Instructions For Main Engine Type S60MC-C

This book must in no case be wholly or partially copied and published or passed to unauthorized persons without the permission of HYUN- DAI HEAVY INDUSTRIES CO., LTD. ENGINE & MACHINERY DIVISION.Instructions for Main Engine Type S60MC-C This book forms part of a set of books consisting of three volumes entitled: Vol. | OPERATION Vol. Il 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’ us 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 - 7780 B&W - 90201 - 00 - 059 10 off (piston ring) If the parts list indicates a ‘MAN B&W Standard No.’ this should also appear in your order. Furthermore, to ensure optimum efficiency, reliabilty and Ifetime 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 avallable to a third party without the written consent of this effect from H.H.1. ENGINE & MACHINERY DIVISION. Hyundai Heavy Industries Co., Ltd. Engine & Machinery Division 1, Jeonha-Dong, Dong-Ku, Ulsan, Korea http://wwew.hhi.co.kr Jies.hyundai-engine.com Engine Customer Support Dept. TEL : (82) (52)-202-7587~90 FAX : (82) (52)-202-7581 E-mail : enginecs okeA NY SYMBOLS DISMANTLE, REMOVE, WITHDRAW MOUNT, CONNECT, FIT UNSCREW, LOOSEN, TURN IN DIRECTION OF ARROW SCREW ON, TIGHTEN, TURN IN DIRECTION OF ARROW CONNECTION OF CRANE LOOSEN - TIGHTEN WITH HYDRAULC TOOLS, RAY ATTENTION, CHECK INDICATES DIRECTION, SHOWS DETAIL CLOSE VALVE, COCK OPEN VALVE, COCK LUBRICATE WITH PRESCRIBED LUBRICANT CLEANINDEX INTRODUCTION CYLINDER COVER PISTON WITH ROD AND STUFFING BOX CYLINDER LINER ... CROSSHEAD WITH CONNECTING ROD . CRANK SHAFT AND THRUST BEARING MECHANICAL CONTROL GEAR STARTING AIR SYSTEM ... EXHAUST VALVE .. FUEL OIL SYSTEM .. TURBOCHARGER SYSTEM . SAFETY EQUIPMENT .... ASSEMBLY OF LARGE PARTS GENERAL TOOLS . 900, - 901 - 902 . 903. . 904 . 905 . 906 . 907 - 912 - 913Cross Section Through Engine Plate 90001-54 HYUNDAI MAN Baw ‘S60MC-C 4. 0 ‘\HYUNDAI MAN Baw Checking and Maintenance Schedule, 26-70MC/MC-C Engines 900-1 The Checking and Maintenance Schedules indicate the intervals at which it is deemed appropriate to inspect the tual components of the engine and to carry out overhauls, if necessary, based on the engine condition or a criterion of time. The stated Regular checks or Service interval are intended primarily as a guide, as differences in the actual service conditions, the quality of the fuel oil or lubricating oll, the treatment of cooling Design modifications may necessitate a revision of the instructions, in which case the revised instructions and changed overhauling intervals, if any, will apply and supersede those originally issued (see e.g our Service Letters). In addition to the checking and overhauling intervals stated in this schedule, please note that the periodical survey requirements of the classification society may require additional checks and reference is made to be carried out, For further information reference is made to the classification society. water, etc., will decisively influence the actual service results, and thus the intervals between necessary overhauling The procedures are divided into five categories: Time-based condition checking procedures marked with a C, under the heading Regular checks or Service interval, deal with the service condition of a number of engine ‘components, and form the basis for estimating whether further ‘overhauling is necessary. In a number of cases the condition checking procedures refer to Volume I of the instruction book, in which more detailed descriptions and working procedures can be found. Condition-based overhauling procedures are marked with an O, under the heading Regular checks or Service interval. Under the heading Refer to (column P), a reference to additional information is stated. This procedure number normally refers to one of the above condition checking procedures which form the basis of the overhaul. For this reason, the intervals stated are for guidance only. Time-based overhauling also marked with an O, under the headings Regular checks or procedures Service interval or Based on observations, are the procedures where an actual basis for estimation is lacking. It is recommended, therefore, to carry out these procedures at the overhauling intervals stated as a basis. The letters O or C in Based on observations (column 8), indicate that special service conditions may make checking or overhauling necessary beyond the actual standard schedules indicated. (continued) When referring to this page, please quote Maintenance Schedule A900SO Edition 0298 Page 1 of 6900-1 Checking and Maintenance Schedule, 26-70MC/MC-C Engines | HYUNDAI MAN B&W. Initial checking procedures Initial adjustment procedures marked with a C, under the heading Check new/overhauled parts at 500, 1000 and 1500 hours (column H), deal with initial checks that must be carried out on a new engine, or when parts. have been replaced. After the three initial checks have been completed, checks need only be carried out as per heading Regular checks or Service interval. When using electronic maintenance planning systems, special attention should be paid to all initial checking procedures, as handling of such procedures often can not be done automatically Instead such procedures must be handled manually. marked with an A, under the heading Check new/overhauled parts at 500, 1000 and 1500 hours (column H), deal with initial adjustment that must be carried out on a new engine, or when parts have been replaced, Alter the three initial adjustments have been completed, adjustments need only be carried out as per headings Regular checks or Service interval. When using electronic maintenance planning systems, special attention should be paid to all initial adjustment procedures, as handling of such procedures often can not be done automatically. Instead such procedures must be handled manually. ‘Special attention should be paid to the chain tighten which must be adjusted three times (at 500, 1000 and 1500 hours of operation) on a new engine, or when chains or | chain wheels have been replaced. Pee ee eee eee Page 2 of 6 When referring to this page, please quote Maintenance Schedule AS0050 Euition 0296HYUNDAI MAN B&W Checking and Maintenance Schedule, 26-70 MC/MC-C Engines 900-4 [V = See Volume | “Operation” JA : Adjustment to be carried out Mi: See makers instructions © : Overhaul to be cartied out R : Parts to be replaced B : Based on observations | 901 Cylinder Cover Indicator cock | 902 _ Piston with Rod and Stuffing box Sa sr and Cylinder Lubrication Sue ines 2S 905 _ Crankshaft and Thrust Bearing Torus bearing Je : Check the condition H! Check new overhauled parts at 500, 1000 and 1500 hours P Referto Fag hace vice eral (1000 hers ofoperatin) Ne [Prosecire [bay [weowylvoml 2 [ «|e |e] 2] «| ale] es] Para * check whenever exhaust valve Ieremoved * check clearances without alsmanting sogments ‘fragrant fl ‘Boarings should only be ‘opened if bearing material When referring to this page, please quote Maintenance Schedule AG0050 Edition 0296 Page 3 of 6900-1 ‘Checking and Maintenance Schedule, 26-70 MC/MC-C Engines MAN B&W HYUNDAI A: Adi V : See Volume I “Operation” 1G: Check the condition justment to be carried out M:: See maker's instructions ©: Overhaul to be carried out H Check new/overhauled parts at 500, 1000 and 1500 hours Parts to be replaced : Based on observations 2 Refer to vex Regular Chocks ‘Service interval 1000 hours of operation) No. | Procedure # Daiy | weeny rontni 2 4] e]s| ele] als} sle emt Tacho pick-up 2 908 2 Mechanical Control Gear 907 Starting Gt Stating ara ei HSI oresSite inal ESS Actuator safety valve. ‘coupling, ited bolts i etbaisias a ‘Fup EROE oT Sia Seaee SUES Functional check of speed-setting system (engine with bridge control system) Starting ar valve Exhaust Valve Exhaust valve ial a aes alia Nimonie exhaust valves thal van aruda Exhaust valve cam col Mw [New or overhauled chain to be or * checkedlretigtened after 500, 1500 and 4000 hours co Cun, * Onyy inspection trough camahat covers Page 4 of8 When referring to this page, please quote Maintenance Schedule A90050 Edition 0296an Checking and Maintenance Schedule, 26-70 MC/MC-C Engines 900-1 R : Parts to be replaced IV = See Volume |"Operation™ M See makers instructions JA : Adjustment to be carried out © : Overhaul to be carried out B : Based on observations IC : Check the condition H : Check new/overhauled parts at 500, 1000 and 1500 hours P : Refer to Regul Cheoks Servos ntoval 1000 hours of operation) Famers No. | Procedure % | Daly [weeny] onml 2] 4 [ 6 | 8 | wl | 2s] a] @] * HIP compound type nozzles ‘ony. Other types: 8000 hours Only inspection through camshaft covers (Check ap and at Turbocharger System "3 eae Check at every port inspection Turbocharger airfiter When referring to this page, please quote Maintenance Schedule AG005O Edition 0296 Page 5 of 6900-1 Checking and Maintenance Schedule, 26-70 MC/MC-C Engines MAN B&W. HYUNDAI V : See Volume I Operation” A. Adjustment to be carried out M: See makers instructions © : Overhaul to be carried out R : Parts to be replaced B : Based on observations ! Ghosetne conation 1 heck newovenated pars a 500, 1000 an 1800 hours P pefors ere wo eae eens — 5 eer sii __ Stan Easorn 5 "Toeerd etc seman error Dean se Govn su dow ss 0 nick ab Chetry and aduer( ol bomoretes ALM “Cheer oc acre ef praevia eM nani ; cee z “Deore mec ctr oon, een ‘oll botiom tank ° Empty and clean tank «certs ans pour When referring to this page, please quote Maintenance Schedule A90050 Edition 0296HYUNDAI Cylinder Cover 101-1 MAN B&W. pai ‘SAFETY PRECAUTIONS. X | Stopped engine X | Blook the starting mechanism X | Shut off starting air supply X | Engage tuning gear X | Shut off cooling water X | Shut off fuel oil Shut off lubricating oi X | Lock the turbocharger rotors Data Ref. Description Value | Unit Do1-01 | Exhaust valve stud, screwing-in torque 450 | Nm 01-02 | Starting valve stud, screwing-in torque 440, | Nm 01-03 | Fuel valve stud, screwing-in torque 1404420 | Nm 01-06 | Cylinder cover, complete 2900 | kg 101-07 | Cylinder cover without valves, 2050. | kg Do1-08 | Cooling jacket 73 | kg Do1-09 | Exhaust valve stud 50 | kg D13-.01 | Hydraulic pressure, mounting 1500 | bar 113.02 | Hydraulic pressure, dismantling 1400-1650 | bar Wen referring to this page, please quote Data 010101 Edition 071 Page 1 (2)101-1 ‘The task-spacific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Cylinder Cover HYUNDAI Data MAN B&W Plate Item No. |Description 90151 46 | Grinding toot for exhaust valve seat 90151 58 | Milling and grinding wheel for fuel valve seat P9015 60. | Milling and grinding whee! for starting valve seat P9015t 83. | Grinding handle Poot61 Cylinder cover tightening tool 9016S Cylinder Cover -Litting Toots Po13st 10 | Hydraulic pump, pneumatic operated Pota5t 46. | Hose with unions (1500 mm), complete 91351 58 | Hose with unions (3000 mm), complete 91361 130 | 9-way distributor block, complete Page 2(2) When referring to this page, please quote Data D10101 Edition 00716HYUNDAI Cylinder Cover MAN B&W Dismantling 901-1.2 Shut off Oil and Water Supply 4. Check engine blocking. Check that the engine is stopped and blocked according to the safety precautions given on the data sheet. 2. Shut off the oil supply. Close the fuel oll supply for the unit con cerned, 3. Shut off the water supply. Close the water outlet above the exhaust valve. Close the water outlet on the exhaust side of the cylinder cover. ‘Shut off the water supply placed on the exhaust side below the exhaust gas receiver. ‘Open the drain next to the inlet valve. When referring to this page, please quote Procedure M90101 Ecklion 0254E Page 1 (14)901-1.2 Cylinder Cover HYUNDAI Dismantling 3 i WTO EET TOT asa MAN B&W Open the venting cock next to the outlet. valve, Dismantling of Pipe Connections 4. Disconnect the oil pipes. Remove the hydraulic high pressure pipe for the exhaust valve. See Procedure 908- 12 Unscrew the drain pipe for the exhaust valve. Remove the fuel oil high pressure pipes. See Procedure 909-14,2. Disconnect the pipes for return fuel oil from the fuel valves. 5. Disconnect the water pipes. Unscrew and remove the water outlet pipes. 6. Exhaust gas compensator. Remove the protective jacket enclosing the insulation for the intermediate pipe or compensator. Remove the insulation. Remove the screws in the flange between the intermediate pipe and the exhaust receiver. Page 2(14) When referring to this page, please quote Procedure M90101 Edition 0254=HYUNDAI Cylinder Cover 9014.2 MAN Baw Dismantling 7. Disconnect the starting air pipe. Cylinder Cover Lifting and Landing 9. Unscrew and remove the control air pipe for the starting air valve. Unscrew and remove the air pipe for the starting valve. Cylinder cover loosening. Remove the protective caps from the cylinder cover nuts. Loosen and remove the cylinder cover nuts, see Data. For use of hydraulic tools, see Procedure 913-1 Cylinder cover supporting tool. Fit the cylinder cover supporting tool in the purposed holes on the uppermost platform. TTT OS When referring to this page, please quote Procedure M90101 Edition 0254 Page 3 (14)901-1.2 Cylinder Cover HYUNDAI Dismantling MAN B&W WROTTREIS 10. Cylinder cover lifting. Hook on the engine toom crane to the lifting attachment on top of the exhaust valve. Check that all cylinder cover connections have been loosened and removed. Lift away the cylinder cover complete. 11. Cylinder cover landing. Land the cylinder cover on the supporting tool. If the cylinder cover is to be overhauled it is recommended instead to land the oylinder cover on a couple of wooden pianks. Note! The cylinder cover supporting tool should only be used when the ship is in Page 4 (14) When referring to this page, please quote Procedure Ms0101 Edition O254EHYUNDAI Cylinder Cover 901-1.2 MAN B&W. Dismantling 42, Remove sealing ring. 2 | Remove and discard the sealing ring between the cylinder cover and cylinder liner. TSOTOT TETAS When referring to this page, please quote Procedure M90101 Edition 0254E Page 5 (14)901-1.3 Cylinder Cover HYUNDAI Overhaul MAN B&W. ROTO TESTOR r= Overhaul Preparations 1. Dismantle valves and pipes. Dismantle all valves and pipes from the cyl- Inder cover. See Procedure 907-2.2, 908- 2.2 and 909-11.2. Dismantie the starting air iniet block and the cooling water outlet block from the exhaust side of the cylinder cover. Remove all studs on top of the cylinder cover. Cooling Water Jacket 2. Remove the cooling water jacket. Mount four eyebolts and the lifting chains as shown in the sketch. Remove the four screws which secure the cooling jacket to the cylinder cover. Lift the cylinder cover free of the cooling jacket and land it on a couple of planks. If the cooling jacket sticks, use dismantling screws to force the jacket/cover apart. Remove and discard the O-rings from the caver, and carefully clean the cooling jacket and the cylinder cover. 3. Mount the cooling water jacket. Provide the cylinder cover with new O- rings, well lubricated with oil. Lift the cylinder cover and guide the jacke/ cover into position. Fit and tighten the screws for the cooling jacket. Page 6(14) When referring to this page, please quote Procedure M90101 Ealtion 0254EHYUNDAI Cylinder Cover 901-1.3, MAN B&W Overhaul Reconditioning of Bores 4 4, Seat recon tools. t The tools for reconditioning of the valve seats are found on tool panel 901. 5. Fuel valve bore. The tool consists of a common spindle with a handle, a guide, a carbon cutter, a seating face cutter and a grinding mandrel. Clean the fuel valve bores using the carbon cutter. If required, recondition the fuel valve seating with the appropriate cutter. TST CTEORE Grind the seating with the grinding mandrel and a grinding compound (e.g. Carborundum No. 200). 5. After the milling/grinding, clean the bore and seating carefully, and check that the seating is not damaged. TTT IONE (=) \Winen reterring to this page, please quote Procedure M90101 Ecdion 0254E Page 7 (14)901-1.3 Cylinder Cover HYUNDAI ‘Overhaul MAN B&W. TET ERGOT 6. Exhaust valve bore. ‘The tool consists of a spindle with a handle and a grinding dise. Alter cleaning the valve bore and seating, grind the seating with the grinding disc and a grinding compound (e.g. Carborundum No. 200). Ater the grinding, clean the bore and seating carefully, and check that the seating is not damaged. 7, Starting valve bore. ‘The tool consists of a guide, a cutter, and a grinding disc. Recondition the starting valve bore and sealing in the same way as described for the fuel valve bore. When replacing the valves on a cylinder cover while it is mounted on the engine, recondition the vaive bores/seating as described here, however, without removing the studs. Page 6 (14) When referring to this page, please quote Procedure M90101 Edition 0254EHYUNDAI Cylinder Cover 901-1.3 MAN B&W Overhaul 8. Indicator - safety valve bore. Clean the bores for safety valve/indicator cock. Preparations before Mounting 9. Fitting of studs. Lubricate the threads with ‘Never Seize’ or molybdenum disulphide (MoS2) and fit the valve studs. Tighten up the stud: accordance with Is the sorewnng-in torque stated on the data fe sheet E Fill up the grooves between the valve studs z and the bores for the valve studs with permatex to prevent water or cil from en- 9. 001-01 tering the bores during operation of the engine. 10. Mounting of valves. Install the valves on the cylinder cover, see Procedures 907-2.4, 908-2.4 and 909-11.4. When referring to this page, please quote Procedure M90101 Edition 0254 Page 9(14)901-1.4 Cylinder Cover HYUNDAI Mounting MAN B&W. Landing Preparation 4. Sealing ring, Check that the liner sealing surface is clean. Place a new sealing ring on top of the oylinder liner. If necessary fit a new ‘klinger’ sealing ring in the groove of the flange of the intermediate pipe. 2. Water connections. Check that the water connections are clean and provided with new O-rings. TET DAT Lubricate the O-rings with Vaseline and fit them on the cylinder liner. [ Revrorarsae Page 10 (14) When referring fo this page, please quote Procedure M80101 Edition C2546HYUNDAI Cylinder Cover 901-1.4 MAN B&W. Mounting Cylinder Cover Mounting 3. Cylinder cover landing. Carefully wipe the cylinder cover contact surface facing the cylinder liner, while the cover is resting on the support. Lift the cylinder cover by means of the crane and lower it carefully into position. During the landing, carefully check that the cooling water connecting pipes engage correctly with the holes in the cooling jacket. 4. Gylinder cover stud - check distance. If the cylinder cover studs have been removed and reinstalled, check the distance the stud is protruding from the cylinder cover. I necessary, adjust to the distance D01-05 by tuming the stud. TOT RSE TOT ATO When referring to this page, please quote Procedure M90101 Edition 0254 Page 11 (14)901-1.4 Cylinder Cover HYUNDAI Mounting MAN B&W VEO SMOS 5, Cylinder cover tightening. Fit and tighten the cylinder cover nuts. For operation of hydraulic jacks, see Proce- dure 913-1. Fit the protective caps on the cylinder cover studs. Fitting Pipe Connections 6, Mount the exhaust gas compensator. Fit the screws of the flange between the intermediate pipe and the exhaust receiver. Note! 2 [rover neem Lubricate the screws with ‘Never Seize’ ‘or molybdenum disulphide (MoS2) before fitting. Fit the insulating jacket around the intermediate pipe. Page 12 (14) When referring to this page, please quote Procedure M90101 Ecition 02546HYUNDAI Cylinder Cover 901-1.4 MAN B&W Mounting 7. Connect the starting air pipe. Connect and tighten the air pipe for the starting valve. Connect and tighten the control air pipe for the starting air valve, 8. Connect the water pips Mount and tighten the water outlet pipes. 9. Connect the oil pipes. Mount the hydraulic high pressure pipe for the exhaust valve. See Procedure 908-1.4. Connect the drain pipe for the exhaust valve. Connect the fuel oil high pressure pipes. See Procedure 909-14.4. Connect the pipes for return fuel oil from the fuel valves. TOT ESRI TESTO CSTE WaT SE When referring to this page, please quote Procedure M90101 Edition 0254E Page 13 (14)Cylinder Cover 901-1.4 Mounting Open Oil and Water Supply 70. 40. Close the drain and open the water supply. Close the venting cock next to the outlet valve. Close the drain next to the inlet valve. Slowly open the water supply valve, placed noxt to the cylinder liner cooling water jacket on the exhaust side. Vent the unit by releasing air through the venting cock next to the outlet valve, When the venting is finished, close the venting cock. Open the two water outlet valves on the exhaust side of the cylinder cover. 11. Open the oil supply. ‘Open the fuel oll supply for the unit con cerned. Wanioraesau When referring to this page, please quote Procedure M90101 Edition 0254 Page 14 (14)HYUNDAI ir Baw Cylinder Cover Panel Plate P90151-0205E 77. ° Oo TT eee °| ° ° a oO Io 105 gas | 046 O74 When referring to this page, please quote Plate P90151 Edition 0205EPlate P90151-0205E Cylinder Cover Panel ue Item Description ca | Item Description 010 | Panel for tools 022 | Name plate 046 | Grinding tool, exhaust valve seat 058 | Milling and grinding tool, fuel valve seat 060 | Milling and grinding wheel, fuel starting valve 071 | Dismantling tool, fuel valve 083 |. Handle, grinding tools 095 | Grinding ring, starting valve seat 105 | Pin spanner, starting valveHYUNDAI i - -( MAN B&W. Cylinder Cover - Tools Plate P90161-0110 P9135] When referring fo this page, please quote Plate P90161 Edition 0110Plate P90161-0110 Cylinder Cover - Tools Item Description tem No. 090 100 Hydraulic jack for cylinder cover Support Stud setter O-ring with back-up ring O-ring with back-up ring Spanner Tommy bar Hydraulic tool set, completeHYUNDAI i : 4 Aaa Cylinder Cover - Support Tool —_—Plate P90163-0004 a ‘When referring to this page, please quote Plate P90163 Edition 0004Plate P90163-0004 Cylinder Cover - Support Tool Item No. Item No. Item Description Item Description 016 | Cylinder cover rackHYUNDAI = Lifti 4 MAN B&W Cylinder Cover - Lifting Tools Plate 90165-0001 When referring to this page, please quote Plate 90165 Edition 0001Plate 90165-0001 Cylinder Cover - Lifting Tools a Item Description Item Item Description No. Pt No. pt 017 Lifting chains for cylinder coverHYUNDAI Piston 102-1 MAN B&W Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X ] Stopped engine X | Shut off starting air supply ~ At starting air receiver X | Block the main starting valve X | Shut off starting air distributor/distributing system supply X | Shut off safety air supply ~ Not ME engines X_| Shut off control air supply X_| Shut off air supply to exhaust valve — Only with stopped lubricating oll pumps X_| Engage turning gear X | Shut off cooling water X | Shut off fuel oi X | Stop lubricating oil supply _] Lock the turbocharger rotors, Data Ref. Description Value [Unit DO1-05 | Cylinder cover stud, check distance 448-149 | mm 02-01 | Test pressure 7 | bar 1002-02 _| Piston rod/crosshead, tightening torque 590 | Nm 1002-03 | Piston rod/crown, tightening torque 580 | Nm 002-05 | Piston skirt, tightening torque 190 | Nm 002-08 | Cooling oi pipe, tightening torque 20 | Nm 002-08 | Piston ring new, radial width 20.2 | mm 02-09 | Piston ring worn, min. radial width a7 | mm 92-10 | Groove No.1, max. vertical height 44.7 | mm 02-11 | Groove Nos. 2, 3 and 4, max. vertical height 11.7 | mm 02-13 | Piston ring new, height of ring No. 4 13.9 | mm 02-14 | Piston rings new, height of ing Nos.2, 3 and 4 109 | mm 02-45 | Minimum free ring gap (before dismanting ) 30.5 | mm 02-16 | Minimum ring gap, ring No. 1 (new ring in new liner } 44 | mm 02-17 | Minimum ring gap, ring Nos. 2, 3 and 4 ( new ring in new liner ) 3 | mm | 002-18 | Vertical clearance, new parts 0.43 | mm D02-19 | Vertical clearance, worn parts, max. 0.92 | mm 002-20 | Piston complete 1600 | kg | p02-21 Piston crown 310 | kg | 02-22 | Piston rod 1050 | kg 002-23 | Piston skirt 95 | kg 002-24 | Piston cooling pipe 36 | kg 002-25 —_|_ Lifting too}, tightening torque 150. | Nm 002-46 | CPRring CL groove, min. depth 1.3. | mm 002-47 | Piston top centre, max. permissible burn-away 9 | mm 002-48 | Piston top centre diameter 280 | mm 1002-49 | Piston top outer ring area, max. permissible burn-away 6 | mm ‘When referring to this page, please quote Data D10201 Edition 0097 Page 1 (2)The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Piston Data HYUNDAI MAN B&W. Plate Item No. Description 90261 40__|_ Lifting too! for piston rod foot Pe0261 75 | Template for piston top 90251 87 | Distance piece for stuffing box 90251 9@ | Cover for stuffing box hole 90251 110 | Pressure test too! for piston 90251 194 | Piston ring expander 90251 188 | Guide screw for piston crown 90284 171 | Dismanting screw piston skirt 90264 Guide ring for piston 90266 Support for piston 90266 Lifting tool for piston | 90366 Crossbar for cylinder liner Page 2(2) When referring to this page, please quote Data D10201 Editon 0097HYUNDAI Piston MAN B&W. Checking 9024.4 Scavenge Port Inspection To detect possible leakages from the piston or oylinder cover, keep the cooling water and cooling cil circulating during the scav- ‘enge port inspection. 4. Scavenge port inspection: The scavenge port inspection is carried out from the scavenge air receiver. An addition- ‘al view of the rings is possible through the cleaning cover on the manoeuvring side. Turn the engine at least % a revolution, and begin with a unit arriving downwards, just above the scavenge air ports. inspect the piston rod and the lower part of the cylinder wall. While the piston is passing downwards, inspect the piston skirt, all the piston rings, the ring lands and the piston top. 2. Ring inspection: Inspect the rings, one at a time, and note down the results. See Volume |, Operation, Chapter 707. 3. Ring tension: Check the tension of the piston rings, by pressing against them with a wooden stick. TERT TENCE 2 —_/ qm When referring to this page, please quote Procedure M90201 Ealtion 0296 Page 1 (21)Piston HYUNDAI Checking MAN B&W. 4, Ring grooves: Measure the total clearance between the piston ring and the ring groove. The total clearance must not exceed the value stated in Data. Measure the clearance at the top (E) and bottom (F) of the piston ring groove. Total clearance = E + F. Uppermost piston ring: If possible, measure the depth of the pressure relief grooves with a calliper. The piston rings must be replaced if the radial depth of the grooves has worn down to less than stated in Data 002-46. Checking, in connection with piston overhaul iston support: Remove the piston from the cylinder and place it on the piston support, See Procedure 902-1.2. For evaluation of the rings, see Volume |, Chapter 707. Note! It is recommended to replace all the piston rings whenever a piston is removed from the engine, When referring to this page, please quote Procedure M90201 Eulition 0296HYUNDAI Piston 9024.4 MAN B&W. Checking 7. Free ring gap: Before dismantling the piston rings, measure the free ring gap of all the piston rings. For dismantling the piston rings, see Proce- dure 902-1.3. Radial ring width: Measure the radial width of the rings. Note down the results See Volume J, Operation, Chapter 707. Ring grooves: Clean the ring grooves and check them for burn marks or other deformation. Measure the ring grooves with a calliper gauge, see Data DO2-10 and DO2-11. Clearance in piston ring grooves: ‘The maximum vertical height in a worn ring groove must not exceed the value stated in Data. The groove is also worn out if ‘there is no chromium layer. If the ring grooves are worn out, the piston crown must be reconditioned, contact MAN Diesel for advice. WED 80TCRS 02-08 =| 02-09 Oe When referring to this page, please quote Procedure M90201 Edition 0296 Page 3 (21)Piston HYUNDAI Checking MAN B&W 10. Piston top template: 1. Page 4 (21) Check that the piston top template is per- manently marked with the piston top centre diameter 002-48, Check that the centre area C has been ked off, and write the maximum permissible burn-away rate on the template. See data D02-47. Mark the outer part of the template R for ring area, and virite the maximum permis sible burn-away rate for the ring shaped area, See data D02-49. Piston crown top: Clean the piston crown and check the burn-away by means of the template. For maximum permissible burn away on the piston top centre area, see Data D02-47. For the ring shaped area, see Data D02-49. Check the burn-away on the whole circum= ference of the piston crown top. If the burn-away exceeds the values given in Data, contact MAN Diesel for advice. Note down the results for later reference. When referring to this page, please quote Procedure M90201 Eaition 0296Piston 902-1.2 Dismantling Preparations in the crankcase 1. Access: Open the crankcase door to the cylinder concerned. ‘Turn the crosshead down far enough to give access to the piston rod stuffing box and the piston rod/orosshead connection, 2. Stuffing box: Release the stutfing box by removing the innermost screws from the stuffing box flange. (On engine models where the drain pipe is, connected directly to the stuffing box: Disconnect the stuffing box drain pipe. Note! Do NOT remove the outermost screws from the flange. 3. Loosen the piston rod-crosshead connection: Remove the screws from the piston rod. iT ARID % | onc0F aR When referring to this page, please quote Procedure M90201 Edition 0296 Page 5 (21)Piston HYUNDAI Dismantling MAN B&W 4, Stuffing box distance pieces: Mount the two distance pieces on the piston rod foot to protect the lower scraper ring and to guide the stuffing box. Preparations on the cylinder top 5. Cylinder cover: Remove the cylinder cover. See Procedure 901-1.2. Make a scratch mark in liner and piston cleaning ring to ensure correct re-mounting. Remove the piston cleaning ring. Carefully remove any wear ridges at the top of the cylinder liner. See Procedure 903-1.3. Page 6 21) When referring to this page, please quote Procedure 90201 Edition 0206 9HYUND: Piston 902-1.2 MAN B&l Dismantling 6. Piston lifting tool: ‘Turn the piston to TDC. The top of the piston is now free of the cylinder liner. Clean the lifting groove of the piston crown and mount the lifting tool. Note! Make sure to mount the lifting tool cor rectiy, so that the claws of the lifting too! enter the lifting grooves of the piston crown. If the engine not is equipped with long dis tance pieces, remove one or two cylinder cover studs, using a stud setter. WRT REET When referring to this page, please quote Procedure M90201 Edition 0296 Page 7 (21)902-1.2 RT TROT HYUNDAI MAN B&W Piston lift 7. Piston ti Lift the piston out of the cylinder liner and guide the piston rod foot through the stuffing box flange. If the engine is equipped with long distance pieces for the stuffing box, the piston rod foot can pass between two cylinder cover studs. Place the two halves of the support around ‘one of the openings in the platform. Low- er the piston rod foot and stuffing box through the opening in the platform. Secure the two support halves with screws and lower the piston on the support. Check the piston is resting on the piston rod flange. Limited lifting height: If the piston rod foot can not be lifted clear of the liner top with the standard lifting tool, contact MAN Diesel for instructions for tited lit. When referring to this page, please quote Procedure M9020" Eaition 0296HYUNDAI Piston 902-1.2 MAN B&W Dismantling 8. Protect the crosshead bearing: Place a cover over the opening for the piston rod stuffing box in the bottom of the cylinder unit. Tum the crosshead down far enough to permit mounting of the protective rubber cover on the crosshead bearing cap. The protective rubber cover is found on tool panel 904, The covers must remain in place to protect the crosshead bearing journal from impurities until the piston is remounted. Clean, measure and recondition the cylinder liner. See Procedure 903-1. When refering o this page, please quote Procedure M90201 Eition 0296 Page 9 (2)902-1.3 Piston HYUNDAI Overhaul MAN B&W Piston support: Place the piston in the support and remove the piston lifting tool. See Procedure 902-1.2. Clean the piston top and the piston rings. Check the free ring gap and the burn-off on the piston top. See Procedure 902-1.1. Remove the stuffing box. See Procedure 902-23. Piston ring dismantling: Take off the piston rings by means of the ring expanders. If the engine is equipped with two ring expanders, the short ring expander is for the uppermost ring. iB E s 2. First remove the uppermost ring, then ring No. two, three and four. Clean and inspect the rings and the ring grooves. See Procedure 902-1.1. Piston crown dismantling: Remove the locking wire and the innermost screws between the rod and the piston crown. Lift the piston crown and skirt clear of the iston rod, TORT COBO Page 10/21) When referring to this page, please quote Procedure M90201 Eaftion 0296HYUNDAI Piston 902-1.3 MAN B&W. Overhaul 4. Piston rod and cooling pipe: ] Remove the screws from the cooling oll pipe flange. Mount the eye bolts and lift out the cooling oil pipe, Clean and inspect the cooling oil pipe and the piston rod, then remount the cooling oil pipe, see Data. Check that the surfaces of the O-ring Do02-22 groove is clean and smooth. Mount a new O-ring on the piston rod flange. RTT ARGO 5. Piston crown turning: Unhook the crane from the piston lifting tool, and connect the lifting too! and the crane hook by means of a wire rope. Lift up the piston crown. Fit two eyeboits in the piston skirt and a wire rope between the bolts as shown in tho sketch. Install a tackle in a suitable place with sufficient space below for the piston crown. Attach the tackle to the wire rope on the piston crown and carefully turn the piston crown upside down. Use both cranes if the engine room is equipped with two cranes. Land the piston lifting tool and the piston crown on a sufficient support of wood pieces. Loosen the piston lifting tool and lift the piston crown clear of the tool. ‘ F E i When referring to this page, please quote Procedure M90201 Edition 0296 Page 11 (21)902-4. Piston HYUNDAI Overhaul MAN B&W 6. Piston crown dismantling and cleaning: Place the piston crown with skirt on a ‘wooden support as shown, Remove the locking wire and the screws in the skirt. If necessary use two dismantling screws to pull the skirt out of the piston crown. Mount two eye bolts in the skirt. Lift the skirt and land it on a couple of planks. Discard the sealing ring on the piston skirt. ‘Thoroughly clean and inspect all parts of the crown and skirt. If coke deposits are found in the cooling spaces of the piston crown, they should be washed clean with Carbon Remover or a similar cleaning fluid. When all coke deposits have been dis- solved, clean and inspect the piston crown again. Note! Coke deposits reduce heat transfer from the piston crown to the cooling oil. The deposits must be removed as a routine procedure when a piston is overhauled. 7. Piston crown assembly: Mount a new O-ring on the piston skirt. Check that the surfaces of the O-ring groove are clean and smooth. Coat the ring with lubricating oil before mounting. ‘Mount the piston skirt on the piston crown. Tighten the screws to specified torque, see data D02-05. Lock the screws with locking wire, see Procedure 913-7. Page 12 21) When referring to this page, please quote Procedtire M90201 Eultion 0296HYUNDAI Piston 9024.3 MAN B&W. Overhaul 8. Piston crown and skirt mounting: Mount the guide screw to ensure the correct positioning of the piston rod in relation to the piston crown. Lubricate the O-ring on the piston rod flange with tubricating oil, Land the overhauled piston crown and skirt (on the piston tod. Remove the guide screw. Mount and tighten the screws between the piston rod and the piston crown, see Data. When referring to this page, please quote Procedure M90201 Edition 0296 Page 13 (21)902-1.3, Piston HYUNDAI Overhaul MAN B&W WRT OETTOVE Sealing ring and pressure test According to current class rules, the piston must be pressure tested hydraulically. It is possible to carry out a test of the sealing rings with compressed air before filling the piston with oil, The sealing ring test can also be carried out when the piston is resting in the support tool. 9, Sealing ring test: Mount the pressure-testing tool on the piston rod foot. Connect compressed air to the testing tool and fil the piston to 4-5 bar. Close the valve on the testing tool and remove the air connection, The piston must now hold the pressure for minimum 30 minutes. 3 RETIN Spray a little soap water on to the surface joints between piston rod/crown/skirt and around the bolt heads to detect leaks. Dry off all soap water. 10. Pressure test: For this test, the piston must be turned upside down (see next step to turn a complete piston). Fill the piston and piston rod with lubricating oil. Mount the pressure-testing tool on the piston rod foot. Pressure-test the piston at the pressure stated on the Data Sheet. Check the contact surfaces of the piston and the sealing rings for tightness. Check that there are no cracks in the piston crown. Turn the piston upside up and drain out the piston cil. Page 14 (21) When referring to this page, please quote Procedure M90201 Ecition 0296HYUNDAI Piston MAN B&W. Overhaul 902-1.3 11. Piston turning: Lift the piston with the normal lifting tool. nt Lower the piston rod foot until it is close to the platform, Land the foot on a wooden block. Lower the piston crown to the platform and land it on a wooden block in such a way that it is possible to remove the lifting tool. Mount an eyebolt in the side of the lifting tool, hook on the crane and remove the lifting tool from the Attach the lifting bracket to the bottom of the piston rod foot. Hook the crane on to the lifting bracket. Lift the piston rod foot clear of the wooden block. Keep lifting until the piston rod is in a vertical position. Note! During the lift, follow with the crane to keep the crane positioned vertically above the lifting point. The stuffing box must be removed. ET SeBROTS When referring to this page, please quote Procedure M90201 Ealtion 0296 Page 15 (21)902-1.3 Piston HYUNDAI Overhaul MAN B&W. 42. Piston completion: Fit the new piston rings (alternately right-hand and left-hand cuts, with the ring gaps staggered 180° and with the TOP mark upwards), using the ring expander, When mounting the piston rings, use the ring expanders to prevent unintended deformation of the rings. Do not expand the rings more than necessary. The uppermost ring (CPR-ring) must be mounted with the short ring expander. Mount the piston rod stuffing box. See Procedure 902-2.3. Page 16 (21) When raterring to this page, please quote Procedure M90201 Edition 0296HYUNDAI Piston 902-1.4 MAN B&W. Mounting Preparation of piston 4. Preparation of piston: Check the piston rings and piston crown in accordance with Procedure 902-1.1, if not already done. Mount the lifting tool on the piston crown. See Data D02-25. 2, Stuffing box position: Ensure that the stuffing box is correctly positioned over the distance pieces mounted (on the piston rod foot. Both the holes for the flange and the drain hole for the drain pipe must be positioned correctly. ROT TORENT When referring to this page, please quote Procedure M90201 Edition 0296 Page 17 21)902-1.4 Piston HYUNDAI Mounting MAN B&W 7 Preparation of cylinder liner TREO SOS Tana ORTFTE 3. 4 Mount the guide ring: ‘Mount the guide ring in the top of the cyi- inder liner. The cut outs for the lifting tool must be turned to fit the piston lifting tool. Stuffing box cover: Remove the cover from the piston rod stuffing box opening in the bottom of the cylinder unit. Clean the stuffing box flange. ‘Crosshead position: ‘Turn the crosshead to a position 45° from TDG (crank web pointing towards exhaust side). Page 18 (21) When referring to this page, please quote Procedure M90201 Edition 0296HYUNDAI Piston MAN B&W Mounting 902-1.4 Mounting of piston 6. Mounting of piston: Coat the O-rings of the stuffing box and the piston rod with oil. Coat the piston rings and cylinder liner with cylinder lubricating oil. Lower the piston into the cylinder liner ~ while guiding the piston rod foot through the cut-out in the stuffing box flange - until the piston rings are inside the liner. 7. Protective cover: Remove the protective rubber cover from the crosshead. 8 Crosshead alignment: ‘Turn the crosshead almost to TDC, while checking that the guide ring of the crosshead enters the centre hole in the piston rod, After turning the crosshead fully to TDC, and ensuring that the piston rod has full contact with the crosshead, unscrew the lifting tool and remove the lifting tool and the guide ring for piston rings. TMS TO ORBIT NT NE When referring to this page, please quote Procedure M90201 Ecition 0296 Page 19(21)902-1.4 Piston Mounting MAN B&W. HYUNDAI a TR TORE TT HANTS 10. oT Stuffing box: Turn down and land the stuffing box on the stuffing box flange. Check that the holes in the stuffing box and stuffing box flange are correctly centered. Tighten the piston rod stuffing box by means of the screws through the inner holes in the stuffing box flange. For Data, see Procedure 902-2. ‘On engine models where the drain pipe is connected directly to the stuffing box: ‘+ Mount the stuffing box drain pipe. Remove the distance pieces from the piston rod foot. Tightening of the piston rod-crosshead connection: Mount and tighten the piston rod screws. Tighten the screws to the specified torque and lock with locking wire. ‘See Data. Use either Data 002-02 or Data D02-07. Piston cleaning ring: Mount the piston cleaning ring in accordance with the scratch mark. If the PC-ring is damaged (broken or cracked}, it must be replaced by another ring. ‘See Procedure 903-1. zg ROT RETIN 8 = When referring to this page, please quote Procedure 90201 Edition 0296HYUNDAI Piston 902-1.4 MAN B&W Mounting 12. Cylinder cover studs: 2 If the cylinder cover studs have been re- : & | moved, remount them, Carefully clean the co surfaces around the base of the studs and f | check the O-rings on the studs. Mount the cylinder cover studs with the stud setter. Screw the stud down to contact and half a revolution back. 13. Cylinder cover: Land the cylinder cover on the liner and check the distance that the stud is protruding from the cylinder cover. If necessary, adjust the distance D01-05 by turning the stud Tighten the cylinder cover nuts and mount the necessary pipes. See Procedure 901-1.4. 414, Running: ‘Smear the piston rod with molybdenum di- ‘sulphide, and turn the crankshaft a couple of revolutions. At the first opportunity, start the engine and keep it running for about 15 minutes at a speed corresponding to "Dead Slow” Ahead. Then stop the engine and inspect the piston rod and stuffing box. When referring to this page, please quote Procedure M90201 Edition 0296 Page 21 (21)HYUNDAI Piston Rod Stuffing Box 102-2 MAN B&W Data SAFETY PRECAUTIONS X | Stopped engine X | Block the starting mechanism X | Shut off starting air supply X_| Engage turning gear X | Shut off cooling water X | Shut off fuel oif X | Shut off lubricating oit Lock turbocharger rotors Data Ref. Description Value] Unit 02-26 Stuffing box flange, outer screws tightening torque 80] Nm 02-27 Stuffing box flange, inner screws tightening torque 80] Nm 02-28 Stuffing box halves, tightening torque 80] Nm 02-29 Uppermost rings, ring-end clearance 6] mm 02-30 Lowermost rings, ring-end clearance 3] mm 002-33 Check length for the six uppermost springs: 002-34 -FO=O0N Lo 618] mm 002-35 -F1= 1534-7 N.. 902] mm 002-36 ~F2=163 +1 10N 983] mm 002-37 Check tength for the four lowermost springs: 002-38 -FO=ON or 606} mm 002-39 -F1=1504-7N. 780] mm 02-40 -F2=200+/-10N....L2= 844] mm Do2-24 ‘Stuffing box complete 110] kg 02-45 Stuffing box half 35| kg ‘When referring to this page, please quote Data D10202 Edition 0047 Page 1 (2)102-2 Piston Rod Stuffing Box HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No.| Description 90251 109] Mounting too! for stuffing box spring 90251 110| Pressure test tool for piston 90251 122| Worktable for stuffing box 90451 118] Rubber cover for crosshead Page 2 (2) When referring to this page, please quote Data 010202 Edition 0047HYUNDAI Piston Rod Stuffing Box 902-2.1 MAN B&W. Checking 1, After the piston rod stuffing box has been dismantled, check the following clearances:. See Procedure 902-2.2. Uppermost scraper ring and sealing rings Clearance at ring ends (scraper ring). Total clearance (scraper ring), (D02-29) Clearance at ring ends (sealing rings). Total clearance (sealing rings). (D02-29) Lowermost scraper rings Clearance at ring ends. Total clearance. (D02-30) The ring clearances stated in Data apply to new rings. As a general guide, it is recommended — depending on the overhauling intervals and one’s own experience — to replace sealing rings and scraper rings when the specified clearance values D02-29 and 002-30 have been halved. 2. Check the length of the springs at different loads. Adjust the loads to achieve the lengths stated in Data. Ifthe loads necessary are outside the limits stated in Data, the springs must be discard- | ed. It is recommended to renew the springs for the sealing rings when the rings are renewed. When referring to this page, please quote Procedure M30202 Edition 0221 Page 1 (9)902-2.2 Piston Rod Stuffing Box HYUNDAT Dismantling MAN B&W. In connection with dismantling of the piston, only the innermost screws in the stuffing box flange should be removed. If, in the period between piston overhauls, it be- comes necessary to inspect the piston rod stuffing box, proceed as follows: 4. Tum the crosshead to about 90° from TDC. Mount the rubber cover around the piston rod to protect the crosshead bearing from impurities. 2, Remove the drain oil pipe and all innermost screws and all outer screws except for two screws placed diametrically opposite in the stuffing box flange, longitudinally to the engine, 3. Mount the worktable around the piston rod so that the two remaining screws in the stuffing box flange can be loosened through the holes. Page 2 (9) When referring to this page, please quote Procedure M90202 Edition 0221HYUNDAI ston Rod Stuffing Box 902-2.2 [xn Baw Dismantling 4, Remove the two long dismantling screws | 4 from the worktable. ‘Mount them in the stuffing box through the holes in the worktable. Remove the remaining two screws from the stuffing box. 5. Turn the piston to BDC, thereby withéraw- ing the stuffing box from the cylinder frame bottom. 6. Remove the two long dismantling screws from the stuffing box and mount them in the worktable. By means of the four short screws in the worktable, press the stuffing box out of the flange. For overhauling the stuffing box, see Pro- cedure 902-2.3. When referring to this page, please quote Procedure M90202 Ealtion 0221 Page 3 (9)902-2.3 Piston Rod Stuffing Box HYUNDAI Overhaul MAN B&W Normally, overhaul of the piston rod stuffing box. is carried out by routine methods in connection with the dismantling (pulling) of the pistons. During such overhauls, the piston rests on a ‘support placed over one of the cut-outs in the top platform. Work on the stuffing box is then carried out from the platform below. Overhaul inside the engine is carried out in the same way as outside the engine. 1, Mount two eye bolts in the stuffing box flange, and hook on two tackles, Lift the stuffing box a little up the piston rod, and mount the worktable round the piston rod at a suitable working height. Land the stuffing box on the worktable, and remove the tackles and eye bolts. 2. Remove the O-ring of the stuffing box. If the O-ring is intact and is to be used agai move it up the piston rod and secure it in this position, for example with tape. Remove the nuts from the stuffing box assembling bolts. Page 4 (9) When referring to this page, please quote Procedure M90202 Edition 0221HYUNDAI Piston Rod Stuffing Box 902-2.3 MAN B&W. Overhaul 3. Take out the six bolts, and pull away one stuffing box half. Mount two eye bolts on the stuffing box half and remove it from the worktable. 4, Using a feeter gauge, measure the vertical clearance of the rings. 5. Remove the remaining stuffing box half and press all sealing rings and scraper rings down against the worktable. 6. Measure the clearance between the ring segments to determine whether replacement is necessary. See Procedure 902-2.1. Dismantle and stack the rings in the same ‘order as when fitted in the stuffing box. Carefully clean all the ring segments. Inspect and assess the surface quality of the sealing rings. If their sliding surfaces have scratches or marks, replace the rings. 7. Check the lengths of the springs. ‘See Procedure 902-2.1. 8. Inspect the surface of the piston rod. If small longitudinal scratches have occurred (caused by poorly adapted stuffing box rings), smooth the piston rod surface carefully with a fine grained carborundum stone. In the case of coarse scratches, it may prove necessary to machine-grind the surface in @ workshop. 9. Clean the halves of the stuffing box housing. When referring to this page, please quote Procedure M90202 Ealtion 0221 Page 5 (9)902-2.3, Piston Rod Stuffing Box HYUNDAI Overhaul MAN B&W 10. Lubricate the piston rod (in the area where all the ring units in the stuffing box will be positioned) with molybdenum disulphide (MoS). Assemble all the stuffing box ring units round the piston rod, on the worktable, in the following way: + Place the lowermost scraper ring segments on the worktable. + Place the spring round the segments, and hook the spring ends together. = Repeat this procedure for the remaining scraper rings. ‘On top of the scraper rings, assemble the two sealing ring units (each consisting of a 4-part and an 8-part ring). Assemble the 8-part sealing ring so that the two guide pins face upwards, place the spring round the segments and, hook the spring ends together. Assemble the 4-part sealing ring above the 8-part sealing ring. Push the two rings together in such a manner that the guide pins in the lower sealing ring engage with the two holes in the upper sealing ring Finally, assemble the uppermost ring unit (consisting of a 4-part scraper ring and an 8-part sealing ring). 14. Use the stuffing box half on the worktable to adjust the height of all the assembled ring units on the piston rod until the ring units are opposite the corresponding grooves in the stuffing box housing. Subse- quently, push the stuffing box half into contact with the piston rod, round the ring units. Note! if the stuffing box is assembled inside the engine, place two pieces of plywood of the same thickness as the flange on the worktable, to ease the assembling. Page 6 (9) When referring to this page, please quote Procedure M90202 Edition 0221HYUNDAI Piston Rod Stuffing Box MAN B&W Overhaul 902-2.3 12. Check the ring clearance again. Then place the other haif of the stuffing box housing on the worktable, pushing it into place round the rings. Mount and tighten up the fitted bolts to the torque specified on the Data Sheet Mount the O-ring the stuffing box groove. 13. Mount eye bolts and wire ropes, and lift the stuffing box a little. Remove the worktable and lower the stuffing box until it rests against the distance pieces on the piston rod foot Remove wire ropes and screws. When referring to this page, please quote Procedure M90202 Edition 0221 Page 7 (9)902-2.4 Piston Rod Stuffing Box Mounting HYUNDAI MAN Baw 1 In connection with mounting of the piston, only the innermost flange screws are to be mounted and tightened, see data. After overhauling the stuffing box inside the engine, assembie the stuffing box halves on top of the four screws. Mount the two long screws from the worktable in the stuffing box. Turn down the short screws so that the stuffing box lands on the flange. Turn the piston upwards until the stuffing box is in piace in the cylinder frame. TRDETTRO Note! Make sure that the two guide pins in the flange enter the guide holes in the bottom. of the cylinder frame. Mount two screws in the flange through the holes in the worktable. Page 8 (2) When referring to this page, please quote Procedure M90202 Edition 022HYUNDAI Piston Rod Stuffing Box 902-2.4 MAN B&W. Mounting 4. Remove the long screws from the stuffing box and mount them in the worktable. Remove the worktable from the piston rod. 5. Mount and tighten all the inner and outer screws for the stuffing box. See Data. 6. Remove the protecting rubber cover from the piston rodicrosshead. ‘Smear the piston rod with molybdenum disulphide. ‘Then turn the crankshaft a couple of revolutions. Start up the engine and keep it running for about fifteen minutes at a number of revolutions corresponding to very slow or idle speed. Then stop the engine and inspect the piston od and stuffing box. When referring to this page, please quote Procedure M90202 Edition 0221 Page 9 (8)HYUNDAI i " E MAN B&W Piston and Piston Rod Panel Plate 90251-246 ‘S60MC-C When referring to this page, please quote Plate 90251 Edition 246Plate 90251-246 Piston and Piston Rod Panel item oe tem’ Ne Item Description Ne Item Description 014 | Panel for tools 026 | Name plate 040 ing tool for piston rod 063 | Lifting tool for liner 075 | Template for piston top 087 | Distance piece for stuffing box 93 | Cover 109 | Hook for mounting of spring 140 | Pressure tester 122 | Worktable 134 | Piston ring expander 458 | Guide screw for piston crown 183 | Pulling tool for stuffing box 200 | Dismantling screw for piston skirtHYUNDAI i i. “ Z MAN B&W. Piston and Piston Rod - Tools Plate P90261-0107 O19 When referring to this page, please quote Plate P90261 Edition 0107Plate P90261-0107 Piston and Piston Rod - Tools Item Item oe hor Item Description Ne Item Description 019 | Guide ring for pistonHYUNDAI i Pist - Plate P90265-0005 band Piston and Piston Rod - Support Tools late P902t When referring to this page, please quote Plate P90265 Edition 0005Plate P90265-0005 Piston and Piston Rod - Support Tools Item Item No. Item Description No. Item Description 010 | Support iron for pistonHYUNDAI i = Li MAN B&W Piston - Lifting Tools Plate P90266-0002 When referring to this page, please quote Plate P90266 Edition 0002Plate P90266-0002 Piston - Lifting Tools Item Item Ne: Item Description Ne! Item Description 016 | Lifting tool for pistonHYUNDAI Cylinder Liner 103-1 MAN B&W Data SAFETY PRECAUTIONS Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear Shut off cooling water ‘Shut off fuel oil ‘Shut off lubricating oil Lock turbocharger rotors x] |x] ]x [x] Data Ref. Description Value | Unit 03-01 Lifting tool screws, tightening torque 160 | Nm 03-03 Cylinder diameter, new 600 | mm 03-04 Piston cleaning ring diameter, new 598.6 | mm 003-05 Cylinder tiner, complete 3356 | kg 03-06 Cooling jacket 286 |ka 03-16 Piston cleaning ring radial width, new 23.1 | mm 03-17 PC-ting/Liner max. wear deviation 0.6 | mm 003-18 PC-ring replacement criteria: Liner diameter: 600 mm Liner wear: Install: 0-060 mm Standard PC-ring (new or max. wear of diameter 0.60 mm) 0.60-1.2mm _ | Oversize PC-ring >41.2mm Dummy ring When referring to this page, please quote Dats 010301 Edition 0052 Page 1 (2)103-1 Cylinder Liner HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No. | Description | 90251 Lifting tool for eylinder liner P9036 Measuring tool for cylinder liner 90362 Cylinder liner ~ extra tool 90366 Cylinder liner lifting tools Page 22) When referring to this page, please quote Data D10301 Edition 0052Cylinder Liner 903-14 Checking 1, Dismount the cylinder cover, the piston cleaning ring and the piston. 1 See Procedures 901-1.2 and 902-1.2. Clean the oylinder liner and scavenge air ports. 2. Position the cylinder liner measuring tool. Measure the cylinder liner with an inside micrometer at the positions indicated on the measuring tool. Take measurements in the fore-and-aft and athwartship directions. Check and assess the condition of the cylinder liner according to the description given in Volume |, Chapter 707. Note! If the cylinder liner is to be replaced, the | piston cleaning ring must also be re- | placed. ROT CBRTCHE 3. Carefully soratch over any scores or marks and grind away the wear ridges. See Procedure 903-1.3, 4, Check the lubricating points of the cylinder by pumping cylinder oil to each lubricating point with the cylinder lubricator. Clean any blocked lubricating duct. Mount the piston and cylinder cover. See Procedures 902-1.4 and 901-1.4. WaRROT OaET CE When referring to this page, please quote Procedure M90301 Edition 0257 Page 1 (10)Cylinder Liner HYUNDAI Checking MAN B&W 5. Piston cleaning (PC) ring: The PC-ring is to be regarded as an inte- grated part of the liner and it is intended to follow the service life of the liner. During inspection of the piston and the liner, the PC-ring must also be inspected. 6. Measure the PC-ring radial width B, and find the most worn place. Compare with Data D03-16 and calculate the wear of the PG-ring, multiply the wear by 2 to get the PC-ring diameter wear. Measure the liner in the fore-and-aft and athwartship directions at piston skirt TDC position, corresponding to measuring point No, 5 on the liner-measuring tool. Compare the measurements with the diameter of a new liner as stated in Data. Calculate the wear of the liner, 7. Compare the PC-ring diameter wear with the wear of the liner. If wear of the two ‘components does not deviate more than 03-17 then reinstall the PC-ring. If the deviation between PC-ring wear and liner wear is more than D03-17 or if the PG-ting is broken or cracked, replace the ring with a new PC-ring, an oversize ring or no ting according to the table in 03-18 on the Data sheet. If it is necessary to install an oversize PC- ring, contact MAN B&W Diesel for advice. When a new liner is installed, also a new PC-ring must be installed. When a new liner is ordered, also a new PC-ring must be ordered. Page 2 (10) When referring (o this page, please quote Procedure M0301 Edition 0257HYUNDAI Cylinder Liner 903-1.2 ie B&W Dismantling 1. Dismount the cylinder cover. See Procedure 901-1.2. 3 Discard the sealing ring from the top of the cylinder liner. ‘Turn the piston down far enough to make it possible to grind away the wear ridges at the top of the liner with a hand-grinder. ‘See Procedure 903-1.3. Dismount the piston cleaning ring and the piston. See Procedure 902-1.2. 2. Screw the two lifting tools on to the cylinder liner. Check with a feeler gauge that there is no clearance between lifting tool and cylinder liner. For tightening torque, see Data, HOO DESTORE 3. Disconnect the oil pipes leading from the cylinder lubricator to the cylinder liner. Dismount the four cooling water pipes - between the cooling jacket and cylinder cover and discard the O-rings from the pipes - and clean them carefully. ‘When referring to this page, please quote Procedure M90301 Edition 0257 Page 3 (10)903-4.2 Cylinder Liner HYUNDAI Dismantling ROT ESTOE MAN B&W Remove the screws of the cooling water inlet pipe. . Attach the crane to the lifting crossbar. Hook the lifting tools on to the crossbar on both sides of the cylinder liner. Lift the liner with the cooling jacket out of the cylinder frame. Note! Low lifting height in the engine room may require the removal of one or more cylinder cover studs before dismantling the cylinder liner. Land the cylinder liner vertically on, for instance, a couple of planks. Clean the cylinder frame internally, taking special care with the contact surfaces for the oylinder liner at the top of the cylinder frame. ‘The lifting tools are also used for transporting the cylinder liner. Page 4 (10) When referring to this page, please quote Procedure MS0301 Ealtion 0257Cylinder Liner 903-1.3 Overhaul 4. Remove the non-return valves for the cylinder liner lubrication Attach two tackles to the crossbar, as shown. Mount two lifting eye bolts in the cooling jacket, Hook the tackles on to the lifting eye bolts ‘on the cooling jacket and haul tight. Loosen the screws on the clamps which fix the cooling jacket to the cylinder liner. Turn the clamps away from the liner. 2. Lower the cooling jacket by means of the tackles and land it on the wooden planks. TROT RTO p 3, Mount the lifting tools on the cylinder liner. See Date. Lift the cylinder liner away from the cooling jacket. Clean the cooling jacket internally. TROT CETOUE TROT GETOR When referring to this page, please quote Procedure M90301 Edition 0257 Page 5 (10)903-1.3 Cylinder Liner Overhaul HYUNDAI MAN B&W. A Ch aT ORTOOE 4, Check and assess the condition of the cy!- inder liner according to the description given in Volume |, Chapter 707. Carefully scratch over any scores or marks ‘on the cylinder liner running surface, by means of a rough grindstone held in the hand. Check in the top of the liner for a wear ridge (where the piston rings reverse direction), If there is any sign of a wear ridge, it Is necessary to create a groove by grinding.The groove serves to prevent the build-up of a new wear ridge. 5. It is recommended to use a wear ridge milling machine to create the groove. For use of the milling machine, see supplier's instruction. 6. Alternatively, place an old piston ring on the top of the piston and turn to a position that enables the grinding disc to rest on the old piston ring while removing the wear ridge. Use a grinding disc with a round edge. Check the distance © before grinding to ascertain that the wear ridge was caused by the top ring at TOC. The maximum depth of the groove is calculated as S_.. = D x 0.0045. Note! It is of the utmost importance that the groove is made with a regular rounding as shown in the sketch. Page 6 (10) When referring to this page, please quote Procedure M90301 Edition 0257HYUNDAI Cylinder Liner 903-1.3 MAN B&W Overhaul 7. Apply a thin layer of grease on the contact surface for the cooling jacket on the liner. Mount the lifting tools on the liner. Lift the liner a little and mount new O-rings for the cooling jacket. Then place the liner in the cooling jacket. Remove the lifting tools. 8. Lift the cooling jacket into position - marking scratches jacket/cylinder liner must coincide (manoeuvre side). ‘When referring to this page, please quote Procedure M90301 Ealition 0257 Page 7 (10)Cylinder Liner HYUNDAI Overhaul MAN B&W. 9. Tum the clamps until they fit in the groove of the liner, and tighten the screws. Remove the tackles and the eye bolts from the cooling jacket. Mount the non-return valves for the cylinder liner lubrication. SCOT HESTON Page 8 (10) When referring to this page, please quote Procedure M90301 Edition 0257HYUNDAI Cylinder Liner 903-1.4 MAN B&W Mounting 1. Mount the lifting tools on the cylinder liner and tighten to the specified torque. o See Data. Hook the lifting tools on to the crossbar, and lift the jacket/liner assembly. Mount the lowermost O-ring and apply a litle lubricating oil on the ring. Check that the joint surfaces on the cylinder frame and cylinder liner are completely clean. Coat the joint surfaces with permatex or a similar liquid sealing compound. TRIO ESTNOT Mount the cylinder liner in the cylinder frame. Replace the O-rings on the water connections and mount the water connec- | 2. tions on the cooling jacket. 3. If one or more cylinder cover studs have been removed during the dismantling, mount the studs. ‘See Procedure 902-1.4, 4. Fit a new gasket between the cooling water inlet pipe and the cooling jacket. Mount and tighten the screws. ST TST When referring to this page, please quote Procedure M90301 Edition 0257 Page 9 (10)Cylinder Liner HYUNDAI Dismanting MAN B&W 5. Screw the pipes from the lubricator on to the non-return valves, but do not tighten, Vent the cylinder lubricating system by pumping all pipes through until oil, without air bubbles, comes out from the union pipe/non-retum valve. When this is in order, tighten the pipes firmly on the non-return valves and again pump until it is certain that each individual lubricating point functions correctly. 6. Lubricate the inside of the cylinder liner with cylinder lubricating oll and mount the piston and the piston cleaning ring. See Procedure 902-1.4. HEROS Note! Make sure to mount the piston cleaning ring correetly, so that the scratching marks are aligned. 7. Mount the sealing ring and the cylinder cover: See Procedure 901-1.4. Tighten the upper water connections on the cooling jacket as soon as the cylinder cover is correctly positioned. \ Tr BOT TOT 1 Page 10 (10) When referring to this page, please quote Procedure M90301 Edition 0267HYUNDAI _[MAN B&W. Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 Cylinder Lubricators 103-2 X | Stopped engine X | Shut off starting air supply — At starting air receiver, X | Block the main starting valve X | Shut off starting air distributoridistributing system supply X | Shut off safety air supply — Not ME-engines X_| Shut off controt air supply X | Shut off air supply to exhaust valve ~ Only with stopped lubricating oil pumps X | Engage turning gear ‘Shut off cooling water Shut off fuel oi ‘Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description Value | Unit 1003-10 | Inlet accumulator, nitrogen pressure, 30 | bar 03-11 | Outlet accumulator, nitrogen pressure, 4.5 | bar 03-13 | Plug screw, tightening toraue, Nm When referring to this page, please quote Data 010302 Eaition 0028 Page 1 (2)103-2 ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the Cylinder Lubricators Data HYUNDAI MAN Baw chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate tem No. Description Poos64 Test Equipment for Lubricators Page 2 (2) \Whon referring to this page, please quote Data D10302 Edition 0028Cylinder Lubricators 903-2.1 Checking Check of Oil Injecti With stopped engine and normally when the system has been disassembled: 1. Press the ESC + PRELUB.--button on the HMI control panel, and check that all ubri- cators are operating correctly by watching the LEDs on the intermediate boxes for each lubricator. 2. If the cylinder cover or the exhaust valve is removed, check inside the liner that all lubricating points are working properiy. Otherwise, remove the covers for scavenge port inspection. Turn the piston to BDC and check inside the liner with a mirror and a powerful light, source that all lubrication points are working properly. RST WRORETEEOOE When referring to this page, please quote Procedure M90302 Edition 0249 Page 1 (12)Cylinder Lubricators HYUNDAI Checking MAN B&W With running engine: 3. Check that all lubricators are operating correctly by watching the LEDs on the intermediate boxes for each lubricator. ‘The LEDs give signal when oil is injected. Check the pressure shocks from the injection of the lubricators on each lubricator pipe by feeling with a hand. If in doubt, disconnect the pipe at the cylinder liner to observe the oil flow, Check of Accumulators: 4. Measuring the nitrogen pre-pressure can only be done with stopped engine and pressure-free lubrication system. Stop both oil pumps. Close the inlet valve and open the equalizing valve on the respective lubricator. The nitrogen pressure in the inlet accumnu- lator (0.7 litre) can be checked without dismounting the accumulator. For use of the pressure setting tool, see Step 5. 5. To measure the nitrogen pressure in the outlet accumulator (0.16 litre), the accumulator or the lubricator with accumulator must be dismounted. See Procedure 903- 2, For nitrogen pressure in the accumulators, see Data. ‘When referring to this page, please quote Procedure M90302 Edition 0249HYUNDAI Cylinder Lubricators 903-2.1 MAN B&W Checking 6. Use of Pressure Setting Too! Assemble the pressure setting tool as ‘shown in Figure 5, and mount the reducing valve on the nitrogen cylinder. If necessary, use a threaded adaptor. Mount a 0-60 bar pressure gauge on the filling valve when the inlet accumulator (0.7 litre) is to be checked, and a 0-10 bar pressure gauge when the outlet accumulator (0.16 litre) is to be checked. 7. Before mounting the filling valve on the accumulator, check that the accumulator top is clean. Mount the filing valve on the relevant accu- mutator with the union nut. Check that valves © and F are closed. Loosen the plug screw in the accumulator using a %” square drive handle in socket E. It is now possible to read the actual nitrogen pressure in the accumulator on the dial ‘gauge on the filing valve. 8 If the accumulator needs to be refilled with nitrogen, open valve A and increase the outlet pressure from valve C on spindie B to 1-2 bar above the pressure stated in Data. Open valve C until the accumulator is filled to the correct pressure. Close valve C and tighten the plug screw with socket E to the torque stated in Data, Release the pressure in the filling valve at bleed screw F. Unscrew the filing valve from the accumulator. Retighten the plug screw to the torque stated in Data. Remount the accu- mutator, When referring to this page, please quote Procedure M90202 Edition 0249 Page 3(12)903-2.2 Cylinder Lubricators HYUNDAI mantling MAN B&W Inlet 2 = Dismantling of lubricators: The engine must be stopped and blocked before dismounting a lubricator. Stop the cylinder oll pump station, 1. Close the supply valve for the lubricator and open the equalizing valve (turn both handles to @ horizontal position). Remove the upper shield, if installed. Disconnect the electrical plug on the side of the lubricator. 2. Unscrew the six screws in the bottom of the lubricator and disconnect the cover with pertaining pipes. 3. Unscrew the four screws on the side that secure the lubricator to the hydraulic block, and remove the lubricator. Special running It is possible to change a lubricator while the engine is running if a spare lubricator with O- rings and the necessary tools is available. The change should be done in a maximum of 15 minutes. + Reduce the engine load to below 40% of MCR + Let the lubricator pump station run + Dismount the lubricator as described in steps 1-3 + Mount a spare lubricator as described in Procedure 903-2.4 Page 4 (12) When referring to this page, please quote Procedure M90302 Eallion 0249HYUNDAI Cylinder Lubricators 903-2.2 MAN B&W Dismantling Dismantling of accumulators: 4, The engine must be stopped and blocked before the accumulator is dismounted, Stop the cylinder oil pump station. Close the supply valve for the lubricator and open the equalizing valve. Note! ‘When the oll pressure is released, a ni- ‘trogen pre-pressure of 25-30 bar will re~ main in the accumulator. Carefully unscrew the accumulator to release the remaining oil pressure in the system, Remove the accumulator from the hydraulic block. inven referring to this page, please quote Procedure M90302 Edition 0249 Page 5 (12)903-2.3 Cylinder Lubricators HYUNDAI Overhaul MAN B&W 1. Place the lubricator in a bench vice with soft "jaws" Remove the adjusting screw with bushings. Unscrew the oil accumulator. Discard the O-ring from the adjusting screw. 2. Remove the screws from the cylinder block. 3. Pull up the cylinder block. Remove the spring and actuator piston with plungers. RE CETOT Remove and discard the O-ring from the cylinder block. Remove the cover for the non-return valves, Take out springs and balls. Remove and discard the O-rings. TGRETENTO Page 6 (12) When referring to this page, please quote Procedure M90302 Edition 2494, Screw out the non-return valves and remove and discard the O-rings. Clean the valves and check them with compressed air 5. Inspect the plungers. actuator piston and cylinder block for wear, using 2 magnifying glass. 6. Fit the non-return valve with new O-rings. Mount the non-return valves in the cylinder block. RREDATOO HYUNDAI Cylinder Lubricators 903-2.3 MAN B&W Overhaul RTOS inen referring to this page, please quote Procedure M90302 Edition 0249 Page 7(12)903-2.3, Cylinder Lubricators HYUNDAI Overhaul MAN B&W. 7. Pre-assemble the cylinder blockwith the actuator piston and plungers to ensure the correct guidance of the plungers, before finally assembling the cylinder block unit. Mount the spring and press down the ac: tuator piston with plungers, Mount an M6 x 60 screw with a washer to keep the spring compressed, Fit the cylinder block with a new O-ring. DRE TERTORT Page 8 (12) When referring to this page, please quote Procedure M90302 Ecltion 0249Cylinder Lubricators Overhaul 903-2.3 3. Remove the cover from the terminal box and disconnect the wires for the feedback (pick-up) sensor. Remove the terminal box and the plug for the solenoid valve. Carefully unscrew the feedback sensor and remove and discard the O-ring, Clean the housing with diesel oil or kerosene and dry with a non-fluffy cloth. 9 Turn the lubricator upside down in the vice. Unscrew the solenoid valve. Discard the O-rings. 10. Solenoid valve: Disassemble and clean the valve. Check the slide for wear. If the slide is scratched or scuffed, the valve must be replaced by a new one. Lubricate the slide with oil and check that the slide can move lightly with a good fit in the housing, ‘Assemble the valve. See also manufacturer's instructions. TREO RETA 0. When referring to this page, please quote Procedure M90302 Edition 0249 Page 9 (12)903-2.3 Cylinder Lubricators HYUNDAI Overhaul MAN B&W. 11. Before mounting the feedback sensor, check that the sensor is flush with the sensor housing, i. Mount the feedback sensor or a new one, if necessary, with a new O-ring. Check with an object with a straight edge (eg. the end of a calliper) that the end of the feedback sensor does not protrude into the actuator piston cylinder. Mount the terminal box. ‘Solenoid valve 11. Connect the wires and mount the cover on the terminal box. ] fo] BN (brown) BK @Bcd |Feedback sensor 13. Mount the solenoid valve fitted with new O-rings. Coat the O-rings with a litle grease to keep the rings in place during mounting, TERETE 13, TRIP CEOTS Page 10(12) When referring fo this page, please quote Procedure M90302 Eultfon 0249HYUNDAI Cylinder Lubricators 903-23, MAN B&W. Overhaul 14. Mount the cylinder block assembly in the cylinder housing. 14, Check that the spring pin engages correctly with the cylinder block assembly. Mount the screws and tighten the block to the housing Remove the M6 x 60 screw with disc. 15. Mount the adjusting screw fitted with a new O-ring and the distance bushing. Mount the oil accumulator. 16. If the lubricator is not to be mounted on the engine immediately after overhauling, cover all openings with plastic to prevent TE TOS Girt from entering the lubricator during stor- | 15. age. Cover all surfaces with a thin layer of oil a iE When referring to this page, please quote Procedure M90302 Edition 0249 Page 11 (12)HYUNDAI Cylinder Lubricators 903-2.4 MAN B&W. Mounting 1, Before mounting the accumulator, check the nitrogen pressure, see Data Mount the accumulator. 2. Mount new O-rings on the hydraulic block and on the cover with pipes. Mount the lubricator and tighten the screws on the hydraulic block. Tighten the screws in the bottom of the lubricator to the pipe connection. Close the equalizing valve and open the supply valve {handles to be in a vertical position). TOR AT Mount the electrical plug. Check the injection of cylinder oil on the feedback LED on | 2. the terminal box for the specific ‘ubricator. TET When referring to this page, please quote Procedure MS0302 Edition 0249 Page 12 (12)HYUNDAI it = MAN B&W Cylinder Liner - Tools Plate P90361-0084 0302 When referring to this page, please quote Plate P90361 Edition 0084Plate P90361-0084 Cylinder Liner - Tools item Item Description tem Item Description No. No. 036 | Cylinder gauge, complete 0301 | Cover for cylinder bore 0302 LadderHYUNDAI Test Equipment for Lubricator Plate P90364-0004 MAN B&W O19 ozo posan4 | | 1 ! Tten No.] AUtepnet ive Thread Type Ne. 032 G3/4"-ISO 228 1 533_391 015 (GUS) 084 w22n1/14" 4 533 391 014 (JAP) 152 G5/8-1S0_ 228 4 533 394 O11 (GB) 164 W24.5x1/14" 1 533_391 012 (USA) 176 wesc 14" {835 391 O18 (KOR) 214 W'21 8x1 /14" $ 533 391 010 (F) When referring to this page, please quote Plate P90364 Edition 0004Plate P90364-0004 Test Equipment for Lubricator vid Item Description ao Item Description 019 Tool box 020 Nameplate 032 | Adaptor 044 Pressure gauge 056 ‘Spanner 068 Pressure gauge 081 | Adaptor 103 Hose with 2 union 115 Quick coupling, minimess 139 | Reducing valve 152 | Adaptor 164 | Adaptor 176 | Adaptor 211 Adaptor 223 | Filling and testing valveHYUNDAI iner - Lifti MAN B&W Cylinder Liner - Lifting Tools Plate P90366-0007 When referring to this page, please quote Plate P90366 Edition 0007Plate P90366-0007 Cylinder Liner - Lifting Tools Item Item ae hoe Item Description No. Item Description 021 | Crossbar for cylinder liner18-02 | Hydraulic pressure, dismantling HYUNDAI Crosshead Bearing 104-1 MAN B&W Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 [X] Stopped engine [XX] Shut off starting air supply ~ At starting air receiver [3c] Block the main starting valve [2C] Shut off starting air distributor/distributing system supply [2C] Shut off safety air supply - Not ME engines [x] Shut off control air supply Shut off air supply to exhaust valve - Only with stopped lubricating oll pumps X_| Engage tuming gear Shut off cooling water Shut off fuel oil [3€] stop tubricating oil supply [__] Look the turbocharger rotors Data [ Ret. Description Value Unit 02-02 _| Piston rod/crosshead, tightening torque 590 | Nm 02-20 | Piston complete 1876 | kg 104-01 | Grosshead bearing, top clearance max. 0.45 | mm Dod-02 | Crosshead bearing, top clearance min. 0,2 | mm 04-08 wedge length, L 15 | mm 04-04 | Grosshead bearing cap 197 | kg 04-08 | Crosshead bearing shell, lower 40 | kg 04-07 | Crosshead bearing cap with bearing shell a4 |kg | D04-21 | Crosshead complete 1250 | kg Do4-66 | Crosshead with piston and guide shoes 3424 | kg 13-01 | Hydraulic pressure, mounting 1500 | bar 1400-1650 | bar When referring to this page, please quote Data D10401 Edition 0076 Page 1 (2)404-4 Crosshead Bearing HYUNDAI Data MAN B&W. “The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate | Item No. Description 90451 | 059 | Lifting attachment - connecting rod Pg04s1 | 072 Chain for suspending piston 90451 | 096 | Bracket for support, cross head 90451 | 106 | Bracket for support, cross head 90464 Crosshead - hydraulic tools 91356 Lifting tools, etc. Poi3ses | 057 | Feeler gauge Page 2 (2) When referring to this page, please quote Data D10401 Ecltion 0076HYUNDAI Crosshead Bearing MAN B&W. Checking 904-14 Tin-Aluminium bearings The top clearance between the journal and a new bearing shell is the result of a summation of the production tolerances of the bearing assembly components. The top clearance for a new bearing will normally be in the range stated in Data. Note that the figures are to be used for guidance only. For the top clearance of a specific bearing, see the measurement in the Adjustment Sheet in Volume 1, OPERATION. 1. Open the crankcase door at the relevant cylinder. 2. Tum the crankthrow concerned to BDC. 3, Measure the clearance in the crosshead bearing by inserting a feeler gauge between the bearing cap and the crosshead journal at the top of the upper bearing shell, at both sides and fore and aft. See Data. 4, The difference between the actual clearance measurement and the measurement recorded in the Adjustment Sheet (or the clearance noted for a new bearing installed later) must not exceed 0.1 mm. If so, the crosshead bearing must be disassembled ‘or inspection. See Procedure 904-1.2. For evaluation of the bearing shell, see Chapter 708, ‘Bearings’ in the instruction ‘book, Volume |, OPERATION. 5. The wear limit for a crosshead bearing shell Is confined to a 50% reduction of the oil wedge length L. If the wear limit exceeds the 50% reduction, the bearing shell must be replaced by anew one. 2. TaD ORCRE HOTT (OilWedge) TROT TEI Wien referring to this page, please quote Procedure M90401 Edition 0261 Page 1 (17)904-11 Crosshead Bearing HYUNDAI Checking MAN B&W 7. Alternate checking method: \ © ee : | 'g é ee Hy Ie ig t e 8 i eR e iz e 9. In case the reason for opening the crosshead bearing is a routine inspection, the following procedure is sufficient. 6. Perform the clearance measurement shown in 904-1:1 section 3. 7. Mount the two eyebolts and tackles in the top of the crankcase in the fore and aft direction. Mount two eyebolts on top of the guideshoes. Turn to BDC, mount the connecting rod lifting attachments on the connecting rod. Use tackles to hold the connecting rod in the vertical position. Dismount the crosshead bearing cap hydraulic nuts. For operation of the hydraulic Jacks, see Section 913. 8. Fit protecting screws or the bearing cap studs. Fit four eyebolts in the bearing cap and use two small tackles in the athwartship direction to lift the bearing cap free of the guidepins and to keep the bearing cap balanced. 9. Use the tackles in the crankcase top to lift the crosshead and piston high enough to allow inspection of the lower crosshead bearing, Note! Enaure that the crosshead is lifted simultaneously fore and aft, Le. by placing marks on the guide planes using a felt tipped pen. 10. If the lower bearing shows no anomalies the piston and crosshead Is lowered again and the crosshead bearing cap nuts are ‘mounted. +1, Recheck the bearing top clearance. Remove all tools. 12. If there are any doubt concerning damage to the upper bearing, the bearing has to be dismantled and checked according to 904-1.2 2 TTT AERC ® When referring to this page, please quote Procedure M90407 Ecition 0261HYUNDAI Crosshead Bearing 904-1.2 MAN B&W Dismantling This procedure applies to the following two dis mantling situations: 7 — * with piston mounted ‘* with piston removed With piston mounted: 1. Turn the crankshaft down far enough to / give access to the nuts and screws on the piston rod. 2. Mount two chains in the inner screw holes in the top of the crankcase, in the athwarthship direction, for suspending the piston rod. OTRO 3, Loosen and remove the piston rod foot hydraulic nuts. For operation of hydraulic jacks, see Procedure M91301. p TROT BESIONE woes aRRTORT ‘When referring to this page, please quote Procedure M9040} Ecition 0261 Page 3(11)Crosshead Bearing HYUNDAI Dismantling MAN B&W 4, Mount a lifting eyebolt on each side of the piston rod. 5. Tum the crosshead to TDC. Hook the chains to the lifting eyebolts in the piston rod. Tum the crosshead downward, and the piston rod will then remain suspended from the two chains. With piston removed: 6. Turn to BDC. 7. Place the spacer rings around the nuts and screw the hydraulic jacks on to the studs. Loosen the crosshead bearing cap nuts. For operation of the hydiraulic jacks, see Procedure 91301. Remove the hydraulic jacks and the spacer rings, and unscrew the nuts. ‘When referring to this page, please quote Procedure M90401 Ecition 02678. Mount the lifting attachments on the head of the connecting rod. 9. Suspend two tackles from the lifting brackets, in the athwarthship direction. 10. Mount the wire guide at the top of the crankcase door frame to prevent damage. Fit four eyebolts in the top of the crosshead bearing cap. Fit protective screws on the bearing cap studs. Hook the tackles on to the eyebolts, and remove the bearing cap from the engine. Check the upper part of the journal. RIOT THOT HYUNDAI Crosshead Bearing MAN B&W. Dismantling TTT 04-07 When referring to this page, please quote Procedure M90401 Edition 0261 Page 5 (11)904-1.2 Crosshead Bearing HYUNDAI Dismantting MAN B&W a 11. Place the bearing cap on one side on a : couple of wooden planks. Check the bearing shell, see Procedure 904-11. 12. Fasten tackles to the fixed lifting brackets ‘on the frame box wall. 1. Turn the crosshead upwards until the piston rod lands on the crosshead. Ensure that the guide ring in the crosshead fits correctly in the centre hole of the piston rod. Do not remove the chains or lifting eyebolts. TORSO ra on aaB HODTOT COON Page 6 (11) When referring to this page, please quote Procedure M90401 Eaition 0261HYUNDAI Crosshead Bearing 904-1.2 MAN B&W. Dismantling 14, Turn to TDG and attach the tackle hooks to the lifting attachments. Haul the tackles tight. 14. 18. Mount the four supports for guide shoes on the crosshead guides. Carefully tum the crank down towards the ‘exhaust side, until the guide shoes rest on the supports. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. Haul the tackles tight. TOGO BOTT 46, Turn the crankthrow carefully towards BDC while ‘following’ with the tackles, thus continuously supporting the connecting rod, 17, With the crosshead resting on the supports, check the lower part of the crosshead journal and the lower bearing shell. Regarding checking of journal and bearing shells, see Volume |, OPERATION, Chapter 708, ‘Bearings’. OO OEOT ROT EBOTE When referring to this page, please quote Procedure M0401 Eattion 0261 Page 7 (1)904-1.2 Crosshead Bearing HYUNDAI Dismantling MAN B&W 7 48. In cases where it is necessary to remove the lower bearing shells, tit the connecting rod towards the doorway on the camshaft 04-06 side, using the tackles. Dismount the locking screws, and turn the bearing shells so far up that an eyebolt can be mounted. Lift the bearing shell out of the engine. Teo SOE Page 8 (11) When referring to this page, please quote Procedure M90401 Edition 0261HYUNDAI Crosshead Bearing 904-1.4 bit Mounting With piston mounted/ With piston removed: 1. Mount and secure the bearing shell in the bearing housing. The excess height X is to ensure the correct tightening-down of the bearing shell and must not be eliminated. 2. Raise the connecting rod to an upright position. Turn to TDC while ‘following’ with the tackles, for assembling the crosshead and the connecting rod. Take care that the guide shoes do not damage the bearing shell. [evaraemaor 8. Remove the supports from the crosshead guides. Remove the tackles from the crosshead. ‘Turn the crank throw to BDC. If the piston is mounted, slowly turn down until itis fully suspended from the chains, ORONO WOOT TERIA When referring to this page, please quote Procedure M90401 Ealtion 0261 Page 9 (11)904-1.4 Crosshead Bearing HYUNDAI Mounting MAN B&W a 4, Lift the bearing cap into the engine. Lower HORE OSES TOTTI, the bearing cap onto the crosshead and remove the tackles. Remove the lifting attachments from the connecting rod and the wire guide from the door frame. Note! Take care that the bearing studs do not damage the crosshead. 5. Remove the protective screws on the beat= ing cap studs and tighten all four crosshead bearing cap nuts simultaneously, See Data. For operation of hydraulic jacks, see Sec- tion 918. 6. Mount the piston. ‘See Procedure 902-1.4. With piston mounted: 7. Turn the crosshead upwards until the piston rod lands on the crosshead, Ensure ‘that the guide ring in the crosshead fits correctly in the centre hole of the piston rod. Page 10 (19) When referring to this page, ploase quote Procedure M0401 Edition 0267HYUNDAI Crosshead Bearing 904-1.4 MAN B&W Mounting 8. Unhook the chains from the lifting eyebolts in the piston rod. Remove the chains and eyebolts from the top of the crankcase, from the piston rod and from the crosshead bearing cap. 9. Tum down to BDC, tighten the hydraulic nuts in the piston rod, and lock with locking wire. See Data. Mount the locking wire in such a way that the wire is tightened if a screw works loose. See Procedure M913-7, When referring to this page, please quote Procedure M90401 Ecition 0261 Page 11 (1)HYUNDAI Crosshead 104-2 MAN B&W. Bt Data. SAFETY PRECAUTIONS Fordetailed sketch, see 900-2 X | Stopped engine X | Shut off starting air supply — At starting air receiver X | Block the main starting valve X | Shut off starting air distibutor/distributing system supply [ x | Shut off safety air supply ~ Not ME engines X_| Shut off control air supply [x | Shut off air supply to exhaust valve — Only with stopped lubricating oil pumps [x | Engage tuming gear [oc] Shut off cooling water [| Shut off tue! oit [x | Stop lubricating oil supply. |] Lock the turbocharger rotors Data Ret. Value | Unit 04-04 | Crosshead bearing cap 277 | kg 004-08 | Cooling oil outlet pipe, tightening torque 80 | Nm 0412 | Guide strip screws, tightening torque 350 | Nm 04-13 | Guide plate, tightening torque 3x360 | Nm | 1x80 | Nm Do4-15 | Telescopic pipe, tightening torque 80 | Nm. Do4-19 | Telescopic pipe, tightening angle eo | ° 04.21 | Crosshead complete 1245 | kg 004-22 | Guide shoe 325 | kg 04-23 | Cooling oll outlet pipe 15 | kg 04-50 | Connecting rod, without beating caps 1820 | kg 13-01 | Hydraulic pressure, mounting 1500 | bar 113-02 | Hydraulic pressure, dismantling 1400-1650 | bar ‘When referring to this page, please quote Data D 10402 Ealtion 0060 Page 1 (2)The task-specific tools used in chapters indicated by the first three digits in the plate number, e.g. P0951 refers to chapter 909. Crosshead HYUNDAI ha MAN B&W. procedure are shown on the plates at the end of this chapter or in the Plate Item No. Description 204s 47 | Wire guide Peoast 84 | Lifting attachment - connecting rod P9odst 120 | Lifting tools ~ crosshead 90451 96 | Retaining tool telescope pipe P0451 406 | Rubber cover for crosshead Pe04s1 118 | Rubber cover for crosshead Pso4s1 143_| Torque wrench offset tool P0462 11 | Guide shoe extractor, complete Ps0d63 Grosshead — hydraulic tools 91361 40 | Hydraulic pump, pneumatic operated 91351 46 | Hose with unions (1500 mm), complete P9135 58 | Hose with unions (3000 mm), complete P91351 117 | S-way distributor block, complete | P9366 Litting tools, ete. | 91359 40 | Torque spanners Page 2 (2) When referring to this page, please quote Data D10402 Edition 0060Crosshead 904-2.2 Dismantling 4. Unbolt the main bearing lubricating oil pipes. 2. Unbolt the cooling oil outlet pipe from the guide shoe and the drain oil slotted pipe. Loosen and remove the screws which secure the telescopic pipe to the guide shoe. In order to reach the screw in the corner behind the telescopic pipe, use the offset tool along with a socket wrench. 8. Mount the retaining too! for the telescopic pipe on the stuffing box housing for the telesconic pipe. Cao Mount two eye bolts in the top of tne crankcase in the fore-and-att direction. ‘Mount two eye bolts in the athwartship direction, and suspend two tackles. i 3 & & t ig When referring to this page, please quote Procedure M90402 Edition 0248 Page 1 (9)904-2.2 Crosshead HYUNDAI Dismantling MAN B&W 4, Turn the crosshead to TDC. ‘Suspend the telescopic pipe by means of the tool. Suspend the piston. To suspend the piston, see Procedure 904-1.2. 5. Turn the crosshead to gain access to the nuts on the crosshead bearing studs, Mount the spacer rings and the hydraulic jacks for loosening the nuts on the cross head bearing studs. OREO For operation of the hydraulic tools, see Section 913, Loosen the nuts, remove the hydraulic jacks and unscrew the nuts. 6. Mount eye bolts in the crosshead bearing cap and hook the tackles on to the lifting brackets in the top of the crankcase. Remove the bearing cap and lift it out of the engine. When referring to this page, please quote Procedure M90402 Edition 0248HYUNDAI Crosshead 904-2.2 MAN B&W Dismantling Lifting of the crosshead: 7a. Mount the special lifting tool on the crosshead. Mount the lifting attachments for fixing the connecting rod, on the head of the connecting rod. Fasten tackles to the lifting brackets on the frame box wall and attach the tackle hooks to the lifting attachments. Haul the tackles tight. Hook the tackles to the top lifting brackets ‘on to the lifting tool on the crosshead, and lift the crosshead. 7b. Alternate method. If the piston has been removed it is advisable to use the engine room crane and the flat plated wire strap to handle the crosshead. “This is done by lowering the strap down through the cylinder and stuffing box and lifting the crosshead in the crosshead fifting tool, This eliminates the need for the tackles placed in the athwartship direction in the crankcase top. 8. Use the tackles to tilt the connecting rod towards the exhaust side, while turning the crankthrow towards the camshaft side. Transfer the tackles from one lifting attachment to another as necessary. When the crankthrow is 90° after BDC, stop turning. By alternate use of the tackles, tilt the connecting rod until it rests against a couple of ‘wooden planks in the bettom of the bedplate. TAOS When referring to this page, please quote Procedure M90402 Evition 0248 Page 3.(9)904-2.2 Crosshead HYUNDAI Dismantling _ TREE [ sisce amore MAN B&W 9. Lower the crosshead to a position just above the main bearing caps. Remove the guide strips and both guide plates from the guide shoes. Mount lifting eye bolts in both guide shoes. 10, Suspend two tackles from the eye bolts in the top of the crankcase, in the fore-and- aft direction, and attach the tackles to the guide shoes. Push one of the guide shoes towards the middle of the crosshead. If necessary, use the guide shoe extractor tool. 11, Pull the “free end” of the crosshead into ‘the neighbouring cylinder unit. Mount the guide shoe extractor on the opposite guide shoe. Pull off the guide shoe, remove the extractor, and lift up the guide shoe. Page 4 (9) When referring to this page, plaase quote Procedure M90402 Ealton 0248HYUNDAI Crosshead MAN B&W Dismantling 904-2.2 12, Pull the crosshead with guide shoe into the ‘opposite neighbouring cylinder unit. 12. Mount the guide shoe extractor tool on the remaining guide shoe. Pull off the guide shoe, remove the extrac tor tool and lift up the guide shoe. 43. Turn the crosshead 90°. 14, Mount the wire guide tool in the framebox door opening. Remove the crosshead from the engine, using wire rope and tackles. OORE DOT Protect the crosshead, for instance with thick or corrugated paper, and land it outside the engine. 13. If necessary, remove the guide shoes from the engine. aR When referring to this page, please quote Procedure M90402 Ealtion 0248 Page 5 (9)904-2.4 SOREN Crosshead HYUNDAI Mounting TaaOE TPABTE 1 2 MAN B&aw Lift the crosshead into the engine, using wire rope, tackles mounted in the top lifting brackets inside the engine. Tum the crosshead 90°, Pull the crosshead to one side under the web plates between the cylinders. Lower one guide shoe in the other side of the crosshead and mount the guide shoe extractor tool. Use the guide shoe extractor tool to pull the crosshead so far through the guide shoe that the other guide shoe can be lowered. Follow the movement of the crosshead with the tackles mounted in the engine. 3. -+| I ig ae & Page 6) When referring to this page, please quote Procedure M8040? Edition 0248HYUNDAI Crosshead 904-24 MAN B&W Mounting 4, Lower the other guide shoe. Use the guide shoe extractor tool to push the crosshead towards the second guide shoe. Remove the extractor tool and adjust the position of the opposite guide shoe. 5. Mount the guide plates on the side of the guide shoes. Tighten the screws and lock them with locking wire. ‘See Procedure 913-7. Remove the eye-bolts from the guide shoes. rarer mROTE Use the tackles in the fore and aft eyebolts | 5. to lift the crosshead to a working position and mount the guide strips on the side of the guide shoes, Tighten the screws and lock them with locking wire. See Procedure 913-7. 6. Using the tackles, lift the connecting rod to a vertical position while turing the crankthrow to BDC. TRON When referring to this page, please quote Procedure M9042 Edition 0248 Page 7 (9)904-2.4 Crosshead HYUNDAI Mounting MAN B&W. 7. When the connecting rod is in a vertical position, lower the crosshead and land it (on the connecting rod, Remove the lifting attachments from the connecting rod head. Remove the lifting tool from the crosshead. 8. Lift the crosshead bearing cap into the engine. 9. Mount the spacer rings and the hydraulic jacks for tightening the nuts on the crosshead bearing studs. For operation of the hydraulic tools, see Procedure 913. Mount the drain oil slotted pipe and the cooling oil outlet pipe on the guide shoe. Turn the crankshaft to TDC. Land the telescopic pipe on the guide shoe. Page 8 (9) When referring to this page, please quote Procedure M90402 Eultion 0248HYUNDAI Crosshead MAN B&W Mounting 904-2.4 10. For tightening the bolt in the comer bel the telescopic pipe, use the offset tool along with the torque wrench. Mount the cooling oil outlet pipe. 11. Mount the lubricating oil pipes on the main bearing caps. 12, Mount the piston. ‘See Procedure 902-1.4. 18. Remove all tools from the engine. Always search the crankcase to ensure that there are no tools, shackles or rags left behind. 10. WOTEETETENTE When referring to this page, please quote Procedure M90402 Ealtion 0248 Page 9(9)HYUNDAI Reciprocating Parts MAN B&W Data SAFETY PRECAUTIONS Fordetailed sketch, see 900-2 X ] Stopped engine X | Shut off starting air supply — At starting air receiver X | Block the main starting valve X | Shut off starting air distributor/distributing system supply X | Shut off safely air supply — Not ME engines X | Shut off control air supply [x | Shut off air supply to exhaust valve - Only with stopped lubriating oil pumps be Fal x x [x 104-3 Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oll supply Lock the turbocharger rotors, Data Ref. Description Value | Unit 04-25 | PF+PA,Nmax. 06 | mm D04-26 | PF+PA,Omax, 14 | mm Do428 | E+G,H+F Nmax 0.55 | mm Do4-29 | E+G,H+F, Nmin. 02} mm 04-30 | E4G,H+R, Omax. 0.85 | mm j 04-34 | SEX, LAY, KX, MEY, Nimax. 0.9 | mm 004-35 | Jax, LY, KEX, MEY, Nomi. 05 | mm D046 | 4X, L¥Y, KEX, MEY, O max. 441 | mm Do4-a1 | ZFIZA O min, 5 | mm N:New and cold engine with staybolts tightened (less than 100 running hours). (0: Engine in service, | | | | When referring to this page, please quote Data D10403 Edition 0044 Page (2)104-3 Reciprocating Parts HYUNDAI Data MAN B&W The task-specitic tools used in this procedure’are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P0951 refers to chapter 909. Plate Item No, Description P9196 57 | Feeler gauge | | ' Page 2 @) When referring to this page, please quote Data D10403 Edition 0041Reciprocating Parts 904-3.1 Checking In order to achieve uniform measuring conditions on board, the ship's trim must be as close as possible to 0°. 1. Mount a transparent plastic tube along the length of the bedplate. Bend each end approx. 250 mm up along the framebox side. See T. Fill the tube with water (possibly coloured) until the water level is approx. 100 mm from the end of the tube. Trim the ship until the difference between the water level S fore and aft is less than 1.5 mm per 1000 mm. Measurements are to be taken with a ruler. 2. Turn the engine in ASTERN direction to 45° after BDC (the guide shoe must rest against the crosshead guide). 3. Mount the toot between the guide shoo/ guide strip. For this purpose, use the third threaded hole from bottom of guide shoe {this hole is normally used for fastening the guide strip to the shoe). Atl, By means of the two screws in the middle of the tool, pull the guide shoes until they rest lightly against the end face of crosshead. Note! When the tool is mounted, it is not possible to turn past TDC and BDC. When referring to this page, please quote Procedure M90403 Edition 0217 Page 1 (3)Reciprocating Parts HYUNDAI Checking MAN B&W| 4, Check the centering of the piston in the oylinder liner by measuring the clearance (from the scavenge air space with a long feeler gauge) between the piston skirt and the cylinder liner in the Fore and Aft positions (PF-PA), D04-25 D04-26 Make sure that the piston is clear of the cylinder liner in the fore-and-aft direction. a 5. Measure the clearance between the guide strips and crosshead guides (J, K, L and -L M). The clearance J, K, L and M is adjusted by the insertion of shims so that it is symmet- rical in relation to the clearance between H the piston skirt and the cylinder liner. Parallelism between the guide strip and guide is to be kept within a tolerance of 0.2 mm per 1000 mm. \s 04-53 Fo D04-54 P18) || Do4-ss B | rus. pune In +t Page 2 (3) When referring to this page, please quote Procedure M90403 Edition 0217HYUNDAT Reciprocating Parts MAN B&W Checking 6. Check the clearance between guide shoe | 6 and crosshead guide (E, F, G and H) with a feoler gauge. exhaust sie 7. It is recommended that the measured results are noted down so that possible later changes can be ascertained. fearon Pustpump ie Patensteer le lex lex lee iss la ler loz ica ict lo lL ke. iw br Comectny wd fa When referring io this page, please quote Procedure M90403 Edition 0217 Page 3 (3)HYUNDAI Crankpin Bearing 104-4 MAN Baw, Data SAFETY PRECAUTIONS For detailed skotch, see 900-2 [C) Stopped engine [| Shut of starting air supply ~ At starting air receiver [x ] Block the main starting valve [3X] Shut off starting air distibutor/dstributing system supply [XC] Shut off safety air supply — Not ME engines 1x] Shut off contro air supply X_| Shut off air supply to exhaust valve ~ Only with stopped lubricating oil pumps X_| Engage turning gear Shut off cooling water Shut off fusl of X | Stop lubricating ol supply [_] beck the turbocharger rotors Data Ret. ~~ Description Value | Unit | | Do4-43 | Crankpin bearing clearance, max. 07 | mm 04-44 | Crankpin bearing clearance, min. 0.45 | mm Do4-46 | Crankpin bearing, upper shell 35 | kg 04-47 | Crankpin bearing, lower shell 28 | kg 04-48 | Crankpin bearing cap + shell + bearing studs 260 } kg When referring to this page, please quote Data 010404 Ealtion 0052 Page 1 (2)104-4 Crankpin Bearing HYUNDAI Data MAN B&W. ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No. Description P90dst 84 | Lifting attachment - connecting rod P9041 59 | Bracket for support, Cross Head Pao4s1 60 | Bracket for support, Cross Head P90461 Connecting Rod - Hydraulic Tools P9062 Lifting too! for crankshaft shell P9135 10 | Hydraulic pump, pneumatic operated Poiast 46 | Hose with unions (1500 mm), complete Potast 58 | Hose with unions (3000 mm), complete 91361 105 | 3-way distributor block, complete 91356 Lifting Tools, Etc. P9136 87 | Feeler gauge Page 2 (2) When referring to this page, please quote Data 010404 Edition 0052HYUNDAI Crankpin Bearing MAN B&W. Checking ‘The bottom clearance between the journal and a new bearing shell is the result of a summation of the production tolerantes of the bearing assembly components. For the bottom clearance of a specific bearing, see the measurement in the Adjustment Sheet in Volume |, OPERATION. 1. Open the crankease door at the relevant cylinder. 2. Turn the crank concerned to BDC. 8. Measure the clearance in the crankpin bearing by inserting a feeler gauge at the bottom of the bearing shell in both sides. See Data for bottom clearance. TO 2 4, The difference between the actual clearance measurement and the measurement recorded in the Adjustment Sheet (or the clearance noted for a new bearing installed later) must not exceed 0.1 mm. If so, the crankpin bearing must be disassembled for inspection. ‘See Procedure 904-4.2, 5, The wear limit for the crankpin bearing shells is based on an evaluation of the Bearing conten at the tre of igen, | ‘An average wear rate of 0.01 mm per & 10,000 hours is regarded as normal. FE 6. For further external inspection of the orank- pin bearing, see Chapter 708 ‘Bearings’ in the instruction book, Volume |, OPERA- TION. SSAC TOOS D04-43 |) D04-44 ‘When referring to this page, please quote Procedure M90404 Edition 0231 Page 1 (8)904-4,2 Crankpin Bearing Dismantling [ ocoraesToaE e 1. 2. HYUNDAI MAN B&W Turn the orank to BDC. Suspend two tackles from the lifting brack- ats, in the athwartship direction. Turn the crank to TDC. Mount eye bolts in each side of the crankpin bearing cap and, using shackles and wire ropes, hook on the tackles and haul tight. Loosen the crankpin bearing stud nuts, using the hydraulic jacks. For operation of the hydraulic jacks, see Procedure 913-1. Remove the hydraulic jacks and the nuts. Lower the bearing cap while seeing carefully that the studs do not damage the crankpin journal. Land the bearing cap on a couple of planks placed in the oil pan. Inspect the bearing shell. For evaluation of bearings, see Volume |, Chapter 708. Page 2 (8) ‘When referring to this page, please quote M90404 Edition 0284HYUNDAI Crankpin Bearing 904-4.2 MAN B&W. Dismantling 5. If the bearing shell needs to be replaced, remove the whole bearing cap from the crankcase. Hook the tackle on to an eye bolt on one side of the bearing cap. Mount the wire guide in the top of the | crankcase door opening. | Using the tackle from the frame box inside wall, together with a tackle suspended from the platform bracket, lift the bearing cap out of the crankcase. lg 6. Place the bearing cap on one side ona | ‘couple of pianks. a Dismount the bearing shell lock sorews and replace the bearing shell by a new one. 6. Note! 04-47 Normally bearing shells are replaced in pairs. If only one of the shells needs replacement, MAN B&W Diese! should be contacted for advice beforehand. het 7. Turn to TDC. le Mount the four supports for guide shoes |# ‘on the crosshead guides. iS ie Carefully turn the crank down until the guide shoes rest on the supports. 7 pee Adjust the support brackets to the guide: shoes so that the weight of the crosshead is evenly distributed on the four supports. A a When referring to this page, please quote Procedure M90404 Edition 0234 Page 3 (8)ee Crankpin Bearing HYUNDAI Dismantling MAN B&W 8. Mount a lifting attachment for securing the connecting rod at the lower end, on one side. Hook on the tackle to a beam under the gallery platform and haul tight. 9. Carefully turn the crankshaft downwards, while ‘following’ with the tackle, making sure that the upper part of the bearing ‘comes completely clear of the recess in the crankshaft when the parts begin to ‘separate’. Continue turning the crankshaft until the bearing surface can be freely inspected. Inspect the bearing shell surface and the crankpin journal. 10. If it is necessary to replace the bearing shell, proceed as follows: Turn the crankshaft to HORIZONTAL. Release the tackle so that the connecting rod is hanging freely. DIST RETOOS = Tao DEROTO Page 4 (8) When referring to this page, please quote M90404 Edition 0231HYUNDAI Crankpin Bearing MAN B&W Dismantling 904-4.2 11, Mount an eye bolt in the bottom of each guide shoe. Suspend two tackles from the eye bolts. 12. Place the lifting tool for the crankpin upper shell on the crank webs and hook the tackles on to the lifting tool. Mount the tool on the bearing shell in the ‘connecting rod, using the tackles, and haul tight. 13. Dismount the bearing shell lock screws. Lower the lifting tool with the bearing shell, using the tackles. " S TROT ITOTS When referring to this page, please quote Procedure M90404 Edition 0231 Page 5 (8)904-44 Grankpin Bearing HYUNDAI Mounting MAN B&W 1. Bearing shells of three mm undersize are 1. available as spares in case of journal recti- fication. Please contact MAN B&W Diesel for advice. Coat the bearing shell surfaces and the journal with clean oil. The excess height X is to ensure the correct tightening-down of the bearing shell, and must not be eliminated. Uf | 2. Lift the upper bearing shell for the crankpin concerned into the crankcase. Carefully lift the bearing shell into position in the connecting rod, and mount the lock screws. aT 3. Remove the lifting tool, the tackles and the eye bolts from the guide shoes. ETT RSET Page 6 (8) When referring to this page, please quote Procedure M90404 Edition 0284HYUNDAI Crankpin Bearing MAN B&W Mounting 904-4.4 4, Hook the tackle on to a beam under the gallery platform and on to the lifting attach- | 4 ment on the connecting rod, and haul tight. Carefully turn the crankshaft upwards, while following up with the tackle, making sure that the upper part of t he bearing enters the recess in the crankshaft when the parts turn together. Remove the tackle and the lifting attachment from the connecting rod. 5. Tum the crosshead to TDC. Remove the guide shoe support brackets from the crosshead guides. TESTIS WIO 9 TESTES When referring to this page, please quote Procedure M90404 Edition 0231 Page 7 (8)904-4.4 Crankpin Bearing HYUNDAI Mounting MAN B&W 6. Suspend the tackles from the lifting brack- 6. ets in the top of the frame box. Lift the bearing cap assembly into the crankcase and land it on a couple of planks placed in the oil pan. 7. Hook the tackles on to the wire ropes and lift the bearing cap into position against the connecting rod. | Caution! g During mounting, take care that the 2 studs do not damage the crankpin jour- 8 nal, and check that the guide pins mounted in the bearing cap enter the holes in the connecting rod. 7. Mount the nuts and, by means of spacer - rings and hydraulic jacks, tighten the ‘ECA crankpin bearing cap. See Data. t H H Hi For operation of hydraulic jacks, see Sec- Hy tion 913. 1 I \ Remove the tackles from the top of the ! ! frame box. \ YY on Check the bearing clearance. 1 See Procedure 904-41. ls i | i D13-01 : Page 8 (8) When referring to this page, please quote Procedure M90404 Edition 0231HYUNDAI Connecting Rod 104-5 MAN B&W. pain SAFETY PRECAUTIONS For dotaiied sketch, see 900-2 X_] Stopped engine [3C] Shut off starting air supply ~ Atsstarting air receiver X | Block the main starting valve X | Shut off starting air cistributor/distributing system supply X | Shut off safety air supply — Not ME engines X | Shut off control air supply | x | Shut off air supply to exhaust valve — Only with stopped lubriating oil pumps [x | Engage turning gear [| Shut off cooling water |_| Shut off fuel oi Fx | Stop lubricating oil supply [__] Leck the turbocharger rotors Data Ref. Description Value | Unit 04-48 | Crankpin bearing cap + shell + bearing studs, 260 | kg 04-50 | Connecting rod, without beating caps 1850 | kg 13.01 | Hydraulic pressure, mounting 1500 | bar 13-02 | Hydraulicpressure, dismantling 1400-1650 | bar When referring to this page, please quote Data D10405 Edition 0051 Page 1 (2)104-5 Connecting Rod HYUNDAI ne MAN B&W. ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P0951 refers to chapter 909. Plate ltem No. Description P904st 47 | Wire guide Pa04st 84 | Liing attachment - connecting rod P9045t 59. | Bracket for support, Cross Head Pa0ast 60 | Bracket for support, Cross Head 90461 Connecting Rod - Hydraulic Tools P1351 10 | Hydraulic pump, pneumatic operated P9135t 46 | Hose with unions (1500 mm), complete P9ta51 60 | Hose with unions (6000 mm), complete Potast 105 | 3-way distributor block, complete 91356 iting Toots, te. Page 2 (2) When referring to this page, please quote Data D10405 Edition 0051HYUNDAI Connecting Rod MAN B&W. Dismantling 904-5.2 1. Tum the crank to BDC. Dismount the crosshead bearing stud nuts. See Procedure 904-1.2. 2. Mount two shackles in the top of the crankcase in the lifting brackets, in the athwartship direction, and suspend two tackles. 3, Turn the crank to TDC. Dismount the crankpin bearing cap, and re- ‘move the bearing cap from the engine. See Procedure 904-4.2. When referring to this page, please quote Procedure M90405 Edition 0228 Page 1 (7)904-5.2 Connecting Rod HYUNDAI Dismantling MAN B&W 4, Mount the four supports for guide shoes on the crosshead guides. Carefully turn the crank down towards the camshaft side, until the guide shoes rest on the supports. Adjust the support brackets to the guide shoes so that the weight of the crosshead is evenly distributed on the four supports. 5. Mount the lifting attachments for securing the connecting rod on the head of the connecting rod. Fasten tackles to lifting brackets A and Bon the frame box wall, and attach the tackle hooks to the mentioned lifting attachments ‘on the connecting rod head. Haul the tackles tight. Also mount a lifting attachment on the lower end of the connecting rod, on the exhaust side. 6. Turn the crankthrow carefully towards BDC. while ‘following’ with the tackles, thus continuously supporting the connecting rod. The crosshead now rests on the four supports. Turn the crankthrow to 90° before BDC. Page 2 (7) When referring to this page, please quote Procedure M90405 Edition 0228HYUNDAI Connecting Rod 904-5.2 MAN B&W Dismantling 7. Shift tackle B from the lifting attachment on ‘one side of the connecting rod to the lifting attachment on the other side, Dismount the jifting attachment on the camshaft side of the connecting rod. Attach a tackle to lifting bracket © on the frame box wall and connect the tackle hook to the lifting attachment on the lower end of the connecting rod. Mount the wire guide on the door frame. Turn the crankthrow towards TDC while ‘following’ with the tackles, thus continuously supporting and guiding the connecting rod towards the doorway. 8. Attach a tackle to the gallery-mounted lift: ing bracket E, and hook on to the lifting attachment on the connecting rod. Shift tackle A from the lifting attachment on the head of the connecting rod to the lifting attachment at the bottom of the connecting rod. Turn the crank carefully upwards while ‘following’ with tackles A, B, C and E, guiding the head of the connecting rod out of the doorway. Shift the tackles from one lifting attachment to the other as necessary. 9. Mount a strap around the connecting rod and suspend the connecting rod from the engine room crane. Shift tackle B from the lifting attachment on the head of the connecting rod to the lifting attachment at the bottom of the connecting rod. Remove tackles A and E. Continue turning upwards till about 30° after TDC while ‘following’ with the tackles and the engine room crane. When referring to this page, please quote Procedure M90405 Edition 0228 Page 3 (7)904-5.2 Connecting Rod HYUNDAI MAN B&W. 10. Shift the tackle from lifting bracket C to A. Lift the connecting rod out of the engine, using the tackles and the engine room crane. Remove the tackles, and lift the connecting rod away by means of the engine room crane, Page 4 (7) When referring to this page, please quote Procedure M90405 Ecition 0228 96 geHYUNDAI Connecting Rod MAN B&W Mounting 904-5.4 1. Equip the connecting rod with the same lift ing attachments as mentioned under dismantling. Turn the crank to a position about 25° past ‘TDC on the camshatt side. Apply clean lubricating oil to the crankpin bearing shell and journal. 2, Carefully lift the connecting rod into the crankcase by alternate use of the engine room crane and the tackles attached to lift: ing brackets A and B. 3. When the end of the connecting rod rests on the crankpin journal, attach a tackle to bracket C and the lower end of the connecting rod. 4, Turn the crankthrow towards BDC, past TDC, while ‘following’ with the tackles and the engine room crane Attach tackle B to the upper end of the connecting rod, Attach a tackle to bracket E and the upper end of the connesting rod. Haul tight and remove the strap around the connecting rod. When referring 10 this page, please quote Procedure M30405 Edition 0228 Page 5 (7)904-5.4 Connecting Rod HYUNDAI Mounting MAN B&W. 5. Turn the erankthrow to 90° before BDC. Shift tackle A from the lower end to the top of the connecting rod. Remove the tackle at E. Shift tackle B from the lifting attachment on, ‘one side to the other side of the connecting rod. Remove the tackle at C and the wire guide on the door frame. Remove the lifting attachment at the lower ‘end of the connecting rod. 6. Turn the crankthrow towards TDC while ‘following’ with the tackles. Caution! Take care that the studs do not damage the crosshead bearing shell. 7. When the crank is in TDC, mount the crankpin bearing cap. See Procedure 904-4.4. ~ SRE Page 6 (7) When referring to this page, please quote Procedure MS0408 Edition 0228HYUNDAI Connecting Rod MAN B&W. Mounting 8. Remove the four supports from the cross- | 8 head guides and the lifting attachments from the connecting rod. Turn the crosshead down far enough to fa- te the tightening of the nuts. 8. Tighten all four crosshead bearing cap nuts simultaneously. See Data. When referring to this page, please quote Procedure M90405 Edition 0226 Page 7 (7)HYUNDAI - MAN B&W. Connecting Rod and Crosshead Plate 90451-126 023 O00), 0009} oOOdoOOO ioONo} joddo loOOo| [oOdo 106 When relerring to this page, please quote Plate 90451 Edition 126Plate 90451-126 Connecting Rod and Crosshead id Item Description iam Item Description Ot Panel for tools 023 | Name plate 047 | Wire guide 059 | Bracket for support of crosshead 060 | Bracket for support of crosshead 072 | Chain for suspension of piston 084 Lifting attachment 096 | Retaining tool for telescope pipe 106 Rubber cover for crosshead | 118 | Rubber cover for crosshead | 120. | Lifting tool for crosshead 143 Toque wrench offset toolHYUNDAT i Z ; 7 HY UNDA Connecting Rod - Hydraulic Tools Plate P90461-0068 089 P9135! _— 100 053 | 068 preeeeaenet a ce 207 When referring to this page, please quote Plate P90461 Edition 0068Plate P90461-0068 Connecting Rod - Hydraulic Tools Item Ne Item Description j item No. Item Description 028 | Hydraulic jack 030 | Support 041 | Tommy bar 053 | O-ring with back-up ring 065 | O-ring with back-up ring 089 | Spanner 100 | Stud setter 207 | Hydraulic toolset, completeConnecting Rod - Tools Plate P90462-0034 HYUNDAI MAN B&W O11 When referring to this page, please quote Plate P90462 Edition 0034Plate P90462-0034 Connecting Rod - Tools Item Item No. Item Description No. Item Description 011 | Lifting too! for crankpin shellHYUNDAI - i MAN B&W Crosshead - Hydraulic Tools Plate P90464-0005 91351 P1351 107 050 203 06t When referring to this page, please quote Plate P90464 Edition 0005Plate P90464-0005 Crosshead - Hydraulic Tools _ Item Description faa Item Description 024 Jack-hydrualic, complete 036 ‘Support 048 | Tommy bar 050 | O-ring with back-up ring 061 O-ring with back-up ring 085 | Key, hexagon socket screw 107 Stud setter 203 Hydraulic toolset, completeHYUNDAI : | TAN Ba Crosshead - Tools Plate P90465-0001 oo When referring to this page, please quote Plate P90465 Edition 0004Plate P90465-0001 Crosshead - Tools Item No. Item Description Item No. item Description 018 Guide shoe extractorHYUNDAI MAN B&W Main Bearing Data 105-1 SAFETY PRECAUTIONS Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear Shut off cooling water Shut off fuel oil X_| Shut off lubricating oil Lock turbocharger rotors = Pe Ref. Description Value] Unit When referring to this page, please quote Data D10501 Edition 0006 Page 1 (2)Main Bearing HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90981 refers to chapter 909. Plate Item No.] Description P90572- Main Bearing - Measuring Tools P91366- 048 | Autolog, measuring tool for crankshaft | | Page 2 (2) When referring to this page, please quote Data D10501 Edition 0006HYUNDAI Main Bearing MAN B&W Checking 905-1.4 General The condition of the main bearings can be checked by: + Deflection readings * Visual checking + Edge checking and ‘+ Measuring of top clearance. Crankshaft deflection readings Crankshaft defiection readings should be taken white the ship is afloat (i.e. not while in dry dock). As the alignment is influenced by the engine temperature as well as the loading conditions, deflection measurements should, for comparison purposes, always be made under nearly the same temperature and load conditions, 1. Place a dial gauge axially in the crank throw ‘opposite the crankpin, as illustrated on the sketch. The correct mounting position is marked with punch marks on the crank throw. See also Chapter 708 in Volume I. 2. “Closing” of the crank throw (compression of the gauge) is regarded as negative (-) and “opening” as positive (+). 3. Set the dial gauge to zero at the B1 side near BDC. Whilst turning clockwise, take the readings when the throw passes the positions: Bt (near bottom) c (camshaft side) T (top) E (exhaust side) B2 (near bottom) 4/2 (B2+B1) = B (ramen wer When referring to this page, please quote Procedure M90501 Edition 0208 Page 1 (5)905-1.4 Main Bearing HYUNDAI Checking MAN B&W 4, When taking deflection readings for the three aftmost cylinders, the turning gear should, at each stoppage, be turned a little backwards to ease off the tangential pressure on the turning wheel teeth, Otherwise, this pressure may falsify the readings. For evaluation of the crankshaft deflection readings, see Volume |, OPERATION, Chapter 708. If the crankshaft deflection (alignment indicator) is approaching the tolerance limits (see Vol. |, OPERATION), the two adjacent main bearings must be checked for wear. See next page for checking of main bearing. If the bearings are found to be in good order, please contact MAN B&W Diesel or the engine manufacturer for checking of the bedplate alignment. As reference, use the "after seatrial” deflection table. ‘The condition of the bearing can be checked as follows: 6. Visually look for bearing metal fragments in the oil pan, and check the filters for metal fragments. Such fragments can be from crosshead, guide shoe or crankpin bearings. If fragments are found, the damaged bearing can be found by edge checking with a feeler. General Bearing damage usually propagates rather quickly towards the edge of the bearing where, eventually, it causes chips to be broken off, which means that loose pieces of white metal can fall down into the crankcase beneath the bearing support. Large, thick pieces will normally be found during a crankcase inspection, and small, thin pieces can enter the filter. A check of the bearing edges together with inspection of the crankcase and the filter normally provides a good indication of the bearing condition. Page 2 (6) When referring to this page, ploase quote Procedure M90501 Edition 0208HYUNDAI Main Bearing MAN B&W Checking 905-1.4 Checking the bearing edges 6. Bearing edges can be checked with a “feeler” that Is able to follow the bearing edge against the journal the whole way round on each side. If white metal is missing at the edge, the tip of the “feeler” will enter the hole, thus locating the damage. In most cases this hole can be seen by the naked eye as a dark spot when using a strong flashlight, The No. 1 and the two aftmost main bearings are more difficult to access on the whole circumference on each side, but it is ‘often possible to bend the “feeler" to suit the situation and thus reach as far round as possible, jire-feelar 7. It is rather easy to make a feeler (see sketch). The “feeler” should be made from a piece of steel wire (e.g. a welding rod) approx. 0.6 - 1 m long depending on the engine type, and 2 to 3 mm thick. Approx. 7 to 10 mm of the wire should be bent to an angle of approx. 65° to form a “feeler tip’. Grind the tip smooth to obtain the shape and dimension shown on the sketch. Note that the thickness of the white metal is approx. 1.5 mm, which is why the tip should be less than 1.2 mm thick, and bigger than the max. top clearance. At the other end of the tip, a “handle” should be made by bend- ing a hook or similar in the same direction as the tip, 6. Note! The above dimensions of the “wire- feeler” are guideline values and may depend on the engine type as well as individual, personal designs. When referring to this page, please quote Procedure M90501 Edition 0208 Page 3 (5)905-1.4 Main Bearing ‘Checking MAN B&W HYUNDAI / 10, Fenn 8. 10. If there is too large a difference in the crankshaft deflection readings (autolog) check the clearance in the individual bearings. Bearing clearance checks should also be carried out during time-based overhauls and surveys. If there is a suspicion of a damaged bearing, it is recommended to edge check the bearing, without opening up, Before measuring, check that the feeler blades are in good condition. The feeler is inserted along the crank throw. When the feeler hits the journal, it is horizontally pushed against the clearance. Now the feeler blade is pushed max. 20 mm into the gap. The clearance is measured at both the fore and the aft part of the bearing. Notel The bearing clearances for a new bearing stated in Data (see Data 105-2) are for guidance purposes only. Page 4 (5) When referring to this page, please quote Procedure M90501 Edition 0208,HYUNDAI Main Bearing 905-1.4 [MAN B&W | Checking 11. The difference between the actual clearance measurement and the measurement recorded in the adjustment sheet (or the clearance noted for a new bearing installed later) must not exceed 0.10 mm. If it does, see Volume |, Operation, Chapter 708. For evaluation of the bearing, see Volume 1, Operation, Chapter 708. If the bearing needs to be diassembled for inspection, see procedure 905-2.2. |. lw Z 5 SB e @ When referring to this page, please quote Procedure M90501 Edition 0208 Page 5 (5)HYUNDAI Main Bearing 105-2 MAN B&W Data SAFETY PRECAUTIONS X | Stopped engine X | Block the starting mechanism X_| Shut off starting air supply X_| Engage turning gear ‘Shut off cooling water ‘Shut off fuel oi X | Shut off lubricating oll Lock turbocharger rotors Data Ref. Description : Value] Unit 05-01 Main bearing, top clearance max. 0.75] mm 05-02 | Main bearing, top clearance 0.45] mm 05-03 | Main bearing cap 507] kg 05-04 —_| Main bearing shell, upper 35] kg 05-05 | Main bearing shell, lower 36] kg D13-01 Hydraulic pressure, mounting 1800) bar 13.02 _| Hydraulic pressure, dismantling 1400-1650] bar When referring to this page, please quote Data D10502 Edition 0052 Page 1 (2)105-2 Main Bearing HYUNDAI! Data MAN B&W. The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909, Plato Item No. | Description 90551 40| Pulley for wire for main bearing 90551 76| Lifting tool - main bearing cap P90551 88. Dismantling tool, main bearing shell 90551 20, Mounting tool for bearing shell P90sst 184| Lifting too! for main bearing shell 90551 220) Wire guide 90561 Main Bearing - Hydraulic Tools 90562 Lifting tool for crankshaft 90572 Main Bearing - Measuring Tools 91954 40] Hydraulic pump, pneumatically operated 91951 22| Hydraulic pump, hand operated 91351 117] S-way distributor biock, complete Po1361 46| Hose with unions (1500 mm), complete P9161 '58| Hose with unions (3000 mm), complete P91356 Lifting Toots, Etc. Page 2(2) When referring to this page, please quote Data D10502 Edition 0052HYUNDAI MAN B&W Positioning the crankshaft 1. Dismantling of main bearing. The bearings are divided into two categories: + The main bearings + The aftmost main bearing often referred to as “Journal bearing” (See Procedure 905-4). 2. Before any dismantling, check and write down the main beating top clearances and crankshaft deflection readings for the cylinder unit concerned. 3. Turn the crank throw to the position shown ‘on the sketch and in such a way that the top of the studs is flush with the crank throw. Main Bearing Dismantling 905-2.2 Aftmost main bearing Journal bearing) ‘Main bearings Thrust bearing Note! Be sure that the crosshead for the neighbouring cylinder is in a higher position than for the cylinder you are working on, otherwise it will be impossible to lift the cap. EXH.SIDE MAN-SIDE When referring to this page, please quote Procedure M90502 Edition 0245 Page 1 (16)905-2.2 aeRO Main Bearing HYUNDAI Dismantling MAN B&W. Oil pipes 4, Disconnect the lubricating oil pipe from the main pipe. Note! ‘On some engines, the oil pipes for the Axial Vibration Damper (AVD) have to be removed together with the oil pipe on main bearing No. 1 Note! ‘Some engines have temperature sensors fitted to the main, crosshead, and crankpin bearings. These sensors must be carefully handled to avoid damaging the equipment. Page 2 (16) When referring to this page, please quote Procedure M90502 Edition 0245HYUNDAI Main Bearing [MAN B&W | Dismantling 905-2.2 Mounting of tools and tackles 4, Mount pulley E on the web plate above the bearing cap. 2. Pulley E is used to lift the main bearing cap vertically and free of the bearing studs. | 4. TREAT When referring to this page, please quote Procedure M90502 Ealtion 0245 Page 3 (16)Main Bearing HYUNDAI Dismantling MAN B&W 3. Mount pulley F in the bottom of the guide shos. ‘On some engines the pulley is mounted in the bottom of the guide screw, and on some engines it is necessary to remove the guide screw before mounting pulley F. 4, Pulley F is used in combination with pulley E, to lift the bearing cap free of the web plate, the guides and the crankthrow. 5. Mount an eye bolt on the opposite web plate. The eye bolt is used in connection with a pull lift, to keep the main bearing cap clear of the guides when itis lifted out of the engine. Page 4 (16) When referring to this page, please quote Procedure M90502 Edition 0245HYUNDAI Main Bearing 905-2.2 MAN B&W Dismantling 6. Mount tackles in the following positions: ‘A. Suspended from a wire strap below the ‘crane beam. Adjust the suspension (fore-aft position) to ensure that chains and wire ropes go free of guides and crosshead. B. In the lifting bracket in the top of the crankcase, camshaft side. . In the lifting bracket below the doorway. D. In the eye bolt on the web plate opposite the pulleys. Mount the wire guide in the top of the doorway. 7. Assemble the main bearing hydraulic jacks ‘on the bearing studs. Connect the hydraulic pump. Loosen the nuts. Remove the hydraulic main bearing tools from the engine, Unscrew and remove the nuts from the main bearing studs. For operation of the hydraulic tools, see Procedure 913-1. 8 Mount the main bearing lifting tool on the ‘main bearing cap, and place the wire rope as shown. When referring to this page, please quote Procedure M90502 Edition 0245 Page 5 (16)905-2.2 Main Bearing HYUNDAI Dismant MAN B&W. 9. Attach tackle A to the wire rope and carefully lift the main bearing cap clear of the studs. 40. The lifting tool has one free wire rope. Place this wire rope around the wheel of pulley F mounted in the guide shoe. Hook the wire rope on to the chain of tackle C. 11. Tighten tackle © and release tackle A, until the main bearing cap is suspended vertically below pulley F. 1. Page 6 (16) When referring to this page, please quote Procedure M90502 Edition 0245HYUNDAI Main Bearing 905-2.2 [MAN B&W | Dismantling 12 12. Release tackle A from the wire rope of the lifting tool. Remove the wire rope of the lifting tool from pulley E mounted on the web plate. Mount the short wire rope with two shackles on the main bearing cap lifting tool. 413. Hook the chain of tackle D on to the short wire rope mounted on the main bearing lifting tool, Tighten tackle D and release tackle C at the same time, to get the bearing cap clear of the guides. 14, Attach the hook from tackle A around the wire rope of tackle B to keep the wire rope free from the crosshead and guide plates. At the same time, release tackle C until the main bearing cap is suspended vertically below tackle B. 14. oo When referring to this page, please quote Procedure M90502 Edition 0245 Page 7 (16)905-2.2 Main Bearing HYUNDAI Dismantling MAN B&W. 18. 15, When the main bearing cap is hanging ver- z " tically below tackle B, remove tackle C and the wire rope around pulley F. Remove the hook of tackle A from the wire rope of tackle B. ~~ Attach tackle A to the short wire rope on the AJ main bearing cap lifting tool. . i Note! + 5 D05-03 Make sure that the wire rope of the main a bearing lifting tool does not scrape z 7 against the edges of the guide shoe. ie - 16. Mount the free wire rope in tackle A. : A Now lift the bearing cap out of the engine and place it on a couple of wooden planks. Removal of upper bearing shell 17. Mount the bearing shell lifting tool on the ><] upper main bearing shell, and remove the shell, using pulley F. A Lift the upper bearing shell out of the en- D i gine in the same way as the bearing cap. s c E 17. A D 7 05-04 fF Page 8 (16) When referring to this page, please quote Procedure M90502 Edition 0245,HYUNDAI Main Bearing 905-2.2 [MAN B&W} Dismantling 18. If the crankshaft is turned with the bearing cap dismounted, use the two stops to pre~ vent the lower shell from being rolled out. 19. Place the crosspiece in the bedplate with the ends resting on the cross girders, and position the hydraulic jacks beneath the web plate as shown. Tighten the screws against the crank webs and compress the jacks. Connect the hydraulic jacks to the high- pressure pump, and raise the pressure until the crankshaft has been lifted 0.2-0.5 mm, but max. the clearance in the two adjacent bearings, Note down the pressure for later reference. 20. Check that there is min. 0.1 mm clearance between journal and bearing shell, or between bearing shell and main bearing support, on both sides of the journal. If the clearance is less than 0.1 mm, move the crosspiece sideways until clearance is Obtained. Normally, adjustment needs to be 0-150 mm to the exhaust side (the side where the clearance is missing). Note! 18, bers (f ALLL The feeler blade must be inserted minimum 60 mm into the gap to pass the bore relief in the bearing shell. Note! The lower shell must be lifted out to the side with the most clearance, which is normally the camshaft side. When referring to this page, please quote Procedure M90502 Eaition 0245 Page 9 (16)905-2.2 Main Bearing HYUNDAI Dismantling MAN B&W 21. S 21. If repositioning of the crosspiece does not ensure a vertical lift, place a §-tonne jack between the side wall and the crank throw, to correct the journal position in this way. ITitis available, note down the pressure applied to the jack. This data is used to ensure that the crankshaft is in the same position when the new bearing is installed. 22. Dismount the locking screws. Place the dismantling tool on top of the lower bearing shell. Make sure that the flap on the dismantling tool enters the oil groove in the bearing shell eo T Note! Itis recommended that the crankshaft lft: ing tool is only removed if itis urgently necessary and then only after the main bearing shell has been reinstalled. Page 10 (16) When referring to this page, please quote Procedure M90502 Edition 0245,HYUNDAI Main Bearing 905-2.2 MAN B&W. Dismantling 23. Pull the lower shell around and up until it | 23: lies over the main bearing journal. Never | use a tackle larger than 0.5 tonne. 24, Take the lower shell out of the engine in the ‘same way as the upper shell, i.e. using the lifting tool Note! While pulling out the shell, it is recommended to hold a foot or hand on the wire rope, to tighten it up and to observe whether the shell is sticking. TTI When referring to this pago, please quote Procedure M90502 Edition 0246 Page 11 (16)905-2.3 Main Bearing HYUNDAI Overhaul MAN B&W Clean and inspect the bearing shells. It is recommended that the main bearing shells be replaced in pairs. If it is nevertheless desired to replace only ‘one shell, this requires a careful evaluation of the condition of the shell that is to be reinstalled. See Instruction book, Volume I, Chapter 708. For advice on replacing individual bearing shells, it is recommended to contact MAN B&W Diesel AVS or the engine builder. Before remounting: + Check the bearing support for damage and burrs. If damage is found, contact MAN B&W Diesel for advice. + Make sure that all parts are clean, use non-fluffy cloth to clean between journal and main bearing support. + Lubricate the bearing journal, the main bearing support and the back of the shell, with main engine lubricating oll. Page 12 (16) When referring to this page, please quote Procedure M90502 Edition 0245HYUNDAI Main Bearing MAN B&W. Mounting 905-2.4 1, Clean and lubricate the journal, the lower bearing shell and the bearing support with clean oil, Place the dismantling tool between the bearing journal and the bearing support. Place the guide tool for the lower bearing shell on the main bearing support, 2. Using the bearing shell lifting tool, the pulleys and tackles, lift the lower bearing shell into the crankcase and land it on the crankshaft journal. Remove the lifting tool from the bearing shell. Check that the hydraulic pressure to the crosspiece jacks corresponds to the pressure used when the lower shell was removed, and that the crankshaft is still lifted max. 0.2 mm. 3. Using the dismantling tool, lower the bearing shell down between journal and support. Remove the dismantling tool and push the shell entirely down with a piece of wood, for stance a hammer handle. To ensure that the shell is correctly mounted, check that the distance from the main bearing support to the shell is equal in both sides. When referring to this page, please quote Procedure M90502 Edition 0245 Page 13 (16)905-2.4 Main Bearing HYUNDAI Mounting MAN B&W. 4, Remove the guide tool when the lower bearing shell has been mounted. Mount the locking screws in the bearing support, Check with a feeler gauge that there is clearance around the head of the locking screws, to ensure correct centering of the bearing shell. 5. Lower the crankshaft and remove the hydraulic jacks and the crosspiece from below 7 the crankshaft. DO05-04 Wipe the contact surfaces between the upper and the lower bearing shells clean with a non-fiutfy piece of cloth EY 6. Land the upper bearing shell on the main journal in the same way as the lower bearing shell. Make sure that none of the edges of the upper bearing shell are resting on the edge of the bearing support. Ifnecessary, place the special tool between the studs and press the shell into place. Clean the contact surfaces between the bearing support and the bearing cap. Make sure that no oil is left on the contact surfaces. 7. Mount the lifting tool on the bearing cap. Using the lifting tool and the tackles lift the bearing cap into the crankcase in the reverse order to dismantling. See Procedure 905-2.2. 8. Using the pulleys mounted inside the crankcase, move the bearing cap into position vertically above the main bearing upper shell in the reverse order to dismantling. See Procedure 905-2.2. Page 14 (16) When referring to this page, please quote Procedure M90502 Edition 0245HYUNDAI Main Bearing [MAN B&W | Mounting 905-2.4 9. Land the bearing cap carefully on the upper bearing shell, using the bearing cap lifting | 100. Check that the spring pin in the support enters the hole in the bearing cap. Take care not to displace the upper bearing | shell. 10, Remove the lifting tool from the bearing cap. Screw the nuts on to the main bearing studs. Using a tommy bar, tighten in small alternate steps the nuts on both sides of the bearing cap. 10. 11, Assemble the main bearing hydraulic jacks on the bearing studs. RTS When referring to this page, please quote Procedure M90502 Edition 0245 Page 15 (16)905-2.4 Main Bearing HYUNDAI Mounting MAN B&W. 12. 13, 12. Connect the hydraulic jacks to the high pressure pump by means of the distributor block and high-pressure hoses. Bleed the hydraulic system and raise the pressure as indicated in Data. Using the hydraulic jacks, fully tighten the nuts on both sides of the bearing cap. For tightening pressure, see Data. For operation of the hydraulic tools, see Procedure 913-1. Remove the bearing cap lifting tool. 13, 14, 14, Note Before removing the hydraulic jacks, check the top clearance between the upper bearing shell and the journal Remove all the tools from the engine. Note! Search the crankcase to ensure that there are no tools, shackles or rags left behind. Page 16 (16) When referring to this page, please quote Procedure M90502 Edition 0245HYUNDAI MAN B&W. Thrust Bearing Data 105-3 x||=] x Data SAFETY PRECAUTIONS ‘Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear ‘Shut off cooling water ‘Shut off fuel oil X_| Shut offtubricating oil Lock turbocharger rotors Ref. Description Value] Unit 05-06 005-07 13-01 13-02 ‘Thrust bearing segment ‘Segment stopper | Hydraulic pressure, mounting | Hydraulic pressure, dismanting 44-66 | kg. 47| kg 1500] bar 1400-1650] bar When referring to this page, please quote Data D10503 Edition 0044 Page 1 (2)105-3 Thrust Bearing Data HYUNDAI MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plato Item No.| Description 90861 100] Too! for turning out segments 90563 ‘Segment Stopper - Hydraulic Tools 91351 10] Hydraulic pump, pneumatically operated 91351 46| Hose with unions (1500 mm), complete 91351 58] Hose with unions (3000 mm), complete 91351 105| 3-way distributor block, complete 91356 Litting Tools, ete. Page 2 (2) When referring o this page, please quote Data 010503 Edition 0044HYUNDAI Thrust Bearing MAN B&W Checking 905-3.1 The clearance in the thrust bearing was measured during testbed trials of the engine and noted down in the ‘Adjustment Sheet’ which is inserted at the front of Volume |, OPERATION. For a new engine the clearance is 0.5-1.0 mm, and for an engine in service it must not exceed 2.0 mm, In service it is only necessary to measure the wear of the thrust bearing pads, and to inspect for white metal below the thrust bearing, 1. To measure the wear in the thrust bearing, it is necessary to dismount the foremost segment stopper. For dismantling the segment stopper, see Procedure 905-3.2. A wear groove of 1 mm is positioned in the uppermost thrust segment. (The segment with thermometers). 2. To measure the wear, the thrust segment has to be pressed against the thrust cam, to eliminate any gap, i.e. by using a suitable crowbar on the back of the segment. If a feeler gauge of 0.1 mm is not able to ‘enter the groove (the wear is more than 0,9 mm), the thrust bearing must be overhauled, 8. Note down the wear for later reference. Cocoon eaearae STE When referring to this page, please quote Procedure M90503 Ealtion 0224 Page 1 (6)905-3.2 Thrust Bearing HYUNDAI Dismantling MAN B&W . Remove the lub. oil pipe from the bearing, the protective shield, and the lub. oil pipe for the thrust segments. . Loosen and remove the nuts from the segment stoppers. For operation of the hydraulic jacks, see Procedure 913-1. Remove the segment stoppers above the thrust segments (AHEAD or ASTERN) that are to be taken out, and lift the stoppers out of the chain casing, Page 2 (5) When referring to this page, please quote Procedure M90503 Edition 0224HYUNDAI Thrust Bearing 905-3.2 (xx al Dismantling 3. Suspend a tackle from the chain tightener bracket above the segments which are to be removed. Nevertheless, the weight is no heavier than it is possible to lift the segment by hand. Mount the too! for turning out the segments on the protective edge on the chain wheel. 4. Turn up the segments, one at a time, by turning the engine, and remove the segment from the chain casing. Inspect the segment and remount it before turning up the next segment. See Procedure 905-3.4. Note! Never remove more than one segment at atime. When referring to this page, please quote Procedure M90503 Edition 0224 Page 3 (6)905-3.4 Thrust Bearing HYUNDAI Mounting MAN B&W 1. Suspend a tackle above the segments which are to be mounted. Still it is possible to lift the segments by hand. Mount the tool for turning out segments on the chainwheel. Land the segment on the journal and ro- move the eye bolt from the segment. Carefully slide the segment on to the segment tool. Turn the engine to dismantle the next segment. See Procedure 905-3.2. 2. After the last segment has been mounted, turn the segment tool up and dismount it. Cor Page 4(5) When referring to this page, please quote Procedure M90503 Eaition 0224HYUNDAI Thrust Bearing 905-3.4 MAN B&W Mounting 3. Mount the segment stopper. Mount the hydraulic jacks and tighten the nuts on the stopper. For operating hydraulic jacks, see Procedure 913-1. 4, Mount the lub. oil pipe for the thrust segments, the protective shield and the lub. oll pipe on the bearing. When referring to this page, please quote Procedure M90503 Edition 0224 Page 5 (6)HYUNDAI Journal Bearing MAN B&W Data 105-4 SAFETY PRECAUTIONS X_] Stopped engine X | Block the starting mechanism X | Shut off starting air supply X | Engage turing gear Shut off cooling water Shut off fuel oil X_| Shut off ubricating oit Lock turbocharger rotors Data Ref, Description Value] Unit 05-11 Min. bearing clearance 0.75) mm Do0s-12 Max. bearing clearance 0.45] mm 05-13 Journal bearing cap 507| ko 05-14 Upper bearing shell 35] kg 05-15 Lower bearing shell 36| kg 05-16 End cover 225| kg 13-01 Hydraulic pressure, mounting 1500| bar 13-02 Hydraulic pressure, dismantling 1400-1650] bar When referring to this page, please quote Data D10504 Edition 0017 Page 1 (2)105-4 Journal Bearing HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90981 refers to chapter 209. Plate | Item No.| Description 90551 88 Dismantling tool, main bearing shell 90551 90 | Mounting tool for bearing shell 90551 111 | Lifting attachment 90551 | 172 _| Mounting tool, thin bearing shell 90551 | 184 _| Liting tool for main bearing shell 90561 Main bearing — hydraulic tools 90562 Litting tool for orankshatt 90572 Main bearing - measuring tools 91351 10 | Hydraulic pump, pneumatic operated P91351 46 | Hose with unions (1500 mm), complete P9135 58 | Hose with unions (3000 mm), complete 91351 405 | 3-way distributor block, complete 91366 61 | Slide caliper Page 2 (2) When referring to this page, please quote Data D10504 Edition 0017Journal Bearing 905-4.1 Checking Aftmost bearing sJournat bearing) 4. Before any dismantling of the journal bearing, check the clearances as described in Procedure 905-2.1. 2. Write down the journal bearing clearances. 3. Also check the journal bearing by visually searching the area underneath the bearing support. E Wan bearings E Ts bai 2 a nw ce | ; e 3 When referring to this page, please quote Procedure M90504 Edition 0216 Page 1 (8)905-4.2 Journal Bearing HYUNDAI Dismantling MAN B&W 7 1, Dismount the screws for the end cover. Mount a %-ton tackle above the end cover. Remove the end cover. Disconnect the lubricating oil pipe from the main pipe. Remove the protective shield for the thrust bearing. Turn the crank throw for the aftmost cylinder to TDC. ‘Mount the extension studs, the spacers, the hydraulic jacks and the nuts on the extension studs. Loosen the bearing stud nuts, using the hydraulic jacks For operation of the hydraulic tools, see Procedure 913-1. Remove the hydraulic main bearing tools from the engine Unscrew and remove the nuts from the bearing studs. Page 2 (8) ‘When referring to this page, please quote Procedure M90504 Edition 0216HYUNDAI Journal Bearing 905-4.2 MAN B&W. Dismantiing 5. Remove the rectangular nut washers from | 5- the bearing cap. Mount the lifting attachment at the journal bearing cap, and lift the cap out of the engine by using the %-lon tackle above the bearing. 6. Mount the lifting attachment on the upper shell, and lift the shell out of the engine. 7. Place the crosspiece under the turning Wheel as shown, Mount a dial gauge to measure the lift of the crankshaft. Tighten the screw against the turning wheel and compress the jacks. pee Connect the hydraulic jacks to the high- | 6. pressure pump, and raise the pressure until the crankshaft has been lifted 0.2-0.5 mm, but max. the clearance in the adjacent bearing. [enmsaraaT When referring to this page, please quote Procedure M90504 Edition 0216 Page 3 (8)905-4.2 Journal Bearing HYUNDAI Dismantling MAN B&W 8. Dismount the locking screws. Place the dismantling tool on top of the low- cer bearing shell. Make sure that the flap on the dismantling tool enters the oil groove in the bearing shell. Pull the lower bearing shell round and upwards until it lies over the bearing journal Never use a tackle larger than 0.5 ton. 9. Take the lower shell out of the engine in the ‘same way as the upper shell, i.e. using the lifting tool Page 4 (8) When referring to this page, please quote Procedure M90504 Edition 0216HYUNDAI Journal Bearing 905-4.3 MAN B&W. Overhaul 4. Clean and inspect the bearing shells. It is, recommended that the main bearing shells be replaced in pairs, If it is nevertheless desired to replace only ‘one shel, this requires a careful evaluation of the condition of the shell that is to be reinstalled. See Instruction book, Volume J, Chapter 708. For advice on replacing individual bearing shells, it is recommended to contact MAN B&W Diesel A/S or the engine builder. 2. Before remounting: + Check the bearing support for damage and burrs. If damage is found, contact MAN B&W Diesel for advice. + Make sure that all parts are clean, use non-fluffy cloth to clean between journal and bearing support. + Lubricate the bearing journal, the bearing support and the back of the shell, with main engine lubricating oil, When referring to this page, please quote Procedure M90504 Edition 0216 Page 6 (8)905-44 Journal Bearing HYUNDAI Mounting MAN B&W. [iaseeor Lubricate the journal, the lower bearing shell and the bearing support with clean oil. Using the bearing shell lifting tool, lift the lower bearing shell into the crankcase and land it on the crankshaft journal. Position the guide tool for the lower bearing shell on the bearing support. Remove the lifting tool from the bearing shell. Lubricate the journal, the lower bearing shell and the bearing support with clean oil Place the lower bearing shell on the journal and push it down by hand. To ensure that the shell is correctly mounted, check that the distance from the bearing support to the shell is equal in both sides. Remove the guide tool when the lower bearing shell has been mounted. Mount the locking screws in the bearing support. Lower the crankshaft and remove the hydraulic jacks and the crosspiece from under the crankshaft. Wipe the contact surfaces between the upper and the lower bearing shells clean with a non-fluffy piece of cloth. Page 6 (8) ‘When referring to this page, please quote Procedure M90504 Edition 0216 ag 1gHYUNDAI MAN B&W Journal Bea Mounting 905-4.4 4. Land the upper bearing shell on the main journal in the same way as the lower bearing shell. Make sure that none of the edges of the upper bearing shell are resting on the edge of the bearing support. If necessary, place the special tool between the studs and press the shell into place. Clean the contact surfaces between the bearing support and the bearing cap. Make sure that no oil is left on the contact surfaces. 5. Mount the lifting tool on the bearing cap. Using the lifting tool and the tackles, lift the bearing cap into the crank casing in reverse order to dismantling. See Procedure 905-4, step 5. Note! Be sure that the cap lands correctly and that the guide pin in the assembly surface enters the hole in the bearing cap. 7. Mount the rectangular nut washers, the nuts, the spacer rings, the hydraulic jacks, and tighten the nuts. See Data. For operation of the hydraulic tools, see Procedure 913-1. SE TE a Ty cel \¥ When referring to this page, please quote Procedure M90504 Edition 0216 Page 7 (8)905-4.4 Journal Bearing HYUNDAI Mounting MAN B&W 8. Note! Before removing the hydraulic jacks, check the top clearance between the upper bearing shell and the journal. 9. Remove all tools from the engine. Note! Search the crankcase to ensure that there are no tools, shackles or rags left behind. 10. Mount the lubricating oil pipe on the bearing cap, and mount the end cover. = \. Page 8 (8) When referring fo this page, please quote Procedure M90504 Edition 0216HYUNDAI Axial Vibration Damper 105-5 MAN B&W Data SAFETY PRECAUTIONS X_] Stopped engine X | Block the starting mechanism X_| Shut off starting air supply X_| Engage turning gear Shut off cooling water Shut off fue! oil X_| Shut of lubricating oi! Lock turbocharger rotors Data Ref. Description Value] Unit 05-18 Inner studs, screwing-in torque 100) Nm Dos-19 Nuts on inner studs, tightening torque 460| Nm 05-22 Outer studs, screwing-in torque 100) Nm 05-28 Horizontal screws, tightening torque 950] Nm 05-24 Horizontal screws, tightening torque/angle 100/40] Nov" 005-25 Damper housing, upper part 600] kg D13.01 Hydraulic pressure, mounting 1500| Bar 013-02 Hydraulic pressue, dismantling 1400-1650] Bar When referring to this page, please quote Data D10505 Ealtion 0037 Page 1 (2)105-5 Axial Vibration Damper HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909, Plate Item No.| Description P90se4 Crankshaft . measuring tools 90463 Crosshead . hydraulic tools P91356- Lifting tools, etc. P91359- Torque spanners P91366- 061 | Slide caliper Page 2 (2) When referring to this page, please quote Data D10505 Edition 0037HYUNDAI MAN B&w Axial Vibration Damper Checking 905-5.1 For checking the effectiveness of the axial vibration damper, it is necessary to measure the longitudinal movements of the fore end of the crankshaft during running. The measurement (or reading) should be taken at the same r/min as during the sea trials. (Pref- erably 90% and 100% of MCR.) As different equipment may be mounted on the specific engines, the checking procedure de- scribes three systems: A; Electronic, with Axial Vibration Monitor B. Mechanical, (without angle encoder fore) C: Mechanical, with angle encoder fore. A: Electronic, with Axial Vibration Monitor A proximeter probe is built on to the lower part of the damper housing. The probe is connected to a control unit which displays peak-to-peak movements and sends signals to the engine control system. 1, Concerning overhaul and setting of the electronic device, refer to makers instructions and Volume 1, Operation, Chapter 701. The peak-to-peak values displayed in mm are to be compared with the original values ‘obtained during sea trial and the limits given in Volume 1, Operation, Chapter 701. If the peak-to-peak value exceeds the Nor- mal Service Value, it is necessary to overhaul the axial vibration damper, see Procedure 905-5.2. When referring to this page, please quote Procedure M90505 Edition 0224 Page 1 (8)905-5.1 Axial Vibration Damper HYUNDAI Checking MAN B&W. pomenraae aa B: Mechanical (without angle encoder fore) 1. Stop the engine. Unscrew the two plugs from the cover at the front of the engine. 2. Mount the shaft piece in the end of the crankshaft, using the handle. ‘After tightening the shaft, dismount the handle. Screw the measuring arm into the small threaded hole beside the centre hole, so that the arm is perpendicular to the shaft piece. Tighten the lock nut. Attach a pencil to the arm. Note! To obtain a correct measurement, the tip of the pencil should protrude 10 mm from the end of the arm. Page 2 (8) When referring to this page, please quote Procedure M90505 Eudition 0224HYUNDAI Axial Vibration Damper MAN B&W. Checking 905-5. 3. Start the engine, and let the speed rise to | 3. the number of revolutions at which the measurement is to be taken. (Preferably 90% and 100% of MCR.) When measuring, press the measuring arm against the shaft piece with the one hand. With the other hand, move a sheet/block of paper, clipped on to a solid backing plate, lightly downwards against the tip of the pencil To ensure a certain inertia, the backing plate should have a mass of approx. 1-2 kg. The axial movements (S2) recorded on th paper must be measured with a slide call per as shown in the sketch. 4. Before comparing the measured value (S2) with the Normal Service Value (S1), stated in Volume 1, Operation, Chapter 701, it is necessary to compensate for the ratio in the tool. For a standard measuring tool (Ly = 38 mm and Ly = 200 mm), the ratio is 5.3. There- fore, the S1 can be calculated as follows: wt 82 s1= 35 If a non-standard tool is used, $1 can be calculated as follows: st=9ax > IF the peak-to-peak value exceeds the Nor~ mal Service Value, itis necessary to overhaul the axial vibration damper, see Procedure 905-6.2. When referring to this page, please quote Procedure M90505 Eaition 0224 Page 3 (8)905-5.1 Axial Vibration Damper HYUNDAI Checking MAN B&W : Mechanical, with angle encoder fore For engines with angle encoder fore, a measuring tool is available for mounting on the angle encoder housing, 4. Stop the engine. Dismount the protection shield over the angle encoder. (Not always on engine). Dismount the cover on the angle encoder housing. Apply some Malycote™ on the fore side of the shaft cam. 2. Mount the axial vibration measuring tool, using the screws from the cover. Attach a pencil to the arm. Note! To obtain a correct measurement, the tip of the pencil should protrude 10 mm from the end of the arm. Page 4 (8) When referring to this page, please quote Procedure M90505 Euition 0224HYUNDAI Axial Vibri 3. Start the engine, and let the speed rise to the number of revolutions at which the measurement is to be taken. (Preferably 90% and 100% of MCR.) When measuring, pull the measuring arm against the shaft cam with one hand. With the other hand, move a sheet/block of paper, clipped onto a solid backing plate, lightly sidewards against the tip of the pencil. To ensure a certain inertia, the backing plate should have a mass of approx. 1-2 kg. The axial movements ($2) recorded on the paper must be measured with a slide calliper as shown in the sketch. 4, Before comparing the measured value (S2) with the Normal Service Value (S1), stated in Volume 1, Operation, Chapter 701, it is necessary to compensate for the ratio in the tool For a standard measuring tool (Ly = 35 mm and Lz = 178 mm), the ratio is 5.1, There- fore, $1 can be calculated as follows: se siz If a non-standard tool is used, S1 can be calculated as follows: =s2x St= 82x If the peak-to-peak value exceeds the Nor- mal Service Value, it is necessary to over haul the axial vibration damper, see Procedure 905-5.2. yn Damper MAN B&W Checking 905-5.1 e When referring to this page, please quote Procedure M90505 Edition 0224 Page 5 (8)905.5.2 Axial Vibration Damper HYUNDAI Dismantling MAN B&W Dismantling of the axial vibration damper is carried out from the crankcase of cyl. No. 1 1, Turn the engine to 90° after TDC. Dismount the lubricating oil pipes for the main bearing and axial vibration damper. Loosen and remove the nuts from the inner studs and the hydraulic nuts from the outer studs. For operation of the hydraulic tools, see Procedure 913-1. Loosen and remove the horizontal screws. Only the upper part of the housing needs to be removed, while the lower half remains mounted on the bedplate, 2. Mount an eyebolt in the centre lifting hole on the upper part. Engines with chain box fore: Mount a tackle in the bracket above the ax- jal vibration damper inside the chain box. Engines without chainbox for Mount a tackle below the fore end platform, and dismount the cover on the lifting hole above the axial vibration damper. 3. By means of the tackle and wire rope, separate and raise the upper part of the damper housing to a position in which It is possible to change the oil seals and springs. Note! Before starting the work under the suspended upper part, secure the upper part with, e.g. a wire rope or another tackle. Page 6 (8) When referring fo this page, please quote Procedure M90505 Edition 0224HYUNDAI Axial Vibration Damper MAN B&W. Overhaul 905-5.3 1. Dismantle and remove the springs from the oil sealing rings. Remove the oll sealing rings. Note! itis recommended to discard both the When mounting the new oil sealing rings, first insert the lower half of the rings in the lower housing. Then press the tension springs into the groove between the oil sealing ring half and the housing. 2, Mount all the upper halves of the oil sealing rings in such a way that the clearance at both joints on each oil sealing ring Is the same. Now hook the new tension springs into place, ensuring that they are centralised in the grooves of the oil sealing rings. springs and the oil sealing rings. Note! The lower half of the oil sealing rings will protrude above the centreline, When referring to this page, please quote Procedure M90505 Edition 0224 Page 7 (8)905-5.4 Axial Vibration Damper HYUNDAI Mounting MAN B&W. a Release and carefully lower the upper part of the damper housing. When reaching the oll seating rings, take care that the rings enter the sealing ring grooves correctly. Before landing the upper part on the lower part, be sure that the guide pins have entered the guide pin holes. Mount and tighten the vertical nuts. See Data. Mount and tighten the hydraulic nuts. For ‘operation of the hydraulic tools, see Proce- dure 913-1 Mount and tighten the horizontal screws. See Data. Note! Search the crankcase to ensure that there are no tools, shackles or rags left behind. Mount the lubricating oil pipes. Engines without chainbox fore: Mount the cover for the lifting hole above the axial vibration damper. Note! After overhaul of the axial vibration damper, it is recommended to check the ‘al vibrations. See Procedure 905-3. 1. Page 8 (8) When referring to this page, please quote Procedure M90505 Edition 0224HYUNDAI Angle Encoder 105-8 MAN B&W. Data SAFETY PRECAUTIONS Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear ‘Shut off cooling water Shut off fuel oil X | Shut off lubricating oi! Lock turbocharger rotors [> P< Data Ref. Description Value] Unit When referring to this page, please quote Data D10508 Edition 0007 Page 1 (2)105-8 Angle Encoder HYUNDAI Data MAN B&W ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No. Description Page 2 (2) When referring to this page, please quote Data 010508 Edition 0007HYUNDAI Angle Encoder 905-8. ae Checking 1. Turn the crankthrow for cylinder 1 to TDC. [7 Check the TDG of cylinder 1 against the mark on the turning wheel. 2. Check that power is supplied to the intermediate box. The green indicator should now light. For adjustment of the angle encoder, see Procedure 905-8.3. 3. Check the rubber damper. Replace if cracked or damaged. ea TSO p NOSE CRT When referring to this page, please quote Procedure M9008 Eultion 0205 Page 1 (4)Sscaaueae Angle Encoder HYUNDAI Dismantling MAN B&W. 1. Remove the inspection cover. Cut the cable tie which holds the rubber damper around the coupling, in the end nearest to the engine, and loosen the coupling. | 2. Loosen the three adjusting screws on the front flange, and remove the angle encoder and the coupling. 3. Screw out the flange sorews and remove \ the encoder housing. Take care not to damage the guide pins. a FRET SO TETRIS Page 2 (4) When referring to this page, please quote Procedure M90SO8 Edition 0205,HYUNDAI MAN B&W 1. Turn the crankthrow for cylinder 1 to TDC. Check the TDC of cylinder 1 against the mark on the turning wheel. Check the TDC position with the pin gauge on the crankthrow, cylinder 1. Angle Encoder Adjustment 905-8.3 Note! Before using the pin gauge, check the measurement from tip to tip with the value stamped on the pin gauge, and/or the check-marks stamped on the fore end of the oylinder frame. 2. Loosen the adjusting screws which fasten the encoder to the housing. Siowly turn the ‘encoder until the green indicator lights on the intermediate box. Tighten the screws to secure the encoder in the correct position. WODSEE-TRIEOT 1 355 RS TREO When referring to this page, please quote Procedure M90508 Edition 0205HYUNDAI Angle Encoder 905-8.4 MAN B&W Mounting 1. Assemble the encoder housing. The two ‘guide pins indicate the correct positioning of the housing. Tighten the screws. 2. Fit the angle encoder and the coupling. Tighten the coupling. Replace the rubber damper if damaged, and mount new cable ties around the rubber damper. Adjust the angie encoder according to Pro- cedure 905-8.3. Note! The adjustment will be easier if mounting is in the same crank position as dismantling. RSD DAOSTT 3. Assemble the cover. When referring to this page, please quote Procedure M90508 Edition 0205 page 4 (4)HYUNDAI Crankshaft, Thrust Shaft, Main Bearing, Etc. - Plate Le Panel 90551-0229 027 ° | ee When referring to this page, please quote Plate 90551 Edition 0229Plate 90551-0229 Crankshaft, Thrust Shaft, Main Bearing, Etc. - 196 Z Panel fe item Description a Item Description 015: Panel for tools 027 Name plate. 040 Wirepulley, main bearing 064 Wirepulley, main bearing 076 | Lifting tool, main bearing cap 088 | Dismantling tool, main bearing shell 080 Mounting tool, thin bearing shell 100. | Tool, turning out segments (Bolted or shrinkcfited Chain Whee!) W1 Lifting attachment 123 Retaining tool, main bearing shell 135 Lifting tool, relief valve 147 | Lifting tool, relief valve 159 Eye bolt 160 Wire 172 | Mounting tool for thin bearing shell 184 Lifting tool, main bearing shell Tightening template AVDHYUNDAI - MAN B&W. Main Bearing - Hydraulic Tools ~— Plate P90561-0064 When referring to this page, please quote Plate P90561 Edition 0064Plate P90561-0064 Main Bearing - Hydraulic Tools Item No. Item Item Description No Item Description 021. | O-ring with back-up ring 033 | O-ring with back-up ring 045 | Lifting tool 057 | Nut 069 | Hydraulic jack, upper 070 | Extension stud 082 | Supporting block 094 | Stud setter 104 | O-ring with back-up ring 116 | O-ting with back-up ring 128 | Hydraulic jack, lower 141 | Hydraulic tool for main bearing, complete 345 | Ball handleHYUNDAI i ? MAN B&W Crankshaft - Tools Plate P90562-0123 When referring to this page, please quote Plate P90562 Edition 0123Plate P90562-0123 Crankshaft - Tools Item Item 7 No. | Item Description No. Item Description 040. | Lifting tool for crankshaftHYUNDAI Segment Stopper and Holding Plate MAN B&W. Down Bolt - Hydraulic Tools P90563-0024 When referring to this page, please quote Plate P90563 Edition 0024Plate P90563-0024 Segment Stopper and Holding Down Bolt - Hydraulic Tools Item aes Item No. Item Description No. Item Description 105 | Hydraulic jack 117. | O-ring with back-up ting 129 | Support 180 | O-ring with back-up ring 142 | Stud setter 154 | Hydraulic jack for segment stopper, complate 237 | Spanner 333 | Tommy barHYUNDAI : : tae ot Thrust Shaft - Tools Plate P90570-0001 When referring to this page, please quote Plate 90570 Eaition 0001Plate P90570-0001 Thrust Shaft - Tools Item Item No. Item Description No. Item Description 039 | Lifting tool for thrust shaftHYUNDAI - ( HYUNDAI Main Bearing - Measuring Tools Plate P90572-0005 Tien] Size Tee] Size (mm) (am) 068 [0.05 332 [0.08 070 0.10 34a fo.i0 082 }o.15 ase Jo. 024 [o.20 368 |o.20 104 Jo.25 ast ]o.25 116 [0.30 393 ]o.30 128 [0.38 203 |o.35 141 fo.40 41s |o.40 153 [ous 227 [owas = 165 [0.50 439 [0.50 17 [0.96 sao [o.ss 189 [0.60 482 Jo.60 190 0.65 aca [o.6s 200 |o.70 476 [o.70 are |o.75 42s [0.78 224 [o.80 sit Jo.8o 236 [0.85 628 Jo.a5 240 |o.90 35 |o.90 261 |0.95 547 Jo.95 When referring to this page, please quote Plate P90572 Edition 0005Plate P90572-0005 Main Bearing - Measuring Tools Item Hem’ i No Item Description pends Item Description 040 | Feeler gauge set 052 | Feeler gauge set 053 | Feeler gauge set 069 | Feeler gauge 070 | Feeler gauge 082 | Feeler gauge 094 | Feeler gauge 104 | Feeler gauge 116 | Feeler gauge 128 | Feeler gauge 141 | Feeler gauge 153 | Feeler gauge 165 | Feeler gauge 177 | Feeler gauge 189 | Feeler gauge 190 | Feeler gauge 200 | Feeler gauge 212 | Feeler gauge 224 | Feeler gauge 236 | Feeler gauge 248 | Feeler gauge 261 | Feeler gauge 332 | Spare tip for feeler gauge 344 | Spare tip for feeler gauge 356 | Spare tip for feeler gauge 368 | Spare tip for feeler gauge 381 | Spare tip for feeler gauge 393 | Spare tip for feeler gauge 403 | Spare tip for feeler gauge 415 | Spare tip for feeler gauge 427 | Spare tip for feeler gauge 439 | Spare tip for feeler gauge 440 | Spare tip for feeler gauge 482 | Spare tip for feoler gauge 464 | Spare tip for feeler gauge 476 | Spare tip for feeler gauge 488 | Spare tip for feeler gauge 511 | Spare tip for feeler gauge 523 | Spare tip for feeler gauge 535 | Spare tip for feeler gauge 547 | Spare tip for feeler gaugeHYUNDAI Chain 106-1 MAN B&W. Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 [X] Stopped engine Shut off starting air supply - At starting air receiver Block the main starting valve Shut off starting air distributor/distributing system supply ‘Shut off safety air supply - Not ME engines Shut off control air supply ‘Shut off air supply to exhaust valve ~ Only with stopped lubricating oil pumps bee Engage tuning gear ‘Shut off cooling water ‘Shut off fuel oil ‘Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description : Value Unit 1" Chain 06-02 _| Teeth on chain wheel, max. wear 0.9 | mm 06-03 | Original length (chain pitch x 10 links) 254 | mm 106-04 | 10 links measurements + 1% of a tensioned chain = ‘scrapping of chain 286.5 | mm 4” Chain 06-18 | Teeth on chain wheel, max. wear 35 | mm 06-19 | Original length (chain pitch x 10 links) 1016 | mm 06-20 | 10 links measurements + 1% of a tensioned chain = | scrapping of chain 1026 | mm When referring to this page, please quote Data D10601 Edition 0057 Page 1 (2)106-1 Chain Data HYUNDAI MAN B&W. ‘The task-specifi c tools used in this procedure are shown on the plates at the end of this chapter or in the chapters incicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate | ttem No. Description 90651 | 044 | Chain assembling tool 90651 | 056 Chain disassembling tool P906st | 093 | Chain assembling too! P9061 | 103 | Chain disassembling tool 91356 Lifting Tools, Etc. 91359 Torque Spanners Page 2 (2) When referring to this page, please quote Data D10601 Faition 0057HYUNDAI Chains 906-14 MAN B&W. Checking 1. The engine is equipped with two sets of chains: ‘© the drive chains for the camshaft ‘* the drive chain for the cylinder lubrica~ tors. Both sets of chains are to be checked and, if necessary, dismantled and mounted in the same way. Note! There are two sets of dismantling and mounting tools available, one for each set of chains. aa SOET 2. Both sets of chains can be accessed from within the chainwheel frame. Carry out the inspection as follows: * Make a general inspection for loose bolts and screws. Bees tla + Inspect lube oi! pipes for damage, and check jet nozzies for possible stoppag- | DO6-02 es or deformations. DO6-18 ‘+ Examine the rubber track of the guide- ways for cracks or other damage. * Replace the guideway if bits have started to be “plucked out” of the rubber track. VOSTRO 4. Check the teeth of the chain wheels. If abnormal wear is found, take a measurement (See Data). Measurements are best taken by placing a short straight-edge over points A and B and then measuring the distance 006-02 or 06-18. When referring to this page, please quote Procedure M90601 Edition 0250 Page 1 (6)906-11 Chains HYUNDAI Checking MAN B&W 5. If abnormal wear is observed at the bottom of the teeth, make a drawing in scale 1:1 of the teeth and wear profile. Draw two rulers on the drawing. For assessing the wear profile, contact MAN Diesel. In most cases, scratches caused by the side plates of the chain will be found on the sides of the teeth. Such scratches can generally be considered normal. Scale 1:1 6. The chains for the camshaft drive are 0 40 matched together to ensure an even load PLL distribution. To keep such matching chains in their pairs, the side plates of the outer link nearest to the assembled link have been marked with year, month, day and chain number. Example: No. 1 order, 840520 1A 840520 18 (840520 2C, possible 3rd chair) No. 2 order, 840520 24 840520 2B (840520 2C, possible 3rd chain) On the same links there is an arrow (>) Which indicates the mounting direction. Check the chains for cracks on possibly defective rollers and side plates. Check that the chain rollers can run freely and that the chain links can freely move ‘on the pin and bushing (that they are not “seized” between the pin and the bushing). tis normal, however, that the rollers get light, circumferential scratches during the running-in period. These fine scratches are of no importance and need not be considered. It is recommended that each single link is checked. Page 2 (6) When referring to this page, please quote Procedure M0601 Edition 0250HYUNDAI Chains 906-11 MAN B&W. Checking 7. Check chain wear by measuring the length of 10 chain links. Use two master squares and a steel measuring tape as shown on the sketch, Compare the result with the value given in Data. If necessary, adjust the chain tightener. See Procedure 906-2.3. WOT ATOHT When referring to this page, please quote Procedure M0601 Edition 0250 Page 3 (6)906-1.2 Ch. HYUNDAI Dismantling MAN B&W It may become necessary to disassemble the chain if, for instance, cracked rollers s ‘or seizures between pin and bushing have NV been discovered during the inspection. ‘See Procedure 906-1.1. i uy Note! Every time a chain link is disassembled, a new link must always be fitted as the link pin press-fit is destroyed when breaking the chain. When a new link is fitted in one chain, the corresponding link in the other chain must also be renewed. TROT EOOT 5 1. Remove the tension on the chain by loosening the chain tightener. (Gee Procedure 906-2.3). Tum the engine until the slack part of the chain, with the chain link that is to be disassembled, is in a favourable position for the work. If the engine is equipped with balanceweights, continue the turning until ‘the balanceweights are hanging vertically downwards, as shown in the sketch. 2. Mount a wire round the link rollers a short distance from the disassembly point, and tighten the wire lightly with a tackle. Protect the link rollers over which the wire is wrapped. TRS CRORE Note! if the chain is to be completely removed, contact MAN Diesel for further information. ‘The riveting of the pins that are to be pressed out is to be chiseled or ground away. Page 4 (6) Wihen referring to this page, please quote Procedure M90601 Edition 0250HYUNDAI Chains 906-1.2 MAN B&W. Dismantling 3. Place the chain bursting tool over the outer chain link, and dismantle the link by alternately tightening the screws on the tool. 2 OOOO When referring to this page, please quote Procedure M90601 Euition 0250 Page 5 (6)906-1.4 Chi Mounting TT TOOT HYUNDAI MAN B&W Before assembling the inner and outer links, clean the pins and bushings. Combine the inner chain tink with the outer chain link and mount the compression tool. Force the loose side plate of the outer link into place by alternately tightening the screws on the compression tool. ‘When the link has been assembled, remove the compression tool and lock the pin ends by riveting. Repeat this procedure until the chain has been assembled. Remove the tackle and wire and adjust the chain tension. (See Data and Procedure 906-: 2.3). Page 6 (6) When referring to this page, please quote Procedure MS0601 Edition 0250HYUNDAI Chain Tightener 106-2 MAN B&W. Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X | Stopped engine X | Shut off starting air supply — At starting air receiver X | Block the main starting valve X | Shut off starting air distributor/distributing system supply X | Shut off safety air supply — Not ME engines X | Shut off control air supply X | Shut off air supply to exhaust valve ~ Only with stopped lubricating oll pumps | Engage turning gear ‘Shut off cooling water ‘Shut off fuet oil X | Stop lubricating oi supply Lock the turbocharger rotors Data { Ret. Description Value 06-21 | Tightening angle = xx hexagons s4o/9 | °/hex 06-25 | Mechanical or blocked chain tightener, clearance ot | mm Winen referring to this page, please quote Data D10602 Edition 0068 Page 1 (2)Tightener HYUNDAI Data MAN B&W 106-2 Chi The task-specifi c tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate | Item No. Description Page 2 (2) When referring to this page, please quote Data 010802 Edition 0068,HYUNDAI Chain Tightener MAN B&W. Adjustment 906-2.3 1. To retighten the chains, loosen nuts A, B, € and D to free the chain tightener bolt. 2. Turn the engine so that the slack part of the chains is on the same side as the tightener wheel. If the engine is equipped with flyweights, continue turning until the flyweights are hanging vertically downwards. 3. Tighten nut B on the chain tightener bolt until there is a clearance between the shaft and the nut as stated in D06-25. Then tighten nut B as stated in D06-21 (see Data), For chain wear, see Procedure 906-1.1. TERA Cor When referring to this page, please quote Procedure M90602 Edition 0231 Page 1 (2)906-2.3 Chain Tightener HYUNDAI Adjustment MAN B&W 4, Tighten nut C hard against the contact face of the shaft, Tighten nut D. Lock nuts C and D with the tab washer. 5. Tighten nut A. Lock nuts A and B with the tab washer. The number of times that retightening can be carried out depends on when the limit for scrapping the chain has been reached. See Data page 106-1, TERETE Page 2 (2) When referring to this page, please quote Procedure M90602 Edition 0234HYUNDAI Camshaft 106-3 MAN B&W Data SAFETY PRECAUTIONS Standard Tools: See Section 913 ‘Stopped engine Block the starting mechanism ‘Shut off starting air supply oe ]<[>]*] Engage turning gear ‘Shut off cooling water ‘Shut off fuel oi! ‘Shut off lubricating oil Lock turbocharger rotors x x Data Ret Descipion Vale Unt D-1_ Pin gauge for top dead centre of crankthrow No. 1 Check measurement 681.5 mm D-2 Pin gauge for camshaft Check measurement 407 mm D-3 Max. permissible change in lead angle 2° corresponding to 3.5mm Page 1 (2)106-3 Camshaft HYUNDAI Data MAN B&W ‘Spare Parts Prater No Deserpton oy Page 2 (2)HYUNDAI Camshaft MAN B&W Checking 906-3.1 4. Turn the crankthrow for cylinder 1 to TDC. Turn in the AHEAD direction to ensure that the tension of the chain on the chain drive is correct. If necessary, adjust the chain tension. See Procedure 906-2.3. Check the TDC of cylinder 1 against the mark on the turning wheel. 2. Check the TDC position with the pin gauge on the crankthrow, D-1. 1. sy 5 Page 1 (3)906-3.1 Camshaft HYUNDAI Checking MAN B&W 3. 3. Position the camshaft pin gauge in the centre punch mark, and measure the deviation, if any, in lead angle. For max. permissible chango, see D-3. 4, Check and adjust the cylinder lubricator. See Procedure 903-2.1. ‘Check the setting of the starting air distrib- tutor. See Procedure 907-1.1 6. When checking the camshaft position, also a check the running surface of the cams. As the inspection must include the entire surface of the cam, the cam should be turned the whole way round during the inspection. SORTS The running surface of the cam must be completely smooth and bright. 6. If light scratches are ascertained, remove them by carefully polishing the cam in the direction of rotation with a fine carborundum stone. Such light scratches can appear if the roller guide and the cam are not correctly aligned. In the event of heavier scratches or direct flaking of the material on the running path, MAN B&W Diesel should be contacted for further instructions. Page 2(3)[HYUNDAI] Camshaft MAN B&W. Adjustment 906-3.3, 1, If the chains prove to be so heavily worn that the deviation between the measuring points and the pin gauge has reached the maximum value stated in Procedure 906- 3.1, MAN B&W Diesel should be contacted for further instructions. Page 3 (3)HYUNDAI Camshaft Bearings 106-4 MAN B&W. Data SAFETY PRECAUTIONS Standard Tools: See Section 913, X | Stopped engine X | Block the starting mechanism ZZ, [x | shut off stenting air supply X | Engage tuming gear rt Shut off cooling water Shut off fuel oi oe X_| Shut off lubricating oi! Lock turbocharger rotors @ Data Seat Ref, Dessition Vole Unit D-1 Weight of bearing cap 16.7 kg D-2 Tightening torque — screws for bearing cap 210 Nm 0-3 Clearance between cap! bearing housing 3440.3 mm D-4 Max. wear of beating shell 0.10 mm —— Page 1 (2)106-4 Camshaft Bearings HYUNDAI Data MAN B&W 019 Plate 90651 1 le i e J Spare Parts Pate — tem No. Desepion ay Page 2 (2)HYUNDAI Camshaft Bearing MAN B&W Checking 1. Dismount the inspection covers from the front of the camshaft housing. Check for wiped-out metal at the bearing ends, and for fragments of metal in the camshaft housing. In the event of any signs of anomalies, the bearing shell must be dismantled for closer investigation and, if necessary, the bearing shell must be replaced. if no anomalies are found during the visual inspection, dismantling need only be carried out in connection with Class surveys. 906-4.1 SRSATAST Page 1 (6)906-4.2 Camshaft Bearing HYUNDAI Dismantling MAN B&W. THEATRE Warning! Before dismantling any camshaft bearings, the main chain must be relieved of tension by loosening the chain tightener to avoid damaging engine parts. See Procedure 906-2.3. 4, Remove the inspection cover from the camshaft housing. Dismount the lubricating oil connecting pipe and the plug screws from the baseplate over the bearing in question. ETS Page 2 (6) Lift the roller guide of the exhaust valve hydraulic pump. See Procedure 908-7. 2. Loosen the bearing cap screws through the holes in the baseplate. Remove the screws from the bearing cap. Mount two 10 mm eye bolts in the pertaining threads on top of the bearing cap. 3. Slide the bearing cap carefully towards the exhaust cam disc. Turn the bearing cap and pull it out through the inspection openingHYUNDAI Camshaft Bearing 906-4.2 MAN B&W Dismantling 4, Place the hydraulic jack in the camshaft housing underneath the circular part of the exhaust cam. Place a dial gauge on the camshaft, and lift the camshaft 0.30 mm. 5. Press lightly on the upper edge of the shell to turn the shell up over the camshaft. Remove the shell from the camshaft housing eRe Page 3 (6)906-4.3 Camshaft Bearing HYUNDAI Overhaul MAN B&W. 1. For assessment of the bearing condition, see Volume | OPERATION, Chapter 708 ‘Bearings’. Inspect the entire surface of the bearing journal for seizures. If seizures are found on the bearing journal surface (on account of bearing breakdown), polish the surface with a fine carborundum stone to re-establish a bright and smooth surface. By closely examining the sliding surface of the bearing shell visually, an impression can be formed of whether the lubrication of the bearing surface has been insufficient or entirely missing. Normally, camshaft bearing damage only occurs due to faulty lubrication. Measure the thickness of the bearing shell with a micrometer to check the amount of wear. Page 4 (6)HYUNDAI Camshaft Bearing 906-4.4 MAN B&W Mounting 1. Clean the bearing journal, the bearing support and the bearing shell 2. Coat the bearing shell with oil, mount the shell on the camshaft, and turn it into place. 3. Place the bearing cap on the camshaft next to the exhaust cam. Note! Eee ee ere | Be careful not to scratch the exhaust cam | rolter surface. Turn the bearing cap to an upright position and slide it carefully onto the bearing shell. Remove the eye bolts and mount the outermost bearing cap screw. 4. Tighten the outermost screw fightly until the clearance given in D06-33 is reached. Then mount and tighten the innermost screw with a torque spanner. See Data D06-31. This procedure ensures that the outermost screw will obtain the correct torque. Check the torque on the outermost screw with a torque spanner. (sraeeaa ae Page 5 (6)Camshaft Bearing HYUNDAI Mounting MAN B&W 5. Check the clearance D06-33, Then mount the lubricating oil pipe and the plug screw in the baseplate. 6. Lower the camshaft into position. Remove the hydraulic jack from the camshaft housing. 7. Clean the camshaft housing and mount the inspection covers.HYUNDAI Moment Compensator 106-5 MAN B&W LMAN B&W} Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X | Stopped engine X_| Shut off starting air supply — At starting air receiver X_| Block the main starting valve X_| Shut off starting air distributor/distributing system supply X_| Shut off safety air supply — Not ME engines X_| Shut off control air supply X | Shut off air supply to exhaust valve — Only with stopped lubricating oil pumps X_| Engage turning gear Shut off cooling water Shut off fuel oil Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description Value | Unit 06-39 | Required spring force 16500 | N D06-46 | Reduction of spring length (Lis measured by the engine builder) L | mm -See the number of mm indicated on the data plate on the spring When referring fo this page, please quote Date 010605 Eoition 0023 Page 1 (2)106-5 Moment Compensator HYUNDAI ae MAN B&W. a The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No. Description P91366 61 Slide caliper Page 2 (2) When referring to this page, please quote Data 010605 Edition 0023HYUNDAI Moment Compensator MAN B&W Checking 906-5.1 If dismantling has been necessary, the flyweights must be assembled in the correct position in relation to the engine crankshaft. Incorrectly mounted fiyweights can cause (heavy) vibrations of the engine. Note! The following applies to a clockwise- rotating engine Aftmost 2nd Order Moment Compensator Turn the crankthrow of cylinder No. 1 in the AHEAD direction to the position shown in the figures for 4, 5, 6-cylinder engines, respectively. Check that the flyweights point vertically downwards (max. deviation one-half chainwheel tooth pitch), Turn the camshaft relative to the crankshaft in accordance with the ‘valve opening diagram’, and then mount the chain. Tighten the chain in accordance with the instruction. See Procedure 906-2.3. Turn the crankthrow of cylinder No. 1 in the AHEAD direction to TDG and carry out fine adjustment of the camshatt. Foremost 2nd Order Moment Compensator Turn the crankthrow of cylinder No. 1 in the AHEAD direction to the position shown in the figures for 4, 5, 6-cylinder engines, respectively. Check that the flyweights point vertically downwards (max. deviation one-half chainwheel tooth pitch) and then mount the chain, Tighten the chain in accordance with the instruction. See Procedure 906-5.3. oy No.1 cylinder No.1 os 2. For S-aylindar ongines Viewed from AFT cylinder No.1 ‘oytindor No.1 Viewed trom FORE Note! For an anticlockwise-rotating engine, the degrees mentioned in the respective figures must be before TDc, not after TOC, 3. For 6-eylindor engin: vlowed from AFT ‘eytindor No.1 ‘cylinder No.1 viewod from FORE When referring to this page, please quote Procedure 906-5.1 Edition 0218 Page 1 (5)906-5.3 Moment Compensator HYUNDAI Adjustment MAN B&W. 1. At the front of the engine, remove the covers from the frame. When tightening the chain, bring the two flyweights to a vertical downward position. Mount an eyo bolt on top of the chain tightener bolt and, by means of a tackle and the ‘engine room crane, suspend the chain tightener bolt while making the tightening adjustment. TRI B-2 Page 2 (5) When referring to this page, please quote Procedure 906-5.3 Edition 0218HYUNDAI MAN B&W 4. Release the lock washers and loosen nuts Al, A2, B1 and B2. Measute the free length of the spring. Moment Compensator Adjustment 906-5.3 Note! To ensure the correct tightening, remove the tackle and the eye bolt from the tight- ‘ening bolt. Tighten nut B1 until the length of the spring has been reduced by the number of mm indicated in DO6-46 to obtain the correct spring force D06-39. Note! OST REO A subsequent check measurement will in most cases show that the free length of the spring has been reduced during operation. Therefore, whenever the chain is to be tightened, the free length is to be measured, and the length of the spring should always be reduced by the number of mm indicated in Dos-46. When referring to this page, please quote Procedure 906-5.3 Edtion 0218 Page 3 (5)906-5.3 Moment Compensator HYUNDAI Adjustment MAN B&W. 7. Tighten nut At lightly. Make sure that this does not further com: press the spring. 8. Tighten nut A2 while holding nut At with a spanner. Lock both nuts with the lock washer. 9. Tighten nut B1 until the thrust flange of the spring lies hard against the distance tube. HOST BETT Page 4 (6) When referring to this page, please quote Procedure 906-5.3 Edition 0218HYUNDAI Moment Compensator MAN B&W. Adjustment 906-5.3 10. Tighten nut B2, and lock both nuts with the | 10- lock washer. 11. Mount the covers on the frame. B-2 HeeET aT When referring to this page, please quote Procedure 906-5. Edition 0218 Page 5 (6)HYUNDAI Replacement of Cams on Camshaft 106-6 MAN B&W Data SAFETY PRECAUTIONS X ] Stopped engine X | Block the starting mechanism - X | Shut off starting air supply X | Engage tuming gear ‘Shut off cooling water X | Shutoff fuel oi! X | Shut off ubricating oil [| Look turbocharger rotors Data Ref. Description fe Value] Unit 006-47 | Exhaust cam screws, tightening torque 900| Nm or 100| Nm +30| ° 06-49 Fuel cam screws, tightening torque 1620! Nm or 100 Nm 430° 06-50 | Fuel cam, marking scratch 418 mm 006-51 Fuel cam, axial movement 155, mm 06-52 _| Exhaust cam, marking scratch 408) mm 06-53 | Exhaust cam, axial movement 490| mm When referring to this page, please quote Data 010606 Edition 0005 Page 1 (2)106-6 Replacement of Cams on Camshaft Data ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No, | Description Z 7 90861 173 | Lifting tool for exhaust valve roller guide 91351 22 | Hydraulic pump, hand operated 91961 46 | Hose with unions (1500 mm), complete 91361 58. | Hose with unions (3000 mm), complete 91351 166 | Angle union Po1a6t 105 | 3-way distributor block, complete 91369 Torque Spanners Page 2 (2) When referring to this page, please quote Data 010606 Edition 0005Replacement of Cams on Camshaft 906-6.2 Dismantling Fuel Cam 4. Remove the front cover of the camshaft housing. 2. Lift the roller guide from the cam in question. See Procedure 909-10. 3. Turn the camshaft so that the marking soratch can be seen. 4. Extend the marking scratch on the shaft by 106-50. See Data. 06-50 When referring to this page, please quote Procedure M90606 Edition 0204 Page 1 (7)906-6.2 Replacement of Cams on Camshaft HYUNDAI Dismantling MAN B&W. 5. 5, Remove the plug from the cam and mount gaskets and snap-on connectors instead. 6. Connect the snap-on connectors to the hydraulic high-pressure pump. Apply oil pressure to the cam, using the high-pressure pump. When oil seeps out along the cam, press oven the cam sideways, in the direction towards the forward end of the engine, lia 7. The cam should be moved as stated in D06-51 1D06-51 to be sure that it gets free of the liner for the roller guide. 8. In case the cam cannot be moved as described in item 6, MAN B&W should be contacted for further instructions. Page 2(7) When referring to this page, please quote Procedure M90606 Edition 0204HYUNDAI Replacement of Cams on Camshaft 906-6.2 MAN B&W. Dismantling Exhaust Cam 8. 9. Remove the front cover of the camshaft housing. 10. Lift the roller guide from the cam in question. See Procedure 908-7. 11. Extend the marking scratch on the indicator drive cam onto the camshatt. Extend the marking scratch on the exhaust cam onto the camshaft by D06-52. See Da- ta. 10. 1. When referring to this page, please quote Procedure M90606 Edition 0204 Page 3(7)906-6.2 Replacement of Cams on Camshaft HYUNDAI Dismantting MAN. aay 12. 13. as = a 12. Dismantle and remove the indicator drive cam from the camshaft when fitted. 43. Remove the plug from the cam and mount gaskets and snap-on connectors instead. 14, Connect the snap-on connectors to the hydraulic high-pressure pump. Apply oll pressure to the cam, using the high-pressure pump. When oil seeps out along the cam, press the cam sideways, in the direction towards the aft end of the engine. Page 4(7) When referring to this page, please quote Procedure M90606 Edition 0204HYUNDAI Replacement of Cams on Camshaft 906-6.2 MAN B&W Dismantling 15. The cam should be moved as stated in 1D06-53 to be sure that it gets free of the liner for the roller guide. 16. In the event that the cam cannot be moved as described in item 14, MAN B&W should be contacted for further instructions. When referring to this page, please quote Procedure M90606 Edition 0204 Page (7)906-6.4 Replacement of Cams on Camshaft HYUNDAI Mounting MAN B&W 1, Fuel Cam 1 FRAO Before mounting the two-part spare cam, the bore and the area on the shaft must be degreased. Place the two-part spare cam on the shaft, mount the four screws, and tighten slightly, so that the gap between the two parts is equal at both sides. Make sure that the marking scratches on the cam and the camshaft coincide, and that the running surface of the cam is opposite the roller. Tighten the screws just hard enough to avoid that the cam slips when the roller guide is lowered onto the cam. Measure the fuel cam lead (see Procedures 909-1 and 909-3) and adjust if necessary. Tighten the screws to DO6-49 and check that the gap is still equal at both sides. Lock the screws with Lox (EN2438). , type 242 Mount the cover on the front of the camshaft housing. Page 6 (7) When referring to this page, please quote Procedure M90606 Edition 0204HYUNDAI Replacement of Cams on Camshaft 906-6.4 MAN B&W ‘Mounting Exhaust Cam 4. 4, Mount the indicator drive cam and adjust according to Chapter 706 in the Operation manual when fitted. Tighten the self-locking nuts as stated in 06-48. 5. Before mounting the two-part spare cam, the bore and the area on the shaft must be degreased. Place the two-part spare cam on the shaft, ‘mount the four screws, and tighten slightly, so that the gap between the two parts is equal at both sides. 6. Make sure that the marking scratches on | 5. the cam and the camshaft coincide, and that the running surface of the cam is opposite the roller. avoid that the cam slips when the roller guide is lowered onto the cam. Tighten the screws just hard enough to if ale if Measure the exhaust cam lead (see Proce- dure 908-5 and adjust if necessary. Tighten the screws to D06-47 and check that the gap is still equal at both sides. Lock the screws with Loctite, type 242 (EN2438). 7. Mount the cover on the front of the cam- | 6, shaft housing. 006-47 06-49 When referring to this page, please quote Procedure M90606 Edition 0204 Page 7 (7)X | Stopped engine X | Block the starting mechanism X_| Shut off starting air supply x Engage turning gear Shut off cooling water Shut off fuel oil X | Shut off lubricating oil Lock turbocharger rotors Data Ref, Deseriton D1 Slackness in 1" chain Value Unit 25-50 mm HYUNDAI Chain Tightener 1” 106-7 MAN B&W. SAFETY PRECAUTIONS Standard Tools: See Section 913 Ze ===e Page 1 (2)106-7 Chain Tightener 1” HYUNDAI Data MAN B&W Spare Parts Plate — Item No. Description Ory Page 2 (2)HYUNDAI Chain Tightener 1” 906-7.1 MAN B&W. Checking 4. Turn the engine so that the slack of the chain occurs on the free length. Measure the slack of the chain manually by moving the chain to the outer positions of the slack and finding the difference between these positions. If the chain tension does not correspond to the measurements stated on the data sheet, adjustment is to be carried out. Page 1 (2)HYUNDAI Chain Tightener 1" 906-7.3 MAN B&W. Adjustment 1. Loosen the screws of the chain tightener, | 1. and by turning the "loose" plate of the chain in such a way that it is in accordance with the limits stated in Data. Again tighten up the screw and check the slack, If the chain tension is in order, lock the screw with locking wire. Page 2 (2)HYUNDAI MAN B&W. ‘S60MC-C Chain Drive and Camshaft Panel Plate 90651-177 109 056 020Plate 90651-177 Chain Drive and Camshaft Panel Na Item Description nat Item Description 019 | Tool panel 020 | Name plate 044 Chain assembling tool 056 | Chain disassembling tool 068 | Pin spanner 070 Hydraulic jack for lift of camshaft 081 | Lifting attachment 093 | Chain assembling tool 103 Chain disassembling toolHYUNDAI - Pil late 105, MAN B&W Crankshaft - Pin Gauge Plate P90664-00( 050 When referring to this page, please quote Plate P90664 Edition 0005Plate P90664-0005 Crankshaft - Pin Gauge Item Item j Item Deser No. Item Description | No. ription 050 | Pin gauge for crankshaftHYUNDAI oe i MAN B&W Camshaft - Pin Gauge Plate P90668-0003 — O11 When referring to this page, please quote Plate P90668 Edition 0003Plate P90668-0003 Camshaft - Pin Gauge Item 3 Item a Ne, Item Description hor Item Description 011 | Pin gaugeHYUNDAI MAN B&W Starting Air Distributor Data 107-1 ‘SAFETY PRECAUTIONS ‘Stopped engine xx P<]x] Engage turning gear ‘Shut off cooling water ‘Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors Data Block the starting mechanism ‘Shut off starting air supply Description value] Unit When referring to this page, please quote Data D10701 Edition 0018 Page 1 (2)Starting Air HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate item No. | Description Pago 2 (2) When referring to this page, please quote Data D10701 Eudition 0018HYUNDAI Starting Air Distributor MAN B&W. Checking 907-1.1 1, Turn the engine to bring the piston of cylinder No. 1 to TDC. Check the position with the pin gauge. See Procedure 906-3.1. 2. Remove the small end cover of the distributor housing. 8. Check that the TDC marking soratch on the starting cam is positioned vertically at the valve slide of cylinder No. 1 4, If necessary adjust the position of the starting cam by loosening the centre screw and turning the starting cam until the TOC marking scratch is positioned vertically at the valve slide of cylinder No. 1. Then tighten the centre sorew. When referring to this page, please quote Procedure M90701 Edltion 0217 Page 1 (6)907-1.3 Starting Air Distributor Overhaul HYUNDAI MAN B&W. Difficulties in starting can be caused by the starting air distributor valve slides “sticking” (see Volume I, Chapter 703), so that these are not activated and pressed against the cam during the starting procedure. This can be caused by too high humidity in the main starting air system, which can result in the formation of rust, .and also by dirt, preventing the slide valves from functioning. In both cases it is necessary to clean the valve slides and the liners in the distributor housing to remove dirt, rust and foreign particles. Experience will show how often this is necessary to prevent starting difficulties, as differenc- ‘8 will be found from plant to plant. 1. Blank off the main starting air and the control air. If this is not possible, lock the main starting valve in the closed position with a padiock. 2. Remove ail the pipes from the end of the distributor. Loosen and remove the screws from the small and large end covers. Dismount the end cover which gives access to the slide valves. 3. Turn the camshaft until the pin of the valve slide (cam follower) can be pushed clear of the starting cam. 4, Remove the screws and the cap from the particular valve slide in question. Remove the guide screw for the valve slide. When referring to this page, please quote Procedure M90701 Edition 0217907-1.3, HYUNDAI Starting Air Distributor MAN B&W. Overhaul 5. Remove the complete slide valve (with | 5: spring and the upper liner) from the distributor housing by means of a brass mandrel. 6. Press-in the spring and remove the two part locking ring. 7. Remove the upper spring guide, the spring, the lower spring guide and the upper liner from the valve slide. 6. 8 & 7. A 8 i When referring to this page, please quote Procedure M90701 Edtion 0217 Page 3 (6)907-1.3 Starting Air Distributor HYUNDAI Overhaul MAN B&W. a> 8. Clean all the sliding surfaces on the valve slide, Check the sliding surfaces for wear and seizures, also check the cam follower for wear. Clean the liners and the distributor housing. Test that the valve slide moves easily in the liners. Note! Polishing of the liners with emery cloth must not take place as small particles of the grinding material can stick in the surface of the liner. Lubricate all parts with Molybdenum Disul- phide (MoS;), also the cam follower must be well lubricated. 9. Place the upper liner, the lower spring guide, the spring and the upper spring Quide over the valve slide. 10. Press-in the spring and mount the two-part locking ring. 14. Mount the complete slide vaive in the distributor housing. (Check that the pin of the valve slide goes clear of the starting cam when mounting). Lubricate the groove in the starting cam with Molybdenum Disulphide (MoS2). Wen referring to this page, please quote Procedure M90701 Edition 0217HYUNDAI Starting Air Distributor MAN Baw. Overhaul 907-1.3 12, Mount the guide screw for the valve slide. | 12. Mount the cap and the screws on top of the slide valve. 48. Check that the piston vaive slides can be pushed up and down by hand just overcom- ing the force of the spring, 14. Finally, mount the two end covers and connect the main starting air and the contro! air. When referring to this page, please quote Procedure M90701 Eoltion 0217 Page 5 (6)HYUNDAI Starting Air Valve 107-2 MAN B&W Data SAFETY PRECAUTIONS ‘Stopped engine Block the starting mechanism Shut off starting air supply Engage tuning gear Shut off cooling water Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors g CODDLEEE Ret. Description Value] Unit Do7-11 Valve tightening angle 60] ° Dor-12 Starting air valve 85) kg When referring to this pago, please quote Data D10702 Edition 0034 Page 1 (2)107-2 Starting Air Valve HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate tem No. Description 90151 95 _| Grinding ring for staring valve 90151 105 | Grinding handle for starting valve Page 2 (2) When referring to this page, please quote Data D10702 Edition 0034HYUNDAI Starting Air Valve 907-21 MAN B&W. Checking 1. When the starting air valve has been over f hauled, see Procedure 907-2.3, connect a supply of working air to the control air inlet at the top of the valve. oo a ‘Check that the valve opens approx. 15-20 mm. 2. Shut off the air supply Check that the valve closes fully. 3. Repeat steps 1 and 2 a couple of times. J When referring to this page, please quote Procedure M90702 Edition 0215E Page 1 (6)907-2.2 Starting Air Valve HYUNDAI Dismantling MAN B&W 1. Shut off the starting air and control air i Dismount the control air pipes Mount two eye bolts in the top cover of the valve. Hook a lifting wire on to the eye bolts. Unscrew the fixing nuts of the starting valve flange. 2. Lift away the starting valve. is 3 2. Do7-12 7 ots t ic ls ie 5 5 Page 2 (6) When referring to this page, please quote Procedure M0702 Edition 0215EHYUNDAI Starting Air Valve MAN B&W. Overhaul 1. Place the starting air valve horizontally in a bench vice provided with “soft” jaws. Remove and discard the O-ring from the valve housing. 2. Loosen and remove the screws from the top cover. Dismount the top cover. 3. Use the face wrench for the spindle as a back-stop when loosening the two screws which tighten the piston to the spindie. Remove the screws and discard the locking device. ‘When unscrewing, the piston will partially be pressed out of the vaive housing due to the spring force. When referring to this page, please quote Procedure M90702 Edition 0215E Page 3 (6)907-2.3 Starting Air Valve HYUNDAI Overhaul MAN B&W. 4, Remove the piston from the top end of the valve housing. Take out the spindle from the bottom end of the valve housing. Remove the spring from the top end of the housing. 5. Apply grinding paste, e.g. carborundum No. 200. Grind the valve housing seating with the grinding ring. 6. When lapping the seatings of the spindle and valve housing to match, use the face wrench to rotate the spindle. ‘As grinding paste, use e.g. carborundum No. 500. ° Page 4 (6) When referring to this page, please quote Procedure M90702 Eudltion 0215EHYUNDAI Starting Air Valve MAN B&W. Overhaul 907-2.3 7. Thoroughly clean the valve housing and all the parts in diesel oil or kerosene. Lubricate all internal parts and sliding surfaces with, 0.g., Molybdenum Disulphide, MoS. Insert the spindle in the valve housing. Then mount the spring in the housing around the spindle and, finally, place the piston on top of the spindle. 8. Fit the discs and the two screws. When tightening the screws, the piston will compress the spring, Tighten the screws continuously until the piston faces tightly against the spindle. Use the face wrench as a back-stop. See Daia. Lock the screws with locking device. For correct use of locking device, see Pro- cedure 913-7. 9. Mount and tighten the top cover. Fit a new O-ring on the valve housing. 10. Check the starting air valve. See Procedure 907-2.1. If the valve is not to be mounted in the engine immediately, cover all openings with plastic to prevent dirt from entering the valve during storage. When referring to this page, please quote Procedure M90702 Edition 0215E Page & (6)907-24 Starting Air Valve HYUNDAI Mounting MAN B&W. 1. 1. Carefully clean the starting valve bore in the cylinder cover and, if necessary, recondition the seat for the starting valve in the bore, see Procedure 901-1.3. If not already done, fit a new O-ring on the overhauled valve and lubricate with ‘Never Seize’ or Molybdenum Disulphide, MoS. For overhaul, see Procedure 907-2.3. 2. Mount the valve in the cylinder cover. 3. Mount the nuts and tighten-up in at least (I) three steps, to reach the full tightening angle, see Data. prereaioar Mount the control air pipe and turn on starting air and control air. D07-12 Page 6 (6) Wien referring to this page, please quote Procedure M90702 Edition 0215EInstruction and Maintenance EEE EE HEHE SS Manual For Main Starting Valve cee a wa, rai nn we Le af” “en oJ LAA ee MODEL : KKMW & KKMO KKMW : MAIN STARTING VALVE WITH SLOW TURNING DEVICE & KKMO : MAIN STARTING VALVE WITHOUT SLOW TURNING DEVICE “ 2HO| BSs=E SUS BSéstct. ” KUMKANG PRECISION CO., LTD.Instruction and Maintenance Manual FR Hl @ For Main Starting Valve Dee! a Iso 9002 217 ecm - CONTENTS - DESCRIPTION 1. Instruction for KKMW Series 2. Instruction for KKMO Series 3. KKBV Series Ball Valve Instruction 4, KKPA Series Actuator Instruction 11~12 “KUMKANG PREGISION CO., LTD.Instruction For @ cumcane Main Starting Valve - KKMw EM PRECISION CO., LID. - General Specification Ball Valve Hydro. Test Pressure : 70 Bar Ball Valve Working Pressure : Max. 40 Bar Ball valve End Connection : DIN PN 40 Bar Actuator Air Source Range : 4~8 ka/ot G Application Fluid : Compressed Air — Operation @ Before operating the valve by controlling the air source Valve to the actuator, check whether the blocking device is at valve operating position. @® For valve operating and closing operation, Fully turn the manual handle to the direction of counter-clook-wise viewing from topside. ® Tum on the control air source valve to.the actuator for each direction. @® When finished engine start up or valve are not using condition, Be sure to close the valve and to blocking the valve by turning manual handle to the direction of clock-wise viewing from topside. KUMKANG PRECISION CO., LTD. ~1-Instruction For 6 KAR kum kang ‘Main Starting Valve - KKMO = PREQSION C0, LTD. 180 9002 21s etA - MAIN STARTING VALVE WITHOUT SLOW TURNING DEVICE ~ General Specification Ball Valve Hydro, Test Pressure : 70 Bar Ball Valve Working Pressure : Max. 40 Bar Ball valve End Connection : DIN PN 40 Bar Actuator Air Souree Range : 4~8 ka/o G Application Fluid : Compressed Air - Operation @® Before operating the valve by controlling the air source Valve to the actuator, check whether the blocking device is at valve operating position. @® For valve operating and closing operation. Fully turn the manual handle to the direction of counter—clock-wise viewing from topside. @ Turn on the control air source valve to the actuator for each direction. @ When finished engine start up or valve are not using condition, Be sure to close the valve and to blocking the valve by turning manual handle to the direction of clock-wise viewing from topside KUMKANG PRECISION GO., LTD.<> KKBV Series Ball Valve Installation H@ KUM KANG Operation & Maintenance Instructions = oily PRECISION CO,, LTD. 2 “ Bo one SSM A. Installation 1. General Keep protective cover in place until moment of install - Valve performance depends upon prevention of damage to ball surface. Upon removal of cover make sure that the valve is completely open and free of obstruction. When dispatched, valves contain a silicon based lubricant which aids the bedding in of the valve, this may be removed with a solvent if found objectionable. Certain ferrous valve are phosphated and oil dipped during the course of manufacture, but the processes used are completely non-toxic and the valve are quite safe to use for edible or potable products. 2. Flanged valves The customer is required to supply the necessary flanges, gaskets and bolting in order to fit the valve into his pipe-work B. Operation 1, Use KUMKANG Valves provide tight shut off when used under normal conditions. If these valves are used in a partially open (throttled) position, seat life may be reduced. Any media which might solidify, crystallize or polymerize, should not bo allowed to stand in the valve cavities unless regular maintenance is envisaged. 2. Manual operation The basic type of wrench which is fitted to all sizes of malleable iron with separate malleable iron stop plate. KUMKANG valves have 1/4 tum operation, closing in a clockwise direction. It is possible to see, where the wrench is correetly fitted, when the valve is open or closed by the position of the wrench: When the wrench is in line with the pipeline, the valve is open when the wrench is across the pipeline, the valve is closed. KUMKANG PRECISION CO.. LTD.<> KKBV Series Ball Valve Installati kum Kang Operation & Maintenance Instructions oo D PRECISION CO,, LTD. iso 9002 217 3. Remote operation Where manual operation is not required, valves may be automated for remote operation, instrument control, etc. A range of pneumatic and electro pneumatic actuators is available. No stop is fitted to the valve, since the stop is normally part of the actuator. Operation will be in accordance with installation, operation and maintenance instructions for the relevant actuator. C. Maintenance 1. General With self-wipe ball/seats and patented pressure equalizing slots. KUMKANG valves have a long, trouble free life, and maintenance is seldom required. But, when necessary, valves may be refurbished by relatively unskilled labour, using a small number of components, none of which require machining in site. KUMKANG valves are designed for easy service and assembly in the field. The following checks should, however, help to extend valve life further, or reduce plant problems. Stem leakage Tighten the gland nut. If it requires excessive tightening. check that valve torque Remains acceptable. If tightening does not solve the problem it will be necessary to dismantle the stem assembly only. It will not be necessary to dismantle the valve. Leakage at body join Check for tightness in the body connector cap-sorews. If slack, tighten-connector flanges are metal to metal, standard wrenches only should be used excessive force will only stretch or strip the bolts. If there is still leakage, this be due to damage to body connector seal and it will be necessary to dismantle valve. In-line leakage Cheek that valve is fully closed. If it is, leakage will be due to damage seat or ball sealing surfaces and it will be necessary to dismantle the valve. KUMKANG PRECISION CO., LTD. aaj<> KKBV Series Ball Valve Installation He kum Kang Operation & Maintenance Instructions [).y «= = PRECISION CO_ LTD. 180 9002 elFeiad Note : Stem leak and leakage at body joint, if not cured by simple means described above, necessitate dismantling valve, but if there is not stem leakage the stem assembly should not be touched Leakage at pipeline joint Test for tightness in the flange bolts. if slack, tighten-valve flange and pipe-work flanges have flange gasket between them, standard wrenches only should be used-excessive force will only the flange, stretch or strip the bolt. if over-tightened, bolts cause flange leaks and slackening of bolts may then sometimes solve the problem. 2. Refurbishing Maintenance kits are available from KUMKANG and consist of the following: 2seat rings, 1 body connector seal, 1 stem thrust seal, 3 gland packing rings, 1 gland nut. Where a valve need repairing, rather that maintaining, it must be notes that only KUMKANG authorized spare part should be used, and these include basio components available from KUMKANG are balls, stems, glands. If additional parts are required, it is normally recommended that the complete valve is replaced. Parts of valves from different series, should nor be interchanged. This is to ensure, so far as is reasonably practicable, that the valve remains capable of being used for the purpose for which it was designed and constructed, without risk to health and safety when properly used. However, if the valve is altered in any way, no liability can be accepted by KUMKANG KUMKANG PRECISION GO., LTD. o5-«> KKBV Series Ball Valve Installation kum Kang Operation & Maintenance Instructions ‘>, y . PRECISION CO, LTD. 's0 9002 eh 3. Safety precautions Before removing valve from pipeline Media flowing through a valve may be corrosive toxic, inflammable, or of @ contaminant nature. Where there is evidence of harmful fluids having flowed through the valve, the utmost care be taken. It is suggested that the following safety precaution should be taken when handing valves. @ Always wear eye shields. @ Always wear gloves and overails. @® Wear protective footwear. @ Wear protective headgear. © Ensure that running water is easily available. © Have suitable fire extinguisher ready if media is inflammable. ®y asking responsible personnel and by checking line gauges, ensure that no pressure exists on either the upstream or downstream sides of the valve, Ensure that any trapped media is released by operating valve slowly to half open position. Leave valve in fully open position before removing from the pipeline. After removing valve from pipeline. If the valve is closed and not in the fully open position as suggested in preceding safety precautions now ensure that any trapped media is released by operating valve slowly to half open position. The safety place to stand. when operating the valve, is away from the end of the stem and to one side. Ideally, the valve should be decontaminated when the ball in the half open position, Leave in fully open position 4. Tools No special tools are required for maintenance of KUNKANG valves. KUMKANG PRECISION CO.. LTD. 6- KKBY Series Ball Valve Installation kum KANg Operation & Maintenance Instructions D. Dismantling If the valve is olosed and not in fully open position as suggested in proceeding safety precaution, refer to these precautions before proceeding further. Also, during dismantling, do not assume that valve is totally decontaminated — harmful fluid, etc., may still be trapped in crevices. Valve should be placed with the body connector uppermost and on a clean surface, the valve preferably clamped or bolted down. To remove body connector, extract body connector mid~flange connection should break open. Repeat if not successful at first try. The body connector should now be lifted vertically from the body and placed on the clean surface with mid-flange uppermost. If the body connector seal comes away easily during removal of body connector, it may be removed at this time. If not leave it until later. With the valve still in the close position the ball may now be lifted from the body cavity, and the seat rings and body connector seal should now exposed in either body or body connector. The seat rings and body connector seal should now be removed. Care must be taken to avoid scratching the machined faces on which they make contact with valve body and body connector. To dismantle stem assembly, first removed the wrench nut, identification plate and wrench from stem. Using wrench to prevent the stem from turning, remove the gland nut, disk spring and gland. It is not normally possible to remove gland packing at this stage. Withdraw stem through body cavity and remove stem trust seal from stem or body recess. Gland packing may now be removed, Clean all components thoroughly and examine all seating/sealing surfaces. If there is a build-up of solids which cleaning fluids will not move-do not soratch the machined surfaces- use a broad, flat, blunt tool. No eroded or corroded leak paths are permissible. If any are found, the part must be replaced. The bail must have no scratches across its seating surfaces and any damage to the port lip will destroy the seal-a damage ball must not be re-used - fit a new one, KUMKANG PRECISION CO., LTD. ated<> KKBV Series Ball Valve Installation kum Kang Operation & Maintenance Instructions a oe 60, LTD. 180 9002 e124 E. Rebuilding Before rebuilding, check that all the correct compositions are available and that they are fit for the purpose. When rebuilding, cleanliness is essential to allow long vaive life and provide cost effective maintenance. Body should be placed with the mid-flange connection uppermost and on a clean surface, the body preferably clamped or bolted down. Fit inner seat ring before stem assembly. Fit stem thrust seal. to stem and insert stem through body cavity into stem hole and fully up into body recess. Fit gland packing, gland and disk with their outer edges touching. Using wrench to prevent stem from turing, fit Gland rut and screw down until disk springs are firmly compressed. Operate stem several times and re~adjust. Over-tightening will only reduce the life of the assembly Now fit wrench, identification plate and wrench nut to stem assembly and move stem into the closed position-wrench across the pipeline. With the stem still in the closed position, the ball may be placed into the body cavity by sliding the ball slot over the stem tang. Open the valve. Fit second seat ring and body connector seal into body. ant of clean grease(such as petroleum jelly) if, compatible with the future pipeline media, will ease the rebuilding by holding the seat rings and insert/body connector seals in place. Use no grease with abrasive additives. With mid-flange facing down and customer flange holes correctly positioned, place the body connector into the body using 2 or 3 body connector cap~ screws to align mid-flange fixing holes. When correctly located, strike body connector with mallet to push down body connector further into body. Fit body connector cap-sorews, and by tightening, pull down body connector until finally both mid-flanges touch. Valve flanges will be metal to metal, standard wrenches only should be sued-excessive force will only stretch or strip the bolts. Test If practical, leak tightness and torque should be checked. KUMKANG PRECISION co., LTD.<> KKBV Series Ball Valve Installation € . Zo . KAB KuM KANG Operation & Maintenance Instructions ‘>", nee vel 80 9002 2 BALL VALVE Type : KKBV Series 150mm Fire-sate. Max. Working Pressure : 40Bar. Test Pressure : 70Bar. Flange Connection. Drilled to DN40x100 or 150 Housing : Cast Stee! (C480). Ball and Stem : ANS! 316/SIS 2343 Upstream seat : Al-Bronze Sealing : Downstream : Seat Ht Modified Fire-safe Gasket(PTFE) KUMKANG PRECISION CO.,LTD.|
KKBV Series Ball Valve Installation He KAR | Ku KANG Operation & Maintenance Instructions == ony ole a PRECISION CO, LI ‘one SI SelA 180 4 Sp roe KUMKANG PRECISION CO., LTD.<> KKPA Series PNEUMATIC ACTUATOR EX? ww kum Kang Operation & Maintenance Instructions Ty) >) = PRECISION C0. LTD. tS0 9002 12378 ACTUATOR Type : Hap Double Acting. Ball valve and actuator to be mounted in closed positioruall dimensions to be in accordance with the drawing rene cose Siren The actuator is of a pneumatic type with a simle and safe construction, ‘ensuring that the actuator operation is reliable regardless of high or low speeds, and a different air gas pressure abt. 2~8.4 kg/ont Operation Conditions Pressure range : 2~8.4 kg/ow Temperature range : -18°C ~ to 100° Direction : Actuators rotate in anti-clockwise direction when the right and air connection is pressurized Media : Air or non corrosive gas. Movement : 90° with up to 1 1/2° overrun each end. KUMKANG PRECISION CO.. LTD.Sai DNV D> D. 7 iH “2. KKPA Series PNEUMATIC ACTUATOR KUMKANG PRECISION CO., kum KANG Operation & Maintenance Instructions PRECISION CO,, LID. <>HYUNDAI High-Pressure Pipe MAN B&W. Data 108-1 SAFETY PRECAUTIONS X | Stopped engine X | Block the starting mechanism, X_| Shut off starting air supply Engage turning gear ‘Shut off cooling water Shut off fuel cil X_| Shut off lubricating oil Lock turbocharger rotors Data Ref. Description Value] Unit 08-01 High-pressure pipe, tightening torque 70) Nm 08-02 Distance of high-pressure pipe lower edge to pressure flange 16| mm Dos-03 High-pressure pipe 38| kg When referring to this page, please quote Data D10801 Edition 0031 Page 1 (2)108-1 High-Pressure Pipe HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No. | Description 90851 142| Grinding mandrel for high-pressure pipe Page 2 (2) When referring to this page, please quote Data 010801 Edition 0031HYUNDAI High-Pressure Pipe [MAN B&W] Dismantling 908-1.2 4. When replacing the hydraulic high-pressure pipe, the exhaust valve or the hydraulic actuator, check and, if necessary, recondition the high-pressure pipe sealing surfaces, 2. Before dismantling the high-pressure pipe, stop the camshaft oil pump. Loosen the screws for the high-pressure pipe and lift the pipe slightly away from the actuator to let the oil in the pipe drain through the drain holes in the actuator. SETTER 2 When referring to this page, please quote Procedure M90801 Edition 02 16 Page 1 (3)908-1.3, High-Pressure Pipe HYUNDAI Overhaul MAN B&W 1. 1. Check the contact surfaces of the pressure pipe for marks and, if necessary, grind the pipe ends by means of the grinding mandret and the two guiding tools. Start grinding with a coarse grinding paste, for example Carborundum No. 200, and fin- 4 ish with a fine grinding paste, for example (- Carborundum No. 500. (Cet vo 2050. 2. After reconditioning the contact surfaces of S$ the pipe, measure the distance from the edge of the thrust bushing to the contact. surface at both ends of the pipe. This measurement is to correspond with the value stated in Data. Check the thrust pads in the exhaust valve and the actuator for marks on the sealing surface. Replace the O-rings on the thrust pads. If considered necessary, replace the thrust pads. Lift the thrust pad free by, for example, using a screwdriver in the groove of the thrust pad. Page 2 (3) When referring to this page, please quote Procedure M90801 Edition 0216HYUNDAI High-Pressure Pipe MAN B&W Mounting 908-1.4 4. Mount the hydraulic high-pressure pipe as follows: Position the high-pressure pipe with the sealing surfaces of the pipe resting on the thrust pads of the exhaust valve/actuator. Take care not to damage the O-rings on the thrust pads. After fitting the pipe correctly in relation to the exhaust valve and actuator, tighten up the screws of the pressure flanges diagonally, see Data. 2. Check the whole system for tightness. See Procedure 908-3.1. When referring to this page, please quote Procedure M90801 Edition 0276 Page 3 (3)HYUNDAI Exhaust Valve 108-2 MAN B&W. Bue SAFETY PRECAUTIONS For detailed sketch, see 900-2 X_] Stopped engine X | Shut off starting air supply ~ At starting air receiver X | Block the main starting valve X_| Shut off starting air distributor/distributing system supply X | Shut off safety air supply - Not ME engines X | Shut off control air supply X | Shut off air supply to exhaust vaive - Only with stopped lubricating oil pumps X_| Engage turning gear X | Shut off cooling water Shut off fuel oil X | Stop lubricating oil supply X | Lock the turbocharger rotors Data Ret. Description Value Unit 08-04 | Safety valve, opening pressure 23 | bar D08-05 | Screws for lifting eye bolt, tightening torque 50 | Nm 08-06 | Oil cylinder, tightening torque 100 | Nm 08-07 | Safety valve, tightening torque 50-80 | Nm 08-09 | Bottom piece seat, grinding angle 29.9-30.0 | ° 08-10 | Valve spindle seat, grinding angle 30.3304 | *° D08-11 | Bottom piece seat, max. grinding 2.3 | mm 008-12 | Gap of bottom piece seat 1 | mm D08-13 | Spindle, max. burn-off 9 | mm 08-14 | Spindle, max. grinding 2 | mm 08-15 | Spindle stem, measuring area, min. 280 | mm 008-16 | Spindle stem, measuring area, max. 410 | mm 008-17 | Spindle stem, min. diameter 71.8 | mm Do8-18 | Bushing max. diameter, top 72.6 | mm 008-19 | Bushing max. diameter, bottom 74.5 | mm 08-20 | Oil cylinder max. inside diameter 86.4 | mm 08-21 | Piston rings, min. thickness 3.2 | mm 08-24 | Exhaust valve, complete 710 | kg Do8-25 | Exhaust valve housing 380 | kg Do8-26 | Oil cylinder 100 | kg Do8-27 | Aircylinder 30 | kg Dos-28 | Spindle 73 | kg 08-29 | Bottom piece 100 | kg Dos-30 | Air piston 9 | kg 013-01 | Hydraulic pressure, mounting 1500 | bar 13-02 _| Hydraulic pressure, dismantling 1400-1650 | bar When referring to this page, please quote Data D10802 Edition 0099E Page 1 (2)108-2 Exhaust Valve HYUNDAI Bae MAN B&W The task-speci. c tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the .rst three digits in the plate number, e.g. P90951 refers to chapter 909. Plate _| Item No Description P90sst | 065 | Lifting tool for exhaust valve P90851 | 077 | Cone ring for pneumatic piston P90851 | 089 | Pressure tester for safety valve P9081 | 090 | Gauge for exhaust valve spindle P9085 | 150 — | Gauge for exhaust valve bottom piece P90as1 | 161 | Lifting too! for exhaust valve spindle P90ast | 185 | Grinding ring for exhaust valve bottom piece 90862 Jack-hydraulic, complete po1sst | 010 — | Hydraulic pump, pneumatically operated P9131 | 046 — | Hose with unions (1500 mm), complete 91351 | 058 | Hose with unions (3000 mm), complete P9151 | 117 | S-way distributor block, complete Page 2 (2) When referring to this page, please quote Data 010802 Ealtion OOSSE ag)HYUNDAI Exhaust Valve MAN B&W. Checking 908-2.1 Checks during running: 4. Check of valve spindle rotation The engine must run when the valve function and spindle rotation are checked. Lift the valve spindle rotation indicator, turn it 90° and let it rest on the air piston, The indicator will now follow the move: ments of the valve spindle and the air ton. During rotation of the valve spincle, the top position of the indicator will change about 6 mm, because of the groove in the piston. During engine operation, the spindle must rotate. The rotation can vary with unit and "aceon a2=201 ‘engine load. In the event of no rotation, at- © tention should be paid to avoid seat problems. When check of the valve rotation is finished, lift the rotation indicator and lock it in the top position. The indicator must not be in constant operation. Exhaust valve performance condition See volume | chapter 706 Performance Evaluation 2. Check of bottom piece sealings With the exhaust valve mounted in the cyi- inder cover, check the cooling water inlet and outlet to the cylinder cover and ex- RETEST haust valve is open. Check the tightness of the sealing rings between the bottom piece and the exhaust valve housing. IF water flows from the small bore on the manoeuvring side of the exhaust valve, the lowermost sealing ring is, leaking. If water flows from the any of the rings, the exhaust valve must be dismounted and the sealing rings replaced. When referring to this page, please quote Procedure M90802 Edition 0273, Page 1 (23)908-21 SAFETYAR SuPewr ‘nn supper TROTTER Sureur Exhaust Val Checking 3. ve HYUNDAI MAN B&W Check with stopped engine: In connection with port stays, at an interval of eg. one month, an easy check of all exhaust valves is recommended. Check of spindle drop-down tim Engage all rotation indicators on the exhaust valves. Shut off and release the spring alr on the valve, next to the engine-side manoeuvring stand, Check the drop down time for all spindles: + Spindles dropping down within 30 minutes: Check and overhaul, See next step “Check of Air Spring tightness”. * Spindles dropping down between 30 minutes and 1 hour: Keep under obser- vation. + Spindles dropping down after 1 hour: OK. When check of drop down time is finished, lift the rotation indicators and lock them in the top position. Page 2 (23) ‘When referring to this page, please quote Procedure M90802 Edition 0273,HYUNDAI Exhaust Valve 908-24 MAN B&W. Checking 4. Check of Air spring tightness Connect compressed air to the non return (A) valve on the air cylinder. Disconnect and remove the drain oil pipe from the oil cylinder (C). Check if air is coming out from: * The bore (B): Leakage from spindle stem sealing , change and overhaul. ‘+ Hole for drain oil (C): If yes, the leakage ‘comes from the safety valve or the air piston. Check the safety valve (0). If air still is coming out, the leakage comes from the air piston: change and overhaul * Remove the air supply to the non-return valve on the air cylinder and check the non-return valve for tightness. The checks is for guidance only, minor cH leaks is difficult to detect. + — TRE OETA ZA When referring to this page, please quote Procedure MS0802 Eaition 0273 Page 3 (23)‘Soniaal Exhaust Valve HYUNDAI Dismantling MAN B&W 4. Close off cooling water Close the cooling water inlet and outlet connections, and drain the exhaust valve. Close the air supply to the exhaust valve. 2, Dismount the oil pipe connections Dismount the high-pressure pipe for the hydraulic valve actuation. ‘See Procedure 908-12 Dismount the retum oil pipe from the exhaust valve. TESTO Page 4 (23) ‘When referring to this page, please quote Procedure M90802 Eulition 0273,HYUNDAI Exhaust Valve praia MAN B&W. Dismantling 3. Disconnect pipe connections Disconnect the cooling water connections from the exhaust vaive and the air pipe for the air spring. Remove the plate jacket and insulation from the intermediate pipe. Loosen the screws which attach the inter- ‘mediate pipe to the exhaust valve housing. ‘Support the intermediate pipe by e.g. a chain block and remove the screws. 4, Dismantling of hydraulic nuts. Remove the protective caps from the exhaust valve studs. Loosen and remove the hydraulic nuts, see Data. See Procedure 913-1. When referring to this page, please quote Procedure M90802 Ealtion 0273 Page § (23)908-2.2 Exhaust Valve HYUNDAI Dismantling MAN B&W 5. Lift of exhaust valve Check all connections to the valve are removed. Attach the crane to the eye bolt fitted on top of the valve and start lifting the exhaust valve. During the lift - check the valve goes clear of all other engine components. Land the exhaust valve on a wooden plate on the platform. Carefully clean the exhaust valve bore in the cylinder cover and recondition the seating and sealing surfaces of the bore, if required. See Procedure 901-1.3. For overhaul of the exhaust valve, see Pro- cedure 908-2.3 Page 6 (23) When referring to this page, please quote Procedure M90802 Edition 0273HYUNDAI Exhaust Valve 908-2.3 MAN B&W Overhaul 1. Oil cylinder Place the exhaust valve on a wooden support on the platform. Remove the nuts and the safety strap from the oil cylinder. Lift away and place the oll cylinder on a ‘wooden support. 2. Conical locking ring Relieve the air pressure through the non-retum vaive from below the piston. Use a small screwdriver to press the ball into ‘the non-return valve. Cover the non-return valve with a rag to catch the oil drops. Unscrew the non-return valve from the air cylinder. Remove the four screws from the flange on top of the air piston and dismount the flange. TEETER Loosen the air piston from the conical looking ring by means of a tin hammer, and remove the conical locking ring. BETTIE When referring to this page, please quote Procedure M9002 Elton 0273, Page 7 (23)908-2.3 Exhaust Valve HYUNDAI Overhaul MAN B&W RTOS iG DO08-29 OSE 3. Spindle Use the oil cylinder as a lifting tool for the exhaust valve housing. Lift the oil cylinder with the crane, and guide it down over the studs for the oil cylinder. Mount four nuts so that the load from the valve housing is evenly distributed. Lift the valve housing clear of the valve spindle, Take care - when the internal O-ring in the air piston and the internal rings for the sealing arrangement at the bottom of the air cylinder pass the groove for the conical ring at the top of the spindle. 4. Bottom piece Unscrew and remove the lock screws which retain the bottom piece. Lift the valve housing approx. 10 mm. If the bottom piece has become stuck, use a tin hammer to release it. Lift the valve housing away and land it on a couple of wooden planks. Remove the oil cylinder. Page 8 (23) When referring to this page, please quote Procedure M90802 Edition 0273,HYUNDAI Exhaust Valve 908-23 Les Overhaul 5. Air piston and cylinder Dismount the air piston from the air cylinder. Mount two eye bolts in the air cylinder and dismount the air cylinder. Remove and discard the O-ring on the air oylinder. 6. Guide bushing lean the exhaust valve housing. Inspect the bushing in the spindle guide for ‘wear and measure the top and bottom di- ameters. See Data. ROTO When referring to this page, please quote Procedure M90802 Ealtion 0273 Page 9 (23)908-2.3 haust Valve HYUNDAI Overhaul MAN B&W. 7 7. Bushing renewal THOS TR TOS If it proves necessary to replace the bushing, remove the screws and knock out the bushing with a hammer and a suitable mandrel. Alternatively, if the extractor tool is avallable, mount the extractor tool and pull up ‘the bushing. The extractor tool is optional, and can be ordered as spare part. When a new bushing is mounted, mount ‘anew O-ring for sealing between bushing and exhaust valve housing. Mount and tighten the screws for the bushing. 8. Bottom piece inspection Before cleaning the bottom piece, See Vol- ume |, supplement 707-03 Inspect and evaluate the seating according to Volume |. Page 10 (23) When referring to this page, please quote Procedure M90802 Edition 0273,HYUNDAI Exhaust Valve MAN B&W Overhaul 908-2.3 9. Bottom piece Measuring In connection with evaluation of the bottom piece according to Volume |, wear or the total amount the seat has been ground, is measured as described below. Use the bottom piece template and a feeler gauge, take measurements G2 and G3. All ‘measurements should be taken at four dia~ metrically opposite points on the circumference of the bottom piece seating. For maximum wear or grinding, see Data 08-11 and 008-12, Hf the seat or the recess G3 is ground, see Data D08 ~ 09 for correct grinding angle. IF the template rests on the lower surface in the groove, ie. G2 = 0, THEN Further grinding or reconditioning is not recommended. 10. Bottom piece sealing face If necessary grind the outside seating. Use carborundum 200 and the special grinding tool. Turn the special grinding tool by hand, turning alternately clockwise and anticlockwise. Grind until a smooth surface is achieved. Clean the bottom piece. When referring to this page, please quote Procedure M90802 Ealition 0273 Page 11 (23)908-2.3 Exhaust Valve HYUNDAI Overhaul MAN B&W 1. TRE TEROTE oT 12. COO DTIOTE Bottom piece sealing rings Mount new sealing rings on the bottom piece. Mount one O-ring in the upper groove. Make sure that the groove for the U-seal is clean. Heat the U-seal in 100°C hot water for min= imum five minutes and then mount it in the groove immediately. Bottom piece mounting Use the oil cylinder as a lifting tool for the ‘exhaust valve housing. Check the face on the valve housing is clean. If fitted, check that the guide pin in the bottom piece enters the hole in the bottom of the exhaust valve housing, Land the exhaust vaive housing on the bottom piece, Mount and tighten the retaining screws for the bottom piece. Page 12 23) When referring to this page, please quote Procedure M90802 Ecition 0273HYUNDAI Exhaust Valve 908-2.3 MAN B&W Overhaul 18. Spindle inspection Before cleaning the spindle, See Volume 1, ‘supplement 707-03 Inspect and evaluate the spindle according ‘to Volume |. 14. Spindle burn-off and grinding check In connection with evaluation of the spindle according to Volume I, burn-off and wear or the total amount the seat has been ground, are measured as described below. The burn-off F1 of the valve spindle is checked by measuring along the spindle template from point A to point D and in point E. For the maximum allowable burn-off, see Data D08-13. The maximum seat grinding, gap G1 is measured between the spindle template, and the seating of the spindle with a feeler gauge. For maximum seat grinding, see data DOB - 14. H necessary to grind the seat, see Data 08-10 for correct grinding angle. 13. When referring to this page, please quote Procedure M90802 Ealtion 0273 Page 13 23)908-2.3 Exhaust Valve HYUNDAI Overhaul MAN B&W = 15. Spindle stem check In connection with evaluation of the spindle according to Volume |, the spindle stem wear Is measured as described below. D08-16 |DO8-15 Check the spindle stem for wear in the area DO8-15 to DO8-16 measured from the top of the spindle. 4 208-17 For minimum stem diameter, see data DO8 17, If the exhaust valve spindle needs reconditioning, contact MAN Diesel for advice. 16. Spindle transport When lifting or transporting the exhaust valve spindle, use the special valve spindle lifting tool. Taaowee Ooze 16. TORTS Pago 14 (23) ‘When referring to this page, please quote Procedure M90802 Ealtion 0273,HYUNDAI Exhaust Valve MAN B&W. Overhaul 908-2.3 17. Spindle bushing sealing-rings Check the top of the spindle bushing and the face on the housing is clean. Fit new o-rings on the spindle bushing as shown in the sketch. 48. Spindle mounting Lubricate the inside of the bushing in the spindle guide with plenty of lubricating oil, Use the oil cylinder as a lifting tool for the exhaust valve housing. Carefully land the exhaust valve housing with the bottom piece on the exhaust valve spindle, Remove the oil cylinder. When referring to this page, please quote Procedure M90802 Edition 0273, Page 15 (23)908-2.3. Exhaust Valve HYUNDAI Overhaul MAN B&W. a 19. Air cylinder CH Compressed Air ao D08-07 RSET Clean the air cylinder. Dismount the safety valve from the air oylinder, use the machined faces to unscrew the valve. Unscrew the plug for the bore to the spindle stem bushing, Blow through all bores in the air cylinder. Clean the bottom of the air cylinder for possible coke deposits. Re- mount the plug. Mount a new O-ring in the groove on the outside of the air cylinder. Safety valve Place the safety valve in the pressure testing device. Connect the testing device with the high pressure pump by means of a hose. Check the opening pressure, see Data. If the opening pressure is not correct, loos en the lock nut and, using a screwdriver, adjust the safety vaive until the correct pressure is indicated. Tighten the lock nut and test the opening pressure once more. Mount a new gasket and a new O-ring on the safety valve. Mount the safety valve in the bore near the bottom of the air cylinder. When mounting the safety valve in the alr cylinder, use only the machined faces on the valve housing and tighten, see Data. Finally, mount the protective cap. Page 16 (23) When referring to this page, please quote Procedure M90802 Edition 0273HYUNDAI Exhaust Valve MAN B&W Overhaul 908-2.3 21. Air cylinder mounting Lubricate the O-rings on the spindle bushing. Carefully land the air cylinder on the exhaust valve housing and check correct engaging with the locating pin. Some engines are not equipped with the locating pin. Note! ‘Take care not to damage the O-rings on the outside of the spindle bushing, 22. Air piston seals Check the teflon. guide ring and teflon sealing ring for wear, if it is necessary to re- 22. place the sealing rings on the air piston, out them and remove them. Be careful not to damage the edges of the fing grooves in the piston. Note! Before mounting, heat the new teflon rings in 100°C hot water for at least five minutes. When mounting the teflon rings, be careful not to damage the running surfaces. ese ROR ‘After mounting, compress the tefion rings by means of the conical ring from tool panel 908. This is done by pressing the air piston through the conical ring. Mount new O-rings in the inside grooves of the air piston. When referring to this page, please quote Procedure M90802 Ealtion 0273 Page 17 (23)Exhaust Valve HYUNDAI Overhaul MAN B&W 23. Air piston mounting IMPORTANT! Fill the bottom of the air cylinder up to the drain hole with clean lubricating oil Clean oil Fit the conical guide ring for the air piston Oil level on the air oylinder. Lubricate the guide ring and the running surface of the air cylinder. 0 Lower the air piston over the valve spindle down into the air eylinder. LD Use a nylon block and a hammer to press the air piston down in the cylinder |x p<] Shut off starting air distributor/distributing system supply Shut off air supply to exhaust valve - Only with stopped lubricating oil pumps Ref. Description Value Unit 08-20 | Oil cylinder max. inside diameter 08-21 | Piston rings, min, thickness 08-82 | Hydraulic actuator, tightening torque 008-33 | Locking plate, tightening torque 08-34 | Hydraulic actuator, tightening angle 08-35 | Hydraulic actuator 85.4 3.2 500 25 95 mm mm Nm Nm kg When referring to this page, please quote Data 010803 Edition 0060 Page 1 (2)108-3 Exhaust Valve Actuator HYUNDAI Data MAN B&W ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate _| Item No. Description 91356 Lifting Tools, Etc. poises | 057 | Feeler gauge Page 2 (2) When referring to this page, please quote Data D10803 Edition 0060 9HYUNDAI Exhaust Valve Actuator 908-3.1 MAN B&W. Checking 1. The non-return valve A is built into the oil inlet pipe to the actuator. A To check the vaive, dismantle and clean it i and connect a supply of working air (7 bar) to the outlet side of the valve (the side facing the actuator). If the air flow can be felt at the inlet side of the valve, the valve must be overhauled. 2. Leakages in the exhaust valve can be measured — during running of the engine — by collecting the oil from the drain pipe C leading from the exhaust valve to the hy- drauli¢ actuator. Leakages may also be caused by leaky non-return valves and loose pressure pipe connections. if the pipe connections are tight and the leak oil amount from the exhaust valve is normal, any abnormally large leakages must originate from the hydraulic actuator from which leak oil quantities cannot be di- reclly registered. The hydraulic actuator is then to be dismantled for checking of the parts. See Procedure 908-3.2 When referring to this page, please quote Procedure M90803 Edition 0227 Page 1 (4)Exhaust Valve Actuator HYUNDAI Dismantling MAN B&W. 1. Stop the engine and shut off the oil supply. Turn the camshaft so that the roller rests on the circular part of the cam. Remove the inspection cover of the roller guide housing to check the position of the exhaust cam. Dismount the inlet pipe and the drain pipe from the exhaust valve. Dismount the high-pressure pipe. See Procedure 908-1.2. 2. Release the mountings for the indicator drive from the actuator housing. Fit eye screws in the lifting holes of the actuator housing and hook on a tackle. Unscrew the nuts on the two short studs, then loosen the nuts on the long studs successively until the roller guide spring is re~ lieved. Dismount the nuts and lift the housing carefully, leaving the piston on top of the roller guide, Remove the spring. 3. Remove the locking plate for the piston. Turn the piston 90° to release it from the bayonet joint. Remove the piston from the roller guide. 4. Overhaul the actuator housing and the piston as required. See Procedure 908-3.3. Page 2 (4) When referring to this page, please quote Procedure M90803 Edition 0227HYUNDAI Exhaust Valve Actuator MAN Baw Overhaul 908-3.3 1, Clean the piston in kerosene and wipe dry | 1 with a clean piece of cloth. ‘Take off the piston rings and check them for wear. If the ring thickness has worn down to the minimum (see Data), discard the rings and mount new ones. Check that the TOP mark on the piston rings faces upwards when mounting. 2. Inspect the sliding surfaces of the piston to ensure that there are no scratch marks or seizure marks. 3. Clean the oil cylinder and inspect the bores for deposits. Check the bore of the oil cylinder for possible scores and measure it for wear. If the bore is seized or worn down to the measurement stated in Data, send the oil cylinder to an MAN B&W authorised work- RTO D08-21 shop for reconditioning. D08-20 WW SS JI When referring to this page, please quote Procedure M90803 Edition 0227 Page 3 (4)908-3.4 Exhaust Valve Actuator HYUNDAI Mounting MAN B&W. 1. Mount the actuator piston in the roller guide and turn 90° to lock it in the bayonet joint, Mount the locking plate and tighten as stated in Data, Lubricate the piston with plenty of camshaft lubricating oil. 2. Mount the spring on the roller guide. Care- fully lower the actuator housing on to the piston, taking care not to damage the piston rings. Mount the washers and nuts on the two long studs and tighten alternately until the actuator housing rests firmly against the roller guide housing. Mount the washers and nuts on the two short studs. Tighten all four nuts as stated in Data. Note! Use only the tightening angle OR the tightening torque, NOT both. 3. Mount the oil inlet pipe and the drain pipe from the exhaust valve. Mount the hydraulic high pressure pipe. See Procedure 908-1.4. When referring to this page, please quote Procedure MS0803 Edition 0227 2 iHYUNDAI MAN B&W. ZEEE] x Data Exhaust Valve Roller Guide Data SAFETY PRECAUTIONS Stopped engine Block the starting mechanism ‘Shut off starting air supply Engage tuning gear Shut off cooling water Shut off fuel oi! X | Shut off lubricating oil Lock turbocharger rotors 108-4 Ref. Description Value| Unit 08-36 08-38 Bushing/shaft pin, max. clearance Roller guide complete When referring to this page, please quote Data 010804 Edition 0031 Page 1 (2)108-4 Exhaust Valve Roller Guide HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, ¢.9. P90951 refers to chapter 909. Plate tem No. | Description Pe0gst 53 | Lifting tool for roller guide Page 2 (2) ‘When referring to this page, please quote Data 010804 Edition 0031Exhaust Valve Roller Guide 908-4.1 Checking 1. The exhaust valve roller guide can be partially checked while mounted on the engine, using the following procedure: Lift the roller guide. See Procedure 908-7. 2. Remove the camshaft inspection cover. Turn the engine to provide the maximum space between the roller guide and the cam disc. Check the movability of the roller by turning this by hand to ascertain if the roller moves freely and without unnecessary resistance or “hard” points. prea Also inspect the surface of the roller for possible damage marks, seizures or scratches. Make sure that no traces of bearing metal exist in the roller guide housing. D08-36 Check the clearance in the slide bearing by lifting the rolier relative to the roller guide and measuring the difference in distance between the cam disc and the roller in the upper and lower positions of the roller. ‘A more suitable and reliable method is to check the roller guide and the bearing clearance when the roller guide is dismounted. For dismantling of the roller guide, see Pro- cedure 908-4.2, 3, Inspect the surfaces of the roller guide and the roller for damage marks, seizures or scratches. 4, To measure the clearance in the roller guide slide bearing, place the roller guide vertically upside down on a couple of planks with the roller hanging freely. 5. Place a dial gauge against the roller. Then lift the roller as much as the clearance per- its, which makes it possible to read the clearance directly on the dial, see Data. When referring to this page, please quote Procedure M90804 Eudition 0217 Page 1 (4)908-4.2 Exhaust Valve Roller Guide HYUNDAI Dismantling MAN B&W. 1. 1. Dismantie the hydraulic actuator above the exhaust vaive roller guide. See Procedure 908-3.2. 2. Mount the roller guide lifting tool as follows: + Lift the lock ring of the tool up on the shaft of the tool. + Place the tool in such a manner that its foot rests on the thrust piece in the bayonet joint of the roller guide. + Turn the tool 90° so as to allow the foot to ‘engage properly in the bayonet joint. + Lower the lock ring, thereby securing the foot in the locked position. Lift the roller guide out of the roller guide housing, using the crane. Take care not to damage the sliding surfaces of the roller guide when lifting. Page 2 (4) When referring to this page, please quote Procedure MS0604 Edition 0217HYUNDAI Exhaust Valve Roller Guide 908-4.3 MAN B&W. Overhaul 1, Inspect and check the exhaust valve roller guide. See Procedure 908-4.1. 2. It is recommended that the roller guide should ONLY be overhauled/dismantied if + irregularities when turning the roller, damage to the roller, + larger clearance than stated on the Data sheet, + seizure marks on the slide surfaces, have been observed during the checking of the roller guide. Note! For disassembling of the roller guide, contact an MAN B&W authorized repair shop. 3. if no irregularities are found, just clean and lubricate the roller guide before remounting it in the roller guide bushing. When referring to this page, please quote Procedure M90804 Edition 0217 Page 3 (4)908-4-4 Exhaust Valve Roller Guide Mounting HYUNDAI MAN B&W. it Mount the lifting tool for the roller guide as follows: + Lift the lock ring of the tool up on the shaff of the tool. + Place the tool in such a manner that its foot rests on the thrust piece in the bayonet joint of the roller guide. + Turn the tool 90° so as to allow the foot to engage properly in the bayonet joint. + Lower the lock ring, thereby securing the foot in the locked position. Lubricate the sliding surfaces of the roller and the roller guide and lower it carefully into the roller guide bushing Remove the lifting tool When mounting the roller guide, check the clearance between the roller guide and the guide plate mounted in the roller guide liner. Turn the camshaft so that the roller guide is lifted approx. 20 mm, The clearance between the roller guide and the guide plate should be the same at both ends +/— 0.1 mm. Mount the actuator. See Procedure 908-3.4. Page 4 (4) When referring to this page, please quote Procedure M90804 Edition 0217HYUNDAI Exhaust Valve Cam 108-5 MAN B&W. Data SAFETY PRECAUTIONS. ‘Stopped engine Block the starting mechanism Shut off starting air supply x] x] x] Engage tuming gear ‘Shut off cooling water Shut off fuel oil Shut off lubricating oit Lock turbocharger rotors x x Data Ref. Description Value] Unit Dos-39 Check liting height 12| mm { | | | When referring to this page, please quote Data 010805 Edition 0010 Page 1 (2)108-5 Exhaust Valve Cam HYUNDAI aaa MAN B&W. ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P9095t refers to chapter 909. Plate tem No. | Description Page 2(2) When referring to this page, please quote Data D10805 Edition 0010 9kHYUNDAI Exhaust Valve Cam MAN B&W Checking 908-5.1 1. Turn the crankthrow of the cylinder concerned to TDC. Check and note down the angle indicated on the turning wheel. 2, Turn in AHEAD direction until the roller guide (measured on the activator plunger) is lifted corresponding to 008-39, and calculate the angle A, which is the number of degrees the crankthrow has turned from TDC position to the present position. For D08-39, see Data, Continue turning AHEAD until the roller guide (measured on the activator plunger) is lifted to distance 008-39, and calculate the angle B, which is the number of degrees the crankthrow has turned from TDC Position to the present position. Note! When calculating the angles A and B, remember to take into account that the scale on the turning whee! shifts from 360 to 0 (zero) degrees. 8. Calculate the lead angle as: 180° Ace Be 2 The illustration shows the position of the exhaust cam when the piston of the relevant cylinder is in TDC. See the Adjustment Sheet in Volume I, OP- ERATION, Chapter 701, for the "lead angle" of the plant in question. 4. The cam lead angle can be checked visually by reading directly the scale position of the exhaust cam over the marking scratch ‘on the camshaft and comparing this angle with the angle stated in the Adjustment Sheet. At the same time, it is recommended to check the position of the camshaft with the pin gauge. See Procedure 906-3.1. When referring to this page, please quote Procedure M90805 Edition 0214 Page 1 (1)HYUNDAI Exhaust Valve Special Running 108-7 MAN B&W Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 Stopped engine Shut off starting air supply — Atstarting air receiver Block the main starting valve ‘Shut off starting air distributoridistributing system supply Shut off safety air supply — Not ME-engines ‘Shut off control air supply Shut off air supply to exhaust vaive — Only with stopped lubriating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil X | Stop lubricating oil supply Lock the turbocharger rotors > fo< [><] [><] Data Ref. Description Value Unit When referring to this page, please quote Data 010807 Edition 0034 Page 1 (2)108-7 Exhaust Valve Special Running HYUNDAI baie MAN B&W. The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No. Description Poo8st 124 | Toolfor emergency open exhaust valve P908st 173. | Lifting tool for exhaust vaive rolter guide Page 2 (2) When referring to this page, please quote Data 010807 Edition 0034 9Exhaust Valve 908-7 Special Running Engine trouble might require that a cylinder be taken out of action. The engine can continue ‘operation with the fuel and exhaust systems of a single cylinder disconnected. See Volume |, Section 704. This can take place with the exhaust valve locked in either the open or the closed position. Either way, carry out the following procedure: 4, Lift the relevant fuel pump roller guide. See Procedure 909-16. 2. Dismantie the hydraulic high-pressure pipe.See Procedure 908-1.3. 3. Dismantle the non-return valve on the oil inlet pipe. Loosen the union nut in the bottom of the oil pipe and turn the pipe to one side. Mount the non-return valve on the oil pipe and blank off the non-return valve with the plug from tool pane! 908. 4. Remove the inspection cover of the camshaft housing. Turn the engine until the exhaust roller guide is at TDC. 5. Position the lifting tool on the actuator and screw the spindle into the top of the actuator piston. Tighten the lowermost nut on the too! to pull up the roller guide as far as possible. Tighten the upper nut of the tool against the lower nut to secure the roller guide in this position. 6. If the cylinder is to operate with the exhaust valve closed, the air supply must remain 2 connected to the air cylinder of the exhaust Us valve. No further action is required. g is K When referring to this page, please quote Procedure M90607 Edition 0226 Page 1 (3)908-7 Exhaust Valve HYUNDAI ‘Special Running MAN B&W. 7. If the cylinder is to operate with the exhaust valve open, continue the procedure as follows: 7. Tur off the air to the exhaust vaive. Remove the venting plug screw, fitted just above the ball cock on the air cylinder, to let the air inside the air cylinder escape. 8. Dismantle the rotation indicator on the oil cylinder and mount the tool for opening of | the exhaust valve. The tool is found on toot 7 panel 908. oe ws a | The tool will keep the piston of the air cyl- eed inder in the bottom position and thus keep the exhaust valve open. 8. af Page 2 (3) When referring to this page, please quote Procedure M90807 Edition 0226 98.HYUNDAI Exhaust Valve 908-7 MAN B&W. Special Running After overhaul of the cylinder unit, re-engage the exhaust valve gear as follows: 9. Loosen the nuts of the lifting tool to lower the roller guide on to the exhaust cam. Re- move the tool. 10. If the engine has been running with the exhaust valve open, remove the tool mounted in the oll cylinder and mount the rotation indicator. Note! The rotation indicator should only be left in the engaged position for short periods of time during operation of the engine. Leaving the rotation indicator in the | engaged position continuously might damage the exhaust valve due to the for- TI mation of a wear groove in the air piston of the exhaust valve. TRE Re-connect the air supply to the air cylinder. 11, Remove the plug from the non-return vaive and re-connect the oil inlet pipe on the actuator housing. 12, Mount the hydraulic high-pressure pipe. See Procedure 908-1.2. 13, Engage the fuel pump roller guide. See Procedure 909-16. When referring to this page, please quote Procedure M90807 Edition 0226 Page 3 (3)HYUNDAI ? MAN B&W Exhaust Valve Panel Plate 90851-0165E. g | I s i 09011} ong ! q q ‘When referring to this page, please quote Plate 90851 Edition O165EPlate 90851-0165E Exhaust Valve Panel Item Item Ne! Item Description ha Item Description 016 | Panel for tools 028 | Name plate 053. | Lifting tool for roller guide 065 | Lifting tool for exhaust valve 077 | Cone ring 089 | Pressure testing device 0-50 bar 090 | Gauge for exhaust valve spindle 100 | Stepped drift 112. | Grinding tool for high pressure pipe 124 | Tool for opening of exhaust valve 150 | Gauge for exhaust valve seat 161 | Lifting tool for exhaust valve spindle 173 | Lifting tool for exhaust valve roller guide 185 | Grinding ring for exhaust valve seatHYUNDAI MAN B&W Exhaust Valve - Tools Plate 90861-27E2Plate 90861-27E2 Exhaust Valve - Tools Item No. Item Item Description tah Item Description 0802 | Piston ring opener for exh. valveHYUNDAI - i ( MAN B&W Exhaust Valve - Hydraulic Tools Plate P90862-0041 —090 (Po1357} (P9135! When referring to this page, please quote Plate P9062 Ealtion 0047Plate P90862-0041 Exhaust Valve - Hydraulic Tools fem Item Description Fd ltem Description 028 | Hydraulic jack, complete 030 | Support 053 | O-ring with back-up ring 065 | O-ring with back-up ring 089 Tommy bar 090 | Spanner 100 Stud setter 207 | Hydraulic tool set, completeHYUNDAI MAN B&W. Inspection of Nimonic Exhaust Valve Spindles Introduction These instructions are a supplement to “Procedure 908-2”, in our “Volume II, Maintenance” instruction book, and should be used in combination with that Procedure during inspection and overhaul of all Nimonic spindles on HYUNDAI- MAN B&W engines, All general data, including specified wear limits for the spindle used on your engine type, are given in Procedure 908-2, DATA. Note down the actual engine data in the ‘DATA"-box in the relevant chapters of these instructions. The procedure is divided into the following eight sections: 1. Spindle identification Page 1 Inspection intervals Inspecting the contact condition of the seat Checking the seat for gas leakage Cleaning and evaluation Inspecting the valve stem wear layer NPanen Seoannn Grinding the spindle seat 1 Sections 3 to 7 are each divided into four steps: + What to do * Acceptance criteria + Remarks + Further action 1, Spindle Identification Markings: The tops of Nimonic spindles are marked: “Nim”, “Nim80A’, “N80A”,"N8O", or “NCF80A". If in doubt, please contact Hyundai Heavy Industries Co.,Ltd. Engine & Machinery Division 1, Jeonha-Dong, Ulsan, Korea Telephone: (052) 202-7587~90 Telex: HHI END K53815.52191 Telefax: (052) 202-7581 Page 1 (11)HYUNDAl| inspection of Nimonie Exhaust Valve Spindles 2. — Inspection Intervals Inspection Inspections: intervals Initial ‘Second ‘Subsequent Normal hours of {After 6,000 hours [After 16,000 hours *) | Every 16,000 hours *) service: Recommended: |After 6,000 hours [Based on condition Based on condition at | (60-60MC at initial inspection [initial and second |3-6.000 hours) inspections “) *) The normal hours of service between overhauls for Nimonic exhaust valve spindles is 16,000 hours (see instruction book Volume ll, Chapter 900). “*) Ifthe spindle condition is very good, the condition of other exhaust valve parts may prove to be the decisive factor in determining the future overhaulinspection intervals. 3. _ Inspecting the Contact Condition of the Seat What to do a Do not clean the spindle disc before inspection. <@ * Visually check that there is inner contact. Fig. 1 shows inner contact between the seats of the spindle and bottom piece, corresponding to slow/low-load/manoeuvring condition. Inner contact Inner part Outer part =| Fig. 1: Inner contact, and zone designation Acceptance criteria ‘There must be contact around the entire inner circumference of the seat. Page 2 (11)A NOA| Inspection of Nimonic Exhaust Valve Spindles Remarks When the valve heats up in service, the angular difference between the spindle and bottom piece seatings will decrease. At steady, full load, the seatings will be parallel, as shown in Fig. 2. ‘Thus, inner contact must be maintained in order to be sure of parallel contact during running. \__ Parallel contact Fig. 2: Contact conaition during running If there is no inner contact, outer contact (Fig. 3) will occur during running, and this will increase the risk of blow-by. A. Outer contact Fig. 3: Outer contact, increased risk of blow-by Further action: @ Fillin Page 11 ‘Exhaust Valve Condition Report’. If the seat contact is incorrect, grind the spindle seating, as described in Step 7. However, before grinding, proceed to Steps 4, 5 and 6. Page 8 (71)HYUNDAI) Inspection of Nimonic Exhaust Valve Spindles 4. Checking the Seat for Gas Leakage What to do [BJ 00 not clean the spindle disc before inspection * Visually check the inner part of the seating for blow-by (Fig. 4 and Photo 1). Blow-by (Co) Le Inner part Fig. 4: Blow-by a 7 Photo 1: Blow-by Acceptance criteria: There must be no blow-by “tracks” across the inner part of the seat (Figs. 1 + 4, and Photo 1) Page 4 (11)Ne Inspection of Nimonic Exhaust Valve Spindles Remarks: Blow-by indications may be associated with large/deep dent marks, and will often form a “gas-jet-fan” in the deposits on the disc cone (Photo 1). The surface of a serious blow-by track/groove will usually show signs of hot corrosion, i.e. it will have an “elephant skin" texture Minor leakages. Small, faint, fan-shaped leakage indications on the spindle cone, just inside the seat area (Photo 2), are harmless. Photo 2: Minor leakages, and “fans” Further action: 4) Fill in Page 11, ‘Exhaust Valve Condition Report’ If blow-by has been found, then grind the seat, as described in Step 7. However, before grinding, proceed to Steps § and 6. 5. Cleaning and Evaluation What to do * Clean the seat with coarse emery cloth. Observe and note down the size and number of dent marks. Also note any possible crack indications. * Check the outer part of the seat for high temperature corrosion (Fig. 1 and Photo 3) Page 5 (11)onic Exhaust Valve Spindles EUAN Inspection of Inner part Outer part Photo 3: Example of high-temperature corrosion at outer part after 33,000 hours © Clean the contact faces on which the measuring template is to be applied, and measure: — the burn-off on the disc underside, = the total amount the seat has been ground. See Vol. Il Procedure 908-2 Acceptance criteria: Dent marks, of varying number and size (up to 8-10 mm), willbe seen on the seating after a few thousand service hours. The first marks may appear as early as after testbed running. In general, dent marks are acceptable and should not necessitate grinding of the seat. If, however, the marks have caused blow-by, then the seat must be ground/reconditioned. Cracks. Any indications of cracks in the seat area should be checked carefully. If cracking is confirmed, contact HYUNDAI-MAN B&W engines. High-temperature corrosion on the outer part of the seat may result in a measurable difference in level between the inner and outer seat zones. In that case the spindle must be ground. However, this will not normally happen before 20 ~ 30,000 hours after the previous grinding. Page 6 (11)HYUNDAI Inspection of Nimonic Exhaust Valve Spindles Lalla Fill in data from * Burn-off on disc underside, (F1) Procedure 908-2 + Total grinding of seat, (Gi). Fr Remarks: es Burn-off rate (disc underside). The number of service hours before shore-side reconditioning usually depends upon the burn-off rate of the disc underside (Table 1) During welding-up of the disc, the seat area will also be reconditioned up to its original dimensions. For this reason we recommend that the interval between seat grindings is adjusted in order to make full use of the 2 mm seat-grinding allowance, before the spindle is sent ashore for reconditioning of the disc underside. (Table 1) Table 1: Permissible burn-off rate before reconditioning of spindle disc underside Further action: Fill in Page 11, ‘Exhaust Valve Condition Report’. If the burn-off or grinding limits have been reached, contact MAN B&W Diesel A/ S for advice on reconditioning. If the seat and the disc underside are acceptable with respect to Steps 3, 4, and 5, then the spindle can be reinstalled without grinding after step 6 has been carried out. Otherwise, proceed to Steps 6 and 7. Page 7 (11)Ne Inspection of Nimonic Exhaust Valve Spindles 6. _ Inspecting the Valve Stem Wear Layer What to do + Clean the valve spindle stem. + Measure the diameter of the spindle stem in the area shown in Volume I, Procedure 908-2. + Check the surface condition of the chrome-plated/HVOF-coated area. Accept iteria: eceptance criteria Fill in data from DATA 908-2 Min. diameter: Must not be less than that stated in Vol. II, Procedure 908-2, DATA. D. i min. diameter of ight SPindle stem: Cracking (“network cracking”) of chrome/HVOF: cracking of the lowermost part of the chrome plating/HVOF- coating (Photo 4) has no significance, and is therefore acceptable. Peeling-off: The chrome plating/HVOF-coating must not show peeling-off Photo 4: Slight cracking (‘network cracking’) of wear layer Further action: Fill in Page 11, ‘Exhaust Valve Condition Report If the spindle stem is acceptable, proceed to Step 7. Otherwise, contact HYUNDAI-MAN B&W engines for advice on reconditioning, Page 8 (11)bree Inspection of Nimonic Exhaust Valve Spindles 7. Grinding the Spindle Seat What to do © Mount the spindle in the grinding machine and, using the dial-gauge positioned just inside the area of inner contact, (see Fig. 5), true-up to within a maximum f 0.05 mm. This is done in order to minimize the amount of material removed during grinding, Max. 0.05 mm. Fig. 5: Truing-up the spindle © Grind the seat according to the special instructions from the grinding machine supplier. Fill in data from DATA 908-2 See also MAN B&W Service Letter SL95-332/UM, “Grinding of Nimonic Exhaust Valve Spindles”. —— Offset angle: Keep the grinding to a minimum! After full contact between grindstone and seat is reached at the beginning of the grinding process: Normally Limit the grinding to 0.2 mm. Rarecases | Remove 0.3 mm or more. Blow-by Continue the grinding until the blow-by marks are removed, Dent marks | It is not necessary to continue grinding until all dent marks have been removed. Page 9 (11)jonic Exhaust Valve Spindles HYUNDAI MANB&W| Inspec Photo 5 shows an overhauled Nimonic valve spindle which is ready for further service, Photo 5: Acceptable seat condition after grinding Acceptance cri The ground surface. The grindstone must have removed -——_—— material from the whole width and the whole circumference Barwane en of the seat. There must be no signs of blow-by. : canes Ge Max. grinding depth: must not exceed the limit (G:) stated in Vol. Il, Procedure 908-2, DATA. If the seat surface is still not acceptable when the max. grinding depth has been reached, contact HYUNDAI-MAN B&W engines for advice on reconditioning Page 10 (11)uN Inspection of Nimonic Exhaust Valve Spindles 8. _ Exhaust Valve Condition Report Exhaust Valve Condition Report [vess engine ype buiderino [atv dismounted frm cy Engine hours ol [Valve no. _| [vive erected overhute by Place Remarks _— [vane mound on oo Engine hours ot Kept as spare (eso) BOTTOM PIECE, Marking ase mata [Hos ater overhaul: Type: ‘Seat material Irs ttt scat contac (inner ote perl No.of den marks lng than = 7 om racks (yes/no) [Blowy (yesino}: Maximum deposit thicknes in cut (mm lbeposi in chamber, extent (mm a positon (dees, O° = port side [roa grinding, Gl (my = S107 Nove! Max grinding. GL sem ZAR a Nk eo nt Marking [ase materia: Hours after overhaul _| ae — = es rar oe ee See eee [stem diameter above sealing area (mmm) . ——— , aoe eee | eh marae Be ee T Welling of ise (Tick off) [ a “4 Disc welding material: me ae = 7 (Fick of lhivor-Cermet | — os. a | spine guide dameterd] Top [Botioméstentofecontiioning | 1st | 20d_{1ous tout SS Se = = a i ee , . = Page 11 (11)HYUNDAI Fuel Pump Lead 109-1 MAN B&W. Data SAFETY PRECAUTIONS Standard Tools: See Section 913. Stopped engine Block the starting mechanism Zz. Shut off starting air supply Engage tuning gear Shut off cooling water ‘Shut off fuel oll Shut off lubricating oll Lock turbocharger rotors, x] x] x]x x x Data Pet, Description Value Unit D-1 Measuring tool constant 80 mm D-2 Lead change at 1 index mark: OF Pray tACk (VIT index) 1mm 0-3 Pymaxchange at 1 mm change oflead 3-4 bar D-4 Index range of Pmactack 0-9 bar When referring to this page, please quote Data Sheet 109-1 Edition 32 Page 1 (2)109-1 Fuel Pump Lead HYUNDAI Data MAN B&W. Plate 90951 - as i a a 8 os SC Sés ie i cea — pa ©_ 3 8 + Spare Parts Plate — tom No, Deserption ay Page 2 (2) When referring to this page, please quote Data Sheet 109-1 Edition 32HYUNDAI Fuel Pump Lead MAN B&W Checking 909-1.1 1. The fuel pump lead a (= the effective lead) is defined as the distance the top of the fuel pump plunger is lifted above the upper edge of the upper cut-off holes in the fuel pump barrel when the piston of the cylinder concerned is in TDC. The measuring tool constant D-1 is calculated at the point where the fuel pump plunger passes the upper edge of the upper cut-off holes at VIT-index 0 (zero). See Data. 2. Turn the engine in AHEAD direction until the main piston of the cylinder concerned is ex- aclly at TDC. See Procedure 906-3.1. Note! The correct distance x can only be measured when the fuel pump plunger is in its delivery stroke. 2. When referring to this page, please quote Procedure 909-1.1 Edition 230 Page 1 (4)909-1.1 Fuel Pump Lead HYUNDAI Checking MAN B&W. 3. Close the fuel oil inlet valve. Open the fuel pump drain cock, enabling the oil to escape. 4, Remove the pin in the forked lever which connects the actuator and the VIT-index arm, Pull out the VITindex arm to index 0 (zero) 5. Dismantle the puncture valve. ‘See Procedures 909-8.2. Note! Before dismantling any part of the fuel pump, make sure that the pump has been 4 relieved of pressure and that all oil has been drained off. See insaeaeens When referring to this page, please quote Procedure 909-1.1 Eaition 230 z & S sHYUNDAI Fuel Pump Lead MAN B&W. Checking 909-1.1 6. Mount the measuring tool on top of the fuel pump top cover. Push the measuring pin fully down into the threaded hole in the top of the pump plunger. Measure the distance x from the top of the measuring pin to the top of the crossbar. The fuel pump lead is then calculated as: a=x- Det. If the VIT-index is not “O" when measurements take place, the VIT-index must be incorporated into the calculations of the fuel pump lead: a D-1 — “ViT-index”. See Data. Note down the result for future reference. For adjustment of fue! pump lead, see Pro- cedure 909-1.3. 7. Remove the measuring tool from the fuel pump. Replace the O-rings on the puncture valve and re-mount the valve in the top cover. See Procedures 909-8.3 and 909-8.4. 8. Reconnect the VIT-index arm to the forked lever. 9. Close the fuel pump drain cock Open the fuel oil inlet valve. When referring to this page, please quote Procedure 909-1.1 Edition 230 Page 3.(4)909-1.3 Eyes 67 8 e eR Fuel Pump Lead Adjustment HYUNDAI MAN B&W. Adjustment of the maximum combustion pressure of a single cylinder can be effect- ed by moving (relatively) the cut-off holes of the pump barrel in relation to the top of the pump plunger. If the maximum combustion pressure is to be increased, corresponding to an increase of the lead a, increase the index on the Pimax-fack (VIT-index arm), relative to the increase required (advancing the injection moment). If the maximum combustion pressure is to be decreased, corresponding to a reduction of the lead a, decrease the index on the Pmaxfack (VITindex arm), relative to the decrease required (retarding the injection moment). Adjust the servo air cylinder by displacing lever F so that the camber height X is evenly distributed. A pre-adjustment is carried out with a control pressure of 2.75 bar, which corresponds to index 7.0 on the Pmayfack in accordance with the diagram. Adjustment of the Pmax is carried out on the Individual fue! injection pump by displacing the connecting link E, The link can be adjusted by approx. 3 index marks. After some readings in service, it may be necessary to make a final adjustment of the Pmax Pressure of the corresponding cylinder. If no further adjustment is possible according to the above procedures, the cam disc has to be adjusted. See Procedure 909-3.3. Page 4 (4) When referring to this page, please quote Procedure 909-1.3 Edition 230HYUNDAI VIT System 109-2 MAN B&W Data SAFETY PRECAUTIONS Standard Tools: See Section 913 Stopped engine Block the starting mechanism EZ. Shut off starting air supply Engage turing gear Shut off cooling water Shut off fuel oi Shut off lubricating oil Lock turbocharger rotors «|x| Data Ret, Desorioton value Unit When referring to this page, ploase quote Data Sheet 109-2 Edition 03 Page 1 (2)109-2 VIT System HYUNDAI Data MAN B&W. Spare Parts Piao = tem No Oosapon oy Page 2 (2) When referring to this page, please quote Data Sheet 109-2 Edition 03HYUNDAI VIT System MAN B&W. Adjustment 909-2.3, The engine may be equipped with either a mechanical or an electronic VIT (Variable Injection Timing) system, If the fuel quality has changed or if the fuel pumps are worn, the Pmax will change. Adjust- ing the Pmax of all the cylinders is done by ad- Justing the VIT system in the following way: Mechanical VIT system 1. The pilot valves have been pre-adjusted to 0.5-5.5 bar control air pressure, corresponding to 0.5-8.0 mm pressing-in of pin c. To check a pilot valve already mounted on the engine, remove the inlet and outlet pipe connections at A and P, and connect a pressure gauge at A and a pipe with work- Ing air (pressure 7 bar) at P, on the pilot valve. Check that the pressure on the pressure gauge and the pressing-in of pin Cis in accordance with the curve. ‘Any necessary adjustment is done by turning adjusting screw B. 2. Fine adjustment of the Pax Pressure in the breakpoint (for all the cylinders) is to be carried out by axial displacement of the bracket with the pilot valve. Release the screw and nut which secure the bracket with the pilot valve to the larger bracket through the slotted holes. Increase the Pmax pressure by moving the pilot valve toward the lever. Decrease the Pmax pressure by moving the pilot valve away from the lever. ‘See also Volume |, Chapter 703. Pama SOT When referring to this page, please quote Procedure 909-2. Edition 205 Page 1 (2)909-2.3 VIT System HYUNDAI Adjustment MAN B&W. Electronic VIT system 3. The adjustment should be based on a set of indicator diagrams taken when the engine is running just above the breakpoint. 4. On the panel in the engine room control room, change the Poet value in accordance with the required increase or decrease in the Pmax pressure, One graduation mark on the Pofiget Scale corresponds to a change in Pmax of 1 bar. 5. Check the adjustment by taking a new set of indicator diagrams while the engine Is running just above the breakpoint. 6. The IP converter mounted on the engine receives a 4-20 mA signal | from the electronic control system and converts this into a 0.5-5.5 bar control air pressure Peontro!- 7. To check the adjustment of the /P converter, operate the panel in the engine control room to supply various signals I to the /P converter. SaaS For operation of the panel, see the panel manufacturer's instructions. (On the pressure gauge mounted on the control air line after the I/P converter check that the control air pressures from the I/P ojo converter are in accordance with the curve, 8. If the control air pressure is not in accord- : ance with the curve, the /P converter must Pow be adjusted. Remove the hood of the /P converter and adjust the I/P converter ac- — cording to the manufacturer's instructions. Pay CI Poors 3 2 * | bd) aS pamoas 2006 Page 2 (2) When referring to this page, please quote Procedure 909-2.3 Edition 205HYUNDAI Fuel Pump Cam 109-3 MAN B&W. Data SAFETY PRECAUTIONS Standard Tools: See Section 913 ‘Stopped engine Shut off starting air supply Engage turning gear et 1 x3m,3x1m ‘Shut off cooling water ‘Shut off fuel oil ‘Shut off lubricating oil x|x]x]x LIx]x Lock turbocharger rotors Data Ret, Description Value Unit When referring to this page, please quote Data Sheet 109-3 Edition 26 7 Page 1 (2)109-3 ‘Spare Parts Plate tem Ne. 90301-xxx 088 Fuel Pump Cam Daia HYUNDAI MAN B&W O19 | i. Plate 90651 056 044 056 E le Deccrpton Packing oy Page 2 (2) When referring to this page, please quote Data Sheet 109-3 Edition 26HYUNDAI Fuel Pump Cam MAN B&W. Adjustment 1. Make sure that the reversing mechanism is in AHEAD position. Remove the inspection cover from the camshaft housing. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 2. Dismount the pipe connections and the Puncture valve from the fuel pump top cover, and mount the measuring tool. See Procedure 909-1.1. Adjust the VIT index to 0 (zero). Turn the engine until the piston concerned is in TOC. Measure the fuel pump lead using the measuring tool. See Procedure 909-1.1. 3. Compare the fuel pump lead with the value in the Adjustment Sheet, and adjust the fuel pump cam as necessary. When referring to this page, please quote Procedure 909-3.3 Edition 220 Page 1 (3)909-3.3 Fuel Pump Cam HYUNDAI Adjustment MAN B&W 4, Turn the camshaft until there is access to the oil ducts in the fuel cam through the inspection opening. Remove the plugs from the oil ducts (using, for instance, a screwdriver). Insert three copper gaskets in each oll duct. Mount snap-on couplings in the oil ducts, but do not tighten them. Fit hoses between the snap-on couplings ote and the distributor block and between the 7 : distributor block and the hydraulic high- pressure pump. 5, Mount the special spanner on the fuel cam 6. disc, ensuring that the two pins enter the holes in the cam. 6. Apply light pressure to the hydraulic system and, after venting the system, tighten the snap-on couplings. Raise the hydraulic pressure until oil seeps ‘out along the camshaft under the cam disc. Turn the cam disc, using the fitted spanner, until the desired change of lead is read directly on the measuring tool.(The necessary turning of the cam disc is calculated as described in Procedure 909-1). To increase lead and Pmax: = turn the cam disc AHEAD. To reduce lead and Pmax’ turn the cam’disc ASTERN. : B i Page 2 (3) When referring fo this page, please quote Procedure 909-3.3 Edition 220HYUNDAI MAN B&W 7. After completing the desired turning of the cam disc, relieve the hydraulic system of pressure and dismount the spanner and the hydraulic equipment. Wait at least 15 minutes — the cam must be allowed time to “settle” - before mounting the plugs again in the oil ducts of the cam dise. After carrying out adjustment, measure the fuel pump lead again (still with VIT index on 0 zero). See Procedure 909-1.1, and re-adjust the cam if required. Note down and file the new results for purposes of comparison with future measurements and adjustment. 8. Mount the inspection cover on the camshaft housing. 9. Mount a new or overhauled puncture valve in the fuel pump top cover, see Procedure 909-8.4. i Fuel Pump Cam Adjustment 909-3.3 When referring to this page, please quote Procedure M909-3.3 Edition 220 Page 3 (3)HYUNDAI Fuel Pump MAN B&W. Data 109-4 SAFETY PRECAUTIONS Stopped engine Block the starting mechanism ‘Shut off starting air supply Engage tuming gear ‘Shut off cooling water Shut off fuel oil ‘Shut off lubricating oil Lock turbocharger rotors x] x] x]< x] Data Ret. Description D-1 Shock absorber, complete 27 kg Vaiue Unt D-2 Pump housing, complete 170 kg D-3 Bottom plate 13kg D-4 Pump housing nuts ~ tightening angle 60° 0-5 Pump housing nuts = tightening torque 785.Nm Standard Tools: See Section 913 Zs, 750-2000 Nm When referring to this page, please quote Data Sheet 109-4 Edition 22 Page 1 (2)109-4 Fuel Pump HYUNDAI Data MAN B&W. e 2B a, 885) 8 ore So e or 6 S20] i am & =) a9 cea —cen a Peay 5 : Spare Parts Pato — om No, Description ay £90901 -xxxx 042 Gasket 3 90901-oxxx 054 Plug screw 2 90901-2000 174 Gasket 4 90904-xxx« 348, Felt ring 2 90904-x0x 419 Circtip 2 Page 2 (2) When referring to this page, please quote Data Sheet 109-4 Edition 22HYUNDAI MAN B&W Fuel Pump 909-4.2 Dismantling 3. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. Dismantle the fuel pump top cover See Procedure 909-5.2. Dismantie the barrel/plunger assembly. See Procedure 909-6.2. Remove the screws holding the fuel olf inlet pipe between the fuel pump and the fuel inlet valve. Remove the fuel oil inlet pipe. Discard the gaskets. Unscrew the nuts at the base of the fuel pump. Fit the lifting tool using the top cover studs/ nuts, and lift the pump housing away. Take care not to damage the threads of the studs. Land the fuel pump on wooden planks. When referring to this page, please quote Procedure 909-4.2 Edition 215 Page 1 (8)909-4.3 Fuel Pump HYUNDAI Overhaul MAN B&W. 3. 4. If the fuel index arm or the VIT index arm: of the fuel pump is moving too tightly, the regulating and timing systems of the fuel pump must be overhauled. 2. In order to carry out this overhaul, the top cover and plungeribarrel assembly of the fuel pump must have been removed, and the fuel pump must have been dismantled from the pump base and landed on wooden planks. See Procedure 909-4.2. See Procedure 909-5.2. See Procedure 909-6.2. 3, Dismantle the actuator and actuator bracket. 4, Dismantle the fuel pump shock absorber. If necessary, overhaul the fuel pump shock absorber. ‘See Procedure 909-9.3. Page 2 (8) When referring to this page, please quote Procedure 909-4.3 Edition 275HYUNDAI Fuel Pump MAN B&W Overhaul 909-4.3 5. Tilt the fuel pump housing into a horizontal position on the wooden planks. 6. Dismantie the screws and the bottom plate from the fuel pump housing. If the bottom plate is stuck, loosen it by ‘screwing two M10x70 mm screws into the holes of the bottom plate. 7. Dismantie the : * Fuel index arm * Sleeve + Regulating guide ETA cor When referring to this page, please quote Procedure 909-4.3 Edition 215 Page 3 (8)909-4.3, Fuel Pump HYUNDAI Overhaul MAN B&W 8. 8. Dismantle the: + Guide screw = VIT index arm ‘+ Timing guide 9. Dismantle and inspect the plug screws in both sides of the fuel pump housing. 3 It heavily eroded, replace the plug screws. 3 Replace the sealing rings and mount the B plug screws. 10. Clean all parts thoroughly in diesel oil or kerosene. Blow dry with compressed air. 11, Mount new sealing rings on the unions. Note! ‘Soak the sealing rings in lubricating oil before mounting. 12. Clean all inside surfaces of the fuel pump Tea 11. housing, Page 4 (8) When referring to this page, please quote Procedure 909-4.3 Edition 215HYUNDAI Fuel Pump 909-4.3 MAN B&W. Overhaul Mounting 14, 18. Lubricate the following with molybdenum disulphide (MoS2): « all internal surfaces of the fuel pump housing * the sliding surfaces of all parts of the regulating and timing systems. © the teeth of the: regulating guide Fa timing guide 5 Vit index arm i fuel index arm. 46. 14, Mount the VIT index arm and the guide sorew. Adjust the position of the VIT index arm so that the scratch mark is aligned with the centre of the fuel pump housing. 15. Mount the timing guide in the fuel pump housing. The timing guide must be mounted in such a way that the scratch marks on the timing guide, is aligned with the scratch mark on the VIT index arm, which must be visible through the hole in the timing guide. Tema 16. Mount the sleeve in the fuel pump housing, ensuring that the notch in the side of the sleeve is aligned with the pin hole in the fuel pump housing. When referring to this page, please quote Procedure 909-4.3 Edition 215 Page 5 (8)909-4.3 Fuel Pump HYUNDAI Overhaul MAN B&W 17. Mount the fuel index arm. ‘Adjust the position of the fuel index arm so that the scratch mark on the fuel index arm is aligned with the centre of the fuel pump housing. 18. Mount the regulating guide in the fuel pump housing. The regulating guide must be mounted so that the scratch mark on the regulating quide is aligned with the scratch mark on the fuel index arm. 19. Mount the bottom plate on the fuel pump housing. When referring to this page, please quote Procedure 909-4.3 Edition 215HYUNDAI Fuel Pump MAN B&W Overhaul 909-4.3, 20. Mount the fue! pump shock absorber. 21. Mount the actuator and actuator bracket. 20. When referring to this page, please quote Procedure 909-4.3 Edition 215 Page 7(8)909-4.4 Fuel Pump HYUNDAI Mounting MAN B&W. Before mounting the fuel pump housing, make sure that all sliding faces and threads. are cleaned and lubricated with MOLYKOTE. antifriction spray D321R or molybdenum disulphide (MoS2). See Procedure 913-11. Lower the fuel pump housing on to the pump base, taking care not to damage the threads of the studs. Remove the lifting tool. Fit and tighten the nuts at the base of the pump housing. Use either the tightening torque or the tightening angle. See Data. Mount the fuel oil inlet pipe between the pump housing and the inlet valve. Mount the barrel assembly in the fuel pump housing. See Procedure 909-6.4. Mount the top cover on the fuel pump housing See Procedure 909-5.4. Mount the puncture valve. ‘See Procedure 909-8.4. Mount the drain oil pipes,and the compressed air pipes. Page 8 (8) When referring to this page, please quote Procedure 909-4.4 Edition 215HYUNDAI MAN B&W Fuel Pump Top Cover Data 109-5 SAFETY PRECAUTIONS Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear Shut off cooling water Shut off fuel oll ‘Shut off lubricating oll Lock turbocharger rotors =|] x] x x x Data Desciston D-1. Weight of top cover D-2 Max. milling/grinding diameter of seat Tightening torque — top cover nuts Value Unit 52 kg 26 mm 300 Nm Standard Tools: See Section 913 ZX —z_ ————S= 140-760 Nm When referring to this page, please quote Data Sheet 109-6 Edition 22 Page 1 (2)109-5 Fuel Pump Top Cover HYUNDAI Data MAN B&W. oma Plate 90951 =i 6 S25) om @__s 44] © g2 cea ee Pe Spare Parts Piate~ em No. Description oy 90901-00%029 Gasket Page 2 (2) When referring to this page, please quote Data Sheet 109-6 Edition 22HYUNDAI Fuel Pump Top Cover 909-5.2 [MAN B&W | Dismantling 1 1. Shut off the fuel oil inlet. Open the drain cock (at the bottom of the pump housing), and drain off any oil left in the high-pressure pipe and the fuel pump. Note ! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. Dismount all drain pipes and the pipe connections to the puncture valve. Dismount the high-pressure pipes between the top cover and the fuel valves. See Procedure 909-14.2. Note ! If the puncture vaive is to be overhauled, remove the puncture valve from the top cover at this stage. See Procedure 909-8.2. ‘Subsequently, the fuel pump lead can be measured ‘See Procedure 909-1.1. 2. Remove the top cover fixing nuts and mount the dismantling screws for top cover in the two threaded holes. Pull the top cover with suction valve and puncture vaive (if still mounted) free by tightening the dismantling screws. When the top cover is loose, remove the dismantling screws and mount the lifting tool in the threaded holes instead. 3. Lift the top cover carefully off For overhaul of top cover, puncture valve and suction valve, see Procedures 909-5.3, 909-7.3, 909-8.3. Discard the gasket. When referring to this page, please quote Procedure 909-6.2 Ealtion 217 Page 4 (3)909-5.3 Fuel Pump Top Cover HYUNDAI Overhaul MAN B&W. If not already done, dismount the protective cap and the puncture valve from the top cover. See Procedure 909-8.2. Dismantie the suction valve and the lock washer from the top cover. ‘See Procedure 909-7.2. Fill the oil ducts of the top cover with vaseline or heavy grease. Screw the guide, with the miller, into the high-pressure pipe thread. Mill the seat until a smooth surface is achieved After completing the milling, use compressed air to blow the vaseline/ grease out from the oil ducts. Clean the top cover with diesel oil/gas oil, and blow dry with compressed air. Note! Make sure that all bores and threads inside the top cover are absolutely clean. If necessary, recondition the seats of the fuel oil high-pressure pipes. See Procedure 909-14. Mount a new lock washer and a new or ‘overhauled suction valve in the top cover. See Procedure 909-7.4. Page 2 (3) When referring to this pago, please quote Procedure 909-5.3 Edition 217HYUNDAI Fuel Pump Top Cover 909-5.4 MAN B&W. Mounting 1, Make sure that the inside of the fuel pump. housing and the top of the fue! pump barrel is completely clean. 2. Mount a new gasket on top of the pump housing. Lubricate all sliding faces, studs and sealing rings with “MOLYKOTE antifriction SPRAY D32IR" or molybdenum disulphide (MoS2), See Procedure 913-11. Mount the overhauled top cover (with overhauled suction valve and reconditioned seatings for the high-pressure pipes) on the pump housing. Check that the guide pin in the top cover enters the hole in the pump housing. ‘Warning ! As a safety precaution, and before mounting the top cover nuts, turn the engine one revolution. When doing this, the top cover must not move upwards! 3. Mount the top cover fixing nuts, and tighten them diagonally to the torque indicated in Data. Measure the lead of the fuel pump and adjust, if necessary. See Procedure 909-1.1. At the same time, it may prove necessary to adjust the lead of the cam disc. See Procedure 909-3.3. 4. Finally, mount a new or overhauled puncture valve on the top cover. See Procedure 909-8.4, Mount the protective cap over the puncture valve and the two screws in the top cover. Mount the high-pressure pipes and the drain screw in the pump housing. Mount the drain pipes on the top cover and the connecting pipe to the puncture valve. Open the fuel oil inlet. When referring to this page, please quote Procedure 909-5.4 Edition 217 Page 3 (3)HYUNDAI MAN B&W. Data Fuel Pump Barrel Assembly 109-6 SAFETY PRECAUTIONS ‘Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear ‘Shut off cooling water Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors x]x<]x]x x x Data Ret, Description D-1 Weight of barrel assembly ‘Value Unit 49kg D-2 Weight of plunger 12kg Standard Tools: See Section 913 ZX When referring to this page, please quote Data Sheet 109-6 Edition 20 Page 1 (2)109-6 Fuel Pump Barrel Assembly HYUNDAI Data MAN B&W os 4 Q fl Ua 2 | Spare Parts Pate Ne. Doseripton oy 90901-xxxx 174 Gasket 1 90901 -xxxx 424 Sealing ring 1 90901-xxxx 664 Sealing ring 2 90904-200% 348 Felt ring 2 Pago 2 (2) When referring to this page, please quote Data Sheet 109-6 Edition 20HYUNDAI Fuel Pump Barrel Assembly MAN B&W. Dismantiing 909-6.2 1, Shut off the fuel oil inlet. ‘Open the drain cock (at the bottom of the pump housing), enabling the oil which is left in the high-pressure pipe and the fuel pump to escape. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. Dismount the pipe connections to the puncture valve. Dismount the fuel oil high-pressure pipes. ‘See Procedure 909-14-2. (At this stage, itis practical to measure the fuel pump lead, see Procedure 909-1) 2. If the top cover is to be overhauled, dismount the puncture valve, See Procedure 909-8.2, 3. Dismount the fuel pump top cover. See Procedure 909-5.2. When referring to this page, please quote Procedure 909-6.2 Edition 215 Page 4 (9)909-6.2 Fuel Pump Barrel Assembly HYUNDAI Dismantling MAN B&W 4, Position the lifting tool for the barrel/plunger assembly (without measuring pin) in such a manner that the two distance tubes of the tool rest on the pump barrel. Make sure that the two guide pins in the bottom of the lifting tool enter the holes in the top of the plunger. 7 Secure the lifting tool by screwing the two Loosen the stop ring on the spindle of the vi tool and press the spindle down against the wy pump plunger. Turn the spindle in this position until the two guide pins engage with the two holes in the plunger top. ighten the centre screw of the spindle against the plunger. 5. Remove the pump barrel guide screw from the pump housing. 6. Disconnect the links for the timing drive and the regulating drive. Dismount the union and pointer for the timing drive and the reg- 7 - ulating drive. Note the position of the scratch mark on the lever arm. Remove the locking plate and the lever arm. Mount the extractor tool and connect the timing toothed rack to the pulling rod by means of the pin. Page 2(9) When referring to this page, please quote Procedure 909-6.2 Edition 215HYUNDAI Fuel Pump Barrel Assembly MAN B&W. Dismantling 909-6.2 7. Turn the nut at the end of the pulling rod, whereby the timing rack will move outwards. Continue turning the nut until the pin reaches the outer position of the slot in the tool, whereby the thread of the fuel pump barrel goes clear of the timing guide, Keep the toothed rack in this position during the overhaul or replacement of the pump. barrel. There is now a distance between the lifting tool and the pump housing. 8. Pull the regulating toothed rack outwards Until the plunger foot has been turned clear of the bayonet joint in the roller guide. This can be ascertained by watching the handles on the spindle of the lifting tool. These will be parallel with the fore-and-aft direction of the engine when the plunger has been turned into position. Remove the cover of the pump base to make sure that the plunger is able to go clear of the bayonet joint. Lift the spindle so that the plunger foot goes clear of the bayonet joint. Move the stop ring of the spindle into contact with the upper flange of the tool, and lock the stop ring in this position by means of the stop screw. 9. Carefully lift the barre/plunger assembly out of the pump housing. Dismount the tool. Press the plunger upwards to the bottom of the barrel, Send the barrel/plunger assembly to an MAN B&W authorized workshop for repair, ‘or overhaul it on board as described in Pro- cedure 909-6.3, When referring to this page, please quote Procedure 909-6.2 Edition 215 Page 3 (9)909-6.3 Fuel Pump Barrel Assembly HYUNDAI Overhaul MAN B&W. Set up the pump barrel/plunger in a bench vice provided with “soft” jaws. Remove and discard the sealing rings from the barrel. Pull the plunger carefully out of the barrel. Carefully clean the plunger (for example in clean kerosene) and wipe dry with @ clean piece of cloth. Also clean the bores in the top of the plunger. Check the plunger for wear or seizure marks. Clean the barrel and wipe dry with a clean piece of cloth. Check the barrel for wear or seizure marks. If either plunger or barrel shows signs of wear or seizure marks, both parts must be replaced, as they are ground to match and cannot be replaced individually. Before mounting new sealing rings on the barrel, heat them in 100°C hot water for at least five minutes. When mounting the new sealing rings on the lower end of the pump barrel, the inner sealing ring must be mounted first. Mount the guide stick in the barrel and position the big cone on the barrel. Place the spring-loaded sealing ring on the cone with the spring facing upwards, see the sketch. Use the pusher tool to push the sealing ring into the groove. Page 4() When referring to this page, please quote Procedure 909-6.3 Edition 215HYUNDAI Fuel Pump Barrel Assembly MAN B&W. Overhaul 909-6.3 5. When mounting the sealing ring in the outer groove, place the spacer tool inside the cone to obtain the correct distance to the groove, and repeat the above procedure. After mounting the sealing rings, compress them by pressing the “sizer” tool over the sealing rings. 6. Mount the guide stick and cone on the top ‘end of the barrel and mount the uppermost sealing ring in the same way as above. Make sure that the spring faces downwards, see the sketch. 7. Lubricate the plunger with molybdenum disulphide (MoS2). Carefully slide the plunger into the barrel and press it to the bottom. Note! Do not use force as this will damage the sliding surfaces of the plunger or barrel If the barrel assembly is not to be mounted immediately, all openings must be covered with plastic to prevent dirt from entering the barrel assembly during storage. When referring to this page, please quote Procedure 909-6.3 Edition 215 Page 5 (9)Fuel Pump Barrel Assembly HYUNDAI Mounting MAN B&W. weyyoore . cs \ Place the supplied measuring pin - which is of the same length as the plunger — on the spindle of the lifting tool, and fasten it by tightening the centre screw of the spindle. Loosen the stop ring on the spindle. Place the tool on the pump housing, and press the spindle down until the pointed ‘end of the measuring pin is in contact with the thrust piece of the roller guide, Then press the stop ring down until it reaches the fiange of the tool and lock it there by tightening the screw of the stop ring against the spindle. The stop ring is to remain tightened in this position until the plunger has been correctly mounted. The engine must not be turned until the mounting of the barrel/plunger assembly has been completed, Dismount the tool from the pump housing and remove the measuring pin from the spindle, Then mount the tool on the barrel/ plunger assembly which is ready for mounting. Secure the tool to the barrel by tightening the two screws, and attach the plunger to the spindle of the tool by tightening the centre screw of the spindle. The tool is thus fixed on the barrel in such a way that its correct positioning is ensured during mounting. Before mounting the barrel/plunger in the pump housing, lubricate the thread for the timing guide and all sealing rings with molybdenum disulphide. Using the spindie of the tool, pull the plunger as high up in the barrel as possible, at the same time turning the spindle so as to position the plunger foot correctly in relation fo the cutout of the regulating guide. When referring to this page, please quote Procedure 909-6.4 Edition 215HYUNDAI Fuel Pump Barrel Assembly MAN B&W Mounting : 3, Pull the regulating toothed rack as far out as possible and check that the extractor tool is mounted correctly on the timing toothed rack when this is in its outer position, 4. Check that the slot in the barre! coincides with the hole for the guide screw. Lower the barrel assembly carefully into the pump housing, If necessary, turn the regulating guide a little (using the toothed rack) to make the foot and the regulating block of the plunger fit properly in the cutout of the regulating guide, Lowering the barrel assembly so far down into the pump housing that the sealing rings of the barrel are about to enter the bore in the pump housing. Then continue pressing down the barrel/ plunger assembly until the barrel assembly rests on top of the timing guide. There will be a gap between the tool and the pump housing. ‘ae When referring to this page, please quote Procedure 909-6.4 Edition 215 Page 7 (9)909-6.4 Fuel Pump Barrel Assembly HYUNDAI Mounting MAN B&W. 5. Loosen the nut on the extractor, disconnect the pulling rod from the timing toothed rack, and remove the extractor. Engaging the thread of the fuel pump barrel with the timing guide is accomplished by pressing-in the toothed rack. (A pressure of about 30 kg may be required). ‘Check that the toothed rack is correctly engaged by pressing-in the rack. When doing this, the pump barre! shall move downwards, The top flange of the tool is now resting on the top of the pump housing 6. After ‘landing’ the barrel assembly, press the plunger down into contact with the thrust piece of the roller guide, Check that the stop disc of the spindie is in full contact with the flange of the tool, as when measuring necessary, turn the regulating guide a little (using the toothed rack) to make the plunger foot fit properly in the cutout of the roller guide. inspect the position of the plunger foot through the inspection hole. When the plunger is in place, press the reg- lating rod in, thereby turning the plunger by means of the regulating guide and causing the plunger foot to “interlock” with the bayonet joint of the roller guide. Check that the plunger is correctly engaged by pulling at the spindle of the lifting tool ‘When doing this, it must not be possible to lift the spindle. Mount the inspection hole cover. Page 8 (9) When referring to this page, please quote Procedure 909-6.4 Edition 215HYUNDAI Fuel Pump Barrel Assembly 909-6.4 (ian Sae Baw Mounting 7. Mount the pointer and union for the timing rack. Mount the links for the timing drive and the regulating drive in place in accordance with the marks. 8. Mount the guide screw for the pump barrel in the pump housing. Remove the centre screw from the plunger, and remove the tool. When referring to this page, please quote Procedure 909-6.4 Edition 215, Page 9 (9)HYUNDAI MAN B&W. Data Fuel Pump Suction Valve 109-7 SAFETY PRECAUTIONS Stopped engine Block the starting mechanism ‘Shut off starting air supply Engege turning gear ‘Shut off cooling water Shut off fuel oil ‘Shut off lubricating oil Lock turbocharger rotors Data Ref. Description D-1_ Tightening torque - suction valve Value Unt 900 Nm Standard Tools: See Section 913 === 750-2000 Nm When referring to this page, please quote Data Sheet 109-7 Edition 16 Page 1 (2)109-7 Fuel Pump Suction Valve HYUNDAI Data MAN B&W. po= om ° a a= = 6 Si0] My am - cea — Pe 2 & Spare Parts Plate — tem No, Deseepion ay 909-xxxx 304 Locking plate 1 909-xxx« 400 Sealing ring 1 Page 2 (2) When referring to this page, please quote Data Sheet 109-7 Eaition 16HYUNDAI Fuel Pump Suction Valve 909-7.1 MAN B&W. Checking 1. Using a brass mandrel, check that the valve slide can slide freely up and down inside the suction valve. 2. Check the seats for tightness by filling the inlet hole with diesel oil or gas oil, and wait five minutes. No oil may seep through the seats of the slide/housing. 3. If the suction valve is not to be mounted on the engine immediately after the checking, cover all openings of the vaive with plastic to prevent dirt from entering the valve during storage. When referring to this page, please quote Procedure 909-7.1 Edition 211 Page 1 (4)909-7.2 Fuel Pump Suction Valve HYUNDAI Dismantling MAN B&W Note! Before dismantling the top cover, it is recommended to dismantle the fuel pump puncture valve, see Procedure 909-8.2. Dismantle the fuel pump top cover and suction valve assembly from the fuel pump housing. See Procedure 909-5.2. 2. Mount two eye bolts in the bottom of the top cover and turn it upside down. 3. Fix the top cover in an upside down position, for example in a bench vice or on top of the fuel pump housing, but then the barrel/ plunger assembly must be removed. See procedure 909-6.2 Release the suction valve lock washer. Dismount the suction valve from the top cover. Remove and discard the lock washer. Page 2(4) When referring to this page, please quote Procedure 909-7.2 Eaition 211HYUNDAI Fuel Pump Suction Valve MAN B&W. Overhaul 909-7.3 4. Set up the suction valve in a bench vice with “soft” jaws and, using a brass mandrel and a hammer, release the spring guide from the valve thrust piece. Disassemble the other parts of the suction valve and clean the parts thoroughly in clean diesel oil. Remove and discard the sealing ring from the valve thrust piece. 2. Inspect the seat of the valve slide and the seat in the thrust piece for damage. If the seats are damaged, both the suction valve and the valve slide must be discarded. Lapping of the seats must not be attempt- 1g in the groove of the sealing ring and position the cone on the thrust piece. Place the sealing ring on the cone and, using the pusher tool, push the sealing ring on to the groove. Note! Make sure that the sealing ring is mounted correctly. See the sketch. After mounting the sealing ring, compress it by pressing the “sizer” tool over the sealing ring. 4. Clean and overhaul all internal parts, and lubricate them with molybdenum disulphide (MoS2). 5. Re-assemble the suction vaive. 6. Check the suction valve after the overhaul. See Procedure 909-7.1. » ERITH When referring to this page, please quote Procedure 908-7.9 Edition 211 Page 3 (4)909-7.4 Fuel Pump Suction Valve HYUNDAI Mounting MAN B&W Fit the fuel pump top cover in an inside down position, for example in a bench vice. Lubricate the thread of the suction valve with copper grease. Make sure that the bore for the suction valve in the top cover is absolutely clean. Fit a new lock washer and mount a new or ‘overhauled suction valve in the top cover. Fit the two screws which secure the lock washer. Tighten the suction valve with a torque spanner. See Data. Lock the suction vaive in position by bend- ing up an edge of the lock washer over one of the flats of the valve. ‘Mount the top cover in the fuel pump hous ing. See Procedure 909-5.4. Page 4 (4) When referring to this page, please quote Procedure 909-7.4 Edition 211Shut off fuel oil ‘Shut off lubricating oil Lock turbocharger rotors Data Fel, Description Value Usit D-1 Puncture valve~ weight 5kg D-2. Puncture valve ~ 890 Nm Stopped engine Block the starting mechanism ‘Shut off starting air supply Engage turning gear ‘Shut off cooling water tightening torque HYUNDAI Fuel Pump Puncture Valve 109-8 MAN B&W. Data SAFETY PRECAUTIONS Standard Tools: See Section 913, Zz === 750-2000 Nm When referring to this page, please quote Data Sheet 109-8 Edition 18 Page 1 (2)109-8 Fuel Pump Puncture Valve HYUNDAI Data MAN B&W. 90951 10 om 2 ag Gri I as SI (St om P <5 cea Spare Parts Plato —tom No. Daserpton ow 90901-xxx 497 Lock washer 4 90901-xxxx 519 Sealing ring 1 90901-xxxx 520 Sealing ring 2 2090100x 556 Gasket 1 90901-xxxx 581 ‘O-ring 2 Page 2 (2) When referring to this page, please quote Data Sheet 109-8 Edition 18HYUNDAI Fuel Pump Puncture Valve 909-8.2 MAN B&W Dismantling 1. Shut off the fuel oil inlet. Open the drain cock at the bottom of the pump housing and drain off any oil left in the fuel oil high-pressure pipe and fuel pump. Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that ail oil has been drained off. 2. Dismantle the control air pipe and the protective cap above the puncture valve. 3. Unscrew and remove the puncture valve from the fuel pump top cover. 4. After dismantling it is recommended always to overhaul the puncture valve. If the overhaul cannot take place immediately after the dismantling, itis reeommend- ed to place the puncture valve immersed in diesel oil until the overhaul. eT When referring to this page, please quote Procedure 909-8. 2 Edition 212 Page 1 (4)909-8.3 Fuel Pump Puncture Valve HYUNDAI Overhaul MAN B&W 4, Remove and discard the O-rings from the puncture valve, Set up the puncture valve in a bench vice with *soft” jaws. Loosen and remove the four screws and dismount the plug. Use a screw to remove the air piston from the housing Remove and discard the sealing rings from the air piston, Disassemble the other parts of the puncture valve, using a brass mandrel and a hammer. Take care not to damage the valve seat. Thoroughly clean all the parts in clean diesel oil. 2. Inspect the conical seats of the valve housing and the valve slide for wear marks or scratches. Ifthe seats are damaged, the valve housing and the valve slide must be discarded. Lapping of the valve seats must not be attempted. Page 2 (4) ‘When referring to this page, please quote Procedure 909-8.3 Edition 212HYUNDAI Fuel Pump Puncture Valve MAN B&W Overhaul 909-8.3 3. When mounting the new sealing rings on the spindle of the air piston, the inner sealing ring must be mounted first. Mount the O-ring in the ring groove and position the large cone on the spindle. Place the sealing ring on the cone and, using the pusher tool, push the sealing ring on to the O-ring in the groove. After mounting the sealing ring, compress it by pressing the ‘sizer' tool, over the sealing ring. Mount the outer sealing ring in the groove using the short cone, and repeating the above procedure. 4. The new ‘sealing ring is mounted on the head of the air piston in accordance with the same procedure as above, Before assembling the puncture valve, lubricate all parts with "MOLYKOTE anti-fric tion SPRAY 0321R" or molybdenum disulphide (MoS>) Mount new O-rings on the housing. 5. If the puncture valve is not to be mounted on the engine immediately after the overhaul, cover all openings of the valve with plastic to prevent dirt from entering the valve during storage. RTT When referring to this page, please quote Procedure 909-8.3 Edition 272 Page 3 (4)909-8.4 Fuel Pump Puncture Valve HYUNDAI Mounting MAN B&W. 2. 1. Make sure that the bore for the puncture valve in the fuel pump top cover is absolute~ ly clean. If this has not already been done, mount new O-rings on the puncture valve. Lubricate the thread of the puncture valve with copper grease. D-2 2. Screw the puncture valve into the bore in a the top cover. Using a crowfoot wrench and a torque ‘spanner, tighten the puncture valve to the torque stated in Data, 3. Mount the protective cap and the control air pipe on top of the puncture valve. 4. If open, close the drain cock on the fuel pump and open the fuel oil inlet valve. i EEE Page 4 (4) When referring to this page, please quote Procedure 909-8.4 Edition 212 ge 90,HYUNDAI Fuel Pump Shock Absorber [MAN B&W] Data 109-9 SAFETY PRECAUTIONS Stopped engine Block the starting mechanism Shut off starting air supply Engage turing gear Shut off cooling water X_| Shut off fuel oit ‘Shut off lubricating oil Lock turbocharger rotors Ref. Description Value] Unit Dos-39 Shock absorber 27) kg When referring to this page, please quote Date D10909 Edition 0026 Page 1 (2)109-9 Fuel Pump Shock Absorber HYUNDAI Data MAN B&W. The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No. | Description Page 2(2) When referring to this page, please quote Data 10909 Edtion 0026HYUNDAI Fuel Pump Shock Absorber 909-9.4 MAN B&W. ‘Checking To ensure satisfactory operation, the function ing of the fuel pump shock absorber should be checked at regular intervals. Normally, inspection is necessary only at the intervals stated in the maintenance programme. The checks should be carried out while the engine is operating 1, Remove the plug from the end cover of the shock absorber. Check that air is ‘pulsating’ through the threaded hole. Short bursts of air should be felt against the hand, corresponding to the strokes of the fuel pump. The air pulses occur when the shock absorber piston is working and the air below the piston is being compressed and forced out through the threaded hole. 2. To check the ‘tightness’ of the piston, measure the amount of leakage oil flowing from the drain pipe of the shock absorber housing. Note down the amounts measured and ‘compare with earlier measurements. Increasing amounts indicate a deteriorating piston sealing. Excessive amounts indicate that the shock absorber requires overhaul ing. See Procedure 909-9.3. When refering to this page, please quote Procedure M90909 Edition 0214 Page 1 (3)909-9.3 Fuel Pump Shock Absorber HYUNDAI Overhaul MAN B&W Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. Remove the shock absorber drain pipe. Place a wire strap around the shock ab- sober and hook on the engine room crane. Loosen the screws holding the shock absorber and remove it from the fuel pump. housing. Remove the plug from the end cover of the ‘shock absorber. Fit a threaded rod between the piston and the end cover to counteract the force of the springs. Loosen the screws of the end cover and remove the end cover and piston. Discard the gasket. Loosen the nut on the threaded rod to relieve the springs and remove the threaded rod. Remove and discard the sealing ring in the shock absorber housing and the wear ring on the piston. Clean all parts and polish the sliding surfaces of the piston and the shock absorber housing. Mount a new sealing ring in the shock absorber housing and a new wear ring on the piston, Mount the springs and the spring guide between the end cover and the piston, using the threaded rod. Lubricate all sliding surfaces and assemble the shock absorber. Take care not to damage the sealing ring or wear ring when mounting the piston. Check that the piston slides easily in the shock absorber housing. Mount the end cover. For tightening the nuts, see Data. Lock with the locking device. Remove the threaded rod and insert the plug, Page 2 (3) When referring to this page, please quote Procedure Me0909 Edition 0214HYUNDAI Fuel Pump Shock Absorber 909-9.3 MAN B&W. Overhaul 7. Fit a new gasket on the fuel pump housing and mount the shock absorber. Mount the shock absorber drain pipe. If an excessive amount of drain oil is stil observed after the overhaul, the shock absorber must be replaced and the damaged one sent to an authorized MAN B&W repair shop for reconditioning, When referring to this page, please quote Procedure M90909 Edilion 0214 Page 3 (3)HYUNDAI Lifting Gear for Roller Guide MAN B&W. Data [X ] stopped engine [x | Shut of starting ir supply ~ At starting a recover [x | Block the main stating valve [| Shut of starting air dstributor/datbuting system supply X | Shut off safety air supply ~ Not ME-engines [X | Shut off contro! air supply [2C] Shut off air supply to exhaust valve — Only wih stopped lubiating oll pumps [XC] Engage turning gear |__| Shut off cooting water Shut of fuel ei X | Stop lubricating ol suppiy Lock the turbocharger rotors Data 109-10 Description Value Unit When referring to this page, please quote Data D10910 Edition 0016 Page 1 (2)109-10 .ecific tools used in this procedure are shown on the plates at the end of this chapter or in the Lifting Gear for Roller Guide HYUNDAI MAN B&W Data the plate number, e.g. P90951 refers to chapter 909. 9. | Description Page 2 (2) When referring to this page, please quote Data D10910 Eaton 0016HYUNDAI Lifting Gear 909-101 MAN B&W Checking Caution! Do not use the lifting tool for the fuel pump roller guide while the engine is running. a fuel pump is to be put out of action, Gisconnect it in the following manner: 4. Stop the engine and engage the turning gear. Remove the inspection cover on the upper part of the camshaft housing in front of the fuel cam for the pertaining roller guide. WR TOOTOCATTCSF Turn the engine until the roller is in the highest position on the cam (on the circular section of the cam). 2. Loosen the lock screw on top of the flange and the nut on the lifting tool. Press the shaft against the roller guide. When the shaft has been pressed fully in, the guide screw is positioned in line with the vertical slot of the flange. WROTE ETCR When referring to this page, please quote Procedure M90910 Edition 0211 Page 1 (2)909-101 Lifting Gear HYUNDAI Checking MAN B&W | raremroaTToRe TRUSTE WTOC 3. Mount a socket spanner, a siide-T handle and an extension pipe on the shaft or the box end of a long combinations wrench, and turn the shaft anti-clockwise until the guide screw is in top of the slot, which indicates that the roller guide is in the lifted position. 4. Lock the shaft in this position by tightening the lock screw and the nut on the lifting tool. ‘Check through the inspection cover opening that the roller guide is clear of the fuel cam. The engine can now operate on the remaining cylinders, see Volume |, Section 704. Re-engagement of the fuel pump roller guide Caution! Re-engagement of the fuel pump roller guide must only take place when the engine is at a standstill. 5. Turn the engine until the circular section of the pertaining fuel cam is positioned up wards, and then lower the roller guide in the reverse order to lifting. NB! Remember to loosen the look screw. 6. When the roller guide has been lowered into the position where the guide screw is in the lowermost position, tighten the lifting tool nut against the flange whereby the lifting tool will be pulled away from the roller guide. The guide screw will now be positioned at the end of the horizontal part of the siot of the flange. Tighten the lock sorew. Page 2 (2) When roferring to this page, please quote Procedure 90970 Edition 0217HYUNDAI Fuel Valve 109-11 MAN B&W Da SAFETY PRECAUTIONS for detailed sketch, see 900-2 ‘Stopped engine Shut off starting air supply — At starting air receiver Block the main starting valve Shut off starting air distributordistributing system supply Shut off safety air supply ~ Not ME engines Shut off control air supply Shut off air supply to exhaust valve — Only with stopped lubricating oil pumps Engage turning gear Shut off cooling water Shut off fuel oil ‘Stop lubricating oil supply ‘Lock the turbocharger rotors CLE Data Ref. Hi Description Value | Unit 09-40 | Fuelvalve opening pressure 300-380 | ber 09.42 | Inletseat, max.ciameter 25 | mm po943 | Fuelvale 13 | I When refering to this page, please quote Data D10911 Edition 0066 ~ Page 1 (2)109-11 Fuel Valve HYUNDAI Bee MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate tem No. Description 90154 071 | Dismanting too! for fuel valve 90951 057 | Milling tool for fuel ol pipe seats 90951 441, | Grinding mandrel for vaive head 90951 055 | Assembling too! for fue! valve 90961 Fuel Vaive tester, complete | 90966 Fuel Valve Nozzle - Tools Page 2 (2) When referring to this page, please quote Data D10911 Edition 0066HYUNDAI Fuel Valve 909-141 MAN B&W Checking 1. Fuel Valve The fuel valves must be given the utmost attention and care, as the greater part of irregularities that may occur during the running of the engine can be attributed to defects in these valves. If the engine gives normal performance in accordance with diagrams and exhaust tempera- tures, it is only necessary to inspect the fuel valves after the service period stated in the Checking and Maintenance Programme. See Chapter 900-1. In order to obtain reliable results during testing of the fuel valves, all fuel valves that are dismantled from the engine must be disassembled, cleaned, inspected and re-assembled before testing. See Procedure 909-11.3 and 909-72.3. Note! In the event that the slide-type fuel vaive i pressure tested without being cleaned between the fuel nozzle and the cut-off slide, the opening pressure value measured might be considerably lower than specified. All fuel valves must be function-tested before being mounted in the cylinder cover. Pressure testing pump Use only hydraulic oil (rust-preventing) with a viscosity of between 7 and 10 oSt at 50°C. For operation of the pressure testing pump, see the supplier's instructions. Note that the high-pressure pump should be periodically checked in accordance with the supplier's instructions. 2. Spring housing To ensure that over tightening has not taken’ place, check that the locking/indicating pin has not been bent or broken off. In the event of over tightening, replace the spring housing by @ new one. TORT OIC ype yy ‘When referring o this page, please quote Procedure M90911 Edition 0245 Page 1 (13)909-11.1 Fuel Valve HYUNDAI ‘Checking MAN B&W. 8 9. Setting-up the fuel valve 3. 8 Place the fuel valve in the test rig and secure it with the spring housings and nuts. Tighten the nuts until the top face of the pressure disc is flush with the top face of the spring housings. Mount the oil pipe between the pressure testing pump and the fuel valve. Pressure testing procedure The following functions of the fual valve must | be checked: Flushing and jet control | * Opening pressure ani matasasaanas! «Sealing test and sliding function TORT OS * Pressure test, O-ring sealing 4, Flushing and jet control Remove air in the system and check the fuel jet in the following way. Slowly increase the oil pressure until straight jets of oil are ejected from the nozzle holes (no atomization). Acceptance criteria: There is to be a continuous jet of oil through at least one of the nozzle holes. aT ERICA ‘Owing to the geometry of the internal part of the nozzle - and because of the height to which the spindle is lifted during pressure testing is lower than the height it is lifted during normal engine operation - the fuel oil will not necessarily flow from all of the nozzle holes. Cause of fault: If the jets do not fulfil the above point, the ‘cause may be: Dirt in the nozzle holes The nozzle is not mounted correctly Page 2 (13) When refering to this page, please quote Procedure 490911 Edtion 0246HYUNDAI Fuel Valve MAN B&W Checking 909-11.1 5. Opening pressure To check the opening pressure, increase the oil pressure until oil is admitted through the nozzle holes. ‘Acceptance criteria: Check the opening pressure on the pressure gauge and compare with Data D09-40 on the datasheet. Note! Do NOT attempt to carry out an atomization test on the slide type fuel valvs, as this may damage the cut-off slide and nozzle. Cause of fault: If the opening pressure is higher than specified in DO9-40, the cause may be that a wrong type of spring is used - replace the spring on the thrust spindle, if necessary, repiace the complete thrust spindle. If the opening pressure is lower than specified in 009-40, the cause may be that the spring has sagged - replace the spring, or add a special thin disc. Note! ‘Special thin discs are available as spares. If a spring or a disc has been changed, the pressure testing procedure of the fuel valve must be repeated. ‘When referring to this page, please quote Procedure M9091 1 Edition 0245 Page 3 (13)909-144 Fuel Valve HYUNDAI Checking MAN B&W 6. Sealing test and sliding function To check the needle valve seat for tightness and the slide for correct closing, Slowly increase the oil pressure to about 50 bar below the opening pressure. Maintain the built-up pressure by closing for the oil supply. Acceptance oriteria: il must not flow from the nozzle holes. The pressure drops relatively slowly to about 45 bar, after which it drops quickly to 0 (the slide is pressed against the conical seat and ‘opens for circulation oil). Ei Coen Note! il flows out of the leak oi! outlet when the fuel valve is full of oil. Cause of fault: If oil flows out of the nozzle holes, the cause is either: ‘+ Defective spindle guide at needle seat, or a sticking spindle. Examine and/or replace the spindle guide. ‘See Procedure 909-12.3. + Too quick pressure dro} - the clearances of the movable parts, both of the spindle guide and of the non-return valve, are 100 large, or the seats between the thrust piece/spindle in the spindle guide or thrust piece/valve slide in the non-return valve are damaged, Examine and/or replace both the spindle guide and non-return valve. See Procedure 909-12.3. See Procedure $09-13.3. If a quick pressure drop from 15 to 0 bar cannot be registered: The valve slide is sticking; or The vent hole in the thrust piece is blocked. If so, disassemble and examine the spindle guide, replace if necessary. See Procedure 909-12.3. Page 4 (13) When refering lo this page, please quote Procedure M9091 1 Eailion 0246HYUNDAI Fuel Valve 909-11.1 MAN B&W Checking 7. Pressure test, O-ring sealing 7. Max. 10 bar To ensure that the leak oil (circulation oil) remains in the closed system, build up a working pressure of about max. 10 bar until oil flows out of the leak oil outlet, Close the leak oil outlet with a gasket and plug sorew. Increase the working pressure to about 100 bar. Acceptance criteria: The built-up pressure of about 100 bar should be maintained. Cause of fault: If oil leaks out at the union nut, the O-ring inside the fuel valve head is defective, and must be replaced. 8. Atomization test TTC ERCAT Note! Do NOT attempt to carry out an atomization test on slide type fuel valves, as this may damage the cut-off slide and nozzle, jon test may damage the valve be- makes the needle oscillate, with a small lift at a very high frequency. The high pressure drop across the cut-off edge and the high contact pressure between slide and fuel nozzle, in combination with the poor lubricity of the test oil, increase the risk of seizures between cut-off slide and nozzle. All of these conditions involve the risk of seizure between the cut-off slide and the nozzle. RT AICS When referring to this page, please quote Procedure M90911 Edition 0245 Page § (13)909-11.2 HYUNDAI Fuel Valve Dismantling MAN B&W. 4. Close the fuel oil inlet and outiet valves, and drain the high-pressure pipe and the fuel valve. Dismantle and remove the fuel oil high- pressure pipe. See Procedure 909-14.2. Disconnect the return oil pipe from the fuel valve. | 2. Remove the nuts and the spring housings. E 3. Take out the valve. If the valve is sticking, lz use the fuel valve dismantling tool to pull H the fuel vaive clear of the top cover. 7 If the valve is not to be overhauled immedi- 2 ately, the valve should be placed immersed in diesel oil until overhauling. 8 5 ig 3. TT EOS When referring (o this page, please quote Procedure M9091 Edition 0245 2 2HYUNDAI Fuel Valve MAN B&W Overhaul 909-11.3 When fuel valves are overhauled, all parts should be handled carefully and be kept clean. ‘i Use only clean, non-fluffy rags for wiping purposes. Make sure to remove all liquid or solid impurities. Whenever fuel valves are overhauled, all sealing rings should be discarded and replaced by new, faultless sealing rings before reassembly. 4. Measure the length A of the protruding part of the nozzle, and write down the result for correct re-assembling of the valve. 2. Place the valve holder in a machine vice, mount the fuel valve in the holder and fit the valve with the guide dise from the grinding tool. 3. Compress the fuel valve and the spring inside, by means of a drilling machine, to avoid seizures in the union thread. Hold the fuel vaive compressed and unscrew the union nut with a hook spanner. Remove the valve from the valve hoider, TTT EOE TET STOO When referring to this page, please quote Procedure M90911 Edition 0245 Page 7 (13)909-11.3 Fuel Valve HYUNDAI Overhaul MAN B&W 4, Pull the valve head clear of the valve hous- 1 (X ing. Remove the: © Non return valve + Thrust spindle parts «Thrust foot * Spindle guide and fuel nozzle from the valve housing. Remove and discard all the O-rings. Page 8 (13) When referring to this page, please quote Procedure M90911 Edition 0245HYUNDAI Fuel Valve MAN B&W Overhaul 909-11.3 5. Carefully clean and examine all surfaces of the: + Fuel valve housing + Fuel valve head * Thrust spindle If necessary, grind the seating surfaces by means of the grinding mandrels supplied and a fine-grain abrasive (such as Carborundum No. 500). This grinding must only be carried out manually. After the grinding, wash the parts in gas oil and biow clean by means of compressed air to remove any remains of the grinding compound. In the event of more serious damage to the seating surface for the high-pressure pipe in the valve head, the milling too! can be used, Normally, the milling tool is turned by hand, but it may be fitted in the chuck of a column-type drilling machine provided that the number of revolutions is kept at a minimum (not exceeding approx. 100 r/min). An ample supply of cut- ting emulsion must be used. Take care not to exceed the maximum diameter of the seat, see Data. When referring to this page, please quote Procedure M0911 Euilion 0245 Page 9 (13)Fuel Valve HYUNDAI ‘Overhaul MAN B&W 6. The complete spindle guide, including the fuel nozzle, should be sent to an authorised MAN B&W repair shop for overhaul. If this is not possible, the spindle guide may be overhauled on board. See Procedure 909-12.3. Note! | Do not attempt to remove the fuel nozzle |from the spindle guide unless the spindle guide has been dismantled. Otherwise the cut-off aged. ie on the spindle may be dam- 7. The non-return valve should be sent to an authorised MAN B&W repair shop for overhaul. If this is not possible, the non-return valve may be overhauled on board. See Procedure 909-13.3. 8. Mount the complete spindle guide, including the fuel nozzle, in the fuel valve housing. Carefully slide the spindle guicle down into the valve holder, and turn the nozzle until the spindle guide engages correctly with the guide pin. Check that distance A corre- 3 sponds to the measurement taken before is the valve was disassembled. 5 IS Note! 8. Make sure that the fuel nozzle and Be, spindle guide engage correctly with the guide pin in the fuel valve housing. This ey, can be ascertained by attempting to turn the nozzle after mounting. It must not be possible to turn the nozzle. IN Yn WIN NAN Ws \ yay aw Hee Voy, e Pe R Ay ie AY i y e Page 10 (13) When referring to this page, please quote Procedure M90911 Edition 0245HYUNDAI Fuel Valve 909-11.3 MAN B&W Overhaul 9. Mount: * the thrust foot * the parts of the thrust spindle © the non-return valve in the fuel valve housing, Mount a new O-ring in the uppermost groove of the fuel valve housing. Lubricate the thread of the valve head with molybdenum disulphide (MoS2). For the correct use of this lubricant, see Procedure 913-11. Fit the valve head with new O-rings. 10. Make sure that the guide pin between valve housing and valve head is intact, and press the valve head down into the valve 4 housing. Ee See that the guide pin between valve hous- E Sooo ing and valve head engages correctly so as = to prevent relative turning of the parts. 10. E Vg ose is e E When referring to this page, please quote Procedure M90911 Edition 0245 Page 11 (13)909-11.3 Fuel Valve HYUNDAI ‘Overhaul MAN B&W 11, Assemble the valve by means of the union nut. Place the valve in the valve holder in a drilling machine. Compress the fuel valve and the spring inside. Keep the valve compressed and tighten the union nut with a hook spanner. After overhaul, the fuel valve must be tested in the test rig. ‘See Procedure 909-11.1. 42. If the fuel valve is not to be mounted in the engine immediately after the overhaul, cover all openings of the valve with plastic to prevent dirt from entering the valve during storage. WODETT BROT Page 12(13) When referring to this page, please quote Procedure M9091 1 Euition 0245HYUNDAI Fuel Valve 909-11.4 MAN B&W. Mounting 1. Before mounting the fuel valve, thoroughly = clean the valve bore in the cylinder cover | 1 and check the seating in the bore for marks which, if any, must be eliminated. (For reconditioning of the valve bores in the 09-43 cylinder cover, see Procedure 901-1.3). If not already done, mount new O-rings on the fuel valve. Lubricate the valve with molybdenum Disulphide (MoS2). | MoS p 2, Mount the valve in position in the cylinder t cover. Mount the spring housings and the nuts. Tighten the nuts until the top face of the pressure disc is flush with the top face of the spring housing. This must be done with great care, as the spring tension in the housing determines the correct tightening of the fuel valve to the cylinder cover as well as the correct compression of the fuel valve. i 8. Lubricate the thread on the union nipple of the fuel oil pipe with a heat resistant anti seize grease before mounting. Note! It is recommended to overhaul the fuel oil high-pressure pipe before mounting. ‘See Procedure 909-14.3. As a minimum, the distance between the fuel oil pipe ends and the thrust | bushings must be checked and, if necessary, adjusted a TT ER | { Mount the overhauled fuel oil high-pressure pipe and the return oil pipe. See Procedure 909-14.4. Note! All fuel valves must be function-tested before being mounted in the cylinder cover, see Procedure 909-11.1. When referring to this page, please quote Procedure M90911 Eciion 0245 Page 13 (13)HYUNDAI Fuel Vaive Spindle Guide 109-12 MAN B&W. Bae SAFETY PRECAUTIONS For detailed sketch, see 900-2 ‘Stopped engine ‘Shut off starting air supply — At starting air receiver Block the main starting valve ‘Shut off starting air distributor/distributing system supply ‘Shut off safety air supply — Not ME engines ‘Shut off control air supply ‘Shut off air supply to exhaust valve — Only with stopped lubricating ofl pumps Engage turning gear Shut off cooling water Shut off fuel oi Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description Value | Unit 08-70 —_|Nozzel spray hole cleaning too! table | Nozzel_| Cleaning | Test Nozze! | Cleaning | Test spray hole | dill pin |] sprayhole | dri pin 090 | 085 | 0.94 1.60 155 | 1.65 0.95 0.90 | 0.99 1.65 1.60 | 1.70 1.00 0.95 | 1.04 1.70 165 | 1.74 1.05 1.00 | 1.09 1.75 170 | 1.80 1.10 105 | 1.14 1.80 175 | 1.85 1.15 1.40 | 1.20 1.85 180 | 1.89 1.20 145 | 1.24 1.90 185 | 1.94 | 1.25 1.20 1.30 1.95 1.90 1.99 | 1.30 1.25 | 134 || 200 1.95 | 2.05 135 | 130 | (139 2.05 2.00 | 209 1.40 135 | 1.44 2.40 205 | 214 1.45 140 | 1.49 2.15 210 | 219 1.50 145 | 1.54 2.20 245 | 2.24 155 150 | 159 2.25 220 | 229 | When referring to this page, please quote Data D10912 Edition 0048 Page 1 (2)109-12 Fuel Valve Spindle Guide HYUNDAI Data MAN B&W. ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No. Description Peoges: Fuel Valve Nozzle - Tools Page 2 (2) When referring to this page, please quote Data 010912 Edition 0048HYUNDAI Fuel Valve Spindle Guide 909-12.3 MAN B&W Overhaul EEE EEE EEE eee EEE eet Note! This instruction is only valid for spindle guides of the slide valve design. Extreme care and accuracy should be exercised when carrying out this operation. Based on service experience it is recommended to replace the complete spindle guide after 16000 hours of operation. 1. Clean the outside of the spindle guide in pure gas oil or similar. The individual parts of the spindle guide are not interchangeable, therefore only one guide is to be disassembled at a time. Note! The spindle guide, thrust piece and spindle are matched parts and may not be re-placed individually. ye SSE RICO 2. Place the spindle guide in a bench vice provided with “soft” jaws, and use the brass mandrel as shown to disassemble the spindle guide. 3. Mount the pulling tool around the fuel nozzle on the spindle guide. Turn the nut to pull the fuel nozzle off the spindle guide. Note! The pulling tool is not standard for all engines, but may be delivered as an optional extra. 4. If no pulling tool is available, the fuel nozzle can be dismantled from the spindle guide using two screwdrivers. Place the screwdrivers opposite each other in the small gap between the fuel nozzle and the spindle guide and very carefully force the fuel nozzle off the spindle guide : When referring to this page, please quote Procedure M90912 Edition 0228 Page 1 (5) TOE RCOT909-12.3 Fuel Valve Spindle Guide Overhaul HYUNDAI MAN B&W. ONT -OROTE H 5. Clean all the parts of the spindle guide in gas oil and wipe dry with a clean piece of cloth. Clean all parts again in gas oil or ‘Electrocleaner’ and wipe dry with a clean piece of cloth. Place all the parts on a clean, soft, lint-free cloth and examine them through an 8-10 times magnification magnifying glass and an inspection lamp. During the examination, pay special attention to the seating surfaces and sliding surfaces of the parts. 6 Remove any deposits or very. fine scratches by placing the spindle, thrust piece or spindle guide respectively in a lathe, as shown, and polishing with a very fine conventional polishing linen ‘grade 360", Use also a little oll for the polishing (a coarser polishing linen must absolutely not bbe used). Note! The sliding surface of the cut-off slide may only be polished VERY carefully. The sliding surface must not be damaged. After polishing, clean the parts again and re-check the seat on thrust piece/spindie, the seat on slide valve/spindle, and the seat on spindle/guide. Use an inspection lamp and an 8-10 times enlargement magnifying glass. If the seats are not in order, Le. if there are pressing-in marks or similar on the seats, the complete spindle guide must be discarded. Page 2(5) When referring to this page, please quote Procedure M9092 Edlion 0226HYUNDAI Fuel Valve Spindle Guide MAN B&W. ‘Overhaul 909-12.3 7. Clean any carbon deposits from the central bore of the fuel nozzle by means of the special brass brush, Clean the fuel nozzle with gas oil and wipe dry with a clean cloth. 8. Read the nominal hole size on the oylindri- cal part of the nozzle, as shown in the figure. The hole size is given in 1/100 mm. Depending on the engine model, there can be one or more different sizes of the holes. Find the correct drill size and matching test pin in the table, D09-70, on the data sheet, via the nominal hole size. Clean the spray holes, using gas oil and the special drills supplied. Note! During this operation be very careful not to push the drill too far to avoid scratching the snug-fit surface on the inside of the fuel nozzle. Then test the spray holes with the test pin. If the test pin is able to enter just one of the holes, the fuel nozzle must be discarded. This also applies to nozzles with oval holes (can be ascertained with a magnifying glass). Check the fuel nozzle before mounting on the spindle guide, the cut-off slide must be able to move freely inside the nozzle. When referring to this pago, ploase quote Procedure M90912 Ecition 0228 RTE OROAT iE EROS TROBE RCO Page 3(5)909-12.3 Fuel Valve Spindle Guide HYUNDAI Overhaul W. TRNTERZBOTT 12. Ss MaDe 10. "1. MAN B&W. Lubricate the spindle and the thrust piece with the cut-off slide with a little Molybde- num Disuiphide (MoS,), see Procedure 913- m1. Assemble the thrust piece, the spindle and the spindle guide and carefully knock the parts together using a soft hammer. Shake the spindle guide back and forth. The spindle with the cut-off slide must be able to slide freely back and forth inside the spindle guide, with a ‘clicking’ sound. Page 4 (5) When referring to this page, please quate Procedure M90912 Edition 0228HYUNDAI Fuel Valve Spindle Guide 909-12.3 MAN B&W Overhaul 13. Lubricate the sliding surfaces of the nozzle and the spindle with a little Molybdenum Disulphide (MoS,). See Procedure 913-11. Mount the nozzle on the spindle guide. Make sure that the half-circle shaped groove on the nozzle and the spring pin are in fine. If nozzle and spindle guide are provided with scratch marks opposite the spring pin, they must be in line, Place the parts on the plane of a drilling machine or hydraulic press and position the mounting tool over the parts. Make sure that all the parts are perfectly aligned. Press the nozzle on to the spindle guide. Note! ‘The mounting tools are not standard for all engines but may be delivered as optional extras. ROSTER If no mounting tools are available, the nozzle can be mounted on the spindle guide using a short piece of pipe. Place the pipe around the nozzle, so that the lower end of the pipe rests on the foot’ of the fuel nozzle. Then press the parts together the same way 2s when using the mounting tools. Check that the spindle inside the spindle guide is able to move freely as in step 10. 14, If the spindle guide is not to be mounted in a fuel valve immediately after the overhaul, cover all openings of the spindle guide with plastic to prevent dirt from entering the spindle guide during storage. When referring to this pago, please quote Procedure M90912 Edition 0228 Page 5(5)HYUNDAI Non-return valve MAN B&W Data SAFETY PRECAUTIONS ‘Stopped engine Block the starting mechanism ‘Shut off starting air supply Engage turning gear ‘Shut off cooling water Shut off fuel oil ‘Shut off lubricating oil 109-13 Lock turbocharger rotors Data Ref. Description Value] Unit When referring to this page, please quote Data D10913 Editon 0031E Page 1 (2)109-13 Non-return valve HYUNDAI Data MAN B&W. ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No. | Description 90951 104 | Flange for dismantling of non-return valve P90968- 075 | Probe light with magnifier, complete Page 2 (2) When referring to this page, please quote Data 010013 Eidion 0031HYUNDAI Non-return valve 909-13.3 MAN B&W. Overhaul Note! Extreme care and acouracy should be exercised when carrying out this operation. 1. Clean the outside of the non-return vaive with pure gas oil. The individual parts are not interchangeable, therefore only one guide is to be disassembled at a time. Note! Except for the slide vaive spring, defective parts cannot be replaced individually by new ones, Place the non-return valve as shown in Fig. 1 in a bench vice provided with “soft” jaws, and disassemble the non-return valve, using the disassembling tool and a hammer as shown. 2. Clean all the parts for the spindle guide in gas oil and wipe them dry with a clean piece of cloth. Finally, clean in either gas oil, kerosene or ‘Electrocleaner’, and wipe the parts dry with a clean piece of cloth. 3. Now place the parts on clean, lint-free rags ‘and examine with an 8-10 times enlargement magnifying glass, and an inspection lamp with magnifying glass as shown in Fig, 3. When referring to this page, please quote Procedure M80913 Edition 0206 Page 1 (2)909-13.3 Non-return valve HYUNDAI Overhaul MAN B&W. Examine the slide faces of movable parts for coating. Vent slide B/housing A will be too tight if there is @ coating. (The letters A~ D refer to the letters/parts in Fig. 2). Fix vent slide B and, subsequently, housing Ain a lathe as shown in Fig. 4 and remove the coating by means of very fine conventional polishing linen ‘grade 360’. Also a little oll should be used (a coarser polishing linen must absolutely not be used). Check spring C for the thrust piece for outside wear marks. If defective, it should be exchanged. ‘Check the seat on thrust piece D/vent slide, and the seat on vent slide/housing. Use an inspection lamp and an 8-10 times enlargement magnifying glass. If the seats are not in order, i.e. if there are pressing-in marks or similar on the seats, the complete spindle guide must be discarded. Mount the non-return valve as follows: + Lubricate all movable parts with molyb- enum disulphide (MoS,). + Place the loosely-assembled non-return valve on the plane of a drilling machine, with the tool positioned as shown in Fig. 6. + Make sure that the thrust piece and the other parts are perfectly aligned and that the thrust piece is guided in the vent slide. + Press the handle until the housing and thrust piece meet, IF the non-return valve is not to be mounted in a fuel valve immediately after the overhaul, cover all openings of the non-return valve with plastic to prevent dirt from entering the valve during storage. Page 2(2) When referring to this page, please quote Procedure M90913 Edition 0206HYUNDAI MAN B&W Fuel Oil High-Pressure Pipe Data 109-14 Data SAFETY PRECAUTIONS X_| Stopped engine X | Block the starting mechanism X | Shut off starting air supply Engage turing gear Shut off cooling water X | Shut off fuel oi ‘Shut off lubricating off Lock turbocharger rotors Description Value] Unit 009-47 09-51 09-52 Fuel oll high-pressure pipe, tightening torque Distance from pipe end to thrust bushing lower edge Fuel oil pipe 190] Nm 14] mm 17| kg When referring to this page, please quote Data 010914 Edition 0065 Page 1 (2)109-14 Fuel Oil High-Pressure Pipe HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No.| Description 90951 057 | Miling too! for fuel cil pipe seats P2095! 070 | Crowfoot spanner Page 2(2) When referring to this page, please quote Data 010914 Ealtion 0065,HYUNDAI Fuel Oil High-Pressure Pipe 909-14.2 MAN B&W Dismantling High-Pressure Pipe with Protective Hose 1. Close the fuel oil. inlet and outlet valves. 2. Using a hook spanner, unscrew the union nut at the fuel valve end of the high-pressure pipe. AB Pull the union nut and the protective hose clear of the union nipple. = Unscrew the union nipple from the fuel valve. D 3. Using a hook spanner, unscrew the union nut at the fuel pump end of the high-pressure pipe. Pull the union nut and the protective hose clear of the union nipple. Unscrew the union nipple from the fuel pump. 4. Lift the pipe ends clear of the fuel valve/fuel pump, and remove the high-pressure pipe from the engine. Note! Itis recommended always to overhaul the high-pressure pipe before remounting it on the engine, See Procedure 909-14.3. The overhaul should preferably take place immediately after the high-pressure pipe has been dismantled. When referring to this page, please quote Procedure M90914 Edition 0233 Page 1 (4)or aa wT Corccor asa Tor Fuel Oil High-Pressure Overhaul MAN B&W ipe HYUNDAI Whenever the fue! oil high-pressure system has been dismantied, it is necessary, before remounting the high-pressure pipes, to carefully inspect the tapered contact surfaces of the pipe ends, together with their seats in fuel valves and fuel pump top cover. Furthermore, the position of the thrust bushing on the pipe end must be checked. If the distance is incorrect, compared with the measurement stated in Data, it should be adjusted by screwing the thrust bushing up or down the pressure pipe. If any of the pipe ends requires reconditioning, dismantle the high-pressure pipe as follows: + Lift up the union nut with flexible protective hose, together with the coupling nut, on the high-pressure pipe and screw off the thrust bushing. + Remove the coupling nut and, when the thrust bushings at both ends of the pipe have been dismounted, pull the flexible protective hose with union nuts off the high-pressure pipe. ‘Shape-up the threads on the pipe ends with the nut die. Page 2 (4) Wen referring to this page, please quote Procedure M90914 Edition 0233HYUNDAI MAN B&W. Fuel Oil High-Pressure Pipe Overhaul 909-14.3 4, Mount the guide on the pipe end, place the miller in the guide and lightly screw on the union nut. 5. Turn the miller with, for instance, a tap ‘wrench while lightly tightening the union nut to provide a suitable pressure between miller and pipe end. During the milling, add drilling oil emulsion liberally. After completing the milling, carefully clean the high-pressure pipe with compressed air. 6. When assembling the high-pressure pipe, screw the thrust bushings so high up on the thread of the pressure pipe that the distance between the pipe end and the bottom ‘edge of the thrust bushing is as stated in Data. Replace the O-rings. Before mounting a high-pressure pipe, check the centre distances between pipe ‘ends and seats, and lubricate the threads of the union nuts with molybdenum disulphide (MoS;). It is of great importance for the mounting, and a condition for obtaining tight joints, that the pipes fit the seats accurately. For reconditioning of seat in fuel valve, see Procedure 909-11.3. For reconditioning of seat in fuel pump top cover, see Procedure 909-5.3. DO9-51 When referring to this page, please quote Procedure M90914 Ecition 0233 Page 3 (4)909-14.4 Fuel Oil High-Pressure Pipe Mounting HYUNDAI MAN B&W Check that the distance between the thrust bushing and the pipe end is correct at both ends of the pipe. See Procedure 909-14.3. Ensure that the fuel vaive is fitted with a new O-ring. Lubricate the thread of the fuel valve with a heat resistant grease. Ensure that the union nipple at the fuel pump end of the high-pressure pipe is fitted with a new O-ring. Lubricate the thread on the union nipple with a heat resistant grease. Mount the high-pressure pipe between the fuel valve and the fuel pump. Screw the union nipples onto the fuel valve and into the fuel pump top cover, by hand. Note! DO09-47 Ah i LE b pelle Page 4 (4) | The nipples must be screwed by hand, as the threads of the union nipples, fuel valve or fuel pump top cover might otherwise be damaged. Tightening with a crowfoot wrench should only be done after both of the union nipples have been screwed into position. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel valve to the torque stated in Data, Screw the union nut onto the union nipple by hand, and tighten lightly with a hook spanner. Use a crowfoot wrench and a torque spanner to tighten the union nipple at the fuel pump to the torque stated in Data. Screw the union nut onto the union nipple by hand, and tighten lightly with a hook spanner. If dismantled, re-mount the return oil pipe ‘on the fuel valve. Open the fuel oil inlet and outlet valves. When referring to this page, please quole Procedure M90914 Edition 0233HYUNDAI Fuel Pump Roller Guide 109-15 MAN B&W. Data ‘SAFETY PRECAUTIONS X_| Stopped engine X_| Block the starting mechanism X | Shut off starting air supply X | Engage turning gear Shut off cooling water X | Shut off fuel oil X | Shut off lubricating oil Lock turbocharger rotors Data Ref. Description ‘Value] Unit Do9-53 Nut, reversing shaft, tightening torque 160| Nm Do9-54 Clearance A 0.6 -3.1) mm 09-55, Clearance B | 43-60) mm 09-56 Clearance C 0.3-0.8| mm 09-57 Roller/bushing/shaft pin, max. clearance 0.5| mm Dos-61 Fuel pump roller guide 96| kg Doo-62 Pump base 118) kg When roferring to this page, please quote Data 010916 Ealtion 0046 Page 1 (2)109-15, Fuel Pump Roller Guide HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate tem No. | Description 90951 250 | Lifting tool for fuel pump roller guide Page 2 (2) When referring (o this page, please quote Data 010916 Edition 0046 oeHYUNDAI Fuel Pump Roller Guide MAN B&W Checking 909-15.1 Roller guide mounted in engine 1. The fuel pump roller guide can be partially checked while mounted on the engine, us ing the following procedure: 2. Lift the fuel pump roller guide. See Procedure 909-10. 3, Remove the cover on the camshaft housing to inspect the fuel pump roller guide. Turn the engine to provide the maximum ‘space between the roller guide and the cam disc. Turn the roller by hand to check that it can move freely and without unnecessary resistance or “hard” points. Also inspect the surface of the roller for possible damage marks, seizures or scratches. Make sure that there are no traces of bearing metal left in the roller guide housing. Check the clearance in the slide bearing by lifting the roller relative to the roller guide and measuring the difference in distance between the cam disc and the roller in the upper and lower positions of the roller. 4. Lower the roller guide onto the fuel cam again. See Procedure 909-10. 5. Using the telegraph, move the roller guide to the AHEAD position. ‘Check that the reversing link is fully tilted ‘over in AHEAD position. Carry out the same check in the ASTERN position When referring to this page, please quote Procedure 909-15.1 Edition 0226 Page 1 (10)909-15.1 Fuel Pump Roller Guide HYUNDAI Checking MAN B&W l 1 x DO9-57 Roller guide removed from engine ‘A more suitable and reliable method is to check the rolier guide and the bearing clearance after the roller guide has been dismounted: 6. Dismount the roller guide from the engine. See Procedure 909-15.2. 7. Check the surface of the roller and the sliding surfaces of the roller guide, and measure any ovainess. 8. Turn the roller guide upside down and land it in a vertical position on a couple of planks, with the roller hanging freely. Measure the clearance in the slide bearing by placing a dial gauge against the roller and lifting the roller as much as the clearance permits. Page 2 (10) When referring to this page, please quote Procedure 909-15.1 Edition 0226HYUNDAI Fuel Pump Roller Guide 909-15.2 MAN B&W Dismantling Note! Before dismantling any part of the fuel pump, make sure that the pump has been relieved of pressure and that all oil has been drained off. 4. Dismantle the top cover of the fuel pump. See Procedure 909-5.2. 2. Dismantie the fuel pump barrel assembly. See Procedure 909-6.2. When referring to this page, please quote Procedure 909-15.2 Edition 0226 Page 3 (10)909-15.2 Fuel Pump Roller Guide HYUNDAI Dismantling MAN B&W 3. Dismantle the fuel pump housing, see Pro- cedure 909-4.2, Note! ‘When lifting the fuel pump housing, take care not to damage the threads on the studs. 4, Loosen and remove the screws from the sealing cap on top of the roller guide inside the pump base. Remove the sealing cap from the roller guide/pump base. Dismantle the lubricating oil pipe and the drain pipe from the pump base. 5. Remove the cover on the camshaft housing to inspect the position of the roller guide. Turn the engine until the roller guide is at BOC. jaomTsz aT or Page 4 (10) When referring fo this page, please quote Procedure 909-16.2 Edition 0226HYUNDAI Fuel Pump Roller Guide 909-15.2 MAN B&W. Dismantling 6. Loosen the nuts on the two threaded studs successively until the roller guide springs are relieved. Remove the nuts, mount two eye bolts in the pump base and lift it away. When lifting, take care that the bushing of the pump base slides against the neck of the roller guide without scratching, Remove the springs from the roller guide. 7. Mount the roller guide lifting tool as follows: * Lift the lock plate of the tool up on the shaft of the tool. * Position the tool so that its foot rests on the thrust piece in the bayonet joint of the roller guide. + Turn the tool 90° so as to allow the foot to engage properly in the bayonet joint. + Lower the lock plate, thereby securing the foot in the locked position. Lift the rolter guide out of the roller guide housing, using the crane. When lifting, take care that the slide surfac- @8 of the roller guide do not scrape against the roller guide bushing. Land the roller guide on wooden planks. 8. Check the roller guide. See Procedure 909-15.1. When referring to this page, please quote Procedure 909-16.2 Eaition 0226 "Page 5 (10)909-15.3 Fuel Pump Roller Guide HYUNDAI Overhaul MAN B&W Tee 2 Inspect and check the fuel pump roller guide. See Procedure 909-15.1. It is recommended that the roller guide should ONLY be dismantled if irregularities when turning the roller, damage to the roller, + larger clearance than stated on the Data sheet, + seizure marks on the slide surfaces, have been observed when checking the roller guide. Note! For disassembling of the roller guide, contact an MAN B&W authorized repair shop. If no irregularities are found, just clean and lubricate the roller guide before remounting it in the roller guide bushing. Page 6 (10) When referring to this page, please quote Procedure 909-15.3 Edition 0226HYUNDAI Fuel Pump Roller Guide 909-15.4 MAN B&W Mounting 1. Lubricate the roller guide with plenty of | 1 camshaft lubricating oil, and mount it in the roller guide bushing, using the lifting tool. During mounting, take care not to scratch the sliding surfaces of the roller guide. Make sure that the pin of the reversing link fits in the bracket of the reversing shaft. 2. After mounting the roller guide with the reversing link, check the clearance between the roller guide and the guide plate mounted in the roller guide bushing. Turn the camshaft so that the roller guide is lifted approx. 20 mm. The clearance C between the roller guide and the guide plate must be the same at both ends ++ 0.1 mm, The clearances A and B between the guideway and the pin of the reversing link (arm) must be checked in the AHEAD and ASTERN positions. Connect working air to the air cylinder, and | 2 check that the reversing mechanism is ‘working smoothly. The clearances A and B must be approx. 7 the same in both positions. See Data. CHIC) ) DO9-54| \ D09-56 When referring to this page, please quote Procedure 909-15 4 Edition 0226 Page 7 (10)909-15.4 Fuel Pump Roller Guide HYUNDAI Mounting MAN B&W 3. 3. If adjustment is necessary, it must take aa TEE place in the ASTERN position. Remove the cover over the shaft connection. Loosen the nut on the reversing shaft and carry out the adjustment. After adjustment, shift to AHEAD position and check the clearances A and B once more. Finally, shift again to ASTERN. Tighten the nut on the reversing shaft to the torque stated in Data, and lock the nut with Loctite type: Screw Lock No. 59. Mount the cover over the shaft connection. Turn the engine until the roller guide is at BDC. ‘Mount the springs and the spring seat discs over the roller guide. Mount the pump base over the roller guide and the springs. Mount the two special nuts on the threaded studs. Using the special tube-shaped socket wrench, tighten the nuts until the pump base Is fastened tightly to the roller guide bushing. Page 8 (10) When referring to this page, please quote Procedure 909-15.4 Edition0226HYUNDAI Fuel Pump Roller Guide 909-15.4 MAN B&W. Mounting 6. Check the movement of the reversing link. | § See Procedure 909-15.1. 7. Replace the scraper rings in the sealing cap as follows: Loosen and remove the screws and nuts from the bottom of the cap, remove the retaining flange and ring holder with scraper A ring. KK Se 8. Replace the O-ring in the top of the cap. Replace the axial scraper ring in the bottom of the cap. Check that the O-ring and scrap- ° er ring are mounted correctly. See the sketch When referring to this page, please quote Procedure 909-15.4 Edition 0226 Page 9(10)HYUNDAI Fuel Pump Roller Guide 909-15.4 MAN B&W Mounting 9, Remove the scraper ring and O-ting from the ring holder. Place the new O-ring in the ring holder. Before mounting, the new scraper ring must be heated in 100°C hot water or oil for at least five minutes. Note When mounting the scraper ring in the groove, fold the ring without making any sharp edges, and be careful not to cut the scraper ring on the edge of the ring groove when pressing it in. RETA T ‘Check that the O-ring and scraper ring are mounted correctly. See the sketch. 10. Assemble the sealing cap, the ring holder and retaining flange. Tighten the nuts on the screws. After tightening, check that the holder can be moved 141. Mount the lubricating oil pipe and the drain pipe on the pump base. Mount the sealing cap on top of the roller guide, over the sealing bush inside the pump base. Tighten the screws and lock with locking wire. 12, Mount the fuel pump housing. See Procedure 909-4.4. Mount the barrel assembly. ‘See Procedure 909-6.4. Mount the top cover. See Procedure 909-5.4. ! When referring to this page, please quote Procedure 909-15.4 Edition 0226 Page 10 (10)HYUNDAI & MAN B&W. Fuel Valve and Fuel Pump Panel Plate P90951-250E 024 nw a 6g 116 2 3S zg 248 When referring to this page, please quote Plate P90951 Edition 250EPlate P90951-250E Fuel Valve and Fuel Pump Panel item i Hem Ne, Item Description had Item Description 010 | Panel for tools o2t | Name plate 045 | Milling tool for fue! oil pipe 055 | Assembling tool 057 | Milling tool for fuel oil pipe seats 069 | Crowfoot wrench 070 | Crowfoot wrench 082 | Crowfoot wrench 094 | Lifting too! for fuel pump 104 | Flange for dismantling of non-return valve 116 | Crowfoot wrench head 141 | Grinding mandrel for valve head 153 | Grinding mandrel for thrust spindle 165 | Grinding mandrel, outside 189 | Lifting tool for fuel pump housing 190 | Screw 200 || Lifting tool for fuel pump 236 | Grinding mandrel, inside 248 | Measuring tool 250 | Lifting tool for roller guide 273 | Pinwrench 307 | Hook wrench 319 | Hook wrench 332 | Tool for P.max rack 344 | Drift for puncture valve 356 | Drift for non return vaive 368 | Drift for spindle guideHYUNDAI zs MAN B&W Fuel Valve - Tools Plate P90961-0069E. When referring to this page, please quote Plate P90961 Edition 0069EPlate P90961-0069E Fuel Valve - Tools (Refer to instruction manual) Item | fem Ne Item Description Na! Item Description 063 | Test rig, completeHYUNDAI : MAN B&W Fuel Valve Nozzle - Tools Plate P90966-0008 ||_-—080 on || For ordering new cleaning tool; please state the number on the fuel nozzle. es Om ~~ o23~_| is jp pa0a74 ou 023 a 212 4 035 SE, 047 ISI CET ss = When relerring to this page, please quote Plate P90966 Edition 0008Plate P90966-0008 Fuel Valve Nozzle - Tools Note: ‘When ordering new cleaning tool, please state P/N on fuel nozzle. at Item Desc a Item Description O11 Tool box 023 Extractor for atomizer 035. | Drift for atomizer 047 | Cleaning brush | 060, Instruction plate | 212 | Toolset, complete |py UNN Fuel Valve - Inspection Tools Plate P90968-0001 When referring to this page, please quote Plate P90968 Edition 0001Plate P90968-0001 Fuel Valve - Inspection Tools a Item Description el Item Description No. 075 | Probe light with magnifier, completeHYUNDAI Fuel Valve Nozzle - Cleaning Tools Plate P90974-0001 MAN B&W 039 206 —[P90966 ot Sy - — 027 When referring to this page, please quote Plate P90974 Edition 0001Plate P90974-0001 Fuel Valve Nozzle - Cleaning Tools Item i eZ Item Non Item Description Nee Item Description 018 | pri 027 | Test mandrel* 039 Pin vice* 206 | Cleaning tool set, complete Note: * When ordering new cleaning tool, please state P/N on fuel nozzle.SAFETY PRECAUTIONS X | Stopped engine X | Block the starting mechanism X_| Shut off starting air supply X_| Engage turning gear X | Shut off cooling water ‘Shut off fuel oll Shut off lubricating oll Lock turbocharger rotors Data el, Description Value Unit D-1 Water inletioutlet cover upto 403 kg. D-2. Air cooler element, 2750 kg Complete with covers up to D-3_ Reversing chamber up to 292 ko HYUNDAI Air Cooler Element MAN B&W Data Standard Tools: See Section 913, Zz, & Hf 4x 2000 kg iH 2x 1000 kg i 110-4 Page 1 (2)Air Cooler Element HYUNDAI Data MAN B&W. Spare Parts Pate - tern No, Description ay ‘See spacial instructions from air cooler element manufacturer. Page 2 (2)HYUNDAI Air Cooler Element MAN B&W. Checking 910-11 1. For the day-to-day checking of the scav- ‘enge air cooler, measure the drop in pressure and temperature of the scavenge air across the cooler while the engine is running. Compate these measurements with the testbed datas For further evaluation of the measurements, see the OPERATION manual, Volume |, Chapter 706. 2. An increase in the air pressure drop across the scavenge air cooler indicates fouling of the air side of the cooler. A decrease in the air temperature drop across the scavenge air cooler indicates fouling of the water side of the cooler. 3. If the measurements indicate fouling of the water side of the air cooler element, the element must be dismantled and overhauled/ cleaned. See Procedure 910-2. See Procedure 910-3. If the measurements indicate fouling of the air side of the air cooler element, it is rec- ‘commended to inspect the air cooler element as follows: 4, Remove the top inspection cover of the air cooler. Unlock and swing open the inspection hatch at the bottom of the air cooler. 5. Visually inspect the air cooler element through the openings. For further information, see the OPERA- TION manual, Volume |, Chapter 702 “Checks during Standstil! Periods”. It the air side of the element is fouled, clean the element using the spray pipe arrangement fitted above the air cooler element. See Procedure 910-3. When referring to this page, please quote Procedure M91001 Edition 0234 Page 1 (9)9104.2 Air Cooler Element HYUNDAI Dismantling MAN B&W. | The cooler element normally does not need to be dismantled for inspection purposes. It is only in the event that the cooler element has suf- | fered damage that it has to be dismantled and replaced. Note! Hee During dismantling, take care not to dam age the cooler element. 1. Close the cooling water inlet and outlet valves. Open the drain cocks on the water inlet/outlet cover to drain off the cooling water. 2. Dismount the cooling water inlet and outiet pipes from the water inlet/outlet cover. | 3. Release the screws and remove the frame around the reversing chamber. Remove and discard the O-ring. Remove the sealing plate. Page 2 (9) When referring to this page, please quote Procedure M9101 Edition 0234HYUNDAI Air Cooler Element MAN B&W Dismantling 910-1.2 4. Mount the first set of guide rails on the frame around the reversing chamber. 5. When mounting the guide rails, hold them Up against the wheels of the cooler element and mount the lowermost screws. Mount and tighten the uppermost screws. Tighten the thrust nuts on the uppermost screws simultaneously. This results in loosening and lifting the cooler element. 6, Mount the lifting bracket on the water inlet/ outlet cover. Mount two travelling trolleys on the beam above the water inlet/outlet cover. Mount a tackle between the travelling trolley nearest to the air cooling housing and the lifting bracket, and use the tackle to lift the air cooler element approx. 1-2 mm. rs When referring to this page, please quote Procedure M91001 Edition 0234 Page 3 (9)910-1.2 Air Cooler Element HYUNDAI Dismantling MAN B&W. 7. Mount a second tackle on the lifting bracket, and use it to pull out the air cooler element approx. half a metre. Shift the liffing tackle between the two travelling trolleys to avoid damaging pipes, valves, etc. 8. Mount the second set of guide rails on the frame around the air cooler element. 9, Pull out the air cooler element until the wheels on the reversing chamber interlock with the recess in the guide rails. Page 4 (9) When referring to this page, please quote Procedure M91001 Edition 0234HYUNDAI Air Cooler Element 910-1.3 MAN B&W ‘Overhaul Cleaning the air side: The air side of the cooler is cleaned by injecting a chemical fluid through the spray pipe arrangement fitted to the air chamber above the cooler element. It is recommended to use one of the foll cleaning fluids, or a similar product. 1) Product: ACC 9, produced by Drew Chemical Corp., New York, USA 2) Product; 808, produced by Vecom int., Maassluis, Holland Cleaning should be carried out in the following sequence: 1. Do not start cleaning until the engine has been at a standstill for about 30 minutes. Do not disconnect the compressed air supply to the exhaust valve. 2. Follow the detailed cleaning instructions displayed at the cleaning pipe on the engine. To ensure satisfactory spraying of tho cleaning fluid, the circulating pump pres- | 2. t tl ‘sure must be at least 0.7 bar. ] pamioasiaor 3. Continue the cleaning process for at least 30 minutes. The time required depends on the frequency with which cleaning is carried out and on the chemical product used, — T, 4. After cleaning, flush the cooler with clean water until the water appearing in the sight glasses is clean and pure. 5. Inspect the elemient as described in Proce- dure 910-1.1. ‘lenin canon enna casing cseion aOR te ang When referring to this page, please quote Procedure M91001 Edition 0234 Page 5 (9)910-1.3 Air Cooler Element HYUNDAI Overhaul MAN B&W. Cleaning the water side 6. Close the cooling water inlet and outlet valves. Open the drain cocks on the water inlet/outlet cover to drain off the cooling water. 7. Dismount the cooling water inlet and outlet pipes from the water inlet/outlet cover. 8. Screw two eye bolts into the upper flange of the water inlet/outlet cover. Mount a lifting wire rope between the eye bolts. Mount a travelling trolley on the beam above the water inlet/outlet cover. Mount a tackle between the travelling trolley and the lifting wire rope. Tighten up the tackle. Page 6 (9) When referring to this page, please quote Procedure M91001 Edition 0234HYUNDAI Air Cooler Element 910-1.3 MAN B&W Overhaul 9. Mount a shackle in each of the two iting ‘eyes on the reversing chamber. Mount two tackles above the reversing chamber. Hook the tackles on to the shackles and tighten up. 10, Remove the screws of the water inlet/outlet cover and the reversing chamber. Lower both covers and land them on a couple of wooden planks. Discard the gaskets. 14, Clean the inside of the tubes, using the cleaning brush (delivered by the cooler element manufacturer) mounted on @ drilling machine. In the event of leakages between | 10, D10-02 cooling tube and tube plate, the tubes are D10-05 rolled with the tube expande (also delivered |. by the cooler element manufacturer). Clean the front-end and aft-end covers inside with a stiff brush and then rinse with fresh water. Replace the anti-corrosion blocks, if necessary. Note! If damaged, the coating inside the covers is to be repaired with the original coating ora similar product. 42. When cleaning is complete, mount the covers in the reverse order to dismantling l (i a Ss ! When referring to this page, please quote Procedure M9101 Edition 0224 Page 7 (9)910-1.4 Air Cooler Element HYUNDAI Mounting MAN B&W. 4. Push the air cooler element inwards approx. one metre. Remove the guide rails from the water inlet’ ‘outlet cover end of the air cooler housing. 2. Clean the frame around the air cooler element and the contact surface of the water inlet/outlet cover. Apply a thin layer of silicone paste to the frame around the air cooler element and the contact surface of the water inlet/outlet cover. Push the air cooler element fully into the air cooler housing. Shift the lifting tackles bsetween the two travelling trolleys to avoid damaging pipes, valves etc. Page 8 (9) When referring to this page, please quote Procedure M9101 Edition 0234HYUNDAI Air Cooler Element MAN B&W. Mounting 910-1.4 3, Mount and tighten all the screws of the water inlet/outlet cover. Remove the tackle and the lifting bracket from the water inlet/outlet cover. 4, Remove the guide rails from the reversing chamber end of the air cooler housing. 5. Mount the sealing plate, a new O-ring and the frame around the reversing chamber. 6. Mount the cooling water inlet and outlet pipes on the water inlet/outlet cover. 7. Close the drain cocks, and open the cooling water inlet and outlet valves. Note! Remember to vent trapped air from the air cooler element. When referring to this page, please quote Procedure M91001 Edition 0234 Page 9 (9)HYUNDAI Non-Return Valve 110-2 MAN B&W. Data SAFETY PRECAUTIONS X | Stopped engine X | Block the starting mechanism X_| Shut off starting air supply Engage tuning gear Shut off cooling water ‘Shut off fuel oil Shut off lubricating oll Lock turbocharger rotors Data Ref. Description Value] Unit When referring to this page, please quote Data D11002 Edition 0007 Page 1 (2)110-2 Non-Return Valve HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No.| Description Po1361 Combination wrenches Page 2 (2) When referring to this page, please quote Data D11002 Edition 0007HYUNDAI Non-Return Valve 910-2.3 MAN B&W. Overhaul The non-return valves are accessed from the scavenge air receiver. Note! ‘Access to the scavenge air receiver must not be attempted until the alr in the receiver is clean. Main Non-Return Valve 1. Inside the scavenge air receiver, lift up the valve flap of the vaive that is to be overhauled. 2, Remove the screws behind the valve flap. Remove the valve from the engine. 3. Remove the spring pin from the valve shaft and knock the valve shaft out of the valve flap. 4, For further dismantling, remove the two screws which hold the clamp and the support together as an assembly. Clean the valve shaft and the slide bearings inside the valve flaps. Lubricate the valve shaft and the slide bearings with molybdenum disulphide (MoS2). 5. Assemble the valve After the overhaul, it must be possible to move the vaive flap by the light touch of a finger. 6. Re-mount the valve in the scavenge air receiver. When refering to this page, please quote Procedure 910-23 Ealtion 0215 Page 1 (1)HYUNDAI Auxiliary Blower 110-3 MAN B&W Data SAFETY PRECAUTIONS X | Stopped engine X | Block the starting mechanism X | Shut off starting air supply Engage turning gear ‘Shut off cooling water ‘Shut off fuel oil ‘Shut off lubricating oit Lock turbocharger rotors Data Ref. Description 10-12 Electric motor, impeller and motorplate 610] kg When referring to this page, please quote Data 11003 Edition 0017 Page 1 (2)110-3 Auxiliary Blower HYUNDAI Data MAN B&W. The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate tem No.| Description 91356, Lifting tools, etc. 91361 Combination wrenches Page 2 (2) When referring to this page, please quote Data D11003 Edition 0017HYUNDAI Auxiliary Blower MAN B&W. ‘Overhaul 910-3.3 1. When cleaning and inspecting the auxiliary blower, disengage the cable connections to the blower motor. Wire ropes with shackle as well as two tackles suspended from mountings on the gallery bracket are to be hooked onto the blower flange, before removing the screw in the flange. 2, The end cover complete with blower can now be pulled free of the suction pipe by means of the two tackles. While pulling out the end cover with the blower assembly, make sure that the blower housing disengages from the air pipe without deforming it Then inspect and clean the blower wheel as well as the blower housing. For overhaul of blower wheel and bearings, see blower manufacturer's instructions. Note! Exercise care when mounting the electric motor with blower wheel, as the blower wheel is to “catch” the guide in the blower housing. poorer When referring to this page, please quote Procedure M91003 Edition 0278 Page 1 (1)HYUNDAI MAN B&W. Butterfly Valves Data 110-4 ‘SAFETY PRECAUTIONS X | Stopped engine X_| Block the starting mechanism X_| Shut off starting air supply Engage turning gear ‘Shut off cooling water Shut off fue! oil ‘Shut off lubricating oil Lock turbocharger rotors Description Value] Unit When referring to this page, please quote Data D11004 Edition 0004 Page 1 (2)110-4 Butterfly Valves HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate ttem No. | Description P91361 ‘Combination Wrenches. Page 2 (2) When referring to this page, please quote Data D11004 Edition 0004HYUNDAI Butterfly Valves 910-441 MAN B&W. Checking 1. Itis important that the automatic non-return | valves (butterfly valves) are always able to | function easily-and unimpeded. | | | The movability of the valve flaps should therefore be checked at suitable intervals. The valves shall open for the air flow from the scavenge air cooler housings to the auxiliary blowers. 2, Tocheck the valve, remove the cover on the top of the butterfly valve. Reach down through the opening in the top of the valve and move the vaive flaps. Comer 3. If the valve flaps in one of the butterfly valves cannot be moved by a light touch of a fingertip, it must be dismantled and overhauled, 4, Re-mount the cover on the top of the butterfly valve. When referring to this page, please quote Procedure M91004 Ecition 0207 Page 1 (1)HYUNDAI Turbocharger Turbine 110-5 MAN B&W. Data SAFETY PRECAUTIONS Standard Tools: See Section 913 Stopped engine Block the starting mechanism Shut off starting air supply Engage turning gear ‘Shut off cooling water Shut off fuel oil ‘Shut off tubricating oil Lock turbocharger rotors Data Ref. Desetstion Value Unit When referring to this page, please quote Data Sheet 110-6 Edition 03, Pago 1 (2)110-5 Turbocharger Turbine HYUNDAI Data MAN B&W. Spare Parts Plate — Rem No, Description ay Page 2 (2) ‘When referring to this page, please quote Data Sheet 110-5 Edition 03 page910-5.3 HYUNDAI Turbocharger Turbine MAN B&W For the turbocharger cleaning in detail, please refer to the manual for the turbocharger seperately provided. Page 1 (1)HYUNDAI MAN B&W Water Mist Catcher Data 110-6 Data SAFETY PRECAUTIONS X_| Stopped engine X | Block the starting mechanism X | Shut off starting air supply Engage tuning gear X_| Shut off cooling water Shut off fuel oi! Shut off lubricating oil Lock turbocharger rotors Ref. Description Value] Unit 10-11 Water mist catcher 180| kg When referring to this page, please quote Data D11006 Edition 0024 Page 1 (2)110-6 Water Mist Catcher HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No. | Description 91356 Lifting tools, etc. Page 2 (2) When referring to this page, please quote Data D11006 Edition 0024 geHYUNDAI Water Mist Catcher 910-6.2 MAN B&W. Dismantling 1. Normally it is not necessary to remove the water mist catcher from the scavenge air cooler housing, If, however, the water mist catcher has been fouled or damaged, it must be dismantled for cleaning or repair. 2. Dismantle the rectangular covers from both the front and aft ends of the scavenge air cooler housing. 3. Loosen the screws at both ends of the water mist catcher. Note! Note the position of the water mist catcher. During mounting, the water mist catcher must be re-mounted in the same position. 4, Pull or push the water mist catcher halfway ‘out and mount an eye bolt in the top of the water mist catcher. Hook a tackle on to the eye bolt and lift the water mist catcher away. Land it on a couple of wooden planks. Note! Take care not to damage the water mist catcher during the lift. 5. Clean the water mist catcher with the same cleaning fluid as used for the scavenge air cooler element. When referring to this page, please quote Procedure M91006 Edition 0219 Page 1 (2)HYUNDAI Water Mist Catcher 910-6.4 MAN B&W Mounting 4. Apply a thin layer of silicone paste to the frame of the water mist catcher on the side which will face away from the engine when the water mist catcher is mounted (the side ‘opposite to the screws). 2, Slide the water mist catcher into the scav- ‘enge air cooler housing. Note! Make sure to mount the water mist catcher correctly. The screws of the water mist catcher must face the exhaust side of the engine. When the water mist catcher is half-way in, remove the tackle and the eye bolt, and push the water mist catcher fully into the scavenge air cooler housing. 3. Tighten the screws at both ends of the water mist catcher. Apply a thin layer of silicone paste on the frame and mount the rectangular covers on the front and aft ends of the scavenge air cooler housing. —~ Toward Engine When referring to this page, please quote Procedure M9106 Edition 0219 Page 2 (2)HYUNDAI ler and Turbocharger Panel Plate 91051-13 MAN B&W. rine 9 ° 8 ° 9 ° ° ° ° °Plate 91051-13 Cooler and Turbocharger Panel Tem a MAN B&W No. fem pescueeen Standard No. o10 | Too! panel *) 021 Name plate 045, Lifting attachment 087 | Guide rail 069 | Guide rail 070 | Guide rail 082 Guide rail 212 | Pulling tool 224 | Eye bolt EN69R12 010- | *) Tool panel, complete 224 With tools *) Optional extrasHYUNDAI - -( MAN B&W Turbocharger System - Tools Plate P91061-0065 acct 5 aad G f 183 ofl When referring to this page, please quote Plate P91061 Edition 0065Plate P91061-0065 Turbocharger System - Tools pa Item Description i Item Description 146 | Blank plate (* 171 | Blank plate (* 183 | Throttle plate (* 195 | Throttle plate (* 205 | Blank plate (* 212 Pulling tool 218 ‘Screw 224 Eye bolt *) Exhaust gas system blanking-off tool. (Only when two or more TC, or Emergency By-pass, are fitted)HYUNDAI Relief Valve 141-2 MAN B&W Data SAFETY PRECAUTIONS For detailed sketch, see 900-2 X ] stopped engine Shut off starting air supply - At-starting air receiver Block the main starting valve Shut off starting ar distributor/cistributing system supply Shut off safety air supply — Not ME-engines ‘Shut off control air supply ‘Shut off air supply to exhaust valve — Only with stopped lubriating oil pumps Engage turning gear ‘Shut off cooling water X_| Shut off fuel of! ‘Stop lubricating oil supply Lock the turbocharger rotors Data Ref. Description Value | Unit When referring to this page, please quote Data D1 1102 Edition 0013, Page 1 (2)414-2 Relief Valve HYUNDAI Data MAN B&W The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate Item No. Page 2 (2) When referring to this page, please quote Date 011102 Edition 0013,HYUNDAI Relief Valve 911-2.1 MAN B&W. Checking 1. During running of the engine, check if there are any leaks. If @ leak occurs, replace the O-ring inside the relief valve. See separate instructions from the valve manufacturer. 2. If work involving risks of mechanical damage to the flame arrester has taken place, a visual inspection of the flame arrester should always be performed before starting the engine. ‘Check on the whole circumference that all the plates in the flame arrester are evenly distributed and that no local openings exist. If one or more plates in the flame arrester are damaged, the relief valve must be disassembled and the flame arrester replaced. See separate instructions from the valve manufacturer. Note! The complete flame arrester has to be replaced after a crankcase explosion. When referring to this page, please quote Procedure M91702 Edition 0217 Page 1(1)HYUNDAI MAN B&W Scavenge Air Receiver Safety Valve Data 111-3 ‘Stopped engine |x] x] x ‘Shut off fuel oil Data ‘SAFETY PRECAUTIONS Block the starting mechanism ‘Shut off starting air supply Engage turning gear Shut off cooling water Shut off lubricating oil X | Lock turbocharger rotors Description Value] Unit When referring to this page, please quote Data D11103 Edition 0001 Page 1 (2)‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Scavenge Air Receiver Safety Valve Data Plate ltem No. Description Page 2 (2) When referring to this page, please quote Data D11103 Edition 0001HYUNDAI Scavenge Air Receiver Safety Valve MAN B&W. Checking i The scavenge air receiver safety vaive is calibrated at the factory and does not require any adjustment. 2. Check the scavenge air receiver safety valve by loosening the counter nut and turn the forced opening screw to open the valve approx. 10 millimetres. Use a piece of cloth to wipe out any dirt from the O-ring packing and close the valve again. Tighten the counter nut. If this operation cannot be performed smoothly, the safety valve must be dismantled and cleaned. When referring to this page, please quote Procedure M91103 Edition 0001 Page 1 (6)911-3.2 Scavenge Air Receiver Safety Valve HYUNDAI Dismantling MAN B&W. 1. Dismount the safety valve from the scavenge air receiver. Page 2 (6) When referring to this page, please quote Procedure M91103 Edition 0001HYUNDAI Scavenge Air Receiver Safety Valve MAN B&W Overhaul 1, Remove the split pin. Unscrew the nut thereby relieving the spring tension. Remove the nut, spring retainer and washers. Keep count of the washers. Pull out the spring. 2. Pull out the valve flap with spindle. If the O- ring seal is damaged remove it without |p damaging the O-ring groove. & 3. Clean the metal surfaces thoroughly. le as When referring to this page, please quote Procedure M91103 Edition 0001 Page 8 (5)911-33 Scavenge Air Receiver Safety Valve HYUNDAI Overhaul MAN B&W a 4. If the O-ring seal has been removed mount ‘anew one using Locktite type AVX and Loc- i tite activator type T or similar. 5. Push inthe valve flap and spindle while taking care not to damage the O-ring seal. 6. Mount the spring, spring retainer and all the washers. Tighten the nut until the split pin can be mounted. 7. Check the valve according to 911-1.1. Page 465) When referring to this page, please quote Procedure M1103 Edition 0007HYUNDAI Scavenge Air Receiver Safety Valve 911-3.4 MAN B&W Mounting 1. Mount the safety valve on the scavenge air receiver, When referring to this page, please quote Procedure M91103 Edition 0001 Page 5 (5)HYUNDAI! Holding Down and End Chock Bolts 112-2 MAN B&W. Data SAFETY PRECAUTIONS [__] stopped engine |_| Block the starting mechanism |_| Shut off starting air supply |_| engage turning gear |_| Shut off cooting water |_| Shut off tuet oi |_| shut off tubricating ot [__] Lock turbocharger rotors Data Ref. Description Value] Unit 112.02 _| Check holding down bolts end end chock bolts for correct tightening after the following service hours: ‘st check 500] hours 2nd check 1000} hours 3rd check 2000) hours 4th check 4000| hours Sth check 8000] hours Subsequent checks at intervats of 8000) hours 113.01 _| Tightening pressure 1800| bar 13-02 | Dismanting pressure +1400-1650| bar When referting to this page, please quote Data D11202 Edition 0009 Page 1 (2)112-2 Holding Down and End Chock Bolts HYUNDAI Data MAN B&W. ‘The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate tem No.| Description P91263 Hydraulic tools for holding-down bolts Bolts and end chock bolts, epoxy P9135 10| Hydraulic pump, pneumatically operated | Page 2 (2) When referring to this page, please quote Data D11202 Edition 0009MAN B&W HYUNDAT Holding Down and End Chock Bolts Checking Note! The hydraulic jack used for tightening the holding down bolts is marked with: For: Holding down bolts The larger jack used for tightening the end chock bolts is marked with: For: End chock bolts Hydraulic tightening of holding down bolts and end chock bolts is carried out as detailed in Section 913-1. The normal tightening pressure is indicated on the Data sheet and is also stamped on the tightening tool. 912-2. When referring to this page, please quote Procedure M91202 Edition 0207 Page 1 (3)912-2. Holding Down and End Chock Bolts HYUNDAI Checking MAN B&W. 1. Checking the Bolt Tightening 1, The holding down bolts and end chock bolts must be checked for correct tightness at the intervals indicated on the Data sheet. For this purpose, raise the pressure on the hydraulic tool siowly while constantly attempting to loosen the nut with the tommy bar. The oli pressure indicated on the pressure gauge when the nut comes loose (loosening pressure’) is to be noted down in the checking table, see drawing Nos. 782225-0 and 782226-2, following which the bolts are tightened to the normal tightening pressure. The condition of the bolted joints, and thus the general condition of the foundation, can be effectively checked by comparing the tables from successive bolt checks. If the ‘loosening pressure’ is below 80 per cent of the tightening pressure, the relative chocks shall always be checked for possible defects. if the chocks are in position and in order, the bolts should be taken out for inspection of threads and contact faces. eeaaIEeT Checking of Epoxy Supporting Chocks 2, if a number of measuring pins have been welded to the tanktop, the heights of the epoxy supporting chocks are to be checked immediately after finishing the checking of the loosening pressures of the holding down bolts and the retightening of these. The distance between the measuring pins and the bedplate is to be measured with a blade gauge and noted down. Any possible setiling of the chocks during the intervals between measurements can thereby be followed. Page 2(3) When referring to this page, please quote Procedure M91202 Edition 0207HYUNDAI MAN B&W Side Chocks and Side Chock Liners 3. Alter fitting the liners to an 80 per cent contact area on both sides of the liners, knock the liners a further 3 to 4 mm inwards. The liners located in way of each main bearing on either side of the engine must be fitted and knocked into position simulta~ neously. The first time the ship is sailing in a fully- loaded condition after the engine has been operating for 1,000 hours, all side chocks should be checked to see whether the liners can be knocked further inward. The fit of the side chock liners should be checked with a feeler gauge each time the loosening pressure of the holding down bolts is checked, and thus at the same time intervals. The feeler gauge is applied at the 7 points indicated on drawing No. 782226-2, and the measurements found are to be entered in the relevant table. These results are used to determine whether refitting or, possibly, replacement of the liners is necessary. If the measurements at 3 points or more have increased 5/100 mm or more from the initial results, we recommend that the following procedure is followed: 1. Loosen the hexagon screws. 2. Try to knock the liner further inward. 3. Measure again at the 7 points indicated on drawing No. 782226-2, If this procedure does not improve the situation, the liner must be removed, and it must be checked that the actual contact area is more than 80 per cent of the possible contact surface areas on both sides of the liner. The liners are secured in their correct position by means of hexagon socket set screws with cup point. Holding Down and End Chock Bolts Checking 912-24 When referring to this page, please quote Procedure M91202 Edition 0207 Page 3 (2)HYUNDAI Checking Hydraulically Tightened Holding Down Bolts MAN B&W MC Engines Drug. 782225-0 Port side Cylinder| Starboard side ‘pressure | % dev. |remarks | No. [pressure | % dev. remarksChecking Side Chocks and End Chocks with Bolts HYUNDAI Drwg. 782226-2 _MC Engines MAN B&W. Port side Starboard side ee Point a Point Ie wrlATBleldlelt lal wm |Al Ble [4lelt]al|™ 1 7 1 2 2D 2 3 3 a 3 4 5 5 6 6 Ti 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 FORE A, B-— AB LJ eas Aaah SS t ° i | — edetg—/\7 2 ~ oe (tL caets Port side H Starboard side Ch jBott| Eure” | Ser Point Point [Dev | S37é° | Bott| Ch No.|No.|*92"°| "se [aTB[e]a]el|albl eae] % [bar | No.|Noy 1 1 Ely | aE b c d d c b Fo——05 =o—o5 sor oot — = No. 2 Contact face No. 1 No.2 rT. ! T 2 8 art gsHYUNDAI MAN B&W Data Stay Bolts Data SAFETY PRECAUTIONS X_| Stopped engine X_| Block the starting mechanism X_| Shut off starting ait supply Engage turning gear Shut off cooling water Shut off fuel oil Shut off lubricating oil Lock turbocharger rotors 112-3 Ref. Description Value] Unit D12.04 | p13.01 | 13-02 Check measurement (Before tightening of STAY BOLTS) Hydraulic pressure, mounting Hydraulic pressure, dismantling 18043 | mm 1500 1400-1650 gg When referring to this page, please quote Data D11203 Edition 0018 Page 1 (2)Stay Bolts HYUNDAI Data MAN B&W. The task-specific tools used in this procedure are shown on the plates at the end of this chapter or in the chapters indicated by the first three digits in the plate number, e.g. P90951 refers to chapter 909. Plate tom No. | Description 91354 10 | Hydraulic pump, pneumatically operated 91351 | 48_| Hose with unions (1500 mm), complete P91351 58 | Hose with unions (3000 mm), complete 91361 105 | 3.way distributor block, complete 91261 011 | Hydraulic jack, complete Page 2 (2) When referring to this page, please quote Data D11203 Edition 0018HYUNDAI Stay Bolts 9123.4 MAN B&W Checking 1. This check can be performed during several | periods of stopped engine, but must be per- ‘One Group formed on complete twin stay bolt groups at ‘One Group a time, thereby ensuring uniform tension in the affected bearings. Note! The first time this check is performed it has to be completed in one operation. The following checks have to be completed within a 500-hour period. 2. Before retightening the stay bolts, remove the protective caps. 3. Check for loose staybolt nuts with the tommy bar. 2 If a loose nut is found, unscrew the nut until a gap occurs between cylinder frame and eS to oS Loosen and unscrew the nut on the oppo- |g site stay bolt. eee creer Check for the correct mounting of the stay bolt by comparing with the check measurement on the Data Sheet. 3. D13-02 If the check measurement is not reached, indicating that the stay bolt is not screwed properly down in the thread of the bedplate, | 49 9, apply a screw and a counternut in the | thread in the top of the stay bolt, and turn the stay bolt until the check measurement [3 data is met. 3 3 4. Retighten the stay bolts in pairs (athwartship), working from fore to aft of the engine. When referring to this page, please quote Procedure M91203 Edition 0212 Page 1 (2)912-31 Stay Bolts HYUNDAI Checking MAN B&W Ee eee eee eee | 5 eee 5. Clean the contact faces and mount the hydraulic tools on a pair of stay bolts positioned opposite each other. Connect the high-pressure pump by means of the high-pressure hoses, so that the two stay bolts are tightened in one operation. 6. Maintain the mounting pressure, and retighten the stay bolt nuts with a tommy bar. Before relieving the system of pressure, check with a feeler gauge that the nuts bear against their contact faces. 7. When all stay bolts have been retightened, reconnect the hydraulic tools to the pair of | stay bolts first tightened. Tighten to 10% below the mounting pressure and check whether the nut is loose. If the nut is not loose: Tighten the stay bolts concerned to the mounting pressure. If the nut is loose: Tighten all stay bolts once again to the O mounting pressure. 8. After completing the retightening procedure, mount the protective caps. N ‘Y, Page 2 (2) When referring fo this page, please quote Procedure M91203 Edition 0212HYUNDAI Crankcase Oil Outlet 9125.4 MAN B&W Checking The crankcase cil outlets guide the lubricating il from the crankcase to the lubricating oil bottom tank. The sealings of the crankcase oil ‘outlets must be checked at regular intervals, for example during dockings. The crankcase oil outlets may be equipped with either rubber diaphragm sealing or metal bellow sealing. — | Note! If the water content of the main engine lube oil is rising, this may indicate that the crankcase oil outlet sealings are frac tured. Rubber diaphragm sealing 1. To access the rubber diaphragm sealing remove: Screws A Grating B Screws C Cover plate D Screws E Steel ring F 2. Lift away the rubber sealing diaphragms G and examine each diaphragm closely. In case of any rips or tears in the diaphragms, they must be replaced. Note! It is strongly recommended to always replace the diaphragms during inspection. unavailable, new diaphragms may be made from three layers of 2 mm thick oil and temperature resistant rubber. 3. Mount: Rubber sealing diaphragms G Steel ring F Screws E Cover plate D Screws C Grating B Screws A. Note! Remember to fit new locking plates at screws A. [woaseaanTeat TERE ROTO Wihen referring to this page, please quote Procedure M91205 Edition 0207 Page 1 (2)HYUNDAI MAN B&W Crankcase Oil Outlet Checking 912-54 Metal bellow sealing 4, Remove all screws A and grating B. 5. Remount four of the screws A at diametrically opposite positions. 6. Remove: Screws C Cover plate D Screws E. E 7. Lift away metal bellow sealing F and exam- G ine it closely. If any cracks or punctures are |g found in the motal below sealing, it must |p be replaced. B LH 2 Note! = itis recommended to always replace the | | 7. metal bellow sealing during inspection. 8. Replace gaskets G and H. 8. Mount metal bellow sealing F 10. Mount: Screws E Cover plate D Screws C. 11, Remove the four screws A. 12, Mount grating B. 18. Mount all screws A. TOTES inen referring to this page, please quote Procedure 491205 Edition 0201 Page 2 (2)HYUNDAI MAN B&W. Large Parts - Tools Plate P91261-0073 SKK OC RARM SS When referring to this page, please quote Plate P91261 Edition 0073Plate P91261-0073 Large Parts - Tools Item Item ; No. Item Description No. Item Description 011 | Hydraulic jack, complete 023 | Sealing ring with back-up ring 035 | Sealing ring with back-up ring 047 | Stud setter 059 | Support 072 | Hydraulic tool set, complete 237 | Spanner 345 | Tommy barHydraulic Tools - End Chock Bolts Plate HYUNDAI MAN B&W (Epoxy Chocks) 91266-0001 eee en Heed eed 144 237 porsst When referring to this page, please quote Plate P91266 Ealtion 0001Plate P91266-0001 Hydraulic Tools - End Chock Bolts (Epoxy Chocks) 1 a Item Description fem | Item Description 097 } O-ring with back-up ring 107 | O-ring with back-up ring +19 | Support 120 | Hydraulic jack, complete 144 | Stee! box 237 Spanner 345 Tommy barMAN B&W HYUNDAI Hydraulic Tools 913-1 . Snap-on coupling . Tool attachment thread Bleed screw Piston . Cylinder Sealing rings Spacer ring |. Tommy bar Nut Stud or bolt . Extension stud Lifting too! S. Clearance U. Milled recess for feeler gauge FASS reOmmgo0D> Studs or bolts provided with threads for attach ing hydraulic tools and with circular nuts must only be loosened and tightened up by means of the hydraulic tools supplied. The jack(s) is/are connected, via a distributor block, to a high-pressure pump, which Is set to deliver hydraulic oil at the pressure indicated on the jack and on the data sheet in the relevant section of this instruction book. The stud or bolt concerned is thereby lengthened relative to the cil pressure applied and the piston area, and the nut can be loosened or tightened, as required, with the aid of a tommy bar. The jacks must never be overloaded or exposed to blows or impacts. They are marked with a “Max. lift’, which must not be exceeded. 1. The hydraulic tools, except those for the main bearings and the cylinder cover, consist of a jack with an internal thread to suit the tool attachment thread on the stud or bolt, and a spacer ring which is to be placed under the jack and around the nut that is to be loosened or tightened. 2. For the main bearings, the hydraulic tool consists of a double jack with two extension studs. This jack is designed for the simulta- neous dismantling of both nuts on one side of the main bearing. When referring to this page, please quote Procedure M91301 Edition 0210 Page 1 (12)913-1 Tools HYUNDAI MAN B&W For the cylinder cover, the hydraulic tool consists of eight individual jacks suspended from a common lifting tool. A spacer ring is mounted below each jack using two spring pins. Operation of the cylinder cover jacks is identical to the operation of the single hydraulic jacks. The hydraulic jacks are so designed that, in the event that the "Max. lft’ limit is exceeded, the pressure is relieved at the bottom of the pressure chamber and the oil will be pressed out into the space between the stud and the spacer ring When the pressure is relieved in this way, the lowermost sealing ring will in most cases be damaged. Therefore inspect and, if necessary, replace this sealing ring The oil used must be pure hydraulic oil or turbine oil (with a viscosity of about SAE 20). Oils such as, for instance, lubricating oil (system oil) or cylinder lubricating oil must not be used, as these oils are normally alkaline and can thus damage the back- up rings. The following instructions must be closely followed to prevent accidents or damage, and after use the jacks should be cleaned and kept in the wooden boxes supplied. Warning! Eye protectors and gloves must be used when using hydraulic tools. Page 2 (12) When referring to this page, please quote Procedure M91301 Edition 0210HYUNDAI Hydraulic Tools MAN B&W Loosening of Nut 913-1 Single Hydraulic Jack 1. Carefully clean the tool attachment thread, the nut and the surrounding parts. Grease the tool attachment thread with molybdenum disulphide grease or with graph- He and oll or similar. Place the spacer ring around the nut in such a position that the tommy bar can be applied through the slot when the nut is to be loosened. 2. Screw the jack on to the tool attachment thread of the bolt/stud, until the cylinder of ‘the jack bears firmly against the spacer ring. ‘Screw back the jack a number of turns, according to the table shown on the sketch, to produce a clearance between the jack and the spacer ring. The clearance between the jack and spacer ring ensures dismantling of the jack after loosening the nut. ‘When loosening nuts on very long bolts (e.g. staybolts) it is recommended to unscrew the jack an additional half turn. Connect the hydraulic jack, the distributor block and the high pressure pump by means of high pressure hoses. Loosen the bleed screw in the jack and fill up the system with oll until oil without bubbles, flows out of the bleed hole. Then tighten the bleed screw again After adjustment, check that the parts are guided correctly together and that there is no clearance between the piston and cylin= der of the jack. MoS, When referring to this page, please quote Procedure M91301 Edition 0210 Page 3 (12)913-1 Hydraulic Tools HYUNDAI Loosening of Nut MAN B&W 3. Increase the oil pressure to the prescribed value. If the nut does not come loose, the pressure may be increased by approx. 150 bar. 4. Unscrew the nut with the tommy bar, making sure that the nut is not screwed up | __ against the jack, 5. Relieve the system of pressure, disconnect the high-pressure pump, and remove the hydraulic tools, Note! Make sure not to exceed the “max lift” stamped on the jack. (earn Page 4 (12) When referring to this page, please quote Procedure M91301 Edition 0210HYUNDAI Hydraulic Tools MAN B&W. Loosening of Nut Double Hydraulic Jack 6. Carefully clean the tool attachment threads, the main bearing studs, the nuts and the surrounding parts, Grease the tool attachment threads with molybdenum disulphide grease or graphite and oll or similar. Mount the extension studs on the main bearing studs. Using the lifting tool, place the spacer ring over the extension studs in such a position that the tommy bar can be applied through the slots for the purpose of loosening the nuts, Press the pistons and the cylinder of both the hydraulic jacks firmly together. Mount the two jacks (one by one using the lifting tool) over the extension studs and land them on the spacer ring. Make sure that both the cylinders of the jacks and the spacer ring are guided correctly together. 7. Screw the upper nuts on to the threads of the extension studs until the cylinders of the jacks bear firmly against each other and against the spacer ring. 913-1 (swore When referring to this page, please quote Procedure M91301 Edition 0210 Page 5 (12)913-4 Hydraulic Tools HYUNDAI Loosening of Nut MAN B&W 8. The clearance between the pistons and the cylinder of the top jack is adjusted by unscrewing the upper nuts 1 turn = 3 mm. The clearance between the jack and spacer ring ensures dismounting of the jack after = loosening the nut. 3 Connect the hydraulic jacks, the distributor block and the high pressure pump by means of high pressure hoses Loosen the bleed screws in both jacks, and fill up the system with oil until oil, without bubbles, flows out of the bleed holes. Re-tighten the bleed screws. Increase the oil pressure to the prescribed value. If the nut does not come loose, the pressure may be increased by approx. 150 bar. wentzan \N 10, Unscrew the lower nuts 1% tums with the tommy bar, making sure that the nuts are not screwed up against the extension stud. NRK, 4 Pee 11. Relieve the system of pressure, disconnect the high-pressure pump, and remove the hydraulic tools. Sis Note! Make sure not to exceed the “max lift” stamped on the jack. \ Page 6 (12) When referring to this page, please quote Procedure M91301 Edition 0210HYUNDAI Hydraulic Tools MAN B&W. Tightening of Nut 913-1 Single Hydraulic Jack 4. Thoroughly clean the nut, the thread, the contact faces, and the surrounding parts. Clean and lubricate the tool attachment thread and the thread in the nut with molybdenum disulphide grease or with graphite and oil or similar. Fit the round nut on the thread and tighten it with the tommy bar. Check with a feeler gauge that the contact face of the nut bears on the entire circumference, Place the spacer ring around the nut in such a position that the tommy bar can be applied through the slot for the purpose of tightening the nut. Press the piston and the cylinder of the jack firmly together. ‘Screw the hydraulic jack on to the tool attachment thread. Make sure that the cylinder of the jack bears firmly against the spacer ring and that the parts are guided correctly together Connect the hydraulic jack, the distributor biock and the high-pressure pump by means of high-pressure hoses. Loosen the bleed screw in the jack and fill up the system with oil, until oil without bubbles flows out of the bleed hole. Re-tighten the bleed screw. When referring to this page, please quote Procedure M91301 Edition 0210 Page 7 (12)913-1 Hydraulic Tools HYUNDAI _Tightening of Nut MAN B&W Coorg 3. Increase the oll pressure to the prescribed value, and tighten the nut by means of the tommy bar applied through the slot of the spacer ring 4. While maintaining the pressure, check with a feeler gauge introduced through the recess at the bottom of the spacer ring that the nut bears against the contact face. 5. Relieve the system of pressure, disconnect the pump, and remove the hydraulic jack. 6. When new studs, bolts or nuts are tightened for the first time, do not remove the jacks, but loosen the nut as described under ‘Loosening’, points 6-7-8, and then tighten the nut again according to the procedure under ‘Tightening’, points 17-18-19. Page 8 (12) When referring to this page, please quote Procedure M91301 Edition 0210HYUNDAI Hydraulic Tools 913-1 MAN B&W. Tightening of Nut Double Hydraulic Jack i 7. Thoroughly clean the nuts, the threads on the main bearing studs, the contact faces, and the surrounding parts. Clean and lubricate the tool attachment thread and the threads in the nuts with molybdenum disulphide grease or with graphite and oil Fit the round nuts on the threads and tighten them with the tommy bar. Check with a feeler gauge that the contact faces of the nuts bear on the entire circumference. Mount the extension studs on the main bearing studs, Using the lifting tool, place the spacer ring over the extension studs in such a position that the tommy bar can be applied through the slots for the purpose of tightening the nuts, 8. Press the piston and the cylinder of both the hydraulic jacks firmly together. ‘Mount the two jacks (one by one using the lifting tool) over the extension studs and land them on the spacer ring. Make sure that both the cylinders of the jacks and the spacer ring are guided correctly together. ‘Screw the upper nuts on to the threads of the extension studs until the cylinders of the jacks bear firmly against each other and against the spacer ring 9. Connect the hydraulic jacks, the distributor block and the high pressure pump by means of high pressure hoses. Loosen the bleed screws in both jacks, and fill up the system with oi until oil, without bubbles, flows out of the bleed holes. Re-tighten the bleed screws. When referring to this page, please quote Procedure M91301 Edition 0210 Page 9 (12)913-1 Hydraulic Tools HYUNDAI Tightening of Nut MAN B&W eT 10. Increase the oil pressure to the prescribed value, and tighten the nuts by means of the tommy bar applied through the slots of the spacer ring. 11. While maintaining the pressure, check with a fecler gauge introduced through the re- cesses at the bottom of the spacer ring that the nuts bear against the contact face. 12, Relieve the system of pressure, disconnect the pump, and remove the hydraulic tools. 13. When new studs, bolts or nuts are tightened for the first time, do not remove the jacks, but loosen the nuts as described under ‘Loosening’, points 12-13-14, and then tighten the nuts again according to the procedure under ‘Tightening’, points 24-25-26. Page 10 (12) When referring to this page, please quote Procedure M91301 Edition 0210HYUNDAI Hydraulic Tools 913-4 MAN B&W. Maintenance 4. The hydraulic jacks require no maintenance except replacement of defective sealing rings, each of which consists of an O-ring and a back-up ring fitted in ring grooves in the piston and cylinder. The piston and cylinder are easily separated by taking out the bleed screw and pressing the parts apart with the help of compressed air. Warning! Aways use protective gloves and eye protection when working with compressed air. Make sure that there are no marks or scratches on the sliding surfaces of the parts. The presence of metal particles will damage the sealing rings. Keep the sliding surfaces and threads coated with acid-free grease or molybdenum disulphide grease. 2. The pistons and cylinders of the double jacks are separated in the same easy way as described for the single jack. TS When referring to this page, please quote Procedure M91301 Edition 0210 Page 11 (12)Hydraulic Tools HYUNDAI Maintenance MAN B&W 3. When changing the sealing rings, first mount the back-up ring and then the O-ring, Note! Note that the back-up ring (1) must be away from the pressure chamber and the O-ring (2) close to the pressure chamber. See the sketch for the correct mounting of both the upper and the lower sealing rings. The same principle applies to all the jacks. 4. After fitting the sealing rings, coat the piston and cylinder with molybdenum disulphide grease and press the piston and cylinder together. See that the rings do not get stuck between the piston and cylinder. Page 12 (12) When referring to this page, please quote Procedure M91301 Edition 0210HYUNDAI Standard Tightening Torques 913-4 MAN B&W When tightening screws or nuts for which no torque is specified in the instruction procedure or the related data sheet, the standard torques specified in this procedure are to be applied. 1. Standard screws and nuts lubricated witha 4, Screws and Nuts with Gam Lock Washer Mia4__[| 90Nm || M30 | 1000Nm M16 | 150Nm || M33 | 1250Nm mis [2i0Nm || Mae | 1700Nm ™20_|290Nm || M39 | 2200Nm Molybdenum Disulphide (MoS,) based Iu- ; - bricant Thread [Tightening] Thread | Tightening ; torque torque Thread [Tightening] Thread [Tightening] ie] 20NNm | M33 | 1500 Nm torque torque m0 | 40Nm ||_Ma6_| 1900Nm Ma Ere tt2 Nin iP T Meer EA00 en Mi2_|_70Nm || _M39_| 2500Nm AiO ESS Nene eee m4_[110Nm ||_Ma2_| $100 Nm eer E60 Nm Ewer Sine Mié_| 165Nm || _Ma5_[ 4000 Nm Mia oo nem {i/EE Madr [260 Ney Mie | 230Nm || _Mas_| 4700 Nm WAG | 735Nm ||_M33_| 1200 Nm Rees HEE canes bre 100 fem thee [1660 Na M22__|470Nm | _MS6_| 6000 Nm MeOE [-2e0.Cim_t/E MseLele10onn we4 | 650Nm | __M60_| 7100 Nm 2. Seltiocking nuts. w27 | 800 Nv || M64] 8500 Nm Senin ™m30_[100Nm Thread [Tightening] Thread Tightening torque torque 2 nie_| 20Nm | M22 | 430Nm io | 40Nm || M24 _| 490Nm — wiz | _60Nm || _M27_|_650Nm i 3. Screws and nuts locked with glue/Lostite. Thread JTightening] Thread [Tightening] torque torque we | 23Nm || M22 | 580Nm Mio | 50Nm || M24 | 680Nm mi2__|_70Nm || M27 | 900Nm mia__[115Nm || M30_[7350Nm Mié | 190Nm || ma3_[1700Nm mia | 270Nm || 36 | 2350Nm M20 | 380Nm ff M39 | 3000 Nm When referring to this page, please quote Procedure M91304 Edition 0201 Page 1 (1)MAN B&W HYUNDAI Torque Spanner 913-5 Before screwing the nuts on, the threads and the contact faces should be greased with a mixture of graphite and oil or molyddenum disulphide with a friction coefficient y= 0.1-0.12 (e.g. MOLYKOTE paste type G). The nuts should fit easily on the thread, and it should be checked that they bear on the entire contact face. In the case of new nuts and studs, the nuts are to be tightened and loosened two or three times, 80 that the thread may assume its definite shape; thus obviating the risk of loose nuts. Nuts secured with a split pin are to be tightened to the stated torque and then to the next split- pin hole. The torque spanner must not be used for torques higher than those stamped on it, and it must not be damaged by hammering on it or the Tike. Rahsol Torque Spanner The handle of the torque spanner is provided with a scale indicating the torques at which the spanner can be set. For setting the spanner at the required torque, there is a ball on a small arm at the end of the handle. ‘When the ball is pulled, a small crank handle appears. A spring-loaded slide in the handle is provided with a mark which, when the crank handle is turned, can be set at the required torque on the scale. The torque spanner works as follows: The above-mentioned spring acts ona pawl system in the handle. When the pre-set torque has been reached, the pawl system is released, at which moment a small jerk is felt in the spanner, and a small click is heard. When the torque spanner is not in use, the spring inside should be released by adjusting to minimum torque. C Se When referring to this page, please quote Procedure M91305 Edition 0205 Page 1(1)HYUNDAI MAN B&W Tightening Gauge 913-6 Proparations Before screwing on the nuts, grease the threads and the contact faces with a mixture of graphite and oil or molybdenum disulphide with a friction coefficient. b= 0.1-0.12 (e.g. MOLYKOTE paste type G) The nuts should fit easily on the thread, and it should be checked that they bear on the entire contact face. Pre-tightening with a torque spanner Before tightening the nits according to a tightening gauge or tightening angle, they must be pre-tightened with a torque spanner. See Procedure 913-5. Apply a pre-tightening torque of: ~ thread M8 ~ M20 = 50 Nm ~ thread M22 — M27 = 100 Nm. — thread M30 - M39 = 150 Nm ~ thread M42 - M48 = 200 Nm This is in order to ensure a uniform basis for the subsequent tightening with gauge or tightening angle. Tightening with a tightening gauge ‘After pre-tightening, place the tightening gauge round the nut, and mark off with chalk on the nut at siot A on the tightening gauge, and make another chalk mark on the contact face at slot B. Then tighten the nut until the two chalk marks coincide. Tightening without a tightening gauge For tightening angles of e.g. 30°-45° and 60°, we usually do not deliver a tightening gauge. Therefore, after pre-tightening, mark the angle on a corner of the nut and on the contact face, respectively. Then tighten the nut until the two marks coincide. When tightening new studs or bolts for the first time, loosen again and repeat the procedure — including pre-tightening with a torque spanner, to allow the parts to settle. See Procedure 913-6. ‘ When referring to this page, please quote Procedure M91306 Edition 0205 Page 1 (1)HYUNDAI Screws and Nuts 913-74 MAN B&W. Locking Some screwed and bolted connections on the engine, as well as some movable joints, are secured against untimely loosening by means of different types of locking devices, ‘When reassembling the engine after overhauls, itis vital that all such screws and nuts are again locked correctly Note! Make sure only to mount locking devices ‘on nuts and screws which have been mounted with locking devices by the engine manufacturer, 1, Lock washers, tab washers, locking plates, etc., must always be replaced. The tab-like projections, etc., on the washers are to be bent back over one of the flats of the screw or nut concerned. 2, Used spring washers must be replaced. 3.- Self-locking nuts may only be used five times. Therefore, give the nut a centre punch mark each time it is loosened To tighten a self-locking nut to a specific torque, first measure the torque required to turn the nut itself, and then add this torque to the torque value stated on the data sheet of a procedure. Kg TTT TROT RTE TOTS When referring to this page, please quote Procedure M91307 Edition 0207 Page 1 (4)Screws and Nuts HYUNDAI Locking MAN B&W Locking wire should be fitted after the screws or nuts have been tightened to the correct torque. Do not overtighten or loosen the units to get a correct alignment of the wire holes. Al- ways fit new wire ater tightening-up the units. Any tendency of the screws or nuts to loosen will be counteracted by a tightening of the locking wire. Do not secure more than four units in a series, unless otherwise specified. Fig. 1: Insert wire, grasp the upper end of the wire and bend it around the head of the screw, then under the other end of the wire, be sure that the wire is tight around the head. Fig. 2: Twist the wire clockwise until it is just short of the hole in the second screw. Keeping the wire under tension, twist it until tight. When the wire is tight, the wire shall have approximately 7-10 twists per 25 mm, One twist is a twist of the wires through an arc of 180°, equal to half of a complete turn Fig. 3: Insert the uppermost wire in the second screw, and pul it tight. TOT Fig. 4: Bend the lower wire around the screw, and under the end protruding from the screw. Fig. 5: Keeping the wire under tension, twist it min. 3 twists, counterclockwise until tight Fig. 6: During the final twisting motion, bend the wire along the screw head. Cut off excess wire. Fig. 7-9: Show the preferred ways of mounting the locking wire on screws with wire holes ori- ented in different angles. aT Page 2 (4) Vihen referring to this page, please quote Procedure M91307 Ealtion 0207HYUNDAI Screws and Nuts MAN B&W. Locking 913-7.1 Fig. 10: Shows how to route the locking wire on screws in different planes. Fig. 11: Wire that passes over the top of a nut is an acceptable alternative only if it routes around the protruding screw thread. Fig, 12: Wire that passes over the top of a nut is also an acceptable alternative if the hole is located as shown in the figure. Fig. 13: Where driling of locking wire holes has caused a thin wall section, route the wire as shown in the figure, to prevent damage to the rut. Fig. 14: Locking wire can be mounted to any other part of the assembly if nothing else is possible, NOTSOT-TOOTOE Fig. 10 f Fig. ‘f Fig. 14 7 Fig. 14 é “9 When referring to this page, please quote Procedure M91307 Edition 0207 Page 3 (4)913-7.4 Screws and Nuts. HYUNDAI Locking MAN B&W. Cam Lock Washers with rising cams on one Fig. 15 side and radial teeth on the other. Fig. 18: The washers are installed in pairs, cam pSeereee face to cam face. When the bolt and/or nut is tightened the teeth grip and seat the mating surfaces, The cam lock washer is locked in piace, allowing movement only across the face of the cams. Any attempt from the bolt/nut to rotate loose Is blocked by the wedge effect og the cams. Fig. 16: Different uses of the cam lock wash- iz ers. E Fig. 17: Don not use the cam lock washers in e | conjunction with other loose washers. Fig. 16 | Cam lock washers must be installed in | pairs and are not to be substituted by other typers of washers. WSIS ATCT Fig. 17 WTO EATOT Page 4 (4) When referring to this page, please quote Procedure M91307 Edition 0207 98HYUNDAI Lubrica' MAN B&W Molybdenum Disulphide (MoS2) The following procedure is to be followed prior to the mounting of metal surfaced parts which are to function as seals. Clean the surface with a cleaning fluid and ensure that the entire surface is completely free of grease. Allow 5 minutes for the cleaning fluid to evaporate. With a clean leathercioth, and using circular movements, rub a mixture of fine- grained particles of Molybdenum Disul- hide (MoS) and mineral oil (e.g. Moly- cote G-n Plus, or the like) hard onto the metal surface. Remove any excessive paste and ensure that the metal surface is only coated with a thin, uniform, layer of the above mixture. Protect the wet paste and cloth from dust or other foreign particles, g Procedures 913-11 When referring to this page, please quote Procedure M91311 Edition 0204 Page 1 (1)HYUNDAI MAN B&W. Working Pressure 1500 bar ao _ Accessories for Hydraulic Tools (1500 am) (3000 mm) (5000 mm) Plate P91351-0037 When referring to this page, please quote Plate P91351 Edition 0097Plate P91351-0037 Accessories for Hydraulic Tools a Item Description vm Item Description 010 | Hydralic pump, pneumatic operated 022] Hydralic pump, and operated 046 Hose with unions (1500mm), complete 058 Hose with unions (3000mm), complete 060 | Hose with unions (600mm), complete 105 | 3-way distributor block, complete 17, 5-way distributor block, complete 130 9-way distributor block, complete 154 Conical valve, 0 - 15 1466 | Angle union 201 | Quick coupling, male 213 | Quick coupling, female 225 Disc, round-plain, Cu o11x3mm_ 237 Bleeder screw 249 | Disc, round-plain, Fe 011x9mm.HYUNDAI Lifting Tools, Etc. Plate P91356-0053 MAN B&W Item ]Stze Tren [Size 020 | mto 114 | mio ost | m2 126 | wre 043 | m6 138 | mie 08s | 20 +40 | a0 067 | M24 454 | M24 079 | M30 163 | mao Tien | Mex.Leod tio’ Stat eHebel tee] Noy; ees 22} 1000 222, 295 3000 234} 2000 260 | 5000 305 | 6.0 asnase oD When referring to this page, please quote Plate P91350 Edition 0053Plate P91356-0053 Lifting Tools, Etc. wom tem Description ttem item Description 020 | Forged-bent screw shackle, 1omm 031 | Forged-bent screw shackle, 12mm 043 | Forged-bent screw shackle, 16mm 055 | Forged-bent screw shackle, 20mm 067 | Forged-bent screw shackle, 24mm 079 | Forged-bent screw shackle, 30mm 114 | Lifting eye bolts, 10mm 126 | Lifting eye bolts, 12mm 138 | Lifting eye bolts, 16mm 140 | Lifting eye bolts, 20mm 151 | Lifting eye bolts, 24mm 163 | Lifting eye bolts, 30mm 210 | Chain tackle, 500kg 222 | Chain tackle, 1000kg 234 | Chain tackle, 2000kg 260 | Chain tackle, 5000kg 295 | Pull lift, 3000kg 305 | Wire rope, 6mHYUNDAI MAN B&W. Open Ended Spanners Plate P91357-0007 Item| Size (mm) O13 65 | 037 75 O47 80 050 85 062 390 When referring to this page, please quote Plate P91357 Ealtion 0007Plate P91357-0007 Open Ended Spanners Item No. Item No. Item Description Item Description 013 | Open-ended spanner, size NV65mm 037 | Open-ended spanner, size NV7Smm 047 | Open-ended spanner, size NV80mm 050 | Open-ended spanner, size NV85mm 062 | Open-ended spanner, size NV9OmmHYUNDAI MAN B&W Open-Ended Slugging Spanners Item Size 164 85 Plate P91358-0014 When referring to this page, please quote Plate P91958 Edition 0074Plate P91358-0014 Open-Ended Slugging Spanners Item No. Item Description Item No. Item Description 164 | Open-ended slugging spanner, size NVé5mmHYUNDAI MAN B&W Torque Spanners Plate P91359-0003 Tten | Terave he) ora | 8-40 ——> a tee rately CO ase (om) 026 | 12.5710 Item | Torque (Nm) 038 | 40-200 Item | Torque (Nm) 040 | 140-760 omni == Teen | Tepay ost | 750-2000 When referring to this page, please quote Plate P91359 Edition 0003Plate P91359-0003 Torque Spanners Item Item Fare No. Item Description No. Item Description 014 | Torque wrench, 8 - 40Nm 026 | Adapter for socket wrench, 10 x 12.5, mm 038 | Torque wrench, 40 - 200Nm 040 | Torque wrench, 140 - 760Nm. 051 | Torque wrench, 750 - 2000NmHYUNDAI Pii MAN B&W jiers Plate P91360-0004 ren | 8535 O10 0.9 balla os fe os | 23 ; ost | 3.2 ie j Item | Size fsa a> — 128 1 oo 30) 1.8 vat | 2s vss | 3.2 When referring to this page, please quote Plate P91360 Ealtion 0004Plate P91360-0004 Pliers ea Item Description Nal Item Description 010 | Pliers for retaining ring, size 0.9mm 021 Pliers for retaining ring, size 1.3mm 033 | Pliers for retaining ring, size 1.8mm 045 | Pliers for retaining ring, size 2.3mm 087 | Pliers for retaining ring, size 3.2mm 128 | Pliers for retaining ring, size 1.1mm 130 | Pliers for retaining ring, size 1.8mm 141 | Pliers for retaining ring, size 2.3mm 163 | Pliers for retaining ring, size 3.2mmHYUNDAI inati MAN B&W Combination Spanners Plate P91361-0052 Item] Size (nm) o15| 10 o27 | 44 033 | 12 o40 | 13 ose | 14 064] 15 076 | 16 oss | 17 090} 18 100 | 19 ana | 2t 123 | 22 135 | 24 147 | 27 159] 30 160 | 32 172 | 34 184] 36 196 | 44 206 | 46 218 | 50 220] 55 231 | 60 When referring to this page, please quote Plate P91361 Edttion 0062Plate P91361-0052 Combination Spanners Item No. Item No. Item Description 015 027 039 040 052 064 076 088 090 100 1 123 135 147 159 160 172 184 196 206 218 220 231 ‘Combination spanners, size NViomm Combination spanners, size NV11mm ‘Combination spanners, size NV13mm ‘Combination spanners, size NV14mm Combination spanners, size NV15mm Combination spanners, size NViémm Combination spanners, size NV17mm, Combination spanners, size NV18mm Combination spanners, size NV19mm, Combination spanners, size NV21mm Combination spanners, size NV22mm Combination spanners, size NV24mm. Combination spanners, size NV27mm Combination spanners, size NV3Omm, ‘Combination spanners, size NV32mm ‘Combination spanners, size NV34mm ‘Combination spanners, size NV36mm Combination spanners, size NV4imm Combination spanners, size NV4émm. Combination spanners, size NV5Omm Combination spanners, size NV55mm Combination spanners, size NV6omm,HYUNDAI MAN B&W. Ring Slugging Spanners Ttee| Size Crm) 022 | 30 034 | 32 046 | 34 068 | 36 060 | 44 071 | 46 83 | 50 095 | 55 105 | 60 417] 65 120 | 70 130 | 75 142 | 80 154] 85 166 | 90 178 | 95 Plate P91362-0069 When referring to this page, please quote Plate P91362 Edition 0069Plate P91362-0069 Ring Slugging Spanners fem Item Description tem ltem Description No. No. 022 | Slugging spanner, ring size NV30mm. 034 | Slugging spanner, ring size NV32mm 046 | Slugging spanner, ring size NV34mm 058 | Slugging spanner, ring size NV36mm 060 | Slugging spanner, ring size NV41mm 071. | Slugging spanner, ring size NV46mm 083 | Slugging spanner, ring size NVSOmm 095 | Slugging spanner, ring size NVS5mm_ 105 | Slugging spanner, ring size NV6Omm. 117. | Slugging spanner, ring size Nvésmm_ 120 | Slugging spanner, ring size NV7Omm. 130 | Slugging spanner, ring size NV75mm. 142. | Slugging spanner, ring size NV80mm_ 154 | Slugging spanner, ring size NV85mm 166. | Slugging spanner, ring size NV9Omm. 178 | Slugging spanner, ring size NV95mm.HYUNDAI MAN B&W. cea Plate P91363-0035 044 056 100 12 When referring to this page, please quote Plate P91363 Edition 0035Plate P91363-0035 Spanners aa Item Description = Item Description No. No. 016 Tool set, complete size 12.7mm 028 Tool set, complete size 19.05mm_ 030 | Box and Key set size 7-19mm 041 Adapter for socket wrench, size "hole x 3/4" sq. 056 Adapter 100 | Socket spanner, sq. drive, size N/V 36mm x 3/4" sq 112 Socket spanner, sq. drive, size N/V 30mm x 3/4" sq. 150 | Spanner 161 | SpannerHYUNDAI MAN B&W Open-ended Spanners Plate P91364-0059 Item Size mm Ot 1a/17 tect 023 | 19/22 When referring to this page, please quote Plate P91264 Edition 0059Plate P91364-0059 Open-ended Spanners ae Item Description vem Item Description 011 | Open ring wrench, 14 - 17mm 023 | Open ring wrench, 19 - 22mmHYUNDAI : MAN B&W Instruments Plate P91366-0066 When referring to this page, please quote Plate P91366 Edition0066Plate P91366-0066 Instruments. ie Hem Description rl tem Description 012 | Indicator, complete 024 | Indicator paper 038 | Plainmeter, complete 024 | Autolog, measuring tool for erankshatt 057 | Feeler gauge 061 | Slide caliper 1501 | Dial gauge and stand too! 1502 | Dial gauge and stand toolHYUNDAI Working Platforms Plate P91368-0007E MAN B&W. 086 = 074 =i When referring to this page, please quote Plate 91368 Ealtion 0007EPlate P91368-0007E Working Platforms. ee Item Description bud Item Description 074 | Platform board 086 Platform boardINDEX TESTING TOOL FOR FUEL VALVE PNEUMATIC-HYDRAULIC HIGH PRESSURE PUMP HAND PUMP. INSTRUCTIONS OF ENGINE INDICATOR OPERATION MANUAL FOR COFFIN PLANIMETERTESTING TOOL FOR FUEL VALVEHANMI POWER HDFD-1100 MANUAL NO : HDFD-1100-0.13 (2009.12) 180 9001 INSTRUCTION MANUAL FUEL VALVE TEST DEVICE MODEL : HDFD-1100 JANN HYDRAULIC MAGKIMERY 0... #700-17, Tai 162 51 305 20-6 T Fay. 182 81 901 i721 E-mail : hmigi@kornet net Jding HANMI POWER 180 9001 CONTENTS ‘A, SPECIFICATIONS = 8. OPERATION INSTRUCTIONS ©, TROUBLE-SHOOTING FOR THE HDFD-1100 TEST AIG . OUTLINE OF THE HOFO-1100 = € Ol CHART APPENDIX ~ GENERAL ASSEMBLY S)DWG No. M12-7100-0.6(STANDARD). 2)DWNG No. M12-7100-2.1(OPTION).....0 - CIRCUIT DIAGRAM (OWG NO. M12-7100-1) ~ ASSEMBLY DRAWING (DWG NO. M12-1100-0) ~ TOOLS (DWG NO. M12-7112-0), ~ SPARE PARTS (OWG NO. M12-7113-0) PAGE HDFD-1100 FUEL VALVE TEST DEVICE PAGE 2 PAGE 3 PAGE T PAGE 8 PAGE 9 PAGE10-1 PAGE10-2 PAGE! PAGEI2 PAGE'S PAGE14,15 1inp HANMI POWER 180 8001 A. SPECIFICATIONS 4, MODEL NO 2. OUTPUT PRESSURE 3, AIR CONSUMPTION MAK. FLOW AT NO PRESSURE . DISPLACEMENT PER CYCLE PUMP SPEED OIL TANK CAPACITY weishr DIMENSION 410, POWER SUPPLY 11, CLASSIFICATION PAGE : 2 HDFD-1100 FUEL VALVE TEST DEVICE HOFD-1100 O-1300BAR AT 108AR AIR INPUT (0-Q00BAR AT 7BAR AR INPUT GOSLITERSICYCLE AT 108AR INPUT 44LITERSICYCLE AT 7BAR INPUT APPROX. 1.2LITERSIMIN AT 7BAR AIR INPUT rect APPROX. 60 CYCLESIMIN, AT 7BAR AIR INPUT 6 LITERS ABT. 115kg AT EMPTY 885mm X 638mm X 1700mm SINGLE PHASE 115-290VAC GAUGE-CLASS 1.0, DISPLAY 02 PERFORMANCE CURVES DISCHARGE (L/MIN) o 200 600 800 ‘1000 PRESSURE (BAR) 1200 1300PAGE : 3 mp-HANMI POWER HDFD-1100 FUEL VALVE TEST DEVICE 160 8001 B. OPERATION INSTRUCTIONS ‘The HOFD-1100 ensures the correct testing of MAN B&W Diesel slide fuel valve. The atomizing test cannot be executed. The below procedure for fuel-valve testing is to be in compliance with the MAN B&W Diesel A/S guidelines for testing of fuel injection valves. Please refer to the MAN B8W manual for general fuel valve maintenance All numbers in the text refer to the numbers found on the HOFO-1100 front panel (see the figure 1, Unit Layout illustrated overleaf.) Pre-testing preparations Before performing any of the tests, the slide-valve must be completely filled with test-oil ZACAUTION “A coupling is separately packed when a product is supplied” When a product is supplied, the coupling is separately packed under an unassembled state. ‘Assemble the coupling packed in tool box to the product. (ee the figure of page 8, No 10 ~ fuel outlet” coupling) = Tum Switch © to position OPENING PRESSURE '™ Close Pressure Release Valve @ by turning clockwise ™ Turn Pressure Control Valve @ clockwise, until the WORKING PRESSURE Display ® shows a pressure above zero” 1 The valve is now filed with oi. When clear oi! without air-bubbles tickles from the venting hole through the breathing-pipe, the vaive is full (\ Please connect vent hose to valve venting hole in advance. ( See next page picture: vent hose) But in case of O-ring seal test, remove the vent hose, then block vent hole to use plug = Turn Pressure Control Valve @ counter-clockwise to switch off air supply ™ Open Pressure Release Valve @ by turing counter-clockwise * NOTE: The HDFO-1100 FUNCTION may be activated during this process, which stop operation. Turn Switch © to RESET and back to OPENING PRESSURE to resume pre-iesting preparationsPAGE : 4 HANMI POWER HDFD-1100 15 001 FUEL VALVE TEST DEVICE VENT HOSE - Opening pressure. — Leak test. " Z'\ 1 fuel valve vent hole is blocked by plug Oil is not spray. ( Figure, VENT HOSE) Test A : Venting function Before performing any of the tests, the slide-valve must be completely filled with test-oil, as described in the section “Pre-testing preparations" © Turn Switch © to RESET position © Close Pressure Release Valve @ @ Turn Switch @ to VENTING PRESSURE position © Slowly adjust Pressure Control Valve ® until the system automatic turns off the Air pump 150 bar © The pressure will slowly decrease on the WORKING PRESSURE Display ®. When the internal leak slide valve opens, the venting pressure is shown on OPENING + VENTING PRESSURE Display ©. © Close pressure control valve @ - turn it counter-clockwise © open Pressure Release Valve ® - turn it counter-clockwisePAGE : 5 HANMI POWER HDFD-1100 FUEL VALVE TEST DEVICE 180 01 - Ca a) 6 © ( Figure 1, Unit Layout ) D Full Stroke Push Button 2) Pressure Release Valve 3) Pressure Control Valve 5) Switch (VENTING / RESET / OPENING) © Air Pressure Gauge (0-10bar) 7 Pressure Display (VENTING + OPENING PRESSURE) ®) Pressure Display (WORKING PRESSURE)PAGE : 6 iin HANMI POWER HDFD-1100 180 8001 Test B . . . . Test C oe Test D . FUEL VALVE TEST DEVICE Opening pressure | The atomizing test cannot be executed. Turn Switch © to RESET position. Close Pressure Release Valve @ Turn Switch © to OPENING PRESSURE position Slowly adjust Pressure Control Valve @ until WORKING PRESSURE ® is around 1S0bar Press FULL STROKE Push Button © Increase pressure using Pressure Control Valve @ until opening pressure is reached The opening pressure is shown on the OPENING + VENTING PRESSURE Display © the pump stops automatically Close Pressure Control Valve @ - turn it counter-clockwise Open Pressure Release Valve ® - turn it counter-clockwise : Leak Test Tum Switch © to RESET position Close Pressure Release Valve @ Turn Switch © to OPENING PRESSURE position Slowly adjust Pressure Control Valve @ until WORKING PRESSURE ® is around 150bar Press FULL STROKE Push Button © Slowly Adjust pressure using Pressure Control Valve @ until displayed WORKING PRESSURE ® is 10-20bar below the opening pressure measured in Test B Close Pressure Control Valve ® - turn it counter-clockwise Open Pressure Release Valve ® - turn it counter-clockwise O-ring Seal Test Turn Switch © to RESET position Close Pressure Release Valve @ Dismantle breathing pipe from the venting hole in the fuelinjection valve headifixture Plug venting hole with plug supplied with the valve holder Turn Switch © to VENTING PRESSURE position Slowly adjust Pressure Control Valve @ until WORKING PRESSURE ® is around 100bar Decrease air pressure using Pressure Control Valve @ until manometer 6) reads Obar Read pressure from WORKING PRESSURE Display @. The displayed pressure should remain stable for a few minutes Close Pressure Control Valve @ - turn it counterclockwise Open Pressure Release Valve @ - turn it counter-clockwisedioup. HANMI POWER 180 9001 PAGE : 7 HDFD-1100 FUEL VALVE TEST DEVICE C. TROUBLE-SHOOTING FOR THE HDFD-1100 TEST RIG Problem Possible solution Explanation Remark INo tests can be preformed niet pressure reads Ober at all times (air pressure lsauge (6 although air supply is working ‘Turn Switch @ to RESET and Seek Te OPENING Pressure When the electronic blocking system in the HOFD-1100 is activated, air supply to the Unit is blocked. The magnet valve is'eleased” by reseting the unit lair supply is turned off laimost immediately after test is started ‘Make sure that the valve iS ir inside the fuel valve filed with oil (clear ol is tickling results in malfunction of the from venting hole when electronic pressure Pressure Control Valve @ is transmiter. turned a few times(clockwise) before attempting to run a test Follow instruction above test A desired test again lair supply is turned off lwhen Full Stroke Button is pressured Reset the unit and start the test again. press the “FULL STROKE" Button © while the Turn Switch © to Reset and | before attempting to run ‘ back to OPENING PRESSURE | | [The HDFD-1100 is plugged Consult with Maker HANMI for lin and turned on, but air maintenance advice. lsupply is never blocked [The display on the HOFD-1100|Check power supply | box is not workingimp. HANMI_POWER D. OUTLINE OF HDFD=1100 Pos. Pos. Pos. Pos. Pos. Pos. Pos. Pos. Pos. Pos. Pos. Pos. Pos. 78 " 12 13 14 Full Stroke Valve (Push Button) Pressure Release Valve Pressure Control Valve / pneumatic reducing valve Pressure transducer (inside HOFD unit) ‘Switch (VENTING PRESSURE/RESETIOPENING PRESSURE) Ar Pressure Gauge for “Inlet air pressure'(O~10bar) Pressure Display with two displays ‘Adapter “air inlet'Ma2x2 High Pressure Outlet “fuel outlet" Filler cap with strainer (inside HDFO unit) Oil fiter (inside oil tank) 2-Way pneumatic valvetinside HOFD unit) Pump AHP-1100(inside HDFD unit) PAGE : 8 HDFD-1100 FUEL VALVE TEST DEVICE (HM-F001-01) (HM-FD04-02) (HM-FD04-03) (HM-FD04-04) (HM-FD04-05) (HMt-FD04-08) (HM-F004-07) (HM-FD04-10) (HM-FD04-11) (HM-FDO4-12) (HM-F004~13) (12-1100-0.0)PAGE : 9 imp HANMI POWER HDFD-1100 FUEL VALVE TEST DEVICE 150 8001 E. OIL CHART 1, Recommendable Oil for Testing Rust-preventing hydraulic oil with viscosity of 7-10 eST at 50°C. 2, Initial Filing Quantity Fill the oil until the level gauge indicates between High and Low. No further replenishment of the oil is required thanks to the close circuit. (see figure 2, Oil level gauge) 3, Draining oil (see figure 3, Oil tank) ilter cap with strainer (Filling oi) Drain plug (raining oil) (figure 2, Oil level gauge ) (figure 3, Oil tank )HOSE, 2 COUPLING (3M) {| sate noes POWER SOURCE 115~250VAC (Wotertignt Plug Be (Coble 1.5504246-5u} a e DETAIL OF AIR INLET 4-014 Hotes / WATERTIGHT PLUG & CABLE GLAND for MI2 BOLT wee ODT AE, | PR FUEL VLE TEST CEWGE (D-1100) Mw.cko1 = Sasa) eaneat GENERAL ASSEMBLY DH.KoO —_ HANMI HYDRAULIC MACHINERY CO., LTD,115~230VAC (Wotetignt Pug & Coble 1.5503246-2u) MOUNTING PLATE a, ‘& [0707021 67.1900 sTE_| REASON FOR MODIFICATION [REV 4-014 HOLES VIEW A —A’ ETAL OF AIR INLET COUPLING jos 1ss00+6-54 CABLE GLAND PG—W3PO(POLYCARBONATE) & C5—15 M.W.CHO! A} ace | ‘$70702 4W:KO0 ‘POET FUEL VALVE TEST EWGE (HOFD-100] PROJECTION _ GENERAL ASSEMBLY = @ DRAWING NO. (pHa HORAUUC MACHINERY CO, LTD. ; Seto M12-7100-2.1SOCKET RAS mA signal no | + Vde out co | +24 Vde out @ | +24 Vde out ‘& | Supply U a © 115/ 230 Voc od oe 15VA L-LL-— «| Ground a. omer 1. FILL STROKE VALVE M=F004=01 2. PRESSURE RELEASE VALVE £004~02 5. PRESSURE CONTROL VALVE Hu=FD04—03, 4 PRESSURE TRANSDUCER (INSOE HOFO UNIT) HM=FD04—08 5. TURN SMITCH (VENTING PRESSURE /RESET/CPENING PRESSURE}M=FD04—09 6. AIR PRESSURE GAUGE (O~10b0r) 7+8, PROGRAMMABLE DISPLAY 9. AIR INLET WITH ADAPTER (W4232°) 10. HIGH PRESSURE OUTLET 11. ALLER CAP WTH STRAINER (NSIOE HOFD UNIT) ss 12, OL FILTER (INSDE OL TANK) Switeh 15. 2-WAY PNEUMATIC VALVE PCB 14, PUMP-AHP=100 (INSIDE HOF UN) 15. AUTO ORAIN FILTER (INSIDE HOFD UNIT) 16. Ol LEVEL GAUGE a R45 Socket Function selector [Far g [Poem Fie ve es oon Goro-10o)[ PROJECTION °F a0 CIRCUIT DRAGRAM eS ¢ even of coa DHKOda.CKIM MWCO) DRAWING NO. a 1 ‘Ay [050201] Revision of power source. DH.KOOB.C.KIM IM W.CHO| HANMI HYDRAULIC MACHINERY CO., LID.FUEL VALVE TEST DEVICE TYPE_: HOFD-1100 ONG. NO. = WI2-7112-0.6 SUPPLY PER SHIP MATERIAL 92 5 4 REMARK BOX ‘COMBINATION Too. SPANNER STEEL (Pua |tl- "F wiser 5 wrens] 1/e|c 3/87 HEXAGON HEAD ‘iN SON ENC PLUG WITH FLANGE sma) | SSOME-C|Sa6uE=a) sau] MR AND GASKET (® correR PRODUCT NO, @USE TO $35/40ME-8, $46/50MC-C, @ sree SSOME-C ENE. SINGLE OPEN Tool, | ENDED SPANNER | STEEL | + DRIER MALE COUPLER OW ©) ENO. Weis Sucaaesse-B ase, EBA 5 SE Sk-£ | fe) (owe, sowc-c, soue-<.700e, | wera Yoe-€ rane SOuCCGONC/—C, KSEME, SPRING HOUSING L MANUFACTURER'S NAME. “oPeosr-Datrer O) "aacci0r20")FUEL VALVE TEST DEVICE TYPE HOFD-1100 staal [DW NO. = N12-7100-0.0 (1/2) SUPPLY PER SHIP ] OLD WG NO. NEW DWG NO.) REMARK No. | NAME SKETCH MATERIAL pee | 1-7 | O-RING | war |r{—| 1] 199 |12-1109-0] Lo28—| | | | T | 00 1-8 SPACER | J acs Jaf) a] APINO |r2a111-9) Back-up | 2+ RING P1100 =12 TeRLON | 1] - | 4 12-1112-0 1-9 PACKING AP1100 1-10 urevane | 1 |= | 4 1211130 SEAL ’ -13 | T | tain | SUPPORT | wes }1|-|1 me | ha-ineo | | | | |] | wor |2f—|2) M0 ha-rniso -19 P1100 i2-1421-0 MANUFACTURER'S. NAME dip) HANMI HYDRAULIC MACHINERY CO., LTD. (0P-052-05(Rev 0) CF) Sore Ta(2T0297) bear |FUEL VALVE TEST DEVICE TYPE HOFD-1100 DWG, NO. : W12-7100-0.0 (2/2) SUPPLY PER_SHIP No. NAME, SKETCH WATER 95 (OLD DNC NO, | NEW DWG NO.) REMARK 2 41100 31 12-1131-0 P1100 N32_([12-1132-0 ner |2|-|2 WASHER, 12-1133-0 ner |8|-| 8 12-1145-0) 41100 48 1-18 O-RING 12-1148-0 1-18 | SPRING ZB" | upto |2|-|2| “1190 |e-tiet-0 G B | -64 | MANUFACTURER'S NAVE inp? HANMI HYDRAULIC MACHINERY CO., LTD. GP-052"Ds(Rev 0} Ge) aU eIH Taa(2100297)PNEUMATIC-HYDRAULIC HIGH PRESSURE PUMP[2] 2002. 08. 26. | PWEVATE Sa aeee AIR DRIVEN HIGH PRESSURE PUMP MODEL : AHP-2500 fae HANMI HYDRAULIC MACHINERY CO., LTD. #715-14, MORA-DONG, SASANG-GU, BUSAN, KOREA PHONE : (051) 305-2511~-6 FAX : (051) 301-1721 HANMI HYDRAULIC MACHINERY CO., LTD.POWERMANE SPECIFICATION * ++ HIGH PRESSURE PUMP UNIT *** 1. MODEL NO. + AHP-2500 . AREA RATIO. :e77 4 ACTUAL AREA RATIO 1266: 1 2. 3 4, AIR CONSUMPTION : 1420 LITERS/MIN. AT 7 BAR AIR INPUT 5. PUMPING SPEED : APPROX. 255 CYCLES/MIN. AT 7 BAR AIR INPUT 6 7, 8 9. DISPLACEMENT PER CYCLE: 3.18 MAX. FLOW AT NO PRESSURE : APPROX. 0.81 LITERS/MIN. AT 7 BAR AIR INPUT TANK CAPACITY : 8 LITER AIR INNER PORT : 1/2" BSP FEMALE WITH INCREASE TO M42 ADAPTER 10. LIQUID OUTLET PORT 21/4" MALE 11, APPROX. DIMENSION 450x341 x400 12. WEIGHT 231 Kg PERFORMANCE CURVES OIL FLOW (L/MIN) 1000 1250«=« 1800S «1750-2000» 2500-2750 OUTPUT PRESSURE (BAR) ==> AREA RATIO. ACTUAL AREA RATIO. HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATE HIGH PRESSURE PUMP AHP-2500 . OIL RETURN VALVE 8, OIL OUTLET MALE COUPLING AIR STOP VALVE (CYCLING VALVE) (HIGH PRESSURE OUTLET) . AIR. PRESSURE CONTROL VALVE 9, SAFETY VALVE (RELEASE VALVE) 4, AIR PRESSURE GAUGE FOR PRESSURE CONTROL 10. OIL TANK . OL PRESSURE GAUGE FOR WORKING PRESSURE 11. PUMP AIR BREATHER (FILLER CAP) 12. OIL LEVEL GAUGE AIR INLET (FEMALE COUPLING FOR AIR HOSE) —13.SUCTION FILTER DWG_ NO. HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATIE OPERATING MANUAL HIGH PRESSURE PUMP AHP-2500 This instruction has been made to facilitate the understanding of the working principles of the pump unit. The various control instruments and maneuvering handle are fitted with a number. These numbers are mentioned in this instruction and are also referring to the numbers found on the drawings showing the complete pump unit. Furthermore, these numbers are found on the instrument panel of the pump unit. Please, read this direction of use carefully before using the pump unit and follow the instructions given vary carefully. 1. BEFORE CONNECTING THE PUMP UNIT The tank is filled with oil through the filler cap (6) in the right side of the top panel. Hydraulic oil : ISO VG32 (MINERAL OIL) a) Open oil return valve (1) by turning anti-clockwise. b) The handle of the regulator valve (3) should be turned 4-5 turns anti-clockwise. This is done to avoid the pump starting at a too high pressure level. ©) Stop valve (2) should be tumed clockwise, to close the valve. This is done to ensure that the pump will not work at will when the primary pneumatic system is connected. 2. CONNECTION OF PUMP ‘Compressed air is led through a flexible hose and is connected to the stud marked “air inlet” (7) on the right side of the cabinet. This stud has a 1/2" BSP female thread with a 1/4" BSP reduction, akcepting either 1/2" or 1/4" hose. To avoid contamination of the pump, it is essential that an effective air filter and water separator is inserted in the air line. A lubro unit should however be avoided - see lubrication instruction on page 4. The hydraulic system is connected to the stud marked “high pressure outlet" (8) found on the left side of the cabinet. This stud has a 1/4" BSP female thread. The pump is now ready for use. 3. START OF PUMP a) Stop valve (2) is turned slowly anti-clockwise, whereby compressed air enters into the Pump unit, which commences to work. The stop valve (2) is also acting as a regulator valve for the pumping speed. b) The regulator valve (3), which is used for adjusting the pressure is now turned clockwise and the hydraulic pressure may now be read on the manometer for pressure control (4). This manometer shows the hydraulic high pressure in bar. HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATIE ©) The oil return valve (1) is closed by turing the knob clockwise and the oil will then run from the oil tank into the hydraulic system. When the hydraulic system has been filled. and the pump has stopped operating, the high pressure reached can be read at the manometer for working pressure (5) found on the left side of the instrument panel. The pump stops automatically, when the required high pressure has been eatablished and holds it infinitely. The pump starts automatically again if a pressure drop occurs in the hydraulic system. 4) High pressure may be relieved from the system by opening the oil return valve (1) (to be turned anti-clockwise). The excessive oil the secondary high pressure system will thereby return to the oil tank in the pump unit. 4. ENDING OF JOB To avoid oil spillage, precautions should be taken to see that the oil is taken back into the oil tank before the connections on the high pressure side are disconnected. This is done by turning the oil retum valve (1) anti-clockwise. Simultaneously the pump should be stopped by turning the stop valve (2) clockwise, and when this valve has been closed, the air hose may be removed and the pump transferred to another job. 5. DATA FOR HIGH PRESSURE The pump unit can deliver a maximum pressure of 2500 bar. At an air pressure of 6.6 bar a safety release valve is in the B+W standard version adjusted to release at a maximum pressure of 1750 bar. This pressure of 1750 bar (which is preset by the factory) secures the rest of the system from overload or faulty operation. The pump may be re-adjusted to blow off at any desired pressure, but maximum 2500 bar. The release valve should be set at approx. 10% above the desired working pressure. 6. CLEANING OF OIL FILTER The filter in the filler cap (6) is removed and cleaned when by re-fling the oil starts running through slowly. 7. LUBRICATION INSTRUCTION WARNING : AVOID AIR LINE LUBRICATION. The pump has been pre-lubricated and a lubro unit will decrease the efficiency of the pump. Air valves should be lubricated periodically. Remove exhaust fittings and valve spool and apply a thin coat of Hanmi hydraulic grease ks-64. It primary airdrive section is dismantled, always apply a thin coat of Hanmi hydraulic grease to entire inner surface of cylinder tube plunger O-rings. HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATE 8. SPARE PARTS Even though the pump unit is a robust and reliable piece of equipment, there may be a need - after a long time of operation - for changing various wearing parts like O-rings. See Skeleton drawing and spare parts list. HANMI HYDRAULIC MACHINERY CO., LTD.AIR_DRIVEN HIGH PRESSURE PUMP MODEL : AHP-2500 DWC. NO.[ AHP2500-MO7-0.2 REMARK DRAWING NO. | (weight) Kg PACKING SEAL 10-1121 -0 ‘SPRING 1121 SPRING eau 10-2139 -0 10-2153 -0 12-1145 “0 12-1146 is Bs A [—ar2e- betaaiiarecaaias! inp) HANMI HYDRAULIC MACHINERY CO,, LTD. ‘GF=052-05(Rev 0} eelRai ‘a(20%297)HAND PUMPMQ SS == HYDRAULIC PUMP HAND OPERATED MODEL : HML-2500 for HANMI HYDRAULIC MACHINERY CO., LTD. #715-14, MORA-DONG, SASANG-GU, BUSAN, KOREA PHONE : (051) 305-2511-6 FAX : (051) 301-1721 HANMI HYDRAULIC MACHINERY CO,, LTD.POWERMATE HYD' PUMP HAND OPERATED. a KER —_MAKE! HANMI HML-2500 WORKING PRESSURE Low RELIEF/HIGH 20 BAR Min. 1800 BAR HYDRAULIC CIRCUIT OIL OUT! PUT VOLUME/STROKE Low HIGH RESERVOIR OIL VOLUME, HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATIE HAND PUMPS IMPORTANT DIRECTIONS ON RECEIVING GOODS ‘Always inspect all the components received in order to ascertain any possible damage caused during transportation. If necessary, put forward a complaint to the forwarder. SAFETY INFORMATIONS Before starting the pump read carefully the manual, particularly the boldface parts and those Indicated by: WARNING : and CAUTION : EURO PRESS PACK DECLINES ALL LIABILITY FOR DAMAGES DERIVING FROM AN IMPROPER USE OF THE PRODUCT. SHOULD YOU HAVE ANY DOUBT REGARDING APPLICATION DO NOT HESITATE TO CONTACT EURO PRESS PACK. WARNING: PLEASE REFER TO THE APPENDIX FOR THE LIST OF COMPONENTS FOR ALL KINDS OF HAND PUMPS. The hand pump reservoir must have a capacity of usable oil sufficient to fill the complete hydraulic system it is connected to (1. flexible hoses + cylinders). WARNING : OIL SHOULD NOT BE ADDED TO THE PUMP RESERVOIR TO COMPLETE THE STROKE OF A CYLINDER WHOSE VOLUME IS GREATER THAN THE PUMP CAPACITY. THIS PRACTISE WILL RESULT IN THE PRESSURIZATION OF THE PUMP RESERVOIR LEADING TO EQUIPMENT DAMAGE AND POSSIBLE INJURY TO PERSONNEL. "Double stage" or 2-speed pumps’ piston features two thrust sections of different diameter. When the load is not present it is the piston wider section that pushes the oil into the circuit so allowing a fast approach to the load. (1st stage at low pressure and high capacity). Under load, the same secyon is automatically excluded by a specific valve. Continuous pumping with the smaller section achieves the maximum pressure by making a reduced effort on the lever (2nd stage at high pressure and low capaciy). The filler cap (HML models) is of the push-button air discharge type to depressurize the reservoir. The pumps can work in a horizontal or vertical position with the pumping head downwards, and are fitted with a threaded hole for the mounting of a gauge(alternatively a gauge adaptor black can be mounted on the oil delivery outlet; both are optional extras). Upon request pumps with HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATE reservoirs different from standard, for higher working pressures of working with other fluids can be supplied. For any specific inquiry please contact our Technical Department. OIL DELIVERY / RETURN The direction of circulation of the oil from the pump to the hydraulic circuit (delivery) and successively from the circuit to the pump (return) is regulated by the control valve mounted on the hand pump head (PICTURE. 1) The pumps are fitted with a 2-way valve ("by-pass") to operate single acting cylinders either gravity or spring return : the pump head has one only delivery - return port. When the valve handwhee! is completely screwed clockwise, repeated action of the lever will introduce oil into pressure to the circuit. By unscrewing it counter-clockwise, oil is allowed to return to the reservoir. In this case it will be useless to operate the lever as the pumped oil will immediately return to the reservoir. HOW TO CHOOSE THE PUMP The selected pump must have a 2-way valve for single-acting cylinders either gravity or spring return and a 4-way valve for single-acting oil return cylinders or double acting cylinders. The reservoir must have a caoacity of usable oil sufficient to fil the flexible hose and the cylinder. If you need a large amount of cil to fill the system and for the approaching of the piston to the load it is advisable to choose a pump with high delivery at low pressure. Hand pumps are recommended for low speed applications. When your application requires higher working speeds it is recommended to choose a hydraulic unit in our wide range of models driven by petrol engines, electric or pneumatic motor. WARNING : IT IS RECOMMENDED TO MOUNT A GAUGE ON THE PUMP OR ON THE CYLINDER IN ORDER TO PREVENT ANY DAMAGES TO THE EQUIPMENT, WHEN LIFTING LOADS WHOSE WEIGHT IS NOT KNOWN, AND ALSO TO BETTER CHECK ANY SINGLE PHASE OF THE LIFTING OPERATION. TO ENSURE A CORRECT WORKING AND A LONG LIFE OF EPP COMPONENTS. CAREFULLY FOLLOW ALL THE DIRECTIONS PROVIDED BY THIS MANUAL. HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATE CORRECT USE OF THE PUMP WARNING : THE PUMP CAN WORK EITHER IN A HORIZONTAL OR VERTICAL POSITION PROVIDED THE HEAD IS DOWNWARDS. (PICTURE. 2) The pump must be placed on a stable and stil plane to prevent it from turing over during operations. The BY-PASS valve must be operated esclusively by hand, Do not use mechanical grips. AIR_IN THE SYSTEM Since air can be compressed if it enters a hydraulic system it can prove dangerous. Before Putting a cylinder under load it it absolutely necessary to bleed the air from the system Simply follow the following directions: (PICTURE. 3) * pump until the piston is completely extended ; invert the cylinder so that the piston head is placed on the bench or on the floor; keep the pump higher than the cylinder open the vaive of the pump ; press the cylinder bottom to help the piston retract. The air will flow from the cylinder and the hose to enter the oil reservoir where it can stay without causing any inconvenience. USE CAUTION : HIGH PRESSURE EQUIPMENT CAN DEVELOP HIGH FORCES IN COMPARISON WITH THEIR DIMENSIONS. DO PAY THE GREATEST ATTENTION WHEN OPERATING. Before starting any operations check the oil level inside the hand pump reservoir. Such level must usually be about 1 cm from the inlet, Add oil if necessary. Make sure the reservoir is net completely full so as to prevent the oil from overflowing from the inlet hole, since during operations increases of the oil volume might occur. IT IS RECOMMENDED TO USE EXCLUSIVELY EPP HYDRAULIC OIL : its viscosity and lubrication characteristics grant the maximum use efficiency and a longer life of equipment. If you need to add large quantities of oil to the pump, it is recommended that the reservoir is drained, thoroughly cleaned with kerosene and filled up with fresh cil HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATIE CAUTION : MAKE SURE THAT ALL THE SYSTEM COMPONENTS ARE SUITABLE FOR THE REQUIRED WORKING PRESSURE. SPECIFIC DIRECTIONS ON THE USE OF FLEXIBLE HOSES CAUTION : DO NOT SUE FLEXIBLE HOSES FOR CARRYING OR DRAGGING PURPOSES Hoses must be placed on a straight line with no obstructions. Ensure that the bend radius is greater than 60 mm, that no heavy load is placed over them and avoid any direct contact with sharp objects. Koop them clear of flames or heat sources. SPECIFIC DIRECTIONS ON CONNECTIONS THROUGH NIPPLES The threaded end connections are either 1/4 or 3/8 NPT male. When tightening, do not use spanner extensions as damage to the threads can occur. Wrap thread with teflon tape (do not use tow as its threads can contaminate the oil of the hydraulic system). SPECIFIC DIRECTIONS ON THE CONNECTIONS THROUGH COUPLERS Ingress of foreign materials into the hydraulic system can cause scoring inside the cylinders or damage the valves seats so compromising their seal and the consequent success of the system operation. Therefore : CAUTION : MAKE SURE THE COUPLINGS ARE CLEAN BEFORE CONNECTING THEM. Dirt can prevent a correct seal and restrict the oil flow since the two seal balls do not properly repel each other. WARNING : MANUALLY SCREW TIGHT THE CONNECTING SLEEVE OF THE FEMALE COUPLING TO THE THREADED SPIGOT OF THE MALE COUPLING. WARNING : ALWAYS SCREW THE PROTECTION CAPS ON THE TWO COUPLING WHEN DISCONNECTED. EURO PRESS PACK DECLINES ALL LIABILITY FOR DAMAGES OF UNSUCCESSFUL OPERATIONS DERIVING FROM IMPROPER USE, OR USE OF ACCESSORIES AND/OR SPARES OTHER THAN THE ORIGINAL ONES. FOR ANY INFORMATION OR EXPLANATION DO REFER TG OUR TECHNICAL DEPART- MENT. HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATE WARNING : ANY MAINTENANCE AND/OR REPAIRING INTERVENTIONS MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. WRONG INTERVENTIONS MAY CAUSE THE LOSS OF WARRANTY! PRESSURE REGULATION - The hand pump safety relief valves are factory set to the maximum working pressure. By requests, this can be set to customer requirements. WARNING : IT IS ABSOLUTELY FORBIDDEN TO SET SUCH VALVE AT A VALUE HIGHER THAN THE ONE SET IN OUR FACTORY. TROUBLE SHOOTING In many cases faults can be determined and EASILY OVERCOME ON SITE, so saving money and time. Please find below a few suggestions for the most common problems. For further details refer to our CUSTOMERS SERVICE. THE PISTON WILL NOT ADVANCE The pump head is not downwards ; The pump valves is open or not properly closed ; There is air in the system or lack of-oil in the pump ; Make sure the pump correctly pumps the oil. If it fails to do so the piston cannot advance. DO NOT OVERLOAD The piston will not advance if the load to be lifted exceeds the capacity of the cylinder in use. In this case the safety valve protects the operator and the equipment by preventing the advance. THE PISTON DOES NOT MAKE FULL STROKE OR ADVANCES WITH JERKS. - There is air in the system (to eliminate it please refer to "Air in the system"). The piston could be bent or deformed causing it to bind with the ring nut, - There is lack of oil in the pump. The piston is limited in its stroke. Refill the oil level in the pump (see "Use). “The hydraulic cylinder's capacity is higher than that of the reservoir. The pump must be replaced with one with higher capacity. THE PISTON DOES NOT KEEP THE LOAD - If when pumping the piston advances, but does not koop its required position, i.e. does not hold pressure, the reason might be found among one of the following causes = 1) The pump does not work properly (check valve). 2) Cylinders seals leak. 3) Oil leakage through the flexible hose connection. HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATE THE PISTON RETURN IS NOT COMPLETE OR SLOWED DOWN This is due to the fact that the oil cannot flow back to the reservoir. Make sure that 1) The pump valve is open. 2) The two couplings are tight so that the two balls repel each other and make the oil flow correctly. 3) The return spring of the cylinder (if fitted) could be broken or loose and the internal walls of the cylinder can be worn. 4) The piston cannot be fully retracted if there is too much oil in the pump. In that case the excess of oil cannot flow from the cylinder to the reservoir. Consequently the piston is not fully retracted. WARNING : FOR GRAVITY RETURN CYLINDERS IT IS NECESSARY TO MAKE AN EXTERNAL FORCE ON THE TOP OF THE ROD SO AS TO MAKE IT RETRACT. WARNING : ALWAYS HELP THE PISTON RETRACT BY PRESSING ON THE RESERVOIR RELIEF VALVE ON THE FEEDING CAP IN ORDER TO DEPRESSURIZE THE SAME (only HML models). OIL LEAKAGE If there is oil leakage from the piston it means the seals are either broken or worn out. Their replacement is simple and quick and can be carried out on site. WARNING : IT IS RECOMMENDED TO KEEP IN STOCK A SPARE REPAIR KIT FOR THE PUMP. APPENDIX A LIST OF HAND PUMPS COMPONENTS SHARED BY THE VARIOUS PUMPS PUMP RESERVOIR LEVER A B c i 7 ie _ Also valid for MOD. HML 1600 / 2500 HML 1600-1 / 1600-1 HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATIE BY-PASS VALVE HANMI HYDRAULIC MACHINERY CO., LTD.POWERMATE —= MOD. : HML-1600, 2500 HML-1600-I, 1600-1 HANMI HYDRAULIC MACHINERY CO., LTO.INSTRUCTIONS FOR USE OF ENGINE INDICATORLEUTERT INSTRUMENTS + CONTROL + AUTOMATION SINCE 1941 Service Instructions Engine Indicator Type 50Z1 F. LEUTERT GmbH & Co. Schillerstrasse 14- Telephone: + 49 - 4131-9590 21365 Adendorf - Telefax: + 49 - 4131-959 111 Germany - E-Mail: sales.maritime@leutert.com http:// www.leutert.com ae505 20 96 26 15 A\ [ATTENTION] /\ Before using indicator, open indicator valve or cock, blow out any dust, and close it again. [CAUTION:] hot gas and particles may be ejected er WEAR GLOVES AND SAFETY GLASSES (| Piston max. size pressure dia.mm | _p in bar 41 | 20,27 30 418 | 9,06 | 150 40 6,41 300 1120 4,53 600 -2-When ordering spare parts, please specity the serial number of your Indicator and advise the part-no. in question. - 38. Under-part.compl 4654.0.11.03100 Pos, Descrintion PartNo, Under-part w.drum-carrier 4654.0.11,03000 4. Drumcarrier 4654.01103008 40, Stop screw 4554.0.11.03003 2 — Spring support compl. 4651.0.1.10090 41. Guide ollcompl.(40)_-4651.0.4.02000 Stop washer 4as4.0.11 10003, Guide rollcompl.(50)_4864.0.1.02000 Retaining ring 4651.0.11.10004 ‘47, Washer10,5 UscheiD10.0070 ‘ScrewM2,5x6 ‘StschaftM25.06 48. Wing nut, M10 ‘Mutter M10.0053 Ring nut 466104140100 43. Drum cover(40) 4g54.0.11.01200 Turning ring 4651.0.11.11001 Drum cover (50) 4661.0.11.01200 Slottednut,small 4654.01.00 50. Drumm knob 46st 0.4. 01001 Cylinder 4,415, 4710 95. Knurled nut 4654.0.11:1008 Wedge 4651.0.11.03102 141. Elastic washer 4651.0.11.10002 Coupling nut 4651.011.03103 —§05. Recording pencil 4654.0.11.11011 Piston 1,415,140 Cylndresipiv text Zsthn00, 0064 Upperpat 12,16 come without piston’ cylinder 4654.0.14.10000 ioneaey eee Recordingmech, compl. 4651.0.11.11000 Pistonrod 1/1, 1/2,1/5 — 4651.0.11.10200 eee sai Pane Springcap 4s64.041.40300 Sor Coupling pin 854.0.14.10008, Seen ees Screwdriver, large 2000.0.00:39318 Coupling link lett 4651.0.14.11300 ‘Serewadriver, small £9000.0.00.38318 Coupling link ight 4654.041.49200 Flatpliars 3000.0.00.39406 cca hae anaiiiies Indieatorcord(hemp}10m $000.0.0038714 Recordinglever 4651.0.14.11100 Indicatorpaper145x6590000.00.39722 Link bolt short 4651.0.11.11004 Indicatorpaper 80x65 3000.0.00.39723 ta ben tee eta eraieed Gylinderspannert/4+4/2 4854.088.2100 Realy arena ase Chlinderspannert/+¥/5 4854.098.02200, naaanaiene tanita Bottecylindercilt0cm? _4854.036.00100 Scr eee mainiinseod Cordstightening hook 4654.0.38.00001 Drumeylinder(40)4664.0.14.01400 Hollowspanner 4654.0.98,00002 Drumeylinder(50) _-4664.0.11.01100 ylinderspanner 4651.0.98.01000 Drum compl. (40) 4651.0.11.01000 Wooden box 4851.1.96.03100 Drum compl (50) 4864.011.01000 ee ene an, Sloneanur ge astattaneer ———_*ilaforepringand wooden scale 3. Drumaxle 4651.0.11.01002 Lie 2 NutMto Muttertt0.0052 3. Drumspring 4854.04101003, Table of Indicator Springs Type 5021 rat-no. |8]8 |8/8/8/8)8/8 8) 2) 2/8/8182 assiomt. {8/3 [8/8/5|8/8| 2 8) £/8/ 8/8 |8 ie 3/5 |8/3/3|3/8|3| 8] 8] 5) 5) 3) 3/3] § Spring-No. | IS Jolelofolnfo/2}=] 2] 2] 2) 8/8]8 3 {aia alslslalsisisisislalsl slaletsle 2 lam 8g |9|a/a/8/a}3|3/a]3] a}3|s)a|s Wi faoa7fscawmmron [zs fzole]afiofe rte s|asfs ]as] [es]? is max prssue vor {2 fas | {se |r] e |r| 1 fr2| 1 | 16| 20 |25 | 20 175 | 8:06 Scale mm bar va] 1 Jos Joa] or fos] os fowl oa tae presse bat aa| s0| 55 feo | 70 | 20 | 100 |125] 150 Tr10 6.47) Sete min? bar oa]as}ow fae |oas [os fos [oz [ars rx. pntsy_ bt 20/100] 110 |120] 140 | 160] 200 |250 | 390 1120] 453] Sate mm var 93) 025}o225] a2 Josefa r25]o1 foors rat. ponnue_ ba +60| 200] 220 |240 | 280 [320] 400 [500 | suoCharacteristics: Manufacturers: F.Leutert GmbH&Co. Height max.:appr.170mm Design: Type 5021 Width max.: appr.75 mm Diagram height: max. 50 mm Diagram length: max. 80 mm (110) Weight: appr. 1,2 kg Drum Diameter: 50 mm (40) Weight incl. wooden box+ Pressure records: up to 600 bar accessories: appr. 5 kg Natural vibration frequency per minute: 3000...12000 (depending on piston and spring) Maximum speed: 400 rpm 300 rpm when using a drum of 50mm dia. The applicability of the indicator not only depends on the speed of the engine, but also on the pressure change rates. Applicability: The standard design of the Leutert indicator Type 5021 is a handy instrument for many applications and is used for taking single diagrams from any internal combustion engines, compressors, blowers, pumps, steam engines and other reciprocating engines. The applicability of the indicator is limited by the natural vibration frequency of its moving parts. The natural vibration frequency is given by the design of the instrument and the piston and spring actually used. Technical notes: The sectional drawing of the indicator Type 50Z1 shows that the under-part (39) is mounted in the drum carrier (1) by means of a slotted nut (29). Depending on the expected maximum pressure, 2 types of under-parts are available: One under-part for any of the interchangeable cylinders for piston 1/1, 1/5 and 1/2 and one for the piston 1/10 and 1/20. Recording mechanism: The recording mechanism must be handled with extreme care; slightest damage may lead to substantial recording errors. The links must never be diassembled and should always be sufficiently lubricated with cylinder oil.The recording pencil (505) is interchangeable. When inserting the upper-part, tighten ring nut (3) just very slightly and use the knurled handle (26) to move the recording levers until the pencil touches the drum. Firmly tighten the ring nut in this position. The stop pin engaging with turning ring (4) is now at the front end of its slot and provides sufficient clearance for engaging and disengaging the recording levers. If the recording pencil is pressed on the drum too hard, faulty diagrams will result. If the ring nut (3) is slackened, the recording levers can be turned around and arrested in any desired position. Piston : Piston (9) is made of one piece with very thin walls to obtain a mass reduction. The piston may be removed by loosening screw (11). If a piston or piston rod is ordered, we generally recommend to send us the indicator. For exchanging piston (9) and cylinder (6) the upper-part is removed after loosening the ring nut (3). The accessory steel key should now be used to unscrew and exchange the cylinder. The piston of the size 1/20 is made of one piece integral with the piston rod. Therefore, when exchanging this piston, the rods must also be removed. For this purpose unscrew the spring cap (13) and remove the coupling pin (15) by gripping its flat head with the small accessory pliers and slightly moving the pin. Now, pull the piston rod downward. When inserting the new piston rod, make sure that the coupling pin is inserted into the link (18a) with the larger bore and into that side of the piston rod which is marked by a punched spot. Indicator spring The indicator spring is a double-coiled, easily interchangeable tension spring. All springs are precisely calibrated and marked with the spring scale and the maximum pressure related toa piston size 1/1. Use small pistons of the size 1/5, 1/10, 1/20 for pressures exceeding 30 bar, then, 5-fold, 10-fold, 20-fold pressures may be indicated with the same springs. Selection as per spring table.When selecting springs note that the highest frequency of natural vibration can be obtained by using the largest piston size possible with appropriately strong springs. When ordering springs, kindly state the serial number of your indicator. Springs of the previous indicator Type 50 have metric thread, those for Type 50Z and Type 50Z1 are threaded to the inch. Mounting the spring: Remove spring cap (13) at the upper end of the piston rod, place the spring over the piston rod so that the small ball on the spring engages with the corresponding slot of the piston rod, and firmly tighten the spring, finally replace spring cap (13). Raising the atmospheric line for low-pressure springs: If necessary, the atmospheric line of the diagram can be raised by placing one or more washers (must be ordered separately) on the spring support before mounting the spring. Paper drum: The standard drums of the Leutert indicators are designed to combine high strength with low mass. The drum is retumed by the incorporated spring (37). Any spring bias can be adjusted during operation by turning drum cover (49). The drum can be disassembled without using a tool simply by pulling off the cover. Drums available for the indicator Type 50Z1: ~- standard drum of 50 mm dia. - special drum of 40 mm dia. Paper drum drive: On engines with an accessible crosshead guide, the paper drum is usually driven from the crosshead guide or from the connecting rods of engine. Then, the piston stroke must be reduced to diagram length by means of stroke reducers. Indicator cord: The cord should be so arranged that the connection is preferably short without unnecessary deviations.Lateral movements of the cord must be avoided as they would lead to errors in the drum motion. The length of the cord should be so dimensioned that the drum will definitely not touch the drum stop (40) below the drum bottom in its dead centre positions. Cord guide rolls are recommended for guiding the cord. Cord tightening hook: It is recommended to use a cord tightening hook. The cord will automatically jam in the slot if it is pulled. Mounting the indicator: The indicator should be mounted preferably near to the engine cylinder to be tested. An indicating valve must be provided. If the indicator connections are arranged at the side of the engine cylinder, the indicator will be in a horizontal position. But neither this, nor suspended arrangement will affect the proper performance of the indicator. Preparatory Work for indicating: Prior to operation, lubricate the operative surfaces of the cylinder, piston, piston rod and piston rod guide with top - quality, non- viscous cylinder oil. ATTENTIO! Make sure that the seat of spring support (2) and the pertaining seat of under-part (39) are absolutely clean before inserting the upper-part. Always blow through the connection line before mounting the indicator to prevent wrong indication of the engine pressure by any condensed water, oil or soot deposits in the connection line. ATTENTIO! The valve ejects hot gas under high pressure. Danger of sparks and burning ! For later evaluation purposes it is very important to note the necessary data on the diagram, such as piston size of the indicator, spring number, engine number etc. Check the maximum pressure of the indicator spring!ATTENTION: Danger of injury during the measuring procedure caused by moving parts such as indicator spring (38), piston rod (26), drum cylinder (8) and pencil lever. Suitable gloves should be worn as the instrument will get very hot during operation. Cleaning and Lubrication: Strictly adhere to the following procedure: After every operation the Indicator must be thoroughly cleaned, oiled and replaced in its box. The instrument should be cleaned with a lint - free rag, the cylinder only with the cylinder cleaner stored in the box. The sliding surfaces of the cylinder and piston rod guide should be lubricated with top - quality, non - viscous cylinder oil (oil bottle stored in the box). If testing internal combustion engines, piston and rod should be lubricated periodically after 10 to 15 diagrams. With the same oil the links of the recording mechanism and the drum running surface should be lubricated occasionally after removing the drum cover. Carbon deposits on the piston or cylinder should never be scratched off, but always be removed by washing them with benzene or petroleum. Other LEUTERT Indicators : - Indicator Type 30 - Indicator for high-speed engines (Bar Spring Indicator Type S1) - Peak Pressure Meter Type MSI3 - Electronic Indicator Type DPI Accessory and Testing Equipment : -Valves ~Diagram paper - Indicator cord -Cord guide rolis -Cordandsteeltape —_- Spring testing devices OurEngineering Service will gladly give you recommendations. 4851.0.98,00020 - 01.99OPERATION MANUAL FOR COFFIN PLANIMETERGe THE PLANIMETER INSTRUCTIONS to measure areas & volumes GEBRUDER HAFF GMBH - TIROLER STR. 5 D-87459 PFRONTEN (GERMANY) TEL. +49/8363/9122-0 - FAX +49/8363/9122-33HAFF-Planimeter No. 313 (for cm’) (Ordering No 313 E) only in case Roller housing Measuring roller scale Dial and indicator ‘Tracing arm vernier Zero setting wheel Set lever = Fine adjustment Ring | Tracing lens = Tracing Point Support rest(for cm? and HAFF-Planimeter No. 315 sq. in.) (Ordering No 315 E) only in case Vernier ‘Supporting wheel Roller housing ff Measuring roller scale Dial and indicator ‘Tracing arm vernier Zero setting wheel Set lever Fine adjustment —— Set screw “Adjustable Ring Tracing lens Tracing Point ‘Support restHAFF-Planimeter No. 317 (for cm’) (Ordering No 317 E) only in case Vernier Supporting wheel Roller housing Measuring roller scale Dial and indicator Zero setting 4 wheel Ring - Tracing lens Tracing Point — Support restAlthough these instructions are written on the assumption that the reader has little or no knowledge of planimeters, engi- neers may well find them to be of interest, particularly towards the end of the booklet. HAFF Planimeters are fitted with a large, crystal-clear tracing lens, and a setting wheel with which to zero the scales. The lens enlarges the view of the line being traced and so makes possible a very high degree of accuracy, the setting wheel is Used to zero the scales without touching the internal mechanism, A. Introduction The planimeter is a simple instrument for the precise measurement of areas of plane figures of any shape. To measure an area itis only necessary to trace the outline of the figure ina clockwise direction with the centrepoint (within the ring) of the tracing lens and to read off the result on the scales. The planimeter consists of 3 separate parts; the tracing arm to which is attached the roller housing the pole arm and the pole plate. The three parts are packed separately in the case. The pole arm is a simple beam. On each endis fixed a ball, one for fiting into the roller housing, the other into the pole plate. The roller housing rests on three supports; the tracing lens, the measuring roller and a supporting wheel. B. Important points HAFF Planimeters are manufactured to give many years of accurate, trouble-free service but as with all precision instruments they must be handled carefully. Whenever the planimeter is not in use it should be stored safely in its case. The most easily damaged parts are the rim and bearings of the roller. The measuring roller is made of hardened steel and has a milled edge. Always use the setting wheel to zero the scales. The roller should run freely with only a little end-float. The accuracy of the planimeter can be checked at any time with the aid of the test area which is provided (see Section D 1).C. Using the planimeter Reading examples Set up the planimeter so that the tracing arm and lens are towards you. Attach the pole arm to the roller housing and to the pole plate, The pole arm should be approximately at right angles to the tracing arm, with the pole on the right (Fig 1). First move the zero setting wheel and watch the scale and the dial. Stop as soon as the 0 on the dial is covered by the indicator and the 0 on the scale is opposite the 0 on the vernier. The instrument is now in its Zero position (Fig. 2). Now move the tracing lens very slightly to the left and stop before the 0 on the vernier has reached the first of the calibrations on the scale. If now, for example, the 4" calibration on the vernier matches a calibration on the scale, then the scale has moved four Vernier Units (VU) towards the first calibration (Fig. 3). Next move the tracing lens a little further to the left until the 0 on the vernier is opposite the first calibration on the scale. The scale has now moved 10 vernier units (10 VU) or one calibration (Fig. 4). Ifthe scale rotates until the 1 on itis opposite the 0 on the vernier, it has then turned through 100 vernier units (100 VU) or ten calibrations (Fig. 5) ‘When the scale has made a complete rotation (passing all the figures from 1 to 9) and has returned to 0, it has turned through 1000 vernier units (1000 VU) or 100 calibrations. The dial now indicates 1 instead of 0 (Fig 6). Each of the ten figures on the dial corresponds to a complete revolution of the scale — 1000 VU To count the total number of units, we read the thousands on the dial, the hundreds and tens on the scale, and the units on the vernier. A final example should make the method of reading quite clear. In fig. 7 the dial is between 3 and 4, so the answer is between 3000 and 4000 VU, the scale has a reading between 47 and 48, so the answer is between 3470 and 3480 VU and the fourth calibration on the vernier corresponds with a calibration on the scale, giving an answer of 3474 VU, This is the sequence of observations which must be made whenever a planimeter reading is taken, and each of the four figures must be checked carefully. With a little practice the readings can be taken quickly and without error.Read here & check here Vernier (fixed) 4 IPTITTTT Measuring roller ° Reading here = 4 VU Vernier (fixed) 10 Measuring roller Fig. 1 Fig. 2 Fig. 3Reading 10 VU & check here Yeni | Oo (fixed) 10 witht MPT T =, Measuring roller vo Fig. 4 Vernier 9 Med) 49 pul ny TNT { thaosucing rote Fig. 5 Fig. 6 | =F aay lo | f*8ag rh cA hay Wt sing Fig. 7The value of the vernier unit (VU) ‘The HAFF Planimeter No. 317 has a fixed tracing arm which is set so that the value of the vernier unit is always 0.1 sq. cm. Number of VU sq.em One vernier unit (VU) = 1 0.48q.6m One calibration on the scale = 10 1.0sq.cm Distance between the numbers onthe scale = 100 10.0sq.cm One revolution of the scale or one calibration on the dial 1000 100.0sq.cm One revolution onthe dial 10,000 1000.0sq.cm The HAFF Planimeters No. 313 and 315 have adjustable tracing arms, the length of which can be varied to select the most useful vernier unit value shown in Table lil and IV (page 15). 1g Pole plate outside the figure” (usual) For these working areas: No. 313 315 317 jem | 20x40|5x65]302 | 20x40|5xe4]309 | 20x 40[5x65|302 The pole plate may be set down in any position outside the figure which allows the tracing lens to be guided round the entire outline. In the case of larger figures consult Section E 2. The length of the pole arm has no effect on the measurement when the pole plate is set down outside the figure. Starting and finishing point Fig. 8Tracing an area 1. Before tracing an area the tracing lens may be: ‘set down inthe middle of the area, The pole arm should be approximately at right angles to the tracing arm. Mark the starting point (which will also be the finishing point) with a line at right angles to the outline (Fig. 8). 2. Position the small centre ring of the tracing lens (which should be held in the right hand) exactly over the starting point (Fig. 9). At the same time, with the left hand, turn the Zero setting wheel until the dial and the scale both return to zero (Fig. 10). 3, Holding the tracing lens as shown in Fig. 9, race the outline inaclockwise direction with the small centre ring. Keep looking inthe direction in which the lens is to travel and try to keep the line inside the ring. 4. |tis impossible to hold the small ring exactly over the centre of the line all the time, so compensate for errors caused by going off the line to one side by going off an equal amount in the opposite direction. Extensive trials show that these errors do balance out. 5.When the outline has been traced and the small ring has returned to the starting point, the reading is taken. Let us assume that the reading is 4175 Vernier Units (VU). 6. The figure 4175 is the number of vernier units in the area. If the HAFF Planimeter No. 317 is being used, the value of the Vernier Unitis 0.1 sq. cm and the area is 4175 x 0.1 sq. cm. If the HAFF Planimeter No. 313 or 315 is being used, the value of the vernier unit and therefore the area, will depend upon the setting of the tracing arm. To find this setting, consult the table in the case and Table Ill or lV page 15. 7. Itis good practice to retrace the perimeter in order to check the accuracy of the measurement. The accuracy can be increased by taking the average of several readings - see Section D on the subject of accuracy.Fig. 9 Fig. 10Areas in different scales ‘The Planimeters Nos. 313, 315 and 317 can be used not only to measure areas in square inches or square centimeters in a scale of 1:1, but equally well to measure areas in any scale, providing that the measurements in sq.in. or sq. cm are con- verted with the aid of the appropriate factor. Shown in Tables land Il. (pages 13 and 14) Example — Planimeter No. 317 (m-system) Assume that a map is drawn to a scale of 1:5000. If an area measured on the map is 125.3 sq. om, the actual area is 125.3 x factor 2500 = 313.250 sq. m or 125.3 x factor 0.25 = 31.825 ha (See Table Il). Example —Planimeter No. 313 or 315 (m- and inch- system) If we assume that the area mentioned in the above examples has been measured with the Planimeter No. 313 or 315, the same result can be obtained if the tracing arm has been set according to the table in the case so that 1 Vernier Unit is equal to 0.01 sq. in. (0.1 sq. cm). Itis better however to aim at greater accuracy, and this can be achieved by choosing a shorter tracing arm setting as shown in Tables II! and IV. This makes the value of the vernier unit smaller; for example, if we make the value 0.008 sq. in (0.04 sq. cm), the measurement may now be 1346 (3130) Vernier Units or 1346 x 0.008 = 10.912 sq. in. (8130 x 0.04 = 125.20 sq. cm), which gives a full size area of 10912 sq. in x factor 0.0062 = 67.65 sq. miles. (125.20 sq. om x factor 0.25 = 31 .30 ha. Table | and Il). If an area is to be measured in a scale which is not shown in Table | or Il, the necessary factor, by which the area in sq. in. or sq. cm must be multiplied in order to obtain the result in sq. ft. or sq. m, can be calculated as follows: Inch Metric (2) Ge) Where f is the required factor and n is the scale realtionship. "Example (Inch): The factor f is required for a map drawn to a scale of 1/5 in. to 1 ft. i.e. 1:60. The area on the map measured in sq. in. can be expressed in 8. ft. by multiplying it by 25. Example (Metric) The factor fis required for a map drawn to a scale of 1:1820. 2 (400) = 18,20? = 331,24 100 The area on the map measured in sq. cm can be expressed in m? by multiplying it by 331.24. Tracer-arm settings for usual scales English Aerafor scale | 1verniorunit at 0.01 sa 1:1200 | 1008q.ft. | 100000q, ft. 72400 | 5008q.ft. | 5000005a. ft 124800 [1000000 sq.ft. ‘arm [_Meter_| Aerat. | Aerator setting [scale | 1VU_| revolution stat [at O.1cm? 100cm* 31.41 | 1:1000 | 10m 10000 m* 25.13_| 12500 | s0m* | 20000m™ 12.57 _| 1:5000 | 100m? | 100000m* 12Tabelle | (Inch-System) Factors by which the measured 13 Scale shown areain sq. in. mustbe onthemap | Seale multiplied to give the answor orplan inthe units shown atthe headof each ofthe columns. $q miles. Full Size 10} — | — | — veFullSize | 40} — | — | = VeFullSize we) — ;— 7) 3in.=1Mt 16. | ort] — | — 1%in. 64. | 0.444) — | — tin. 144.) 1.0 | — | — Sain. 256. | 1.778) — | — vain. 57. | 40 | — | — in. to2a. | 7.11 | — | — vain. 2304. |16.0 | — | — win. 9216. joao | — | — 1 — | 100) — | — tin — | 400; — | — Jin. — | 1600.)0.0367; — tin — | 2500,/0,0574) — Jin. — | 4356.|0.1 - Jin. — | 6400,0.147 | — in. — | 10000,/0.2206| — — | 10851,/0.2491) — tin. — | 17424/04 | — tin — | 27777.0.6377| — tin — | 40000./0.918 | — - — | 43403.|0.9963] — tin — | 90000.|2.0664] — tin — }108900.|2.5 _ — |160000./3.673 | — — _|173611.|3.98530.0062] — |435600.| 10.0 |0.0156] — | — | 400 |0.0625| — | — | 996 10.1557 — — | 160.0 |0.25 — | — |6227 |o973 640.0Tabelle Il (Metric System) Factors by which the measured area in sq. cm must be multiplied to give the answer in the units shown at the head of the columns. 0.01 0.0225 0.04 0.0625 0.09 0.414 7 0.16 250 0.25 275 0.5625 :100 1.0 1125 1.5625 £250 6.25 500 25.0 650 42.25 750 56.25 1000 100.0 11250 156.25 21440 207.36 1500 225.0 2000 400.0 2500 625.0 2880 829.44 3000 900.0 4000 1600.0 5000 2500.0 10000 10000.0 + 25000 50000 100000 * For measuring areasin the inch system with the planimeter 317. ‘The factor 0.155 is sq in, 14Tabelle Ill (Inch System) for 313 and 315 Tracingarmsetting | CorTotn. (Adjustable with the 10 sq.cm ‘in 10sq. in. Area Test Area) Test rea 1 4 Eon - approximate | ea exact | 0.010sq.in. | 10sq.in. 0.016sq.in. | 10sq.in. 0.014sq.in. | 10sq.in. 0.012sq.in. | 10sq.in. 0.008sq.in. | 10sq. in 0.006 sq. in. | _10sq. in. i Correctno. Tracingarmsetting | siemerunis | area (adjustable withthe 10sq.cm | in100sq.cm Test Area) | TestArea 1 3 4 approximate exact exact 31,41 O71 eG cm 100 sq.cm 28,27 “| o.09sq.6m | 100s9.cm 25.13 ~ [0,08 sa.em | 10059.0m 21,99 : 0,0759.em 100sq.cm 18,85 : J 0,06s9.em | 100sq.em 15,7 0,05sq.0m | “100sq.em “a pd ee re 12,57 0,04 sq. cm 15Adjustment of the setting of the tracing arm for variations in paper (313 and 315) It is possible that measurements made on some papers may give results which are slightly incorrect. This error can be removed by making a very small change in the setting of the tracing arm. Tables III and IV show in column 1 the approximate tracing arm settings for various vernier values. They are calibrated at the factory. Column 2’is provided so that the exact values may be recorded for the individual instrument after they have been determined with the aid of the test area (fig. 11) for 100sq. cm. The procedure is as follows: Position the tracing arm see section E in accordance with the label in the case so that, for example, at a setting of 31.41, 1 vernier unit (VU) = 0.1 sq. cm. and 1 revolution of the measuring roller scale = 100 sq. cm. when the scale is 1:1 Trace round the test area once. Make a note of the resulting reading in VU. If this is not exactly 1000, adjust the tracing arm setting to correct the error. (When the tracing arm setting is reduced, the reading will be increased, and vice versa.) When repeated measurements with the test area have proved the accuracy or this setting, read the position of the tracing arm, for example 31.54. This new setting is 1.004 times the original setting of 31.41. Now, all the readings given in column 1 of table IV should be multiplied by 1.004 and written in column 2. (Also in table II) nevertheless the test for 100 sq. cm was used) Also, all the tracing arm settings on the label in the case should be multiplied by 1.004 before starting to take measurements. This instruction is equally true for both the inch, and metric type planimeters. D. Accuracy 1. The precision of the instrument The accuracy of the instrument can easily be checked with the added test area (ellipse) for 100 sq. cm. This area is in the form on an allipse having an area of exactly 100 cm’ printed on film (fig. 11) a) Place the Planimeter as shown in the illustration, and measure the area of the ellipse as described on Page 9. ‘The measurement is correct when the measuring roller has made one complete revolution — from 0 to 0. This is equal to 1000 vernier units x 0.1 = 100 cm?. See Figs. 2 and 6. 16b) You can make some more circuits and record the reading after each. Two characteristics sets of readings are given below. Check A CheckB 1001 VU 1000 VU 2002 ” 2000 " 3002 ” 2999 4002 " 3999 5001 ” 4999 " 6001 ” 5998 " 7002 " 6997 " 8002 ” 7997 " 9003 * 8996 * 10003 * 9996 * Check A shows a small error in the initial setting of the vernier. The readings show how accurate the planimeter is. The error present in the first reading remains about the same in each successive reading, thus we can justifiably attribute it to human error in the initial setting, Check B shows a small but increasing deviation as each measurement is made. Both checks indicate an instrument error of less than 0.1% when measuring an area of 100 sq. cm (10 sq. in.). ) Further checks can be made with various distances between the pole and the test rule, moving the pole from the right to the left side, and by tracingin the opposite direction. These checks will show small variations in the results which vary for each instrument. The main purpose is to ensure that the instrument is in a generally good condition and is capable of giving consistent results. Ifitis found that the instrument gives higher readings when the pole is on ‘one side rather than the other, a measurement can be taken with the pole in each position and the average used. 7Fig. 11 2. Environmental factors External conditions are just as important as the accuracy of the individual instrument. The quality of the surface over which the measuring roller moves is perhaps the most important factor. I the paper is crumpled or torn, or has pin-holes in it, orifitis wavy or uneven in any way, accurate results can not be expected. The texture of the paper does not matter as long as itis constant over the whole surface. When working on an inclined plane the accuracy will be reduced and the possibility of accidental damage increased. The instrument is accurate at 20 degrees Centigrade = 68 degreeds Fahrenheit. 3. Human error ‘Some people obtain better results than others. A good eye, a steady hand and patience when tracing the outline are most important for good results. Good light and a comfortable working position also play a decisive role. 184. The size of the area to be measured Ifa square with sides 1 in. long is traced with an error of 0.01 in, outside the square, the area will be shown as 1.04 sq. in. instead of 1 sq 4% error. If the same mistake is made with a2 in. square, the result will be 4.08 sq. in. = a 2% error. The result for a 10 in. square will be 100.4 sq. in. = a 0.4% error. The larger the figure, the smaller the percentage error. Areas larger than that shown in Fig. 3 can be measured by placing the pole inside the figure. The accuracy of the measurements made in this way can be checked by drawing large circles of known radius and comparing the measured area with the calculated area. The values agree very closely, and it cannot be said that measurements taken with the pole inside the figure are, to any significant extent, less accurate than those taken with the pole outside. It has also been found that, contrary to statements often made in instruction books for planimeters, the accuracy does not decrease when the area is close to that of the neutral circle. To sum up, we can say that repeated careful measurements in favourable conditions will ensure an accuracy within plus or minus 0.1% with HAFF Planimeters, when the area to be measured is greater than 100 sq. cm (10 sq. in.). 19E. Significancy of the adjustable tracing arm and pole arm of 313 and 315 1. The adjustable tracing arm a) Purpose ‘As shown in the Tables Il! and IV several Vernier Units (VU) can be choiced. Especially for measuring small areas, small Vernier Units should be prefered. The accuracy of the result will be better. Every planimeter has its own characteristics which change in the course of time as parts wear. These changes can be compensated for, by adjustment to the tracing arm setting. Any change in the scale of old maps - caused perhaps by instability in the material on which they were drawn — can be allowed for in this way. A check can be made at any time with the test area, and any necessary correction can be made by the user himself — see Section D. (In the case of the No. 317 Planimeter a check can be made but there is no provision for adjustment). b) Setting the arm Loosen the set lever by moving the lever to the right. The roller housing can now be slid along the tracing arm, and using the fine adjustment wheel, set exactly to the required reading. The procedure is as foliows: —if the tracing arm is tobe set to a reading shown in Tables Ill or V, move the roller housing until the zero of the tracing arm vernier is close to the required setting, then with the thumb of the right hand press the fine-adjustment roller against the tracing arm. Light pressure is then sufficient to move the roller housing to the right or left until the setting is exactly as required. The set lever is moved to the left to lock it and the setting is checked. ( The general principle of using the vernier is set out in Section C, but in this instance be sure to tead the scale and vernier from right to left). The scale on the tracing armis arbitrary and serves only to make it easy to repeat settings previously determined.2. The adjustable pole arm on 315 a) Purpose Measuring large areas The length of the pole arm has no effect on the measurement when the pole is set down outside the figure, but itis, advantage that with it the maximum working area can be increased. It can also be useful to shorten the pole arm when working on a small drawing board. It is completely different when measuring with the pole inside the figure. In this case the length of the pole arm is, of decisive importance. When measuring areas larger than 20 x 40 om (8 x 16in.) or 30cm @ (12in. ) the pole must be placed inside the figure. The circumscription is done in the same way as when the pole is outside the figure, thatis, in a clockwise direction. To interpret the result, a constant which is printed on the table in the case, must be used. This constant is given in sq. cm and sq. in. and is the area of the circle which the tracing lens follows round the pole when the axis of the measuring roller is a tangentto the circle and the measuring roller does not rotate. If the area to be measured is larger or smaller than the constant circle, the rea~ ding given will be the number of vernier units by which the area is larger or smaller than the constant circle. Ifthe area is larger than the constant circle, the scale will have moved forward, and the area according to the scale is simply added to the area of the constant circle. If the area is smaller, the scale will have moved back, so that the reading will be the complement of the number required. To calculate this number, subtract the reading from 10000, This gives the number of vernier units the scale has turned through. Change this into an area in the appropriate units and subtract it from the area of the constant circle. The table inside the case shows the settings for both of the arms at which the constant circle has an area of 2000 sq. om and 200 sq. b) Setting the arm Loosen the set screw by turning it to the left. The inner square beam of the pole arm can now be moved gently. The set screw is then tightened by turning it to the right. Example 1. An area is measured with the pole inside the figure and the tracing and pole arms have been set according to the table. The reading is 2785 VU x 0.01 = 27.85 sq. in. When taking the measurement, the scale was moving forward, so the area is bigger than that of the constant circle and must therefore be added to it. 200 sq. in. plus 27.85 sq. in. is 227.85 sq. in. The area measured is 227.85 sq. in. atExample 2 (Uncommon). When taking the measurement, the scale moved backwards. The reading went to 7865 so the scale had turned through 10000 minus 7865 vernier units or 2135 VU. 21.35 x 0.01 sq. in. = 21.35 sq. in. This area is sub- tracted from that of the constant circle. 200 sq. in. minus 21.35 8q. in. is 178.65 sq. in. is 178.65 sq. in. = the area measured. Planimeters No. 313 and 317 These planimeters can also be used for taking measurements with the pole inside the figure, even though they do not have adjustable pole arms. The only difficulty is that the area of the constant circle will not be a simple figure (2000 sq. cm and 200 sq. in.) as with the 315 — itis on the label in the case —but itis stil used in exactly the same way. General An other way to measure large areas is to divide the area into measurable segments, measuring each separately and adding the results. 22F. Examples of applications To find the volume of earth required for an embankment. Sections of the embankment are drawn on the plan, their areas are measured and plotted in the form of a graph, the area under the graph is measured and from this the volume of the embankment is calculated. veh ne wenn an £7” th Taems te rho 3 Ji s Lf Forth to be ‘moved (w) are Fig. 12 e ‘The procedure is as follows. 1. From a contour map of the area, draw a series of sections as shown in Fig. 12 — the number and spacing of the sections depends on the rate of change of the shape of the sections. Itis not necessary to have the vertical and horizontal axes drawn to the same scale, in the example shown (reduced in scale) the width of the roads ina scale of 1 cm to.5m, while the height of the piled up earth and the length are toa scale 23of 1 cm to 4m. It must be remembered however, when measuring the cross-sectional areas, that 1 cm x 1 cm represents 5m x 4m. 2, Measure the cross-sectional areas and transfer them to the graph drawn alongside, in their appropriate positions. Join these points with a smooth curve in the usual way. 3. The area under the graph represents a volume in which 1 om x tom x 1 cm has a value of 5 m x 4m x 4mor 80 cu. m. That is, the area of 1 sq. cm under the graph represents a volume of 80 cubic metres of earth. 4. This area is now traced round and, for example, a result of 57.50 sq. cm obtained. The volume respresented by this value is 57.50 x 80 cu. mor 4600 cu. m. The method is equally valid, no matter what scales or units are being used. Calculation of the weight of a lamina The problem is to find the weight of a lamina such as that shown in Fig. 13. First calculate the volume by multiplying the measured surface area by the known thickness of the material, then multiply this by the density. In the example shown, the area is 8.5 sq. om, the thickness 0.12 om and the density of the material 7.86 gm/cc. The weight is then: — 8.5 x 0.12 x 7.86 = 8.017 gm. Fig. 13 Calculation of the capacity of a reservoir ‘A map showing contour lines for the area of the reservoir is required, and on this should be marked the proposed water level (Fig. 14). Then proceed as follows: — 1. In some convenient scale draw a vertical axis representing the depth of the water in the units being used. In this case the contour lines are at 10 metre intervals and the maximum depth is a little over 60 metres. 242. Measure the surface area of the water and transfer this to the horizontal axis at the zero depth level. This will be the maximum area and therefore the longest horizontal mea- ‘surement on the graph. Continue this process, measuring the area at each level and plotting the value on the graph. Join the points with a smooth curve. 3.Caloulate the volume represented by 1 sq. cm under the curve. In the example, 1 sq. cm = 10 m depth x 1000 sq. m area = 10000 cu. m, so that 1 sq. cm under the curve represents 1 x 10‘ cu. of water in the reservoir. 4, Measure the area under the curve in sq. cm — in this case 18.2 sq. cm — and convert this to a volume in cu. m by multiplying by 10*. The capacity of the reservoir is: 18.2 x 10 1.82 x 10° cu.m We can calculate the volumes of lakes etc. in the same way (provided that the contour lines are known for the various depths) and of objects above ground level in reverse profile, soto speak, such as slag heaps, tips and mounds of all types, whether man-made or natural 25To construct the integral curve of a given curve Erect ordinates to divide the given curve, (Fig. 15), into segments. They are shown equally spaced, butit is often better to arrange the spacing to suit changes of curvature. Draw up a table with four rows and as many colums as there are ordinates — including the extremes. Starting at the right hand or upper limit, with the planimeter reading zero, trace along the x-axis towards the left, noting in Row 2 in the table, the reading at the foot of each ordinate, until the left hand or lower limit is reached — the readings should be entered in the table in the same order as they are taken, i. e. from right to left. Having noted the last reading in the last space Row 2, put the same figure in the first - left hand— space in Row 1. Now trace round the curve as far as the intersection of the first ordinate with the curve, and then down the ordinate to the x-axis, where another reading is taken and entered in the table in Row 1 — starting from the left. Retrace the ordinate up to the curve again, along the curve and down the next ordinate to the x-axis and note the reading. Repeat the process all the way ronnd the curve until the right hand limit is reached. Sub- tract the values in Row 2 from the correspondig ones in Row 1 and enter the results in Row 3. These are the integrals, expressed in vernier units, of the curve between the lower limit and each of the ordinates. Convert these into units of area by multiplying them by the appropriate factor and enter them in the last row in the table. From these, and from the known upper and lower limits of the integration, draw the graph of the integral curve (Fig. 16) The second and succeeding integral curves can be drawn in the same way. 26A-point-at-a-time integration with Planimeter 313, 315 or 317 Integrand curve 1) Erect ordinates of suitable tle : intervals. 2) tort of the ri ui ce the as 2 fen tecfion, following ’ ° sien ” - Fig. 15 4) Enter the readings inthe table. 4) Enter the differences: VU 5) Mutiply by 0.1 for sq. em. Reodings (ee pars oes ]oere | poe vane oeoe| 9075] ane [a> azo] ass] em [ore | cov evs] eer poe] 9 [soe] vase] o727| “al fer" we | #| 7] | a8] ee] 0 | aoe] 200] 0] | P| -2 sa. em["o [20 | ao [rao] 2ns 0000 | 9002990] 920] 0 6) Plot the integral points 7) Draw the integral curve sodsq.em 27 z Fig. 16G. 1) 2) 3) 4) 5.) Formulas F=Lx U[sq. cm] F =N x f{sq. cm] Lx U=N x fo[sq. om] Meanings: F = Area(sq. cm] L= Length of the tracing arm (cm) from middle of the ring in the tracing lens up to the middle of the hole in the roller housing. (numbers engraved on the adjustable tracing arm are L:5. U = Circumface of the measuring roller d x 7 = ~ 6m N= Number of Vernier Units (VU) for one revolution of the measuring roller = 1000. fo = Value of 1 VU for scale 1 : 1 sq. cm or sq. in. 2 t= (a9 ) *to192- Meanings: { = Value of 1 VU for scale 1: sq.m n= scale fo = Value of 1 VU for scale 1: 1 sq. om nv? f= (=) % fo [sq. ft.] Meanings: f= Value of 1 VU for scale 1 :n sq. ft. n= scale fo = Value of 1 VU for scale 1 : 1 sq. in, 28Contents Page ‘A Introduction . .4 B_ Important points .. . ce 4 C__ Using the planimeter 5 Reading examples Working areas i 8 The value of the Vernier Unit ........... 8 Tracing round the figure . . . : 9 Areas in different scales... . : 1 D Accuracy 16 Test Area oe . 16 E_ Significancy for No. 313 and No. 315 -- 20-22 1. Adjustable tracing arm -. 20 2. Adjustable pole arm . . 2 "Pole inside the figure”... 66... .eeeee eee 24 F Examples of applications... - 23-26 Volume of earth for an embankment .. Weight of a lamina : +. 24 Capacity of a reservoir .. Construction of the integral curve... . G Formulas...Manufacturer of HAFF Planimeters: GEBRUDER HAFF GMBH D-87459 PFRONTEN (GERMANY) HAFF Planimeters are imported by

Instructions For Main Engine Type S60MC-C

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Instructions For Main Engine Type S60MC-C

Uploaded by

Copyright:

Available Formats

You might also like