UKPTE0601A

USER’S TEXT
MAINTENANCE COURSE

MAINTENANCE FOWA
Electronically Controlled Heavy Duty
High Pressure Common Rail
fuel injection system (HPCR)
Fuel Management
MAINTENANCE FUEL MANAGEMENT FOR USER’S TEXT
MAINTENANCE
FOWA HPCR SYSTEM COURSE

Content 1
1. Emission gas becomes increasingly a critical issue from now on
2. Generation process of pollutants and environmental measures
3. Emissions regulations and enforcement date (as an example)
4. Innovative environmental protection technologies incorporated into 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 portions
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
<Results>
• Air pollution
Deterioration of • Reduction in production
emission gas • Shortening of machine
life
• Increase in downtime
• Increase in repair cost

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2. Generation process of pollutants and environmental measures

Measures to
Environmental Pollutants Products or Danger to public Sources of Environmental meet the
issues climate changes health release technologies emission
regulations

Rising Gas emissions

Global Increasing temperature Abnormal Energy-saving
from urban
warming CO2 Sea surface
elevation
weather
activities technology
Operation
technology
Ozone layer Release of Increase in
harmful Cataract, skin Operation
Gas emissions efficiency
depletion CFC's ultraviolet light cancer
from factories

NOX Acid rain Deforestation

SO2

Photochemical Eye irritation,

NOX pain on the Exhaust gas
HC smog throat control
Air pollution * Automobile Purification
Carbon monoxide Headache, emissions, etc technology
CO dizziness,
nauseousness
Suspended particulate
matter Lung cancer,
PM bronchitis,
asthma

* When compared to gasoline engines, diesel engines emit much PM and NOX but fewer CO2
because of its superior fuel consumption.
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3. Emissions regulations and enforcement date (as an example)

(Scheduled)
NMHC+NOX Black smoke
PM
Nonmethane density at
Enforcement NOX HC Suspended
Regions Emissions regulations Output class hydrocarbon abrupt
date Nitrogen oxide Hydrocarbon particulate
+ Nitrogen acceleration
matter
oxide with no load

Unit
   (%)
(g/kWh)

Law concerning emissions 75-130kW 2007/10 3.6 0.4 - 0.2 25

Japan control of specified special
vehicles 130-560kW 2006/10 3.6 0.4 - 0.17 25

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

USA EPA Tier3
130-560kW 2006/01 - - 4.0 0.2 -

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

Europe Stage3A
130-560kW 2006/01 - - 4.0 0.2 -

Examples of Komatsu machines 75 - 130kW : PC160 - PC200-8

conforming to the regulations 130 - 560kW : PC220-8 - PC1250-8, WA380-6 - WA600-6

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4. Innovative environmental protection technologies incorporated

into Komatsu engines
Clean Ex. Gas
Heavy Duty Engine (exhaust
emission control) New Combustion
Cooled EGR System Chamber
reduces PM and
NOX

Heavy Duty
HPCR System

Economical
Engine Silent Engine
(Low fuel (Low noise)
Consumption)
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 injection system
Maximum injection pressure Injection nozzle Maximum injection pressure Injector
500 - 800kg/cm2 (Mechanical 1200 - 1600kg/cm2 (Electronically
type) controlled)

Solenoid
Common rail valve

Two way
type valve

Drain

In-line
injection pump
Supply
pump
Fuel is injected
into the cylinder. Fuel is injected
Features Features into the cylinder.
• Fuel injection pressure depends on the engine • Supply pump pressurizes fuel to a high
speed. pressure and controls the pressure.
• Injection nozzle is fixed pressure regulator. • High-pressure fuel is stored in the accumulator
• Injection timing is fixed or proportionally (Common Rail).
controlled using a timer. • Injection quantity and injection timing are
controlled electronically by the controller.

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6. HPCR fuel line 

Controls injection
ECU  quantity, injection 
Solenoid 
timing, etc. Injector
valve 

Controller
Bar filter
Strainer
Fuel cooler
High-pressure fuel (Depending on
(  1600kg/cm2) machine model)


Fuel tank

Common rail Fuel is injected

into the cylinder.

Large capacity Pre

priming pump Main fuel
(Depending on fuel filter
machine model) filter (10µm)
 (2µm)
Coarse filter 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
Controller (ECU)
Example of 114 series engine
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8. Supply pump producing high pressure fuel (Key parts for HPCR)
(Maximum injection pressure : 1200 - 1600kg/cm2)
Supply pump for Supply pump for Supply pump for 125, 140
107 series engines 114 series engines and 170 series engines
Supply High pressure
Plunger pump head fuel outlet
Outlet valve

Gear pump Inlet valve

Camshaft
Cam housing
Gear pump
High pressure fuel outlet: 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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QUIZ

1. Name any three pollutants in the air?

ANS: 1. SOx Sulfur oxide

2. CO2 Carbon dioxide
3. CO Carbon monoxide
4. NOx Nitrogen oxide
5. PM Particulate Matter
6. HC Hydrocarbon

2. What is the operating pressure for High Pressure Common

Rail (HPCR) Fuel Injection System?

ANS: 1200 to 1600 kg/cm2

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10. Fluid fuel to use

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

Manual.

Ambient Temperature
Recommended
Reservoir Fluid Type -22 -4 14 32 50 68 86 104 122ºF Komatsu Fluids
-30 -20 -10 0 10 20 30 40 50ºC

ASTM Grade No.1-D S15

ASTM Grade No.1-D S500
Fuel tank Diesel fuel
ASTM Grade No.2-D S15
ASTM Grade No.2-D S500

*ASTM: American Society of Testing and Material

• 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/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.
<Comparison of filter roughness and close things>
Bacteria
Main fuel filter Red blood cell Pre fuel filter White blood cell Human hair (50 - 80µm)

0 2 8 10 25 50
(Micron)

• 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  Sliding portion of
portion command piston
The sliding The armature The sliding
portion being plate being portion being
whitened tarnished to  whitened
Causes: Dust, brownish-red Causes: Dust, Water
Water

Causes: Water,
Rust 


 Sliding portion of
 Outer valve seat  Nozzle needle seat nozzle needle
The sliding
portion being
whitened
Causes: Dust,
 Water

Worn seat Worn seat portion

Causes: Dust, Causes: Dust
Degraded viscosity 

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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 (2µm) and a pre fuel filter (10µm).
 The pre fuel filter has a water separator.
High-performance main fuel filter (2μm) Pre fuel filter for HPCR system (10μm)
2-μm filter paper of
Komatsu genuine
filters
(Photomicrograph)
Use
Komatsu
genuine
filters!!

Standard
replacement
interval:
Every 500
Use Standard
hours
Komatsu replacement
interval:
genuine Every 1,000 Water separator
Drain the water and
filters!! hours 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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Water and dusts are the greater enemy for the HPCR fuel injection
system, which caused the system failure.

Replacing the fuel filter and proper handling of fuel ( refilling,

storage and transportation ) are equally important to prevent water
and dusts entering the fuel system.

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14. Points to notice when replacing the main fuel filter

Refer to Operation and
Maintenance Manual
because the procedure
varies depending on
Points to notice when machine models.
replacing the filter
 When replacing the filter, install the new
filter without filling the filter element 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

When replacing the filter, make sure

that dusts never enter the 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)  Pour fuel into  After filling the  Apply engine oil to packing surface of
is attached to the new the new filter new filter the pre fuel filter cartridge thinly, and
filter cartridge before cartridge with cartridge with then, install it on the filter holder.
filling it with fuel. cap (A). (Never fuel, remove cap Tighten the filter cartridge 1/2 to 3/4
pour fuel into (A) and dispose turn after the packing surface on the
the center hole.) of it properly. cartridge has contacted the sealing
surface of the filter holder.

(A) (A)

(A)

When replacing the filter, make sure that dusts never enter the fuel line.
* Refer to 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 move into the fuel lines easily in operation.)
Be sure not to damage Be sure to put the
or lose the strainer fuel tank cap tightly
during fueling. not to come away.

   

If any empty space is

left in the tank, dew
condensation water To prevent the formation
formed by of any condensation, fill Drain the water and
temperature changes up the tank with fuel sediment from the tank
between night and after daily operation is before starting daily
day may get mixed in completed. operation and about 10
with the fuel. 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 fuel
• 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.

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)

Precipitate dust and
x Filter Primary Receiving Storage Fuel Tank
water fully.

INFLAMMABLE x
Upper
Ram

Tanker

x
Secondary
Storage
x

Fuel Tank Lower Ram

1.) Primary Receiving Storage Fuel Tanks : -

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

Engine with EGR Engine without EGR

Sulfur content (%) Oil change interval Sulfur content (%) Oil change interval
Less than 0.2 500 hours Less than 0.5 500 hours
0.2 - 0.5 250 hours 0.5 - 1.0 250 hours
0.5 and up Not recommendable 1.0 and up Not recommendable

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

Oil change interval is reduced to half of (1) described above.
Engine with EGR Engine without EGR
Sulfur content (%) Oil change interval Sulfur content (%) Oil change interval
Less than 0.2 250 hours Less than 0.5 250 hours
0.2 - 0.5 125 hours 0.5 - 1.0 125 hours
0.5 and up Not recommendable 1.0 and up Not recommendable

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Appendix

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(Reference) Global Environment (Energy Consumption)

Europe
Japan
アメリカ
USA
Middle East,
Gulf Countries

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)
NOx: Nitrogen oxide
CO: Carbon monoxide
Sun's rays CO2: Carbon dioxide
Infrared absorption HC: Hydrocarbon
PM: Suspended
CO2 particulate matter
Global warming SOX: Sulfur oxide
Rising temperature CH4 COX SOX CH4: Methane
N2O COX NOx PM N2O: Nitrous oxide
SOX PM

SOX HC SOX
NOX HC
Wind

Advection and
PM COX NOx

diffusion
HC NOX NOx SOX NOx
Air
PM pollution
Photochemical
smog
Strong irritating Acid rain PM
molecule Defoliation
in forests HC
HC NOX NOx
PM NOX NOX NOX SOX CO2 Sources NOx NOx
NOX PM of release HC
HC NOX HC CO PM HC
NOx PM
NOx HC NOx
HC NOX PM PM

Global warming
Rising of sea level

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