HPCR FuelManagement(E)

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Electronically Controlled Heavy DutyHigh Pressure Common Railfuel injection system (HPCR)

Fuel Management

Electronically Controlled Heavy DutyHigh Pressure Common Railfuel injection system (HPCR)

Fuel Management

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UKPTE0601AUSER’S TEXTMAINTENANCE COURSE

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FUEL MANAGEMENT FOR HPCR SYSTEM

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Content 11. Emission gas becomes increasingly a critical issue from now on2. Generation process of pollutants and environmental measures3. Emissions regulations and enforcement date (as an example)4. Innovative environmental protection technologies incorporated into

Komatsu engines5. HPCR system is distinct from conventional fuel injection system6. HPCR fuel line7. HPCR high pressure line (external view)8. Supply pump producing high pressure fuel (Key parts for HPCR)9. Common rail accumulating high pressure fuel constantly (Key parts

for HPCR)10.Fluid fuel to use11.Fuel management12.Examples of tarnished and worn injector internal parts and sliding

portions13.HPCR system adopting a main fuel filter and a pre fuel filter14.Points to notice when replacing the main fuel filter15.Points to notice when replacing the pre fuel filter

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Content 2

16.Pre fuel filter cartridge replacement procedures17.Examples of engine starting failure due to filter clogging18.Removing the water and sediment in the fuel tank19.Preventing water and dust from entering the storage fuel20.Proposed Fuel Storage System (For large-scale system)21.Engine oil change interval(Reference) Global Environment (Energy Consumption)(Reference) Global Environmental issues (Global warming,

photochemical smog, acid rain and air pollution)

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1. Emission gas becomes increasingly a critical issue from now on

<Causes>• Bad fuel management

(water, dust)• Poor periodic maintenance• Improper machine operation

<Results>• Air pollution• Reduction in production• Shortening of machine

life• Increase in downtime• Increase in repair cost

Deterioration ofemission gas

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2. Generation process of pollutants and environmental measures

Air pollution

Ozone layer depletion

Environmental issues Pollutants

CO

Products or climate changes

Danger to public health

Cataract, skin cancer

Headache, dizziness, nauseousness

PM

Environmental technologies

Sources of release

* Automobile emissions, etc

Gas emissions

from factories

Exhaust gas control

Purification technology

Energy-saving technologyOperation technologyOperation efficiency

Gas emissions

from urban activities

NOXSO2

Global warming

IncreasingCO2

Rising temperatureSea surface elevation

Release ofCFC's

Increase in harmful

ultraviolet light

Abnormal weather

NOXHC

Acid rain

Photochemical smog

Carbon monoxide

Suspended particulatematter

Deforestation

Eye irritation, pain on the

throat

Lung cancer, bronchitis,

asthma

* When compared to gasoline engines, diesel engines emit much PM and NOX but fewer CO2 because of its superior fuel consumption.

Measures to meet the emission

regulations

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Regions Output class Enforcement date

NOX

Nitrogen oxideHC

Hydrocarbon

NMHC+NOX

Nonmethane hydrocarbon + Nitrogen

oxide

PM Suspended particulate

matter

Black smoke density at

abrupt acceleration with no load

Unit (g/ kWh)

(%)

75-130kW 2007/10 3.6 0.4 - 0.2 25

130-560kW 2006/10 3.6 0.4 - 0.17 25

75-130kW 2007/01 - - 4.0 0.3 -

130-560kW 2006/01 - - 4.0 0.2 -

75-130kW 2007/01 - - 4.0 0.3 -

130-560kW 2006/01 - - 4.0 0.2 -

75 - 130kW : PC160 - PC200-8130 - 560kW : PC220-8 - PC1250-8, WA380-6 - WA600-6

Examples of Komatsu machines conforming to the regulations

Emissions regulations

Law concerning emissions control of specified special vehicles

EPA Tier3

Stage3A

Japan

USA

Europe

3. Emissions regulations and enforcement date (as an example)

(Scheduled)

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Clean Ex. GasEngine (exhaustemission control)reduces PM and

NOX

4. Innovative environmental protection technologies incorporated into Komatsu engines

EconomicalEngine

(Low fuelConsumption)

Silent Engine(Low noise)

Heavy DutyCooled EGR System

Heavy DutyHeavy DutyHPCR SystemHPCR System

New CombustionChamber

Air to Air ChargeAir Cooling System

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Features• Supply pump pressurizes fuel to a high

pressure and controls the pressure.• High-pressure fuel is stored in the

accumulator (Common Rail).• Injection quantity and injection timing are

controlled electronically by the controller.

5. HPCR system is distinct from conventional fuel injection systemIn-line pump fuel

injection systemHPCR fuel

injection system

Supplypump

Injector (Electronically

controlled)

In-line injection pump

Fuel is injectedinto the cylinder.

Injection nozzle

(Mechanical type)

Fuel is injectedinto the cylinder.Features

• Fuel injection pressure depends on the engine speed.

• Injection nozzle is fixed pressure regulator.

• Injection timing is fixed or proportionally controlled using a timer.

Maximum injection pressure500 - 800kg/cm2

Maximum injection pressure1200 - 1600kg/cm2

Solenoidvalve

Drain

Two waytype valve

Common rail

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6. HPCR fuel line

Controller

Fuel tank

InjectorECU

High-pressure fuel( 1600kg/cm2)

Fuel is injectedinto the cylinder.

Bar filter

Solenoidvalve

Fuel cooler(Depending on

machine model)

Strainer

Waterseparator

Controls injectionquantity, injectiontiming, etc.

Mainfuelfilter(2µm)

Prefuelfilter(10µm)

Supply pump

Large capacitypriming pump

(Depending onmachine model)

Common rail

Coarse filter

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7. HPCR high pressure line (external view)

Controller (ECU)Supply pump

Electronicallycontrolled injectors

Main fuel filter

Common rail

High pressuretube connector

Example of 114 series engine

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8. Supply pump producing high pressure fuel (Key parts for HPCR)

PlungerOutlet valve

Inlet valveGear pump

Gear pumpCam housing

High pressurefuel outlet

Gear pump inlet

Supplypump head

Supply pump for107 series engines

Supply pump for114 series engines

Supply pump for 125, 140 and 170 series engines

High pressure fuel outlet:

Camshaft

(Maximum injection pressure : 1200 - 1600kg/cm2)

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9. Common rail accumulating high pressure fuel constantly (Key parts for HPCR)

Common rail pressure sensorPressure limiter

Common rail

High pressuretube connector

From supply pump

Container to store a certainamount of high pressure fuel

Example of 107 series engine

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10.Fluid fuel to use

•Be sure to use fluid fuel specified in Operation and Maintenance Manual.

•The machine may not conform to the emissions regulations if fuel other than those recommended is used.

•The use of fuel other than those recommended may have a damaging effect on the engine.

Reservoir Fluid Type

ASTM Grade No.1-D S15ASTM Grade No.1-D S500

ASTM Grade No.2-D S15ASTM Grade No.2-D S500

*ASTM: American Society of Testing and Material

-22 -4 14 32 50 68 86 104

20 30 40 50ºC

RecommendedKomatsu Fluids

Fuel tank Diesel fuel

Ambient Temperature122ºF

-30 -20 -10 0 10

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• The clearances in supply pumps and injectors have an accuracy in units of micrometer since the fuel injection pressure for HPCR system is extremely high (1600kg/cm2).

• Therefore, the invasion of water and dusts into the fuel line shall be controlled more strictly compared with conventional fuel injection systems. Accordingly, a pre fuel filter of 10µm with water separator and a main fuel filter of 2µm are installed in HPCR system.

• It is extremely important to prevent water and dusts from entering the fuel since more than 85% of fuel system failures are caused by water and dusts in the fuel.

11.Fuel management

(Micron)2 8 25 50100

<Comparison of filter roughness and close things>

Main fuel filter Human hair (50 - 80µm)White blood cellPre fuel filterRed blood cellBacteria

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12.Examples of tarnished and worn injector internal parts and sliding portions

Outer valve seat

Armature plate top face Inner valve slidingportion

Sliding portion ofcommand piston

Sliding portion ofnozzle needle Nozzle needle seat

Causes: Dust,Water Causes: Water,

Rust

Causes: Dust, Water

Causes: Dust,Degraded viscosity

Causes: Dust

Causes: Dust,Water

The sliding portion being whitened

Worn seat portion


The armature plate being tarnished to brownish-red


Worn seat

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2-μm filter paper of Komatsu genuine filters (Photomicrograph)

13.HPCR system adopting a main fuel filter and a pre fuel filter

Standardreplacement

interval:Every 1,000

hours

Standardreplacement

interval:Every 500

hours

UseKomatsugenuinefilters!!

UseKomatsugenuinefilters!!

Pre fuel filter for HPCR system (10μm)High-performance main fuel filter (2μm)

* Refer to Operation and Maintenance Manual for details of replacement interval and procedures.

Water separatorDrain the water and sediment from the separator at daily

checking before starting operation.

To prevent dust and water from entering the fuel line, HPCR system adopts a main fuel filter (2µm) and a pre fuel filter (10µm).

The pre fuel filter has a water separator.

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Be sure not to use imitation filters. If imitation filters are used, the capture efficiency of dust in

the fuel is lowered, resulting in early wear of inner parts of the supply pump and injectors.

The use of imitation filters leads to increases in machine downtime and maintenance cost that are far beyond the temporary filter cost.

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14.Points to notice when replacing the main fuel filter

Points to notice whenreplacing the filter When replacing the filter, install the

new filter without filling the filter without filling the filter element with fuelelement with fuel. (Reason: To avoid intrusion of dust if filling the new filter with fuel)

Make sure that the o-ring is fitted properly.

Fill the new filter with fuel by operating the priming pump.-Manual priming pump :107,125,140 series engines-Electric priming pump :114,170 series engines

* Refer to Operation and Maintenance Manual for details of replacement interval and procedures.

Refer to Operation and Maintenance

Manual because the procedure varies

depending on machine models.

When replacing the filter, make sure that dusts never enter the fuel line.

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15.Points to notice when replacing the pre fuel filter

(WIF sensor is installed on 107 and 114 series engines only.)

• Disconnect the connector of the Water In Fuel (WIF) sensor before removing the pre fuel filter.

• Remove the water separator (transparent bowl fitted with the sensor).

• Replace the pre fuel filter with the new one.

WIF sensor

Priming pump

Pre fuel filter

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16.Pre fuel filter cartridge replacement procedures

After filling the new filter cartridge with fuel, remove cap (A) and dispose of it properly.

Pour fuel into the new filter cartridge with cap (A). (Never pour fuel into the center hole.)

Confirm that cap (A) is attached to the new filter cartridge before filling it with fuel.

(A) (A)

(A)

* Refer to the Operation and Maintenance Manual for details of replacement interval and procedures.

When replacing the pre fuel filter, fill the new filter cartridge with fuelfill the new filter cartridge with fuel according to the following procedures before installing it. (Reason: To reduce the number of times of priming pump operation for air bleeding)

When replacing the filter, make sure that dusts never enter the fuel line.

Apply engine oil to packing surface of the pre fuel filter cartridge thinly, and then, install it on the filter holder. Tighten the filter cartridge 1/2 to 3/4 turn after the packing surface on the cartridge has contacted the sealing surface of the filter holder.

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<Pre fuel filter> <Main fuel filter>

The engine failed to start due to the filters clogged with dusts introduced at fueling.

17.Examples of engine starting failure due to filter clogging

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18.Removing the water and sediment in the fuel tank

If any empty space is left in the tank, dew condensation water formed by temperature changes between night and day may get mixed in with the fuel.

Drain the water and sediment from the tank before starting daily operation and about 10 minutes after refueling.

When refueling, make sure that dusts never enter the fuel tank.

To prevent the formation of any condensation, fill up the tank with fuel after daily operation is completed.

Be sure to put the fuel tank cap tightly not to come away.

Be sure not to damage or lose the strainer during fueling.

• Water introduced in the fuel causes rust on piping parts and early wear of sliding parts such as supply pump, injectors, etc. due to reduced lubricating ability.

• Be sure to drain the water and sediment accumulated in the fuel tank before starting daily operation.(They are mixed in with the fuel and move into the fuel lines easily in operation.)

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19.Preventing water and dust from entering the storage fuel

When storing fuel in drums, put the cover on the drums or place the drums horizontally to prevent rainwater, etc. from entering them.

OKOK

• Dusts mixed in with the fuel accelerate filter clogging and reduce engine output. The fuel circulation is also deteriorated causing early wear of supply pump and injectors internal parts.

When refueling fuel from a drum, make sure that dirt on the bung and dust accumulated on the bottom of the drum do not enter the refill fuel.

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1.) Primary Receiving Storage Fuel Tanks : -a.) Main function is to store dis-charged fuel from tanker for

2 ~ 3 days to collect sediments before transferring to Secondary Storage Fuel Tank.

2.) Secondary Storage Fuel Tanks : -a.) To store clean fuel for consumption via kiosk.

INFLAMMABLE

Mobile

Kiosk

x

x

x

x

Lower Ram

UpperRam

Primary Receiving Storage Fuel Tank

Secondary StorageFuel Tank

x Filter

Tanker

Created by KAP Svc Dept

Precipitate dust andwater fully.

20.Proposed Fuel Storage System (For large-scale system)

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Engine oil change interval by sulfur content of fuel(1) In case of using Komatsu genuine oil or API CH-4, API CI-4, JASO

DH-1 oils

21.Engine oil change interval

(2) In case of using API CF-4 (or CF-4/SG) oilOil change interval is reduced to half of (1) described above.

Engine with EGR Engine without EGRSulfur content (%) Oil change interval Sulfur content (%) Oil change intervalLess than 0.2 500 hours Less than 0.5 500 hours0.2 - 0.5 250 hours 0.5 - 1.0 250 hours0.5 and up Not recommendable 1.0 and up Not recommendable

Engine with EGR Engine without EGRSulfur content (%) Oil change interval Sulfur content (%) Oil change intervalLess than 0.2 250 hours Less than 0.5 250 hours0.2 - 0.5 125 hours 0.5 - 1.0 125 hours0.5 and up Not recommendable 1.0 and up Not recommendable

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Appendix

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(Reference) Global Environment (Energy Consumption)

USA

Europe

アメリカJapan

When observing the Earth at night from outer space, the areaswhere a large amount of energy is consumed are shining brightly.

Middle East, Gulf Countries

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(Reference) Global Environmental issues (Global warming, photochemical smog, acid rain and air pollution)

NOx

NOx NOxPMPM

CO2Sun's rays

PM

CO2

CO2

NOx

SOX

COX

PMNOx

SOX

NOxCOXPM

COPM

PM NOxNOx

Wind

PMNOX

PM

NOx

COX SOX

NOX

NOX

NOX

NOX SOX

HC

HC

NOx HCHC HC

PM

NOx: Nitrogen oxideCO: Carbon

monoxideCO2: Carbon dioxideHC: HydrocarbonPM: Suspended

particulate matter

SOX: Sulfur oxideCH4: MethaneN2O: Nitrous oxide

NOX

NOX

NOX NOX

HC

HC

HC

HC

HCHC

SOX

SOX

Infrared absorption

Global warmingRising temperatureCH4

CO2

N2O

Photochemicalsmog

Strong irritatingmolecule

Acid rainDefoliatio

n in forests

Global warmingRising of sea

level

CO2

Air pollutionPMOz

one

depl

etio

n

Incr

ease

in h

arm

ful

ultra

viole

t lig

ht

Rele

ase

of C

FC's

NEXT

Sourcesof release

Adve

ctio

n an

ddi

ffus

ion

Documents

HPCR FuelManagement(E)