No.s16-008 eae BBR me OSAKA, 92076 APAN ae 4 SBME F OMB OUT susvect Plunger Stick of FO. Injection Pump aA ae HFO 380~700 cSt {#8 DK, DC, DE WORM lapeticaace enaane | DK. DC, DE type GENERATOR ENGINE with KFO 380~700 e8t FUEL OIL ne NOTE SEER AY 7 OR EEN SAGEM SREY, Recently we have experienced daroge ofthe puro tat seems to be MY KY FOMAOREAKICONT bEMEL TED, ZO os Pa CORT LOS LAMM SLORRE FE LTE ROR! ZOMREELO TBO ET, PALIT ILI RAEI TF YP BRDEROOMRERN TORT, BRELELTAS OWS, HRRMOLE FIC D Mat AEC EDRMORME, 7977 OAC ERB EO RELI 70 > 7 AMREN TED ET, Uae) 7 oMRORRL RE) WEED REEL ALONE AT LERER, HALO PPL DEBOBKE LCE FRO 2B ame 4 1H Mane LTO eM KE STE 2 Sanat ; Pee SURO RMTSME LCoS HELE LARUE, caused by stick of the plunger of the F.O nection pump. Ax the result of nepaction, we found thatthe stick ofthe plungar is caused by varias tnd diferent factors. This Technical Information summaries the ‘heromenon and eauses based on our experiences that has beon gained ‘rough Feed back from the feld as well a various investigation rests, We have recsived reports about Plunger Stick of FO injection purp (coating type plunge) The incdents were mostly acknowledged by the excessive devation ofthe exhaust gas {amporature (alarming), krocking sound when the plunger sick was occurred and ticking ofthe rack bar ofthe F-0. jection ‘bump that is found when the engine was stopped |LLPhenomenon and Factors of the Plunger Stick] We ean classify the factors of Plinger Stck in two categories of followings in accordance withthe analysis report ofthe failures, 1) Seizure occurred mainly at phnger body The damage tock place at the center pat of the plunger with wide area, The surface the barrel becomes rough and the {2p between the plunger snd the barel becomes worn fe wel, When the HO isnot completely replenished «and Femained inside of the pump, the residual remains and Ceeled down by MDO oF MGO, increase the resistance and reduce the clearance and finaly cause the seizure, Daphee Gre sms O77 LPL AC ORME 125797 Fe BE 8, DBE, 997 iS Bhi BA. ET FY Acmsint Ebene, BRULEE Y We AMICAL HY SHEN RUHL SMC AMGIC LB eM eR WAYNE SUTRR LOC WO ETO OBS ORT, LORE IV TY EAL AOMNMIR 1207929 val LIRR ORE HAPS I PMB WEL CHRON C20 BY, 2) Even if the plungor and barel do not have soratches and/or Seizure, Ue gap batween plunger and bara smaller, and the plunger shows the same damage tke the stick In this ease, although the FO rack show stuck condtion, but ‘may move again after the ar running or the worst case ‘the rack bar is kopt in stick condition. As forthe factor, {2 thinefm ike coating is formed with Zine and Sulfur adhesive tothe inner surface of the barrel and the outer surface of the plingERI ERS RRGMRT IIT, Monica RIL COE AO CHE RIDIL ETE Sv MRO 2 teROmR] Rao OBA 2 L-CS Nt AAR ARSE EOMEH 8 eA x OME ARSE ATL REVEL SLL LT Io ORME 1297971 OSAMGSRET, QoS —7 4 MERI IY PrORaNt, 2 DRERMAE BLY HIE Heese, DMRS MS OR < 22, ARRAS HAARE AD Eee 7 977 aL ET, Ae Leeann 7 eo CM LAER, MRE READ (Oc BUA LEE LE, PARC LORIE, Chime rea BUA BER, BHI Y AORN ORI RMSRRRCA TENS LBMETS = LAME OEY, mre i eo | == eRe aRe aoe Bn nner mi om ° it Come i «fet me “The tin-flm ke coating grows a6 thick a8 meron proportional to the operation hours In the ease. once te plunger and the barrels cleaned and ound no ertches or sezuro, te plunger and the Barel can bo used further Inner Surface of Baro 2 [Consideration for formation of the thin-film lke coating J ‘Aa a tendency of the recent malfunction, wen the thin-fm Ike costing i formed inside ofthe barrel, grows vp and ts thickness exceeds more than 6 merons andthe thin-film lke coating i generated at more than half ofthe tircunference of the barre the clearance between the barre! andthe pliner decreases jeopardizing the movement lof the plunger. The plunger withthe carbon coatng featur low friction by ‘the coating, thus it ean stand with stick in short tme however ifthe clearance between the plunger and the barel decreases tue to formation ofthe thir-filn tae costing, the plunger finaly stuck and as general tendency, sticks atthe top ofthe F.0. tam stroke, [As a result of vestigation of damaged ful injection pumps, ie was identified that the thin-film like costing fe made of compound of zine and sub. ‘The auf is derived from the fuel oll hile zine and calcium are derived from additives ofthe lubricating oi The bench test that i conducted by lsboratory confns that these elements forms thin-film Ike coating under higher temperature condition. BOD KLLATDO NR MOM ER SBME *) FX analysis result of thin film-like coating3. [HawREOA = XA] LRnEmORE sn Sak TARE CH LIER, 1, ARLE RY RROD 7 ine 25 2. HAODTRR, 792 Ir Me wich Lo URE RCL HRRR Efe CH Ree LT 8, ARIE C18 LAAN LRAT S BH mn, ERODED R O79 Pa REA ORAS RUM LBS RSWIMB SRE, BLT IZ Te DEIIDOTEC ERAS HL ZOE AMET BOONE RAT CHAO ERIM E NTS LUE TH, eRLEY. ees COS EAOPAMIRAOSOTICSRT SE tat 4 77 v exon LO 2 BOI CORE LE LCRA L-CISAR Wy BA EEO AICIY Bb GHW EU MESH EEN RIT I rT 8 AR ET, FERNS REIS 8 ELC I EN CES, RAE FEICRLET, ft 1. MARMROB OH AMMMNRE TINE EEN, ARNRR:5~ 100/89 2. EOL 9NDORUAGOICHD HX SMO TAUTE APRAEBL LORS EORVRREDN CHM, LORD, WOKE 3 OBELED DIARY TREE ARTES OMELET 2, EO1K 5 ALUNICRRBNELET D PLEIN 709 7 OMS EMTS, MEY AP IC ko CASSEL LORRAIN 72 AAbHETO, TOMAR MAETICY MDM ome ROLES, 8. AREY 7 oat: SETAE 7-309 000~ G0 CO EAA LORIMER TRITIYI, ROEM OLTD RENEE, Leow Hi eeR UCOET 27972 veo SEN OGUR LB, tie 9 04) Leese L CHa BRL, MeOH kis ZOM SH COs ET. ZOE DI MMIC NRT OY EBT S. ERD IRE, MAORI Y CARD D ET, AL HaORe THI Fee RAT, 1 ABER OTOANNLE SOREL LAP Zu, rT 2 RL FIRM ES, ODMR | DHS IE LCM ERS SL RIPE GAIN? 4 kel ISH 7 ORR UNIONS DMI MI=Wwo, MoOIcHID ABE “cht ‘8.[Mechaniom of formation of the thin-fim lice coating) “The reel that wat confirmed by «sane king exaination to elucidate the gneraton mechariom ofthe thir fin tke svt se mentioned above ies follows {Dn the sae! coking examination, the sample geace (SCM#80 mates) teat haated up an the thin fm le coating i generate when a heating ferrgeratare reached 230°, 2) Ana result of analyse of adhsion the nradont constitution was the sune as forthe fl that was found the Pinger and Baral {DR wae confnred that longor the testi perio. thixer the coating ‘thane ie confirmed Wren the temperature ofa pings and the bral rgher th tn-fim tho coat becomes ticker However, tte beleve that he tompersture ofthe pang doesnt ineease at Fig a 250°C and we judged tet coud be accelerated under ie ign pressure 4. [Countermeasures for Plunger Stick] ‘As emlaied nthe above“ L{Phenorenon and Factors of the unger Stil tere are two factors for fares such asthe ace which longer sick occur atthe tine af «changing the ‘oll thus HFO is net bing corpletely replaced and ether fave winch» plunger stick occur fer uae of reulrntoral, “Therefore we wows The you to cerry out the fuel ol chenge ver correcty'naseardance with the engine natruction ‘eanual (rts! points are shown as foows Juin the oate of fue changes. ‘Temperature Inclination Rate: §-10°C/in. 2 When changing the fuel ol to MDO or MGO from HFO, apply the load ‘more than the lower loa lint higher a possible of the engine ‘output and carry out clearing operation with th load more than 80 Ininutes wth MDO or MGO. Stop the engine afterwards within fve minutos. Confer the movement ofthe rack af the fuel ijection pump afer stop ofthe engine ‘The required tine of complete replenishment from the HFO to MDO ‘or MGO subject tothe actual capacty ofthe fuel ol supply system, £0 please confirm the actual tine required for the complete replenishment. hange over, avoid any sudien temperature Fuel jection Purp shall be martamed at each 4000~6000 engine running hours. The cleaning of a plunger and the barrel are recommended whenever you do the maintenance a5 Shaveng fin the next page In doing 30, the clearing of the plangor and the barrel is recommended as shown inthe rext page When fuel oi of more than $80 oSt as chown in the above is used, adattves (ze, calium) those elamants are Served from the ibriating ol and sulfur derived from the FO react and generate tin-fim ike costing and its thickness inreases with engine running hours. ‘Thatefore itis effective to prevent the stick by the thir-flm lice coating by removing such coating wth the cleaning procedure forthe bara and the plunger regularly atthe ‘maintenance of FO. injection pump. In adétion, followings {re recommanded to decrease the adhesion ofthis Ike ‘eating 1) FO heating temperature shall nt be more than required ‘The FO temperature tobe as low as possible tobe kept vithin the allowable lower it. 2) HFO shal be circulated stale and constant fow with enough quant {9 FO circulation flow shall not be stopped even if engine is atthe stopping condition For example, when you re the fuel line and /or the plumbing werk i necessary, ‘change the fuel oi fom HFO t2 MDO/MGO before hand‘Seitehing trom Diesel Fusl Ol te Heavy Ful Os Vecuty at egg et ‘5. [RECOMMENDED CHANGE OVER PROCEDURE 1 4 LOAD to be applied at the time of the fuel oll change over period $ _ Hm (kWe) LowLoad Limit ii lEngine Type ‘Output (ke) tke) sf [nine speed [7207750 min-1] 900min-1 [720/780 min-]_ S00min1 rH fsoc-1710) NA 85 WA > 100 ~ [sOC-171A) N/A 580. NAL > 120 = fox-20 0 70 | > 0 | > 160 | Se ce | te | ome | ca | sam oven san ey fox-z6 1720 wa | >250 | Wa af of nL Woe es | wa | >a50 | wa 2 foxze 7015 wa >«o | Wa 1) (sae, | [cna ene ee ox-za ao wa | >50 | wa B] [Seteerme| [stommeem te joe-1e 5 aio [_> 129] > 0 ° [sor-29 140 1425 > 230 > 300 Say | ocnse 205 wa | >s00 | wa eoc-ae seo wa | >e00 | wa Taihchang fom Paavy Poa Gi a iawat Fost OF si a abate hy Sm outta a 3 = Smad i — ' Cases simi zs \ eee 5 Scronwcneattol a | — i i 6. L792 91 RMI4 07 409-O8% 1 De-S2MIRRIIC CARMA L NRA FRIe Le, BEAL RIL CRO CAP BUR TORE IET ZH ELE ombewa conn, iret cid LORRET IY Ty OBROMBE SA GET. ERED AY hOGMLTHSHED LSD eat [osor3] EBA, 9. Damage ofthe ftar eloment for the plunger hérication J “The attached dela shows the damage ofthe flr netald on Do-82 “The serene deform and its fitration sen has gone hes iso lng working a theft forthe alanger ication ne “The element was deformed so i was not aopery ted, and caused pungs sek Refer to tochical information (6507-18)1 79724 ALOM MEL PRIN 7RRBLES 279 2 rR AURORE RIC SLAF OCIEMCE RO, ‘SIMONE: 4000~6000 EMIS (792 oe eT PS OC COMMER 7 EARL, TIL TT RULER AE, Om REM 8, 1) eR (seam Yt 2) ABYFLIA b (BBO OF: BM Ay Ke. 748) 3) me QAaYFTI4 PERU, BERD EY AAO NT, AOD AIRE HD, QAA FIFE HEBER IEA LANIBIMAL RU aeRO, 93 OI) SURE L FICUhL aaa, OFFI YMAWTH, ABV FIFE KEATS MRE AT RECHT, MRR, MOURMET Ty REMUS A ALS PRE LEED AYDEN MS CRIT 8, ‘Thin ike coating 7 Cteaning method of the Pinger and Barrel] The clearina method explained as follows shal be raferred when ou carry oUt inspection ofthe plunger stick and leo {atthe time oF the fuel ol injection pump maintenance. Mairtanance interval: At every 4000~8000 operation hours {Clearing method of the plunger barel inner surface) (Doicmartle the fuel injection pump and remove the slunger and the barrel. @ Prepare the clearing took. 1) Barrel clearing bar forthe electri ding machine) 2) Scotch Bright (# 800 or equivalent: 3M pad No.7448) 3) leaning Oil (Kerosene) @ lnmarse Scotch Brite to kerosene, and wrap ito the tip of ‘the bar and then attach the bar tothe electric dling machin @ Wan above Scotch Brite around the bar and insert it to the barrel inside and starts dell and then move itup and down for abovt 30 seconds ‘As forthe Plunger, Wrap the plunger wth the Scotch Brite and sorb the surface gently © Use clean washing ol so theta smal lion substance isnot left inthe pnger surface and barel ater clearing “Tool name Bar, barel cleaning Parts No.NWOOBO1O8«A ‘Seoweh Bite Parts No. NWO0EO22144 (GM: No.74¢8) #800 ofthe barrel {Lut the pad 50 to 60 mm length 2.lnsert the pad inthe sit and wrap around the bar aso fallow the turing rotation ofthe cil 3. The lamete of the padi adjusted soasto sightly exceed the inner bore