies.
− In case of doubt regarding environmentally sound disposal,
request information from local authorities or specialist dis-
posal companies.
Constituent parts of the device If no return or disposal agreement was made, send the dismantled constituent
parts to a recycling centre:
 Scrap metals.
 Recycle plastic elements.
 Dispose of remaining components, sorted according to material.
Constituent parts of the device designated with the adjacent symbol should
never be disposed of as regular household waste. Disposal of these compo-
nents may only be performed by locally authorised specialist companies.
Fig. 77: Not household waste

Index
14 Index
Connector X6 ................................................. 51
A Industrial ETHERNET connection................... 51
Accident................................................................19 optical receiver ............................................... 48
Additional applicable documents .............................3 optical transmitter ........................................... 47
After maintenance .................................................98 Power supply ................................................. 47
Alarm codes........................................................ 100
Pressure sensor ............................................. 52
Alarm indicator ......................................................17
Relay factory default settings.......................... 50
Alarm status..........................................................53
Connector
Ambient conditions................................................35
Analogue inputs and outputs .................................48 analogue inputs and outputs........................... 48
ATEX marking.......................................................21 CAN bus ........................................................ 51
Industrial ETHERNET connection................... 51
B J3 .................................................................. 52
Base plate with damping system ...........................41 optical receiver ............................................... 48
Brief description ....................................................11 optical transmitter ........................................... 47
Power supply ................................................. 47
C Pressure sensor ............................................. 52
Calibrating the pressure sensor .............................79 Relay factory default settings.......................... 50
CAN bus ...............................................................51 X1 .................................................................. 47
Certificates............................................................36
X2 .................................................................. 47
Changing the IP address .......................................77
X284 .............................................................. 51
Checking pressure ................................................89
Checking the optical measuring track .................... 91 X3 .................................................................. 48
Circuit board .........................................................46 X4 .................................................................. 48
Cleaning the optical measuring track ..................... 97 X5 .................................................................. 50
Communication interface.......................................35 X6 .................................................................. 51
Complete view .................................................. 9, 37 Contact data ........................................................... 3
Component description Contact partner ....................................................... 3
Base plate with damping system ..................... 41 Contents of these instructions ................................. 3
Housing..........................................................41 Copyright ................................................................ 3
Oil mist ventilation pipe...................................39 Customer service.................................................... 3
optical measuring track ...................................40
D
Pressure sensor .............................................40
Connected load.....................................................33 Detailed view .................................................. 10, 38
Connecting network with DHCP server .................. 65 Device
Connecting the device directly to the PC ............... 64 connecting directly to the PC .......................... 64
Connecting the network ........................................64 connecting to network with DHCP server ........ 65
Connecting the transmitter and receiver ................ 97 connecting to the mains supply....................... 62
Connections and ports connecting to the network............................... 64
analogue inputs and outputs ...........................48 earthing.......................................................... 62
CAN bus ........................................................51 installing......................................................... 61
Circuit board...................................................46 removing ...................................................... 104
Connector J3..................................................52 shielding ........................................................ 62
Connector X1 .................................................47 Dimensions and weights ....................................... 33
Connector X2 .................................................47 Disassembly
Connector X284 .............................................51 Device ......................................................... 104
Connector X3 .................................................48 Housing ....................................................... 103
Connector X4 .................................................48 Disconnecting the transmitter and receiver ............ 93
Connector X5 .................................................50

Index
Display and operating elements M

Motor run signal .............................................49
Maintenance schedule .......................................... 84
Oil mist test button..........................................42 Maintenance work
Output signal ..................................................49 Calibrating the pressure sensor ...................... 79
Reset button...................................................45 Checking pressure ......................................... 89
Signal LEDs ...................................................42 checking the optical measuring track .............. 91
Web interface .................................................43 cleaning the optical measuring track ............... 97
Disposal.............................................................. 107
Connecting the transmitter and receiver ......... 97
Disconnecting the transmitter and receiver ..... 93
E
Inserting cables in the housing ....................... 96
Earth connector ....................................................18
Installing the transmitter and receiver ............. 96
EMC standard.......................................................33
Performing oil mist test on the web interface ... 85
Environmental protection.......................................31
Error codes ......................................................... 100 Performing the oil mist test manually .............. 87
Error status ...........................................................53 Removing the cable from the housing ............. 94
Removing the transmitter and receiver ........... 94
F Replacing the pressure sensor ....................... 89
Fault indications ....................................................99 Starting the oil mist test via CAN .................... 88
Alarm codes ................................................. 100 Testing relays................................................. 65
Error codes .................................................. 100 Materials............................................................... 55
Signal LEDs ................................................. 100 Measurements ...................................................... 33
Fault indicator .......................................................16 Misuse.................................................................. 15
Fire .......................................................................19 Motor .................................................................... 35
First aid.................................................................19 Motor run signal .................................................... 49
Foreseeable misuse..............................................15
Functional description ...........................................39 N
Name plate ........................................................... 36
H Normal status ....................................................... 53
Housing ................................................................41
O
removing ...................................................... 103
Housing cover.......................................................18 Obligations of the operator .................................... 26
Oil mist test button ................................................ 42
I Oil mist ventilation pipe ......................................... 39
Operating concept
Industrial ETHERNET connection .........................51
Inserting cables in the housing ..............................96 password-protected menus ............................ 67
Installation Structure of the web interface ......................... 67
Connecting network with DHCP server ........... 65 User role ........................................................ 67
Connecting the device ....................................62 Operating states
Connecting the device directly to the PC ......... 64 Alarm status ................................................... 53
Connecting the network ..................................64 Error status .................................................... 53
Earthing the device.........................................62 Normal status ................................................. 53

Operation ............................................................. 69
Installing the device ........................................61
Installing the transmitter and receiver .................... 96 Changing the IP address ................................ 77
Intended use .........................................................15 logging into the web interface ......................... 70
logging out from the web interface .................. 80
L Saving the error and event list ........................ 78
Logging into the web interface...............................70 Setting parameters ......................................... 72
Logging out ...........................................................80 Setting the date .............................................. 70
Logging out from the web interface........................ 80 Setting the time .............................................. 70
Login ....................................................................70 switch off. ....................................................... 81
switching on ................................................... 69

Index
Operator ...............................................................26 S
Optical measuring track
Safety devices
Receiver.........................................................40
Earth connector.............................................. 18
Transmitter .....................................................40
Housing cover ................................................ 18
Optical receiver .....................................................48
Optical transmitter .................................................47 Signal LEDs ................................................... 16
Other signs Steel plate...................................................... 18
Connection diagram .......................................20 Saving the error and event list............................... 78
Scope of delivery .................................................. 11
Earthing .........................................................20
Service ................................................................... 3
Installation diagram ........................................20
Setting parameters ............................................... 72
Output signal .................................................. 34, 49
Setting the date .................................................... 70
Overview
Setting the time..................................................... 70
Brief description .............................................11 Signage ................................................................ 20
Complete view............................................ 9, 37 Signal LEDs............................................ 16, 42, 100
Detailed view ............................................ 10, 38 Alarm indicator ............................................... 17
Scope of delivery ............................................11 Fault indicator ................................................ 16
Signage..........................................................20 Software version ................................................... 35
Starting the oil mist test via CAN ........................... 88
P Steel plate ............................................................ 18
Packaging.............................................................59 Storage ................................................................ 59
Parameter list Structure of the web interface ............................... 67
Switch off.............................................................. 81
Activating the motor run signal ........................ 74
Switching on ......................................................... 69
Adjusting the oil mist sensor ...........................74
Symbols
CAN bus setting .............................................77
in the instructions ........................................... 13
Crankcase pressure monitoring ...................... 74
on the packaging............................................ 57
Pressure range...............................................74
Real-time clock...............................................75 T
Relay functions...............................................75 Technical data
Selection of relays ..........................................76 Ambient conditions ......................................... 35
Password protection .............................................67
ATEX marking ................................................ 21
Performing oil mist test
Certificates ..................................................... 36
manually ........................................................87
Communication interface ................................ 35
on the web interface .......................................85
Connected load .............................................. 33
Personal protective equipment .............................. 30
Personnel qualifications ........................................28 Dimensions and weights................................. 33
Potential equalisation ............................................18 EMC standard ................................................ 33
Power supply ........................................................47 Measurements ............................................... 33
Pressure connection .............................................52 Motor ............................................................. 35
Pressure sensor....................................................40 Name plate .................................................... 36
Procedure in the event of faults .............................99
Output signal.................................................. 34
Process description...............................................39
Relay ............................................................. 34
R Software version ............................................ 35

Weights.......................................................... 33
Relay ....................................................................34
Testing relays ....................................................... 65
Relay factory default settings ................................50
Tools .................................................................... 55
Removing the cable from the housing.................... 94
Transport inspection ............................................. 57
Removing the transmitter and receiver .................. 94
Troubleshooting
Replacement parts ................................................25
Procedure in the event of faults ...................... 99
Replacing the pressure sensor ..............................89
Requirements of personnel ...................................28 Troubleshooting table ................................... 101
Reset button .........................................................45 Troubleshooting table ......................................... 101
Responsibility of the operator ................................ 26

Index
U
Use.......................................................................15
User role ...............................................................67
W
Web interface .......................................................43
Help page.......................................................45
Home page ....................................................43
Info page ........................................................44
Weights ................................................................33

Operation- and maintenance
manual for explosion relief valves
type EVO
Application: Oil mist- and Gas explosions
Version 4.01
HOERBIGER Wien GmbH

Seestadtstraße 25
A-1220 Vienna
Operation- and maintenance manual
For Explosion Relief Valves type EVO
Version 4.01
Content
1. INTRODUCTION ............................................................................................................... 3
2. DESIGN OF EXPLOSION RELIEF VALVE TYPE EVO .................................................... 5
3. DESIGN LIMITS ................................................................................................................ 6
4. OPERATION ..................................................................................................................... 7
5. FITTING ON THE MACHINE ............................................................................................ 8
5.1 General remarks ............................................................................................................ 8
5.2 Leak oil return ................................................................................................................ 9
5.3 Recommended safety area .......................................................................................... 10
6. INSPECTION .................................................................................................................. 11
6.1 Regular inspection........................................................................................................ 11
6.2 Inspection after an explosion ........................................................................................ 11
6.3 General inspection procedure ...................................................................................... 11
6.3.1 Inspection of the flame arrester ............................................................................................. 11
6.3.2 Inspection of the valve sealing ............................................................................................... 13
7. MAINTENANCE .............................................................................................................. 14
7.1 Cleaning of flame arrester and exchange of O-ring ...................................................... 14
8. MARKING ....................................................................................................................... 17
9. TABLE OF CHANGES .................................................................................................... 18
All rights, errors and changes reserved!

@ Copyright HOERBIGER 2017 -2-
Version 4.01
1. Introduction
This operation- and maintenance manual is valid for the following valves:
EVO Series
1
Valve Relief area
Part number Old-Part number
type [cm²]
98EVO 59.4 1077 30-WS9098
122EVO 95 81127 30-WS9122
150EVO 143 147751 30-WS9150
162EVO 177 1076 30-WS9162
173EVO 201 135135 30-WS9173
224EVO 346 137830 30-WS9224
266EVO 499 1004 30-WS9266
1
Please consider the efficiency mentioned in the table on page 6 “design limits”.
CE type examination certificate: FTZU 15 ATEX 0196X
Issued by: Physikal Technical Testing Institute

FTZU 1026
Pikartaska 7
71607 Ostrava Radvanice
Czech Republic
Manufacturer: HOERBIGER Wien GmbH

Seestadtstraße 25
A-1220 Vienna, Austria
Phone: +43-1-22 440
mailto: sales.ev@hoerbiger.com

Version 4.01
Used symbols:
Read and understand operator’s

manual before using this equipment!
Safety advice
Risk of injury
Functional advice
Concerning correct function
IACS UR M9, M10 and M66 Rules

IACS Directive for application of explosion relief valves on marine engines.

Version 4.01
2. Design of explosion relief valve type EVO
Position Description
1 Seat
2 O-ring
3 Distance bolt
4 Distance tube
5 Valve plate
6 Flame arrester
7 Expand metal (filter strip)
8 Spring
9 Cover
10 After final test and inspection the valve gets equipped with a shear nut. The shear
nut must not be removed!
11 Leak oil return
Delivery scope doesn’t include bolts and gasket required for mounting.

Version 4.01
3. Design limits
The HOERBIGER explosion relief valve type EVO covered in this manual is designed for
protection of engines crankcases within following design limits:
Operating pressure: 1 bar absolute (atmospheric conditions in the

crankcase)
Operating temperature: -20° to + 100°C
KGmax
Size Pred max [barg] Pstat [barg] Pmax [barg] EF [%]
[bar.m.s-1]
98 EVO
122 EVO
150 EVO
162 EVO
3 0,05 ~ 0,1 50 8 60
173 EVO
204 EVO
224 EVO
266 EVO
*The largest protected volume Vmax which may be protected by one explosion relief valve
has to be clarified together with the manufacturer.
Operation beyond these design limits is prohibited. HOERBIGER’s warranty and

liability becomes invalid immediately in case of improper application.
HOERBIGER explosion relief valves type EVO are components for diesel, dual
fuel and gas engines which necessarily require a connection to the engine to
describe a functional machine. Thus the instructions of the engine manufacturers
are of prior validity to the operator.
The selection of the venting area has to be done according to existing standards
and guidelines. It is not allowed to change one of the parameters that are part of
the calculation of the venting area. This means as soon as anything changes for
example the KG value, the sizing of the venting area has to be checked against all
design limits.

Version 4.01
4. Operation
Explosion relief valves type EVO protect personnel and equipment in the event of an oil mist- or
gas explosion in crankcases of diesel, dual fuel and gas engines. In this document diesel, dual
fuel and gas engines are called “machine”.
In case of an explosion the valve plate lifts up and relieves the overpressure through the
integrated flame arrester. Therefore no flame transmission to the outside of the valve must be
considered. Immediately after the pressure vent, the valve plate closes and prevents a fresh air
inrush. Hence secondary explosions are avoided.
Since the valve closes immediately after the pressure vent, no gas will be released to the
environment. For that reason no immediate shutdown of the engine is required.
The below mentioned and all relevant instructions given by the engine manufacturer have to be
obeyed.
The valve also is approved for indoor applications according to ATEX.
For reasons of the remaining heat, the explosion relief valve must not be touched
after an explosion – Danger of severe injury!
After an explosion the relief valve has to be exchanged at the next scheduled
IACS maintenance shutdown. Furthermore the instructions of the engine manufacturer
have to be observed.
Contact the manufacturer HOERBIGER Wien GmbH in case of any damages or

malfunctions of the valve, e.g. leakage.
During operation of the system, no work at the valve is allowed.
In case of visible damage of the valve, the valve has to be replaced.
The shear nut (position 10) must not be removed. All work to disassemble the
valve is forbidden. HOERBIGER’s warranty and liability becomes invalid
immediately in case of an opened seal.

Version 4.01
5. Fitting on the machine

5.1 General remarks
All work done on the valve like mounting or dismounting has to be carried out by
skilled personnel wearing suitable protective clothes and using appropriate tools.
Sharp edges and the weight of the valve may lead to injuries of personnel. Due to
improper handling the valve might drop and hurt personnel.
The lamellas of the flame arrester must not be painted, coated or manipulated in
any other way. All components of the flame arrester must not be damaged during
work.
The valve always has to be mounted on the outside surface of the machine /
protected volume. Mounting the valve in wrong way inside of the protected
volume leads to a non-fulfilment of its safety function!
During fitting the valve to the machine the information stated in the assembly
drawing must be observed. The required number of bolts has to be used, the
assembly torque is specified in the assembly drawing. A suitable gasket has to be
used in between the explosion relief valve and the counter flange of the machine.
It has to be observed that there is enough space for accessing the valves, to
enable a visual check of the condition at any time.

Version 4.01
5.2 Leak oil return

The valve has a bore hole for leak oil return. The leak oil return can be activated
by setting a counter hole through the sealing and counter flange of the protected
machine if required. If the leak oil return has been activated, design modifications
are required to avoid oil mist-/ gas escape to the outside (e.g. syphon, oil trap).
The diameter of the counter hole and syphon shall be at least the diameter of the
oil return hole (10mm). The explosion relief valve has to be mounted with the leak
oil return hole in “six o’clock” position to maintain the backflow of the leaking oil.
The siphon (U-shaped piece of pipe) is welded to the counter flange (see pictures
below). As an alternative standard hydraulic fittings can be used to mount a piece
of pipe to the counter flange.
Syphon
Activated leak oil drain Leak oil drain not activated

(Syphon is not scope of supply)

Version 4.01
5.3 Recommended safety area

The valve shall be located such, that hot gases are not directly blowing to areas
where operating personnel will typically remain (such as gangways,
panels,…etc.). It is recommended to maintain a safety distance of 2 meters in
radial direction and 0.5 meters in axial direction, which is defined as hazardous
area (see sketch below).
Individuals, who have to stay due to operational reasons around the defined
hazardous area, have to be instructed about the predominant hazards.
HOERBIGER explosion
0,5m relief valve
Recommended
safety distance
2m

@ Copyright HOERBIGER 2017 - 10 -
Version 4.01
6. Inspection
6.1 Regular inspection
For a safe operation of the explosion relief valve a regular inspection (acc. to chapter 6.3) is
mandatory, depending on the operating condition, but at least 1 time a year.
6.2 Inspection after an explosion

After an explosion the valve needs to be inspected according to chapter 6.3.
In addition the instructions of the engine/machine manufacturer have to be obeyed.
After an explosion the relief valve has to be exchanged at the next scheduled
IACS maintenance shutdown. Furthermore the instructions of the engine manufacturer
have to be observed.
6.3 General inspection procedure

During the inspection the following points should be checked and recorded:
- Visual inspection of the overall condition of the valve (no damage or corrosion)
- Inspection of the flame arrester according to chapter 6.3.1.
- Inspection of the valve sealing according to chapter 6.3.2.
If no deviations are detected, the explosion relief valve can continue the operation.
6.3.1 Inspection of the flame arrester

The flame arrester has to be inspected in terms of possible damages (abnormal gaps of
the flame arrester layers).
The following pictures demonstrate a flame arrester in proper condition and in bad
condition as well:

Version 4.01
In this case the flame arrester is in good condition:
In this case the valve has to be replaced:
Additionally the flame arrester has to be checked against extensive contamination and
deposits, which might influence the pressure relief function.
When a flash light is placed on one side of the flame arrester, the light shine must be
visible at the opposite side, to make sure that the flame arrester is not clogged by dirt
accumulations.

Version 4.01
flash light
In case of extensive dirt accumulations between the flame arrester layers,

the flame arrester has to be cleaned by suitable cleaning equipments (e.g.
vacuum cleaner) or with other adequate methods (e.g. compressed air, non-
corrosive and inflammable substance), at standstill of the engine.
If abnormal gaps on the flame arrester can be observed, the valve has to be
replaced.
Furthermore you have to obey the instructions of the engine/machine

manufacturer.
6.3.2 Inspection of the valve sealing

If there is leakage observed, the internal O-ring seal has to be replaced – see
chapter 7.1.
Furthermore the instructions of the engine/machine manufacturer have to be

obeyed.

Version 4.01
7. Maintenance
The explosion relief valve is almost maintenance free, nevertheless to guarantee a proper valve
function during the lifetime, we recommend to replace the sealing ring of the explosion relief
valve after 16,000 hours in operation.
Additionally following remarks have to be obtained for a safe explosion relief valve operation:
For proper operation the flame arrester has to be kept clean.
In case that dirt is collected on the flame arrester, it has to be cleaned with
compressed air or respectively with a non-corrosive and inflammable substance
(degreaser) at standstill of the machine.
The internal O-ring might lose the sealing function through ageing or chemical
attacks. In case of gas/oil leakage the O-ring has to be replaced during the next
scheduled shutdown, either by HOERBIGER or by trained stuff according
procedure described in chapter 7.1.
All instructions of engine–manufacturers and all advices for secure operating and
mounting of explosion relief valves given in the previous chapters are valid.
7.1 Cleaning of flame arrester and exchange of O-ring

The cleaning of the flame arrester and the exchange of the O-ring should be done by skilled
personnel according to the following steps:
1. Dismantle the explosion relief valve from the counter flange.
2. Push the valve plate open against the spring force by using adequate tool (i.e. hydraulic
press, drilling machine etc.). Before you reach into the valve with your hands it is mandatory
to add protection against sudden reclosing (i.e. appropriate piece of wood or similar)

Version 4.01
The pictures above are showing how to push the valve plate open by using a drilling machine
with a simple rod (the machine must be not switched on). Please make sure that the coating of
the valve plate won`t be damaged.
3. Clean the flame arrester by blowing air from the inside to the outside of the flame arrester.
4. Remove the old O-ring by using an adequate tool (i.e. screwdriver) and clean the O-ring
groove.

Version 4.01
5. Before mounting the new O-ring apply glue to the O-ring groove. Please make sure that the
glue is spread uniformly in the O-ring groove.
6. Insert the O-ring and clean the O-ring before closing the valve plate.
7. Mount the valve onto the machine, as described in chapter 5.
Take care when using cleaning agents or glue! Please follow the manufacturer’s
safety instructions carefully.
NOTE:
As glue “PATTEX classic” made from Henkel corp. can be used:
To ensure an even and thin application,

4 parts of glue can be mixed with 1 part cellulose thinner.

Version 4.01
8. Marking
The marking of the type plate is as following:
Marking explosion relief valve EVO

Version 4.01
9. Table of changes
The operational manual is part of the documentation for the classification society
IACS to obtain the approvals according IACS Rules M66. HOERBIGER has to report to
the classification society if there are any changes.
version date author comment

1.01 21.7.2008 BHA, HAT, RAX first version
1.02 2.12.2008 RAX Pictures added for
siphon and service
procedure
1.03 16.07.2012 HAT Safety Distance
2.00 04.11.2015 DSU Marking, Design limits,
ATEX conform
3.00 20.12.2016 EH Address change,
Marking, adding number
of type approval and
company, which has
issued the type
approval
4.00 08.08.2017 HAT, EH, DSU Layout, Inspection,
Delete of the warranty
4.01 01.08.2018 EH Change company name

Wärtsilä is a global leader in smart technologies and complete lifecycle solutions for the marine and energy
markets. By emphasising sustainable innovation, total efficiency and data analytics, Wärtsilä maximises the
environmental and economic performance of the vessels and power plants of its customers. Wärtsilä is listed
on the NASDAQ OMX Helsinki, Finland.
See also www.wartsila.com
WÄRTSILÄ® is a registered trademark. © 2021 Wärtsilä Corporation.
Find contact information

for all Wärtsilä offices worldwide
www.wartsila.com/contact

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Engine Operation and Maintenance

Date of issue 19.01.2021

Product type W16V32

Product number XAAB614715, XAAB614722, XAAB614725

Oil mist detector 4

This page intentionally left blank

Created by Checked by Approved by ENG. no

On engine Gnd strap 24 VDC SUPPLY MCM SIGNALS page 27/5C

1,5 mm² Blue (WDE-1)

1,5 mm² Violet (WDE-1)

MCM-1 WCS MCM-2 LDU

Set ESM CAN termination resistor

X31-20 to XM7-10 IB724 Local control indication page 9/8E

X31-21 to XM7-11 IB726 Remote indication page 9/8E

X31-26 X12-8 DI4 OS7343

X31-27 X13-2 DI5 OS7344

X31-28 X13-4 DI6 IB724

X31-11 to XM7-8 OS7308 Remote shutdown reset

QU700 oil mist detector

ESM 2 x 1,5 mm²

MCM-1 3 x 0,5 mm²

W161 2 x 1,5 mm²

MCM-2 2 x 1,5 mm²

X11 RS-232 (Not in use)

IOM-DE IOM-A1 IOM-A2 IOM-A3 IOM-FE IOM-TC

WDE-1 WA1 WA2 WA3 WFE WTC

White White White White White White 120 Ω

CHASSIS CHASSIS CHASSIS CHASSIS CHASSIS CHASSIS

* Leave inner shielding unconnected at this end

IOM-B1 IOM-B2 IOM-B3

WB1 WB2 WB3

White White White 120 Ω

CHASSIS CHASSIS CHASSIS

* Leave inner shielding unconnected at this end

WOMD-2 QU700 ID=2 X31-3

3 x 0,75 mm² Amplifier

DAAF075204 3 x 0,75 mm²

AI2 2 x 0,5 mm²

AI3 2 x 0,5 mm²

AI5 2 x 0,5 mm²

AI6 2 x 0,5 mm²

2 x 0,5 mm² CHASSIS

AI8 2 x 0,5 mm²

AI2 2 x 0,5 mm²

AI3 2 x 0,5 mm²

AI5 2 x 0,5 mm²

AI6 2 x 0,5 mm²

AI7 2 x 0,5 mm²

AI8 2 x 0,5 mm²

AI2 2 x 0,5 mm²

AI5 2 x 0,5 mm²

AI7 2 x 0,5 mm²

Ref (0V) X41-6 X43-4 -

3 x 0,75 mm² 2 x 0,5 mm²

AI1 2 x 0,5 mm² AI9 2 x 0,5 mm²

AI2 2 x 0,5 mm² AI10 2 x 0,5 mm²

AI3 2 x 0,5 mm² AI11 2 x 0,5 mm²

AI5 2 x 0,5 mm² AI12 2 x 0,5 mm²

AI6 2 x 0,5 mm²

2 x 0,5 mm² AI8 2 x 0,5 mm²

2 x 0,5 mm² AI9 2 x 0,5 mm²

2 x 0,5 mm² AI10 2 x 0,5 mm²

AI5 2 x 0,5 mm² X31-3

AI6 2 x 0,5 mm²