Komatsu HPI

The SAA6D170 - HPI fuel system is the The SAA6D170 - HPI fuel system is the newest in fuel technology from newest in fuel technology from Cummins & Komatsu The fuel system Cummins & Komatsu The fuel system offers infinitely variable injection offers infinitely variable injection timing using a simple. Efficient design, timing using a simple. Efficient design, with injection pressures beyond any with injection pressures beyond any current Cummins or Komatsu fuel current Cummins or Komatsu fuel systemsystem

SAA6D170 - HPI fuel systemSAA6D170 - HPI fuel system

ApplicationsApplicationsThe HPI engine The HPI engine

will be used will be used first in the first in the D375A-3 and D375A-3 and the WA600-the WA600-3m/c. It will be 3m/c. It will be used in other used in other machines that machines that currently use currently use the SD170 to the SD170 to meet Tier II and meet Tier II and Euro 2 Euro 2 emissions.emissions.

HPIHPI

What is HPI?What is HPI?

Sec 2

HPI is High Pressure InjectionHPI is High Pressure Injection

WHY ?WHY ?Why do we need new Why do we need new

HPI Injected Engines ?HPI Injected Engines ?

WHY - High Pressure InjectionWHY - High Pressure Injection

WHY - High Pressure InjectionWHY - High Pressure Injection

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EPA Euro IIEPA Euro II

Sec 2

The HPI 170E-3 meets the strict exhaust gas regulations (USA: EPA regulations for the year 2001, EU: regulations for the year 2002, Japan: construction equipment regulations for the year 2004).

At the same time, they are high performance, high efficiency engines which achieve low fuel consumption, low noise, improved exhaust gas color, and improved acceleration.

These engines have been newly developed to meet various purposes of use as the power unit for construction equipment and industrial machinery.

The HPI fuel The HPI fuel system system features a features a mechanicallmechanically actuated, y actuated, open nozzle open nozzle type type injector.injector.

HPI fuel system

Electronic controlsElectronic controlsUses the latest Uses the latest

generation of generation of Cummins Cummins electronic electronic controls, controls, provides precise provides precise fuel management fuel management and infinitely and infinitely variable injection variable injection timing.timing.

Fuel system components Fuel system components

• Mechanical system componentsMechanical system components• Electronic control system componentsElectronic control system components

Mechanical systemMechanical systemThis schematic provides

an overview of the mechanical system of the HPI fuel system:

• Fuel filter head and fuel filter element

• Fuel pump• Fuel control valve

assembly• Fuel manifolds• HPI injector• Fuel cooler

Fuel PipingFuel Piping

Fuel FiltersFuel FiltersFuel flow from the Fuel flow from the

supply tank is supply tank is directed to the directed to the dual fuel filter dual fuel filter head The fuel head The fuel filters have water filters have water separators and 2 separators and 2 micron filtermicron filter

Compact Fuel Pump ComponentsCompact Fuel Pump Components1.1. Fuel pump Fuel pump

assembly controls assembly controls the basic pressure the basic pressure of the fuel. of the fuel.

2.2. The fuel supplied The fuel supplied from fuel tank from fuel tank passes through passes through fuel filter, is then fuel filter, is then sucked up by gear sucked up by gear pump, and is pump, and is supplied to supplied to control valve control valve assembly.assembly.

Compact Fuel Pump ComponentsCompact Fuel Pump Components

3.The discharge 3.The discharge pressure of the pressure of the fuel pump is fuel pump is controlled to a controlled to a suitable level bysuitable level by

adjusting the adjusting the opening angle of opening angle of fuel pump fuel pump actuator .actuator .

The Compact pump output is controlled by ECM. The Compact pump output is controlled by ECM. The Calibration determines the pressure The Calibration determines the pressure

characteristics over the complete RPM range.characteristics over the complete RPM range.

Pump OutputPump Output

Pump output Flows to the control Pump output Flows to the control ValveValve

Control valve assemblyControl valve assembly The core of the The core of the

SAA6D170 - HPI fuel SAA6D170 - HPI fuel system is the control system is the control valve assembly. Fuel valve assembly. Fuel flow produced by the flow produced by the pump is delivered to the pump is delivered to the control valve assembly. control valve assembly.

The assembly consists of The assembly consists of a shut down solenoid a shut down solenoid valve, two fuel actuator valve, two fuel actuator valves, and two fuel valves, and two fuel pressure sensors. The pressure sensors. The ECM mounts on the ECM mounts on the front of the assembly front of the assembly housing.housing.

The control valve The control valve assembly has one fuel assembly has one fuel inlet port and two inlet port and two outlet ports. Each outlet ports. Each outlet port is controlled outlet port is controlled by a separate actuator.by a separate actuator.

The fuel rail actuator The fuel rail actuator controls the fuel controls the fuel required for required for combustion.combustion.

The timing fuel The timing fuel actuators controls the actuators controls the fuel necessary to fuel necessary to control injector timingcontrol injector timing

Control valve assemblyControl valve assembly

The SAA6D170 - HPI fuel system utilizes the The SAA6D170 - HPI fuel system utilizes the Pressure/Time concept like the PT fuel system. Pressure/Time concept like the PT fuel system. The PT is completely mechanical and relies on The PT is completely mechanical and relies on mechanically adjusted flow areas to regulate mechanically adjusted flow areas to regulate fuel pressure. The SAA6D170 - HPI fuel system, fuel pressure. The SAA6D170 - HPI fuel system, however, controls fuel pressure by electronically however, controls fuel pressure by electronically adjusting flow areas of the actuatorsadjusting flow areas of the actuators

Pressure/Time conceptPressure/Time concept

Rail pressure controlRail pressure controlThe actuator is an electronically controlled spool The actuator is an electronically controlled spool

type control valve The coil receives a PWM signal type control valve The coil receives a PWM signal from the ECM. Depending on the signal from the from the ECM. Depending on the signal from the ECM, the spool will move to the left uncovering ECM, the spool will move to the left uncovering the inlet port and allowing fuel flowthe inlet port and allowing fuel flow

The control valve The control valve assembly assembly receives fuel flow receives fuel flow from the fuel from the fuel pump inside the pump inside the control valve control valve assembly, the assembly, the fuel flow Divides fuel flow Divides to supply both to supply both control systems.control systems.

Fuel Pressure Control ValveFuel Pressure Control Valve

The control system The control system that maintains fuel that maintains fuel rail pressure rail pressure consists of a rapid consists of a rapid restart fuel shut-restart fuel shut-off valve, fuel rail off valve, fuel rail actuator and fuel actuator and fuel rail pressure rail pressure sensor.sensor.

Fuel flows through Fuel flows through the rapid restart the rapid restart fuel shut-off valve fuel shut-off valve first and then to first and then to the fuel rail the fuel rail actuatoractuator

Fuel Pressure Control ValveFuel Pressure Control Valve

The fuel rail The fuel rail pressure sensor pressure sensor monitors this monitors this pressure and pressure and Sends this Sends this information to the information to the ECM.ECM.

Rail pressure controlRail pressure control

Timing control systemTiming control systemThe control system The control system

that maintains that maintains the timing rail the timing rail pressure consists pressure consists of timing rail of timing rail actuator and actuator and timing rail timing rail pressure sensor. pressure sensor.

Fuel pressure in Fuel pressure in the timing rail is the timing rail is controlled by the controlled by the timing rail timing rail actuator which is actuator which is also controlled also controlled by the ECM.by the ECM.

Timing control systemTiming control system

The timing rail The timing rail pressure sensor pressure sensor monitors the monitors the pressure, and pressure, and Sends this Sends this information back information back to the ECMto the ECM

Fuel flows from the Fuel flows from the control valve body control valve body through the fuel through the fuel transfer tubes to transfer tubes to the fuel manifold. the fuel manifold. There are two There are two manifolds, the front manifolds, the front manifold serving manifold serving cylinders 1 through cylinders 1 through 3 and the rear 3 and the rear manifold manifold 4 4 through through 6 Each manifold has 6 Each manifold has three passages three passages timing rail, fuel rail, timing rail, fuel rail, and drain.and drain.

Fuel FlowFuel Flow

In applications In applications where the fuel where the fuel supply tank is supply tank is higher than the higher than the into the system into the system when the when the engine is not in engine is not in operationoperation

Rail & Timing PressureRail & Timing Pressure

Fuel coolerFuel coolerThe correct fuel The correct fuel

temperature is critical temperature is critical to the proper to the proper operation of the HPI operation of the HPI fuel system Thus, a fuel system Thus, a fuel-cooling radiator is fuel-cooling radiator is mandatory. mandatory.

Fuel coolerFuel cooler1. Mount bracket2. Corea. From injectorb. To fuel tank

SPECIFICATIONSCooling method: Air cooledCore type: CF40, (4.5/2P)Heat dissipation surface: 6.45 m 2Heat dissipation amount: 11.63 kW {10,000 kcal}/hFuel pressure: Max. 5.88 kPa {0.06 kg/cm 2 }(When fuel temperature at cooler inlet port is 100°C)

The SAA6D170 - The SAA6D170 - HPI fuel HPI fuel system system features a features a mechanically mechanically actuated, actuated, open nozzle open nozzle type injector.type injector.

SAA6D170 - HPI fuel systemSAA6D170 - HPI fuel system

Injector FlowInjector Flow

The new injector has The new injector has three individual three individual moving sectionsmoving sections

The lower plunger,The lower plunger, The timing plungerThe timing plunger The upper plungerThe upper plungerAll of these plungers All of these plungers

are coated with are coated with Titanium Nitride to Titanium Nitride to resist scuffing wear resist scuffing wear and provide and provide maximum service lifemaximum service life

SAA6D170 - HPI Fuel System SAA6D170 - HPI Fuel System InjectorInjector

We will start with We will start with the cam follower the cam follower on the outer base on the outer base circle All three circle All three plungers are in plungers are in contact with each contact with each other, as the other, as the camshaft rotates, camshaft rotates, the follower rolls the follower rolls toward the inner toward the inner base circle which base circle which causes all three causes all three plungers to plungers to retract. retract.

Injection CycleInjection Cycle

When the lower When the lower plunger plunger retracts far retracts far enough, the enough, the rail feed port rail feed port is uncovered is uncovered and fuel is PT and fuel is PT (Pressure-(Pressure-Time) metered Time) metered through an through an orifice into the orifice into the cup.cup.

InjectionInjection CycleCycle

Timing and Rail MeteringTiming and Rail MeteringThe Rail pressure The Rail pressure

will be controlled will be controlled electronically and electronically and can be as high as can be as high as 290 psi or as low 290 psi or as low as 2 psi The lower as 2 psi The lower plunger is in its plunger is in its fully retracted fully retracted position when the position when the spring retainer spring retainer contacts the contacts the ledge.ledge.

The cam follower The cam follower continues to roll continues to roll toward the inner toward the inner base circle, allowing base circle, allowing the timing and upper the timing and upper plungers to continue plungers to continue moving upward. moving upward. When the upper When the upper plunger retracts far plunger retracts far enough, it uncovers enough, it uncovers the timing feed port the timing feed port and fuel is also PT and fuel is also PT metered through an metered through an orifice into the orifice into the timing chamber.timing chamber.

Timing and Rail MeteringTiming and Rail Metering

End of timing meteringEnd of timing meteringAs the cam follower As the cam follower

starts up the starts up the injection ramp of injection ramp of the camshaft, the the camshaft, the upper plunger will upper plunger will move down and move down and close the timing close the timing feed port to end feed port to end Timing Metering. Timing Metering. The fuel that The fuel that metered into the metered into the timing chamber is timing chamber is now trapped now trapped between the upper between the upper plunger and the plunger and the timing plunger.timing plunger.

The amount (volume) The amount (volume) of fuel metered into of fuel metered into the timing chamber the timing chamber determines the determines the separation between separation between the upper and the upper and timing plungers The timing plungers The amount of amount of separation separation determines the determines the effective length of effective length of the injector plunger. the injector plunger. This length This length determines when determines when injection will start. injection will start.

Timing ControlTiming Control

Changing the Changing the overall plunger overall plunger length changes length changes the start of the start of injection.”injection.”

Timing Timing ControlControl

The separation The separation between the between the plungers varies plungers varies from a minimum from a minimum of 2 mm to of 2 mm to around 9 mm around 9 mm This separation This separation is sometimes is sometimes referred to as referred to as “over-travel”“over-travel”

The trapped fuel The trapped fuel becomes a solid becomes a solid link and all link and all three plungers three plungers move down move down together As the together As the lower plunger lower plunger moves, the rail moves, the rail feed port is also feed port is also closed.closed.

Timing ControlTiming Control

The timing and upper The timing and upper plungers have a plungers have a diameter of 15 mm, diameter of 15 mm, compared to the 11 compared to the 11 mm diameter of the mm diameter of the lower plunger. This lower plunger. This difference in difference in diameter reduces diameter reduces the pressures in the the pressures in the timing chamber to timing chamber to approximately 50 approximately 50 percent of the percent of the injection pressures.injection pressures.

Therefore, if the Therefore, if the pressure in the pressure in the timing chamber is timing chamber is 15,000 PSI, 15,000 PSI, pressure in the cup pressure in the cup can be as high as can be as high as 25,000 PSI. This 25,000 PSI. This reduction ratio reduction ratio allows the injector allows the injector train to operate train to operate with minimum with minimum stress and wear yet stress and wear yet still produce still produce extremely high extremely high injection pressuresinjection pressures

InjectionInjection beginsbeginsThe downward The downward

velocity of the velocity of the plungers will plungers will increase as the increase as the follower follower continues up the continues up the injection ramp of injection ramp of the camshaft.. the camshaft.. When the When the pressure in the pressure in the cup exceeds the cup exceeds the pressure in the pressure in the cylinder, cylinder, injection begins.injection begins.

End of injectionEnd of injection Injection ends as the Injection ends as the lower plunger lower plunger makes contact with makes contact with the nozzle seat At the nozzle seat At approximately the approximately the same time, the same time, the groove in the groove in the timing plunger timing plunger aligns with the aligns with the groove in the groove in the barrel, opening the barrel, opening the spill port The spill port The timing fuel then timing fuel then spills as the upper spills as the upper plunger continues plunger continues its stroke.its stroke.

During this spill During this spill process, the drilling process, the drilling in the timing in the timing plunger regulates plunger regulates the fuel pressure in the fuel pressure in the timing chamber the timing chamber to keep a load on to keep a load on the lower plunger the lower plunger This pressure is This pressure is necessary to necessary to prevent the lower prevent the lower plunger from lifting plunger from lifting before mechanical before mechanical contact occurs contact occurs between the upper between the upper and timing plungers.and timing plungers.

End of injectionEnd of injection

A spill ring is A spill ring is positioned over positioned over the spill port the spill port because the timing because the timing fuel spilling from fuel spilling from the chamber is the chamber is under pressure, under pressure, The spill ring acts The spill ring acts as a pressure as a pressure deflector to deflector to prevent damage to prevent damage to the injector bore in the injector bore in the cylinder head the cylinder head from the continual from the continual release of high release of high pressure fuel.pressure fuel.


During the last 5 mm of During the last 5 mm of upper plunger travel, upper plunger travel, the nose on the bottom the nose on the bottom of the upper plunger of the upper plunger engages with the port in engages with the port in the timing plunger The the timing plunger The clearance between the clearance between the two parts acts as an two parts acts as an additional flow additional flow restriction on the fuel in restriction on the fuel in the port This additional the port This additional restriction keeps restriction keeps pressure on the lower pressure on the lower plunger while the rest of plunger while the rest of the timing fuel is spillingthe timing fuel is spilling


This feature is This feature is needed to needed to ensure that the ensure that the lower plunger lower plunger does not unseat does not unseat during the during the transition from transition from the ramp to the the ramp to the nose of the nose of the camshaft lobecamshaft lobe


SD170 Design ChangesSD170 Design Changes•HPI Electronic Fuel SystemHPI Electronic Fuel System

•Rear Camshaft driveRear Camshaft drive

•New Camshaft with injector lobeNew Camshaft with injector lobe

•Redesign Cylinder HeadRedesign Cylinder Head

•New Intake ManifoldNew Intake Manifold

Electronic ControlsElectronic ControlsKOMATSU Presents the SAA6D170 - HPI ENGINE KOMATSU Presents the SAA6D170 - HPI ENGINE

CONTROL SYSTEMCONTROL SYSTEM

Electronic ControlsElectronic ControlsThe SAA6D170 - The SAA6D170 -

HPI, like the HPI, like the other Cummins other Cummins electronic electronic engines, is engines, is commanded by commanded by an Electronic an Electronic Control Module Control Module (ECM). The (ECM). The SAA6D170 - HPI SAA6D170 - HPI fuel system ECM fuel system ECM contains the contains the latest technology latest technology from Cummins from Cummins Electronics. Electronics.

Electronic ControlsElectronic ControlsThe ECM’s main task The ECM’s main task

is to manage the is to manage the fuel control fuel control system that system that operates the operates the engine The ECM engine The ECM samples all inputs, samples all inputs, processes the processes the data, and outputs data, and outputs signals to the rail signals to the rail and timing control and timing control actuators many actuators many times each second. times each second.

Electronic ControlsElectronic Controls

The ECM can make The ECM can make changes to rail changes to rail and timing and timing pressures very pressures very quickly, quickly, responding responding instantly to the instantly to the slightest slightest variations in variations in operating and operating and environmental environmental conditions.conditions.

Electronic ControlsElectronic Controls For example, look at For example, look at when the operator when the operator opens the throttle opens the throttle to increase engine to increase engine speed The ECM will speed The ECM will consider the request consider the request for increased engine for increased engine speed, the actual speed, the actual engine speed, and engine speed, and all other inputs. It all other inputs. It will then compare will then compare this data to its this data to its calibrated data to calibrated data to determine the determine the appropriate signal appropriate signal changes.changes.

ECM Temperature Sensors InputsThere are three temperature There are three temperature

sensors The temperature sensors The temperature sensors provide critical sensors provide critical temperature information to the temperature information to the ECM the temperature sensors ECM the temperature sensors areare

• Coolant temperature sensorCoolant temperature sensor• Intake manifold temperature Intake manifold temperature

sensorsensor• Fuel Temperature SensorFuel Temperature Sensor

Coolant temperature sensor The coolant The coolant

temperature temperature sensor is mounted sensor is mounted in the thermostat in the thermostat housing The housing The information this information this sensor obtains is sensor obtains is utilized by the utilized by the ECM to help make ECM to help make decisions for decisions for timing and engine timing and engine protectionprotection

Intake manifold temperature sensor

The intake manifold air The intake manifold air temperature sensor ‘s temperature sensor ‘s mounted in the mounted in the aftercooler housing aftercooler housing and measures air and measures air temperature after the temperature after the cooler core. The cooler core. The information this sensor information this sensor obtains is utilized by obtains is utilized by the ECM to help make the ECM to help make decisions for timing decisions for timing and engine protection.and engine protection.

Fuel temperature sensor

Fuel temperature sensorFuel temperature sensorThe fuel temperature The fuel temperature sensor is installed to thesensor is installed to thecontrol valve unit. It detects control valve unit. It detects the pressure of the fuel the pressure of the fuel supplied from the fuel supplied from the fuel pump and inputs anpump and inputs ananalog signal to the analog signal to the controller.controller.

ALL TEMPERATURE SENSORS

Temperature CTemperature C Temperature FTemperature F ResistanceResistance

00 3232 30K to 36K30K to 36K

2525 7777 9K to 11K9K to 11K

5050 122122 3K to 4K3K to 4K

7575 167167 1350 to 15001350 to 1500

100100 212212 600 to 675600 to 675

ECM pressures sensors Fuel Rail Pressure SensorFuel Rail Pressure Sensor

The fuel rail The fuel rail pressure sensor is pressure sensor is mounted in the mounted in the fuel control valve fuel control valve assembly and assembly and measures measures pressure actual pressure actual fuel in the rail fuel in the rail supplying the supplying the injectorsinjectors

Fuel timing pressure sensor

The fuel timing The fuel timing pressure sensor is pressure sensor is also mounted in also mounted in the fuel control the fuel control valve assembly It valve assembly It measures actual measures actual fuel pressure in fuel pressure in the rail supplying the rail supplying the timing the timing chamberschambers

Oil pressure sensorThe oil pressure The oil pressure

sensor is mounted sensor is mounted in a main rifle port in a main rifle port above the ECM. It above the ECM. It measures main measures main system oil system oil pressure. The pressure. The information this information this sensor obtains is sensor obtains is utilized by the utilized by the ECM to make ECM to make decisions for decisions for engine protection.engine protection.

OIL RESSURE SENSOR

Pressure (kPa) Pressure [psi] Voltage (V)0 0 0.39-0.58172 25 1.39-1.61344 50 2.39-2.61517 75 3.39-3.61689 100 4.39-4.61

OIL OR COOLANT PRESSURE SENSOR

Pressure (kPa) Pressure [psi] Voltage (V)0 0 0.39-0.58172 25 1.39-1.61344 50 2.39-2.61517 75 3.39-3.61689 100 4.39-4.61

Ambient air pressure sensor The ambient air The ambient air

pressure sensor pressure sensor is mounted on is mounted on the fuel control the fuel control valve assembly valve assembly below the ECM below the ECM The ECM The ECM utilizes the utilizes the information information received from received from the sensor to the sensor to make decisions make decisions for engine for engine protection. protection.

Ambient air pressure sensor

In high altitude In high altitude operation, the operation, the engine is engine is derated to derated to prevent prevent turbocharger turbocharger overspeedoverspeed

AMBIENT AIR PRESSURE SENSOR

mmHg inHg Voltage (V)259 10.2 1.67-1.99517 20.4 3.05-3.29621 24.4 3.58-3.82776 30.5 4.38-4.62

AMBIENT AIR PRESSURE SENSOR

Engine speed sensor The engine speed The engine speed

sensor is sensor is located in the located in the Flywheel Flywheel housing It housing It detects the detects the flywheel teeth flywheel teeth and sends and sends signals to the signals to the ECM The ECM ECM The ECM processes these processes these signals to signals to determine determine engine speed.engine speed.

Engine Speed Sensor (ESS)

The sensor has a The sensor has a dual signal dual signal output providing output providing two separate two separate signals to the signals to the ECM. Even if one ECM. Even if one signal is lost, signal is lost, the engine will the engine will continue to continue to operateoperate

ECM Switched Inputs

Idle Validation SwitchThe idle validation The idle validation

switch is located switch is located in the throttle in the throttle Pedal assembly Pedal assembly It provides a It provides a confirming signal confirming signal to the ECM as to to the ECM as to the position the position (released or (released or depressed) of depressed) of the throttle the throttle pedalpedal

Coolant level switchThe coolant switch The coolant switch

monitors the coolant monitors the coolant level in the radiator level in the radiator top tank If the fluid top tank If the fluid level drops below a level drops below a predetermined point predetermined point the switch will open, the switch will open, indicating a low indicating a low fluid level to the fluid level to the ECM The information ECM The information this sensor obtains this sensor obtains is utilized by the is utilized by the ECM to make ECM to make decisions for engine decisions for engine protection.protection.

Feedback inputs In addition to In addition to

monitoring the fuel monitoring the fuel and timing pressure and timing pressure sensors to determine sensors to determine actual pressures, the actual pressures, the ECM also monitors ECM also monitors the current returning the current returning from the rail and from the rail and timing control timing control actuator valves. This actuator valves. This feedback information feedback information provides confirmation provides confirmation of correct valve of correct valve operation.operation.

Operator inputsThe two main inputs The two main inputs

from the operator from the operator are the key switch are the key switch and the throttle and the throttle The position of the The position of the key switch key switch determines the determines the state of engine state of engine operation (on of operation (on of off), and the off), and the position of the position of the throttle determines throttle determines the desired engine the desired engine speedspeed

ECM System OutputsThere are six system There are six system outputs Three of the outputs Three of the outputs control the outputs control the fuel rail, timing rail , fuel rail, timing rail , and fuel and fuel shutdown.functions shutdown.functions The fuel and timing The fuel and timing control actuator control actuator valves are spool type valves are spool type valves. The spools are valves. The spools are controlled by an controlled by an electromagnetic electromagnetic device which is device which is commanded by the commanded by the ECM The ECM ECM The ECM produces the produces the following signals.following signals.

ECM System Outputs Fuel control Fuel control

actuator valve actuator valve signal - PWM signal - PWM (Pulse Width (Pulse Width Modulation) duty Modulation) duty cyclecycle

Timing control Timing control actuator valve actuator valve signal - PWM duty signal - PWM duty cyclecycle

Fuel shutoff - power Fuel shutoff - power to the shutoff to the shutoff solenoid valvesolenoid valve

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