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Fuel System C6.6 - Caterpillar
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Illustration 1
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Fuel System C15, C16, and C18 - Caterpillar Electronic Engine
Electric diagram of the basic fuel system (typical example)
(1) Electronic unit injector
(2) Solenoid for the fuel injection pump
(3) Wastegate solenoid (if equipped)
(4) Position sensor (fuel injection pump)
(5) Fuel injection pump
(6) Crankshaft position sensor
(7) Boost pressure sensor
(8) Fuel pressure sensor
(9) Engine oil pressure sensor
(10) Inlet air temperature sensor
(11) Coolant temperature sensor
(12) Diagnostic connector
(13) Electronic control module (ECM)
Low Pressure Fuel System
Illustration 2
Low-pressure fuel system (typical example)
(1) Primary fuel filter
(2) Water separator
(3) Fuel transfer pump
(4) ECM that is fuel cooled.
(5) Fuel cooler (optional)
(6) Secondary fuel filter
(7) Fuel Injection Pump
(A) Outlet for high-pressure fuel to the high-pressure fuel manifold
(B) Return from the Pressure Relief Valve (PRV) on the high-
pressure fuel manifold
(C) Return to fuel tank
(D) Return from the Electronic Unit Injectors
(E) Fuel in from the fuel tank
Fuel is drawn from the fuel tank (E) through a 18 micron Primary
fuel filter (1) and the Water separator (2) to the Transfer pump (3).
The transfer pump increases the fuel pressure to 400 kPa (58 psi)
to 500 kPa (72.52 psi). The fuel is pumped through the optional
fuel cooler (4) to the ECM (5). The fuel cools the ECM. The fuel
passes from the ECM to a 4 micron fuel filter (6). The fuel filter
removes particulates from 18 microns to 4 microns in size in order
to prevent contamination of the high-pressure components in the
fuel system. Fuel passes from the Fuel filter to the Fuel injection
pump (7). The fuel is pumped at an increased pressure to the Fuel
manifold (rail).
Excess fuel from the Fuel manifold (rail) returns to the tank through
a non-return valve. There is a small orifice in the fuel filter base in
order to purge any air back to the tank.
The leak off fuel from the electronic unit injectors returns from a
connection in the cylinder head to the pressure side of the transfer
pump.
High Pressure Fuel System
Illustration 3
High-pressure fuel system (typical example)
(1) Electronic unit injector
(2) Fuel manifold (rail)
(3) Fuel pressure sensor
(4) Fuel pressure relief valve
(5) Fuel transfer pump
(6) Solenoid for the fuel injection pump
(7) Fuel injection pump
(8) Fuel pump gear
The fuel injection pump (7) feeds fuel to the high-pressure fuel
manifold (2). The fuel is at a pressure of 70 MPa (10152.7 psi) to
130 MPa (18855 psi). A pressure sensor (3) in the high-pressure
fuel manifold (2) monitors the fuel pressure in the high-pressure
fuel manifold (2). The ECM controls a solenoid (6) in the fuel
injection pump (7) in order to maintain the actual pressure in the
high-pressure fuel manifold (2) at the desired level. The high-
pressure fuel is continuously available at each injector. The ECM
determines the correct time for activation of the correct electronic
unit injector (1) which allows fuel to be injected into the cylinder.
The leakoff fuel from each injector passes into a drilling which runs
along the inside of the cylinder head. A pipe is connected to the
rear of the cylinder head in order to return the leakoff fuel to the
pressure side of the fuel transfer pump.
Components of the Fuel Injection System
The fuel injection system has the following mechanical
components:
a. Primary filter/water separator
The primary filter/water separator is located between the fuel tank
and the priming pump.
b. Fuel priming pump
Illustration 4
Hand fuel priming pump
The pump has a plunger (1) which is manually operated in order to
prime the fuel system. Air is removed from the fuel system to the
fuel return line to the tank. The fuel transfer pump is located in the
fuel injection pump.
-Fuel transfer pump
-Secondary fuel filter
-Fuel injection pump
-Fuel injectors
-Fuel manifold
-Pressure relief valve
-Fuel pressure sensor
Fuel Pump Assembly
The fuel pump assembly consists of a low-pressure transfer pump
and a high-pressure fuel injection pump. The pump assembly is
driven from a gear in the front timing case at half engine speed.
The fuel injection pump has two pistons that are driven by a
camshaft. There is a cam for each piston and each cam has three
lobes. The fuel injection pump delivers a volume of fuel six times
for each revolution. The stroke of the pistons is fixed. The injector
will use only part of the fuel that is delivered by each stroke of the
pistons in the pump. The solenoid for the fuel injection pump is
controlled by the ECM in order to maintain the fuel manifold
pressure at the correct level. The solenoid allows excess fuel to be
diverted away from the fuel manifold and back to the tank. A
feature of the fuel injection pump allows fuel to return to the tank
continuously.
Fuel Injection Pump
Illustration 5
The fuel injection pump has the following operation:
-Generation of high-pressure fuel
The fuel output of the fuel injection pump is controlled by the ECM
in response to changes in fuel pressure.
Fuel Transfer Pump
Illustration 6
-The fuel transfer pump is a serviceable component.
-The fuel transfer pump provides a relatively low fuel pressure to
the fuel injection pump. The fuel transfer pump has a regulating
valve in order to control the low pressure. The fuel transfer pump
circulates fuel through the primary fuel filter and the secondary fuel
filter. The fuel transfer pump has a fuel bypass valve in order to
allow the low-pressure fuel system to be primed.
Shutoff
The engine shuts off by interrupting the fuel supply. The engine
electronic control module (ECM) specifies the amount of fuel. The
quantity of the fuel that is required by the ECM is set to zero.
Control
Illustration 6
#Electronic control for the fuel system (typical example)
The ECM determines the quantity, timing, and pressure of the fuel
in order to be injected into the fuel injector.
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The ECM uses input from the sensors on the engine. These
sensors include the speed/timing sensors and the pressure
sensors.
The ECM controls the fuel pressure by increasing or decreasing
the flow of fuel from the fuel injection pump. The ECM controls the
timing and the flow of fuel by actuating the injector solenoid.
The amount of fuel is proportional to the duration of the signal to
the injector solenoid.
Fuel Injectors
Illustration 7
-The fuel injectors are not serviceable.
When the ECM sends a signal to the injector solenoid, a valve
inside the injector opens. The valve allows the high-pressure fuel
from the fuel manifold to enter the injector. The pressure of the fuel
pushes the needle valve and a spring. When the force of the fuel
pressure is greater than the force of the spring, the needle valve
will lift up.
The timing and duration of injection is controlled by a solenoid
valve in the injector. The valve has two positions. In the closed
position, the valve closes the inlet to the injector. In this position,
fuel above the injector needle is allowed to vent through the leakoff
port.
In the open position, the valve opens the inlet to the injector.
Simultaneously, the valve closes the leakoff port in order to allow
high-pressure fuel to flow to the needle. When the solenoid valve is
closed, some fuel escapes past the valve in order to vent through
the leakoff port. A certain volume of fuel always flows from the
leakoff port. If the volume of fuel increases beyond a critical level,
the fuel injection pump will not be able to maintain pressure in the
fuel manifold. The faulty electronic unit injector must be identified
and replaced.
When the signal to the injector ends, the valve closes. The fuel in
the injector changes to a low pressure. When the pressure drops
the needle valve will close and the injection cycle stops. When the
needle valve opens, fuel under high pressure will flow through
nozzle orifices into the cylinder. The fuel is injected into the cylinder
through the orifices in the nozzle as a very fine spray.
The needle valve has a close fit with the inside of the nozzle. This
makes a positive seal for the valve.
Fuel Manifold
Illustration 8
The fuel manifold (1) stores high-pressure fuel from the fuel
injection pump. The high-pressure fuel will flow to the injectors.
The fuel pressure sensor (2) measures the fuel pressure in the fuel
manifold (1).
The relief valve (3) will prevent the fuel pressure from getting too
high.
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2 Responses to "Fuel
Fuel System C6.6 - Caterpillar
Electronic Engine"
ANONYMOUS THURSDAY, DECEMBER 15, 2022 AT 5:39:00 PM
PST
To start the c 6 engine what rail presure need
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ANONYMOUS TUESDAY, JUNE 20, 2023 AT 7:16:00 PM PDT
up
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