Es31110-30 Rev.07 Eesf2884 en

래[csr0214]시험평가2실 2016.08.26 17.
1
기 술 표 준 (SHT/SHTS) 1/33
(SPEC NO) ES31110-30
ENGINEERING STANDARD
1. Purpose
d.
This Engineering Standard is to secure adequate quality through specification standardization.
Note: This Engineering Standard is an extension of engineering design drawing and so all
components shall satisfy the overall requirements of this Standard along with the requirements and
t
single component standards on the detailed drawing.
.,L
2. Scope of application
2.1 This standard specifies test method and standards for reliability of electrical driving fuel pump
Co
module (hereinafter referred to as module) of in-take type applied to the engine using diesel.
2.2 If instructions on the drawing differ from those of this standard, the instructions on the drawing
take precedence.
2.3 All specimens, which are randomly selected, examined parts from the proto process and the
production process (including pilot process), must satisfy this specification to carry out the
d
specified process in this document. Relevant supplier should establish a reliability verification
system themselves to qualify the design of part with sufficient number of samples.
In
3. Definition of terms
3.1 Fuel Pump Complete
NO Item NO Item
AM
1 ELECTRIC FUEL PUMP 6 HOSE

2 PIPE 8 ASSIST PUMP
3 RESERVIOR CUP 9 MOUNTING PLATE
4 FILTER -PUMP 10 CHECK VALVE
D
5 SPRING-CUSHION 11 SENDER ASS'Y
3.2 Fuel Tank Complete

N
: A component as unit supplied to H/KMC, fuel tank assembly + functional parts, such as fuel
pump and valves, and hoses.
YU
4. General and indications on the drawing

4.1 Shape and structure
As for the detailed shape, structure and corresponding size, comply with the drawing.
H
4.2 Dimension and thickness

- Satisfy requirements for dimension, allowance and materials.
4.3 Material and plating specification

- Satisfy performance and regulations
1F-SG-00002 현대ㆍ기아 자동차
HYUNDAI ㆍ KIA MOTOR
현담산업(주) / 오관범 / 2016-03-07 11:39/ 본 문서는 현대기아자동차의 정보자산이므로 무단으로 전재 및 복제할 수 없으며, 이를 위반할 시에는 당사 사규 및 관련 법규에 의해 제재를 받을 수 있습니다.
래[csr0214]시험평가2실 2016.08.26 17.1
4.4 Working condition
d.
: Working environment temperature, installation position, used fuel, etc. (Unless otherwise specified,
refer to the condition below.)
- Working environment temperature: -40℃ to 80℃
t
- Installation position: Inside the fuel tank at the rear floor
.,L
- Used fuel: Diesel on the market (Including BD05 and BD10)
- Working area: High temperature(80℃), highland (1500m), diesel on the market
Co
- Requirements for other environment
. When diesel on the market and bio-diesel are used at high temperature, on high altitude road
or in general environment conditions, there shall be no problems with supplying fuel and
materials such as rubber, plastic, steel, etc., and components in actual vehicle conditions shall
function properly as warranted during the warranty period specified in SR.
d
.There shall be neither swelling, contraction due to performance degradation of the materials
and components nor crack due to fatigue durability.
In
. There shall be neither fuel leakage nor problem with supplying fuel resulting from leakage on
the assembled, molded and connected parts in general driving environments during vehicle
life.
AM
4.5 Evaluation condition

- Unless otherwise specified, comply with the standards below.
. Test supplying voltage and pressure: 13V, system supplying voltage by engine
. Allowance of test voltage: ±0.1V (Measure characteristic) / ±0.5V (Measure durability)
. Allowance of test pressure: ±5kpa
D
. Test oil: REG DIESEL (KS M 2610), BIO DIESEL (BD10 / EN590 standard fuel)
. Test temperature: Unless otherwise specified, conduct the test at room temperature (20℃) and
N
allowance of evaluation temperature in this engineering standard is ±2℃.

. Standard pressure and flow rate: As for reference fuel pressure and newly developed engine of
the vehicle system, comply with the drawing and LPC requirements.
YU
4.6 Indications on the drawing

- Fuel pump module (Including the sender)
. Pump installed-location and attached position, and used fuel
H
. W/H connector specification, terminal arrangement, W/H specification

. Target warranty period
- Pump motor
. The supplied voltage (Supplying method), Fuel pump pressure (Discharge pressure
and maximum closing pressure), flow rate and current consumption
래[csr0214]시험평가2실 2016.08.26 17.1
- Fuel sender
d.
. Sender characteristic: Resistance by oil level (capacity) (or voltage and allowance
included)
. Sender structure and assembly position
t
. Working voltage / current
.,L
. Contact point pressure on the substrate
5. Requirements
※As for the required minimum quantities by evaluation item, comply with Table 1 in Annex
Co
PUMP
Test existence
Evaluation item Evaluation standard
method
Yes No
There shall be neither crack, corrosion, deformation,

Appearance - ● ●
nor etc.
Insulating
100 ㏁ or more
d - ● ●
In
resistance
Basic performance
Sealing of the
There shall be no leakage under pressure of 850kPa - ● ●
high pressure part
AM
There shall be no leakage under pressure of 50kPa.

Plating sealing (In the case of certification for China, 80kPa and 30 - ● ●
sec shall be the standard.)
Sealing
of the power There shall be no leakage under pressure of 50kPa - ● ●
connected part
D
Basic
Satisfy specification on the drawing. (Including
performance (Room 6.1.1 ●
temperature) sender)
N
180N or more in each direction

Strength on the
There shall be no harmful abrasion such as crack on 6.1.2 ● ●
port
Basic performance
the plate.
YU
Reservoir cup
The amount of leakage shall be 1cc/hr or less. (Except
leakage 6.1.3 ● ●
for the amount of water evaporated)
characteristic
Check valve closing

H
Minimum oil lever shall be 10mm or less. 6.1.4 ● ●

characteristic
Shall be higher than the maximum consumption

Assist pump suction amount of the engine. (The limit value on the drawing)
6.1.5 ● ●
performance Liquid level in the sub tank shall be the same or
higher than one of the fuel tank.
래[csr0214]시험평가2실 2016.08.26 17.1
ASSIST pump back

MAX PRESSURE ≤ SYSTEM B/PRESSURE
d.
pressure 6.1.6 ● ●
standard
performance
1) The pressure dropping within 30 min after tuning off
power and reaching target pressure shall be 20% or
Characteristic of
t
less than initial pressure
keeping remaining 6.1.7 ●
) 2) The pressure dropping within 12 hours after turning
.,L
pressure
off power and reaching target pressure shall be 25%
or less than initial pressure.
1) The force shall be 98 N or more when it is damaged
Nylon tube
Co
after the test. 6.1.8 ● ●
tension force
2) The tube shall not be damaged after the test
Shall be 90 % or more than reference fuel pressure of
Supplying stability 6.1.9 ● ●
the fuel discharging system
Accuracy of fuel
sender full status Load shall be 2.5kgf or more 6.1.10 ● ●
instruction
High temperature
test
d
After the test, satisfy basic performance in Article 6.1.1 6.2.1 ● ●
In
Environment test
Low temperature
test
Cold and heat
resistance cycle After the test, satisfy basic performance in Article 6.1.1 6.2.3 ● ●
AM
test
High temperature
and humidity test
There shall be neither corrosion, discoloration, swelling,
Salt water spray
softening nor deformation after the test. 6.2.5 ● ●
test
Satisfy basic performance (6.1.1)
D
Complex Satisfy basic performance (6.1.1, 6.1.4, 6.1.5,

6.3.1 ●
operation durability
6.1.7) after the test.
N
Vibration
After the test, satisfy basic performance in Article
resistance and 6.3.2 ● ●
6.1.1
durability
Durability test
YU
ON-OFF After the test, satisfy basic performance in Article

6.3.3 ●
Durability 6.1.1. No damage or injury on the components.
- Satisfy basic characteristic (4.5.1)

- The changed rate of contact resistance on the
H
Stroke durability cable of pump power terminal shall be within 10%

6.3.4
test
- Resistance change of the sender shall be within
5% or less.
- There shall be neither damage nor defective.

래[csr0214]시험평가2실 2016.08.26 17.1
Satisfy the basic performance. There shall be no
d.
damage occurring after testing at acceleration of 40g.
Drop test 6.4.1 ● ●
There shall be no fuel leakage due to damage on the
plate after test at acceleration of 45g
Other
Noise The peak of noise by frequency shall be within standard
t
6.4.2 ●
characteristic in 6.4.2.5.
.,L
Wireless When fuel pump operates, there shall be no noise due
frequency to interruption. 6.4.3 ●
interruption (Satisfy ES96200-00.)
Co
※ For the pump module responding to bio diesel of 15% or more in SR, additionally conduct the
durability characteristic item (6.3) and noise test (6.4.2), using the corresponding fuel.
6. Test method
6.1. Basic characteristic
6.1.1 Basic performance
1) Purpose
d
In
- To check fuel supplying performance in change of environmental temperature in the
module status.
2) Evaluation condition
- Test voltage: 8±0.1V, 13±0.1V
AM
- Test pressure: Pressure in the drawing

- Used fuel: REG DIESEL
- Fuel temperature: Room temperature (25℃)
- Amount of fuel: The MODULE shall be dipped at least 1/2.
3) Evaluation device/Device
D
- Performance testing equipment

N
YU
H
4) Test method and order

- Install the product to the performance testing equipment (refer to figure) and conduct

래[csr0214]시험평가2실 2016.08.26 17.1
the test once fuel temperature satisfies standard temperature.
d.
- After applying a standard voltage to the product, adjust valve to satisfy pressure on the
drawing.
- Then, measure the discharging flow rate.
t
5) Evaluation results
.,L
- Voltage /Pressure /flow amount data
- As for evaluation results, comply with evaluation standards in Requirement 5. .
Co
6) Additional check list
- For items which are not specified, pre-approval from responsible managers in HKMC is
required prior to the test.
- As for the test quantities, comply with the quantities indicated in Annex. .
6.1.2 Strength on the port

1) Purpose
d
In
- To check the strength of the port side by external shock
- Test temperature: Room temperature
- Test condition: PUSH
AM
- Test direction: X, Y, Z (3 directions)

- Test speed: 200mm/min
3) Evaluation device
- Tension /pressure test equipment
D
N
YU

- Install the product to the tension and pressure test equipment.
H
- Using the tension/compression test equipment, apply load to a point 3mm inward from the
end of the port at a standard speed.
- Repeat the test in direction X, Y and Z in the same method. However, use each sample for one
direction
래[csr0214]시험평가2실 2016.08.26 17.1
- Tension and pressure load value of each direction \
d.
- As for evaluation results, comply with evaluation standards in Requirement 5.
t
.,L
Co
6.1.3 Reservoir Cup leak characteristic
1) Purpose
- To check the fuel conservation capability for securing startability during parking on a
slope for a long period
- Test fuel: REG DIESEL
d
In
3) Evaluation device/device
- Leakage test equipment of the reservoir cup
AM
D

N
- Measure initial weight of a reservoir cup.

- Fill the reservoir cup 100cc and measure weight.
- Tilt the cup 15% (8.4°) and 30% (16.7°) respectively in the left and right and then leave it alone.
YU
- 24 hours later, check the weight of the reservoir cup and calculate the amount of leakage by
time.
-If the check valve is not dipped under fuel, conduct the evaluation with the minimum amount
H
at a time the check valve is dipped.

- Amount of leakage (Except for evaporation amount)

래[csr0214]시험평가2실 2016.08.26 17.1
d.
required prior to the test. .
6.1.4 Check valve opening characteristic
t
1) Purpose
.,L
- To check the minimum amount at time fuel flows into the reservoir cup when a vehicle is
filled with fuel for the first time
Co
- Test direction: Fuel tank as assembled when the reservoir cup is maintained to be level
- Simple chamber and beaker
d
In
Beaker
Test tank
AM

D
- Install the fuel tank to the temporary chamber as in attached (So that the fuel tank is installed
as assembled (to be level).
N
- Fill the temporary chamber with test fuel by means of a beaker.

- Stop filling fuel once fuel flows into the reservoir cup and at this time measure its height.
- Height (H) = Oil surface height at a time fuel flows into the reservoir cup
YU
- Height (H) measuring data
- For evaluation results, comply with evaluation standards in Requirement 5.
H
- As for the test quantities, comply with the quantities indicated in Annex.
6.1.5 Suction performance of assist pump (JET NOZZLE)

래[csr0214]시험평가2실 2016.08.26 17.1
1) Purpose
d.
- To check suction performance of the assist pump (JET Nozzle) when the engine consumes
maximum fuel.
t
.,L
- Oil level of the bath: 25±2mm
Co
- Oil level of the reservoir cup: Conducted when the reservoir cop is full of fuel.
- A device of evaluating stability of fuel supplying
(1). General type
Suction flow
석션 유량 = QS - QR
d
In
rate Power
Power
전원 전원
Flowmeter
유량계 +- Flowmeter
유량계 +-
QS QR P1 Pressure gauge for measuring

back배압측정용
pressure 압력계
AM
Reservoir
리저버 컵 cup
Chamber
챔버
PUMP 2. PUMP 1.
D
Fuel 25 mm
연료 A/P
N
(2). Saddle type

YU
H

래[csr0214]시험평가2실 2016.08.26 17.1
유량계
Flowmeter
d.
Suction flow Pressure gauge for QS
석션
rate유량 = QS Power
전원 배압측정용
measuring 압력계
back pressure
+- Flowmeter
유량계
Power
전원
t
+- P1 QR
.,L
Reservoir
리저버 컵cup
Co
연료
Fuel
Chamber
챔버 Sub-module
서브 모듈
PUMP 2. PUMP 1. A/P
25 mm
연료
Fuel
d
In
- Install the product to the evaluation device and apply power of the pump for the return
capacity.
- Adjust voltage to be a standard return capacity (QR) and apply power of the pump for suction
AM
flow rate
-Adjust voltage until oil level of the reservoir cup is full to adjust suction flow rate (QS).
- Once oil level of the reservoir cup becomes full, measure suction flow rate (QS).
- General fuel tank: Suction flow rate (QS) = Suction flow rate (QS) – Return flow rate (QR)
- Saddle fuel tank: Suction flow rate (QS) = Suction flow rate (QS)
D
- ① RETURN JET TYPE (Regulator return type)

QR = Minimum return flow rate (The minimum pump flow rate under 12V @ - the WOT flow
N
rate or 40L/H)
② SUPPLY JET TYPE (Dual return method)
QR = minimum flow rate of passing the assist pump (nozzle) (Refer to the drawing)
YU
- When suction performance of the saddle type fuel tank is evaluated, conditions of the sub-
suction line shall be the same as those of an actual vehicle (length and internal diameter).
- Suction flow rate (QS) data
H


래[csr0214]시험평가2실 2016.08.26 17.1
d.
6.1.6 Back pressure characteristic of the assist pump
1) Purpose
t
- To check pressure gradient characteristics of the regulator and assist pump
.,L
Co
- Oil level of bath: 25±2mm
- Device of testing stability for supplying fuel
d
- Install the product to the evaluation device and apply power to the pump for return flow rate.
- Adjust voltage to be a standard return flow rate (QR).
In
- ① Shall be tested only for RETURN JET TYPE (Regulator return method).
QR = Maximum return flow rate
(With the pump: maximum pump flow rate under 13V @ specified on the drawing)
(Without the pump: Engine maximum return flow amount)
AM
② It is not needed to test the SUPPLY JET TYPE (Dual return type).
- Back pressure measurement data (MAX PRESSURE)
-As for evaluation results, comply with evaluation standards in Requirement 5.
D
-For items that are not specified, pre-approval from responsible members of HKMC is
N
6.1.7 Remaining pressure conservation characteristic

YU
1) Purpose
- To check remaining pressure conservation characteristic for securing vehicle’s startability
- Test voltage: 12V ±0.1V
H

- Test fuel: Refer to evaluation fuel by item in Attachment 2
- Test pressure: 196 kPa
- Evaluation period: 15 min
래[csr0214]시험평가2실 2016.08.26 17.1
d.
- Performance testing equipment
FUEL CUT VALVE
전원
t
Power P/REG for test:
TEST용 P/REG. :
+ - P1 P/REG.
SYSTEM PRESSURE + 5OkPa
.,L
Co
Oil level:
유면높이 1/2 or equivalent
: 1/2상당

- Install product module to the tank for test
d
2) Apply power and then turn it off after pressure reaches standard value or more
In
3) Start to measure pressure when it reaches to a standard fuel pressure.
4) 15 min later, measure pressure drop
- Install the product to the performance testing equipment and apply power.
- Adjust the valve to set test pressure, block pipe with remaining pressure power and turn
AM
off power
- Measure initial pressure, and then 15 min later, measure pressure again.
- Pressure drop calculation = (Initial pressure – Pressure after 15 min) / 15 min
- Pressure drop data by time
D

N
YU
6.1.8 Nylon tube tension force

H
Test jig
Tension (universal) test

equipment

래[csr0214]시험평가2실 2016.08.26 17.1
d.
< Figure 8>
1) Purpose
t
- To check connection stability on the pressure applied areas in the module status
.,L
Co
- Temperature to be left at: High temperature (60℃), Low temperature (-40℃)
- Time to be left alone: High temperature (4Hrs), Low temperature (4Hrs)
- Test speed: 100mm/min
- Tension/pressure test equipment, thermo-hygrostat
d
In
- After installing one end of the tube to the jig, leave it alone for 4 hours at room and high
temperature (60℃).
- Within 20 min after it is left alone, pull it out at 100m/min until the tube is damaged.
- Check tension force when it is damaged.
AM
- Leave alone the tube at -40°C for 4hr.

- Make stroke motion when bending both ends of the tube at an angle of 180 °, or in a full
condition of the module.
- Tension force evaluation data by temperature condition
D

N
YU
6.1.9 Fuel supplying stability

1) Purpose
- To check the stability of fuel supply in a slope status of an actual vehicle
H
- Test voltage: 12 ±.1V
- Test quantities: Normal capacity of 10% in the fuel tank + Invalid remaining amount of fuel
래[csr0214]시험평가2실 2016.08.26 17.1
Classification Evaluation condition
d.
Fuel tank normal capacity of 10% and on a slope at gradient of 20% in
the left and right and of 30% in back and forth
t
On a slope Driving for 30 mins in the Idling status (Fuel of 1.0 to 1.5L/H might be
.,L
consumed.)
Engine of 2.4 or less : 1.0L/H, 2.5~3.0: 1.2L/H
Check the fuel discharging amount after driving it in the turning
Co
Turning
condition for 1 min at 37.5 ℃ with fuel of 10% (fuel of 15L/H might be
condition
consumed)
- Device of testing stability for supplying fuel
Pressure meter
dFlowmeter
In
AM
<DIESEL>
- Apply real the fuel tank in the test which could be divided for convenience.
- Install the fuel tank to the jig, the bottom shape will not be deformed when the incision tops.
- Apply transparent tube which ID 8mm (It can be changed after consultation) to the fuel line.
- Position of P/Regulator above 350mm on the pump plate, total length is maintained 2.5~3.5m.
D
- Position of Valve2(Control valve of flow fuel consumption) is maintained within 1m from Valve1.
- Position of beaker is lower than the fuel tank.
N
- Tolerance of manometer is maximum +/-10kPa.

YU
- Apply power of 13.5V to the fuel pump and operate it for 1 min(all valve closed).
- Slopes left condition : Operate the fuel pump on the flat and tilt the fuel tank less than 5 min.
H

래[csr0214]시험평가2실 2016.08.26 17.1
t d.
.,L
Co
d
- Fill the fuel line pressure and arrival time when the fuel pump is restarted after each left.
- Feed line pressure must be eliminated(lower than 1bar) immediately(less than 5 sec) from valve1
In
when power is off.
- Left and right curve driving condition: Driving the engine for 1 in the curve driving condition on
a slope at gradient of 37.5° (The fuel of 15L/H might be consumed)
AM
- The fuel discharging pressure by condition shall be 90% or more than pressure of the
system.
- The time to generate pressure (capable of re-ignition) shall be within 3 sec in the slop
condition.
D
N
YU
6.1.10 Accuracy of the sender full status instruction

1) Purpose
- To check changed characteristic of the sender resistance by a motion of the fuel pump
module
H
- Installation condition: In-vehicle Installation condition
- Installation jig and push-full gauge

래[csr0214]시험평가2실 2016.08.26 17.1
(Back and
d.
X forth)
Sender resistance (Ω)
(Left and right)
(-) (+) Y
t
.,L
G/F
Applied load (F)
Co
Fix the height Applied load (F)
of G/F
H

d
In
- Install the fuel pump to the jig and fix it to the sender float of G/F.
- Gradually apply load at height of 30mm from the reservoir floor in the left/right/back/forth,
respectively.
- Measure load at a time sender resistance on the G/F is changed.
AM
- Applied load data
D

N
6.2 Environment characteristic

6.2.1 High temperature test
YU
1) Purpose
- To check change in dimensions and electrical characteristics of each part at high
temperature
H
- Test temperature: 80±3℃

- Time to be left alone: 1,000 hrs
- Condition to be left: The tank is assembled and the specimen does not operate, without test
oil in the specimen.
래[csr0214]시험평가2실 2016.08.26 17.1
- Thermostatic bath
t d.
.,L
Co
- Put the product into the equipment and set temperature inside the test chamber to be
standard temperature.
d
- After leaving it alone for a standard period, evaluate performance.
In
- Basic performance evaluation and characteristic data after the durability test
AM

6.2.2 Low temperature test

1) Purpose
D
- To check change in dimension and electrical characteristic of each part at low temperature
N
- Test temperature: -40℃

- Time to be left alone: 96hr
YU
- Condition to be left: The tank is assembled and the specimen does not operate, without test
oil in the specimen
- A constant temperature and humidity chamber
H

- After putting the specimen into equipment, drop temperature by stage as follows; -10℃ for
24Hrs, -20℃ for 24Hrs, -30℃ for 24Hrs, -40℃ for 24Hrs (The tank is assembled.)
- After completing the test, conduct the air-tightness test on the assembled part of the pump
plate and fuel tank.

래[csr0214]시험평가2실 2016.08.26 17.1
- The specimen does not work.
d.
t
.,L
Co
6.2.3 Heat and cold resistance cycle test

1) Purpose
- It is to evaluate stability of the module depending on change in external environment
temperature
d
In
- Test temperature: 80℃x1hr ↔ -35℃x1hr / 1 CYCLE (Temperature shall be changed in 5 min)
- Test period: 100 CYCLES (200Hrs)
- Thermal impact test equipment
AM
High temperature Low temperature
Water and oil bath

D

N
- High and low temperature of the device shall be adjusted to be a standard temperature.
- Surface temperature of the test chamber shall reaches standard temperature in 10 min after
YU
putting the specimen.

- The specimen does not work. .
H

래[csr0214]시험평가2실 2016.08.26 17.1
80℃
t d.
20sec 1hr
.,L
0℃
1hr 20sec
Co
-35℃
6) Additional check list d
In
- For items that are not specified, pre-approval from responsible managers in HKMC is
AM
6.2.4 High temperature and humidity test method

1) Purpose
-To check stability of the module at external environment condition such as high
temperature and humidity
D
- Test temperature: 80±3℃

- Test humidity: 90 to 95RH% (Relative humidity)
N
- Test period: 1,000 hrs

- Thermo-hygrostat chamber
YU

- Put a product into the device and set temperature and humidity of the test chamber to be
standard conditions.
- Leave it alone a product in a standard period and then evaluate performance.
H
래[csr0214]시험평가2실 2016.08.26 17.1
d.
6.2.5 Salt water spray test
t
1) Purpose
.,L
- To check corrosion on the fastening parts of the tank by salt water. (Test only for steel
plate specification)
Co
- Test fuel: Distilled water (PH) + NaCl 5%
- Temperature in the test equipment: 35℃±1℃
- Salt water spray pressure: 117kPa
- Test period: For evaluation period by product (plating and coating thickness), comply with
MS standard.
d
In
- Salt water spray test equipment
AM
Salt water spray test equipment

D
- Install the product to the test chamber and fix it to the inside of the chamber.
- After adjusting temperature inside chamber to be a standard temperature, spray salt water.
N
-Shape (figure) data after the durability evaluation
YU

H
6.3 Durability characteristic

6.3.1 Complex environment operation durability test
1) Purpose
래[csr0214]시험평가2실 2016.08.26 17.1
- To check effect on the module and rubber parts by fuel and fuel pressure during operation
d.
at high temperature.
- Test fuel: General Diesel and general winterized diesel
t
- Test temperature: 23℃ → 80℃ →90℃ →100℃ →-35℃
.,L
- Test voltage: 13V ±0.3V (ON 15min ↔ OFF 30s)
- Test period: 400hrs → 400hrs → 95hrs →5 hrs → 100hrs
Co
- Fuel replacement cycle: 168Hrs
Item Working fuel Temperature Time (Hour) Note
General Diesel
Condition
General winter diesel

d
In
Fuel replacing cycle
- High temperature durability test equipment
AM
D
N
YU

- Fill the test tank with test fuel, set test voltage to be standard pressure and operate the
module (According to the basic measurement by vehicle)
- Set the device so that temperature of test fuel is adjusted to standard temperature.
H
- Turn on or off the product in a standard period.

- Dip 1/2 or more of the module under fuel.
※However, Conditions in Item 6.1.5 can be substituted with the following condition;

래[csr0214]시험평가2실 2016.08.26 17.1
checking overflow of fuel in the module reservoir within 10 min in the engine maximum
d.
consumption conditions.
t
.,L
Co
6.3.2 Vibration resistance and durability
1) Purpose
- To check crack on resin and rubber components by vibration stress and separation on each
connected area.
d
In
- Installation condition: A fuel tank as assembled
- Test fuel: No fuel applicable
- Location of vibration sensor: The center on the plate
- Vibration condition: All tested in Condition 2
AM
- Condition 1) 4G X 13HZ X 1,500,000 in the up and down

- Condition 2) If resonance frequency exists; conduct test in the up/down (4 hours), left/right
(2 hours), and back/forth (2 hours) by resonance frequency of 2G X
If resonance frequency does not exist, conduct test by resonance frequency of 2G X
67Hz in the same direction and period above
D
N
- Vibration test equipment

YU
H

래[csr0214]시험평가2실 2016.08.26 17.1
t d.
.,L
Co
Vibration test equipment

- Install the product to the jig for test. d
- Install the jig for test to the product and evaluate resonance frequency.
In
- Conduct the vibration test for the product in the standard condition (Condition 2)
- Pump and sender basic evaluation data after the durability test
AM
. Sender resistance by oil level height (Satisfy sender’s basic resistance properties)
D
6.3.3 On-off durability test
1) Purpose
N
- To check effect on the module and rubber material components by stress of fuel and fuel
pressure during operation at high temperature.
YU
- Test fuel: General diesel and winter diesel
- Test temperature: 60℃(Mode 1) / 80℃(Mode 2)
H
- Test voltage: Mode 1. 13V ±0.3V (ON 2min ↔ OFF 10s)

Mode 2. 13.5V ±0.3V (ON 3s ↔ OFF 2s)
- Test period: Mode 1. 500hrs
Mode 2. 350hrs
- Fuel replacement cycle: 168Hrs

래[csr0214]시험평가2실 2016.08.26 17.1
- Follow below table in Mode 2.
d.
Standard pressure of
fuel pressure Test pressure (ON) Test pressure (OFF)
t
controller
500kPa↓
.,L
700kPa OkPa
※ If the pressure exceeds 500kPa, it is made after consultation with the representative.
Co
- High temperature durability test equipment
Mode 1
- Fill the test tank with test fuel, set voltage and pressure according to standards in
the drawing, and operate the module (According to basic measurement method by vehicle
model)
d
- Set up apparatus so that temperature of the test fuel is maintained within standard
In
temperature.
- Turn on and off the product for a standard time.
- The module shall be dipped at least 1/2 under fuel.
AM
Mode 2
- Fill the test tank with FUEL-D, set test temperature 60±3℃, and soak test module during
300hr (Install the test module that is sodden)
- Set the test equipments that the specified temperature is maintained after install test
moduel that is sodden in FUEL-D in the test tank with test fuel more than 1/2.
D
- Operate repeatedly 3sec ON – 2sec OFF during specified time with test voltage after
connect FEED and RETURN.
N
- Basic evaluation data after the durability test
YU

H
6.3.4 Stroke durability test

1) Purpose

래[csr0214]시험평가2실 2016.08.26 17.1
- To check the damage of fuel pump module by the repeated stress of contracting and
d.
expanding the fuel tank
t
- Stroke condition: Original installation height→ Expanded (2 sec)→ Return (2 sec)→
.,L
Contracted (2 sec)→ Return (2 sec) / 1 cycle
- Test period: 30,000 cycles ((1 cycle: 8 sec, refer to Figure 18)
Co
- Current on the pump: Based on the standard of drawing (Do not apply current to the
sender.)
- Stroke height: Plastic (± 15mm), Steel (± 10mm)
Classification Evaluation condition
Up and down
stroke
The number of
d
Plastic (± 15mm), Steel (± 10mm)
In
30,000 cycle (1 cycle : 8sec, Refer to Figure 18)
stroke
- Repeat load test equipment
AM
Apply current
(refer to the
drawing)
Stroke Stroke
Resistance
Tank installation Tank
height installation
Resistance height
D
Max. 20mm
N
Fix the lower part of

the module

YU
- Fix the product to the evaluation device.

-For the initial installation height, comply with standards on the drawing. Then, check it is
operating properly, referring to the stroke standards.
- Forcibly short-circuit the power connector of the pump.
H
- Apply current to the module power unit.

- Measure voltage drop of the module power unit. (Check the sender by resistance value)
- Basic characteristic data after the durability test
-As for evaluation results, comply with evaluation standards in Requirement 5.
래[csr0214]시험평가2실 2016.08.26 17.1
d.
t
.,L
6.4 Others
6.4.1 Drop test
Co
1) Purpose
- To check impact stability of the fuel pump module
- Impact condition: Free drop
d
- Impact direction: Front, left, left and right when installed to an actual vehicle
- Function drop: Collision load of 40G, Collision time: 10 to 15ms
In
- Rupture drop: No limit applicable, Collision time: 10 to 15ms
- Drop impact test equipment
AM
D

N
- Install a product to the jig

- Install an acceleration sensor to the evaluation jig.
- Freely drop the product to check a height in the function drop test conditions
YU
(collision load and impact period).

- After installing specimen to the jig and evaluate the function drop test to check
performance of the product.
- Install the product to the jig after checking performance, increase collision load at the
H
highest point of the device, and freely drop it to rupture the supporting structure of the
bracket on the fuel pump module.
(If the supporting structure is not ruptured, freely drop it repeatedly until it is broken.)
- Repeat the test in the same method in each direction; left, right, front and rear.
- However, one specimen is tested in only one direction.
래[csr0214]시험평가2실 2016.08.26 17.1
d.
- Function drop test: Shape and damage of the module, pump damage and function
degradation.
- Rupture drop test: Whether the shape on the plate surface is damaged or broken.
t
.,L
Co
6.4.2 Fuel pump noise characteristic

1) Purpose
d
- To evaluate noise when it is attached to the fuel tank.
In
- Test voltage: 13.5±0.1V(The test voltage of fuel pressure controller type is applied to the
reference input FPCM).
- Fuel temperature: Room temperature
.Winter fuel at low temperature: Evaluate the noise in 30 min after soaking the specimen at
AM
–20℃ for 12hr with the tank as assembled

.Summer fuel at low temperature: Evaluate the noise in 30 min after soaking the specimen
at -10℃ for 12 hr with the tank as assembled
(If it is not possible to supply winter fuel because it’s summer, it is allowed to use summer
fuel for the test, instead of the winter fuel):
D
- Test fuel: Refer to the test fuel by item in attachment 2

- Fuel oil level: WARNING, 1/2, FULL OF FUEL TANK
N
YU
H

래[csr0214]시험평가2실 2016.08.26 17.1
t d.
.,L
- Anechoic chamber and FFT ANALYZER
- BIW as assembled as in an actual vehicle
Co
d
In
AM
D
N

YU
[Unapplied type of fuel pressure controller]

- Install the fuel tank to BIW as assembled as in an actual vehicle. (According to the fuel tank
band or bolting installation method)
- Install the product to the fuel tank and check oil level by resistance value of sender, filling
H
fuel
- Install the microphone to a point 600mm upward from the module.
- Apply power and adjust valve under standard pressure on the drawing to measure peak and
overall value of the noise.
[Fuel pressure controller type]
래[csr0214]시험평가2실 2016.08.26 17.1
- Install the fuel tank to BIW as assembled as in an actual vehicle. (According to the fuel tank
d.
band or bolting installation method)
- Install the product to the fuel tank and check oil level by resistance value of sender, filling
fuel
t
- Install the microphone to a point 600mm upward from the module.
.,L
- After operating the fuel pump module under the following conditions to measure the noise
make respectively.
Co
(However, test of idle condition will be performed according to pass flow rate of the subject
vehicle engine.)
IDLE condition Full Duty condition
Target pressure
4.8 4.8
(bar, abs)
Pass flow rate of

U-ENG : 90
R-ENG : 100
d 13.5V feed rate
In
flowmeter(LPH) (Engine consumption + Return
flow rate)
AM
- Data of measuring peak and overall value of noise

- Overall noise is less than 55dB(A).
- Meet the following noise regulation value of the frequency-dependent.
[Evaluation standard]
D
N
YU
A(dB(A)) B(dB(A)) C(dB(A))

H
(0~250Hz) (250~800Hz) (800~10KHz)

Unapplied type of fuel pressure controller 33 45 26
Fuel pressure IDLE condition 28 40 26
controller type Full Duty condition 33 45 26

래[csr0214]시험평가2실 2016.08.26 17.1
d.
- As for items which are not specified, pre-approval from responsible managers in HKMC is
t
.,L
6.4.3 Wireless frequency interruption
1) Purpose
Co
- To check the noise characteristic of the module by electromagnetic waves
- Test fuel: Diesel
- Test voltage: 13±0.5V
- Test pressure: Pressure specified in the drawing (Segment at the feed side)
- Test oil level: Oil level at normal capacity of 50%
d
In
- Electromagnetic wave test equipment
- COMPLY WITH ES 96200-00.
AM
- Evaluation data of single component compatibility in ES 96200-00

- As for evaluation results, comply with evaluation standards in Requirement 5. .
(ES 96200-00: comply with the test items by component specified in ES)
D

N
7. Relevant standards
1) KS Standards
YU
- KS D 9502: Corrosion resistance test method of vehicle parts

2) HKMC Standards
Classification SPEC NO Specification Note
MS MS184-01 Pb-free solder paste
H
Standard test method-plastic molding products for

MS MS200-37
fuel
MS MS201-01 Marking method of vehicle component materials
MS MS201-02 Ban on using harmful materials for vehicles
Material performance of POLYAMIDE6 for
MS MS211-44
vehicles(for unreinforcing fillers)
래[csr0214]시험평가2실 2016.08.26 17.1
Material performance of POLYAMIDE66 for

MS MS211-46
d.
vehicles (for unreinforcing fillers)
MS MS269-03 Soft molding rubber standard
Synthetic rubber- for protection against dust in the
MS MS266-10
t
fuel tank
MS MS913-02 Contact point material for fuel sender
.,L
ES ES01000-00 Symbol mark indication standardization
ES ES05213-00 Commercial tolerance (Rubber part)
ES ES05224-00 Commercial tolerance-Plastic mouldings
Co
ES ES05206-00 Commercial tolerance (PRESS processing )
ES ES05227-00 Tightening torque of bolt
ES ES31110-20 Fuel pump module – Gasoline, FFV
ES ES31105-20 Variable pressure control DC fuel pump controller
ES ES31111-01/02/ Fuel pump (GSL, DSL)
ES
ES
ES94460-10/20
ES31380-01
d
Fuel sender assembly
Fuel pressure regulator
In
ELECTROMAGNETIC COMPATIBILITY (Except
ES ES96200-00
for item 5 and 6)
ES ES91101-00 ELECTRICAL WIRING-COMPLETE
Wiring harness marking and methods on the
ES ES91100-00
drawing
AM
ES ES91500-00 Connector general for low voltage and wiring

Appearance evaluation standards on soldering
ES ES90000-01
areas of electronic unit
Exfoliation evaluation standards of electronic unit
ES ES90000-02
semi-conductor
Electronic unit circuit board environment reliability
D
ES ES90000-03
standard
Pb-free environment reliability test standards for
ES ES90000-04
N
vehicles
ES ES95400-10 Environment test for vehicle electronic equipment
KS-R 3017, M2612,
KS Electrical motor for vehicle fuel pump
YU
R1034
8. Annex
This Annex specifies minimum required quantities by evaluation item.
H
Annex Table 1. Minimum evaluation quantities

Evaluation quantities
Evaluati
(Quantity of samples to test /Quantity of samples to
on method Evaluation item
record)
No
Prototype (ESIR) Mass-production
래[csr0214]시험평가2실 2016.08.26 17.1
Basic
d.
6.1.1 performance(Room ALL ALL
temperature)
t
Strength on the port
6.1.2 3/3 3/3
.,L
part
RESERVOIR CUP
6.1.3 3/3 3/3
LEAK characteristic
Co
CHECK VALVE
6.1.4 3/3 3/3
opening characteristic
Basic characteristic
Assist pump suction

6.1.5 3/3 3/3
performance
Assist pump back
6.1.6
pressure performance
Remaining pressure
d 3/3 3/3
In
6.1.7 3/3 3/3
conservation
Nylon tube tension
6.1.8 3/3 3/3
force
AM
Fuel supplying
6.1.9 3/3 3/3
stability
Accuracy of Fuel
6.1.10 sender full status 3/3 3/3
instruction
D
6.2.1 High temperature test 3/3 3/3

6.2.2 Low temperature test 3/3 3/3
Environ-ment
N
Cold and heat cycle

6.2.3 3/3 3/3
test
YU
High temperature and

6.2.4 3/3 3/3
humidity test
6.2.5 Salt water spray test 3/3 3/3
Complex environment
6.3.1 6/6 6/6
H
operation durability
Durability test
Vibration resistance
6.3.2 3/3 3/3
and durability
6.3.3 ON and off durability 3/3 3/3
6.3.4 Stroke durability test 3/3 3/3
8/8 (2ea for the front 8/8 (2ea for the

6.4.1 Drop test /rear/ left, right and front, rear, left, right
side) and side)
6.4.2 Noise characteristic 20/20 5/5
Other
Wireless frequency
6.4.3 3/3 3/3
interruption
* Supplier itself shall manage Mill Sheet of components and submit it at the request of H/KMC.
* If the responsible team of H/KMC requests, the test item and the number of specimens can be
altered after discussion.
* The number of specimens for evaluation tests specified in Annex Table 1 is the required minimum
quantity by H/KMC, and Supplier (which requests approval) is responsible for adjusting the quantity to
secure reliability of components.
* When submitting test reports, comply with the following instructions:
1) Specify Pass/Fail judgment of each test item and test results by the number of test pieces.
2) Attach and submit pictures of components and test equipment (the installed status) before and
after the test.


Es31110-30 Rev.07 Eesf2884 en

Uploaded by

Copyright:

Available Formats

Es31110-30 Rev.07 Eesf2884 en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Es31110-30 Rev.07 Eesf2884 en

Uploaded by

Copyright:

Available Formats

래[csr0214]시험평가2실 2016.08.26 17.

1 ELECTRIC FUEL PUMP 6 HOSE

5 SPRING-CUSHION 11 SENDER ASS'Y

3.2 Fuel Tank Complete

4. General and indications on the drawing

4.2 Dimension and thickness

4.3 Material and plating specification

4.4 Working condition

4.5 Evaluation condition

allowance of evaluation temperature in this engineering standard is ±2℃.

4.6 Indications on the drawing

. W/H connector specification, terminal arrangement, W/H specification

There shall be neither crack, corrosion, deformation,

There shall be no leakage under pressure of 50kPa.

180N or more in each direction

Check valve closing

Minimum oil lever shall be 10mm or less. 6.1.4 ● ●

Shall be higher than the maximum consumption

ASSIST pump back

Complex Satisfy basic performance (6.1.1, 6.1.4, 6.1.5,

ON-OFF After the test, satisfy basic performance in Article

- Satisfy basic characteristic (4.5.1)

Stroke durability cable of pump power terminal shall be within 10%

1F-SG-00002 현대ㆍ기아 자동차

Satisfy the basic performance. There shall be no

Noise The peak of noise by frequency shall be within standard

- Test pressure: Pressure in the drawing

- Performance testing equipment

4) Test method and order

1F-SG-00002 현대ㆍ기아 자동차

the test once fuel temperature satisfies standard temperature.

6.1.2 Strength on the port

- Test direction: X, Y, Z (3 directions)

4) Test method and order

- Tension and pressure load value of each direction \

4) Test method and order

- Measure initial weight of a reservoir cup.

at a time the check valve is dipped.

1F-SG-00002 현대ㆍ기아 자동차

4) Test method and order

- Fill the temporary chamber with test fuel by means of a beaker.

6.1.5 Suction performance of assist pump (JET NOZZLE)

(1). General type

QS QR P1 Pressure gauge for measuring

(2). Saddle type

1F-SG-00002 현대ㆍ기아 자동차

- ① RETURN JET TYPE (Regulator return type)

- As for evaluation results, comply with evaluation standards in Requirement 5.

1F-SG-00002 현대ㆍ기아 자동차

6.1.7 Remaining pressure conservation characteristic

- Test fuel: REG DIESEL

4) Test method and order

- For evaluation results, comply with evaluation standards in Requirement 5.

6.1.8 Nylon tube tension force

Tension (universal) test

1F-SG-00002 현대ㆍ기아 자동차

- Leave alone the tube at -40°C for 4hr.

- For evaluation results, comply with evaluation standards in Requirement 5.

6.1.9 Fuel supplying stability