Page

H25/33 1/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
G09100 1B

Maintenance Guidance for Marine Auxiliary Engine

Description Overhaul Interval

: Planned Overhaul
Section
: Confirm after Overhaul/New Remark
No.
: based on observation

Major Fasteners - Retightening

M15000 Nuts for Cylinder Head
M33200 Nuts for Counter Weight : Confirm tightening
M13250 Nuts for Main Bearing Cap after overhaul or
M31000 Nuts for Connecting Rod refitting.
M25000 Nuts for Camshaft
M35300 Nuts for Timing Gears
Bolts for Engine Block and Base Frame
Bolts for Turbocharger
Major Bearings – Inspection
M13250 Main Bearings
M13250 Thrust Bearing (Axial Clearance Check)
M32120
Con Rod Bearings (Big/Small Ends)
M32130
M25000 Camshaft Bearings (Clearance Check)
M11100 Resilient Mounts – Inspection
Resilient mount – Retightening
Bolt for base frame and resilient mount
Nut for resilient mount and foundation
Cylinder Unit and Con. Rod- Inspection
M21200 Intake/Exhaust Valve, Seats and Guide
M15000 Cylinder Head Cooling Water Space
M21300 Checking & Adjustment of V/V Clearance
Indicator Valve
M15100 Cylinder Liner – Reconditioning (Honing)
M31100 Piston, Piston Pin and Piston Rings
M31000 Measure Big-end Bore, Check Clearance
M32130 between Piston Pin & Small End
Crankshaft and Gears - Inspection
Flywheel Gear Rim Teeth
M33100 Crankshaft - Deflection Check
Torsional Vibration Damper : Fluid sample Only for viscous damper
Timing Gears and Pump Driving Gears
M35300 (Clearance and backlash check)
Valve Operating Mechanism
Tappet Roller Shaft and Bearing
M23000 (Check Clearance)
Rocker Arms Shaft and Bearing
M21210 (Check Clearance)
M23000 Contact Faces of Cam and Tappet Roller

HYUNDAI HEAVY INDUSTRIES CO., LTD. Engine & Machinery Division 05.09/KJC
 Page
H25/33 2/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
G09100 1B

Maintenance Guidance for Marine Auxiliary Engine

Description Overhaul Interval

: Planned Overhaul
Section
: Confirm after Overhaul/New Remark
No.
: based on observation

Control System – Function Check

G40000 Governor Linkage – Function Check Weekly
Check Governor Oil Level
Daily
(See Manual for Governor)
Normal Clearance:
G45001 RPM Pickups – Clearance/Safety Device Check
1.0 ~ 2.0 mm
M45200 Temperature / Pressure Switches
Fuel Injection Equipment -Inspection
G05100 Analyze Oil Properties (Sample) Every Bunkering
M51100 Fuel Injection Pump
Fuel Injection Valve
M52000 (Check and Adjust the Opening Pressure)
Replace if necessary

M56000 Fuel Oil Filter – Clean

Lubricating Oil System
G06200 Analyze Oil Properties (Sample) Monthly
M61000 Lubricating Oil Pump - Replace Bearing
M62000 Lubricating Oil Cooler – Clean
M63000 Lubricating Oil Filter – Clean & Replace
M67000 Centrifugal Filter – Clean and Replace Monthly
Thermostatic Valve – Inspection
G60000 (Clean & Check the elements)
Cooling Water System
G07100 Cooling Water – Replace Water
M71000 Cooling Water Pump – Replace Sealing Ring
G70000 Thermostatic Valve – Inspection
Compressed Air System
Starting Valve for Main & Emergency
O02300 (Function Check)
Monthly

Air Motor Inspection (See Manual for Air Motor)

G40000 Check Compressed Air System Weekly
Air Filter & Air Vessel – Pressure Check Daily
Combustion Air System
Clean Air Filter (See Manual for Turbocharger) Every 500hrs running
M80000 Clean Turbine (Water-washing) Every 200hrs running
M80000 Clean Compressor (Water-washing) Every 24~50hrs running
Check Expansion Joint Weekly
M84000 Clean Charge Air Cooler

* When doing maintenance and overhaul work, seals (o-rings & gaskets, etc.) should be renewed.
* The overhaul intervals stated above are only for guidance as these depend on the actual service
condition, the quality of used fuel or lubricating oil, the treatment of cooling water and so on.

HYUNDAI HEAVY INDUSTRIES CO., LTD. Engine & Machinery Division 05.09/KJC
 Page
H25/33 3/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
G09100 1B

List of Consumable Parts for One Engine

Z=Number of cylinder

Quantity for the operating hours

Section
Parts Description
No. 4000 8000 12000 16000 20000 24000 28000 32000

Covers for Engine Block

C19300 O-ring for crankcase door 1x(Z+1) 2x(Z+1) 2x(Z+1) 3x(Z+1) 4x(Z+1) 5x(Z+1) 5x(Z+1) 6x(Z+1)
C19300 O-ring for cam shaft room cover - - - - 1xZ 1xZ 1xZ 1xZ
C21100 O-ring for cylinder head cover 0.5 x Z 1 x Z 1 x Z 1.5 x Z 2 x Z 2.5 x Z 2.5 x Z 3 x Z

Bearings
C13250 Journal bearing - - - - - 1xZ+2 1xZ+2 1xZ+2
C32000 Big-end bearing - - - - - 1xZ 1xZ 1xZ
C32000 Small-end bearing - - - - - 1xZ 1xZ 1xZ

Cylinder Unit
C21100
Intake v/v with seat and v/v guide - - - - - 1xZ 1xZ 1xZ
C21200
C21100
Exhaust v/v with seat and v/v guide - - - - - 1xZ 1xZ 1xZ
C21200
C22000 Packing for indicator v/v & v/v complete - - - 1xZ 1xZ 1xZ 1xZ 2xZ
C31100 Piston ring-top ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
C31100 Piston ring-2nd ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
C31100 Piston ring-scraper ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
C15100 Flame ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
C15100 Gasket between head and liner - - - 1xZ 1xZ 1xZ 1xZ 2xZ
O-rings for cylinder liner and
C15100 - - - 1xZ 1xZ 1xZ 1xZ 2xZ
Cooling water jacket (set)
C21100 O-rings for cylinder head (set) - - - 1xZ 1xZ 1xZ 1xZ 2xZ
C21100 Sealing ring for valve stem 4xZ 4xZ 4xZ 4xZ 8xZ

Fuel Injection Equipment

C51100 Fuel pump plunger and barrel - - - - - - - 1xZ
C52000 Fuel injection nozzle with dowel pin - 1xZ 1xZ 2xZ 2xZ 3xZ 3xZ 4xZ
C52000 O-ring for fuel valve - 4xZ 4xZ 8xZ 8xZ 12 x Z 12 x Z 16 x Z
O-rings for fuel injection pipe block
C52300 - - - 1xZ 1xZ 1xZ 1xZ 2xZ
(set)
O-rings for fuel feed pipe connection
C53000 - - - 1xZ 1xZ 1xZ 1xZ 1xZ
(set)

Lubricating Oil System

C61000 Bush for lube oil pump - - - 5 5 5 5 10
C61000 O-ring for lube oil pump - - - 1 1 1 1 2
C61000 O-ring for lube oil pump - - - 1 1 1 1 2
C62000 O-ring for lube oil cooler connection - - 10 10 10 20 20 30
C63000 Lubricating oil filter cartridge 4 8 12 16 20 24 28 32
C63000 O-ring for lube oil filter cartridge 2 2 2 2 4
C64000 O-ring for lube oil thermostat valve 1 1 1 2 2 2

HYUNDAI HEAVY INDUSTRIES CO., LTD. Engine & Machinery Division 05.09/KJC
 Page
H25/33 4/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
G09100 1B

Quantity for the operating hours

Section
Parts Description
No. 4000 8000 12000 16000 20000 24000 28000 32000

Cooling Water System

C71000 Oil seal for HT-and LT-pump - - - 2 2 2 2 4
C71000 Mechanical seal for HT-and LT-pump 2 2 2 2 4
C71000 O-rings for HT and LT-pump - - - 2 2 2 2 4
C71000 O-rings for HT and LT-pump - - - 3 3 3 3 6
C71000 O-rings for pump connection piece - - - 4 4 4 4 8
C71000 Self locking nut for pump shaft - - 1 1 1 2 2 3
C71000 Self locking nut for pump shaft - - 1 1 1 2 2 3
C74000 O-rings for C.W thermostat valve - - 2 2 2 4 4 4
C78000 O-rings for cyl. head C.W connection - - 10 10 10 20 20 20

Charge Air Cooler

C81000 Gasket for compressor out - - - 1 1 2 2 3
C84000 Gasket for air cooler - - - 1 1 1 1 2
C84000 Gasket for air cooler cover - - - 1 1 1 1 2
C84000 O-ring for water connection piece - - - 8 8 8 8 16

Turbocharger
Turbine nozzle ring
- 1 1 2 2 3 3 4
(See Manual for Turbocharger)

* The list of consumable parts stated above is only for guidance as this depends on the actual service
condition, the quality of used fuel or lubricating oil, the treatment of cooling water and so on.

HYUNDAI HEAVY INDUSTRIES CO., LTD. Engine & Machinery Division 05.09/KJC