HYUNDAI-MAN B&W DIESEL ENGINE INSTRUCTION BOOK
SEC. NO. SHIP DESIGN OFFICE SHIP TYPE C3B6 SHIP OUTFITTING DESIGN DEP'T 1 22,500 CBM CLASS LPG/NH3 CARRIER
TEL. NO. SHIP NO. SHIP NAME 23778 2351 MAERSK GLORY (IMO 9531466)
NAME OF DRAWING APPROVEL3 B. H. KIM
CHECKED M. T. LEE CODE BOOK FOR MAIN ENGINE DRAWN
DATE 2010. 05.20 SCALE DRAWING NO. 6U-2811-001 ^. / A HYUNDAI HEAVY INDUSTRIES CO., LTD CONSOLIDATED NO. IMO 9531466 HHI-2351 >""=!: rn S) O > (O o < a sr z C o- Co (3O c 3 -• (O H m (O o o- (O p-o er o 0 3 o0 m z S. o O o Q) Z £ 3- m 'i^r fi>= " •< S «> o > TI o O 2 5" il so . tu -< 3 O. g •O <2 a < - O=: < w z i« •r o. Instructions for Main Engine
Type S50IVIC-C
This book forms part of a set of books consisting of three volumes entitled:
Vol. I OPERATION Vol. II MAINTENANCE Vol. Ill COMPONENTS AND DESCRIPTIONS
The purpose of these books is to provide general guidance on operation and maintenance and to describe the constructional features of a standard version of the above engine type. Deviations may be found in a specific plant. In addition, the books can be used for reference purposes, for instance in correspondence and when ordering spare parts.
It is essential that the following data is stated in spare parts orders as it is used by use to ensure the supply of the correct parts for the individual engines:
1. Name of vessel 2. Engine No. built by 3. Plate No. 4. Part No. 5. Quantity required (and description)
Example: M/S Nybo - 7730 B&W - 90201 - 00 - 059 10 off (piston ring)
Furthermore, to ensure optimum efficiency, reliability and lifetime of the engine and its components, only original spare parts should be used.
The designation 'D' used in texts and illustrations refers to the information given on the data sheets inserted in the respective books.
As reliable and economical operation of the diesel engines is conditional on correct operation and maintenance, it is essential that the engine-room personnel is fully acquainted with the contents of this book.
This book is subject to copyright protection. The book must not, either wholly or partly, be copied, reproduced, made public or in any other way made available to a third party without the written consent of this effect from H.H.I. ENGINE & MACHINERY DIVISION.
Hyundai Heavy Industries Co., Ltd. Engine & Machinery Division 1, Jeonha-Dong, Dong-Ku, Ulsan, Korea http://www.hhi.co.kr http://cs.hyundai-engine.com
Engine Customer Support Dept. TEL : (82) (52)-202-7587~90 FAX : (82) (52)-202-7581 E-mail : [email protected] CONTENTS
A. EXPLANATION & CODE BOOK CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR COMPONENTS EXHAUST VALVE FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS GENERAL TOOLS m X •n z> Si o o o D m D O O CONTENTS
A. EXPLANATION & CODE BOOK CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR COMPONENTS EXHAUST VALVE FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS GENERAL TOOLS CO Ol >"< o z c O "'S Ö
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2 (D (O O O o
00 CYLINDER COVER
PISTON WITH ROD AND STUFFING BOX
CYLINDER LINER AND CYLINDER LUBRICATION
CROSSHEAD WITH CONNECTING ROD
CRANKSHAFT, THRUST BEARING AND TURNING GEAR
MECHANICAL CONTROL GEAR
STARTING AIR COMPONENTS
X EXHAUST VALVE LU O FUEL OIL SYSTEM
TURBOCHARGER SYSTEM
SAFETY EQUIPMENT
ASSEMBLY OF LARGE PARTS i 901.01-46
Cylinder Cover
General
The cylinder cover is made of steel and has a central bore for the exhaust valve, which is attached by means of four studs. The cover furthermore has bores for the fuel valves, which are mounted with tubular spacers and nuts. Other bores have been provided for starting valve, starting air inlet, safety valve and indicator cock.
A cooling jacket is mounted on the lower part of the cylinder cover, whereby a cooling water space is formed.
Another cooling water space is formed around the exhaust valve seat, when the exhaust valve is installed. These two spaces commu• nicate through a large number of oblique /radial cooling bores in the cover.
The water is supplied from the cooling jacket surrounding the cylinder liner and passes through water transitions to the cooling jacket surrounding the cylinder cover and, further on, through the cooling bores, to the space around the exhaust valve seat.
From here the water is discharged to the main cooling water outlet pipe.
The cylinder cover is tightened against the top of the cylinder liner by means of nuts and long studs fitted in the cylinder frame. The nuts are tightened by means of hydraulic jacks.
Sealing between the cylinder cover and cylinder liner is obtained by means of a sea• ling ring, made of mild steel. HYUNDAI Cylinder Cover Plate P90101-0163 MAN B&W
C-C
A-O-A
B-O-B
When referring to this page, please quote Plate P90101 Edition 0163 Plate P90101-0163 Cylinder Cover
Item Item Item Description Item Description No. No.
018 Screw 031 Protective cap 043 Nut 055 Stud 079 Nut 080 Stud 092 Cylinder cover 102 0-ring 114 Cooling jacket 138 Nut 151 Distance pipe 163 Stud 187 Screw CYLINDER COVER
PISTON WITH ROD AND STUFFING BOX §
CYLINDER LINER AND CYLINDER LUBRICATION
CROSSHEAD WITH CONNECTING ROD
CRANKSHAFT, THRUST BEARING AND TURNING GEAR
MECHANICAL CONTROL GEAR
STARTING AIR COMPONENTS
Xu EXHAUST VALVE Q FUEL OIL SYSTEM
TURBOCHARGER SYSTEM
SAFETY EQUIPMENT
ASSEMBLY OF LARGE PARTS CM 902.01-65
Piston with Rod and Stuffing Box
Piston and Piston Rod The oil is passed on theough a number of bores in the thrust part of the piston crown Plate 90201 and to the space around the cooling oil pipe in the piston rod. The piston consists of two main parts: From the bore in the piston rod foot, the oil is • Piston Crown led through the crosshead to a discharge spout and to a slotted pipe inside the engine • Piston Skirt frame as well as through a control device for The piston crown is tightened to the upper checking the flow and temperature. end of the piston rod by means of screw. The screws are locked with locking wire. The piston rod foot rests on a face cut out in the crosshead pin and is guided by a pipe in The piston skirt is tightened to the piston the crosshead. crown by means of flanged screws. A shim is inserted between the piston rod and The screws are locked with locking wire. the crosshead. The thickness of the shim is calculated for each engine, in order to match The piston crown is provided with the actual engine layout. chromium-plated grooves for four piston rings. The one uppermost rings have increased The rod is fastened to the crosshead pin by height. means of four screws. The screws are locked with locking wire. Piston ring No. 1 is a Controlled-Pressure Relief ring (CPR). CPR rings may have been coated on the external surface. Handle with Piston Rod Stuffing Box care, as impact may cause the coating to The bore for the piston rod in the bottom of crack and peel off. the scavenge air box is fitted with a piston rod stuffing box, which is designed to prevent the The piston rings Nos. 2, 3 and 4 have lubricating oil in the crankcase from being oblique cuts : drawn up into the scavenge air space. - piston ring No. 3, The stuffing box also prevents scavenge air has a right-hand cut, (in the scavenge air space) from leaking into and the crankcase. - piston rings Nos. 2 and 4, The stuffing box is mounted on a flange which has a left-hand cuts. is bolted to the bottom of the scavenge air At the top, the piston crown has a groove for space. the fitting of lifting tools. The stuffing box is removed together with the The piston rod has a through-going bore for piston rod during piston inspection, but can the cooling oil pipe,which is secured to the also be dismantled for inspection in the piston rod top by means of flanged screws. crankcase while the piston remains mounted in the engine. Cooling oil is supplied through a telescopic The stuffing box housing consists of two pipe connection on the crosshead and passed parts, which are bolted together. through a bore in the piston rod foot and, through the cooling oil pipe in the piston rod, to the piston crown. 902.02-65
The housing is provided with seven The parts are held in place round the machined ring grooves : piston rod by means of helical springs, which are located in machined grooves on - The uppermost groove provided with a the outside of the scraper rings and sealing four-part scraper ring with oblique edges, rings. which serves to prevent sludge from the scavenge box from being drawn down to Gaps at the end of the ring segments the other rings. ensure that the rings will bear against the piston rod even in worn condition. Furthermore, an eight-part sealing ring is located below the scraper ring to prevent scavenge air from passing downwards along the piston rod.
The scraper ring and the sealing ring are guided by two cylindrical pins.
- The next two ring grooves are each provided with a four-part sealing ring and an eight-part sealing ring below. The rings are guided by two cylindrical pins.
- The four lowermost ring grooves are fitted with three-part scraper rings which scrape the lubricating oil off the piston rod.
Each of the three parts consists of a base ring with two machined grooves, each containing a pressed-in lamella, with a scraping edge facing the piston rod.
From the three lowermost grooves, the oil is returned to the crankcase, through bores in the stuffing box housing.
Through bores in the housing and a pipe, the uppermost scraper ring groove communicates with a control funnel on the outside of the engine.
This funnel provides a means of checking that the sealing rings and scraper rings are functioning correctly :
- Blow-by of air indicates defective sealing rings, while excessive oil indicates defective scraper rings. HYUNDAI Piston and Piston Rod Plate P90201-0204 MAN B&W
When referring to this page, please quote Plate P90201 Edition 0204 2 CDCXI-^CJ)CJTji.-».OCDQ0CJ)CJ1-t>-C0K)-»^ 5^ "^ fi) hJOCD-sICJIOOOOOJGjJi-OCD-JCnOO-i. o•-• Pi •D WTJDDTJTITJTJTlTIWCOr-cocncrt (O O q w' A A w' -S' w' 55' öö' w" q q O q q q ro 2 0=j"3'o™ OOOPft) CD ?rCD 2 5 g3CQ(Q:3^333:3?S5-$§? o C/) 3 -1 o ""."•. ">. "^ • gi S o 3 O 3 o (D (A O •n "D •-• O 3 3» w" o 3 Q) 3 a 3» oIf °i 3 7J O a
(D 3 Ö (D (A O
O 3 HYUNDAI Piston Rod Stuffing Box Plate 90205-0115 MAN B&W
>-216
When referring to this page, please quote Plate 90205 Edition 0115 Plate 90205-0115 Piston Rod Stuffing Box
Item Item Item Description Item Description No. No.
013 Nut 025 Housing for stuffing box 037 Scraper ring 049 Scraper ring 050 Flange 062 Guide pin 086 Screw 098 Spring pin 121 Lamella 145 0-ring 157 Scraper ring 169 Sealing ring 170 Sealing ring 182 Screw 204 Fitted bolt 216 Housing for stuffing box, complete 241 Spring 253 Spring CYLINDER COVER
PISTON WITH ROD AND STUFFING BOX
CYLINDER LINER AND CO CYLINDER LUBRICATION
CROSSHEAD WITH CONNECTING ROD
CRANKSHAFT, THRUST BEARING AND TURNING GEAR
MECHANICAL CONTROL GEAR
STARTING AIR COMPONENTS
X EXHAUST VALVE U Q FUEL OIL SYSTEM
TURBOCHARGER SYSTEM
SAFETY EQUIPMENT
ASSEMBLY OF LARGE PARTS eo6 903.01-62
Cylinder Liner and Cylinder Lubrication
Cylinder Frame Rubber rings located in machined grooves in the cylinder liner ensure cooling water sealing. The cylinder section of the engine consists of a cast cylinder frame, which is tightened The part of the cylinder liner which is located together with the framebox and the bedplate in the scavenge air space of the cylinder by means of stay bolts, the bottom end of frame is provided with a number of scavenge which is screwed into the bedplate. air ports, which are uncovered by the piston when this is in its bottom position. The scav• If the cylinder frame consists of more than enge air ports are bored at an oblique angle one part, these parts are tightened together in to the axis of the cylinder liner so as to give the vertical joints. the scavenge air a rotary movement in the cylinder. A central bore for each cylinder, at the top of the cylinder frame, encloses the cylinder In the free part of the cylinder liner, between liners. the cooling jacket and the cylinder frame, there are a number of bores with non-return A central bore for each cylinder, at the bottom valves for supply of lubricating oil to the of the cylinder frame, encloses the piston rod cylinder. stuffing boxes. On the working surface of the cylinder the On the exhaust side of the cylinder frame bores are connected to a lubricating groove to there are openings which connect the ensure an even distribution of the oil. scavenge air spaces around the cylinder liners with the longitudinal scavenge air Cylinder Lubricators receiver of the engine. Plate 90305 Furthermore, there are inlet pipes for cooling and lubricating oil. The cylinder frame is fitted with two cylinder lubricators. The lubricators incorporate a The cylinder frame is provided with cleaning number of oil pumps, corresponding to the and inspection covers giving access to the number of lubricating orifices in cylinder liners. scavenge air spaces. The lubricators are inter-connected by means Studs for fastening the cylinder covers are of shafts with couplings which are rjgid in the mounted in the cylinder frame. direction of rotation.
Cylinder Liner The lubricators are driven through a gear transmission from the end of the camshaft. The cylinder liner is tightened against the top of the cylinder frame by the cylinder cover, so For fixed pitch propeller plants (FPP), the that it can expand freely downwards when lubricators are speed-dependent, where the heated during the running of the engine. cylinder oil dosage follows the engine speed. For controllable pitch propeller plants (CPP), A rubber ring is located in a machined groove the lubricators are mean indicated pressure on the external diameter of the cylinder liner, (MEP)-dependent, where the cylinder oil in order to guide the liner in the cylinder dosage follows the engine load. frame. The lubricators are of the load-change The cylinder liner is surrounded by a cooling dependent (LCD) type. jacket. 903.02-62
For engines fitted witii a Woodward governor, tine LCD lubricators are controlled by an electronic unit, which nnonitors the position of the fuel regulating shaft.
For engines fitted with an electronic governor, the LCD lubricators are controlled directly by the governor.
The LCD lubricators can operate in two modes:
• LCD mode: The lubricators supply the pre-set extra amount of cylinder oil during STARTING, manoeuvring and sudden load changes. This reduces the liner wear rate.
• Fixed-position mode: The lubricators supply the pre-set extra amount of cylinder oil per revolution continuously.
Regarding the cylinder lubricators proper, reference is made to the special instruction manuals supplied.
See also Vol. I, OPERATION Chapter 707. HYUNDAI Cylinder Frame Plate 90301-0167 MANB&W
When referring to this page, please quote Plate 90301 Edition 0167 Plate 90301-0167 Cylinder Frame
Item Item Item Description Item Description No. No.
015 Screw 027 Protective cap 039 Nut 040 Stud for cylinder cover 052 O-ring 064 Screw 076 Distance pipe 088 Nut 111 Stud 123 Cylinder frame 135 Distance pipe 147 Nut 159 Distance pipe 160 Stud 172 Distance pipe 184 Distance pipe 196 Fitted bolt 206 Cover 218 Screw 231 Cap nut 243 Screw 255 Protective pipe, complete 267 O-ring 279 Packing 292 Nut 302 Stud 314 Cover 326 O-ring 351 Screw 363 O-ring 375 Cleaning cover 399 Stud 409 Screw HYUNDAI Cylinder Liner and Cooling Jacket Plate 90302-0184 MANB&W
010
022
034
142 154 ^^-^S^tfe
201 2 1 3 201 66 i -irS 78 r^'-fl r\r "'•J -',1 >
058 ~1x 071
When referring to this page, please quote Plate 90302 Edition 0184 Plate 90302-0184 Cylinder Liner and Cooling Jacket
Item Item Item Description Item Description No. No.
010 Cooling jacket 022 Gasket 034 Piston cleaning ring* 046 Cylinder liner 058 Packing 071 Plug screw 095 Clamp 105 Screw 117 0-ring 129 0-ring 142 Stud 154 Nut 166 Cooling water connection 178 Packing 201 Sealing ring 213 Cooling water connection 225 Screw
Note: * Two designs aviable: 1. Standard Cleaning ring. 2. Retrofit piston cleaning ring. HYUNDAI Cylinder Liner - Details Plate 90304-0037 MAN B&W
01 1
When referring to this page, please quote Plate 90304 Edition 0037 4:o^ CoO No3 -o^ fi) --4 en CO -»• (D (O X < X Z O O Q> (t) O c <" Q) 3 cn CD Q. -!, o D CD • CQ £• o —I o 3 («D^ < 3 -4 <03 CD (oD O (/) O O 3 •5' T3 CD O CD 3 O 5" a
3
I Ö 5 (D •-^ &)
(D 3 o O 3 HYUNDAI Cylinder Lubricator Unit Plate P90307-0020 MAN B&W 222 305 A-A 305 < When referring to this page, please quote Plate P90307 Edition 0020 Plate P90307-0020 Cylinder Lubricator Unit Item Item Item Description Item Description No. No. 018 Ball valve 031 Stud 043 Nut 055 Hydraulic block 067 Plug screw 079 Intermediate pipe 080 0-ring 102 Membrane accumulator 114 Gasket 138 Coupling 151 Hydraulic block 187 Stud 199 Ball valve 222 Screw 305 Lubricator 317 Screw 329 Non-return valve 330 0-ring 342 Adjusting screw 354 Coupling 366 Distance pipe 378 Cover 391 Cylinder block 413 0-ring 425 0-ring 437 Screw 449 0-ring 462 Plug 474 Screw 486 Inductive sensor 498 Cabel gland, complete 521 Plunger 533 Spring 557 Cylinder housing 569 Plunger 582 Plug 594 0-ring 604 Housing 616 0-ring 641 Solenoid valve, complete 653 Screw 677 Cable 689 Cable gland, complete 690 Membrane accumulator 700 Gasket HYUNDAI Intermediate Box Plate P90308-0012 MAN B&W 074 A 1 013 12 3 4 5 J1 — hi m \oo\i 3 1 2 3 4 5 6 a 32 32 S) Bi I m ii ~h n -ft :^ i„;i. Jr7 ^Z^ M//7en referring to this page, please quote Plate P90308 Edition 0012 ^o eon o-t» . CoO ->o• -t^ o CD -^ OJ (D 13 (O a (/) O m 5" O K^il% CO o ^ ? Oi " o? .C D3 o CD 9: ?• 00 9J 3 Q) CO 3.2.S- 3 Ö ^ ° o- O o M != o s 8 O 53 •O _ "O Ü3 CD o s: CD 3 CD cn 3 •-^ 3 Q. Ei' (D CO o X 3 o (D O O 3 HYUNDAI Cylinder Lubrication System - Details Plate P90309-0016 MAN B&W When referring to this page, please quote Plate P90309 Edition 0016 Plate P90309-0016 Cylinder Lubrication System - Details Item Item Item Description Item Description No. No. 019 Steel pipe 020 Pipe holder 032 Screw 044 Steel pipe 056 Pipe holder 068 Coupling 081 Steel pipe 103 Steel pipe 115 Steel pipe 127 Coupling 139 Pipe holder 140 Distributor block 152 Screw 176 Coupling 188 Coupling 211 Steel pipe 223 Steel pipe HYUNDAI Cylinder Lubrication - Electronic Components Plate MAN B&W P90312-0004 159 Co) BCU IN CONTROL 160 .o o OL, AUTO/MCU/BCU non '°LJ.LJ. LJ. LJ.LJ'°- (o) Co) 196 052 064 076 A-A 206 When referring to this page, please quote Plate P90312 Edition 0004 Plate P90312-0004 Cylinder Lubrication - Electronic Components Item Item Item Description Item Description No. No. 015 Name plate 027 Pilot lamp 039 Name plate 040 Selector switch 052 Terminal 064 Terminal 076 Din rail 088 Terminal 111 Terminal 159 HMI panel 160 Mounting plate 184 Nut 196 Screw 206 Terminal CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR COMPONENTS uX EXHAUST VALVE FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS POG 904.01-54 Crosshead with Connecting Rod The crosshead is provided with two guide- The crosshead block is provided with bores shoes fitted floating on the crosshead ends. for distributing the oil supplied through the telescopic pipe, partly as cooling oil for the The centre part of the crosshead is housed piston, partly as lubricating oil for the cross- in the crosshead bearing. head bearing and guide shoes and - through a bore in the connecting rod - for lubricating The crosshead bearing cap is provided with the crankpin bearing. a cut-out enabling the piston rod to be assembled with the crosshead journal. The two sliding faces of the guide shoes are lined with cast-on white metal. The crosshead bearing is equipped with two lower bearing steel shell, which are lined The crosshead is guided by crosshead guides with tin-aluminium. Furthermore, the lower in the engine framebox and properly secured shell have an overlayer coating of lead, tin against displacement by guide strips fastened and copper, and a flash-layer of tin. See to the guide shoes. also Vol. I, OPERATION, Chapter 708. The crosshead pin and guide shoes are There is no upper bearing shell, as white tightened together by means of plates and metal has been applied directly onto the inner screws, located at the lower part of the pin. diameter of the crosshead bearing cap. The crosshead bearing is assembled by The piston rod foot rests on the crosshead, and means of four studs and nuts. The nuts are is guided by a guide ring in the crosshead. tightened by means of hydraulic tools. A shim is inserted between the piston rod and The crankpin bearing is fitted with bearing the crosshead. The thickness of the shim is shells lined with tin-aluminium and a calculated for each engine, in order to match flash-layer of tin, and assembled by means of the actual engine layout. two studs and nuts. The nuts are tightened by means of hydraulic tools. The piston rod is fastened to the crosshead by means of four screws, which are locked Both the crosshead bearing shells and the with locking wire. crankpin bearing shells are retained in posi• tion by means of screws fitted in the bearing The telescopic pipe, which supplies lubricating housings. and cooling oil to the crosshead, crankpin and piston, is mounted on top of one of the guide Furthermore, the bearing assemblies are shoes. guided into position by guide pins. The guide shoe is also fitted with a counterweight in order to balance the weight of the telescopic pipe. The outlet pipe for piston cooling oil is mounted on top of the other guide shoe. The outlet pipe slides within a slotted pipe inside the engine framebox, and from there the oil is led through a control device for each cylinder for the purpose of checking the temperature and flow before the oil is passed on to the lube oil tank. CM in OT— I o r- ro CO O^ o o> 0) +>* iS Q. T3 (0 0) x: (A (A O CNJ O lo T3 O C c (O .o •D O s DC 'S- o O) Ol C +3 'ro O 5: 0) -S c "o c o- o O) t/} Ü CD CD O) CÜ CL .CO 5 O) .c s 'S CM 'II- ro -^ o o c CD Plate 90401-0152 Connecting Rod and Crosshead Item Item Item Description Item Description No. No. 019 Plate 020 Screw 032 Locking wire 044 Screw 068 Crankpin bearing shell, complete 081 Screw 093 Screw 103 Outlet pipe 115 Guide shoe, fore 139 Guide strip 140 Crosshead bearing shell, lower part 152 Connecting rod 176 Screw 188 Shim* 211 Crosshead bearing cap 235 Guide pipe 247 Crosshead 260 Crankpin bearing cap 272 Guide pin 284 Screw 306 Distance piece 318 Bushing 331 Housing for stuffing box 343 Telescope pipe 355 Screw 379 Stud 380 Nut 402 Guide shoe, aft 414 Shim* 426 Shim* 438 Screw 451 Nut 463 Stud 475 Guide pin 487 Screw 509 Counterweight 510 Spring pin 558 Connecting rod, complete Note: * Please state thickness of shims HYUNDAI Lubricating and Cooling Crosshead Plate MANB&W Crankpin and Main Bearing P90403-0008 When referring to this page, please quote Plate P90403 Edition 0008 CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR COMPONENTS Xu EXHAUST VALVE Q FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS in 905.01-51 Crankshaft, Thrust Bearing and Turning Gear Crankshaft Thrust Bearing Plate 90501 Plate 90505 The crankshaft is semi-built, i.e. the parts are The thrust bearing serves the purpose of either shrunk or welded together. transmitting the axial thrust of the propeller through propeller shaft and intermediate shafts The main bearings are lubricated via a main to the ship's hull. lubricating oil pipe that branches off to the individual bearings, whereas oil for lubricating The thrust bearing is incorporated in the the crankpin bearings is supplied from the aftermost part of the engine bedplate. crossheads through bores in the connecting rods. The crankshaft is provided with a thrust collar which transmits the thrust to a number of At the aftmost end of the crankshaft a turning segments mounted in a thrust shoe on either wheel and a thrust collar for the thrust bearing side of the thrust collar. is fitted. The thrust shoes rest on surfaces in the thrust The chainwheel for the camshaft drive is fitted bearing housing and are held in place by on the thrust collar. means of four stoppers. The segments have white metal cast on the wearing faces against At the foremost end of the crankshaft, a turning the thrust collar. wheel, a torsional vibration damper and a chain See also Vol. I, OPERATION, Chapter 708. wheel drive for the 2nd order moment compensator may be installed. The thrust bearing is lubricated from the pressure lubrication system of the engine. The Axial Vibration Damper oil is supplied between the segments through spray pipes and spray nozzles. In order to counteract heavy axial vibrations, and any resultant adverse forces and vibrat• The thrust bearing is provided with alarm, ions, the engine is provided with an axial slow-down, and shut-down devices for low lube vibration damper on the foremost end of the oil pressure and high segment temperature. crankshaft, see Plate 91211. See also Vol. I, OPERATION, Chapter 701. The damper consists of a 'piston' and a Turning Gear slit-type housing located in front of the foremost main bearing. The 'piston' is made as an Plate 90510 integrated collar on the foremost main bearing journal, and the housing is mounted on the The turning gear is attached to the engine foremost main bearing support. bedplate and is driven by an electric motor incorporating a disc brake. The axial movement is damped due to the 'restrictions' incorporated in the bores which Through a belt drive and a planetary gearing, interconnect the oil-filled chambers on the two the motor drives a horizontal shaft equipped sides of the 'piston' . with a gear wheel which can be axially displaced by means of a hand wheel, so as to Lubricating oil is supplied to both sides of the engage with the turning wheel of the engine. 'piston' from the main system. 905.02-51 The turning gear is provided with a safety arrangement consisting of a lever which must be lifted before the gear wheel of the turning gear can be made to engage with the turning wheel. Immediately this lever is lifted away from the disengaged position, an interlock valve inserted in the starting air system of the engine is actuated. This interlock prevents starting air from bearing supplied to the engine as long as the turning gear is in the engaged position. See also Vol. I, OPERATION, Chapter 703. When the safety lever is in its bottom position, it prevents the gear wheel of the turning gear from engaging with the turning Wheel. Warning ! During any dismantling of working parts of the engine, the turning gear must be in engaged position in order Dismantling of to prevent outside forces from turning the engine, thus working parts: causing injuries to personnel or damage to the machinery. See also Vol.11, MAINTENANCE, 'DATA' pages. The turning gear must be in the disengaged position Pressure testing of during pressure testing of starting valves, as a leaky valve may cause the engine to rotate, and damage the starting valves: turning gear See Vol. 1, OPERATION, Chapter 703. HYUNDAI Crankshaft Plate 90501-0169 MAN B&W 012 When referring to this page, please quote Plate 90501 Edition 0169 o o o o o 2 æ •^j CD CO -^ cji CO -^ CD ro Pi (D (O c/) O TI O O O o o 0> IT r ' o i^^%-^s iij = =3 ?r ci S ^ ^ CrDr 03^ CD_ 3 (O (Da tn o ^ T3 •->• O 3 o Q) (/) 3- (D 3 (D 3 o (D (A O O 3 HYUNDAI Arrangement of Fore End Plate P90502-0063 MAN B&W 018 102 031 163 043 175 354 < 067 209 080 271 092 When referring to this page, please quote Plate P90502 Edition 0063 Plate P90502-0063 Arrangement of Fore End Item item Item Description Item Description No. No. 018 Screw 031 Gasket 043 Cover 067 Screw 080 Screw 092 Cover, complete 102 Gasket 114 Plug screw 126 Plug screw 138 Cover 163 Stud 175 Nut 199 Gasket 209 Shield, upper 210 Chain wheel 222 Flange 234 Screw 271 Shield, lower 283 Tuning wheel 305 Stud 317 Nut 329 Nut for hydraulic tightening 330 Disc 354 Shield "Fore", complete HYUNDAI Arrangement of Angle Encoder Plate 90503-0018 MAN B&W A-A 225 A When referring to this page, please quote Plate 90503 Edition 0018 Plate 90503-0018 Arrangement of Angle Encoder Item Item Item Description Item Description No. No. 037 Screw 049 Angle encoder 050 Enclosure, complete 074 Screw 086 Shaft 098 Housing 108 Damping plate 121 Coupling 133 Cable tie 157 Tool 169 Packing 170 Spring pin 182 Screw 194 Spring lock 204 Shield lower part 216 Packing 228 Shaft 253 Packing 265 Washer HYUNDAI Axial Vibration Monitor Plate P90504-0010 MANB&W When referring to this page, please quote Plate P90504 Edition 0010 -i -i -i -». o o ^^ 2 t;i CA) ro ->• jii. CJO 2 ^* 0) ro CD ^ C^ -t». NI (D •D > < cn Ü3 cn -0 (O 1 m q S q -o- O — CO CD o CD CD U1 o Ö3 Q . ~ CD 7 o O ; ii 3 3 o :3 o ;:v (D o —1 O 8 T 3 "S" T3 CD CD 53 " > X < 5" 3 o3 3 3 a O 3 HYUNDAI Thrust-and Guide Bearing Plate P90505-0175 MANB&W )-349 When referring to this page, please quote Plate P90505 Edition 0175 Plate P90505-0175 Thrust- and Guide Bearing Item Item Item Description Item Description No. No. 002 Screw 014 Self-locking nut 026 Lubricating oil pipe 038 Segnnent stopper 051 Spray pipe 063 Segment with sensor pockets 075 Segment "Ahead" 099 Clamp 109 Lubricating oil pipe 110 Lubricating oil pipe 134 Self-locking nut 146 Guard 157 Lubricating oil pipe 171 Clamp 183 Lubricating oil pipe 205 Nut 217 Stud 229 Segment stopper 242 Segment stopper 266 Segment stopper 301 Spray pipe 313 Screw 325 Lubricating oil pipe 337 Screw 350 Scraper ring housing, upper part 362 Fitted bolt 374 Scraper ring housing, lower part 386 Nut 398 Guide pin 408 Screw 433 Scraper ring housing, complete 457 Guard 516 Stud 528 Lubricating oil pipe 553 Screw 565 Oil throw ring, upper part 577 Oil throw ring, lower part 589 Oil throw ring, complete 600 Fitted bolt 612 Screw 624 Scraper ring, upper part 636 Scraper ring, lower part 648 Nut 661 Scraper ring, complete HYUNDAI Turning Gear Plate 90510-84 MAN B&W S50MC-C 02 o o o o o o o &) ->j en cji -P>- CO ro ->• P i (D (O z O g OD T) g 2 O E. en' c/)' 2. 3 c/)' £u U1 ^* r-* - I- f I-t - ff) !3 5 5 CQ '* 00 "^ '" CQ CD •O T3 ^' 03 •O T3 CQ CD 0 Q . 3 CD D < (D o' (A CD O T •O r* O 3 c 5" O fi) 3 (D 3 D (D (A O O 3 HYUNDAI Turning Wheel Plate 90510-85 MANB&W S50MC-C _ o o o 0) CO l\ 3 -»• Pi (D (O Z -n H O t= s: '^ en '^ CSD" ^3 CX 5- er CQ 00 %^ ^iV Ol :T (0 CD CD 3 D (D 0) O T T3 !-• O 3 c s" (O (D 3 O 3 D (A O O 3 CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR COMPONENTS X EXHAUST VALVE LU Q FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS 906 906.01-72 Mechanical Control Gear Chain Drive Regarding absolute wear of the chains, see Vol.11, MAINTENANCE, Procedure 906. Plate 90600 Camshaft The camshaft with cams for operating the fuel pumps, exhaust valves and indicator drives Plates 90611 - 90613 (option) is driven from the crankshaft through The camshaft is built together of a number of a chain drive located at the aft end of the camshaft sections. The sections are assem• engine. bled by means of flange couplings which are joined together with fitted bolts and nuts. The chain drive consists of two identical roller chains running on chain wheels fitted on the In addition to the coupling flanges, the cam• crankshaft and the camshaft. The chains are shaft sections have, for each cylinder : kept tightened by means of a chain tightener placed between the two chain wheels. - one cam for operation of the fuel pump - one cam for the exhaust valve. The long free lengths of the chains are guided - one cam for the indicator drive (option). by rubber-clad guide bars. Lubricating oil is supplied through spray pipes fitted at the The cam for the indicator drive is in two parts, guide bars and chain wheels. which are assembled by means of two fitted bolts. The starting air distributor is driven directly from one end of the camshaft, and the The camshaft is carried in single-shell(lower cylinder lubricators are driven from the other shell) bearing assemblies, which are fitted in end of the camshaft. the roller guide housings between the cam discs for fuel pump and exhaust valve. The Chain Tightener bearings are of the thin-shell type. The bearing caps are tightened against the The chain tightener consists of a chain camshaft housing by means of flanged tightener bracket which is pivoted on a shaft screws. pin and a chain wheel. See also Volume I, OPERATION, Chapter 708. The chain wheel has a shrunk-in bearing bushing and is mounted on a shaft between The coupling flanges and the fuel pump and the side plates of the bracket. exhaust valve cams are shrunk onto the shaft by heating. Dismantling of flanges is effected The chain tightener is operated by a tightener bolt in the free end of the forked arm for the by forcing lubricating oil in between the shaft chain wheel. The tightener bolt extends and the flange, see Volume II. through a pin that is free to turn in the chain casing. The same procedure is used for turning the fuel cam with a view to adjusting the fuel cam top lift and also when adjusting the camshaft Caution ! in case the chains have become worn and Before retightening the chain, the engine elongated following retightening. must be turned into such a position that the chain is slack at the side where the The camshaft rotation constantly follows that chain tightener wheel is fitted and the of the crankshaft. When the engine is counterweights, if any, are hanging reversed, the position of the rollers of the vertically downwards in order not to affect individual fuel pump roller guides, is being the chain. shifted in relation to the respective cam discs, 906.02-72 thus altering the fuel pump timing to suit the spindle which is able to move up and down, new direction of rotation. corresponding to the movement of the main See Chapter 909. piston within the engine cylinder. This motion is transmitted from the indicator cam through After the engine has been testrun, the a roller at the bottom of the spindle. At the camshaft parts and the cylinder frame will be top, the spindle has an eye to which the provided with pin gauge marks, and the indicator cord is fastened after the indicator necessary pin gauges are delivered together has been mounted on the indicator valve. with the engine, enabling the camshaft timing to be checked and readjusted if the parts During normal running of the engine, the have been dismantled. spring-loaded spindle is lifted clear of the indicator cam, the handle of the spindle being The pin gauges are marked with : in the locked position. • engine type When diagrams are to be taken, the handle is • engine number turned 90° whereby the spindle enters a key- way which enables the spindle to be lowered • point of application, onto the indicator cam. The keyway will guide • the distance in mm the spindle during its up-and-down movement. between the measuring points, For use of the indicator, see Volume I, Furthermore, the length of the pin gauges is OPERATION, Chapter 706. indicated in the relevant section of the maintenance book (Volume II) for the plant. Moment Compensators 2nd order moment Indicator Valve 4, 5 and 6-cyl. engines have a 2nd order Plate 90612 external moment which might excite vibration of the hull and deckhouse. Each cylinder is fitted with an indicator valve, which communicates with the combustion Based on calculations, these cylinder numbers chamber of the cylinder through a bore. The may be provided with flyweights built into the indicator valve is a double-seated valve with a main chain drive. spring-loaded closing face. Flyweights may also be built into a second In order to prevent overstressing, close the chain drive, which is driven from the fore end valve with a light hand before starting the of the crankshaft. This chain drive is equipped engine, and retighten the valve when the with a spring-loaded chain tightener. engine has reached its normal service temperature. Optionally, an electrically driven compensator can be installed outside the engine. Indicator Drive (option) 1st order moment Plate 90612 4-cyl. engines may have a rather high 1st An indicator cam is fitted for each cylinder. An order external moment, and can, therefore, be indicator drive is arranged above this cam. provided with a 1st order moment compensator arranged as adjustable The indicator drive consists of a spring-loaded counterweights on the fore and aft ends of the crankshaft. 906.03-72 Alternatively, the 1st order moment com• pensator can be arranged in the main chain drive. This moment compensator consists of a (new) chain-tightener wheel with an incorporated counterweight and a counterweight rotating with the crankshaft. If the chain drives for the above compen• sators have been dismantled, the flyweights must be positioned correctly in relation to the crankshaft of the engine. See the instruction bool<, Vol. II, MAINTE• NANCE. In correctly fitted moment compensators may excite heavy vibrations. Load Transmitter A load transmitter may be mounted on the fuel regulating shaft to give a remote indication of the fuel pump index. HYUNDAI Arrangement of Chain Drive and Camshaft Plate P90600-0081 MAN B&W When referring to this page, please quote Plate P90600 Edition 0081 HYUNDAI Chain Drive and Guide Bars Plate P90601-0073 MANB&W 016 028 136 161 173 When referring to this page, please quote Plate P90601 Edition 0073 Plate P90601-0073 Chain Drive and Guide Bars Item Item Description Item Item Description No. No. 016 Screw 028 Locking wire 041 Guidebar 053 Bracket 065 Screw 089 Screw 090 Bracket 100 Guidebar 112 Screw 136 Chain, complete 148 Chain link, complete 161 Outer link 173 Inner link HYUNDAI Chain Drive - Lubrication Plate P90602-0126 MAN B&W 202 When referring to this page, please quote Plate P90602 Edition 0126 Plate P90602-0126 Chain Drive - Lubrication Item Item Item Description Item Description No. No. 023 Spray pipe 035 Lubricating pipe 047 Lubricating pipe 059 Spray pipe 060 Spray pipe 084 Lubricating pipe 096 Spray pipe 106 Lubricating pipe 118 Spray pipe 131 Lubricating pipe 143 Spray pipe 155 Spray pipe 179 Lubricating pipe 180 Lubricating pipe 192 Lubricating pipe 202 Steel pipe 226 Steel pipe 238 Steel pipe CO o O o> Q. 0) •i* //J/////// / "7~/_ ^ (O "^"^ ITTI '^~^ '"'"''' _a ^^ c !^^ .o 0c) i 0) CO / / j ^ / / / o £ oCO O) CT) i- Q- c CO C O ^ I D CC CT^ O C\ J O J "co ^ O J C\ J ^ 5: o o o- CU to ttj O) CC Q. .to -C O) c r- 0 ^ O ^ O ^ 1 ^ v D ^ r o iD r - ^ O J K ) ID rv i ^ vX ) o ^ o j n o o o o o o o c -C Plate P90603-0114 Chain Tightener Item Item Item Descr ption item Description No. No. 017 Nut 029 Locking plate 030 Guide nut 054 Guide nut 066 Tightening bolt 078 Nut, self-locking 101 Cover 113 Screw 125 Locking wire 137 Shaft 150 Screw 162 Screw 174 Flange 186 Stop screw 198 Shaft 208 Cover 221 Screw 245 Bracket 257 Chain wheel 269 Bushing 270 Shaft 282 Distance piece 304 Coupling 316 Lubrication oil pipe 328 Lubrication oil pipe 341 Coupling 365 Distance pipe 377 Screw 389 Nut 390 Stud 400 0-ring 412 Guide pin 424 0-ring 448 Shaft HYUNDAI Intermediate Chain Wheel Plate P90604-0049 MANB&W 061 085 When referring to this page, please quote Plate P90604 Edition 0049 &> coc»0)ai-f>.coi\ioo^cDcoro-^ co-^æo5-p^[\Dooio3-^0)-p!'ro P| (D TI (O O0W2:a)a)oa5a)O"n(/)C3 O O) O • O =S "O CD '* (D CQ ^- CD. o CD 3 (O D (D tf) O T3 O 3 3 Of* -i 3 o Q. fl> 0) O 3 3- 3r o o (D a tf) O O 3 HYUNDAI Bearing Housing - Mounting Plate P90610-0113 MAN B&W n r\ 039 ^-t^O 040 When referring to this page, please quote Plate P90610 EdItionO113 Plate P90610-0113 Bearing Housing - l\/lounting Item Item Description Item Item Description No. No. 015 Screw 027 Bearing cap 039 Bearing sinell in 2/2 040 Bearing iiousing 064 Nut 076 Stud 111 Guide screw 123 Guide pin 135 Guide pin 147 Shim 160 Bearing cap 172 Thrust ring 196 Bearing housing 218 Screw HYUNDAI Camshaft Plate 90611-E115 MANB&W S50MC-C ? 1^ 00 o When referring to this page, please quote Plate 90611 Edition E115 Plate 90611-E115 Camshaft Item Item Description Item Item Description No. No. 010 Camshaft 015 Chain wheel 027 Locking wire 034 Exhaust cam 039 Screw 040 Gear wheel 046 Fuel cam 052 Thrust disc 058 Indicator cam complete 083 Plug 117 Socket head bolt 130 Nut 901 Gear wheel* * To be mounted if woodward governor is used. HYUNDAI Indicator Drive Plate 90612-51E MAN B&W 327 207 339 352 173 185 303 >303 459 460 When referring to this page, please quote Plate 90612 Edition 51E cncnoiuicjicri-fi.j^-fi.ji.^^i.cocococococorvjroNDKDMivjro-'-'-^-^-^-^oooooooo 2 æ^O)-P^cjocD<»a)CJicoMC»^aicoMocoæo)Oi^t>oooo^-^coro-'cooo~viO)cri-P>.t\o-' (D ocD~siw--^c3)03-^ococno3æc:DMCD^cooj-^æci)-^o-viuicoooa)-f^rooco-vitnGo-^æc3) (D (O O x o 3 3 O. o' fi) o (D < (D 3 D (D 0) O O 3 HYUNDAI Arrangement of Camshaft Plate 90613-85 MANB&W S50MC-C sm fO Q Ol a lo O OJ 059 fe \3r KA ^ ) ^ ^ I \ \"L\ v \ s-^^X \ s \ S \ i _ -1.-100000 0 &> co-'Coæ-vicnco M -'CBCJJJ^tVJCOCilOi P| O O O) 3 v> =r O) 0 3 D (D (O O O 3 HYUNDAI Arrangement of Governor Plate P90615-0135 MAN B&W - 107 When referring to this page, please quote Plate P90615 Edition 0135 _ ^corv5-^oc»^cj)Co->. 2 .p>.t\30CD^CnCO-'0>t\D Pi (D 13 CO S"°5§öm=qc. qc O 0 = CDCD0CnCDQ.CD9J O) • o < 3 CO —1 Ol 1CD3 o o (P 0) 03 o o ^ c1—*- •o o 5' 3 0) 3 (Q 3 (D 3 (D 3 O o < o 3 O O O HYUNDAI Regulating Shaft Plate 90618-E106 MAN B&W S50MC-C _r$[i -tgh When referring to this page, please quote Plate 90618 Edition E106 Plate 90618-E106 Regulating Shaft Item Item Item Description Item Description No. No. 019 Forked lever 020 Pin 032 Circlip 044 Pull rod complete 068 Bearing 093 Regulating shaft 103 Bearing 127 Distance pipe 139 Washer 140 Self-locking nut 164 Washer 176 Fitted bolt 188 Eye bolt 211 Spring 235 Spring pin 247 Clamping arm 259 Screw 260 Lock washer 284 Spring loaded lever complete 306 Screw 318 Guide pin 343 Nut 355 Lock washer 367 Lever 380 Spring pin HYUNDAI Load Transmitter Plate P90619-0037 MAN B&W When referring to this page, please quote Plate P90G19 Edition 0037 Plate P90619-0037 Load Transmitter Item Item Description No. 014 Cover 038 Nut, self-locking 051 Pull rod, complete 063 Washer 087 Fitted bolt 099 Clamping arm 109 Nut, self-locking 122 Clamping arm 134 Plate 146 Screw 158 Disc 171 Screw 195 Potentiometer Note: HYUNDAI Emergency Console Plate 90620-68 MAN B&W S50MC-C Non-Reversible TYPE 655 667 Plate 90620-68 Emergency Console Item Item Item Description No. Item Description No. 021 Screw 738 Bearing 033 Handle 751 Pressure switch 045 Shaft 763 Screw 057 Self-locking nut 775 Bellows gland 069 Washer 070 Plate 082 Stop ring 094 Bushing 104 Shaft 116 Spring lock 128 Washer 141 Stud 153 Handle 165 Key 177 Grease nipple 189 Self-locking nut 190 Washer 200 Emergency console 212 Forked lever 224 Screw 248 Pointer 261 Screw 273 Angle lever 285 Slide shoe 307 Lock washer 319 Screw 320 Hand wheel 332 Thrust ring 356 Split pin 368 Screw 381 Retaining ring 403 Tapered pin 415 Clamping block 427 Spindle 440 Stop valve 464 Nut 476 Ball bearing 488 Circlip 511 Self-locking nut 559 Valve "Ahead-Astern" 572 Valve "Remote-Emergency" 584 Screw 631 Screw 643 Sealing ring 655 Name plate 667 Screw 680 Thrust ring 692 Start valve 714 Ball bearing 726 Circlip HYUNDAI Arrangement of Layshaft Plate 90621-62 MAN B&W When referring to this page, please quote Plate 90621 Edition 62 Plate 90621-62 Arrangement of Layshaft Item Item Description Item Item Description No. No. 015 Lever, complete 027 Grease nipple 039 Lever 040 Cone 052 Pin 076 Lever 088 Screw 111 Washer 123 Bushing 147 Screw 159 Washer 160 Bushing 172 Lever 184 Switch 196 Cone 206 Self-locking nut 218 Washer 243 Screw 255 Nut 279 Impact socket 280 Impact handwheel 292 Pin 302 Stop ring 314 Clamping arm 338 Pull rod 351 Fitted bolt 363 Self-locking nut 387 Screw 399 Lock washer 410 Fitted bolt 422 Fitted bolt 446 Pull rod, complete HYUNDAI Moment Compensator Plate P90625-0042 MANB&W \ \ \ ^////^\\\^///// VÄ 174 y\lhen referring to this page, please quote Plate P90625 Edition 0042 Plate P90625-0042 Moment Compensator Item Item Description Item Item Description No. No. 017 Guidebar 029 Bracket for guideway 030 Screw 042 Locking wire 054 Screw 066 Screw 091 3®" Chain, complete 101 CInain link, complete 113 Outer link 125 Inner link 137 Flyweight, complete 149 Chain wheel 150 Bushing 174 Flyweight 208 Screw 233 Shaft 245 Distance pipe, L=40 257 Screw 270 Sealing ring 282 Nut 294 Stud 316 0-ring 328 Guide pin 353 Screw 365 Locking wire HYUNDAI Chain Tightener for IVIoment Compensator Plate MANB&W P90626-0026 ^ n in ^ o OJ -!* vO vO CO (> T- ^ c\j n yo ID yQ r- CO 0^ o n n n r\j n n ^0 n n ^ ^ ID r- ^ c\j CM DJ O) ^ ^ CO ^ -- CM ro -^ Æ o o o o o When referring to this page, please quote Plate P90626 Edition 0026 Plate Chain Tightener for IVloment Compensator P90626-0026 Item Item Item Description Item Description No. No. 012 Bushing 024 Pin 036 Flange 048 Locking plate 061 Screw 085 Tightening bolt 097 Nut 107 Locking plate 119 Neck nut 132 Thrust flange 144 Spring 156 Distance tube 181 Disc 193 Forked lever 215 Eccentric 227 Chain tightener wheel 240 Shaft 252 Screw 264 Nord-lock washer 276 Flange 311 Flange bearing 323 Shaft 335 Screw 359 Guide pin 360 0-ring 372 Stud 384 Nut 396 Sealing ring 406 Screw 418 Distance pipe CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR COMPONENTS uX EXHAUST VALVE FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS 106 907.01-83 Starting Air System The starting air system consists of the maintain this speed independently of the manoeuvring system and the starting air engine load. components. Speed-setting during manual control: The following items are described : During control from the engine side control console, the governor is disconnected from • Manoeuvring System the fuel pumps, and the speed control is effected through the regulating handwheel. • Main Starting Valve See also Vol. I, OPERATION, Chapter 703 and Plate 90620. • Starting Air Distributor Reversing system: • Starting Valve The reversing system contains two pneumatic valves (AHEAD and ASTERN). These valves Manoeuvring system control the reversing cylinder of the starting See also Vol. I, OPERATION, Chapter 703. air distributor and the air cylinders for reversing the fuel pump rollers. The manoeuvring system is of electric/pne• umatic design. It is designed for : Safety system: The safety system is separately supplied with • Control from engine side control air and is controlled by the engine monitoring console. system (with separate power supply). In case See also Chapter 906 of shut-down, the safety system leads an air signal to the puncture valve on each fuel pump, • Remote control from engine thereby cutting-off the delivery of high-pressure control-room and/or bridge. fuel oil, after which the engine stops. The system consists of three sub-systems: The safety system is connected during all modes of engine control. • The regulating system • The reversing system Main Starting Valve • The safety system. Plate 90702 Regulating system : The main starting valve is interposed in the starting air main pipe. By means of the regulating system it is possi• ble to start, stop and control the engine. The main starting valve consists of a large ball valve and, optionally, a smaller ball valve The START and STOP functions are cont• which is fitted as a by-pass for the large valve. rolled pneumatically. Both valves are operated by means of pneumatic actuators. Speed-setting during remote control: During remote control, the speed-setting is If the smaller ball valve is installed, an controlled by the control handle on the adjusting screw will be mounted for setting the manoeuvring console, which sends a signal to slow-turning speed. the governor system. Furthermore, a non-return valve is incorporated The engine speed depends on the magnitude which prevents blow-back in the event of of the signal. The governor system will excessive pressure in the starting air line. 907.02-83 The main starting valve is equipped with a For an engine which runs clockwise during blocking device consisting of a plate which, by AHEAD (seen from aft), the outer recesses means of a handwheel, can be made to block control starting in AHEAD direction, and the inner the actuators. recesses control starting in ASTERN direction. The ball valves and their actuators are, Through the short recesses, starting air is together with the non-return valve and supplied to each starting air valve in turn. blocking device, built together to form a unit. Each of the short recesses is divided into two On receipt of telegraph order 'Finished with parts. The part, which during AHEAD or engine' , move the blocking device to the ASTERN is the first in the running direction, BLOCKED position. gets its supply air from space AI and the next gets its supply from space A2. To avoid alarm, move the telegraph handle into STOP position Through the long recesses, the starting valves that are not supplied with starting air are Warning vented. Through bores, the long recesses communicate with the central space between During all inspections of the engine, the the shaft and the reversing disc and from blocking device of the main starting valve there leads through bores in the distributor must be in the BLOCKED position. housing, to the atmosphere. The only exception is when the starting valves are tested for tightness, in which Reversing disc: case the blocking device of the main starting The reversing disc is designed with two sets valve must be in the WORKING position of bores opposite the mentioned two sets of and the shut-off valve for the starting air concentric recesses in the distributor disc. By distributor must be in the CLOSED position. means of an air cylinder connected to the arm See Vol. I, OPERATION, Chapter703, ' of the reversing disc, one of these sets of Operations after arrival in port' . bores can be cut off while the other set of bores is brought to communicate with the Starting Air Distributor outlet holes which lead to the starting valves. Plate 90703 Furthermore, for engines with remote control, the reversing arm acts as a cam for two The starting air distributor is mounted on the 3-way valves, controlling the end positions of end of the engine and is driven from the end the reversing movement. of the camshaft through gear wheels. Housing: The distributor consists of: Each outlet hole from the distributor housing • Distributor disc leads to a starting valve, and the position of • Reversing disc the reversing disc determines whether air for AHEAD or ASTERN running is supplied to the • Housing starting air valves. • Shaft and bushing Shaft and bushing: Distributor disc: The shaft rotates in a bushing fitted in a bore Short and long recesses are milled into the placed centrally in the distributor housing. The contact face of the distributor disc. They form shaft is driven by the camshaft through gear two concentric circles. wheels. The distributor disc is mounted on the 907.03-83 other end of the shaft. space A2 continues a short time (adjustable) in order to facilitate the starting. During running, the distributor disc is kept free of the reversing disc by means of oil pressure: The venting of space A1 means that the opening of the starting valves is delayed and Closest to the distributor disc, the bushing has a that fuel oil therefore can be injected into the larger diameter than at the other end. The oil cylinder without any risk of blowback to pressure, which is applied at the centre of the starting air pipes. bushing, acts on different shaft diameters and gives a small displacement of the distributor disc. Starting Valve Function: Plate 90704 When control air is admitted to the starting air The starting valve (spring-loaded) is fitted on distributor, a control air pressure builds up in the cylinder cover. It is controlled by control spaces A1 and A2, causing distributor disc B air from the starting air distributor 90703. to be pressed against the reversing disc. Function: Control air passes through bores in the distributor disc to the short recesses, and When the main starting valve is open, cham• further on through bores in the reversing disc ber P of the starting valve is pressurised and via bores in the distributor housing to the through the starting air pipe. starting valve, thus activating the starting valve. The starting valve is kept closed by the The long recess in the distributor disc spring. When chamber U above the piston of communicates with the remaining starting the starting valve is pressurised with control valves through the bores in the reversing disc air from the starting air distributor, the starting and the distributor housing. The pilot air from valve opens, and starting air now flows from the starting valves is vented through these the starting air pipe to the cylinder. bores and through bores in the distributor disc and the distributor housing to the atmosphere. When the starting period is finished, chamber U is vented through the vent pipe of the When the crankshaft starts turning, the starting air distributor, and the starting valve distributor disc also turns, thereby moving the will close. short recess from one bore into a position opposite the next bore. Thereby the starting Venting of the starting air in chamber P and valve which is connected with this bore is the starting air pipe takes place slowly supplied with control air, and the starting valve through small holes in the starting air pipe. opens. Simultaneously, the long recess in the distributor disc is positioned opposite the bore from the starting valve activated directly before, and the control air of that starting valve is vented, causing the valve to close. When the start level RPM of the crankshaft has been reached, and the START signal is vented, space A1 is vented through a pneumatic valve. At the same time the fuel pump puncture valves are vented, causing fuel oil to be injected into the cylinders. The control air supply through HYUNDAI Main Starting Valve Plate P90702-0070 MAN B&W 948 When referring to this page, please quote Plate P90702 Edition 0070 Plate P90702-0070 Main Starting Valve item Item Item Description Item Description No. No. 015 Screw 936 Repair kit, main actuator, slow turning* 027 Switch 948 Repair kit, main ball valve, slow turning* 039 Distance pipe 052 Screw 064 Plate Note: 076 Ball valve with actuator* 111 Plug screw 123 Packing ring *When ordering spare parts for this item 135 Packing ring please state manufacturer's part no. 147 Plug screw 159 Intermediate piece 172 Nut 184 Washer 196 Handwheel 206 Locking plate 231 Spring 243 Spindle 267 Nut 279 Screw 280 Nut 292 Starting air pipe 302 Packing ring 326 Screw 338 Washer 351 Guide pin 363 Sundry chain 375 Split pin 387 Keyring 399 Screw 409 Nut, low 410 Ball valve with actuator* 422 Screw 434 Packing ring 446 Disc 458 Housing 471 Screw 483 Screw 495 Stud 505 Starting air pipe 517 Housing 529 Non-return valve 530 Nut 542 Adjusting screw, "slow turning" 900 Repair kit, slave actuator, slow turning* 924 Repair kit, slave ball valve, slow turning* HYUNDAI Starting Air Distributor Plate 90703-E82 MAN B&W S50MC-C oo a> oo When referring to this page, please quote Plate 90703 Edition E82 Plate 90703-E82 Starting Air Distributor Item Item Item Description Item Description No. No. 010 Screw 022 Gasket 034 Screw 046 Name plate 058 Bracket 083 Fitted bolt 095 Self-locking nut 105 Air cylinder 117 Spring pin 129 Screw 130 3/2-way valve 154 Stud 166 Nut 191 Guide pin 201 Guide pin 225 Gear wheel 237 Lock washer 249 Nut 262 Bushing 274 Spring pin 286 Key 298 Screw 308 Bracket 333 Distributor housing 345 Shaft 357 Sealing ring 370 Reversing disc 382 Sealing ring 394 Distributor disc 404 Piston ring 416 Cover 428 Fitted bolt 441 Washer HYUNDAI Starting Valve Plate P90704-0061 MAN B&W -016 -028 P o r\r \/^ 1 12 w\^ y\j •124 136 When referring to this page, please quote Plate P90704 Edition 0061 Plate P90704-0061 Starting Valve Item Item Item Description Item Description No. No. 016 Screw 028 Cover 041 Packing 053 Nut, self-locking 077 Piston 089 Spring 090 Distance pipe 100 Liner 112 Valve housing 124 Sealing ring 136 Valve spindle CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR COMPONENTS X EXHAUST VALVE LÜ Q FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS 806 HYUNDAI Engine Types 50-98MC Description MAN B&W A90030-0003 908 Exhaust Valve Exhaust Valve Each cylinder cover is equipped with an exhaust valve, which is mounted in a central bore in the cylinder cover. The valve housing is attached with four studs and nuts to form a gas-tight seal against a seat in the cylinder cover. Valve housing The valve housing has an exchangeable bottom piece. The bore for the valve spindle is provided with an exchangeable spindle guide liner. Cooling The valve housing is water cooled, the cooling water is passed to the valve housing after it has passed the cylinder cover. The water is discharged from the upper part of the valve housing. On the front of the valve housing there is a cleaning cover through which the cooling water space can be checked and cleaned. Valve spindle The part of the spindle stem which travels within the sealing arrangement of the air cylinder is coated with a wear resistant mixture of metal carbide and super alloy, applied by the HVOF process. On the lower cylindrical part of the valve spindle a vane wheel is fitted which causes the valve spindle to rotate while the engine is running. Lifting / rotation check rod : To enable checking the functioning of the exhaust valve while the engine is running, a 'lifting / rotation check rod' is mounted on top of the hydraulic cylinder on the exhaust valve. Spindle rotation is indicated by regular changes in the top and bottom positions of the check rod. Note! This check rod is only for checking purposes, and must not be permanently activated. Pistons At the top the spindle, two pistons are fitted: 1. Air piston The piston serves to close the exhaust valve. The piston is locked to the spindle by a two- 2. Hydraulic piston The piston serves to open the exhaust valve. The hydraulic piston has two piston has two piston rings and a damper arrangement, designed to damper the closing of the valve. When referring to this text, please quote Description A90030 Edition 0003 Page 1 (3) Description Engine Types 50-98MC HYUNDAI MAN B&W A90030-0003 Caution ! After the exhaust valve has been overhauled, it is important to check the damper, to avoid knocking. See Volume II, MAINTENANCE, Procedure 908. Air cylinder The air cylinder is mounted on top the valve housing. Air for closing the exhaust valve is supplied through a non-return valve to the space below the piston. A safety valve is mounted in the bottom of the air cylinder. The safety valve is connected to the drain pipe which leads to the camshaft housing. Hydraulic cylinder The hydraulic cylinder is attached with studs and nuts on the air cylinder on top of the exhaust valve housing. The exhaust valve is opened by the valve spindle being forced down by the piston in the hydraulic cylinder. Throttle / valve: On some engine types, a combined throttle / valve designed for deaerating the oil system is fitted at the top of the cylinder. When the exhaust valve is closed, the pressure in the hydraulic cylinder is low. A thrust spring opens the valve, enabling oil and air, if any, to escape through the throttle. The oil is led through a duct to the space around the air cylinder and is drained off through a bore X, together with leakage oil from the piston. When the exhaust valve is activated, the high oil pressure closes the valve, and the oil flow stops. Sealing System Sealing air (where used): A sealing air arrangement is fitted around the spindle shaft below the air cylinder. The sealing air is supplied from the air cylinder via a sealing air control unit. The sealing air will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the pneumatic system of the valve gear. The oil content in the air from the air cylinder improves the service condition of the sealing rings. The sealing air control unit contains a valve which automatically cuts off the air flow when the engine is in FINISHED WITH ENGINE status, and a filter housing. page 2 (3) When referring to this text, please quote Description A90030 Edition 0003 HYUNDAI Engine Types 50-98MC Description MAN B&W A90030-0003 Sealing oil (where used): A sealing oil arrangement is fitted around the spindle shaft below the air cylinder. The sealing oil is supplied from a control unit fitted on top of the exhaust valve hydraulic actuator. During the exhaust valve lifting period, oil escapes from the hydraulic actuator through the restriction chamber to the control unit which, in turn, gives a certain amount of oil (dosage oil) to the exhaust valve spindle. The sealing oil will prevent the exhaust gas and particles from penetrating upwards and wearing out the running surfaces and polluting the pneumatic system of the valve gear. The oil improves the service condition of the sealing rings. Exhaust Valve The exhaust valve is actuated by a cam on the camshaft through a hydraulic Actuating Gear transmission. Hydraulic cylinder The hydraulic cylinder is attached to the camshaft housing by studs and nuts. A piston enclosed in the hydraulic cylinder rests on a thrust piece in the neck of the roller guide and is locked to the roller guide by a bayonet joint. The hydraulic cylinder on the camshaft housing is connected to the hydraulic cylinder on the exhaust valve by a high-pressure pipe. Oil is supplied from the lubricating oil system through a non-return valve. Leakage oil from the hydraulic cylinder on the exhaust valve is drained through a pipe connection. Puncture Valve On 4-cylinder reversible engines as well as on 5-cylinder reversible 50MC engines, a puncture valve may be mounted on the exhaust valve actuator. During starting, this valve prevents the exhaust valve from opening during the first part of the actuator piston's upward stroke. This function prevents the starting valve and exhaust valve from being open at the same time, thus ensuring a safe start. When referring to this text, please quote Description A90030 Edition 0003 Page 3 (3) HYUNDAI Exhaust Valve - Lower Parts PlateP90801-0213 MANB&W P90803 When referring to this page, please quote Plate P90801 Edition 0213 Plate P90801-0213 Exhaust Valve - Lower Parts Item Item Item Description Item Description No. No. 013 Packing 025 Cover 037 Screw 049 Exhaust valve housing 050 Screw 062 Spring pin 074 Bottom piece 086 0-ring 098 Sealing ring 108 Screw 121 Sealing ring 133 Spindle guide 145 Sealing ring 157 Thread insert 169 Packing ring 170 Plug screw 182 Packing ring 194 Plug screw 204 Flange 216 Packing 228 Exhaust valve spindle HYUNDAI Exhaust Valve - Upper Parts Plate P90803-0049 MAN B&W P90804 y 600 589 P90801 When referring to this page, please quote Plate P90803 Edition 0049 Plate P90803-0049 Exhaust Valve - Upper Parts Item Item Item Description Item Description No. No. 014 Eye bolt 026 Screw 038 Plate 051 Orifice plug 063 Disc 075 Packing 087 Steel pipe 109 Oil cylinder 110 Disc 122 Locking plate 134 Screw 158 Pipe 171 Union nut 183 Reducing nipple 195 0-ring 205 Spring 217 Disc 229 Point screw 230 Rod.lift-rotation check 254 Dowel pin 278 Packing ring 301 Spring pin 325 Nut 349 Plug screw 362 Screw 374 Cam lock washer* 386 Flange 398 Cone 408 Sealing ring 421 Sealing ring 433 Piston, air cylinder 445 Sealing ring 457 Sealing ring 469 Air cylinder 482 Non-return valve 494 Piston ring 516 Piston, actuator 528 Slide 541 Piston 553 Spring 565 Disc 589 Stud 600 Piston actuator, complete Note: * Cam lock washers are to be supplied by MAN Diesel only. (O o o • o oo o CD OL O re SU 'ro *-' o O (O i- re Q. i- o Q. Q. D > tf) 3 ro X LJJ CO O O 0) O Ji. ro en cji -^ ^1 (D TJ (O >*• Z O CO O O o O A S, w 00 "D CD O ,1^CQ >< ^ < o C TJ TJ (D (D -t 3 TI 0) W Ö 3 O (D tf) O O 3 HYUNDAI Exhaust Valve - Actuator Plate P90805-0141E MAN B&W For 5S50MC-C 267 279 267 When referring to this page, please quote Plate P90805 Edition 0141E c o u (A O a E 0) (O 3 U < E 0) (A re LU c o o Q. (/) E L_ 0 LU 0) O Cl) 0) Q o r7i l- -0^ > co é CD ^ 0 O) £ -q •g 'tf) CD g> CO c '3 > 3 0) I.. CD ^ •i O) >- en en i_ u cn en 55 en o- II lO c 5 3 5 cm r c O oj *; Ü .£ o; _0 C5 CD c: 0 ~ j«: 3 = ^ •o -o o C CD 1» -•—• tn "- •- n .«_( CD 0 "O CD .E "5 o ^ 3 CD ^ 3 = .W O 0 CX 0 3 0 CD Item Item Item Description Item Description No. No. 010 U-bolt 017 Connector 018 Gasket 034 Screw 046 Support 058 Coupling 083 Sealing ring 095 Sealing ring 117 Pipe, L=2160 129 Coupling 142 Thrust flange 154 Sleeve in 2/2 166 Screw 178 O-ring 201 High-pressure pipe 213 Spring ring 225 Intermediate piece 237 High-pressure pipe, complete HYUNDAI Arrangement of Cooling Water Pipes Plate 90810-43E MAN B&W S50MC-C 227 239 240 252 276 288 097 When referring to this page, please quote Plate 90810 Edition 43E Plate 90810-43E Arrangement of Cooling Water Pipes Item Item Item Description Item Description No. No. 012 Valve 024 Coupling 061 Butterfly valve 073 Screw 085 Pipe 097 Screw 107 Packing 120 Ball valve 132 Drain pipe 168 Pipe (inside valve housing) 181 Packing 193 Screw 203 Screw 227 Screw 239 Nut 240 Packing 252 Orifice plate 276 Cooling pipe 288 Packing 323 Cooling pipe 347 Screw 359 Compensator 372 Pipe 396 Packing 406 Screw 418 Screw 431 Cooling pipe 443 Orifice plate 455 Nut CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR COMPONENTS uX EXHAUST VALVE FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS 606 HYUNDAI Engine Types 35-98MC Description MAN B&W A90030-0001 909 Fuel Oil System Fuel Pump Each engine cylinder is equipped with its own fuel pump, which is mounted on the camshaft housing over the camshaft section corresponding to the cylinder concerned. The pump housing is attached to the camshaft housing by studs and nuts. The square base of the fuel pump housing is provided with a groove to receiver any leakage oil, which is subsequently drained off through a drain pipe. In the base, a bore is provided for at toothed rack, i.e. ttie regulating guide, which controls the quantity of fuel oil delivered by the pump. Furthermore, for the VIT-type fuel pump, another bore is provided above the bore for the regulating guide. This bore is provided with a rack, i.e. tlie timing guide, which controls the engine timing. At the top. The pump housing is closed by a top cover. The top cover is provided with a suction valve and a puncture valve. These two valves are on some engine types combined into one unit. The pump housing contains the plunger and barrel. The plunger and barrel are matched parts, and must not be replaced individually. The pump plunger is provided with a guide block designed to travel in the milled keyway in the regulating guide. At the bottom it has a foot which rests on a steel disc in the bayonet joint at the roller guide neck. A clearance of approx. 0.1 mm between the plunger foot and the roller guide permits turning of the plunger in the roller guide. The regulating guide is able to turn in the bottom of the pump housing. On the outside the regulating guide has a toothed rim to mesh with the above-mentioned toothed rack at the base of the pump housing. The toothed rim and toothed rack are marked with lines enabling the parts to be positioned correctly after disassembly. The toothed rack is linked together with the regulating gear of the engine through a spring-loaded connection. Thus, in the event of a sticking pump plunger, the regulating gear for the remaining fuel pumps will not be blocked. The pump barrel is provided with oil cut-off holes, which are covered and uncovered during the travel of the plunger within the barrel. This function, in conjunction with the turning of the plunger effected by the regulating gear, serves to regulate the amount of oil injected into the engine cylinder. Two screw plugs are fitted in the pump housing opposite the cut-off holes of the barrel. The oil jets which are ejected through the cut-off holes at the end of the delivery stroke will hit the screw plugs, which can be replaced when they are eroded. When referring to this text, please quote Description A90030 Edition 0001 Page 1 (4) Description Engine Types 35-98MC HYUNDAI MAN B&W A90030-0001 Injection timing Fuel pumps without VIT (Variable Injection Timing): The pump barrel is attached to the top cover by means of screws. The lower part of the barrel is guided in the bore of the pump housing. Two sets of 0-rings and back-up rings are fitted in grooves on the outside of the barrel and the pump cover to seal between pump barrel / pump cover and housing. A number of semi-circular shims are inserted between the top cover and the pump housing. By removing or inserting such shims, the pump barrel can be slightly lowered or raised in relation to the plunger, and in this way the initial moment of fuel oil injection into the engine cylinder can be adjusted, and the maximum combustion pressure thus changed. Refer to Volume II, Chapter 909, regarding adjustment of the maximum combustion pressure. VIT-type fuel pumps: The pump barrel is guided at the top and bottom of the pump housing. Low friction sealing rings are fitted in grooves in the barrel to seal between barrel and housing. The barrel is provided with a drain bore between the sealing rings at the lower end. The pump barrel has a threaded lower end which fits into the internal threads of the timing guide. The timing guide has a gear rim to mesh with the upper toothed rack at the base of the pump housing. The gear rim and toothed rack are marked with lines enabling the parts to be positioned correctly after disassembly. The toothed rack is linked to a servo-air cylinder which is controlled mechanically or electronically in relation to the engine load. The position of the upper toothed rack determines the vertical position of the barrel relative to the plunger through the threaded connection. In this manner the initial moment of fuel oil injection into the cylinder can be adjusted by a servo-air cylinder. The pump barrel is prevented from turning by a guide screw mounted in the pump housing. Puncture valve In the top cover of the pump, a puncture valve is fitted. The puncture valve consists of a piston which communicates with the control air system of the engine. In the event of actuation of the shut-down system, and when STOP is activated, compressed air is supplied to the top of the piston, causing the piston with pin to be pressed downward and keep the suction valve in the open position. This will 'puncture' the oil flow to the fuel valve. As ling as the puncture valve is activated, the fuel oil is returned through bores to the pump housing, and no injection takes place. page 2 (4) When referring to this text, please quote Description A90030 Edition 0001 HYUNDAI Engine Types 35-98MC Description MAN B&W A90030-0001 Fuel Oil Injection During the suction stroke, the spring-loaded suction valve opens and the delivery chamber is filled with oil. As soon as the plunger has covered the cut-off holes during its upward movement in the pump barrel, the injection commences through the fuel valves. The injection will last until the cut-off holes are uncovered by the oblique cut-off edges of the plunger, following which the oil is forced through two milled grooves at the side of the plunger and out through the cut-off hoes of the barrel during the rest of the delivery stroke. Shock absorber A shock absorber is installed on each pump housing or in the main fuel pipe to take up pressure variations. Fuel Pump The camshaft housing contains the fuel pump and exhaust valve actuating gear Actuating Gear for each cylinder. The fuel pump is actuated by a cam on the camshaft. The movement is transmitted through the roller guide to the plunger in the barrel of the pump housing which - through the high-pressure pipes - is connected with the fuel valves on the cylinder cover. Reversible engines: The roller guide of each fuel pump incorporates an angular displaceable reversing link. Reversing is achieved by shifting the roller in the fuel pump drive mechanism at each cylinder. The link connecting the roller guide and roller is provided with a reversing arm, and a pivot is mounted at the top end of the reversing arm. The pivot travels in a reversing guide connected to an air cylinder. The link is self-locking in either the AHEAD of ASTERN position without the aid of external forces. Each cylinder is reversed individually, and the reversing mechanism is activated by compressed air. The reversing arrangement may incorporate a damper in order to reduce the mechanical stresses. Fuel Oil High- All high-pressure pipes in the system are provided with a protective outer pipe. Pressure pipes The space between the pipe and the protective outer pipe communicates, through bores in the union nipples, with a drain bore in the pump top cover. Fuel Oil Leakage A fuel oil leakage alarm is required for Unattended Machinery Spaces, UMS. Alarm 35-98MC : Each fuel pump is, via drain pipes, connected to a common drain tank, which incorporates a level switch. The drain tank is also equipped with an overflow pipe, which has a small drain bore below, whereby oil from small leakages can be drained to the outlet, without actuating the level switch. When referring to this text, please quote Description A90030 Edition 0001 Page 3 (4) Description Engine Types 35-98MC HYUNDAI MAN B&W A90030-0001 In the event of pipe fractures or major leakages in the system, the abovementioned bore will not be large enough to allow the increased oil quantity to pass, and the oil level in the drain tank will rise until it reaches the lever of the overflow pipe. The rising oil level will cause the level switch to set off an alarm. 50-98MC : Alternatively to the common drain tank, the drain pipes on 50-98MC engines can be connected to a diaphragm valve, which sets off an alarm and activates the puncture valve, which sets off an alarm and activates the puncture valve in order to stop the fuel oil flow from the pertaining pump. On 60-98MC engines, which are provided with pneumatically operated fuel pump roller guide lifting gear, automatic activation of the lifting gear by the diaphragm valve can be arranged in order to stop the fuel oil flow from the pertaining pump. Puncture valve The fuel valve consists of a valve head and a valve housing. Fitted within the valve housing is a non-return valve and a spindle and spindle guide with a pressure spring, and a nozzle. The spindle may be provided with a cut-off slide. When the fuel valve is fitted in the cylinder cover, the valve parts are tightened together by the pressure from the securing nuts. Functioning The functioning of the fuel valve is as follows : The electrical fuel oil primary pump circulates preheated oil through the fuel pump and fuel valve. The fuel il passes through the fuel valve, leaving through a circulation bore and the return oil pipe on the valve head. When the pressure at the beginning of the fuel pump's delivery stroke has reached the predetermined pressure, the circulating bores is closed. When the pressure has reached the predetermined opening value for the fuel valve, the spindle will be lifted and oil injected through the nozzle into the engine cylinder. On completion of the fuel pump's delivery stroke, the valve spindle is pressed against its seat and injection now ceases. Then the circulating bore is uncovered, and oil starts to recirculate through the valve. page 4 (4) When referring to this text, please quote Description A90030 Edition 0001 HYUNDAI Fuel Pump PlateP90901-0177 MAN B&W When referring to this page, please quote Plate P90901 Edition 0177 TI •-vi-vj-Ni~Ni-^cj)CJ)ci)cncX)C35CT)CT) TI C O "O c cDCDcoææcxiæ-vj Kl-^OiDOO^a^CO T3 c35.fi.roroocD^4^ Pi -DD-DCD-UO"DCJ) T3' «• £• 5J T3' 0 3 03 0 ocQ^. cü.^ y-cn 0 TD CD ^ 0cn iQr 3 =0=*•. iü0- ;5 0 CQ < 2 C 0 ^ S "ir^ : 0 (D Z3 03 3 CQ T3 D (D (A 0 2. •0' r* 5" 3 HYUNDAI Fuel Pump Gear Plate P90902-0153 MANB&W P90905 P90913 When referring to this page, please quote Plate P90902 Edition 0153 c o Ü w O E (O E O Q. E 3 Q. 3 % a. c E o o Ü CD CD •g cn -q c u '•3 C3) (A C3) to tD 0) cn C CD cn x CL O 0) w c to to to to CO CO I Q. CD .n. ^- tD c c CD (D Ü cn cn CO cn in E O C) > Ü CD c 0 Q . (0 •O o O c c : tn _ tD c CD c o o to to X o ^-. c: E - 2 E CO C ')_ • E cn "CL O) ! l cn l^"c5n cn Ü "c:. O) 'CL P O ) en CD cn CM r 'CL-Q 0 O ) 1 - c CD cn cn •— 5.C.Ec CO g c c ^^ (D m (D ^ 0 0 5 CD .E c Q. 1^ cn O Ü O 3 CD to to c 2 o - o c o CD t o tn CO = t o ;u ?-S o - E c: Ü 10 O) ^ "5 3 _t O 3 n c ; g 0 3 _ _tO Ü CO 3 o Ü Ü i5 o 13 ^ 2 r (- .!=>—.= —'—'vj—'_)0.ii:Cja)_)>-u—'WL^UJ:ii^O^—'-J-'towj^uo 3 t o i — - ^ CD o LL C O CL C L CO ^C C" CQ Q C O O h- CC CD 'u o P 3 CO C O CO Q CO cr> Q |CLOOCOCDCD_IU.COCOCQÜ2C/)COCOLLI_ICOZCLCLCLOLJ-COQC O Q. 0) CM'3-COOO-^COU^I^KO-<3-COT-COlOI^OCM- 013 When referring to this page, please quote Plate 90904 Edition 0057 Plate 90904-0057 Fuel Pump - Details Item Item Item Description Item Description No. No. 013 Shock absorber, complete 025 Spring guide 037 Bottom flange, complete 049 Packing 050 Plug screw 062 Nut 074 Locking washer 086 Stud 098 Spring, left-hand 108 Spring, right-hand 121 Packing 133 Sealing ring 145 Stud 169 Screw 170 Packing 182 Housing 194 Wearing ring 204 Piston 228 Plug 241 Nut 253 Washer 265 Bracket 277 Screw 289 Actuator 290 Banjo coupling 300 Screw 324 Guide screw 336 Toothed rack for regulation 348 Felt ring 361 Pointer 373 Toothed rack for timing 385 Forked lever 397 Nut 407 Union nut 419 Circlip 420 Pin 432 Forked head 444 Forked head 456 Adjusting screw 468 Nut HYUNDAI Reversing Mechanism Plate P90905-0025 MAN B&W When referring to this page, please quote Plate P90905 Edition 0025 Plate P90905-0025 Reversing Mechanism Item Item Item Description Item Description No. No. 019 Shaft 020 Guide for reversing 032 Distance pipe 044 Self-locking nut 056 Guard 068 Screw 093 Cover 103 Screw 115 Bolt 127 Flange for air cylinder 139 Reversing mechanism, complete 152 Screw 164 Bush 176 Air cylinder 211 Screw 223 Union 235 Reducing socket 247 Ball valve 259 Union HYUNDAI Fuel Valve Plate P90910-0148 MAN B&W When referring to this page, please quote Plate P90910 Edition 0148 Plate P90910-0148 Fuel Valve Item Item Item Description Item Description No. No. 016 Thrust piece 041 Cut-off shaft 053 Spindle guide 065 Nozzle 077 Spindle guide, complete 089 0-ring 090 Holder, complete 100 Guide pin 112 Union nut 124 0-ring 148 0-ring 161 Valve head 173 Guide pin 185 Spring 197 Non-return valve, complete 219 Thrust spindle 220 Spring 232 Spring guide 244 Thrust foot 268 Disc 950 Additional disc, +30 bar* Note: * Optional extras HYUNDAI Fuel Valve Function Plate P90911-0022 MAN B&W 4 2 * 3 1^ When referring to this page, please quote Plate P90911 Edition 0022 5 5F *-• fi) Pi o p a ="0 Z o(O 5. f^ o - o (O 6 "1 A I < (D C (T> 3 O o" 3 3 o O O 3 HYUNDAI High-Pressure Pipes Plate P90913-0129E MAN B&W 132 .1 ' • 1. 073 156 When referring to this page, please qoute Plate P90913 Edition 0129E Plate P90913-0129E High-Pressure Pipes Item Item Item Description Item Description No. No. 012 High-pressure pipe, complete 024 Union nipple 036 Thrust bushing 048 Union nut 061 High-pressure pipe 073 Flexible hose, complete 097 0-ring 107 Union nipple 119 0-ring 132 High-pressure pipe, complete 156 High-pressure pipe CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR COMPONENTS uX EXHAUST VALVE Q FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS o O) 910.01-55 Air System of Engine (Regarding the turbocharger, see the producer's special instructions) The engine is supplied with scavenge air water mist catcher and the non-return valves. from one turbochargers mounted at the aft end of the engine. The receiver and the cylinder frame communicate through circular openings. Alternatively, one or two turbochargers may be located on the exhaust side. The two auxiliary blowers are placed at the aft end of the air cooler housing. The suction The engine exhaust gas drives the turbine side of the auxiliary blowers is connected to wheel of the turbocharger and, through a the space before the non-return valves in the common shaft, the turbine wheel drives the air cooler housing. The discharge side is compressor wheel. connected to the scavenge air receiver via a non-return valve, in order to prevent reversed air flow. See also item, "Non-return valves", The compressor draws air from the engine further on. room, through air filters. From the compressor outlet, the air passes through the charging air pipe to the charging air The scavenge air receiver is provided with coolerfP/ate 91005) where the air is cooled man-hole covers and also a safety down. valvefP/ate 91103). The charging air pipe, with compensator, is Running with Auxiliary Blowers insulated and can be clad internally with a sound-absorbing material. During starting of the engine, and when the engine is running at low load the The air is designed to separate condensate turbocharger is not able to supply enough air from the air. See also 'Charging Air Cooler' for the engine process. In these cases a in this Chapter pressure switch will automatically start the auxiliary blowers. The air is pressed into the scavenge air receiver through non-return valves mounted When the auxiliary blowers are operating, In the air cooler housing after the water mist they draw air from the engine room through catcher. The non-return valves (flap valves) the turbocharger's air filter and compressor open by pressure from the turbocharger. side. From the scavenge air receiver, the air flows This enables the turbocharger to maintain a to the cylinder through the scavenge air ports reasonable number of revolutions during when the piston is in the bottom position. starting and at low load. When the exhaust valves open, the exhaust gas is pressed into a common exhaust gas The air passes through the charging air pipe, rece'wer(Plate 91003), from where the gas the charging air cooler, and the water mist drives the turbine of the turbocharger with an catcher, to the suction side of the blowers. even and steady pressure. From the blowers, the air is discharged to the scavenge air receiver via non-return Scavenge Air Receiver valves. Plate 91001 The non-return valves fitted in the air cooler The scavenge air receiver is a container housing are now closed due to partial vacuum and gravitation acting on the valve flaps. having a large volume. The receiver is bolted on to the cylinder frame. A lack of air supply will occur if the Scavenge air is collected in the receiver after non-return valves do not close. the air has passed through the cooler, the 910.02-55 Non-Return Valves led to the exhaust gas receiver where the pulsatory pressure from the individual exhaust It is of the utmost importance that the valves is equalized and led to the non-return valves of the auxiliary blowers turbocharger at a constant pressure. always function correctly and move easily. This can be checked by moving the valves The exhaust gas receiver is fastened to the manually, e.g. in connection with the regular seating by flexible supports. Compensators scavenge port inspections. are inserted between the receiver and the exhaust valves, and between the receiver and The non-return valves protect the blowers and the turbocharger. engine during: Inside the exhaust gas receiver a protective • Starting the auxiliary blowers grating is mounted before the turbocharger. • Running with auxiliary blowers. For quick mounting and dismounting of the Starting the auxiliary blowers: joints between the receiver and the exhaust valves, clamping rings are used to hold the 1) Owing to the relatively high starting current, parts together. The exhaust gas receiver and the blowers start in sequence, with 6-10 the exhaust pipe are insulated. seconds in between. The exhaust receiver may be provided with The non-return valve of the blower that has by-pass flanges for : not yet started must be in the closed position to prevent the blower from rotating • Emergency running without turbochargers backwards. Otherwise, there is a risk of burning out the electric motor when it • Improvement of fuel consumption at part starts. load 2) If an auxiliary blower fails to start, the Turbo Compound system (TCS). non-return valve must be in the closed position. Otherwise, the operating blower will not be able to draw fresh air in Charging Air Cooler through the turbocharger and air cooler. This is due to differences in the air flow Plate 91005 resistance. The charging air cooler insert is of the block Running with auxiliary blowers: type. It is mounted in a housing which is welded up of steel plates. In the event of failure of an auxiliary blower during running, the non-return valve must The cooler housing is provided with inspection close to ensure the continued supply of fresh covers. air to the engine. See 'Starting the auxiliary blowers' , Item 2, The air cooler housing has been prepared for above. cleaning of the cooler insert without removing it. This is achieved by means of a built-in Exhaust Gas Receiver spray-arrangement. See also Vol. II, 'Maintenance' , Chapter Plate 91003 910. From the exhaust valves, the exhaust gas is The cooler is designed with an air reversing 910.03-55 chamber which has a water mist catcher incorporated. The water mist catcher is built up of a number of lamellas which separate the condensation water from the scavenge air during the passage of the air flow. The separated water is collected in the bottom of the cooler housing from where it is removed by a drain system. Caution ! It is important to check that the drain functions correctly, as otherwise water droplets may enter the cylinders. See Volume. /, OPERATION, Chapter 706, 'Cleaning of Turbochargers and Air Coolers' An alarm device for high water level in the drain system is installed. El. Panels for Auxiliary Blower See special instructions supplied by the engine builder. HYUNDAI Turbocharger System Plate P91000-0016 MANB&W Running on Auxiliary Blower When referring to this page, please quote Plate P91000 Edition 0016 HYUNDAI Scavenge Air Receiver Plate MAN B&W P91001-0172 150- -221 When referring to this page, please quote Plate P91001 Edition 0172 Plate Scavenge Air Receiver P91001-0172 Item Item Item Description Item Description No. No. 017 Screw 029 Guard 030 Screw 054 Spacer 066 Screw 078 Scavenge air reciever 091 Packing 101 Plug screw 113 Plug screw 137 Sectional iron 149 Sectional iron 150 Stud 162 0-ring 174 Plate 186 Plate 198 Stud 221 Nut Note: HYUNDAI Arrangement of Charging Air Pipe Plate P91002-0120 MAN B&W When referring to this page, please quote Plate P91002 Edition 0120 roru-'-^-^-^-^ooooooo a> -^OCOCJl-P^-^OCOCX3C3)-ti. O 3- (D O) (O 5" (Q •O 3 Ö (D tf) O O 3 HYUNDAI Exhaust Pipes and Receiver Plate P91003-0176 MAN B&W When referring to this page, please quote Plate P91003 Edition 0176 Plate P91003-0176 Exhaust Pipes and Receiver Item Item Description No. 018 Nut 031 Screw* 055 Plug screw 067 Gasket 079 Packing 080 Compensator 092 Grid 102 Exhaust receiver 114 Wing nut 126 Plate 151 Insulation cover 163 Wing nut 175 Nut 187 Insulation cover 199 Screw* 209 Gas inlet 210 Packing 222 Plug screw 234 Gasket 246 Rivet 258 Insulation material 271 Manhole cover, complete 283 Packing 295 Clamp 305 Ditance pipe 317 Screw* 330 Washer 342 Split pin 354 Hinge rod 366 Insulation plate cover 378 Heating shield 391 Screw* 401 Screw* 413 Lock washer 425 Nut 437 Stud 449 Packing 450 Insulation cover 474 Compensator 486 Plate 498 Gasket 508 Plug screw 521 Gasket 533 Plug screw 545 Plug screw 557 Gasket Note: * These screws are special screws for hot joints, they are marked with a "T", and MUST NOT be used elsewhere! HYUNDAI Exhaust Receiver - Details Plate P91004-0052 MANB&W 108 When referring to this page, please quote Plate P91004 Edition 0052 Plate P91004-0052 Exhaust Receiver - Details Item Item Description No. 013 Distance pipe 025 Screw* 037 Support 049 Nut 050 Screw 074 Spring pin 086 Spring pin 098 Clamp 108 Support 157 Distance pipe 169 Shim 170 Spring plate 182 Clamp 194 Spring pin 204 Washer 216 Screw* 228 Screw 253 Nut 265 Support 277 Screw Note: * These screws are special screws for hot joints, they are marked with a "T" and MUST NOT be used elsewhere ! o C«4 in o o O) Q. O Q. c .o •5 ÜJ o O Ol O O o. CD O. •ä o Cr CD CD CD CDI C c CD -C o o 2 -p^ -^ Ji. CD P i (D TJ •D ^" * Z (O 03 CD < o 03 -• O CD S Z^ •3 C1D S•• O O "Cl 3 ™ R 0 O cn -^ IH? 1—^ —. (D X CD 3 CD ii; 03 rS. O .-• CQ i-t CD o !=*• W 3CD^ * (A CD -a o 0) •^ i CD •5' ^ "0 c 03 O^ ' g-^ 3 ^^ —h c o -1 -< CD ^* -i_ =J- cn" c/3' o o (D (O o 3 O o (I) o o 3 HYUNDAI Arrangement of Auxiliary Blower Plate P91006-0047 MAN B&W 087 099 When referring to this page, please quote Plate P91006 Edition 0047 Plate P91006-0047 Arrangement of Auxiliary Blower Item Item Item Description Item Description No. No. 014 Cam locl< washer 026 Screw 051 Washer 063 Nut 087 Auxiliary blower* 099 Auxiliary blower* Notes: * When ordering spare parts for this item, please state manufacturer's Part No. oCO o o I CO CM r\ ) •* ^ CO LO r - 0^ ^ o o^ o ^ CM ro LO OD r - lo o r\j ro roi r ^ ro CM OJ CM r ^ O) Q. o a. @1[^ i- C3 0o0 o U o O c .o Ol]^ o00 o Oi E o. 0) *•> •S w CL >. en O o- ©cz V) c O) 75 cu 0) CD CT3 O) Q. .to 5 in 1^ 0^ o ^ CM n -^ C o o o o c Plate P91008-0008 Sealing Air System for Turbocharger Item Item Item Description Item Description No. No. 015 Coupling 027 Adaptor 039 Ball valve 040 Drain pipe 064 Packing ring 076 Screw 088 Nut 123 Packing ring 135 Screw 147 Coupling 159 Drain pipe 160 Packing ring 172 Screw 184 Lubricating oil pipe 196 Plug screw 218 Steel pipe 231 Coupling 243 Lubricating oil pipe 255 Screw 267 Nut 279 Packing ring 292 Screw 302 Nut 314 Packing ring 326 Lubricating oil pipe 338 Sight glass 351 Plug screw HYUNDAI Air Cooler System - Cleaning Plate P91009-0055 MAN B&W When referring to this page, please quote Plate P91009 Edition 0055 Plate P91009-0055 Air Cooler System - Cleaning Item Item Item Description Item Description No. No. 010 Plug screw 022 Hose connection 034 Ball valve 046 Nipple 058 Packing ring 071 Screw 083 Plug screw 117 Plug screw 129 Butterfly valve 130 Plug screw 154 Butterfly valve 166 Blank flange 191 Adjustable elbow coupling 213 Steel pipe 237 Adjustable t-coupling 249 Adjustable straight coupling 250 Ball valve 262 Stuaight stud coupling 286 Blank flange HYUNDAI Air Cooler Frame Plate P91010-0025 MANB&W 016n 077 089 089 124 A-A B-B V \ \ \ V =?r=^ S-* 435- 435 352 Y388 447- 459 / L4I 1 ^423 364 ^3E L4: TT7r=11 When referring to this page, please quote Plate P91010 Edition 0025 Plate P91010-0025 Air Cooler Frame Item Item Description No. 016 Stud 028 Nut 041 Cleaning pipe 053 Spray nozzle 017 Cover 089 Screw 112 Cover 124 Cover 148 Packing 161 Plug screw 173 Plug screw 197 Cover 207 Air cooler frame 220 Plug screw 232 Jacketed packing 244 Cylindrical dowel 268 Screw 281 Flow controller 303 Screw 315 Distance pipe 327 Nut 352 Angle profile 364 Angle profile 388 Screw 411 Washer 423 Angle profile 435 Screw 447 Plate 459 Plate HYUNDAI Arrangement of Non-Return Valve Plate P91011-0032 MAN B&W 01 1 When referring to this page, please quote Plate P91011 Edition 0032 Plate P91011-0032 Arrangement of Non-Return Valve item Item Description No. 011 Shaft 035 Disc 047 Cam lock washer* 059 Screw 072 Sealing ring 084 Sliding bearing 096 Valve flap 118 Spring pin 131 Holder Note: * Cam lock washers are only to be supplied by MAN B&W Diesel HYUNDAI Arrangement of Non-Return Valve Plate P91011-0033 MAN B&W When referring to this page, please quote Plate P91011 Edition 0033 Plate P91011-0033 Arrangement of Non-Return Valve Item Item Description No. 011 Holder 023 Spring pin 035 Shaft 059 Screw 060 Cam lock washer* 072 Disc 096 Sliding bearing 106 Sealing ring 131 Valve flap 143 Sliding bearing Note: * Cam lock washers are only to be supplied by MAN B&W Diesel CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR COMPONENTS X EXHAUST VALVE aLU FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT O) ASSEMBLY OF LARGE PARTS a> 911.01-16 Safety Equipment Safety Valves - Relief Valves Safety Cap in Starting Air Line On the exhaust side of the engine a number If the bursting disc of the safety cap is of spring-loaded relief valves are fitted, which damaged due to excessive pressure in the will open in the event of an excessive pres• starting air line, overhaul or replace the sure arising in the crankcase, for instance as starting valve which caused the burst, and a result of the ignition of oil vapour. mount a new disc. Regarding how to : If a new disc is not available immediately, turn the cover in relation to the cylinder, in order to • avoid evaporation of the lubricating oil, reduce the leakage of starting air. • detect oil mist using an 'Oil Mist Detector' See Vol. I, OPERATION Chapter 704 Note ! Mount a new bursting disc and return the Warning I cover to the open position at the first Do not stand near crankcase doors or opportunity. relief valves - nor in corridors near doors to the engine room casing in the event of an alarm for: a) oil mist b) high lube oil temperature c) no piston cooling oil flow, or d) scavenge box fire Alarms b, c and d should be considered as pre-warnings of a possible increasing oil mist level. See also out Service Letter SL97-348/ERO The scavenge air receiver is fitted with a safe• ty valve which is set to open should the pressure in the scavenge air receiver exceed a value somewhat higher than the normal scavenge air pressure of the engine. In some cases it may be necessary to open the valve manually, see Vol. I, Chapter 704, "Turbocharger Surg i rig". Each starting valve inlet pipe is provided with a safety cap. The safety cap consists of a bursting disc enclosed by a perforated cylinder and a perforated cover in order to protect any bystanders, in the event of a burst. The cover is provided with a check plate, which shows if the bursting disc has been damaged. HYUNDAI Relief Valve Plate P91102-0028 MAN B&W P.C.D When referring to this page, please quote Plate P91102 Edition 0028 O O O O fl) Ol Ji. NO _». GO -». 00 03 ^1 * z :t] c? ^ o O;? ^ ^ A =^ q $2. ,3 ^ 9 CO O ro X -> o »CQ * < ro » 03 o < o 3 73 i. ro R ro 3 ro 3 TI O 00 3 ro=:c -Q ro O w b o ro CD 03 03 tf) Ol o äS 3 3 ro 3 B * O) 3 3D 1 2. < Si. < P i ro 3 a ro v> o o 3 HYUNDAI Safety Valve - Scavenge Air System Plate P91103-0018 MAN B&W on 060- 072- 4.7 Bar abs 035 155 When referring to this page, please quote Plate P91103 Edition 0018 _»._>._>._i._>.0000000 0) cn^co-»^oco~>JO>ui-c>.co-i- oico->-ooa)c3)MOCD-sicn->^ ^1 ^CD CD ----^^^~ro_Ä O Cd o 3 o -1 o O 00 o 3 CA T3 O CD ^ CD •O r* O Q) 3 O < < o o < (D 3 O CO (D •< (O 3 ••+ o (D n (A o 3 o 3 HYUNDAI Arrangement of Safety Cap Plate P91104-0063 MAN B&W 017 < When referring to this page, please quote Plate P91104 Edition 0063 Plate P91104-0063 Arrangement of Safety Cap Item Item Description Item Item Description No. No. 017 Bursting cap, complete 029 Fitted bolt 030 Check plate 042 Wing nut 054 Screw 066 Washer 078 Bursting cap cover 091 Perforated cylinder 101 Housing 113 Bursting disc 137 Starting air pipe, complete 150 Gasket 162 Nut 174 Screw 186 Safety cap 198 Screw CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER AND CYLINDER LUBRICATION CROSSHEAD WITH CONNECTING ROD CRANKSHAFT, THRUST BEARING AND TURNING GEAR MECHANICAL CONTROL GEAR STARTING AIR COMPONENTS uX EXHAUST VALVE Q FUEL OIL SYSTEM TURBOCHARGER SYSTEM SAFETY EQUIPMENT ASSEMBLY OF LARGE PARTS CM O) 912.01-58 Assembly of Large Parts Bedplate, Framebox, etc. temperature and flow, and for temperature and flow alarms, is installed in conjunction The bedplate is made in one section, with the outlet pipe. consisting or two welded, longitudinal girders See also Vol. I, OPERATION, Chapter 701. and a number of cross girders which support the main bearings. The main bearings, which The bedplate of the engine is positioned on are of the thin-shell type, consist of steel either epoxy or cast iron supporting chocks shells, lined with tin-aluminium and coated and bolted to the engine seating in the ship with a tin-flash layer. by means of long holding-down bolts, which See also Vol. I, OPERATION, Chapter 708. are equipped with distance tubes of cast iron. Each main bearing has one main bearing Plate 91215 shows the holding-down bolts, caps which is secured by four studs and nuts, which have spherical washers and nuts with designed for tightening by means of hydraulic spherical contact face on the lower end of the tools. bolts. The contact faces of the topplate for the spherical washers must be plane. The aft end of the bedplate incorporates the thrust bearing as well as the chain drive. See The engine is secured in the athwartship also Chapter 905. direction by a number of side chocks fitted in both sides in way of bedplate crossgirder. The At the foremost end of the bedplate, an axial side-chock liners are tapered 1:100 and are vibration damper is fitted. (Plate 91211). fitted from the aft end at both sides of the Regarding the design and functioning of the engine. axial vibration damper, See Chapter 905. The side-chock liners are secured in their A framebox is bolted on to the top of the correct position by means of inside-hexagon bedplate. Like the bedplate, the framebox screws. consists of one section with the chain drive located at the aft end. Together, the bedplate The engine is secured in the fore-and-aft and the framebox constitute the crankcase of direction by one end chock with one the engine. end-chock bolt with spherical washer at the aft end of each of the two longitudinal girders The framebox is fitted with steel-plate doors of the bedplate. The end-chock liners have a for access to the crossheads and to the main 1:100 taper and are fitted from above. and crankpin bearings. Regarding the engine seating for the specific The bedplate, the framebox, and the cylinder engine, see the supplier's special instructions. frame, which rests on top of the framebox, are tightened together to form one unit by means of stay bolts, the bottom of which is screwed into the bedplate. For each cylinder, the framebox is equipped with a slotted pipe in which the piston cooling oil outlet pipe fitted to the crosshead is able to travel. From the slotted pipe the cooling oil is, through an outlet pipe, led to the oil tray of the bedplate. Equipment for local checking of the cooling oil HYUNDAI Arrangement of Stay Bolts Plate P91201 -0093 MAN B&W 014 When referring to this page, please quote Plate 91201 Edition 0093 2 Co» -o^ CJo l CoO Mo -o^ z sr u ^ CJl -»• c» (3) -t^ P i o CD W Z TI O) O) O) 3 CO 3 o w o o 3 HYUNDAI Frame - Details Plate P91204-0035 MAN B&W 213 225 "^JOII I Ijyi lO^r^ A When referring to this page, please quote Plate P91204 Edition 0035 Plate P91204-0035 Frame - Details Item Item Item Description Item Description No. No. 010 Lubricating oil pipe 022 Lubricating oil pipe 034 Oil pipe for damper 046 Oil pipe for damper 071 Bracket 083 Screw 095 Bracket 105 Lubricating oil pipe 117 Nut, self-locking 129 Stud 130 Screw 142 Pipe clamp 154 Screw 166 Screw 191 Pipe holder 213 Screw 225 Oil pipe for damper 286 Spacer, tubular 298 Stud 308 Nut, self-locking CO oin CM T- a. 0) *-• iS 1 < Q. I 2 < o CO 0^ o rvi •^ lO vO 1^ CO •* ^ -* •4 c: X .o O QQ § O LO r~ - a> o oj o c\j Q c\j ro o •.- •>j in CNJ E ro ro •«- '- ro ro T— (0 CJ5 v_ CL. U. ai ro •<* 00 ro in •^ CM o Ol o Ol o o- 0) to CC Q) "5. oT D5 CC CL .CO -C ^^ Ol o o Cvi •* C35 CO 0> C o o o •^ Ol c CD tn^^ji.ji.j^cococooococorororotvj-^-^-i-' -^ooooooo ooo^o)c;i-j-oo^tn-ti-coi\)C7i*>.co-^oojs.iv)-^ OCD0005tn->.M-». ?? Q) CJ)-fi.l\3OCD-^CD(3^l\DOCD^C35-t>.r0CDtn00-^l\D oocDcnw-^ooc:^ I-» o OWSOMOtJOTlW WOODTlÜDC/DO'DOZWCO-n TI 03 O O -o 9c^o"ao3^o5o O O 03 m ?" 05 O 3 O 05 0) (O O CO (Q < Q. CD Q. cn CQ -5" ro —^ ro TT CD 3 2: •=>' 3 3 3 (O CD CD CD CD CD o m' I—•- —< CD L. C) CT !T Ol (n •D Q. (--D\ 0 O O O CD 0 X O X (D CO Q. 3 —^ O CO CD O CD o 05 05 (D tf) O O 3 fi> 3 o CO o 3 3 a (D tf) O O 3 HYUNDAI Arrangement of Piston Cooling Plate P91207-0082 MANB&W _L_i._i_i-i.oOOOo O 2 Qo-sicn-u-'co^ocnji.ro * * fi> CJ3-fi.OCDCO-iOOCJ)-t^t\3CD O •O (O zcoDCocncjgüJCowa) ro o -si "* ( u -o " ^ " O ^ ? • (T> O "' C Q C D C Q 3 -— • 3 o c s o 00 (D lO o (0 •—• o ^ TO I-* o Q) 3 3 (O (D 3 (D 3 31 w" P g O 3 O o o_ 5" CQ 3 D (A o O 3 HYUNDAI Chain Wheel Frame - Upper Plate P91208-0005 MANB&W When referring to this page, please quote Plate P91208 Edition 0005 2 c3^CT)CJ)cnCT)CJ)cntncncjicjicn-P>--P>.-ti.ji.-^-P>.-^cocococotoi\ororv3r\ot>ot>o-t-^-i-^-^ooooooo Z cDoocn.>.co-^cooocj)Co-^oco-vic3)cnco-^ococ!>-;i.tv)oo-vicn.ti.ro-^ooocnco-^oco-^cj)-ti.coro-^ O ü^(JOOoo)-P^oco-^lCJOo-l^^^^3CD^cn-^ooc:>cJ)0•vlcoooo)^^o^alCo-^CJ)^^cD-^I~>JCo-toocJ5•^^o ^ m (D 13 <£> o o -p Dwæoo^æzac/jzawcoooocnæwwr-wWOWOOOWTIZOCOCOa g O æ T] o _x C^ 0) o o o £D -H o CO c /"i ^- ^*^ /^ *— 1»^ £<"•=• ^T"C r~C en^- ' *"•• f^ ^j- 03 N3 £2. DJ ?r QTI^CD CL > ^CD C2.C3.C D ^CD rmf /T( s o Ci.t Q -& CD 03 en O o s < "" CD c < 13 00 "* ^<- m O O x; -* cQ o O CD • CD cn =1 CD =;• .-CD CD 3- CD CL m o -D C •o •O S. "D CD D3 •g 0 o TJ "D O "O T3' CD CD CD 3 o 0 CJ1 03 D (D 3 (A CD O C •5" T3 CD I-f 5" 3 o 3r a 5" o (D ?ff 0) 3 CD 3 D (D (A O O 3 HYUNDAI Bedplate Plate P91210-0108 MAN B&W 013 037 086 145 098 157 108 216 121 228 When referring to this page, please quote Plate P91210 Edition 0108 Plate P91210-0108 Bedplate Item Item Description Item Item Description No. No. 013 Nut 037 Stud 050 Screw 062 Bedplate 086 Main bearing cap 098 Spring pin 108 Main bearing upper shell 121 Main bearing lower shell 145 Screw 157 Grate 194 Locking plate 216 Screw 228 Cover plate HYUNDAI Axial Vibration Damper Plate P91211-55 MAN B&W >235 When referring to this page, please quote Plate P91211 Edition 55 Plate P91211-55 Axial Vibration Damper Item item Item Description Item Description No. No. 019 Spring 020 Spring 044 Screw 056 Restriction for damper 081 Restriction for damper 093 Restriction for damper 103 Screw 127 Oil seal in 2/2 139 Oil seal in 2/2 164 Nut 176 Nut 188 Stud 211 Stud 235 Axial vibration damper, housing, complete 259 Damper housing, upper part 260 Guide pin 272 Damper housing, lower part HYUNDAI Holding-Down Bolts and End-Chock Bolts Plate MAN B&W (Epoxy Chocks) P91216-0017 When referring to this page, please quote Plate P91216 Edition 0017 Plate P91216-0017 Holding-Down Bolts and End-Chock Bolts (Epoxy Chocks) Item Item Item Description Item Description No. No. 028 Screw 041 Washer 053 Locking plate 077 Liner for side chock, port side 089 Liner for side chock, starboard 100 Liner end chock 112 Spherical washer 124 Spherical washer 136 Nut for hydraulic tightening 148 Protective cap 173 Protectice cap 185 Nut for hydraulic tightening 197 Distance pipe 219 Spherical washer 220 Spherical washer 232 Holding-down bolt 256 Stud for end chock bolt S912-36 Top Bracing of Main Engine (Shipyard work to be carried out against special order only) By means of top bracing the main engine, it If ascertaining relative movements larger than will in most cases be possible to obtain such ±0.02mm, increase the tightening by 40%(at a high natural frequency of the system all top bracings). At the same time, observe at "engine - ship's side - ship's bottom" that which tightening torque the nuts at all top annoying vibrations of the engine top or ship's bracings, are loose. If the relative movement hull will be eliminated. (after having increased the tightening torque) has still not disappeared, increase the Top bracing is usually mounted on the tightening torque with an additional of 40%, uppermost platform brackets on the starboard and again observe the loosening torque at side (rear side) of the engine, and is executed each bolt. as shipyard work in accordance with our principle drawing. After some time in service the top bracing might become ineffective (due to setting or The top bracing, including the friction shims, wear of the friction material). The tightening should be checked at the same intervals as should therefore be checked (as described apply to the holding-down bolts in order to above) if: ensure that the tightening force is correct. 1) Unexpected change of level of hull - Bolts for top bracing are to be tightened by vibrations are observed, or means of a torque wrench. As regards tightening force, see drawing No. 785310-4. 2) The turbocharger(s) start to vibrate intensely. When during the trial trip the engine has If the above-mentioned is not observed, the reached its working temperature, the two bolts checking should be carried out once or twice for the frictional assembly of the top bracing a year. are loosened. After approximately one minute the bolts are tightened again. This procedure To check the setting of the ship (alteration of is carried out for each individual top bracing. full form) in relation to the top bracing, mount a device which enables a possible setting to If one or more links are omitted, the tightening be measured by means of a dial gauge, as torque of the remaining links are to be shown on drawing No. 782561-5. Two pieces increased accordingly. If, for example, 4 links of square bar iron can, for instance, be are specified and 1 is omitted, the 3 welded to the topbracing and the fastening=on remaining links are to be tightened by 33.3% point on the casing so that, after marking with extra. The tightening should be checked as e.g. a centre punch, they together form a follows : well-defined measuring distance. A suitable distance between the measuring points would Check if relative movements occur between be 200 mm. top bracing and fastening plate (casing side or guider). This can be carried out by placing a Checking for possible settings of the ship's dial gauge (or similar) as shown on drawing hull should be made 3-4 times a year. In the No. 782561-5. Carry out checking of the top case of tankers, further measurements should bracing at the forward end, the centre, and be taken after loading and unloading, and the aft end of the engine. also when the ship has had a rough trip. Any movement can also be measured by The draught of the ship should be noted at means of, for instance, an ASKANIA each measuring. If exceptional deviations are vibrograph with a high gear ratio, fastened to ascertained, special precautions are to be the top bracing with the contact point touching taken. the casing. ij;;.g^j.i;'::5::.T;"}.J't.:-2;:n.. !•>« 9f«»arlr •' '-'-••^ •fü-;:.i:."":iK;-!;:'n'i=:i,::: r':u:; ::.t!::-:,::^:.'i:?n:'.-!.'a.:!5i''i!:; s:::?.. «I sgg eaaais«! wgoia« son a-jsoi ••£=• wawoi;» ts. HAI. ga «mu. oisraini ^>ii ng«w wswiia rawe ae •8Suo. Bolts for top bracing ore to be tightened by meons of o to rque wrench . The bo Its ot the ennqin e side ore to be tightened to 470 Nm. The bo Its at the hull side are to be tightened to 120 Nm. When during the triol trip the engine has reoched its working temperature, the two bolts for the frictionol assembly of the top broclng at the hull side are to be loosened'. After approximately one minute the bolts are tightened again. This procedure is to be corried out for each individual top brocing. Moke sure thot the beams are supported in the vertical direction during this operation. The tightening should be checked as follows: Check if relative movements occur between top bracing ond fastening plate (cosing side or girder). This con be carried out by pTocing o dial gouge (or similar) as shown on drwg. No. 0/88449-9. Corry out checking of the top brocing at the forward end, the centre, and the oft end of the engine. If relotive movements lorger than t 0.02 mm ore ascertained, increase the tightening torque ot the bolts at the hull side to 215 Nm (at all top bracings). At the some time, observe ot which tightening torque the nuts ore loosened at oil top bracings. If the relative movement (öfter hoving increased the tightening torque) has still not disappeared, increase the tightening torque to 310 Nm, and ogoin observe the loosening torque ot each bolt. After some time in service top bracing might become ineffective (due to setting or wear of the friction material). The tighten• ing should therefore be checked (as described above) if: 1) Unexpected change of hull level - vibrotions are observed, or 2) The t u rbochio rge r (s ) start to vibrote intensely. If the above-mentioned is not observed, the checking should be carried out once or twice a year. il „ SuppltiMnI 0>>9 no.! Pralaclian; Mot« (kfh Uolorlol / BIOAli: 10788449-9 Cleanior'a Idcnl. no.; Dlit.: LleofiBor't Uotorlol / Blonk: Q792358-4.0 Dal« Da«. Chk. Appd. A.C. E CHon90 / Roplacoatnl C.N« Roplacad by Idont. No.: 8S 'E a .il 980813IKJWISDCILSJI * U 0 Similar Orowing Ne.: RoploeoiMfit of Ident. No. Sea I a I Sil«: Typo: Poqo No.: A4 L-S5QMC/S50MC-C | 01 (01 ) A Into. Na.: OotcrIptIon: ld«nl. Ne.l 384618 TOP BRACING INSTRUCTIONS A14-166630-4 HSEF-li2IO-013(RI) i'asäsc?) i^nasf A4(2IO(in»297m)aait» • inf. I»««thar «llh (la twppltaaoti, •• Ih* prap*rt|r ol HHI-CUl gud •wiMtCl to C9fr'>t**' pr»l»cl(OA. Tha •olsr.al 1» «l»c*d al IK« «l«p»a«l «I Ih« r«clpl««l ••l«l|r ••n u»«. and anly Imt thd ««Aultclvfc, r«f«ir ar w«* B» «riaiiial HHI-Cia p.ftdwclt, «CCC'dini Itt G««(r*cl •' elhar «ritlan «arttiwnl hd«««« •ilh IMI-CW. Thd Mlvrl« , »ithtf mliallf tt pdrlfit, »d cdpidd. rdprdducdd. "odd pdblie »r id 0H|| dllidf ddy diddf dvdjigbid Id ddf Ihirpd parl|P ailhdul Ita arlltdn eMMHl U hil llliel >i»m milcia. 1M •ald'rial ;«,tl Ml id irddiiairid öriiöndid'dvirid da« Ikiid'porlv, ddilkdr drtit) nor bf luccddildd Id ikd >i|kid dl Idd idClriddiV Ol sgg tioassa wgiis» g«n> aggui oisgi «i3iiiii;i as- n«i. ra mm. »i££a»ni ¥gi M-.;aiii u^Kwn mate gg •ssuo. Transverse top bracing Forces from engine and a) b) minimum required rigidity Eng i ne bore of hull side. ±kN MN/m 98 248 230 90 209 210 80 165 190 a): Force per bracing 70 126 170 a t spec i f i ed numbe r 60 93 140 50 64 120 b): Minimum horizontal 46 55 110 r i g i d i ty. Ho r i zonta I i nsta II a 42 45 100 t i on of the Top 35 32 85 bracing is requ i red Suppt«m«nt Owg no.: Projaet ion: Uoia (k4): Uotariol / Blank: Ltconsor'a I danI. no.: Licanaor't Malarial / Blank: H 0792027-7,0 Ool« Das. Chk. Appd. A.C. E Chonqa / Rflplocanant C.No 8s Raplaead by tdant. No.: ^ tt «3 4 t 980808KJWSDCLSJ * • Sla>t lor 0roi>in9 Ho. |R«p)oc*«i«nl o I ld*nl. No. Scala I Si It is importont that the reinforcement is ploced so that it supports the top bracing in the centreline. ^Z3£S^ Correct Supptaawat Omit« na.: '•;acti»ll: atari«! / Slank: icans*r'( l««Mt. a»,i Licaniar'• Ustariai /Hi 0788443-9.0 Chama / Ki^lacaaiawl lUpiicarf by l«*At. Ha. l^'''•'•'• V Incorrect 11 »IMU tt ik* llaMMl •' tk« fMlylMl ••lalT ••< kit aw MM, «M «air fa' Iha vMrfaitttf«. fa#«ir «p •» M »fifiMi Mti-CW #ta*M(a. ataa'^ia« •>••«•* •*•< I* aap Ibltd «•«If. aaltlWf «Kaal >a( kr aMcaaaalM la IM 'ifkta al Ua »•cl»t*al. lRt»lK«Miil ør («aal. Ok.: ggj eoaggt »i?iiBM s»m »MM »SSM «BIWJI »E. nu. g« anu. weg«— »•• »g«» »3IBWI ;•»& Bl leauD. sTaäSär^a^wTTact r>M S.02a|o.l»|o.l|0.2|0.4|tt.l|l,l|s.l|l,3|l2.>| 29 | W |ifc'iiw laria^ 384608 Data for top brae i ng IA13-166601 •0^ HSEF.ki2tO-Ota|ltt) Safi3S(9) S^'AISS« O(420nMi2S7iw«iM:ii _LJi L_ _!!_! I L_ Top bracing «htould only be Inetalled on one liefe, either the exhouet eld« or the monceuvrino »Ida. If top bracing hcs to be instfll led on manoeuvring side, please contact KHI-EMD. Horizontal vibration« on lop of englns are caused by the guide force moments. For 4-7 cyHnder englnee the K-momenl Ts the nojor exc t tat Ion source ond for lorqer cy11nder nutnbere on X-moitient le the nwjof OKcitotion sou rce. Far enQinas vlih vibrotlons excUed t>y on 0 0 o cd X-moirent, bracing at the ««ntre of t^e engine are of only minor ieiportanea. 1 Top brocing la nornally ploced en exhoust side, bul con optionolly be ploced on monoeuvrIng e ide. 1 2 1 3 A C |r/cl : 0 0 I i I 2 1 3 j < S C |vc| Hor Izont0 I d1stonce bat we en top bracing r Ix point ond < CyI.I 0 - 425 b - 1275 c - 2125 1 2 3 U 5 6 C VC d - 2975 e - 3625 ( - 467S g - 5523 3 Oa e h " 6375 i 1 ^ ' ' ' f, 7 The complete orrcngement to be delivered by the «hipyord. 0 Oo b J J; i I 2 3 I 4 1 S I 6 7 8 C |l/c| Top brocIng Turbochor^g r /, Cent re I In« cy1 Inder r CyMniJ.r number 'Sn:fiKi-V.t>=^ \"t BEDSHdSS 3 snni ' PKTC:: «FT SIDE. I 01 (01 I ^mmm u tfi twit. n:m^** »rtm «r« >m» ll M. ei »^. nf'l Ml lilip" a |g.-mttbi±m:i-.ts~iÆ ^m TOP BRACING ARRA»4i;EMENT AIO-265365-6!