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.INDEX Table of Content and Introduction Safety General Description Structural Parts Driving Gear Vibration Control Cylinder Unit Bearings Lubricating Oil System Compressed Air System Fuel System . Hydraulics Electronics Cooling Water System Gas and Air System « Performance Operation Control System Tools Spare Parts Installation Delivery Service Info Subsupplier's Info 02 05 o7 10 14 18 ape. 25 30 34 42 45 47 50 54 63 66 70 76 79 82 85 88 1HYUNDAI MAN B&W 0205-0100-0001 It Is Important that ali MAN Diesel engines are operated within the given specifications and performance tolerances specified in the engines’ Technical Files and are maintained according to the MAN Diese! maintenance instructions, in order to comply with given emission regulations. In accordance with Chapter | of the code of Federal Regulations, Part 94, Subpart C, §94.211, NOTICE is hereby given, that Chapter | of the Code of Federal Regulations, Part 94, Subpart K, §04.1004 requires. that the emissions related maintenance of the diesel en- gine, shall be performed as specified in MAN Diesel instructions, including, but not limited to, the instructions to that effect included in the Technical File. 14)HYUNDAI MAN B&W Technical Documentation MAN B&W G80ME-C9.2-TH Original instructions 12)IHYUNDAI MAN B&W) f ba fe = Ss S tes MAN Diesel & Turbo DK-2450 Copenhagen SV Phone +45 3385 1100 Fax +45 3086 1030 info-cph@mandieselturbo.com www tnandieselturbo.com Copyright © MAN Diesel & Turbo Allnights reserved, including reprinting, copying (Xerox/microfiche) and translation. 2@HYUNDAI MAN B&W Preface Introduction 0220-0100-0001 Preface Chapter Preface Chapter 0240-0100-0002 s £ 3 Ey 3 iS = =) 5 iB = FS} 3 & 3 a S S s Br eeu cy 10)HYUNDAI MAN B&W. 0220-0100-0001 Introduction < 3 A 3s £ 1. MAN Diesel | PrimeServ = 2. The manual ‘The MAN Diesel Group offers worldwide round-the-clock service, 365 days a year. Apart from the MAN Diesel service headquarters in Augsburg, Copenha- gen, Frederikshavn, Holeby, Stockport, St. Nazaire, Turbocharger and service centres on all continents provide comprehensive and continuous support. The Jong service life associated with MAN Diesel engines dictates a spare parts programme that ensures components are available for engines in operation for decades. Based on high-capacity machines, MAN Diesel service production facilities are able to comply with special customer requests with the utmost pre~ Cision and flexibility. 24-hour hotiine number: +49 1801 15 15 15 bitp:/www.mandiesel.com/orimesery The purpose of this manual is to provide general guidance regarding the op- eration anc maintenance, of a standard version of a MAN Diesel product e.g. main engine, auxiliary engine or propeller as well as to describe the design features of such @ product. This manual is of guidance only and if any doubt should arise regarding any data stated in this manual then the engine builder's documentation should be reffered to and/or MAN Diesel contacted. Deviations from a MAN Diesel product may be found in a specific plant. Ifs0 such deviations should be noted when ordering spare parts. Reliable and economical operation of the MAN Diesel product is conditional upon its correct operation and maintenance in accordance with MAN Diesel's, instructions and recommendations/quides. Consequently, itis essential that the engine room personnel are fully acquainted with the content of this manual. Furthermore, to ensure optimum efficiency, reliability and ittime of the product {and its components, only original spare parts should be used when replacing parts of the engine. S 3 I a 8 5 Pa a] 8 Ss 14)HYUNDAI] 0220-0100-0001 MAN B&W} 3. The manual structure ‘This manual is divided in to several chapters. Each chapter covering the com- plete documentation for its relevant content. Each chapter is made up from several document types e.g. 1065-0100-0001. ‘The documentation type number is the third and fourth digit, eer C0) Examples of document types are as follows. 15 - Preface 45 - Description 85 - Drawings 65 - Maintenance Workcard 70-90 - Spare part plates. ‘The following 5-8 digits are the Identification (ID) number of the document in the relevant chapter of a certain document type. ‘The last 4 digits form the edition number. Example: 2272-0420-0028 2 2 (0420 0028 Chapter | Document Type | 1D Number | Edition 4. Data designations Designations in a Workcard starting with a “T” or “F* refer to the information siven on the data sheets inserted in the beginning of the relevant Workcard. 5. Referring to this manual ‘When contacting MAN Diesol referring to this instruction manual, please include tile, edition no., and, if relevant, page no. Example: Piston - 2265-0401-0028 - Page 2 For a specific engine, also specify the name of the vessel, IMO number, engine number and engine builder. Example: Bow Firda - 9250751 - 052024 - MAN Diesel - 2272-0420-0028 = S i 3 I S &S x =I 2a)0220-0100-0001 6. Ordering of Spareparts \When ordering/requesting spare parts for any product by MAN Diesel, add the following information to ensure delivery of correct parts for the specific en gine: Document ID, Part Number, Quantity and Description. Notice tht a part ‘number can also be a Sensor cod identification number (e.g. PT 8501) as de- scribed in chapter 70 - Controi System. Tete ac) Example: Bow Firda - 9250751 - 052024 - MAN Diesel - 2272-0420-0028-017 - 8 pes - (Piston ring no. 1) NB! Item no, “000” orders the complete assembly as displayed on the plate. 7. Service Letters In order to ensure up-to-date manuals on operation and maintenance, MAN Diesel and its licensees, reguiarly send out Service Letters, containing first-hand information regarding accumulated service experience. Service Letters can either deal with specific product types or contain general instructions and recommendations for all products in a product range, and are used as a reference when we prepare up-dated instruction manual editions. ‘Therefore, since new Service Letters could be of great importance to the opera- tion of the plant, we recommend that the engine staff file them to supplement the relevant chapters of this manual or add them to chapter 88 - Sarvice Info, 8 Internet services MAN Diesel is always working on new and better ways to provide up-to-date in- formation and documentation for its customers. Visit our homepage for further details about the current services offered and how to access these. 9, Additional Information Further details may be found in: = Sub-supplier manuals ‘= Plant installation Drawings = Shop trial report = Sea trial report = EIAPP Technical File = s ig 3 I 2 Ss 8 I 3)HYUNDAI 0220-0100-0001 [MAN B&W) neces Us te) S =) i a s a 3 gs 8 ] 10. 1 Copyrights This manual is subject to copyright protection. The manual must not, wheter in whole or in part, be copied, reproduced, made public, or in any other way made available to any third party, without the prior writen consent of MAN Diesel. Responsible publisher MAN Diese! Tegiholmegade 41 DK-2450 Copenhagen: Denmark Homepage: http:/vww:mandiesel com Telephone: +45 33.65 11 00 Telefax: +45 93 85 10:30 VR. No.:31 61 17 92 44)HYUNDAI MAN B&W Table of Content Introduction 0240-0100-0002 “This chapter of the instruction book is intended to provide the user with a table of ‘where the various instructions are located. In addition this chapter is intended to provide the user with @ guide of how to use the instruction book as well as a description of the logical structure of the instruc- tion book. § 3 8 3 £ = % € Fe = 5 8 3 4 3 5 ud 1)HYUNDAI MAN B&W. Preface Chapter Safety 0540-0100-0002 Description Safety Precautions .. 0545-0100-0008 Tool Plate Safety Equipment 0570-0100-0001 a Fe r= 5 EI 2 i & 1)HYUNDAI MAN B&W. 0540-0100-0002 Safety ‘This chapter of the instruction book is intended to provide the user with relevant etaiis ofall the safety precautions which must be observed during operation end maintenance of the engine in order to obtain safe and reliable conditions. Hy 1)HYUNDAI MAN B&W 0545-0100-0006 1 General Correct aperation and maintenance, which Is the aim of this book, are crucial points for obtaining optimum safety in the engine room, The general measures ‘mentioned here should therefore be routine practice for the entire engine crew. 2 Engine Room Staff g aH A 8 3 cS a ‘4 fe Operation & Maintenance of MAN BSW Engines is to be cartied out by qualified professional personal e Mcimum safety eaioment requirements: 1. Safety Shoos. & 2, Hearing protection. 8, Bole suitor other protective wear, 3. Special Dangers Keep clear of the space below a crane with load. ‘Opening of cocks may cause discharge of hot liquids or gases. ‘Observe which way liquids, gases or flames will move, and keep clear. Dismantling of parts may cause the release of springs. Do not stand near turbo chargers in case of any abnormal running. Do not stand near crankcase doors or relief vaives - nor in corridors near doors to the engine room casing - when alarms for oit mist, high lube oil temperature, no piston cooling oil low, or scavenge box fire is registered. See also Section 6645, ese PTS0545-0100-0006 HYUNDAI MAN B&W. 4 Turning Gear @ a S s cs z 2 S Cy CCRT RLLLy Perry Before engaging the turning gear, ensure that the starting air supply is shut of, the main starting - and siow tuming valve are blocked and that the indicator cocks ere open. \When the turning gear is engaged, check that the indicator lamp “Turning gear in’ has switched on. The turing gear remote control is a critical devise and should always be kept in optimal working condition. Any fault in the devise or cable must be rectified before use. When operation the turing gear itis important to note the following: ‘The turning gear to bo operated by the remote control and only by the person ‘working on engine. Warnings must be given before each tuming. Operation of the turning gear from the switchboard must not take place while maintenance work is in progress in the engine. ‘Block the switch or place a sign “Do not touch” 5 Entering the Crankcase or Cylinder Always ensure that the turning gear is engaged and the brake is active, to prevent external forces or unbalance of the crankshaft from turning the crankshaft. ‘Check beforehand that the starting air supply to the engine and the starting air dis ‘ributor, is shut off and that the main starting valve is locked, In case of oll mist alarm, precautions must be taken belore opening to crankoase (0 chapter 6645-0300). Ventilate the crankcase about 30 minutes after stopping the engine, before entering, ‘Working inside the crankcase requires the use of fall protection harmess and, arrestor equipment. Working in the crankcase is minimum a two man job and good comunication must bbe maintained at all times. 2soe HYUNDAI MAN B&W 0545-0100-0006 ‘The turning gear must always be operated by the person(s) who enters the orank- case or cylinders. ‘The engine must never be turned with personal inside, 8 i i 6 Cleanliness ry 4 “The engine and engine roorn should be kept clean and tidy, OA iy rags must never be left around the engine room spaces as thay are highly famable and slippery. Remove any ol spi at once. I there is a risk of grit or sand blowing into the engine room, stop the ventiation end close the entiating ducts, skylights and engine room doors, ‘Welding, or other work which causes spreading of grit and/or swerf, must not be carried out near the engine unless itis closed or protected, and the turbocharger air intake fiters covered “The exterior ofthe engine should be kept clean, and the paintwork maintained, 80 that leakages can be easiy detected. 7 Fire Keep the areas around the relief valves free of oil, grease, etc. to prevent the risk of fire caused by the emitted hot i ‘the event that the relief valves open. Do not weld or use naked tights in the engine room, until it has been ascertained that no explosive gases, vapour or Iquids are present. Hf the crankcase is opened before the engine has cooled down, welding and the use of naked flames will involve the risk of explosions and fire. The same applies to inspection of ol tanks and of the spaces below the floor. Attention is furthermore drawn to the danger of fre when using paint and solvents having a low flash point. Porous insulating material, scaked with oil from leakages, is easly inflammable and shoud be renewed. See also chapter 6645-0290, 6645-0300 and ‘Sealing Materials’ in this chapter PUT 3m0545-0100-0006 8 Order/Tidiness Fs a Hy £ E = : F 9 Spares 10 Lighting Tey CU) HYUNDAI MAN B&W Hand tools should be securely fastened and placed on easily accessible tool pan- e's. Speciat tools should be fastened in the engine room, close to the area to be used. No major objects must be left unfastened, and the flaor and passages should be kept olear. Large spare parts shouid, as far as possible, be placed near the area to bs used, well secured, and accessible by crane. ‘All spares should be protected against corrosion and mechanical damage. The stock should be checked al intervals and replenished in good time. ‘Ample working light should be permanently installed at appropriate places in the engine room spaces, and portable working light should be obtainable everywhere, 24 safely lamps must be avaliable for use inside the engine. 11 Harmful materials Atways follow the manufactures specific instructions, ie. the material safety data sheet, Use protective gloves, goggles, breathing mask and any other recommended pro- tective gear, as stated in the material safety data sheet While handing harmful materials is it important to secure proper ventilation and shielding if needed. In the event of leaks or spillage, spread binding agants immediately and disposal according to the material satety data sheet 12 Lifting precautions Lif of engine components needs to be planned through all sieps of the lifting pro- cedure, When liting toads below 500 kg the use of a tackle is required. Lifting attachments are to be tightened into full contact with the component to be ited! Only use designated liting points, see Instruction Manual for guidance. 40HYUNDAI MAN B&W 0545-0100-0006 13. Working air Make sure the lowest Safe Working Load (SWL of the liting equipment in the Iit- ing chain is never exceeded. Keep lifting equipment clear of sharp edges. ‘Make sure to attach the load correctly on the crane hook. Always keep clear of the space below a crane with load. Use of working air requires safety goggles and gloves. Avoid blowing pressurised air directly at skin, 14 Sealing Materials 15 Hot Surfaces 16 Alarms Use gloves made of neopren or PVC when removing O-rings and other rubber! plastic-based sealing materials which have been subjected to abnormally high temperatures. First aid measures: In the event of skin contact - rinse with plenty of water - remove all contaminated clothing - consult a doctor - dispose of all material and ‘loves in accordance with laws and regulations. Beware of hot surfaces and use gloves. Itis important that all alarms lead to prompt investigation and ramady of the error. No alarm is insignificant. The most serious alarms are equipped with slow-down ‘and/or shut-down functions. Itis therefore important that all engine operation per- sonal are familiar with and well rained in the use and importance of the alarm sys- tom. PA 3 a é 3S ‘A Fe Cee 6)HYUNDAI 0545-0100-0006 MAN B&W. 17 Safety Precautions at Maintenance Before maintenance work is carried out, the engine must be stopped and blocked ‘according to the safety precautions given on the specific Data Page. Stop the Engine Shut eft starting ak supply - At stating ar receiver ‘Shut off starting ak Gstrbutor/distioutng systern supply ‘Shut of safety ar supply - Not ME Engines ‘Shut off contra ar supply 2 3 Fa Fe £ & re Pe © Shut of air supply to exraust valve - Only whan stopped lubricating oll pumps ) Engage turing gear “0 Shut off cooling water 3 Shut off fut oil Stop lubricating of supply Shut down hycraule power supply StATNGARSUPPLY VV FS srmeumsurer Py The crawing geste approximate locaton ofthe vahes concerned cateoeccncse ESso1304:0-00 HYUNDAI MAN B&W 0545-0100-0006 18 Datasheet signs Datasheets may include warning signs for special dangers that could arise in con- rection with the maintenance procedures. Pa S 5 FA Fy 4 rs ra 3 & Warning signs Mandatory action signs sonra Waning sen A ener mandate atin sign Explosive materia A Wear ear protection rep) AN were prtcion parse Da wee sty owes Etecticty / lwear protective gloves overnead vad Ja |wear face shield it sutoco wear head protection ensting ier ask lowneascorace | AY iar rept prteton ronmase WN ear satey harness. lonishing of hands. Jom pisconnect before canying out reverence Pressurized cynger AN er Cau Tenn am0570-0100-0001 MAN B&W) HYUNDAI oil Dia 742i) quawidinby Ayayeg DUE o12 024 1@HYUNDAI 0570-0100-0001 IMAN B&W. tem no Qty Designation 012 - — Fallarrest block 024 = Salety hook 036 = Rescue harness 5 3 bd 3 2 3 § 5 E 20)HYUNDAI MAN B&W Preface Chapter Description Maintenance General Description Software License. Designations (C1085 Section ... Maintenance Schedule. Maintenance Schedule 9740-0100-0002 19748-0150-0002 0745-0600-0001 0745-0800-0002 0760-0300-0002 0760-0801-0003 s = S A id Es = 4 B A ky Table of contents +)0740-0100-0002 General Description ‘This chapter of the instruction book is intended to provide the user with informa- tion regarding the software license which applies to this instruction book. In adai- tion various naming conventions (designations) used in the instruction book are explained, 3 5 7)HYUNDAI MAN B&W. 0745-0150-0002 Standard Conditions of Software Licence ‘Sofware supplied by MAN Diese! & Turbo separately or included as a part of any ‘system or embedded in any device is licensed by MAN Diesel & Turbo A/S (‘MAN Diese! & Turbo") subject to the customer's acceptance of the folowing standard conditions of cence, TAKING THE SOFTWARE IN USE WILL INDICATE THE CUSTOMER'S ACOEPT- ANCE OF THESE CONDITIONS. 1 Right of Ownership 2 Copyright 3 Support 4 Updating Software is delivered under a non-exclusive and non-transferable user's licence from MAN Diese! & Turbo against a onca-for-all fe. MAN Diesel & Turbo and its software suppliers retain the right of ownership to the software. {f the engine plant - for which the software is acquired - is transferred to a third pparty the customer has the right to assign the licance to this third party, provided thal the third party agrees to the terms of this licence agreement and provided that the customer does not retain any copies of the software, ‘The customer must not copy the software or ary part thereof. Furthermore the ‘customer is not alowed to make the software available to a third party or to reverse engineer, decompile or disassemble the software. If required by the customer MAN Diesel & Turbo shall provide technical support for installation and training in use of the software against separate payment. The non-exclusive user's icence doss not include any updating of the software. If and to the extent MAN Diesel & Turbo updates the programs or develops new ver- sions, such updates or new versions shall be made available to the customer ‘against separate payment. 5 Warranty & Liability MAN Diesel & Turbo warrants that the software and data media containing the software are free of defects in material and workmenship at the time of delivery. If ‘the software and data media are found to be defective and are retumed to MAN Diesel & Turbo within 90 days trom the date of daiivery, they willbe replaced fr of charge. 2 fA I Ss 2 5 F 3s 3 Ce Imuiy 72)0745-0150-0002 HYUNDAI MAN B&W Fa 4 8 cS] sa FS By 5 C7 Sry PR eta Except as stated above, MAN Diesel & Turbo discieims lability for breach of condi- tions or warranties, ether expressed or implied, with respect to the software and ‘data media, including werranties of suitebilty and applicabilty for a particular pur- pose. MAN Diesel & Turbo's liability for damages to the customer for any cause whatso- ‘ever, regardless of the form of any claim or action, shall not exceed the total licence fee paid by the customer for the license to use this software under this license agreement, MAN Diesel & Turbo shall in no event be liable for any dam- ‘ages resulting from loss of data, profi ts or use of equipment, or for any special, incidental consequential damages arising out of or in connection with the use or performance of the software. ‘The limitations in abilty stipulated above in this clause 0 shall also apply to MAN Diesel & Turbo's software suppliers, MAN Diese! & Turbo's tenders and contracts with customers regarding dalvery of ata and programs, inclucing the present licence agreement, shal be interpreted according to Danish Law. 2@)HYUNDAI MAN B&W. 0745-0500-0001 Normal layout \ Port side of ship _/ 4} Forward (fwd) \ \ i Pesan) Starboard (stb) side of ship Fore end Manoeuvring side of engine \ Aftend \ \ propeiter_/ D & 4 Clockwise direction of rotation _ defined from aft end of engine \Ssteth 3] Cyl. nos. always counted from fore end Exhaust side of engine (0745-0500-0001C01 Dr cn 3 8 By T(t)0745-0800-0002 HYUNDAI MAN B&W. wongas ss019 #1171911] eee es So y3d)3)9) 1)HYUNDAI MAN B&W 0760-0300-0002 General ‘The Checking and Maintenance Schedules indicate the intervals at which itis deemed appropriate to inspect the individual components of the engine and to ‘carry out overhauls, necessary, based on the engine condition or a criterion of time. The stated Regular chacks or Service interval are intended primarily as a guide, as differences in the actual service conditions, the quality of the fuel oil or lubricating oli, the treatment of cooling water, etc., will decisively influence the actual service results, and thus the intervals between necessary overhauling, Design mocifcations may necessitate a revision of the instructions, in which case the revised instructions and changed overhauling intervals, if any, will apply and supersede those orginally issued (See e.g our Service Letters). In addition to the checking and overhauling intervals stated in this schedule, please rote thet the periodical survey requirements of the classification society may require additional checks and reference is made to be carried out. For further infor- mation reference is made to the classification society. ‘The procedures are divided into five categories: Time-based condition checking procedures marked with @ C, under the heading Regular chooks or Service interval, deal with the service condition of a number of engine components, and form the basis for estimating whether further overhauing is nacessary. In a number of cases the con- ition checking procedures refer to the operation chapter of the instruction book, in which more detailed descriptions and working procedures can be found. Condition-based overhauling procedures marked with an O, under the heading Regular checks or Service interval. Under the heading Refer to (column P), a reference to adaitional information is stated. ‘This procedure number normally refers to one of the above condition chacking procedures which form the basis of the overhaul. For this reason, the intervals sta~ ted are for guidance only. Time-based overhauling procedures ‘also marked with an O, under the headings Reguiar checks or Sanvice interval or Based on observations, are the procedures where an actual basis for estimation is lacking. itis recommended, therefore, to carry out these procedures at the over- hauling intervals stated as a basis. “The letters © or C in Based on observations (column 8), indicate that spacial serv- ice conditions may make chacking or overhauling necessary beyond the actual standard schedules indicated. Trea 2 s rt Ey FS S tA g 8 2 Ss = co = = Fs 12)0760-0300-0002 HYUNDAI MAN B&W. cs 3 Fy ES s cA g 8 2 5 = cS Es 8 5 Initial checking procedures marked with a C, under the heading Check new/overhauled parts at 500, 1000 and 1600 hours {colurnn Hj, deal with inital checks that must be carried out on a new engina, or when parts have been replacad, ‘After the three intial checks have been completed, checks need oniy be carried ‘out as per heading Regular checks or Service interval. \When using electronic maintenance planning systems, special attention should be paid to al initial checking procedures, as handing of such procedures often can ot be done automatically. Instead such procedures must be handled manually Initial adjustment procedures marked with an A, under the heading Check new/overhauled parts at 500, 1000 and 1800 hours {column H), deal with inital adjustment that must be carried aut on ‘a new engine, or when parts have been replaced. After the three intial acjustments 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 al inital 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 tightener, 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. 2)0760-0301-0003 MAN B&W) HYUNDAI’ See ee Ea ere a TUCO (UCN MUMS) UILan TLD LT) BT a ROR) ‘SuoyoUs seam BuseeqGupieba1 eye £01108 puE 0010-SpGz UONEDSE 086 : ‘Su 9914) PanueWLs;p Uadsq seu LO} otf USL UO “palpeisul s!1veuidinbe CuvowoWN ream BuUe=e : perRuO 8q feu NEWIOAG : Z -siueu6e eneyew Buseeq pu synu 900) 4 9 0 | seqepins pur sejzzou heids oun EUS v vo vo seve, UY 1090-sori alu 9 9 sued L090 ° pou Budouu0g Locos ww | 0'9 | eo 9 eaysso1D t0z0-s0ri Ons | Steg Buyeooidiooy to10-sort 109 60 * oO SswoyUEID 3 5 é s6upoeig doy }og0-s901 u luo 22nNO 10 e8e9U219 2 9 soa fess 2 9 ‘siJ0g yOOUD Pug pus Lmog BUIPIOHY wojoo | fF ° AIeA Jollou @5eD3)ULID seg lemons a[ale{xl[afa;e{efrlzlrlH eunpeaod oN (uoyeredo yo sinou o00Px) euequl Santas Oy es Uopipuoo aig 49049 = sunoy 0084 PUP OOD ‘90s Ye sued pemeUiaxe/MOU MOBY =H suojenosqo vo poses : 10 poue9 0g 0} MEWOAD : 0 ho pouteo 9q 0) uowsn/py = peoeidal eq 0} seg: ‘UoRONASU! 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S4eNeUI 895: WL uonduosep 285 : A 3(6)HYUNDAI MAN B&W) 0760-0301-0003 “(oursious Buppryoup s189K g -xeU! 20 snoN QgO'ze: 5 ‘aWIED wal v 9 ‘sosuag wawecedsig 1090-$82¢ | wal v 2 s10sueg Aural roro-sezr wal v 9 swosueg [ane Loeo-seze wal iv 2 soyonu0g eameiodusoy, 1820-909 wal v 2 suosueg aunjeledie, Loz0-seze wal ov 9 sipjonuog eineserg tsto-sezr wa] v ° ‘suosuag aunsseid toro-sezr soquaioaia o alu ° 2 og 180 Kddhg 100d NeAPKH lozi-sese wie dw dung sunespéy e10j0@ soqesuEdWOD eq wef ow 80H eunecoid-y6IH ope KH wo 9 J8ln4 @ULd HO OAneADAH alo 2 4801, oBeyeo7 worst o4neaphe|| Loot-s8si ° ‘dang santo oHPEIDKH o90-sesr wfulo s semen wonton isso-seer ov] o 2 soqejnunooy Loso-sesr 0’ wun 9puiKo oaneipii | Loro-seee o}o weiss o4ne pH toco-soy wy fo und jo anes Lozb-s987 vo AeA Ka}eG JOTENIDY ONEA ° : : uowemoy even vsnewca |, > LoL0-s99y ‘sonesps ov a[elef[wlo{a,el|le{[»lezelrtea einpeaoie oN {(wonezedo jo sinow o00Lx eeu eoiniog op 1ej01 UogipUe® ey 29849 =D ‘sy Q0St PUE OOO ‘00S IP Swed pelne\eno/MeU 799KO : H suojenosqo vo pose : 4h peie0 24 04 MBL:END : ‘ho paireo 2g 0} 3uouenipy : 0aide! oq 0} Sued: ‘uoRanAsU! eu! 308 Uvonduosep 228: Ne ee on] Ea aa CRB Oo Reel ese aI Cam TLR U bol) OAR Oca 460760-0301-0003 SEE ee PUTO EC) CaM ceed LatyUanV eM Tb Pac) pats PTT BC) i 7a) baile 9 “0020-$h99 uonduoseg, ° ‘Buyuuny ejoeds oneA yoneU oL0-se9 wonezedg 99 ° 2 Jenejpey iene L080-sers ° ° conten ssed-fa Se Lo80-save Wa] o'o ° sobseyooqny 1020-065 ° 9 onten Aiajes senejoeys ay aBuanzos Loso-seps ° domojg Areypeny bos0-sers ° AIPA UIMIBE-UON 391000 sty @BLaAEOG Loso-sers ° NEA WIMEL-UON JemorE ArDCy Lo80-sers 00 J2USIBO ISIN BIEN Loz0-sers a for wershs ay efuenz9s, LoLo-sars waysAs ay pue seg +3] wy 2 ‘yoyiis 1809 Bun ° ° alo ° w]e tost-sezy wa} oo ° lozt-seze alo ° toos-sezr a[sle[zf[afale|lel|e ‘inpeddig "ON HYUNDAI MAN B&W (voneiedo jo sinoy 0001x) eMeiUI eOIAies WoRduosap 208AHYUNDAI MAN B&W, 0760-0301-0003 swueueg ‘inpaooig Supeouam t000-s892 uy resp 1020-999) 2A o4MEIPK oz0-s997 suena Bupton, ‘020-s902 Sinn pue smaiog 090-5992 9Bnep Byvoubu, toro-seez sauueds endo, 020-5902 senbie} Bauey6iL prepueis tozo-s90 wlio 9 to10-se0u ou o wn Od }OSt-$902 WA] WO Josuag oyoeL W0z1-s902 wh | vio sepoots eviy | 1014-902 wats4sosu09 o a[elel[efelalepel>lete ainpaoedd oN {vonesodo yo soy o00F x) eae eons 915g Uonpuo9 eta ¥o=uD 7 sinou Oost PUP 0001 ‘0081 sued poIne\AoAE/MOU HOU : ‘suoye1seeqo U0 posta | 1Ro poues 94.01 MEIN : she putea 6q 0} wausnipy: ¥ ‘eoe|co! oq OF sed ‘wonDnast §e¥eU! 988 : VI UoRBIOSEP 698: A SE ee eon) CUM CMC) Ueeeracy Uan mM at | aU CA) PTC P ORC 66HYUNDAI MAN B&W Preface Chapter Structural Pants phe 1040-0100-0002 ff Work Card Crankoase Reliefe Valve, Data ene 1065.0100-0001| Crankcase Reliete Valve 4065-0101-0002 fim Holding Down Bolts, Data 1085-0200-002 FY Holding Down Bolts .. a 1085-0201-0002 Sy Stay Bolts, Data... : 1065-0300-0012 FH Slay BOMS atone 1065-0301-0003 fil ‘Crankcase Oil Outlet, Data 1065-0400-0001 Crankcase Oil Outlet 1068-0401-0001 Tool Plate Hydraulic Tools for Holding-Down Bolts +1070-0220-0003, Hydraulic Tools for Large Parts 41070-0300-0006, ‘Crankshaft Tools. 7 41070-1030-0008 ‘Thrust Shaft Tools. 41070-1040-0007 Plate Crankcase Relief Valve . i 1072-0100-0002 Holding Down and End Chock Bots +1072-0200-0001 Stay Bolt... 2 +1072-0300-0001 Bed Plate o 1072-0400-0017, Frame Box, Details. el 1072-0830-0020 Frame Box, Covers .. 1072-0840-0018 Cylinder Frame, Details 1072-0710-0015 Crankshaft ‘Tuming Gear Turning Wheel . 7 Piston Cooling Arangemert ... Hyd, jack for Turning Gea. 1072-1000-0012 1072-1 100-0006E 1072-1200-0017 1072-1400-0002 1072-2000-001 Py ro s = 5 Es 3 i 0)HYUNDAI MAN B&W. 1040-0100-0002 General Engine Seating Holding down bolts Staybolts Bedplate Framebox Relief Valves WARNING Section: 10-01YY Regarding the engine seating for the specific engine, see the supplier's special instructions. Section: 1OXX-02YY ‘The bedplate is secured to the bottom of the ship by means of holding down bolts. Py 4 Ed = £ 2 = 7 Section: 100-097 ‘The bedplate, framebox and the cylinder frame are tightened together to form one Unit by means of staybotts. Section: 100-04VY ‘The bedplate is made in one section. The bedplate consists of two welded, longl= tudinal girders and a number of cross girders which support the main bearings. Each main bearing has one main bearing cap which are secured by studs and nuts, designed for tightening with hydraulic tools, ‘See also Description 2545-0 100 and Chapter 26 "Bearings". “The bedplate is fitted with an axial vibration damper. For the design and function- ing of the axial vibration damper, see also Chapter 18 “Vibration Contror”. Section: 10°0-06Y {A framebox is bolted to the top of the bedpiste. The framebox is made in one piece, Together, the bedplate and the framebox constitute the crankcase of the engine. ‘The tramebox is fitted with steelplate doors for access to the crossheads and to the main and crankpin bearings. For each eylinder, the framebox is equipped with a siotted pipe in which the piston ‘cooling oil outit pipe is fitted to the crosshead shoe is able to travel. From the slotted pipe the cooling ol is, through an outlet pipe, led to the oil tray of the bed- plate. Equipment for local checking of the coating cil temperature and flow, and for tern= perature and flow alarms, is installed in conjunction with the outlet pipe. See aso Descriotion 7045-0100. ‘On the exhaust side of the engine a number of spring loaded reli valves are fitted, ‘which will open in the event of excessive pressure in the crankcase/ chain casing, for instance as a result ofthe ignition of oil rit. Keep the areas around the relief valves free of oil, grease, etc. to prevent the risk of fire caused by hot air/gas emitted in the event that the relief valves open. eo rnmeury 14)1040-0100-0002 Pa = i cs 3 Fd Cylinder Frame Bores and openings Crankshaft BLU oem 7d Cylinder cover studs HYUNDAI MAN B&W Regarding how to: ‘avoid evaporation of the lubricating oil n the crankcase, : ‘detect oil mist in the crankcase using an ‘Oil Mist Detector’. ‘See Description 6645-0300. Do not stand near crankcase doors or relief valves - or in corridors near doors to the engine room casing in the event of an alarm for: a) oll mist »b) high lube oil temperature ‘¢) no piston cooling oil flow, or d) scavenge box fire ‘Alarms b, ¢ and d should be considered as pro-wamings of a possible increasing oil mist level. See also our Service Letter SL97-348/ERO. If there has been a crankcase explosion, the complete flame NOTICE arrester of the relief valves must be replaced. Section: 10%07YY ‘The oyiinder frame is designed win an integrated camshaft housing, The oylinder section is tightened together with the engine framebox and the beclate by means of stay bots. Alternatively es a complete welded assembly integrating the scav- lenge a receiver into the cylinder frame. Central bores at the top of the cylinder frame enclose the cylinder liners. Central ‘bores in the bottom of the cylinder frame enclose the piston rod stuffing boxes. (On the exhaust side of the cyinder frame there are openings which connect the ‘scavenge air space around the cylinder liner with the longitudinal scavenge air receiver of the engine. There are also inlet pipes for cooling and lubricating oll. The cylinder frame is provided with cleaning and inspection covers giving access to the ‘scavenge air spaces. ‘Studs for fastening the cylinder cover are mounted in the oylinder frame. The crankshaft is either of the semi-built type, where the parts are shrunk together. 2 (4)HYUNDAI MAN B&W Turning Gear 1040-0100-0002 ‘The main bearings are lubricated via @ main lubricating oil pipe that branches off to the individual bearings, whereas oil for lubricating the crankpin bearings is supplied from the crossheads through bores in the connecting rods. ‘The crankshaft is provided with a chain wheel for the camshaft drive and a turning ‘wheel. Furthermore, a tuning wheal, @ torsional vibration damper and a chain whee! drive for 2nd order moment compensators are installed, if required accord- ing to vibration calculations. See chapter 18 “Vibration Contro!”. Marine engines (except geared plants): {At the aftmost end of the engin, a thrust bearing is fitted, See chapter 25 “Bear ings’ Stationary engines and geered marine piants: ‘The crankshaft is provided with a collar for the guide bearing. The purpose of the {guide bearing is to keep the crankshaft in is proper position in the axial dlrection. ‘The turning gear is fastened to the engine bedplate and is driven by an electric motor. Via a worm gear and a following planetary gearing, the motor drives a horizontal shaft equipped with @ gear wheel, which can be axialy displaced manually so as to ‘engage with the turning wheel of the engine. This displacement is performed by means of a big vertical lever placed on the pro- tecting shiold of the gear wheal. A small vertical lever, placed on the end cover of the protecting shield of the turning gear, focks the position of the big laver in, respectively, engaged and disengaged position between the gear wheel and turn- ing wheel Locking is performed by engagement of a tap of the smalilever into two notches Of the big vertical aver. When the big lever is in its most forward position, the turning gear is not engaged with the turning wheel. Engagement of the gear wheel with the turning wheel is achieved by moving the big lever to its most aftwards position. In this position, an interiock valve inserted in the starting air system of the engine Is actuated by the big lever. This interlock pre~ vents starting air from being supplied to the engine as long as the turning gear is in the engaged postion. ‘Through an inspection groove at the top of the protecting shield, it must always be ensured that the gear whee! isin correct position according to the planned opera- tion of the turning geer. Always ensure that any of the two positions of the big lever (engagement/cisen- gagement of the turning wheel] is locked by the small lever. ‘See also Description 6645-0120. 2 2 5 4 £ 3 2 7] Ree od 3 (4)1040-0100-0002 2 s & FS -} 3 2 ra BORO Emu HYUNDAI MAN B&W Dismantling of working parts: During any dismant of working parts of the engine, the tuming gear must be in the engaged position in order to prevent outside forces. from tuming the engine, thus causing injuries to personnel or damage to the machinery. See Workcards, Datapages. Pressure testing of starting valves: Tho turning gear must be in the disengaged position during pressure testing of starting valves, as a leaky valve may cause the engine to rotate, and damage the tuming gear. See Description 6645-0170. 4)9080-00 HYUNDAI MAN B&W. 1065-0100-0001 Safety ~ Stop the Engine ee Precautions (50 Shut of Santing ai supply “A Staring air reostver Fs fer cetaied sketch r ra} ee 0645-0100 a 2 [Se 5 - Gy pert safety a s [PSP shut off conwel ar eupely Fe Engage turing gear eo g 677 Biep lubricating of supe =e z @ ot down Mcrae PONer supely Fy By & rs £ cy Data Description Value Tabi ery on purpose, No Data needed [ Dae 1)1065-0100-0001 HYUNDAI MAN B&W Tools Ss I ¢ e s a] a Es By od A & Se SST) The task-specific tools used in this procedure are shown on the plates at the end ofthis chapter or in the chapters incicated by the fst two cigits inthe plate num- bor, €.g. 2570-0010 refers to chapter 25, Bearings. Plate tem No, _Deseriphion ‘Tabla is emply on purpose. No special tools needed, 212)1065-0101-0002 Leaks During Running During running of the engine, check if there are any leaks. If aleak occurs, replace the O-ring inside the relief vaive. ‘See separate instructions from the valve manufacturer, D es ed $ Fy 2 Ss 5 es 2 a s s ry 4 Ghecking the plates If work invotving risks of mechanical damage to the flame arrester has taken place, a visual inspection of the flame arresier should always be performed before starting the engine. Cheek on the whole circumference that all the plates in the flame arrester are evenly distributed and that no local openings exist. Ifone or more plates in the flame arrest- er are damaged, the relief valve must be disassembled and the flame arrester replaced. ‘See separate instructions from the valve manufacturer. ‘The complete flame arrester has to be NOTE replaced after a crankcase explosion. BLS Mca 1o6s-o101-oncaose 14)HYUNDAI MAN B&W. 1065-0200-0002 Safety 7 Stop the Engine Precautions oe eta skatoh $860 0545-700 A®@ Data 76-02 Hy¢rauic pressure, mount =) 3 3 7 3 2 S z = Fy = By A ry Ey = ad J Es overt Ps mrnm Uy Pat1065-0200-0002 HYUNDAI MAN B&W £ a it a Ff Fy 2 ro ot = Pr oI 5 os 2 A 6 = esmiaumuid Tar 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 frst two digits in the plate num- ber, @.g, 2570-0010 refers io chapter 25, Bearings. Plate 1070-0200, 7870-0100, 7670-0100 ttem No, on oar Description Hydraute Tools for End- Chock Bolts Hydraule pump, pneumaticaly operated Hose with unions, 1800 mm 2Q)HYUNDAI MAN B&W 1065-0201-0002 Tightening the Holding Down and End Chock Bolts Ls 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 7665-0101. The normal tightening pressure is indicated on the Data sheet and is also stamped on the tightening tool. ca a = o - ‘ So S ps J a x ° 8 2 iz 2 = i] = =e Ss S 2 iS a a Dare 1065-0201-0002 161065-0201-0002 POWER sure elaa fe) cece) Lott] Work Card Pe s Ss 2 = ed ia nA oS Ss ‘Checking the bolt tightening Checking of epoxy ‘supporting chocks ‘The holding down bolts and end chock bolts must be checked for correct tight- ress at the intervals indicated on the Data sheet. For this purpose, raise the pressure on the hydraulic tool slowly while constant- ly attempting to loosen the nut with the tommy bar. The oil pressure indicated (on the pressure gauge when the nut comes loose (ioosening pressure’) is, to be noted in the checking tables, see pages 4 and 5, following which the bolts are tightened to the normal tightening pressure. ‘The condition of the bolted joints, and thus the general condition of the foun- dation, can be effectively checked by comparing the tables from successive bolt checks, I 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. 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 retight- ening of these. The distance between the measuring pins and the bedplate is to be measured with a blade gauge and noted down. Any possible settling of the chocks during the intervals between measurements can thereby be followed, 26)Side chocks and side chock liners 1065-0201-0002 Alter fitting the finers to an 80 per cent contact area on both sides of the lin- ‘rs, knock the liners a further 3 to 4 mm. inwards. The liners located in way of each main bearing on either side af the engine must be fitted and knocked into position simultaneously. The first time the ship is sailing in a fully-loaded concition after the engine has been operating for 1,000 hours. all side chooks should be checked to see whether the liners can be knocked fur ther inward, eae The fit ofthe 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 fesler gauge is applied at the 7 points indicated in the table on page 5, 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 necessary, If the measurements at 3 points or more have increased 5/100 mm or more: from the initial results, we recommend thet 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 in the table, 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. 7 a 4 = 3 — o 2 - a = 3 Ss — oS =f a =) Ss oS e = Ss a =) = a S 4 Sa 1065-0201-0002 36)HYUNDAI 1065-0201-0002 MAN B&W Holding down bolts Port side [cylinder] Starboard side ome | ae [emeis | No. [peswe [am [ome = = = o 3 2 by 5 pi i} =) ~ ro 2 fz 2 = i =) 2 S e ES S a =) = hs Ss Es z 5 * i {0ss-c20r-0097008 arty Bisse AU ett 46)HYUNDAI MAN B&W. 1065-0201-0002 ‘Side chocks and pal end chock bolts = Port side starboard side 4 le Point Cynder Point loos] mTATB]cldftelf |g] no, Al Bil c{dle]f[g | c= 7 ; T| & 2 = Z| Fa 3 3 3 oo 4 4| be 5 + 5 3 6 | 7 7) & & 5) ie E 9 z i 10 ot i TT] FS 12 12] 13 LE a 14] pt Es FORE — AB s a ar | starboard side Point [Bim [Be Peo] cn ela] BTeT ae] % [bar | No-|No. ft z E be 4 city — ae we __ Contact face a a2 2.8 AFT Bf 05-201 2001008 1065-0201-0002 car) 56)HYUNDAI MAN B&W 1065-0300-0012 Safety [87 Sop the Engine ; Precautions 5 2 (or datied shot cy 580 0548-0100 Fe i} z= a Data Ref. Description (FIO? | Check measurement "176.01" Hyrule pressure, demanting [F702 [yea ress, uring Mae “0 112)1065-0300-0012 Special Tools g s 8 i | a cy Peel Scere RHE HYUNDAI MAN B&W. “The task-specifc tools used in this procedure are shown on the plates at the lend of this chapter or in the chapters indicated by the first two digits in the plate number, ¢.g. 2570-0010 refers to chapter 25, Bearings, 7572-0100 08 757B.0106 | os wth ater, 3000 ra TeTE0100 | 118 Sway sour beck compete 2@)HYUNDAI MAN B&W. is Remove Caps. Check for loose nuts Tightening sequence 1065-0301-0003 ‘The first time this check is per- formed it has to be completed in one operation. The following checks have to be completed within a 500-hour period. Before retightening the stay bolts, remove the protective caps, Check for loose staybolt nuts with the tommy bar i 110-7 Hf a loose nut is found, unscrew the nut until a gap occurs between cyi- inder frame and nut Loosen and unscrew the nut on the 4 C7 Mar BUS UXIU tL) Placing of hydrauiic tools Tightening stay bolts (On completion 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, 50 that the two stay bolts are tightened in one pair. Reconnect the hydraulic tools to the air of stay bolts first tightened. Tighten to 10% below T76-2 and check if the nut is loose. If the nut is not loose: Tighten the stay bolts to T76-2. Ifthe nut is loose: Tighten all stay bolts once again to 176-2. Atter completing the retightening proce- ‘dure, mount the protective caps. HYUNDAI MAN B&W 2 S: +055-0901-0002002 e 2 1066-0004 0002005 2@)