E20110325959 - 1-Fuel Inj V.V Atom and Pump

Engine & Machinery Division Tel No.
+82 52 202 9457

1,Jeonha-Dong,Dong-Ku Fax No +82 52 202 7581
Ulsan, Korea 682-792 E-mail: enginecs@hhi.co.kr
Service Letter
Date : March 22, 2011

Ref. No.: HHI-HSM-SL-11-007
Design Improvement of Fuel Injection Valve Atomizer and Fuel Injection

Pump Sealing for HiMSEN H21/32 Engine
Dear Sirs,
Recently, there has been a modification on fuel injection valve atomizer and fuel injection pump sealing
method for HiMSEN H21/32 engines.
The purpose of the modification on atomizer is to improve life time of nozzle. At next, the purpose of the
modification on fuel injection pump sealing (from o-ring/back-up ring to Teflon Spring ring) is to
maximize the sealing effect of plunger/barrel inside not to cause contamination of L.O in a sump tank. For
more technical details, please find the attached technical circular.
HHI-EMD has developed these new atomizers/Teflon spring rings, and this concept will be the standard
on new-building H21/32 engines since November, 2011. Furthermore, HHI-EMD has decided to supply
these improved parts to your good vessels equipped with H21/32 engines in guarantee period as of 30th
May, 2010. These parts will be supplied at free of charge for our valued customers’ satisfaction.
In this regard, kindly advise us of the delivery address where you wish to receive the modified atomizers and
Teflon spring ring with the required tool by sea freight since the middle of April, 2011. (Due to the
manufacturing schedule, they will be available since the middle of April, 2011). If you have any local
forwarder in Korea, we are also available to dispatch the spare parts there so please inform us of the address.
In case you have some current-design spare parts of atomizers, you’re kindly requested to consume all
current-design spare parts of atomizers on board first and then install the improved parts delivered.
Please be noted that the above modifications can be carried out by owner’s personnel without difficulty
referring to the attached replacement procedure. Meanwhile, in case that the vessel needs HHI-EMD’s
support, HHI-EMD is available to assist the vessel by arranging the supervisor when the vessel calls to the
ports where HHI-EMD Branch office is located. (Rotterdam, Singapore, Dubai, and Korea)
1/2
We hope that the above is of service to you.
Faithfully yours,
S. G. Cha, General Manager

Engine Customer Service Dep’t
Engine & Machinery Division
Tel. : + 82 52 202 9457 Fax : + 82 52 202 7581
E-mail: enginecs@hhi.co.kr
Enclosed : 1. Technical Circular

2. Part list for Improved Parts (Manual)
3. Assembly Procedure
2/2
TECHNICAL CIRCULAR
SUBJECT: IMPROVEMENT OF FUEL INJECTION VALVE
TYPE: H21/32
Ref. No.: TEC2010/003/R1

Date: 12th Nov. 2010
Page 1 of 4
TECHNICAL CIRCULAR Ref. No.: TEC2010/003/R1
[GENERAL]
The fuel injection valve has continuously been improved over the years, with all modifications
being extensively tested in service to verify the improved performance. The test results and the
general service results gained in recent years, have led us to introduce a new design improvement
for fuel injection valve on HiMSEN H21/32 four-stroke engine.
[PHENOMENON]
The unexpected high exhaust gas temperature was intermittently detected during engine
operation in specific condition. The reason for the high temperature is not only improper operation
but also insufficient life time of fuel injection nozzle.
[IMPROVEMENT]
We have pursued the objective to develop fuel injection valve design that is extremely durable
with respect to wear on the nozzle and poor atomization. During this process, we have succeeded
in finding suitable solutions as follows.
1. Material combination of nozzle body and needle

It was found that the material combination of the nozzle body and the needle had made
a big effect on their wear rate. The wear rate leads to a different life time of the nozzle.
Page 2 of 4
ENGINE & MACHINERY DIVISION
Tel: +82-52-202-7274, Fax: +82-52-202-7696, E-mail: k240hhi@hhi.co.kr
<Improvement >
Three kinds of material combination test were fulfilled. Each result is listed in the table
below. The wear depth of current model that has the material of NT 200 and SKH 51 for
body and spindle is 7~11 ㎛. On the other hand, the wear depth of ‘Case A’ is 3~4 ㎛ after
same operating hours. The ‘Case A’ material combination has shown the best wear
resistance, which helped the nozzle get better reliability.
Material Combination Wear rate Remark
Case A 3~4 µm Best
Case B 5 µm
Current 7~11µm
Table 1. The test result of H21/32 nozzle body wear rate
2. Opening pressure of fuel injection valve

It has been found that the opening pressure is the other cause of high seat wear rate.
The higher opening pressure is, the higher initial spring force is. If the initial spring force is
reduced by 10%, the impulse can be reduced by about 20%.
<Improvement>
In order to reduce impulse power on nozzle by spring force, opening pressure of fuel
injection valve has been decreased from 450 bar to 420 bar. Longer nozzle life time by the
optimized opening pressure has been proved in field tests.
Page 3 of 4
With these design improvements, a significantly longer life time of fuel oil injection nozzle
can be obtained.
[SUMMARY]
Design improvement;
- New material combination of atomizer
- Opening pressure reduced to 420 bar from 450 bar
The above mentioned improvements result in better atomizer reliability.

[The end]
Page 4 of 4
TECHNICAL CIRCULAR
SUBJECT: IMPROVEMENT OF FUEL INJECTION PUMP
TYPE: H21/32
Ref. No.: TEC2010/004

Date: 6th Dec. 2010
Page 1 of 3
TECHNICAL CIRCULAR Ref. No.: TEC2010/004
[ GENERAL ]
The fuel injection pump has continuously been improved over the years, with all modifications
being extensively tested in service to verify the improved performance. The test results and the
general service results gained in recent years, have led us to introduce a new design improvement
for fuel injection pump on HiMSEN H21/32 four-stroke engine.
[ PHENOMENON ]
O-ring which separate fuel oil and drain oil space inside of fuel oil pump could be hardened,
cracked and damaged by a chemical reaction with high acid fuel, overheat during operation or miss
assembling in rare case. At that time, too much of the fuel oil could flow into drain oil passage
through the damaged or hardened o-ring. Then, the drain hole could become clogged.
Figure 1. Oil flow in the fuel injection pump Figure 2. Damaged O-ring
In that case, the fuel flow could make a lubricating oil contamination because the fuel pressure
is higher than the sealing oil pressure.
[ IMPLEMENTATION ]
The fuel oil leakage caused by the damaged or hardened o-ring can be solved by replacing the
existing o-ring with a new teflon spring seal ring. The teflon spring seal ring has better abrasion
resistance, better heat resistance, and better chemical resistance.
(For the installation of teflon sealing ring, please refer to the attached manual sheet ‘M51102 –
Installation of Teflon Ring’.)
Page 2 of 3
TECHNICAL CIRCULAR Ref. No.: TEC2010/004
Part No. Description Q’ty / Cyl.

Part No. Description Q’ty / Cyl.
A51000-116 O-ring 2
A51000-1E-116 Teflon ring 2
A51000-117 Back up ring 4
[ O-ring ] [ Teflon spring seal ring ]
Attachment: The instruction manual for installation of teflon ring – ‘M51102’ 1 copy
[The end]
Page 3 of 3
Page
H21/32 1/3
Section No. Rev.
Fuel Injection Pump Ass’y Assembly Drawing & Part List
연료 분사 펌프 어셈블리 조립도 및 부품 목록
A51000 1E
A52300
100 912
911
A25000
Part List
Weight
Item No. Description Q’ty / Cyl. Remarks / See Note
(kg)
100 Fuel Injection Pump Complete 1 32.0

911 Stud (M16) 4 0.13
912 Nut (M16) 4
HYUNDAI HEAVY INDUSTRIES CO., LTD. Engine & Machinery Division 11.03/YTY
Page
H21/32 2/3
Section No. Rev.
A51000 1E
Page
H21/32 3/3
Section No. Rev.
A51000 1E
Part List
Weight
Pos. No. Item No. Description Q’ty / Cyl. Remarks / See Note
(kg)
1 101 Pump housing 1set

2 102 Bolt 1
3 103 Gasket 1
4 104 Socket head bolt 1
6 106 O-ring 3
8 108 Delivery valve ass’y 1set
8-1 181 Delivery valve case 1
8-2 182 Delivery valve 1
8-3 183 Spring 1
8-4 184 Return valve 1
8-5 185 Spring 1
8-6 186 Pin 1
15 115 Plunger ass’y 1set
16 116 Seal ring 2
18 118 O-ring 2
20 120 Control rack 1
21 121 Seal ring 1
22 122 Control sleeve 1
23 123 Pointer 1
24 124 Shim 1
25 125 Bolt 2
26 126 Seal ring 1
27 127 Plug 1
28 128 Gasket 1
29 129 Deflector 2
30 130 Gasket 2
31 131 Spring seat 1
32 132 Spring 1
33 133 Spring seat 1
34 134 Plate 1
35 135 Tappet ass’y 1
36 136 Pin 1
37 137 Bolt 2
38 138 Shim 1
Page
H21/32 1/3
Section No. Rev.
Fuel Injection Pump Installation of Teflon Ring
연료 분사 펌프 (Separate) 테프론 링의 설치
M51102 1A
연료 분사 펌프의 분해 Disassembling a Fuel Injection Pump

매뉴얼 M51000 / M51100 연료분사펌프 정비점검 According to the manual M51000 / M51100
절차에 따라 연료분사펌프를 엔진블럭에서 분해한 후, ‘Maintenance Procedure’, dismantle the fuel injection
플런저와 배럴을 빼낸다. pump from engine block, and disassemble the plunger
and barrel.
테프론 링의 설치 Installation of Teflon Ring
1. 그림 1과 같이 테프론 링 조립용 툴을 준비하고 1. Check the installation tool of teflon ring of each
부품이 모두 있는지 확인한다. part [fig.1].
2. 테프론 링은 가능하다면 80~90℃로 가열하여 재 2. Heat up the teflon ring to 80~90℃ for having
질이 유연성을 가져 설치에 용이하도록 한다. flexibility, if possible.
3. 그림 2와 같이 보호틀을 수평한 바닥에 놓고 배 3. Put the barrel on the protection jig not to fall
럴을 뒤집어 보호툴에 끼워 조립시 흔들리지 않 down during inserting teflon ring. [fig.2]
도록 한다.
Fig. 1 Fig. 2
4. 그림 3와 같이 하부 링 조립용 슬리브를 조립하 4. Set in the long sleeve on the barrel, [fig.3] and
고, 그림 4와 같이 조립된 슬리브에 테프론 링을 insert the teflon ring on the sleeve. [fig.4] The
끼운다. 이 때 스프링의 방향은 반드시 상부를 direction of spring should be upside.
향하도록 끼워야 한다. The direction of spring must be
스프링의 방향을 반드시 확인한다. confirmed.
5. 그림 5, 6과 같이 링 팽창용 툴을 상부에 조립한 5. Input the expanding sleeve on the long sleeve,
후 아래방향으로 눌러 테프론 링이 배럴의 홈으 and push the teflon ring to the lower groove on
로 끼워지도록 한다. the barrel. [fig.5, 6]
Fig. 3 Fig. 4 Fig. 5 Fig. 6
Page
H21/32 2/3
Section No. Rev.
M51102 1A
6. 그림 7과 같이 상부 링 조립용 슬리브를 조립하 6. After assembling the short sleeve on the barrel
고, 그림 9와 같이 조립된 슬리브에 테프론 링을 [fig.7], input the teflon ring on the sleeve. [fig.9]
끼운다. 이 때 스프링의 방향은 반드시 하부를 The direction of spring must be positioned
향하도록 끼워야 한다. downward.
7. 그림 10과 같이 링 팽창용 툴을 상부에 조립한 7. Input the expanding sleeve on the short sleeve,
후 아래방향으로 눌러 테프론 링이 배럴의 홈으 and push the teflon ring to the upper groove on
로 끼워지도록 한다. the barrel.
너무 과도한 힘으로 눌러 테프론 링이 Be careful not to push the teflon ring with
배럴의 홈을 벗어나지 않도록 주의한다. the excessive force.
Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11
8. 그림 12과 같이 테프론 링 자리잡기용 툴을 하 8. Holding the adjusting tools by hand [fig.12],

부 홈에 위치시킨 후 양손으로 잡고 양쪽에서 힘 press the tools both sides to shrink the teflon
껏 눌러 팽창한 테프론 링이 수축되도록 한다. ring. [fig.13] Press the adjusting tools turning the
[그림 13] 방향을 바꾸어가며 테프론 링이 홈에 direction to fit the teflon ring on the groove.
잘 들어가도록 수축시킨다.
9. 그림 14와 같이 상부 홈도 하부 홈과 동일한 방 9. On the upper groove, do the same method of

법으로 테프론 링을 축소시킨다. shrinking the teflon ring.[fig.14]
Fig. 12 Fig. 13 Fig. 14
Page
H21/32 3/3
Section No. Rev.
M51102 1A
10. 그림 15와 같이 베럴 조임용 툴을 양손으로 잡 10. Assemble the adjusting shell for barrel with 4EA
고 베럴에 맞춘 후 M12 볼트 4개로 틀을 조립 of M12 bolts. Tighten the bolts by turns not to be
한다. 이 때 한 쪽으로 치우치지 않도록 번갈아 unbiased.(Reference : the clearance of adjusting
가며 체결한다. (참고 : 모두 조였을 때 양쪽으로 shell : 1mm)
약 1mm의 간극이 생성된다.)
11. 볼트를 분해한 후 만약 그림 18,19와 같이 변형 11. After disassemble the adjusting shell, the
이 발생한다면 8~9번 절차를 반복하여 변형부를 deformation of teflon ring can be occurred.
완만하게 한다. [fig.18] [fig.19] Then repeat the 8~9 step to make
even surface on teflon ring.
Fig. 15 Fig. 16 Fig. 17
Repeat below
steps to correct
the deformation.
Fig. 18 Fig. 19

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Engine & Machinery Division Tel No.

+82 52 202 9457

Date : March 22, 2011

Design Improvement of Fuel Injection Valve Atomizer and Fuel Injection

S. G. Cha, General Manager

Enclosed : 1. Technical Circular

SUBJECT: IMPROVEMENT OF FUEL INJECTION VALVE

Ref. No.: TEC2010/003/R1

1. Material combination of nozzle body and needle

Material Combination Wear rate Remark

Case A 3~4 µm Best

Table 1. The test result of H21/32 nozzle body wear rate

2. Opening pressure of fuel injection valve

The above mentioned improvements result in better atomizer reliability.

SUBJECT: IMPROVEMENT OF FUEL INJECTION PUMP

Ref. No.: TEC2010/004

Part No. Description Q’ty / Cyl.

[ O-ring ] [ Teflon spring seal ring ]

100 Fuel Injection Pump Complete 1 32.0

1 101 Pump housing 1set

연료 분사 펌프의 분해 Disassembling a Fuel Injection Pump

Fig. 3 Fig. 4 Fig. 5 Fig. 6

Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11

8. 그림 12과 같이 테프론 링 자리잡기용 툴을 하 8. Holding the adjusting tools by hand [fig.12],

9. 그림 14와 같이 상부 홈도 하부 홈과 동일한 방 9. On the upper groove, do the same method of

Fig. 12 Fig. 13 Fig. 14

Fig. 15 Fig. 16 Fig. 17

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