Transcript CATERPILLAR Common Rail Fuel System

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CATERPILLAR
Common Rail Fuel System
CATERPILLAR Common Rail Fuel System
CATERPILLAR Common Rail Fuel System
CATERPILLAR Common Rail Fuel System
Orifice
CATERPILLAR Common Rail Fuel System
Electronic Control Module
(ECM)
• ECM Controls:
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CATERPILLAR Common Rail Fuel System
Fuel Pressure
Speed Governing
Air/Fuel Ratio
Start/Stop Sequence
Engine Protection
Devices/ Diagnostics
Fuel Pump Function
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Pump Raises Pressure
ECM tells Injector to Fire
Rail Pressure Drops
ECM Detects Pressure Drop
–Sensed by Fuel Rail
Pressure Sensor
• ECM tells Pump Solenoid to
Increase Volume
–Also tells Pump Solenoid
to Spill fuel once pressure
is reached
• Do it Again!
CATERPILLAR Common Rail Fuel System
Oil lubrication
Fuel Leak off to Tank
Fuel in from
Secondary Filter
To Fuel HP
Manifold
Pump Speed
To
Secondary
Filter
Position Sensor
Locks the Pump
CATERPILLAR Common Rail Fuel System
From
Primary
Filter
Transfer Pump
Driven by High Pressure Pump
Draws Fuel through Primary
Filter
Output Pressure
300 to 600 kPa
Transfer Pump Primed by
Priming Pump
Hand or Electric
CATERPILLAR Common Rail Fuel System
High Pressure Fuel System
Do’s & Don’ts
Fuel Manifold
Do Check for leaks
Do Not Loosen HP Connection
with Engine Running
Do Replace HP Pipes After they
are Loosened
Do Replace ALL Hp Pipes if new
manifold is Installed
Do Not Force Pipes to Fit
Do Cap Manifold and Injector
Connections Immediately when
HP Pipe is removed
CATERPILLAR Common Rail Fuel System
Injector Lines
High PRV
Rail Pressure Sensor
Fuel Pressure Relief Valve
Protects System from OverPressure
Opens at Constant Pressure of 160
MPa (23,000 PSI)
Withstands Spikes to 190 Mpa
(27,500 PSI)
Returns fuel to Tank
CATERPILLAR Common Rail Fuel System
High Pressure
Relief Valve
Fuel Return from Head
Excess Fuel Returned to
Transfer Pump
Not High Pressure
CATERPILLAR Common Rail Fuel System
Fuel
Return
from
Head
LIne
Injector Function
Injector De-energizes
Valve Closes
Unused fuel flows back to
Transfer Pump via passage
in the Head
CATERPILLAR Common Rail Fuel System
Fuel Injector
Do’s and Don’ts
Do Write down the Injector
Serial Number
and Confirmation Code before
you install the Injector
Do use Cat ET to Program ECM
with proper Injector Trim File
Do Look for the Trim File CD in
the Injector Box
CATERPILLAR Common Rail Fuel System
Injector Adaptive TRIM
Fuel System Optimization Routine
Runs every hundred hours or so
Audible changes when engine is running
NO performance or Power Changes
Everything’s OK
Similar to HD ACERT engines
CATERPILLAR Common Rail Fuel System
CATERPILLAR Common Rail Fuel System
Cat Common Rail Fuel System
C175
Advantages
High Pressure Rail
Meets emissions
Lower fuel consumption
Better transient response
High Pressure
Pump
Primary Fuel Filter/
Water Separator
Cooler
Secondary Fuel Filters
Electric Priming
Pump
CATERPILLAR Common Rail Fuel System
Fuel Tank
Cat Common Rail Fuel System
Low Pressure Fuel System
 FTP
 Electric Priming
 Filtration
CATERPILLAR Common Rail Fuel System
Cat Common Rail Fuel System
Fuel System
 HP Pump
 Double Wall Lines
 Double Wall Rails
 Flow Limiter
 Injector
CATERPILLAR Common Rail Fuel System
Cat Common Rail Fuel System - HP Rail
HP Rail
Low Pressure
Injector return
Double Wall
Crossover Line
CATERPILLAR Common Rail Fuel System
Pressure Sensor
Double Wall
Lines From HP Pump
To Rail
High Pressure Fuel System Hardware
PRV
PRV Outlet
HP Outlet
Oil Supply
Camshaft
FTV Drive
Oil Return
CATERPILLAR Common Rail Fuel System
Flow Control
Valve
Flow Limiter
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Flow Limiter
 Protection Device
Against Cylinder Over
Fueling
 Piston Moves With
Every Injection
 Trips at Set Point To
Prevent Continuous
Injection and Remains Spring
Shut
Piston
CATERPILLAR Common Rail Fuel System
CATERPILLAR Common Rail Fuel System
CATERPILLAR Common Rail Fuel System