for cylinder lubrication and valve seat lubrication on large 4-stroke diesel engines Valve seat lubrication Cylinder lubrication Version 04
Page 2 for cylinder lubrication and valve seat lubrication on large 4-stroke diesel engines Table of contents for cylinder lubrication and valve seat lubrication on large 4-stroke diesel engines 1 1. Description of system components 3 1.1 Lubrication systems 3 1.1.1 Principle of cylinder lubrication 4 1.2 UD gear pump unit 5 1.2.1 Functional description 5 1.1.2 Principle of valve seat lubrication 7 1.3 RA radial piston pump unit 8 1.3.1 Functional description 9 1.4 PBA progressive block feeder on baseplate 10 1.4.1 Functional description 10 1.5 Monitoring 13 1.5.1 Functional description 13 1.6 BVRK progressive block feeder 14 1.6.1 Functional description 14 The system description explains the function and design and does not constitute assembly or operating instructions. Consult the accompanying documents for all instructions regarding assembly and operation.
Page 3 1 Description of system components 1.1 Lubrication systems An attached lubrication system is essential for the proper, smooth and low-wear operation of large diesel engines. Depending on the size and type of the engine, the cylinder bushings and sometimes the inlet valve seats are lubricated with engine lubricant oil by various combinations of lubrication pumps and progressive feeders. The lubrication system operates according to the following principle: The gear pump unit is supplied with oil through the main oil line on the diesel engine. This feeds the oil into a progressive block feeder on a baseplate. The hydraulically controlled feeder distributes the oil into the lubrication lines leading to the outlets on the cylinder bushing or inlet valve seat. V-type engines can be equipped with an additional dual-outlet progressive feeder after the pump, which distributes the oil evenly through both cylinder banks. The lubrication system can be monitored (only when using cylinder lubrication) for correct operation at the block feeder using an attached proximity switch.
Page 4 1.1.1 Principle of cylinder lubrication Basic sketch of cylinder lubrication Item Description 8 1 UD gear pump unit 2 PBA Progressive block feeder on baseplate 3 Proximity switch 4 Supply line (connection to main oil line on engine) 5 Return lines (return of excess oil into the cylinder crankcase) 7 9 6 Lubrication lines (two per cylinder) 7 Cylinder bushing 8 Lubrication holes (shown in gray) 9 Cylinder crankcase 1 2 3 6 5 Sketch used with permission of MAN Diesel SE, Augsburg, Germany 4
Page 5 1.2 UD gear pump unit 1.2.1 Functional description UD gear pump units are rotary positivedisplacement pumps. The pump body contains two counter-rotating gears. A gear is driven by the electric motor's drive shaft. The oil is drawn in by the rotary motion of the two gears. The oil is then delivered to the pump outlet between the tooth gaps and the gear chamber wall. A pressure regulating valve protects the pump from excessively high pressures. Gear pump units with a nominal volumetric flow of 0.12 to 0.35 l/min are used depending on the size and type of the engine. On large diesel engines, special vibrationresistant multi-range electric motors are used that fulfill marine regulations. Pressure side Inlet bore (suction side) Sectional view of UD gear pump unit
Page 6 Example: UD 0.12 / 60 PB 07 C4019 Type: Gear pump unit, horizontal Nominal volumetric flow: 0.12 = 0.12 l/min 0.18 = 0.18 l/min 0.25 = 0.25 l/min 0.35 = 0.35 l/min Design key: C4019 = 0.25 kw, (assy. 71C90), vibration-resistant design, top terminal box, marine design with DIN 89280 cable fitting, with pressure regulating valve, max. admission pressure 5 bar C4029 = Same, but with pole-changing 0.09/0.15 kw motor C4031 = Same as 4029, but with protection class IP 56 Operating pressure: 60 = Max. 60 bar Protection class: 07 = Protection class IP 55 F 08 = Protection class IP 56 Motor code letter: AF = 240/400 V - 50Hz 240/400 V - 50Hz 1500... PB = Same, pole-changing 7501500
Page 7 1.1.2 Principle of valve seat lubrication Basic sketch of valve seat lubrication Item Description 1 RA radial piston pump unit 8 2 Block feeder on PBA baseplate 3 Proximity switch (optional) 4 Supply line (connection to main oil line on engine) 7 5 Return lines (return of excess oil into the engine crankcase) 6 Lubrication line 3 2 7 Nozzle 8 Inlet valve 1 6 5 4 Sketch used with permission of MAN Diesel SE, Augsburg, Germany
Page 8 1.3 RA radial piston pump unit Sectional view of RA 1M radial piston pump unit Item Description 1 Drive element (with oil drain port) 2 Spacer ring (with inlet bore) 3 Pump element with 1 outlet consisting of: pump ring R, pump shaft W, piston K, adjusting plate V, pressure spring D and sealing rings R 4 Cover 5 Threaded rod 6 Cap nut Oil drain port Adjusting plate (V) Piston (K) with pressure spring (D) Outlet G 1/8, shown transposed by 45 Suction groove Pump shaft (W) Outlet
Page 9 1.3.1 Functional description The pump element is secured between the drive element and cover by two threaded rods. Figure 4, section A-B, shows two pistons guided in the radial bore. A spring constantly presses both pistons against the elliptical surface of the adjusting plate. Two opposing piston strokes thus occur simultaneously at each revolution of the pump shaft. In the suction phase (negative pressure), the pistons move apart and the oil enters the piston clearance through the suction groove and the control bore. If the pump shaft continues to rotate, the duct between the suction groove and control bore is closed, which ends the suction phase. Until bottom dead center is reached, the pistons continue to move against each other and thereby generate the necessary pressure. The rotary motion of the pump shaft connects the oil-filled piston clearance with the control bore, allowing the oil to discharge through the outlet. The delivery volume is adjusted using the adjusting plate. The position of the elliptical surface of the pistons is adjusted relative to the position of the control bore. The piston stroke remains the same; the effective piston stroke is changed, setting range 7... 20 mm 3 /rev and outlet. Example: Type: RA = Radial piston pump Drive 1M = Electric motor drive, coaxial 2M = Geared electric motor drive Gear ratio: 00 = 1:1 05 = 5:1 Number of pump elements: 1 = 1 with 1 outlet RA 1M 00 / 1 / 4036 AF07 Motor code letter: AF07 = Electric motor, Protection class IP 55F, temperature class F Design key: 4021 = Electric motor, vibration-resistant design, top terminal box, marine design with DIN 89280 cable fitting, max. admission pressure 5 bar, oil drain port G 1/8, positioned laterally at port 4035 = Same, pump element internally consolidated from dual-outlet to single-outlet, feed rate 14... 40 mm 3 /rev and outlet 4036 = Same as design 4021, but with oil drain port on bottom 4043 = Same as design 4035, but with oil drain port on bottom
Page 10 1.4 PBA progressive block feeder on baseplate 1.4.1 Functional description The block feeders on baseplate PBA 1 are set to a fixed piston displacement per outlet and cycle of 0.12 or 0.23 cm 3. The volumetric flow fed via a pipe is forcibly distributed in a predetermined ratio to the outlets, i.e. to the lubrication points or the downstream progressive feeders. Pistons aligned in series meter the lubricant for two opposite outlets each and control the function of the neighboring piston. This way, the function of the block feeder can be checked by monitoring any piston with a proximity switch. The task of the progressive feeder is to consecutively distribute specified portions of the pressure-fed lubricant to the connected lubricant points. The lubricant continues to discharge as long as it is pressure-fed to the progressive feeder. The specified portions are generated through the piston movement. Two lubricant outlets on the two end positions of the piston travel are allocated to each piston. If lubricant is pressure-fed, the pistons of a feeder move in turn to their end position. The piston movement displaces a portion of the lubricant that is upstream of the piston to the downstream outlet. The movement of a piston can only start after the upstream piston has been moved to its end position. If all pistons are in their left or right end position, internal connecting bores in the feeder ensure defined and continued running of the pistons. When all pistons have been moved once to the left as well as to the right end position, all connected lubricant points have been supplied once with the preset lubricant quantity. The portions for both outlets are determined by the diameter and the travel of the piston. The selection of the required portion is made during the design of the feeder. A subsequent change of the portions is only possible through modification of the feeder. Ports not in use must not be closed!
Page 11 Functional diagram of PBA progressive block feeder on baseplate Number of outlets 10 or 20 20 10 9 8 7 6 5 4 3 2 1 Inlet L R Example: PBA 1 G 20 / 7 D 18/00 4006 Type: PBA = Progressive block feeder on baseplate Size: 1 = 700 cm 3 /min inlet volumetric flow Design: G = on baseplate Number of outlets: 10 = 10 outlets 20 = 20 outlets Piston diameter: 5 = 5 mm (0.12 cm 3 /stroke) 7 = 7 mm (0.23 cm 3 /stroke) Monitoring: / = None C = With proximity switch, front right D = With proximity switch, front left E = With proximity switch, behind right D = With proximity switch, behind left Proximity switch: 00 = None 18 = M18x1 Attachments: 00 = None Design key: 5000 - Up to 12 outlets = Proximity switch at last port from inlet - 14 or more outlets = Proximity switch on 6th port from inlet - Proximity switch with M12x1 plug with cable box aligned toward inlet, - Baseplate: All outlets G 1/8 5001 / 4008 - Up to 12 outlets = Proximity switch at last port from inlet, - 14 or more outlets = Proximity switch on 6th port from inlet, - Proximity switch with 6 m cable aligned toward inlet, with version 4008 also against inlet possible (E / F) aligned, - Baseplate: All outlets G 1/8 4002 - Up to 12 outlets = Proximity switch at last port from inlet - 14 or more outlets = Proximity switch on 6th port from inlet, - Proximity switch with M12x1 plug with cable box aligned toward inlet, - Baseplate: Outlets 1 to 6 = G 1/8 Outlets 7 to 10 = G 1/4 4006 / 4007 - Up to 12 outlets = Proximity switch at last port from inlet - 14 or more outlets = Proximity switch on 6th port from inlet, - Proximity switch with 6 m cable aligned toward inlet, - Baseplate 4006: Outlets 1 to 6 = G 1/8 Outlets 7 to 10 = G 1/4 - Baseplate 4007: All outlets G 1/8
Page 12 PBA progressive block feeder on baseplate in special design with proximity switch Block feeder D F 35 T 45 6.5 8.5 Baseplate Feeder example: 24-3510-1163 PBA1G20/7D18/00/4006 Proximity switch complete (cast) Proximity switch housing Tightening torque 4.2 Nm for M6x20 DIN 912 screw Feeder example: 24-3510-1166 PBA1G20/7F18/00/4008 Inlet G1/8 58 6.5 247 Outlet G1/8 E on designs 4002 and 4006: Outletts 1 bis 6 = G1/8 Outletts 7 bis 10 = G1/4 Feeder example: 24-3510-1167 PBA1G20/7E18/00/4008
Page 13 1.5 Monitoring 1.5.1 Functional description A proximity switch (1) and visual stroke monitoring can be attached to the progressive block feeders to monitor the volumetric oil flow. The housing of the visual stroke monitoring unit contains a metal rod (2), also called the plunger rod, that is coupled to the distributor piston. The rod no longer moves outward if the distributor piston (3) movement necessary for lubricant distribution does not occur. This visually indicates a malfunction/lack of lubrication pulse. A proximity switch (1) can be attached to record and evaluate this process. The proximity switch does not generate any pulses when the plunger rod has stopped moving, and the attached evaluating instrument reports a malfunction. Progressive block feeder with proximity switch BN BK BU
Page 14 1.6 BVRK progressive block feeder 1.6.1 Functional description Progressive block feeders are preferred for controlling the flow from UD pump units into two portions (application on V-type engines). Each portion is distributed further into a downstream PBA progressive feeder and the respective cylinder or valve seat. The sequence for positively actuated hydraulic control is identical to that of the PBA progressive feeder described above. The advantage of this sequential phase control: The entire feeder blocks even if only one outlet is closed. This blocking behavior allows reliable and inexpensive monitoring because only one piston needs to be monitored using the proximity switch.
Page 15 Dimension drawing of BVRK progressive block feeder with 2 outlets BVRK 06/00 B1 SW14 A 6.8 40 18.5 Ø11 3.5 56 61 A G1/8 4,5 Ø6.6 90 3.5 25 20 20 Outlets G1/8" 25 20 20 Outlets G1/8" 29.5 28 67 72 10 70 90 Inlet G1/4" Ø6.6 (7.5) 75 2.5 28 (7.5) 85 100 40 48 26.5 37.5 Inlet G1/4" View A View A
951-240-001- The contents of this publication are the copyright of the publisher and may not be reproduced in whole or in part without permission of SKF Lubrication Systems Germany GmbH. Every care has been taken to ensure the accuracy of the information contained in this publication. However, no liability can be accepted for any loss or damage, whether direct, indirect or consequential, arising out of use of the information contained herein. All SKF products may be used only for their intended purpose as described in these assembly instructions with associated operating instructions. If assembly/operating instructions are supplied together with the products, they must be read and followed. Not all lubricants can be fed using centralized lubrication systems. SKF can, on request, inspect the suitability of the lubricant selected by the user for pumping in centralized lubrication systems. Lubrication systems and their components manufactured by SKF are not approved for use in conjunction with gases, liquefied gases, pressurized gases in solution, vapors or such fluids whose vapor pressure exceeds normal atmospheric pressure (1013 mbar) by more than 0.5 bar at their maximum permissible temperature. Particular attention is called to the fact that hazardous materials of any kind, especially the materials classified as hazardous by EC Directive 67/548/EEC, Article 2, Para. 2, may only be filled into SKF centralized lubrication systems and components and delivered and/or distributed with such systems and components after consulting with and obtaining written approval from SKF. SKF Lubrication Systems Germany GmbH Motzener Strasse 35/37 12277 Berlin Germany PO Box 970444 12704 Berlin Germany Tel. +49 (0)30 72002-0 Fax +49 (0)30 72002-111 www.skf.com/lubrication SKF Lubrication Systems Germany GmbH 2. Industriestrasse 4 68766 Hockenheim Germany Tel. +49 (0)62 05 27-0 Fax +49 (0)62 05 27-101 www.skf.com/lubrication