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UKPTE0601A

MAINTENANCE COURSE

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Electronically
Controlled
Heavy
Duty
Electronically Controlled
Heavy
High Pressure
Common Rail
Duty
fuel
(HPCR)
Highinjection
Pressuresystem
Common
Rail
fuel injection system (HPCR)

Fuel Management
Fuel Management

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Content 1
1.
2.
3.
4.

Emission gas becomes increasingly a critical issue from now on

Generation process of pollutants and environmental measures
Emissions regulations and enforcement date (as an example)
Innovative environmental protection technologies incorporated int
o Komatsu engines
5. HPCR system is distinct from conventional fuel injection system
6. HPCR fuel line
7. 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 use
11.Fuel management
12.Examples of tarnished and worn injector internal parts and sliding p
ortions
13.HPCR system adopting a main fuel filter and a pre fuel filter
14.Points to notice when replacing the main fuel filter
15.Points to notice when replacing the pre fuel filter
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Content 2
16.Pre fuel filter cartridge replacement procedures
17.Examples of engine starting failure due to filter clogging
18.Removing the water and sediment in the fuel tank
19.Preventing water and dust from entering the storage fuel
20.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

Deterioration of
emission gas

<Results>
Air pollution
Reduction in productio
Shortening of machine
life
Increase in downtime
Increase in repair cost

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2. Generation process of pollutants and environmental

measures
Pollutants
Pollutants

Products
Products or
or
climate
climate
changes
changes

Danger
Danger to
to
public
public health
health

Sources
Sources of
of
release
release

Global
warming

Increasing
CO2

Rising
temperature
Sea surface
elevation

Abnormal
weather

Gas
emissions
from urban
activities

Ozone layer
depletion

Release of
CFC's

Increase in
harmful
ultraviolet
light

Cataract, skin
cancer

NOX
SO2

Acid rain

Deforestation

NOX
HC

Photochemical
smog

Eye irritation,
pain on the
throat

Environmental
Environmental
issues
issues

Air
pollution

Carbon monoxide
CO
Suspended particulate
matter
PM

Headache,
dizziness,
nauseousness

Gas
emissions
from
factories

* Automobile
emissions, etc

Environmenta
Environmenta
ll technologies
technologies

Measures
Measures to
to
meet
meet the
the
emission
emission
regulations
regulations

Energy-saving
technology
Operation
technology
Operation
efficiency

Exhaust gas
control
Purification
technology

Lung cancer,
bronchitis,
asthma

* When compared to gasoline engines, diesel engines emit much PM and NO X but fewer C
because of its superior fuel consumption.
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3. Emissions regulations and enforcement date (as an

example)
(Scheduled)

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4. Innovative environmental protection technologies

incorporated into Komatsu engines
Heavy Duty
Cooled EGR System

Clean Ex. Gas

Engine (exhaust
emission control)
reduces PM and
NOX

New Combustion
Chamber

Heavy Duty
HPCR System

Economical
Engine
(Low fuel
Consumption)

Silent Engine
(Low noise)
Air to Air Charge
Air Cooling System

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5. HPCR system is distinct from conventional fuel injection

system
In-line pump fuel
HPCR fuel
injection system

Maximum injection pressure

500 - 800kg/cm

Injection
nozzle
(Mechanical
type)

injection system

Maximum injection pressure

1200 - 1600kg/cm2

Injector
(Electronically
controlled)
Solenoid
valve

Common rail
Two way
type valve

Drain
In-line
injection pump

Features

Fuel is injected
into the cylinder.

Fuel injection pressure depends on the

engine speed.
Injection nozzle is fixed pressure
regulator.
Injection timing is fixed or proportionally
controlled using a timer.

Supply
pump
Fuel is injected
into
the cylinder.
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.

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6. HPCR fuel line

Controls injection
quantity, injection
Solenoid
timing, etc.
valve

ECU

Controller

Injector

Bar filter

Strainer

Fuel cooler

High-pressure fuel
( 1600kg/cm2)

(Depending on
machine model)

Fuel tank
Fuel is injected
into the cylinder.

Common rail

Large capacity
priming pump
(Depending on
machine model)

Coarse filter

Main
fuel
filter
(2m)

Pre
fuel
filter
(10m)
Water
separator

Supply pump
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7. HPCR high pressure line (external view)

Electronically
controlled injectors

Common rail
High pressure
tube connector
Main fuel filter
Supply pump
Example of 114 series engine

Controller (ECU)
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8. Supply pump producing high pressure fuel (Key parts

for HPCR)
(Maximum injection pressure : 1200 - 1600kg/cm2)
Supply pump for
107 series engines
Outlet valve

Gear pump

Supply pump for

114 series engines

Supply
Plunger pump head

Supply pump for 125, 140

and 170 series engines

High pressure
fuel outlet

Inlet valve
Cam housing
Gear pump

High pressure fuel outlet:

Camshaft

Gear pump inlet

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9. Common rail accumulating high pressure fuel constantly

(Key parts for HPCR) Container to store a certain
amount of high pressure fuel

High pressure
tube connector

Common rail

From supply pump

Pressure limiter

Common rail pressure sensor

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.

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11. Fuel management

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/cm 2).
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 10m
with water separator and a main fuel filter of 2m are installed
in HPCR system.
<Comparison
of filter roughness and close things>
Bacteria
Main fuel filter Red blood cell Pre fuel filter

10

(Micron)

White blood cell

25

Human hair (50 - 80m)

50

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.

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12. Examples of tarnished and worn injector internal parts

and sliding portions
Inner valve sliding Armature plate top face
portion
The sliding
portion
being
whitened Dust,
Causes:
Water

Sliding portion of

command piston
The sliding
portion
being
whitened Dust, Water
Causes:

The
armature
plate being
tarnished to

brownish- Water,
Causes:
red
Rust

Outer valve seat

Sliding portion of

Nozzle needle seat

nozzle needle

The sliding
portion
being
whitened Dust,
Causes:

Worn seat
Worn
portion
Causes:
Dust
se Dust,
Causes:
at
Degraded viscosity

Water

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

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

High-performance main fuel filter (2m) Pre fuel filter for HPCR system (10m
2-m filter paper
of Komatsu
genuine filters
(Photomicrograph)

Use
Komatsu
genuine
filters!!

Standard
replacement
interval:
Every 1,000
hours

Use
Komatsu
genuine
filters!!
Standard
replacement
interval:
Every 500
hours
Water separator
Drain the water and
sediment from the
separator at daily
checking before starting
operation.

* Refer to Operation and Maintenance Manual for details of replacement

interval and procedures.

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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 when

replacing the filter

Refer to Operation
and Maintenance
Manual because the
procedure varies
depending on
machine models.

When replacing the filter, install the

new filter without filling the filter
element with fuel.
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
When replacing
the filter,
make
-Electric
priming pump
:114,170
series
sure
that
dusts
never
enter
the
engines

fuel line.

* Refer to Operation and Maintenance Manual for details of replacement

interval and procedures.

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15. Points to notice when replacing the pre fuel filter

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.

Priming pump
WIF sensor
Pre fuel filter

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

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16. Pre fuel filter cartridge replacement procedures

When replacing the pre fuel filter, fill 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)

Confirm that cap

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

(A)

Pour fuel into

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

After filling the

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

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.

(A)

(A)

When replacing the filter, make sure that dusts never enter the
fueltoline.
Refer
the Operation and Maintenance Manual for details of
replacement interval and procedures.

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17. Examples of engine starting failure due to filter

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

<Pre fuel filter>

<Main fuel filter>

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18. Removing the water and sediment in the fuel tank

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
lines
easily in
Be sure
not tomove into the fuel
Be sure
to put the
damage or lose the
fuel tank cap
operation.)
strainer during
tightly not to
fueling.

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.

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

come away.

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.
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19. Preventing water and dust from entering the storage

Dusts
fuelmixed 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.

OK

When storing fuel in drums, put the

cover on the drums or place the drums
horizontally to prevent rainwater, etc.
from entering them.

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

x

Filter Primary Receiving Storage Fuel Tank

INFLAMMABLE

Precipitate dust and

water fully.

Upper
Ram

Tanker

Secondar
y Storage
Fuel Tank

Lower Ram

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.

Mobile

Kiosk

Created by KAP Svc Dept

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21. Engine oil change interval

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

(2) In case of using API CF-4 (or CF-4/SG) oil

Oil change interval is reduced to half of (1) described above.

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Appendix

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(Reference) Global Environment (Energy Consumption)

Europe
USA

Middle East,
Gulf Countries

Japan

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

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(Reference) Global Environmental issues (Global warming,

photochemical smog, acid rain and air pollution)
CO2

Sun's rays

CO2

CO2

Infrared absorption

CO2

Rising temperature
CH4

In Oz
c on
ul rea e d
Re tra se e
le vi in ple
as ol h ti
e et ar on
of li m
CF gh ful
C' t
s

N 2O

PM
NOX

NOX HC
HC

NOX

Photochemical
smog
Strong irritating
molecule

HC NOX
NOX
HC

NOX
HC

NOX

NOX

HC
NOX

SOX HC SOX
PM COX NOx
NOx SOXNOx
Acid rain
Defoliatio
n in
forests

COX NOx
SOX PM

Air

PM pollution

PM
HC
NOx
SOX

CO2
PM
CO
NOx NOx
PM

COX

SOX
PM

Advection and
difusion

Global warming

NOx: Nitrogen oxide

CO: Carbon
monoxide
CO2: Carbon dioxide
HC: Hydrocarbon
PM: Suspended
particulate
matter
SOX: Sulfur oxide
CH4: Methane
N2O: Nitrous oxide

Sources
of release

HC NOx
PM

Wind

NOx
HC
PM

NOx
PM HC

Global warming
Rising of sea
level
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