Engine & Machinery Division Tel No.

+82 52 202 7590 / 7588

1,Jeonha-Dong,Dong-Ku Fax No.+82 52 202 7581
Ulsan, Korea 682-792 e-mail: enginecs@hhi.co.kr

Service Letter

Date: September 12, 2008

Ref No.: K190-HiMSEN-34

Regular Overhaul Notice for HiMSEN Engine

HiMSEN Engine H17/28, H21/32, H25/33

Dear Sirs,

The purpose of this letter is to inform about the regular maintenance schedule and
consumable parts for maintenance of HiMSEN engine. The maintenance schedule
varies whether HiMSEN engine is designed for marine auxiliary engine or stationary
engine. The regular overhaul is to be carried out every 16,000 hours for marine
auxiliary engines, while 12,000 hours is needed for stationary engines.

The following lists indicate the various items of the programmed condition-based
and scheduled maintenance overhauling procedures plus consumable parts for one
engine during the maintenance. The stated “Maintenance Guidance” can only be
used as guidance, as a difference in the actual operation conditions, the quality of the
fuel oil, lubricating oil, etc. will decisively influence the service results.

Piston taken out for overhaul Cyl. head and piston disassembled

1/2
Please note the following lists are samples for reference, and the lists for your
HiMSEN engine can be found from HiMSEN instruction book volume one, M09
ENGINE MAINTENANCE GENERAL section.

The regular overhaul is generally carried out by one supervisor, two skilled
technicians, and two workmen for 5 days. If you need any technical support or
supervision for regular overhaul of HiMSEN engine, please make a contact to us and
we will provide technical information and dispatch engineers with necessary spare
parts for routine maintenance and additional parts in case of incident on your request.

We hope that the above is of service to you.

Faithfully yours,

S. G. Cha, General Manager

Engine Customer Service Dept
Engine & Machinery Division
Tel.+82 52 202 7313 Fax.+82 52 202 7581
E-mail. enginecs@hhi.co.kr, jung372@hhi.co.kr

Enclosed. Maintenance schedule and List of consumable parts

2/2
 Page
H21/32 1/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
엔진 정비 일반사항 정비점검 계획
G09100 2B

Maintenance Guidance for Stationary Engine

Description Overhaul Interval

■ : Planned Overhaul
Section
Remark

12,000
15,000
18,000
21,000
24,000
Others
◆ : Confirm after Overhaul/New

1,000
2,000
3,000
6,000
9,000
No.

200
◎ : based on observation

Major Fasteners - Retightening

◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆
M15000 Nuts for Cylinder Head
M33200 ◆ : Confirm tightening

■ ■ ■ ■ ■ ■ ■
Nuts for Counter Weight
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/SWS
 Page
H21/32 2/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
엔진 정비 일반사항 정비점검 계획
G09100 2B

Maintenance Guidance for Stationary Engine

Description Overhaul Interval

■ : Planned Overhaul
Section
Remark

12,000
15,000
18,000
21,000
24,000
Others
◆ : Confirm after Overhaul/New

1,000
2,000
3,000
6,000
9,000
No.

200
◎ : based on observation

Control System – Function Check

G40000 Governor Linkage – Function Check Weekly

■
Check Governor Oil Level
(See Manual for Governor) ■ Daily
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
■

Monthly
(Function Check)
■ ■ ◎

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/SWS
 Page
H21/32 3/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
엔진 정비 일반사항 정비점검 계획
G09100 2B

List of Consumable Parts for One Engine

Z=Number of cylinder

Quantity for the operating hours

Section
Parts Description
No. 3000 6000 9000 12000 15000 18000 21000 24000

Covers for Engine Block

A19300 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)
A19300 O-ring for cam shaft room cover - - - - 1xZ 1xZ 1xZ 1xZ
A21100 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
A13250 Journal bearing - - - - - 1xZ+2 1xZ+2 1xZ+2
A32000 Big-end bearing - - - - - 1xZ 1xZ 1xZ
A32000 Small-end bearing - - - - - 1xZ 1xZ 1xZ

Cylinder Unit
A21100
Intake v/v with seat and v/v guide - - - - - 1xZ 1xZ 1xZ
A21200
A21100
Exhaust v/v with seat and v/v guide - - - - - 1xZ 1xZ 1xZ
A21200
A22000 Packing for indicator v/v & v/v complete - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A31100 Piston ring-top ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A31100 Piston ring-2nd ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A31100 Piston ring-scraper ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A15100 Flame ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A15100 Gasket between head and liner - - - 1xZ 1xZ 1xZ 1xZ 2xZ
O-rings for cylinder liner and
A15100 - - - 1xZ 1xZ 1xZ 1xZ 2xZ
Cooling water jacket (set)
A21100 O-rings for cylinder head (set) - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A21100 Sealing ring for valve stem 4xZ 4xZ 4xZ 4xZ 8xZ

Fuel Injection Equipment

A51100 Fuel pump plunger and barrel - - - - - - - 1xZ
A52000 Fuel injection nozzle with dowel pin - 1xZ 1xZ 2xZ 2xZ 3xZ 3xZ 4xZ
A52000 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
A52300 - - - 1xZ 1xZ 1xZ 1xZ 2xZ
(set)
O-rings for fuel feed pipe connection
A53000 - - - 1xZ 1xZ 1xZ 1xZ 1xZ
(set)

Lubricating Oil System

A61000 Bush for lube oil pump - - - 4 4 4 4 8
A61000 O-ring for lube oil pump - - - 1 1 1 1 2
A61000 O-ring for lube oil pump - - - 1 1 1 1 2
A62000 O-ring for lube oil cooler connection - - 10 10 10 20 20 30
A63000 Lubricating oil filter cartridge 4 8 12 16 20 24 28 32
A63000 O-ring for lube oil filter cartridge 2 2 2 2 4
A64000 O-ring for lube oil thermostat valve 1 1 1 2 2 2

HYUNDAI HEAVY INDUSTRIES CO., LTD. Engine & Machinery Division 05.09/SWS
 Page
H21/32 4/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
엔진 정비 일반사항 정비점검 계획
G09100 2B

Quantity for the operating hours

Section
Parts Description
No. 3000 6000 9000 12000 15000 18000 21000 24000

Cooling Water System

A71000 Oil seal for HT-and LT-pump - - - 2 2 2 2 4
A71000 Mechanical seal for HT-and LT-pump 2 2 2 2 4
A71000 O-rings for HT and LT-pump - - - 2 2 2 2 4
A71000 O-rings for HT and LT-pump - - - 3 3 3 3 6
A71000 O-rings for pump connection piece - - - 4 4 4 4 8
A71000 Self locking nut for pump shaft - - 1 1 1 2 2 3
A71000 Self locking nut for pump shaft - - 1 1 1 2 2 3
A74000 O-rings for C.W thermostat valve - - 2 2 2 4 4 4
A78000 O-rings for cyl. head C.W connection - - 10 10 10 20 20 20

Charge Air Cooler

A81000 Gasket for compressor outlet - - - 1 1 2 2 3
A84000 Gasket for air cooler - - - 1 1 1 1 2
A84000 Gasket for air cooler cover - - - 1 1 1 1 2
A84000 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/SWS
 Page
H21/32 1/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
엔진 정비 일반사항 정비점검 계획
G09100 1B

Maintenance Guidance for Marine Auxiliary Engine

Description Overhaul Interval

■ : Planned Overhaul
Section
Remark

12,000
16,000
20,000
24,000
28,000
32,000
Others
◆ : Confirm after Overhaul/New

1,000
2,000
4,000
8,000
No.

200
◎ : based on observation

Major Fasteners - Retightening

◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆
M15000 Nuts for Cylinder Head
M33200 ◆ : Confirm tightening

■ ■ ■ ■ ■ ■ ■
Nuts for Counter Weight
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
H21/32 2/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
엔진 정비 일반사항 정비점검 계획
G09100 1B

Maintenance Guidance for Marine Auxiliary Engine

Description Overhaul Interval

■ : Planned Overhaul
Section
Remark

12,000
16,000
20,000
24,000
28,000
32,000
Others
◆ : Confirm after Overhaul/New

1,000
2,000
4,000
8,000
No.

200
◎ : based on observation

Control System – Function Check

G40000 Governor Linkage – Function Check Weekly

■
Check Governor Oil Level
(See Manual for Governor) ■ Daily
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
■

Monthly
(Function Check)
■ ■ ◎

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
H21/32 3/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
엔진 정비 일반사항 정비점검 계획
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

A19300 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)
A19300 O-ring for cam shaft room cover - - - - 1xZ 1xZ 1xZ 1xZ
A21100 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
A13250 Journal bearing - - - - - 1xZ+2 1xZ+2 1xZ+2
A32000 Big-end bearing - - - - - 1xZ 1xZ 1xZ
A32000 Small-end bearing - - - - - 1xZ 1xZ 1xZ

Cylinder Unit
A21100
Intake v/v with seat and v/v guide - - - - - 1xZ 1xZ 1xZ
A21200
A21100
Exhaust v/v with seat and v/v guide - - - - - 1xZ 1xZ 1xZ
A21200
A22000 Packing for indicator v/v & v/v complete - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A31100 Piston ring-top ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A31100 Piston ring-2nd ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A31100 Piston ring-scraper ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A15100 Flame ring - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A15100 Gasket between head and liner - - - 1xZ 1xZ 1xZ 1xZ 2xZ
O-rings for cylinder liner and
A15100 - - - 1xZ 1xZ 1xZ 1xZ 2xZ
Cooling water jacket (set)
A21100 O-rings for cylinder head (set) - - - 1xZ 1xZ 1xZ 1xZ 2xZ
A21100 Sealing ring for valve stem 4xZ 4xZ 4xZ 4xZ 8xZ

Fuel Injection Equipment

A51100 Fuel pump plunger and barrel - - - - - - - 1xZ
A52000 Fuel injection nozzle with dowel pin - 1xZ 1xZ 2xZ 2xZ 3xZ 3xZ 4xZ
A52000 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
A52300 - - - 1xZ 1xZ 1xZ 1xZ 2xZ
(set)
O-rings for fuel feed pipe connection
A53000 - - - 1xZ 1xZ 1xZ 1xZ 1xZ
(set)

Lubricating Oil System

A61000 Bush for lube oil pump - - - 4 4 4 4 8
A61000 O-ring for lube oil pump - - - 1 1 1 1 2
A61000 O-ring for lube oil pump - - - 1 1 1 1 2
A62000 O-ring for lube oil cooler connection - - 10 10 10 20 20 30
A63000 Lubricating oil filter cartridge 4 8 12 16 20 24 28 32
A63000 O-ring for lube oil filter cartridge 2 2 2 2 4
A64000 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
H21/32 4/4
Section No. Rev.
Engine Maintenance General Maintenance Schedule
엔진 정비 일반사항 정비점검 계획
G09100 1B

Quantity for the operating hours

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

Cooling Water System

A71000 Oil seal for HT-and LT-pump - - - 2 2 2 2 4
A71000 Mechanical seal for HT-and LT-pump 2 2 2 2 4
A71000 O-rings for HT and LT-pump - - - 2 2 2 2 4
A71000 O-rings for HT and LT-pump - - - 3 3 3 3 6
A71000 O-rings for pump connection piece - - - 4 4 4 4 8
A71000 Self locking nut for pump shaft - - 1 1 1 2 2 3
A71000 Self locking nut for pump shaft - - 1 1 1 2 2 3
A74000 O-rings for C.W thermostat valve - - 2 2 2 4 4 4
A78000 O-rings for cyl. head C.W connection - - 10 10 10 20 20 20

Charge Air Cooler

A81000 Gasket for compressor out - - - 1 1 2 2 3
A84000 Gasket for air cooler - - - 1 1 1 1 2
A84000 Gasket for air cooler cover - - - 1 1 1 1 2
A84000 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