Structure & Function Fuel System: SAA6D170 - HPI

Technical Presentation Kit
Engines
SAA6D170 - HPI
Structure & Function

Fuel System
KT9000101
Feb 2001
Menu Exit
SAA6D170 - HPI
SAA6D170 - Design Change TPK

02/01
Page 3-2
 HPI Electronic Fuel System
 Rear Camshaft Drive
 New camshaft with injector lobe
 Redesign Cylinder Head
 New Intake Manifold
KT9000101 - Structure & Function Menu Exit

SAA6D170 - HPI
SAA6D170 - Engine Layout TPK

02/01
Page 3-3
To Air Cooler

SAA6D170 - HPI

02/01
Page 3-4

SAA6D170 - HPI
SAA6D170 - Fuel Pump Mounting TPK

02/01
Page 3-5

SAA6D170 - HPI

02/01
Page 3-6
Speed sensor(2 coils) Speed sensor

for ECM for machine

SAA6D170 - HPI
SAA6D170 - Engine Name Plate TPK

02/01
Page 3-7

SAA6D170 - HPI
SAA6D170 - Engine speed sensor for ECM TPK

02/01
Page 3-8
2 magnetic coils
 Both coils failed ~ engine shut-down,
 1 coil failed ~ fault code display, but
engine continue to run

SAA6D170 - HPI
SAA6D170 - HPI fuel system TPK

02/01
Page 3-9
The SAA6D170 - HPI

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

Applications SAA6D170 - HPI
TPK
02/01
Page 3-10
The HPI engine will

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

SAA6D170 - HPI fuel system
SAA6D170 - HPI
TPK
02/01
Page 3-11
ECM
Injector
Control valve assy
Timing Rail actuator
103 MPa
Timing Rail
pressure sensor
Shut off valve

172MPa
Fuel Rail actuator
Oil Cooler
Fuel Rail
pressure sensor
Fuel pump
Pump Pump pressure

actuator sensor
Filter

SAA6D170 - HPI fuel system
SAA6D170 - HPI
TPK
02/01
Page 3-12
The SAA6D170
- HPI fuel
system
features a
mechanically
actuated,
open nozzle
type injector.

SAA6D170 - HPI
Cummins electronic controls TPK

02/01
Page 3-13
Uses the latest

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

SAA6D170 - HPI
SAA6D170 - HPI fuel system TPK

02/01
Page 3-14
HPI

SAA6D170 - HPI
TPK
02/01
Page 3-15
Let’s start by looking at the

hydro-mechanical
components

SAA6D170 - HPI
Hydro-mechanical system TPK

02/01
Page 3-16
This schematic provides

an overview of the
Hydro-mechanical
system of the HPI fuel
system:
•Fuel filter head and fuel
filter element
•Fuel pump
•Fuel control valve
assembly
•Fuel manifolds
•SAA6D170 - HPI
injector
•Fuel cooler

SAA6D170 - HPI
Fuel Piping TPK

02/01
Page 3-17
1. Fuel pump
2. Fuel pipe (from pump to
ECVA)
3. Fuel pipe (from filter to
pump)
4. Fuel filter
5. Fuel inlet
6. Fuel timing
7. Fuel rail
8. Fuel pipe (for fuel
timing)
9. Fuel pipe (for fuel rail)
10. Fuel pipe (return)
11. ECVA (ECM controller)

SAA6D170 - HPI
Fuel Piping TPK

02/01
Page 3-18

SAA6D170 - HPI
Fuel Filters TPK

02/01
Page 3-19
Fuel flow from the supply

tank is directed to the
dual fuel filter head The
fuel filters have water
separators and elements
that filter down to 10
microns.Water separator
elements are mandatory
as the actuators in the
control valve body are
sensitive to water .The
maximum inlet restriction
at the filters is 4 in Hg
with a clean filter and 8 in
Hg with a dirty filter.

SAA6D170 - HPI
TPK
Fuel Filters & Piping 02/01

Page 3-20
Fuel inlet
Drain

SAA6D170 - HPI
TPK
Fuel Piping 02/01

Page 3-21

SAA6D170 - HPI
TPK
Fuel Manifold mounted on cylinder head 02/01

Page 3-22
Water bleed piping

SAA6D170 - HPI
Fuel Filters TPK

02/01
Page 3-23
1. Filter bracket
2. Filter element
3. Filter case
4. Drain plug
a. From fuel tank
b. To fuel pump Cartridge
SPECIFICATIONS
Filtering area: 1 m 2 x 2

SAA6D170 - HPI
Compact Fuel Pump Components TPK

02/01
Page 3-24
 Fuel pump assembly

controls the basic
pressure of the fuel.
 The fuel supplied
from fuel tank
passes through fuel
filter, is then sucked
up by gear pump,
and is supplied to
control valve
assembly.
SAA6D170 - HPI
Compact Fuel Pump Components TPK

02/01
Page 3-25
 The discharge
pressure of the fuel
pump is controlled to
a suitable level by
adjusting the
opening angle of fuel
pump actuator
Pump Actuator

SAA6D170 - HPI
Fuel Pump Drive TPK

02/01
Page 3-26
Oil Pump Alternator & Fuel

Idler gear Crankshaft pump
Drive gear
Water pump Idler gear

SAA6D170 - HPI
Camshaft Drive TPK

02/01
Page 3-27
Camshaft
Idler gear
Idler gear
Crankshaft

SAA6D170 - HPI
Injector Drive TPK

02/01
Page 3-28

SAA6D170 - HPI
Pump Output TPK

02/01
Page 3-29
The Compact pump output is controlled by ECM.

The Calibration determines the pressure
characteristics over the complete RPM range.

SAA6D170 - HPI
Pump output Flows to the control Valve TPK

02/01
Page 3-30

SAA6D170 - HPI
Control valve assembly TPK

02/01
Page 3-31
The core of the

SAA6D170 - HPI fuel
system is the control
valve assembly. Fuel
flow produced by the
pump is delivered to the
control valve assembly.
The assembly consists
of a shut down solenoid
valve, two fuel actuator
valves, and two fuel
pressure sensors. The
ECM mounts on the front
of the assembly
KT9000101 - Structure & Function housing. Menu Exit
SAA6D170 - HPI
Control valve assembly TPK

02/01
Page 3-32
The control valve

assembly has one fuel
inlet port and two outlet
ports. Each outlet port is
controlled by a separate
actuator.
 The fuel rail actuator
controls the fuel
required for combustion.
 The timing fuel actuators
controls the fuel
necessary to control
injector timing
SAA6D170 - HPI
Pressure/Time concept TPK

02/01
Page 3-33
The SAA6D170 - HPI fuel system utilizes the

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

SAA6D170 - HPI

02/01
Page 3-34
For an example of the

Pressure/Time
concept, let’s consider
the following. With
equal sources of
pressure connected to
passages of different
flow areas, if both
systems are allowed to
flow for the same
amount of time, more
fluid will be collected
in the container of the
system with the larger
flow area.

SAA6D170 - HPI

02/01
Page 3-35
If passages of equal
flow area are now
connected to
unequal sources of
pressure and the
time the fluid is
allowed to flow is
held constant, more
fluid will be
collected in the
container of the
system that has a
greater source of
pressure.

SAA6D170 - HPI

02/01
Page 3-36
Thus, if the flow

area and flow
time is held
constant the
pressure
determines the
amount of fluid
collected

SAA6D170 - HPI

02/01
Page 3-37
Finally, if passages
of equal flow area
are connected to
equal sources of
pressure, the time
the fluid is allowed
to flow will
determine the
amount of fluid
collected.

SAA6D170 - HPI

02/01
Page 3-38
Thus, if the flow area

and fluid pressure
are held constant.
The time determines
the amount of fluid
collected

SAA6D170 - HPI

02/01
Page 3-39
These three
illustrations
provide an
excellent
example of the
Pressure/Time
concept used in
the QSK 19 fuel
system rail and
timing systems.

SAA6D170 - HPI
Fuel Pressure Control Valve TPK

02/01
Page 3-40
The control valve

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

SAA6D170 - HPI

02/01
Page 3-41
The control system

that maintains fuel
rail pressure
consists of a rapid
restart fuel shut-off
valve, fuel rail
actuator and fuel
rail pressure
sensor. Fuel flows
through the rapid
restart fuel shut-off
valve first and then
to the fuel rail
actuator
SAA6D170 - HPI

02/01
Page 3-42
Fuel in from pump To Timing rail To metering rail
Actuator
Fuel Temp. Pressure sensor

sensor
Shut-off valve

Rail pressure control SAA6D170 - HPI
TPK
02/01
Page 3-43
The actuator is an electronically controlled spool

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

Pressure Actuator SAA6D170 - HPI
TPK
02/01
Page 3-44
Filter screen

Rail pressure control SAA6D170 - HPI
TPK
02/01
Page 3-45
The fuel rail

pressure sensor
monitors this
pressure and
sends this
information to the
ECM.

SAA6D170 - HPI
Timing control system TPK

02/01
Page 3-46
The control system

that maintains the
timing rail pressure
consists of timing
rail actuator and
timing rail pressure
sensor. Fuel
pressure in the
timing rail is
controlled by the
timing rail actuator
which is also
controlled by the
ECM.
SAA6D170 - HPI
Timing control system TPK

02/01
Page 3-47
The timing rail

pressure sensor
monitors the
pressure, and send
this information
back to the ECM

SAA6D170 - HPI
Fuel Flow TPK

02/01
Page 3-48
Fuel flows from the

control valve body
through the fuel
transfer tubes to the
fuel manifold. There
are two manifolds,
the front manifold
serving cylinders 1
through 3 and the
rear manifold 4
through 6. Each
manifold has three
passages timing rail,
fuel rail, and drain.
SAA6D170 - HPI
Fuel piping TPK

02/01
Page 3-49
Drain

SAA6D170 - HPI
Fuel Flow TPK

02/01
Page 3-50
Drillings in the cylinder

head intersect with the
fuel manifold. Timing
fuel and rail fuel pass
through the cylinder
head to the injector.
Drain fuel from the
injectors passes
through the cylinder
head to the fuel
manifold. We will talk
about the HPI fuel
system injectors later in
the program.
SAA6D170 - HPI
Rail & Timing Pressure TPK

02/01
Page 3-51
In applications
where the fuel
supply tank is
higher than the
into the system
when the
engine is not in
operation

SAA6D170 - HPI
Fuel cooler TPK

02/01
Page 3-52
The correct fuel

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

SAA6D170 - HPI
TPK
Fuel cooler 02/01

Page 3-53
1. Mount bracket
2. Core
a. From injector
b. To fuel tank
SPECIFICATIONS
Cooling method: Air cooled
Core type: CF40, (4.5/2P)
Heat dissipation surface:
6.45 m 2
Heat dissipation amount:
11.63 kW {10,000 kcal}/h
Fuel pressure: Max. 5.88 kPa
{0.06 kg/cm 2 }
(When fuel temperature at
cooler inlet port is 100°C)
SAA6D170 - HPI
Fuel cooler TPK

02/01
Page 3-54
This causes all drain fuel

to flow through the
cooler. Although heat is
dissipated from the fuel
by the supply tank, the
use of the fuel cooler
insures positive
temperature control. The
typical drain fuel flow
rate is 2 GPM. Also, the
cooling radiator can
have no more than a 5
PSI restriction.
SAA6D170 - HPI
KOMATSU Presents the SAA6D170 - HPI TPK

02/01
Page 3-55
HPI

SAA6D170 - HPI
Komatsu Asia & Pacific Training Centre TPK

02/01
Page 3-56
KT9000101 - Structure & Function Menu Sec

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Structure & Function Fuel System: SAA6D170 - HPI

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Technical Presentation Kit

Structure & Function

SAA6D170 - Design Change TPK

 HPI Electronic Fuel System

 Rear Camshaft Drive

 New camshaft with injector lobe

 Redesign Cylinder Head

 New Intake Manifold

KT9000101 - Structure & Function Menu Exit

SAA6D170 - Engine Layout TPK

KT9000101 - Structure & Function Menu Exit

SAA6D170 - Engine Layout TPK

KT9000101 - Structure & Function Menu Exit

SAA6D170 - Fuel Pump Mounting TPK

KT9000101 - Structure & Function Menu Exit

SAA6D170 - Engine Layout TPK

Speed sensor(2 coils) Speed sensor

KT9000101 - Structure & Function Menu Exit

SAA6D170 - Engine Name Plate TPK

KT9000101 - Structure & Function Menu Exit

SAA6D170 - Engine speed sensor for ECM TPK

KT9000101 - Structure & Function Menu Exit

SAA6D170 - HPI fuel system TPK

The SAA6D170 - HPI

KT9000101 - Structure & Function Menu Exit

The HPI engine will

KT9000101 - Structure & Function Menu Exit

Shut off valve

Pump Pump pressure

KT9000101 - Structure & Function Menu Exit

KT9000101 - Structure & Function Menu Exit

Cummins electronic controls TPK

Uses the latest

KT9000101 - Structure & Function Menu Exit

SAA6D170 - HPI fuel system TPK

KT9000101 - Structure & Function Menu Exit

Let’s start by looking at the

KT9000101 - Structure & Function Menu Exit

Hydro-mechanical system TPK

This schematic provides

KT9000101 - Structure & Function Menu Exit

Fuel Piping TPK

KT9000101 - Structure & Function Menu Exit

Fuel Piping TPK

KT9000101 - Structure & Function Menu Exit

Fuel Filters TPK

Fuel flow from the supply

KT9000101 - Structure & Function Menu Exit

Fuel Filters & Piping 02/01

KT9000101 - Structure & Function Menu Exit

Fuel Piping 02/01

KT9000101 - Structure & Function Menu Exit

Fuel Manifold mounted on cylinder head 02/01

Water bleed piping

KT9000101 - Structure & Function Menu Exit

Fuel Filters TPK

KT9000101 - Structure & Function Menu Exit

Compact Fuel Pump Components TPK

 Fuel pump assembly

Compact Fuel Pump Components TPK

KT9000101 - Structure & Function Menu Exit

Fuel Pump Drive TPK

Oil Pump Alternator & Fuel