hpcr fuelmanagement(e)
DESCRIPTION
HPCR FUEL MANAGEMENT SYSTEMTRANSCRIPT
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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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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 sliding portion being whitened
The armature plate being tarnished to brownish-red
The sliding portion being whitened
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