USER’S TEXT

MAINTENANCE COURSE

IN T ENANCE FOW
MAElectronically Controlled Heavy Duty A
High Pressure Common Rail
fuel injection system (HPPR)

Fuel Management
Contents 1 Do you know that: ........................................................ 3
2 Failure due to water, Part 1 ............................................ 4
3 Failure due to water, Part 2 ............................................ 5
4 Failure due to dust, Part 1 .............................................. 6
5 Failure due to dust, Part 2 .............................................. 7
6 Increase of water and dust in fuel during the fuel supply chain ........... 8
7 points to prevent water and dust from entering the fuel ........... 9
Point 1 Before starting daily operation ................................ 10
Point 2 After finishing daily operation................................. 11
Point 3 When refueling the machine .................................. 12
Point 4 When needed .................................................... 13
Point 5 When storing fuel ............................................... 14
Point 6 When replacing fuel filter ...................................... 15
Point 7 When purchasing fuel filter .................................... 16
To be concluded ........................................................... 17
1 Do you know that:

More than 85%

of failure causes of engine fuel system is;

Water and Dust

3
2 Failure due to water, Part 1 4

Sliding portion of the injector has been blanched white

Fuel injector seizes. by water.This shows that lubrication was poor.

Fuel burns imperfectly.

Piston seizes.

Engine is badly damaged.

Sliding portions of fuel system are lubricated with fuel. If the fuel contains low viscosity water, sliding
portions of supply pump and injectors may be lubricated badly, resulting in seizure of them.
3 Failure due to water, Part 2

Rust is formed on the top metal of fuel element.

Rusts are formed on fuel tank,
fuel piping, valves and upper
portion of fuel element.

Injectors wear early.

Fuel leak amount increases.

Engine cannot start.

5
4 Failure due to dust, Part 1 6

Worn needle seat surface of injector,

Needle seat of injector wears. resulting in sealing failure.

Fuel injection quantity

increases.

Engine output increases.

Engine is damaged. Power train component

is damaged.
5 Failure due to dust, Part 2

Early clogged fuel pre-filter

Fuel element clogs early.

Common rail pressure drops.

Engine cannot start.

7
 6 Increase of water and dust in fuel during the fuel supply chain 8

User’s
Oil factory Tank lorry Gas station Machine Fuel filter
storage tank
Water and dust quantity

Water
Dust
Conventional fuel filter

Ecot3 filter

Fuel supply chain

 7 points
to prevent water and
dust from entering
the fuel
Point 1 Before starting daily operation 10

Be sure to discharge the water and sediment in the water separator and
fuel tank before starting daily operation.

Discharge the water and sediment Discharge the water and

in the water separator. sediment in the fuel tank.
* When refueling the machine during operation, discharge the water and sediment in the fuel tank about 10 minutes
after the refueling.
Point 2 After finishing daily operation
Be sure to fill the fuel tank up after finishing daily operation.

If the tank has empty

space, dewdrops will Fill the fuel tank up after
be formed as a result finishing daily operation
of temperature in order to prevent the
changes of night and formation of any
day, and water drops condensation.
will enter the fuel.

Sliding portions of fuel system are lubricated with fuel. If the fuel contains low viscosity water, sliding portions of supply
pump and injectors may be lubricated badly, resulting in seizure of them.
11
Point 3 When refueling the machine 12

Be sure to clean around the filler port and to use clean feeders in order to prevent dust from entering the
fuel when refueling the machine.

Clear filler port Clean feeder To be continued a little more.

Point 4 When needed
Be sure to clean inside of the fuel tank according to need.
• When a failure has occurred in the fuel system
• When the gauze filter gets clogged in one or two days after cleaning it

Fuel tank circulation Clean inside of the fuel tank entirely by changing the position where the
cleaning equipment suction and discharge nozzles are placed.

13
Point 5 When storing fuel 14

Be sure to store fuel drums horizontally indoors.

Point 6 When replacing fuel filter
In order to prevent dust from entering fuel,

Never fill the main filter with fue Fill the pre-filter with fuel without removing the cap
Cup Cup

Cup

* Refer to the Operation and Maintenance Manual for details of

filter replacement interval and method, etc.
15
Point 7 When purchasing fuel filter 16

Be sure to purchase and use Komatsu genuine fuel filters.

Regarding filters:
Imitation filter
• Use filters specified in the Operation and
Maintenance Manual.
The adhesion
strength of the end • Purchase filters from Komatsu certified distributors.
face is insufficient.

The mesh of the

filter paper is
coarse.

The filtration
area is small.

Komatsu certified distributor

* The use of imitation filters of low filtration efficiency may lead to internal part wear of the fuel supply pump and
injectors, making you bear the expense not to compensate for the temporary filter cost.
 To be concluded

It has been an important point for the protection of engine to prevent water and dust from
entering fuel.

Fuel supply pump and injectors for the engines with common rail fuel injection system,
that have been developed to conform to the emission regulations, have been made with
clearance between sliding portions to an accuracy of some micrometers.

Therefore, strict fuel management is requested than ever before in order to prevent water
and dust from entering fuel.

We hope the forementioned “7 points” work for your fuel management and you use your
Komatsu engine in good condition over a long period.
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