QST30 High Pressure Fuel Line Failures

Jan01 Sep04

Last Updated: Jan. 13, 2005 Joe Worthington Product Engineering QST30

Power Generation Failures

High Pressure Fuel Line Failures - QST30 PG
Concern

Jan'01 - Sep'04

No. of Failures

4
1800 rpm

3
1800 rpm

2
1500 rpm

1
1800 rpm 1500 rpm 1500 rpm

0 LB1 LB2 LB3 LB4 LB5 LB6 RB1 RB2 RB3 RB4 RB5 RB6 Fuel Line Location

Industrial Failures
High Pressure Fuel Line Failures - QST30 Industrial
Concern

Jan'01 - Sep'04

14

No. of Failures

12 10 8 6 4 2 0 LB1 LB2 LB3 LB4 LB5 LB6 RB1 RB2 RB3 RB4 RB5 RB6 Fuel Line Location All Industrials Euclid-Hitachi

High Pressure Fuel Line Failures by Customer

High Pressure Fuel Line Failures by Customer
Jan'01 - Sep'04

45 40 35 30 25 20 15 10 5 0

No. of Failures

CUMMINS CUMBERLAND INC (Ind)

HITACHI CONSTRUCTION TRUCK (Ind)

CUMMINS SOUTHERN PLAINS INC (PG)

CUMMINS ATLANTIC INC (PG)

CUMMINS JAPAN LTD (PG)

LORAM MAINTENANCE OF WAY, INC (PG)

SDMO (PG)

Industrials Built vs. Industrials Failed

Industrial Engines Built vs. Industrial Engines Failed (by Ship Date)

Percentage of Industrial Engines Failed vs. Industrial Engines Built (by Ship Date)

30
Percentage of Failures

25

20 15 10 5 0 All Industrial Built All Industrial Failed

100 90 80 70 60 50 40 30 20 10 0

No. of Engines

May-98

May-99

May-00

May-01

May-02

May-03

Engine Ship Date

Engine Ship Date

May-04

Jan-98

Jan-99

Jan-00

Jan-01

Jan-02

Jan-03

Sep-98

Sep-99

Sep-00

Sep-01

Sep-02

Sep-03

Ja

Ja

Ja

Ja

Ja

Ja

Ja

Jan-04

n98

n99

n00

n01

n02

n03

n04

Euclid-Hitachi Built vs. Euclid-Hitachi Failed

Euclid-Hitachi Built vs. Euclid-Hitachi Failed (by Ship Date)

Percentage of Euclid-Hitachi Engines Built vs. EuclidHitachi Engines Failed (by Ship Date)

16 14 12 10 8 6 4 2 0 Jan- Jan- Jan- Jan- Jan- Jan- Jan- Jan98 99 00 01 02 03 04 05 Engine Ship Date

Percentage of Failures

No. of Engines

250 200 150 100 50 0

Euclid-Hitachi Built Euclid-Hitachi Failed

Jul-98

Jul-99

Jul-00

Jul-01

Jul-02

Jul-03

Jan-98

Jan-99

Jan-00

Jan-01

Jan-02

Jan-03

Engine Built Date

Jan-04

Jul-04

High Pressure Fuel Line Failures Engine Build Date

Right Bank Industrial Fuel Lines

RB#3

Blue Boxes represent Locations of Existing Clamps

LB#2

Left Bank Industrial Fuel Lines

LB#4
Blue Boxes represent
Locations of Existing Clamps

Conclusions
Clearly Euclid-Hitachi is failing many more fuel lines than any other customer One potential cause is 2100 rpm operating speed RB#3 Fuel Line appears to have a much higher failure rate than any others (both Power Generation & Industrial)

CKEC Failure
CKEC failed RB#3 Industrial Fuel Line during 500 Hour Stop Cycle Endurance Testing (Test consists of 4 minutes at 2100rpm & 3000ft-lbs) CKEC failure examined and root cause was high cycle bending fatigue

Proposed Solution Power Generation

Komatsu has performed previous testing of high pressure fuel lines for development of 1.1MW Power Generation Engine (1500 & 1800 rpm) Komatsu found high stress levels on RB#3 high pressure fuel lines Propose Implementation of KPCR 02-005 to improve high pressure line clamping after clarifying effectiveness at 2100 rpm and higher CKEC has revised Komatsu design to work with Cummins tube clamp and now has design for Power Generation

Layout for RB3 Bracket (Power Generation)

Komatsu RB3 Test Results 1.1 MW PG

Design Factor Comparison Passing Criteria: > 1.2 1800rpm 1 Failed 1500rpm 0.8 Failed

Original

R3

Improved R3 Clamping

2.24

Passed

1.91

Passed

Proposed Solution Industrial

Currently Industrials have single tube clamps on R1 & L6
Bracket that supports clamp at R1 also will work in R3 location Add additional R1 bracket (3093687) to R3 location

Number of Failures & Cost of Solution

Power Generation RB3 Industrial RB3

No. of Failures: 4 Cost of Bracket (Quote): $13.38

No. of Failures: 13 Cost of Bracket (Production): $11.50

Right Bank #3 Industrial Fuel Line Failure Up-fit Kit*

Parts Needed: 1 3093687 Bracket, Fuel Plumbing 1 3092334 Spacer, Mounting 2 3093624 Clamp, Tube 1 3093734 Screw, Hexagon Head Cap 1 3093764 Screw, Hexagon Head Cap 1 68368B Spacer, Mounting Remove Existing: 1 3094813 Screw Hexagon Head Flange (from rocker lever box location)

*Adding this additional brace will require the turbocharger supply line be rerouted behind the fuel injector drain line

Right Bank #3 Industrial Fuel Line Failure Up-fit Kit Layout

3093764 Hex Head C/S 68368B Mounting Spacer 4068681 Hose Brace 3093687 Fuel Line Bracket 3092334 Mounting Spacer

Rocker Lever Box