This file included fuel consumption of construction machinery such as motor grader,vibratory roller,skid steer loader,Generator.....All values are got by actual construction site situations.Full description
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Application Engineering Bulletin Subject: QST30 Electric Fuel Supply System
This AEB is for the following applications: Automotive Industrial Power Generation
Author: Curtis Kwasniewski Date September, Septembe r, 2002
Purpose: The purpose of this document is to discuss the construction, operation, and advantages of the Electric Fuel Supply System.
Scope: This document applies to QST30 engines, both Generator Drive and Industrial.
Background: The QST30 fuel systems require require small pumps to draw fuel from the fuel ta nk and deliver it through the fuel filters to the injection pumps at approximately 35psig. All engines built prior to March of 2002 included two mechanically driven plunger lift pumps that were attached to the sides of the Bosch fuel injection pumps. In March 2002 Cummins Inc. will introduce a new system that uses two electric roller-vane pumps that are integrated into the fuel filter head (see Figure 1 ) to replace the mechanically driven lift pumps. The new system is called the Electric Fuel Supply (EFS) s ystem and it offers significant benefits for operation and service of the QST30 engine. The EFS will not entail any change in engine envelope.
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Construction: The EFS system consists of the following components: • • • • • • •
Electric Fuel Supply Pumps Combination Fuel Filter Head and Pump Manifold FS1006 Fuel Filter with Water Separator Fuel Manifolds with Integrated Fuel Shut-off (FSO) Valves Fuel Fittings and Connections Wiring with EFSS Power Relay Pressure and Temperature Sensors
System specifications are detailed in Appendix 1 . Electric Fuel Supply Pumps Two electric pumps are used in parallel to deliver fuel from the fuel tank through the filter to the fuel injection pumps. The two pumps are mounted in the fuel filter head and they both discharge into a single fuel filter (see Figure 2 ). The pump set is capable of pumping 1000 lbs/hr (454 Kg/hr) of fuel at 40 psi (276 kPa). The two pumps are wired in series so that they can be powered by a 24V supply but each pump will operate at 12V.
Figure 2: EFS Filter Head Top View
Please be aware that the electric fuel supply pumps will draw 6 to 8 amps from the batteries at all times while the engine is running. 3
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Combo Fuel Filter Filt er Head & Pump Mani Man ifold
The fuel filter head for the EFS system holds the two electric fuel supply pumps as well as the FS1006 fuel filter (see Figure 3 ). The head also has ports to hold the fuel inlet fitting and the fuel pressure and temperature sensors (optional).
Figure 3: EFS Filter Head Assembly
FS1006 Fuel Filter with Water Separator
The QST30 fuel supply system was originally designed to use two FF202 fuel filters. The FS1006 filter includes the Fleetguard StrataPore TM synthetic media that improves filtration efficiency, contaminate capacity and media life. The FS1006 filter is efficient at removing contaminates as small as 10 micron which helps to protect the fuel injection pumps from wear. The StrataPore TM media also provides 95% water separation efficiency. The excellent excellent characteristics of the FS1006 filter and the steady pressure supply of the electric fuel pumps make it possible to achieve 500 hour change intervals with a single filter element compared to the two elements that were required for the original fuel supply system design. 4
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Fuel Manifold with Integrated FSO Valve
The EFS system includes a fuel manifold on each side of the engine. The fuel manifolds are used to distribute fuel to the injection pumps and direct overflow fuel back to the fuel tank (see Figure 4 ). Each manifold has a built-in built-in fuel shut-off (FSO) valve. The FSO is a solenoid operated valve that prevents fuel flow to the injection pumps when the engine is not running or when a shutdown command is received. One of the two fuel manifolds contains a bypass valve that will relieve pressure in excess of 80 Psi (552 kPa) directly to the return line. The return fuel flow from the injectors passes through the manifold before returning to the fuel tank by a common header.
Figure 4: Fuel Manifold Detail
Fuel Connections
Fuel connections to the various components of the electric fuel system are made using banjo connectors. The connections have been sized to avoid confusion. All pressurized supply connections connections are M16 banjo connectors and all drain connections are M14 or M8 banjo connectors. 5
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Pre-filters
The electric fuel system requires the use of a 140-Micron 140-Micron (maximum) pre-filter. This prefilter should be installed prior to the fuel inlet to the filter-head. Option FS5033 or equivalent. Wiring with EFS Power Relay
The power to the electric fuel supply pumps is supplied from the 24V batteries through a power relay (see Figure 6 ). The circuit for f or the EFS power relay may either be contained in an external jumper harness that is added to the engine (Part Number 4068049) or it may be integrated into the base-engine harness (3093696 for Generator Drive engines, 4067866 for Industrial engines). On industrial engines engines the signal for the power relay comes directly from the the keyswitch so that whenever the keyswitch is “on” the electric pumps will also be “on”. For Generator Drive engines using the GCS controller and the INPOWER service tool, the signal to the power relay comes from the ECM, so the pumps are energized whenever the generator is commanded to start. Wiring for the EFS is built into the engine wiring harness for these engines. No additional customer interface is required for these engines. Corporate Generator Sets and Generator Drive engines using the INSITE service tool will use the jumper harness harness with the EFS. No interface interface changes changes will be required for for Corporate Corporate Generator Generator Sets.
Figure 6: EFS Power Relay Circuit
Engines using the INSITE service tool will require OEMs purchase and install the jumper harness harness to use the EFS. Power Power to the EFS relay, relay, in jumper harness equipped equipped engines, will be provided by the signal to the FSO valves. When the FSO valves are commanded to open the EFS will be energized. The fuel pumps are wired in series so that two 12V pumps can be powered powered from a 24V supply. Please be aware that the electric fuel supply pumps will draw 6 to 8 amps from the batteries at all times while the engine is running 6
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Pressure and Temperature Sensors Industrial and Generator Drive engines with the new version of the base-engine wiring harness (3093696 for Generator Drive engines, 4067866 for Industrial engines) will include a pressure sensor and a temperature sensor for the fuel supply. The sensors will be mounted into the fuel filter head (see Figure 7 ). The fuel supply temperature sensor will be in the flow path immediately after the fuel supply pumps and immediately im mediately before the fuel filter. The fuel supply pressure sensor will be in the flow path immediately after the fuel filter. This arrangement arrangement will allow the ECM to detect low system pressure due to plugged filters.
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Operation When the ECM detects a start condition (for Generator Drive) or when the key switch is in the “on” position (for Industrial) the relay energizes. When the relay is energized the pumps are powered. With the relay energized the pump set delivers fuel to the injection pumps until the engine is shut down. In the event of short-circuit an integrated 20 amp fuse will open to prevent damage. damage. If the ECM commands a shut down (either planned or unplanned) the power to the FSO solenoid is interrupted. On industrial engines the electric pumps will continue to pump until the keyswitch is turned “off” but with the FSO valves closed there will be no fuel flow to the injection pumps. On Generator Drive engines, when the power to the FSO valves is interrupted the power relay will also de-energize and the electric pumps will stop.
Advantages The Electric Fuel Supply System has the following advantages. Less Complex Fuel Lines: Li nes: Because the FSO valves are integrated integrate d into the fuel manifold and the lift pump and fuel filter are combined in a single filter head, the number of fuel lines is dramatically decreased and simplified. Fewer fuel lines will reduce the possibility possibility of leaks and simplifies trouble-shootin trouble -shooting g and repair. •
Consistent Fuel Flow at All Engine Speeds: Because Because the speed of the electric lift pump is independent of the engine speed it supplies a constant fuel flow to the injection pumps at all engine speeds. This results in higher fuel pressures at starting which leads to better starting characteristics and a smoother running engine at low speeds. •
Improved Filtration: The FS1006 fuel filters offer superior protection for the engine. Use of the electric fuel supply p umps allows a single FS1006 filter to accommodate the entire fuel flow for the engine. The Stratapore media used in the FS1006 filters allows for extended filter service intervals. •
Simplified Simplified Trouble-Shooting Trouble-Shooting and Service: Service: The The electric lift pump has fewer fewer parts and a much simpler design. With fuel line connections that are sized to minimize confusion and a single fuel filter the service of the system becomes greatly simplified. The electric pumps can be energized while the engine is not running so that problems with the fuel supply system can be diagnosed independently. •
Provisions for Priming Priming the Fuel System: System: The The electric electric fuel supply pumps pumps can can be energized before the engine engine is started. This will fill the fuel system and bring it up to pressure before the engine engine is cranked. Priming the fuel system will improve the first injection events making the engine easier to start. Additionally, if the fuel system is drained for any reason (such as fuel filter change) purging air from the system is simplified by energizing the pumps. •
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Appendix 1: System Specifications
Electrical: Operating Voltage: Current Draw: Fuse Rating:
