Page

H21/32 1/1
Section No. Rev.
Timing Gear Arrangement General Instruction
⹖┊ᦣ ெ⍊ ᧆ⯮ṗ⹲ ┒᦮ ❖⯾
G35000 1B
G
G
ল␪# Description
⹖┊ᦣ# ெ⍊⓮# ᧆ⯮# ṗ⹲ဪ# ⸂ᕃ⸂# Ṻ㊚ぎ# ெ⍊/# ㋲# The timing gear arrangement consists of a
ল⓮# ⋚┊ቺ᝗# ெ⍊# Ⓐၞぎ# ᦥ# ⰶ# Ṻ㊚ぎ# ଂᅯ# ெ⍊ᗲ# crankshaft gear, one Idling gear assembly, and a
ଂệᆲၺ1# ⸂ᕃ⸂# Ṻ㊚ぎখ# ㋲᨞# 㐢▚㋮᠊/# ⰶ# Ṻ㊚ぎဪ# camshaft driving gear. When the crankshaft rotates
⋚┊ቺ# ெ⍊ᜒ# ⽋㌊# ᅯ┒㋲# ᦿ㌻ⓒᗲ# 425# 㐢▚㋲ၺ1# one time, the camshaft rotates a half in the same
 direction through the idle gear.

ⰶ# Ṻ㊚ぎ# ଂᅯெ⍊# # # # # # A35000
# # # # # # # # # # ဪ# ኪ›⸂ᜒ# ⽋ The camshaft drive gear A35000 is fixed

㌊Ẳ# ⰶ# Ṻ㊚ぎ⍦# ᬖ⦿ᆲၺ1# to the camshaft through disc.

⋚┊ቺ᝗# ெ⍊# # # # # #A35000

# # # # # # # # # ဪ# ⸆# ெ⍊⏖# ┧ⓖ# ெ The idling gear A35000 consists of big

⍊খ# ⎊ᦫⓢᆲ# Ⓐၞぎ┊ၺ1# ┊# ெ⍊ဪ# ⰶ# Ṻ㊚ぎ# ଂᅯ and small gear parts, which are shrink fitted. It can

ெ⍊ᜒ# ᰒ๎# 㑚# ⒭# ᦿ㌻ⓒᗲ# ቺ⍊๎ၺ1# be take out upward, after the camshaft gear is

 dismantled.


⸂ᕃ⸂# Ṻ㊚ぎ# ெ⍊# # # # # # A35000
# # # # # # # # # # ဪ# ⒚⯮੶▫# ㋖ The crankshaft gear A35000 is of two

ⓚ# খ❚# ᇦ# ᬖᬚⓒᗲ# ᬚᝂ# খျ㋲# ⹖┛┊ၺ1# ┊# ⸂ᕃ⸂# parts type with locating pins. It can be dismantled

Ṻ㊚ぎ# ெ⍊ဪ# ⍪❚# ᮪ᗳ⓮# ⮷᠊# ⱺᨚᜒ# ⽋㌊# ᬚ㌊# খ through the side cover of engine block.

ျ㋮ၺ1#

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 07.03/YJHG
 Page
H21/32 1/3
Section No. Rev.
Crankshaft Gear Assembly Assembly Drawing & Part List
⸂ᔧ⸂ Ṻ㊚ぎ ெ⍊ ⍊Ở᮪ᝂ ☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
A35000 1B
G

G
G
G
116 115 111
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G 192 110 191
G
G
G
Part List
G

Weight
Item No. Description Q’ty / Eng. Remarks / See Note
(kg)

110 Crankshaft gear ass’y 1 40 Incl.item 111,115,116

111 Crankshaft gear 1 39
115 Socket head bolt 4
116 Cylindrical pin 2
191 Hex.bolt 9
192 Cylindrical pin 1
G

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 06.05/YJHG
 Page
H21/32 2/3
Section No. Rev.
Idle Gear Assembly Assembly Drawing & Part List
⋚┊ቺ ெ⍊ ⍊Ở᮪ᝂ ☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
A35000 1B
G
G
G 222
G
294
G
G
G 293
G 221
G
223
G
G
291
G
G
292
G
G
G
G
G
G
210 213 212 211

Part List
G

Weight
Item No. Description Q’ty / Eng. Remarks / See Note
(kg)

210 Idle gear ass’y 1 44 Incl.item211,212,213

211 Idle gear - big 1 24
212 Idle gear - small 1 18
213 Bearing bush for idle gear 1 2
221 Shaft for idle gear 1 12
222 Orifice for idle gear lub. 1 0.5
223 Support for idle gear 1 13
291 Socket head bolt 4
292 Hex. bolt 6
293 O-ring 1
294 Socket head bolt 2
G

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 06.05/YJHG
 Page
H21/32 3/3
Section No. Rev.
Camshaft Gear Assembly Assembly Drawing & Part List
ⰶṺ㊚ぎ ெ⍊ ⍊Ở᮪ᝂ ☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
A35000 1B
G
G
G 393 395 311 332 396 331

G
G 409
G 333
G 334
G
G 398
G
G 335

G
394
G
G
G
397
G
G
G
G
Part List
Weight
Item No. Description Q’ty / Eng. Remarks / See Note
(kg)

311 Camshaft gear 1 31

331 Thrust bearing support 1 21
332 Thrust bush for camshaft 2
333 Thrust shaft for camshaft 1 11
334 Flange for camshaft thrust 1 1.2
335 Cover for thrust bearing 1 1.5
393 Stud bolt 12
394 Hex.bolt 6
395 Nut 24
396 O-ring 1
397 Cylindrical pin 1
398 Socket head bolt 4
409 Hex.bolt 8
G

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 06.05/YJHG
 Page
H21/32 1/4
Section No. Rev.
Timing Gear Arrangement Assembly Drawing & Part List
⹖┊ᦣ ெ⍊ ᧆ⯮ ṗ⹲ ☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
A35000 2B
G

222

294

232 294

Weight
Item No. Description Q’ty / Eng. Remarks / See Note
(kg)

222 Orifice for idle gear lub.(nozzle)-CW 1 0.5 Engine rotation CW

232 Orifice for idle gear lub.(nozzle)-CCW 1 0.5 Engine rotation CCW

294 Socket head bolt 2

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 07.08/YJHG
G
 Page
H21/32 2/4
Section No. Rev.
Crankshaft Gear Assembly Assembly Drawing & Part List
⸂ᕃ⸂Ṻ㊚ぎ ெ⍊ ⍊Ở᮪ᝂ ☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
A35000 2B
G

G
G
G
116 115 111
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G 192 110 191
G
G
G
G
Part List
Weight
Item No. Description Q’ty / Eng. Remarks / See Note
(kg)

110 Crankshaft gear ass’y 1 40 Incl.item 111,115,116

111 Crankshaft gear 1 39
115 Socket head bolt 4
116 Cylindrical pin 2
191 Hex.bolt 9
192 Cylindrical pin 1
G

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 07.08/YJHG
 Page
H21/32 3/4
Section No. Rev.
Idle Gear Assembly Assembly Drawing & Part List
⋚┊ቺ ெ⍊ ⍊Ở᮪ᝂ ☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
A35000 2B
G
G
G
G
G
G
G 293
G 221
G
223
G
G
291
G
G
292
G
G
G
G
G
G
210 213 212 211

Part ListG
Weight
Item No. Description Q’ty / Eng. Remarks / See Note
(kg)

210 Idle gear ass’y 1 44 Incl.item211,212,213

211 Idle gear - big 1 24
212 Idle gear - small 1 18
213 Bearing bush for idle gear 1 2

221 Shaft for idle gear 1 12

223 Support for idle gear 1 13

291 Socket head bolt 4

292 Hex. bolt 6

293 O-ring 1
G

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 07.08/YJHG
 Page
H21/32 4/4
Section No. Rev.
Camshaft Gear Assembly Assembly Drawing & Part List
ⰶṺ㊚ぎ ெ⍊ ⍊Ở᮪ᝂ(Bolt) ☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
A35000 2B
G
G
G 311 393 395 332 396 331
G
G 409
G 333
G 410
G
G 334
G
G 398

G
G 335

G
G 394
397
G
G
G
G
Part ListG
Weight
Item No. Description Q’ty / Eng. Remarks / See Note
(kg)

311 Camshaft gear 1 31

331 Thrust bearing support 1 14
332 Thrust bush for camshaft 2
333 Thrust shaft for camshaft 1 11
334 Flange for camshaft thrust 1 1.2
335 Cover for thrust bearing 1 1.4
393 Hex.bolt 10
394 Hex.bolt 6
395 Washer 10
396 O-ring 1
397 Cylindrical pin 1
398 Socket head bolt 4
409 Hex.bolt 8
410 Gasket 1
G

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 07.08/YJHG
 Page
H21/32 1/4
Section No. Rev.
Timing Gear Arrangement Assembly Drawing & Part List
⹖┊ᦣ ெ⍊ ᧆ⯮ ṗ⹲ ☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
A35000 3B
G

222

294

232 294

Weight
Item No. Description Q’ty / Eng. Remarks / See Note
(kg)

222 Orifice for idle gear lub.(nozzle)-CW 1 0.5 Engine rotation CW

232 Orifice for idle gear lub.(nozzle)-CCW 1 0.5 Engine rotation CCW

294 Socket head bolt 2

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 07.08/YJHG
G
 Page
H21/32 2/4
Section No. Rev.
Crankshaft Gear Assembly Assembly Drawing & Part List
⸂ᕃ⸂Ṻ㊚ぎ ெ⍊ ⍊Ở᮪ᝂ ☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
A35000 3B
G

G
G
G
116 115 111
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G
G 192 110 191
G
G
G
G
Part List
Weight
Item No. Description Q’ty / Eng. Remarks / See Note
(kg)

110 Crankshaft gear ass’y 1 40 Incl.item 111,115,116

111 Crankshaft gear 1 39
115 Socket head bolt 4
116 Cylindrical pin 2
191 Hex.bolt 9
192 Cylindrical pin 1
G

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 07.08/YJHG
 Page
H21/32 3/4
Section No. Rev.
Idle Gear Assembly Assembly Drawing & Part List
⋚┊ቺ ெ⍊ ⍊Ở᮪ᝂ ☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
A35000 3B
G
G
G
G
G
G
G 293
G 221
G
223
G
G
291
G
G
292
G
G
G
G
G
G
210 213 212 211

Part ListG
Weight
Item No. Description Q’ty / Eng. Remarks / See Note
(kg)

210 Idle gear ass’y 1 44 Incl.item211,212,213

211 Idle gear - big 1 24
212 Idle gear - small 1 18
213 Bearing bush for idle gear 1 2

221 Shaft for idle gear 1 12

223 Support for idle gear 1 13

291 Socket head bolt 4

292 Hex. bolt 6

293 O-ring 1
G

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 07.08/YJHG
 Page
H21/32 4/4
Section No. Rev.
Camshaft Gear Assembly Assembly Drawing & Part List
ⰶṺ㊚ぎ ெ⍊ ⍊Ở᮪ᝂ(Bolt) ☆ᝓᅚ ᦥ ᬖ㈞ ᠿᗳ
A35000 3B
G
G
G 311 393 395 331
G
G
399 396
G
G
398
G
G
333
G
G
G
394
G
G
G 397
G
G
G
G
G
G
Part ListG
Weight
Item No. Description Q’ty / Eng. Remarks / See Note
(kg)

311 Camshaft gear 1 31

331 Cam thrust bearing ass’y 1 20
333 Thrust shaft for camshaft 1 10
393 Hex.bolt 10
394 Socket head bolt 8
395 Washer 10
396 O-ring 1
397 Cylindrical pin 1
398 O-ring 1
399 O-ring 1
G

G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 07.08/YJHG
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 Page
H21/32 1/4
Section No. Rev.
Camshaft Gear Assembly(Bolt) Maintenance Procedure
ⰶ Ṻ㊚ぎ ଂᅯெ⍊ ⍊Ở᮪ᝂ(᪒ぎ) ▫ᯚ▦ਖ ▞⦾
M35300 2A
G
G #

⹖┊ᦣ# ெ⍊⓮# ▫ᗂ# Alignment of Timing Gears

⹖┊ᦣ# ெ⍊ဪ# ⎆ᙢ# ᬚṂ⓮# ⹖┊ᦣ઒# 㓷2ᧆெ⓮# ⑊ᅯ# The timing gears control the timing of fuel injection
ⓚ# ▲⍊㋮᠆/# ┊ਙⓖ# ⍪❚# ệျ઒# ⁶ᙆệⓚ# ⒚㌊# ⚧␪㋮ and movements of intake and exhaust valves, which
ၺ1G is critical for the engine performance and reliability.#
ெ⍊⓮# ⹖┊ᦣⓖ# ☆▫㋶# ᾮ# ⍜੶/# ၾ❖# ▫ᯚ# 㑚# ெ⍊⓮# The timing of the gears is not adjustable and only
╂☆ᝓ# ⁲/# ▫㏫㋲# ▫ᗂⓚ# ㋚␪ᗲ# ㋲ၺ1G needs correct alignment when remounting of the
G gears after maintenance.#
㋮ฮ⓮# ┝ᾮᔒᅚ# ▲႖ᗲ# ▫ᗂᆮ❖# ⋠ⓒ᠊/# ㋒› Misalignment of even one tooth causes
⼺઒# ᧎ᮢ⓮# ▧⪟ⓚ# Ⓐᦲ⁲⸺᠆/# ┊ਙⓖ# ▚⩊# ⍪❚⓮# ₂গ㋲# ἦ touching of piston and valves which results serious
ṗ⓮# ⑦┎┊# ᆿၞၺ1# ዆ᔒẲ/# ⋚ᔮ⓮# ᾲẲᜒ# ▫㏫㔞# ⚖ᾮ㌊⌒# ㋿ damage of the total engine. Therefore, the procedures
ၞၺ1G below should be kept exactly.# #

G #
41 ▲# 4᨞# ⁺ᝆცখ# WGF+ṗṂ▦,⍦# ⒚⯮㋮ᅚᗳ# ⸂ᕃ⸂# 1. Turn the crankshaft so that cylinder no.1 shall be
Ṻ㊚ぎᜒ# ᅢᝆၺ1# ㊢ᔒ┊# 㒶઒# ⸂ᕃ⸂# Ṻ㊚ぎ⓮# ṗ in TDC (top dead center). Check TDC mark on
Ṃ▦# ᝞⹏ⓚ# ㏫┎㋲ၺ1# ┊ዢ/# எᝒ# 4઒# য┊# ⸂ᕃ⸂# flywheel and crankshaft. In this case, the split
Ṻ㊚ぎ⍦# Ẻ⯮ᆲ# ெ⍊⓮# ᬚ㋶Ặ┊# ᾮㅟⓒᗲ# ᆲၺ1# line of the two part gears on crankshaft also
# should be horizontal as shown in fig. 1.
#

#
#

#
# Split line to be
Horizontal
#

#
#

#
No.1 Cyl. TDC
#
#

# Fig.1 Check TDC mark on flywheel and crankshaft +㊢ᔒ┊㒶# ᦥ# ⸂ᕃ⸂# Ṻ㊚ぎ⍦# ┞ဪ# ṗṂ▦# ᝞⹏# ㏫┎,

# G

#
G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 06.04/YJHG
 Page
H21/32 2/4
Section No. Rev.
Camshaft Gear Assembly(Bolt) Maintenance Procedure
ⰶ Ṻ㊚ぎ ଂᅯெ⍊ ⍊Ở᮪ᝂ(᪒ぎ) ▫ᯚ▦ਖ ▞⦾
M35300 2A
G
#

51 ⋚┊ቺ# ெ⍊খ# ᬚ㌊ᆮ⍊# ┞ၺ᠊/# Ẻ⯮㋮₃⁲⎺1# ⋚┊ 2. Mount idle gears if disassembled. The idle gears
ቺ# ெ⍊ဪ# ᝞⹏઒# ખਗ਼⍜┊# Ẻ⯮㌊ᅚ# ᆿၞၺ1# may be mounted regardless of markings.
61 எᝒ# 5⏖# য┊# ⰶ# Ṻ㊚ぎ# ெ⍊ᜒ# ቺ⍊⏂ᖺ/# ⍪❚# ᮪ 3. Lift the camshaft gear and insert it through the
ᗳ# ṗᬖᜒ# ⽋㋮⎂# ெ⍊⓮# ┝᯾┊# ⎺┒# ᬚᣊ# ༎✦# ᵦ opening of the engine block carefully while
ᝢ# ⋚ၞᔒ# ┎▧# ᬖ㈞઒# ▧⪟㋮❖# ⋠ᅚᗳ# ெ⍊ᜒ# ☆ avoiding not touching the teeth with adjacent
₂›ᖓਢ# ๊ᝆၺ1# parts and oil spray nozzle as well as shown in fig.
# 2.
71 ⋚┊ቺ# ெ⍊# ⒚⍦# ⰶ# Ṻ㊚ぎ# ெ⍊ᜒ# ⏂ᖺ# ༩ⓖ# 㑚# 4. Lay the camshaft gear on the idle gear and roll
ⰶ# Ṻ㊚ぎখ# ┞ဪ# Ẻ⯮# ⒚⯮ᗲ# ଊᖺ# ๊ᝆၺ1# down to the mounting position with the camshaft.
81 ⰶ# Ṻ㊚ぎ# ெ⍊⓮# ṗṂ▦# ᝞⹏ⓚ# ㏫┎㋲ၺ1# ┊ਙⓖ# 5. Check TDC marking on the camshaft gear which
எᝒ# 6઒# য┊# ⍪❚# ᮪ᗳ⓮# ⮷᠊઒# ▫ᗂᆮ⍊⌒# ㋲ၺ1# should be aligned with side surface of engine
ᝢ┒# ▫ᗂ┊# ᆮ❖# ⋠⋮ၺ᠊/# ⰶ# Ṻ㊚ぎ# ெ⍊ᜒ# ⌓চ# block as shown in fig. 3. If not aligned, rotate the
ቺ⍊⏂ᖺ# 㐢▚⁲⸺᠊Ẳ# ெ⍊# ┝᯾⓮# ᝴ᣒᝒ# ❖▦ⓚ# camshaft gear by lifting slightly and change the
ᦪ൒ၺ1# ṗṂ▦# ᝞⹏┊# ▫ᗂᆶ# ዢ௢❖# ┊ᖆ# ઒▫ⓚ# matching point of the teeth. Repeat this
᦮᪋㋲ၺ1# procedure until the TDC markings aligned.
91 ⰶ# Ṻ㊚ぎ⓮# ⒚⯮ᜒ# ㏫┎㋮੶# எᝒ# 6⓮# Ylhz# D⏖# 6. Check position of camshaft and rotate camshaft
য┊# ⰶ# Ṻ㊚ぎ⓮# ⒚⯮੶▫# ㋖┊# ⰶ# Ṻ㊚ぎ# ெ⍊⏖# to match the positioning pin on camshaft to
᝴ᅚᗳ# ⰶ# Ṻ㊚ぎᜒ# 㐢▚⁲⸾ၺ1# camshaft gear as shown in View A of fig. 3.
#

# #
# #
# #
# #
# # Oil Spray Nozzle

# #
# #
# #
# #
TDC Marking
# #
# #
# #
# #
# #
# #
# #
# Fig.2 Mounting of the camshaft
# gear +ⰶ# Ṻ㊚ぎ# ெ⍊⓮# ☆ᝓ,
G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 06.04/YJHG
 Page
H21/32 3/4
Section No. Rev.
Camshaft Gear Assembly(Bolt) Maintenance Procedure
ⰶ Ṻ㊚ぎ ଂᅯெ⍊ ⍊Ở᮪ᝂ(᪒ぎ) ▫ᯚ▦ਖ ▞⦾
M35300 2A
G
# #

:1 ⒚⯮੶▫# ㋖ⓒᗲ# ੶▫⁲⸺ெ# ⒚㌊# ⰶ# Ṻ㊚ぎ# ெ⍊ᜒ# 7. Push camshaft gear toward camshaft to fit in
ⰶ# Ṻ㊚ぎ# ⡓ⓒᗲ# ᦖ੶# ┚⁲ᗲ# ႖গᦿ㌻ⓒᗲ# ᇦল⓮# positioning pin and assemble the gear and shaft
☆┎ぎ# ฮṂᜒ# ┊␿㋮⎂# ெ⍊⏖# Ṻ㊚ぎᜒ# ☆ᝓ㋲ၺ1# temporarily by two sets of joint screws diagonally.
;1 ၺ⁲# ⰶ# Ṻ㊚ぎ# ெ⍊⓮# ▫ᗂⓚ# ▦ਖ㋲ၺ1# ⰶ# Ṻ㊚ぎ# 8. Check alignment of camshaft gear again. TDC
ெ⍊⏖# ㊢ᔒ┊㒶# ṗṂ▦# ᝞⹏ⓖ# எᝒ# 6઒# য┊# ᆮ⍊ marks of camshaft gear and flywheel should be
⌒# ㋲ၺ1# as shown in fig. 3.
ṗṂ▦# ᝞⹏ⓖ# ▲# 4᨞# ⁺ᝆც⓮# ṗṂ▦ⓚ# TDC marking means TDC of No. 1
⓮ᦎ㋿ၞၺ1# cylinder.
#

# Markings #
View A

# #
Positioning Pin
# # TDC Markings
(Displaced)
# A #

# #
# #
# #
# #

# #
# #
# #
# # Camshaft
# # Disc for camshaft gear
# #
Camshaft Gear
# #
# #
Fig.3 Check TDC markings on the flywheel and the camshaft gear
# +㊢ᔒ┊㒶# ᦥ# ⰶ# Ṻ㊚ぎ# ெ⍊⓮# # ṗṂ▦# ᝞⹏# ㏫┎,G
# #

<1 ᠾቶ# ⩊੆# ᪒ぎᜒ# ☆ᝓ㋮੶/# ႖গ# ᦿ㌻ⓒᗲ# ㋮ฮ⊿# 9. Assemble all sets of joint screws and tighten
☆┎ၺ1# them one by one diagonally.
᪒ぎᜒ# ☆ᝓ㋮ெ# ▚/# ฮṂṆ⍦# ᡆᝂ⳪ぎᜒ# Coat Molykote on the thread of the
ᦪᜊ₃⁲⎺11# bolt before assembling.
᪒ぎ⏖# ⏖Ừ⓮# ṗ⹲ᜒ# ▦ਖ㋮₃⁲⎺1# ἦṗ Check the condition of bolts and
ᆲ# ᪒ぎ⏖# ⏖Ừᜒ# ╂# Ṃ␿㋮❖# ᝦ੶/# Ṟ# ᾲ▫㈞ᝢⓚ# Ṃ␿㋮ washers. Do not reuse damaged ones. Use only
₃⁲⎺1# எᖝ❖# ⋠ⓒ᠊# ㈖⍊❖੶# ᬖẲ❚# ᬖ㈞┊# ⍪❚⍦# ₂ new genuine screws. Otherwise, loosened or
গ㋲# ἦṗⓚ# ┒ⓒ⹂# ᾮ# ┞⁋ၞၺ1G broken screws may cause serious damages on the
# engine.#
G
HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 06.04/YJHG
 Page
H21/32 4/4
Section No. Rev.
Camshaft Gear Assembly(Bolt) Maintenance Procedure
ⰶ Ṻ㊚ぎ ଂᅯெ⍊ ⍊Ở᮪ᝂ(᪒ぎ) ▫ᯚ▦ਖ ▞⦾
M35300 2A
G
# #

431 ㊢ᔒ┊㒶ⓚ# ᅢᝂ᠊Ẳ# 㐢▚# ṗ⹲ᜒ# ▦ਖ㋲ၺ1# 㐢▚# 10. Turn the flywheel and check feeling of the
⁲# ၺᜎ# ᯚ▫ṗ▗┎# ▖㌃┊# ဦಊ❚ၺ᠊# ✟⁲# 㐢▚ⓚ# rotation. If any abnormal resistance is detected
▫❖⁲⸺੶# ┊▚# ⒚⯮ᗲ# ᆮᅢᝆၺ1# எᝂ੶# ฮẲ# ṗ during turning, stop the turning immediately and
Ṃ▦# ᝞⹏ⓚ# ╂㏫┎㋮੶# ┊▚# ▞⦾ᜒ# ዆ᜎၺ1# return to previous position. Then, recheck TDC
# markings and the above procedures.
ᠾቶ# ⰶ# Ṻ㊚ぎ# ⎆੆ᬖ⓮# ᝞⹏# ṗ⹲ᜒ# ㏫┎㋲ၺ1# Check markings for the connection of every
# camshafts.
+# # # # # #M25000
# # # # # # # # # ⓮# “எᝒ# 5# ⌧⡓# ⰶ# Ṻ㊚ぎ⍦# ┞ဪ# (See “Fig. 2 According TDC markings on both
ṗṂ▦# ᝞⹏⓮# ┒⯮”ᜒ# ⧎☆㋮₃⁲⎺1,# camshafts” in M25000 )#
# #

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#

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H21/32 1/9
Section No. Rev.
Engine Automation System General Instruction
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ল␪# Description
⍪❚# ┦ᅯ# ▲⍊# ⁲›⻲ⓖ# ▲⍊/# ᠾၞ⻆᝗# ᦥ# ⋞▚# The engine automation system consists of control,
⁲›⻲ⓒᗲ# ଂệᆮ⍊# ┞ⓒ᠆/# ┊ਙⓖ# ெ᪎▗ⓒᗲ# monitoring and safety system, which basically satisfies
੶঳⓮# ␪ଂᜒ# ᝢ☇㋮ᅚᗳ# Ẻਗ਼ᆮ⍊# ┞ၺ1# # the requirements of customers.
#
গ☛# ỒẲ⏖# ਢ┊❖ဪ# ⍪❚# ᪎⩊⍦# Ẻ⯮ᆮ⍊# ┞ⓒ᠆/# The sensors and indicators are installed on engine
▲⍊⏖# ᠾၞ⻆᝗ⓚ# ⒚㌊# ⍪❚⮷# ウໂ⍦# ⎆੆ᆮ⍊# ┞ၺ1# properly and connected to the power system panel for
⍪❚ⓖ# ઋெ# ᦥ# ▚┦⁳# ៪ⱺၞ✮ⓚ# ⽋㌊Ẳ# ▲⍊⁶㏎⍦# control and monitoring. The engine responds to the
ⓧႋ㋮ਢ# ᆲၺ1# # control signals via pneumatic and electronic
# mechanism of the engine.
எᖂᥖᗲ/# ⍪❚┊# ┧ᅯ㋮੶# ┞ဪ# ᅯ⋞⍦ဪ# ❗ᛮ# Therefore, electrical power of DC24V and
57Y⓮# ▚ᖻ઒# ⌓# 63edu⓮# ⋫⬫# ઋெဪ# ਗ਼ἣ# compressed air of about 30 bar should be supplied
ઋடᆮ⍊⌒# ㋲ၺ1# consistently during engine operation.
#
␎ᬖ# ઋெ# ⺇⸂ᗲᬖ⻆# ઋடᆮဪ# ⋫⬫# ઋெဪ# ⍪❚# The compressed air supplied from the air reservoir is
⁲ᅯ઒# ▫❖ᜒ# ⒚㌊# Ṃ␿ᆮဪ# ⁲ᅯ# ઋெ# ᠾ⻆# ⚒ᩖ⓮# lowered to a proper pressure through reducing valve
দ⋫᧎ᮢ⍦# ⓮㌊Ẳ# ▗▫# ⋫ᖻⓒᗲ# ไ⋚❚ၺ1# around staring air motor, which is used for starting and
# # # # # #G01400
# # # # # # # # # # ᜒ# ⧎☆㋮₃⁲⎺1# stopping the engine. See G01400
#
┦ᅯ# ⑊▚# ⁲›⻲⍦# ႖㋲# ᧆખ઒# ▚ெ# 㐢ᗲဪ# ⍪❚⍦# As the piping and electrical circuits for the
዆ᔒ# ၺᜒ# ᾮখ# ┞ⓒᥖᗲ/# く▫# ㊚ᗲ△ぎ᝞ၺ# ▲ઋᆮဪ# automation system may be different from engine by
লᩚᣎẲᜒ# ⧎☆㋮₃⁲⎺1# engine, please refer to the separated documents
provided for the specific project.
⍪❚# ┦ᅯ# ⁲›⻲⓮# ▫ᯚဪ# ┦ਿ┊# ┞ဪ# The maintenance of the engine auto-

❗⑦⍦# ⓮㌊Ẳᝢ# ᾮ㌟ᆮ⍊⌒# ㋿ၞၺ1# ☆▫# ᬞᕟ┊ฮ# ⏂ᦪᜊ❖# mation system should be carried out only by qualified

ᡑ㋲# ▫ᯚဪ# ⍪❚ⓚ# ▲⍊㋶# ᾮ# ⍜ᅚᗳ# ㋮᠆# ₂গ㋲# Ṃ੶ᜒ# personnel. Maladjustment or tactless repair cause the

⪞ᔮ㋶# ᾮ# ┞⁋ၞၺ1# # engine uncontrollable and results serious accidents.

#
⍪❚⮷# ▲⍊# ウໂⓖ# ੶঳⓮# ␪ଂ⍦# ዆ᔒ# ⑦ਆᝂ# ⍪❚# The engine automation system can provide
▲⍊ᜒ# ⒚㋲# ▧ἣ⻆ᦎึ# Ꭶ㋲# ▲ઋ# খျ㋮ၺ1# # connections for remote control system depending on
the customers’ requirements.
⍪❚ ┦ᅯ ⁲›⻲⓮ ெ᪎▗┎ ெျⓖ ၺⓢ઒ যၺ; The basic functions of the engine automation system
are as follows;
• ⍪❚ ⁲ᅯ ⁲›⻲ • Engine Starting System.
• ⍪❚ ▫❖ ⁲›⻲ • Engine Stop System.
• ⍪❚ ἣᅚ ▲⍊ ⁲›⻲ • Engine Speed control System.
•G ⍪❚ ⋞▚ ⁲›⻲ • Engine Safety system

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⍪❚ ⁲ᅯ ⁲›⻲ Engine Starting System
⍪❚ⓖ# ⁲ᅯ␿# ઋெᠾ⻆⍦# ⓮㌊Ẳ# ⁲ᅯᆮ᠆/# ┊ਙⓖ# The engine is started by a starting air motor which is
⋫⬫# ઋெ⍦# ⓮㌊# ┧ᅯᆲၺ1# எᝒ# 4ⓖ# ⍪❚# ⁲ᅯ␿# operated by compressed air. Fig 1 shows the
⋫⬫# ઋெ# ⁲›⻲ⓚ# ฮ⹖๎# Ặᅚ┊ၺ1# compressed air system for starting engine.
#
7
#
3
# 5
Reduction valve,

#
2 Compressed air inlet
8
#
Safety valve:

# 9
1 1 Air start motor
# 2 Relay valve
3 On-off valve for shutdown & overspeed stop
# 4 Governor with stop solenoid valve
5 Air starting valve/Emergency start valve
# 6 6 Stop cylinder in each fuel injection pump
7 Air filter
# 8 Fuel rack limiter valve

4 9 Fuel rack limiter

#
# Fig. 1 Diagram for starting compressed air system +⁲ᅯ# ⋫⬫# ઋெ# ⁲›⻲␿# Ặᅚ,
#
▲⍊# ウໂ⍦# ┞ဪ# ‘VWDUW’# ᨚげⓚ# ྚᜊ᠊# ⋫⬫# ‘START’ button on the control panel activates
ઋெখ# ⁲ᅯ# ઋெ# ᠾ⻆⍦# ઋடᆮᅚᗳ# ⁲ᅯ# Ἢᖞ༎┊ቲ# starting solenoid valve opened to supply compressed
᧎ᮢᜒ# লᦿ⁲⸺੶/# எᖆ# 㑚# ઋெ# ⁲ᅯ# ᠾ⻆⓮# air into the starting air motor. Then, the pinion of the air
㋒ၞ⍎┊# ⍪❚# ㊢ᔒ┊㒶⓮# ெ⍊ᝒ⍦# ᝴ᣒᝂਢ# ᆮ⍊# starting motor is engaged with the gear rim of the
⍪❚⓮# ⸂ᔧ⸂# Ṻ㊚ぎᜒ# 㐢▚⁲⸾ၺ1# # engine flywheel and turns crankshaft of the engine.
዆ᔒẲ/# ⍪❚⓮# 㐢▚# ἣᅚখ# ⎞▫ᆲ# ἣᅚ⍦# ᅚႂᆮ᠊/# Hence, when the engine rotating speed reaches
⁲ᅯⓚ# ⒚㌊# ⎆ᙢখ# ⎆ἢ⁺ᗲ# ᬚṂᆲၺ1# எ# 㑚/# ⁲ᅯ┊# predetermined speed, fuel oil is injected into the
਎ᝂ᠊# ⁲ᅯ# ઋெ# ᠾ⻆⓮# ㋒ၞ⍎ⓖ# ▫㌊❚# ἣᅚ⍦Ẳ# combustion chamber for self-rotating. Then, starting is
ᝒெ⍊ᗲᬖ⻆# ᬚᝂᆲၺ1# # completed and the pinion of the air starting motor is
# disengaged from the gear rim at predetermined speed.
#
#
⍪❚ ▫❖ ⁲›⻲# Engine Stop System
⍪❚ⓖ# ▲⍊# ウໂ⍦# ┞ဪ# ‘VWRS’# ᨚげ# Ꭶဪ# The engine is stopped when pressing ‘STOP’ button
‘HPHUJHQF\# VWRS’# ᨚげⓚ# ྚᜒ# ੓⑆ฮ# ‘DXWR# or ‘EMERGENCY STOP’ button on control panel
VWRS’# ⁶㏎⍦# ⓮㌊Ẳ# ▫❖ᆲၺ1# intentionally, or by ‘AUTO STOP’ signal.
⍪❚# ┦ᅯ# ⑊▚# ⁲›⻲ⓖ# ⍪❚⓮# ᯚ▫ṗ# ṗ⹲ᜒ# Engine automation system generate ‘AUTO STOP’
দ❖㋮⎖ⓚ# ዢ# ‘DXWR#VWRS’# ⁶㏎খ# ᦲṳᆲၺ1# # signal when abnormal condition of the engine is
# # # G01400
# # # # # # # # # # ᜒ# ⧎☆㋮₃⁲⎺1# detected. See G01400
#
# #
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# #
⎆ἢ⁺# ๊⍦# ⎆ᙢখ# ᬚṂᆮ❖# ⋠ⓒ᠊# ⍪❚ⓖ# However, the engine is stopped fundamentally when
▫❖㋲ၺ1# ┊ਙⓖ# গ# ⎆ᙢ# ᬚṂ# ㄢ㊚⓮# ᔯ┊# ▫❖# the fuel injection into the combustion chamber is
⒚⯮ᗲ# ⑖❗⎖ၺဪ# ਙⓚ# ⓮ᦎ㋲ၺ1# ᠾቶ# ⎆ᙢ# ᔯⓖ# stopped. This means that the rack of each fuel injection
ெਗ਼▗ⓒᗲ# ㋮ฮ⓮# ▲⍊⬫⍦# ⎆੆ᆮ⍊# ┞ⓒ᠆/# Ꭶ㋲# pump is moved to stop position by stop signal. Every
⋫⬫# ઋெખ⍦# ⎆੆ᆮ⍊# ┞ၺ1# fuel rack is connected to common control shaft
# mechanically and also connected to common
# compressed air line pneumatically.
዆ᔒẲ/# ⎆ᙢ# ᔯⓚ# ▫❖⒚⯮+3⓮# ྞஞ⒚⯮,ᗲ# Therefore, there are two ways of moving fuel racks
⑖❗┊ਢ# ㋮ဪ# ᄆ⍦ဪ# எᝒ# 5⏖# য┊# # ᇦ# খ❖# ᦿᨫ┊# to stop position (Zero index) as shown in fig 2.
┞ၺ1#
#
#
Fuel Injection Pump
#
#
#
#
# Compressed Air for ‘STOP’
# STOP

#
# Spring loaded flexible lever
# Fuel Rack
Fuel control shaft
#
# Fig. 2 Engine stop by fuel rack +⎆ᙢ# ᔯ⍦# ⓮㋲# ⍪❚# ▫❖,
#
⩁➎/# ெਗ਼▗┎# ▫❖⍦# ⓮㋲# ਙ┎ᄆ/# ┊ਙⓖ# ᔯⓚ# The one is by the mechanical stop, which pull the
খᨚພ# Ꭶဪ# ᾮᅯ# ▲⍊# ᖞᨚখ# ▫❖# ⒚⯮ᗲ# ႏெဪ# racks to stop position by the governor or the manual
ਙ┊ၺ1# ‘VWRS’# ᨚげⓖ# খᨚພখ# ‘VWRS’# ⒚⯮⍦# control lever. ‘STOP’ button activates the governor to
༩⎂❖ᅚᗳ# ㋲ၺ1# # be ‘STOP’ position.
ᇮ➎/# ⋫⬫ઋெ⍦# ⓮㋲# ▫❖# ᦿᨫ┎ᄆ/# ┊ਙⓖ# The other is by the pneumatic stop by compressed
খᨚພᎦဪ# ᾮᅯ▲⍊# ᖞᨚ⓮# ▲⍊⍜┊# ઋெ⋫⍦# ⓮㌊# air, which pushes the rack to stop position regardless
▫❖⒚⯮ᗲ# ᔯⓚ# ᦖ⍊๊ဪ# ਙ┊ၺ1# ‘HPHUJHQF\# of the governor control. ‘EMERGENCY STOP’ button
VWRS’# ᨚげ# Ꭶဪ# ‘DXWR# VWRS’# ⁶㏎ဪ# ᠾቶ# ⎆ᙢ# or ‘AUTO STOP’ signals activates the stop solenoid
ᬚṂ# ㄢ㊚⍦# ⋫⬫# ઋெᜒ# ઋட㋮ெ# ⒚㌊# ▫❖# valve to supply the compressed air for all fuel injection
Ἢᖞ༎┊ቲ# ᧎ᮢᜒ# ┧ᅯ⁲⸺᠆/# ┊# ⁶㏎ဪ# ᅯ⁲⍦# pumps. This ‘EMERGENCY STOP’ signal also
খᨚພ# Ꭶ㋲# ▫❖# ⒚⯮ᗲ# খਢ# ㋲ၺ1# activates governor’s stop simultaneously.
#
#
#
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எᖂฮ/# ┊ᖂ㋲# ᇦখ❖# ᦿᨫⓖ# গগ# ெਗ਼▗ⓒᗲ# However, these two ways are mechanically
ᅛᝓ▗┊᠆/# ᖞᨚ⍦# ┻⦿ᆲ# ›㊚᝗⍦# ⓮㌊# ┊ᖂ㋲# independent each other and the spring-loaded levers
ெਗ਼▗# Ⓐ⎆ệ┊# খျ㌊❚ၺ1# # provide mechanical flexibility between them.

⍪❚ ἣᅚ ▲⍊ ⁲›⻲# Engine Speed Control System

⍪❚# ἣᅚဪ# ⎆ᙢ# ᬚṂ# ㄢ㊚⓮# ᔯ⍦# ⎆੆ᆲ# খᨚພ⍦# Engine speed is controlled by a governor that links
⓮㌊Ẳ# ▲⍊ᆲၺ1# খᨚພ# ⁲›⻲ⓖ# ⍪❚⓮# ἣᅚ# ᩖ㏪ᜒ# to the racks of fuel injection pumps. Governor system
⹦❖㋮᠆# Ẻ▫ᆲ# ἣᅚᜒ# Ⓐ❖㋮ெ# ⒚㌊Ẳ# ⎆ᙢ# ᬚṂ⓮# detects speed variation of the engine and controls
⌧ⓚ# ☆▞㋲ၺ1# # # amount of fuel injection to keep the setting speed.
#
41 খᨚພ# 1. Governor
⍪❚# ▗␿ᦿ⁳⍦# ዆ᔒ# ၺ⌧㋲# ⹖┛⓮# খᨚພ# Various types of the governor system are
⁲›⻲┊# ⍪❚⍦# ▗␿ᆲၺ1# ዆ᔒẲ/# く▫# খᨚພ# applicable for the engine depending on the engine
⁲›⻲⍦# ႖㋲# লᩚ# ❖⯾Ẳᜒ# ⧎☆㋮₃⁲⎺1# applications. Therefore, please refer to the
எᖂฮ# ெ᪎▗ⓒᗲ# ၺⓢ઒# য┊# খᨚພ⍦ဪ# Ỏখ❖# separated manual for the specific governor system.
☛ᛮখ# ┞ၺ1# # However, there are three types of the governor
- Ⓐ⋫⁳# খᨚພ# +ㇲ⚖,# basically as follows;
- ⋚ึᗲஎ# ⹖┛⓮# ▚ெ⁳# খᨚພ# +Ặ⹳Ṃ⌧,# - Hydraulic Governor (Standard)
- ኪ❖⻎# ⹖┛⓮# ▚┦⁳# খᨚພ# +Ặ⹳Ṃ⌧,# - Analog type electric Governor (Option)
- Digital type electronic Governor (Option)

51 খᨚພ# ቲᔒ┊ᮢ# 2. Governor drive

▚ெ⁳# ⹖┛⓮# খᨚພဪ# ▲⍊ᖻⓚ# ⒚㋲# ▚⑦/# Electric type governors require electric power,
┒᦮▗ⓒᗲ# ❗ᛮ# 57Yᜒ# ㋚␪ᗲ# ㋲ၺ1# # normally DC 24V, for the control force.
㋮❖ᝢ# Ⓐ⋫⁳# ⹖┛⓮# খᨚພဪ# ▲⍊ᜒ# ⒚㋲# However, hydraulic type governor requires
Ⓐ⋫ᖻⓚ# ᦲṳ⁲⸺ெ# ⒚㌊# ␎ᬖ# ଂᅯ# ᦎⲖၞ✮ⓚ# external driving mechanism for generating
㋚␪ᗲ# ㋮ᥖᗲ# ⍪❚⓮# ⹖┊ᦣெ⍊⍦# ⎆੆ᆮ⍊# hydraulic force for control, which is coupled to the
ଂᅯᆲၺ1# A41000 timing gear of the engine. A41000
#
Ⓔ㏲Ⓐဪ# Ⲗ┊₇⍦# খઋᆲ# ⽋ᗲᜒ# ⽋㌊Ẳ# ⍪❚# Lubricating oil is supplied to the rotating parts
⁲›⻲# ⎺┒ᗲᬖ⻆# 㐢▚# ᬖ⒚ᗲ# ઋடᆮ❖ᝢ# Ⓐ⋫⁳# from the engine system oil via drilled holes of the
খᨚພဪ# ┦⩊⓮# ᅛᝓᆲ# Ⓔ㏲Ⓐ# ⁲›⻲ⓚ# খ❖੶# casing. However, hydraulic governor has it’s own
┞ၺ1# খᨚພ Ẻ᠛Ẳ ⧎☆# # lubricating oil system.# See Manual for Governor
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61 ⎆ᙢ# ▲⍊# ᝗⸂┻⯮# 3. Fuel control linkages
খᨚພখ# ⎆ᙢ# ᬚṂᕟⓚ# ▲⍊㋮ᅚᗳ# ㋮ெ# Fuel control linkages transfer the rotation of
⒚㌊Ẳဪ# ⎆ᙢ# ▲⍊# ᝗⸂┻⯮⓮# எᝒ# 6઒# য┊# governor terminal shaft to move the fuel rack in
⎆ᙢ# ᔯⓚ# ⑖❗┊ਢ# ㋮ெ# ⒚㌊Ẳ# খᨚພ# ▲⍊⬫⓮# order to control quantity of fuel injection by
㐢▚⑊ᅯⓚ# ▚ႂ⁲⸾ၺ1# governor as shown in fig 3.
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
#
Fig. 3 Fuel control linkage +⎆ᙢ# ▲⍊# ᝗⸂┻⯮,
#
#
ᯚᗳ# ੶঳⍦ਢ# ┎ᅚᆮெ# ▚⍦# ⎆ᙢ# ▲⍊# ᝗⸂┻⯮ᜒ# Though the fuel control linkages were adjusted and
⍪❚៪┊ⱺখ# ☆▫㋲# 㑚# ੶▫⁲Ⳇ❖ᝢ/# খᨚພ# ⻆ᦎึ# fixed by engine maker before delivery, the movements
Ṻ㊚ぎ⏖# ⎆ᙢ# ᔯ⓮# ⑖❗┚ⓖ# ⍪❚ⓚ# ⁲ᅯ㋮ெ# ▚# ᵦᝢ# of governor terminal shaft and fuel racks should be
⋚ၞᔒ# ⍪❚ⓚ# ⑊▚㋮ဪ# ᅯ⋞⍦ᅚ# ㌃ṗ# ▦ਖ㋮⎂⌒# checked before engine starting and during engine
㋲ၺ1# # operation.
#
#
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┒᦮▗ⓒᗲ/# ᝗⸂┻⯮ᜒ# ☆▫㋶# ㋚␪ဪ# ⍜ၺ1# எᖂฮ# Normally, it is not necessary to adjust the linkages.
ᝢ┒# Ṟᗲ⑊# খᨚພ# Ꭶဪ# Ṟᗲ⑊# ⎆ᙢ# ᬚṂ# ㄢ㊚ᜒ# However, if a new governor or new fuel injection
Ẻ⯮㋮ਆฮ# Ꭶဪ# ⎆ᙢ⓮# ⌧┊# டਿ㔞# ᩖ㏪ᆲၺ᠊/# pumps installed or the quality of fuel oil changed
᝗⸂┻⯮⓮# ⑖❗┚ⓚ# ▦ਖ㌊⌒# ㋮੶/# ┊ਙⓖ# significantly, the movement of linkages should be
Ⓐ┦ਿ┦⍦# ⓮㌊# ╂☆▫ᆮ⍊⌒# ㋲ၺ1# # # checked and readjusted by a qualified person.
খᨚພ# ⻆ᦎึ# Ṻ㊚ぎ⓮# オ# ௎┊+dup# ohqjwk,ဪ# The arm length of governor terminal shaft influences
খᨚພ⏖# গ# ⎆ᙢ# ᔯ઒⓮# ெਗ਼▗# ⎆੆# ᯚⒾ⍦# ⎗㌻ⓚ# the mechanical link ratio between the governor and
⚖ၺ1# ┒᦮▗ⓒᗲ# オ# ௎┊ဪ# ;3(⓮# খᨚພ# ┎ᄇ›খ# every fuel rack. In general, the arm length shall be
⌓# 433(# ᬖ㋮# ⁲⓮# ⎆ᙢ# ᔯ# ┎ᄇ›⏖# Ẳᗲ# adjusted in such a way that governor index of 80%
┒⯮㋮ᅚᗳ# ☆▫ᆲၺ1# matches to the fuel rack index corresponding to 100%
G load approximatelyUG G
G G
খᨚພᜒ# Ṟ# ਙⓒᗲ# ૦⩊㋶# ዢ⍦ဪ/# খᨚພ⓮# ਢ┎# ন# When replacing the governor with new one, the
☆▫ⓚ# ▦ਖ㌊⌒# ㋮᠆/# ㍢゛ⓚ# ⍋▲㋮ெ# ⒚㌊Ẳ# ᦮ቲ⁲# gain values of governor should be checked and
☆▫ᆮ⍊⌒# ㋮ဪᄆ/# ┊# ┧⍛ⓖ# খᨚພ# ៪┊ⱺ⍦Ẳᝢ# ㋶# adjusted to avoid hunting, which should be carried out
ᾮ# ┞ၺ1# ⻆ᦎึ# Ṻ㊚ぎ⓮# オ# ௎┊ᅚ# ⎃⁲# ▦ਖ# ᦥ# only by governor maker. The arm length of terminal
╂☆▫ᆮ⍊⌒# ㋲ၺ1 shaft also should be checked and readjusted if
necessary.

㋮ฮ# Ꭶဪ# ᠝# ল⓮# ⎆ᙢ# ᬚṂ# ㄢ㊚ᜒ# Ṟᗲ⑊# ਙⓒᗲ# When replacing one or some fuel injection
૦⩊㋶# ዢ⍦ဪ/# ⎆ᙢ# ᔯ# ┎ᄇ›ᜒ# ☆▫㌊⌒# ㋶# ㋚␪খ# pumps with new one(s), fuel rack index may be
┞ၺ1# ⏲๦㋮᠊# Ṟᗲ⑊# ⎆ᙢ# ᬚṂ# ㄢ㊚ဪ# ┒᦮▗ⓒᗲ# adjusted. Because a new fuel injection pump normally
ၺᜎ# ⁺ᝆც⓮# Ṃ␿ᆲ# ㄢ㊚᪊ၺᅚ# ᝤⓖ# ⎆ᙢᜒ# injects more fuel than worn pumps of other cylinders,
ᬚṂ㋮ெ# ዢᣎ┊ၺ1# ┊ਙⓖ# ⁺ᝆც# Ṃ┊⓮# ᬞ୶ኇ㋲# which results in unbalanced combustion between
⎆ἢᜒ# ⪞ᔮ㋲ၺ1# ⫲੶# ⎆ἢ# ⋫ᖻ઒# ᠾቶ# ⁺ᝆც⓮# cylinders. Check maximum cylinder press-ures and
ᧆெ# খ›# ⎾ᅚᜒ# ▦ਖ㋲ၺ1# ᝢ┒# ⁺ᝆც# Ṃ┊⍦# exhaust gas temperatures of all cylinders. If the
ㅎ⦾খ# ઒ᅚ㋮᠊/# ᖞᨚᜒ# ㈖⍊# ⎆ᙢ# ᔯⓚ# ☆▫㌊⌒# deviations between cylinders are excessive then fuel
㋲ၺ1# # A41000 G01400 rack should be adjusted by means of loosening the
G lever. A41000 G01400
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⎆ᙢ# ᝗⸂┻⯮# ⁲›⻲⓮# ☆▫ⓖ# ┦ਿ┞੶# The adjustment of fuel linkage system
੓㍮┞ဪ# ❗⑦⍦# ⓮㌊Ẳᝢ# ᾮ㌟ᆮ⍊⌒# ㋲ၺ1# ☆▫# ᬞᕟⓖ# should be carried out only by qualified and experience-
⍪❚⓮# ઒ᬖ㋮# ṗ⹲⓮# ⑦┎┊# ᆮ᠆# ₂গ㋲# Ṃ੶ᜒ# ⪞ᔮ㋶# ᾮᅚ# ed personnel. Maladjustment may cause the engine
┞ၺ1 overload and result serious accidents.

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Section No. Rev.
Engine Automation System General Instruction
⍪❚ ┦ᅯ ⁲›⻲ ┒᦮ ❖⯾
G40000 2A
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⍪❚ ⋞▚ ⁲›⻲# Engine Safety System

⍪❚ⓖ# ᯚ▫ṗ▗┎# ⑊▚# ṗ⹲⍦# ႖ᯚ㋮⎂# ⍪❚ⓚ# The engine has a safety system to protect the
᪊㏎㋮ெ# ⒚㋲# ⋞▚⁲›⻲ⓚ# ଂᯚ㋮੶┞ၺ1# # engine against abnormal operating condition.
੓੶⏖# ┦ᅯ# ▫❖ဪ# Ẻ▫ᆲ# ᯚ▫ṗ▗┎# ⑊▚# ☆ਊ# # # # # # # The
# # # # #alarm
### and auto stop will be active electronically
⍦# ዆ᔒẲ# ▚┦▗ⓒᗲ# ┧ᅯ㋲ၺ1# # G01400 according to the predetermined abnormal operating
┦ᅯ⁲›⻲# ᩚᅚ# ❖⯾Ẳ# ⧎☆# # conditions. G01400
# See separated manual for automation system.
▚┦⁳# ┦ᅯ# ⁲›⻲઒ဪ# ᩚᅚᗲ/# ⁺ᝆც⍦# ઒ᅚ㋲# Besides electronic automation system, a mechani-
⎆ᙢ# ᬚṂᜒ# ᝟ெ# ⒚㌊# ெਗ਼▗# ⎆ᙢ# ▲㋲# ┻⯮খ# cal fuel limiter is installed on the engine to avoid ex-
Ẻ⯮ᆮ⍊# ┞ၺ1# # A41000 cessive fuel injected into cylinders. A41000
⎆ᙢ# ▲㋲# ┻⯮ဪ# খᨚພ# ⚒⒚⍦# Ẻ⯮ᆮ⍊# ┞ⓒ᠆/# The fuel limiter is installed near the governor and
ၺⓢ઒# যⓖ# ᇦ# খ❖# Ṃ㌃⍦# ႖ᯚ㋮⎂# ⎆ᙢ# ▲⍊⬫⓮# limits rotation of the lever on fuel control shaft against
㐢▚ⓚ# ெਗ਼▗ⓒᗲ# ▲㋲㋲ၺ1# # two cases as below;
#
41 ઒# ᬖ㋮# ⎆ᙢ# ▲㋲┻⯮# 1. Over load fuel limiter
⎆ᙢ# ▲⍊# ᖞᨚখ# খᨚພ⍦# ⓮㌊Ẳฮ# ᾮᅯⓒᗲ# When fuel control lever rotates toward maximum
⫲႖# ⎆ᙢ# ᔯ# ⒚⯮ᗲ# 㐢▚㋶# ዢ/# எ# ⑖❗┚ⓖ# எᝒ# fuel rack position by governor or manual lever, the
7⍦# ᪊⎂❚# ਙ⨮ᖒ# ㋒›⼺⍦# ⓮㋮⎂# ▲㋲ᆲၺ1# movement will be limited by piston as shown in fig
▲㋲# নⓖ# ›⼶ㄒᗲ# ☆▫# খျ㋮᠆/# 443(# ᬖ㋮# 4. The limit values can be adjusted by the stopper,
᪊ၺ# ไⓖ# ᬖ㋮⍦# ṗⓧ㋮ဪ# ⎆ᙢ# ᔯ⓮# ┎ᄇ›# which should be set to the index value of the fuel
নⓒᗲ# ᝴⬪⍊◎⌒# ㋲ၺ1# # racks corresponding to lower than 110% load.
#
#
#

Compressed Air for Stop

STOP

Lever Air Cylinder

Fuel Control Shaft

Fig. 4 Mechanical fuel limiter against overload +઒ᬖ㋮⍦# ႖ᯚ㋲# ெਗ਼▗# ⎆ᙢ# ▲㋲┻⯮,G

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HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 06.05/CJCG
 Page
H21/32 8/9
Section No. Rev.
Engine Automation System General Instruction
⍪❚ ┦ᅯ ⁲›⻲ ┒᦮ ❖⯾
G40000 2A
G

┦ᅯ# ⁲›⻲ⓚ# ▫ᯚ㋲# 㑚# ㏏ⓖ# ⁲㍮# ⑊▚⓮# After maintenance of automation system or
੓⑆⍦# ⎆ᙢ# ▲㋲┻⯮ᜒ# ไⓖ# ᬖ㋮ᗲ# ᝴⬮# 㑚/# ⑊▚# ṗ⹲ᜒ# in the case of trial running, it is recommended to adjust
▦ਖ# ㏫┎㋮᠊Ẳ/# ▦❚▗ⓒᗲ# ᬖ㋮ᜒ# ✳খ⁲Ⲳ# எዢ᝞ၺ# ᝴⬪⍊# the limiter to be set to lower load point and to be
☆▫㋮₃⁲⎺1# # increased gradually by checking engine operating
# conditions.
#
›⼶ㄒ⓮# ⫲☛▗┎# ☆▫# 㑚/# ᦮ቲ⁲# ੶▫# After final adjustment of the stopper, be
ພぎᜒ# ☆⎂⌒# ㋿ၞၺ1# எᖝ❖# ⋠ⓒ᠊# ▲㋲┻⯮⓮# Ẻ▫ন┊# sure to fasten the lock nut. Otherwise, setting value of
ᩖ㋮⎂# ₂গ㋲# Ṃ੶ᜒ# ⪞ᔮ㋶# ᾮ# ┞⁋ၞၺ1# # the limiter may be changed, which may cause serious
accidents.
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2. ⁲ᅯ ⎆ᙢ ▲㋲ ┻⯮ 2. Starting fuel limiter
ኪ►⍪❚ くệṗ ⁲ᅯெচ ᅯ⋞⍦ဪ ⻆᪊ During starting period, the turbocharger is out of
઒டெখ ▫ṗ▗ⓒᗲ ┧ᅯ㋮❖ ⋠ⓒᥖᗲ ⎆ἢઋெ normal operation and therefore diesel engine is
ᬖ☇ⓒᗲ ┎㌊ ₂㋲ ᝺⎆ⓚ Ⓐᦲ㋮ဪ ᬞ⏚▚ ⎆ἢ always in the incomplete combustion due to lack of
ṗ⹲⍦ ┞ਢ ᆲၺ. ኪ❖⻎ খᨚພဪ ⁲ᅯ⚧⍦ air, which results in heavy smoke. Digital
⎆ᙢ ▲㋲ ெျⓚ খ❖੶ ┞ⓒฮ ᦮᠊⍦ Ⓐ⋫⁳ governors have fuel limiting function for starting,
খᨚພ⍦ဪ ┒᦮▗ⓒᗲ எᖆ ெျⓚ খ❖੶ ┞❖ while hydraulic governor normally has not.
ᡑ㋮ၺ. However, the engine has adjustable fuel limiter
዆ᔒẲ, ⍪❚⍦ဪ খᨚພ ⹖┛⍦ ખਗ਼⍜┊ for starting period regardless of the governor type.
⁲ᅯ⁲⍦ᝢ ⎆ᙢᜒ ▲㋲㋮ဪ ┻⯮খ Ẻ⯮ᆮ⍊ ┞ၺ.

#
#
#
#
#
Compressed Air for Stop
#
#
# STOP
#
##
Lever Air Cylinder

Fuel Control Shaft

Fig. 5 Mechanical fuel limiter for starting +⁲ᅯ␿# ெਗ਼▗# ⎆ᙢ# ▲㋲# ┻⯮,G

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HYUNDAI HEAVY INDUSTRIES CO., LTD.G G G G G Engine & Machinery Division 06.05/CJCG
 Page
H21/32 9/9
Section No. Rev.
Engine Automation System General Instruction
⍪❚ ┦ᅯ ⁲›⻲ ┒᦮ ❖⯾
G40000 2A
G

⁲ᅯ⁲ ઒ᅚ㋲ ᝺⎆ᦲṳⓚ ᦿ❖㋮ெ ⒚㌊, ઒ᬖ㋮␿ The fuel limiter piston for over load is also used for
⎆ᙢ ▲㋲ ㋒›⼺ⓚ Ṃ␿㋮⎂ ⁲ᅯ⚧ ઒ᅚ㋲ ⎆ᙢ starting limiter to avoid excessive fuel injected into
ᬚṂᜒ ▲㋲㋲ၺ. cylinder during starting period to avoid heavy smoke.
⍪❚# ┦ᅯ▲⍊# ⁲›⻲ⓖ# ⁲ᅯ⁲/# ⁲ᅯ␿# Ἢᖞ༎┊ቲ# During starting period, the engine automation system
᧎ᮢᜒ# ┧ᅯ⁲Ⲳ/# எᝒ# 8⍦Ẳ⏖# য┊# ⋫⬫ઋெখ# ⎆ᙢ# activate starting solenoid valve to supply compressed
▲㋲# ᗲቲᜒ# ᦬ⓒᗲ# ᦖਢ# ㋲ၺ1# ┊ዢ⓮/# ▲㋲# ⒚⯮ဪ# air to push the fuel limiter piston as shown in fig 5. The
੶▫ฮṂᜒ# ㈒# 㑚# খ┊ቲᗲ# ☆▫㋶# ᾮ# ┞ၺ1# ☆▫# limiting position can be adjusted by guide when
㑚⍦ဪ# ᦮ቲ⁲# ੶▫ฮṂᗲ# ੶▫⁲Ⲳ⌒# ㋲ၺ1# # loosening locking screw. Be sure to lock the locking
# screw after adjustment.
#
▲㋲# ⒚⯮ဪ# ┒᦮▗ⓒᗲ# ⌓# 83(# ᬖ㋮⍦# The limiting position is set to about 50%
᝴⬮ၺ1# எᖂฮ# ⍪❚# ⁲ᅯ# ☆ਊⓖ# ㎚❖# ☆ਊ઒# ⎆ᙢ# ☆ਊ⍦# ⸆# load normally. However, engine starting condition
⎗㌻ⓚ# ᦱெ# ዢᣎ⍦/# ᝢ⌓# ▲㋲# ⒚⯮ᜒ# ც# ไⓖ# ᬖ㋮⍦# ᝴⬪᠊# depends very much on the site condition and fuel
᝺⎆ⓖ# ⚚⍊ቺ❖ᝢ# ⁲ᅯệ┊# ⋛㏪ᆲၺ1# ዆ᔒẲ/# ⁲ᅯ┊# condition. If limiting position is set to lower load, then
⍊ᗋਆฮ# ᝺⎆⓮# ▫ᅚখ# ༨ⓚ# ዢ⍦ဪ# ⁲ᅯ# ⎆ᙢ# ▲㋲# ┻⯮ᜒ# smoke level will be lower but start ability will be worse.
☆▫㌊⌒# ㋲ၺ1# It is recommended to adjust the starting fuel limiter
when starting is difficult or smoke level is too high
during starting.


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