Engine Works & Wears

Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics
Single Fuel System

Function of Fuel System

Meters the amount of fuel to achieve desired power Regulates engine speed and timing sequence Helps control emissions

Fuel System Operation

Types of Fuel Systems

Pump & Line
Current Scroll Fuel System New Scroll Fuel System Sleeve Metering Fuel System (SMFS) Program Electronic Engine Controls (PEEC) 1981 MUI 1983 NSFS 1988 EUI 1994 HEUI

Unit Injection
MUI EUI HEUI Common Rail (Single Fuel)

1973 CSFS

Pre 1970 1970

1975

1980

1985

1990

1995

2000

2005

Timeline
1974 SMFS 1987 PEEC 2004 Rail

Fuel Delivery - History

Pre-Combustion (PC) Direct Injection (DI)
Fuel Line Fuel Line Fuel Injector Electrical Wire Glow Plug Pre-Combustion

Fuel Injector
Fuel Injector Housing Nozzle Assembly Mechanically Controlled Unit Injector

Heat Plug

Piston

Piston

Pre-Combustion

Direct Injection Pencil Style

Direct Injection Unit Injector

Sleeve Metering Fuel System

Barrel

Plunger

Fill Port

Sleeve Spill Port

Filling

Begin Injection

Continue Injection

End Injection

Scroll Metering Fuel System

Pump & line governor Few moving parts Simple mechanical governor Easy starting & service More tolerant of dirt Economical

MUI System
A unit injector is positioned above each cylinder A mechanically actuated governor controls fuel rate (scroll metered) with flyweights and springs Timing is fixed

EUI System

A unit injector is positioned above each cylinder An Electronic Control Module (ECM) controls fuel rate and timing Injectors are mechanically actuated by a camshaft

EUI - Injector Fill

Without pressure from the rocker arm, a spring keeps the plunger retracted

Fuel flows into the injector through the fill / spill port, past the solenoid valve and into the barrel

EUI - Injection
On a signal from the ECM, the solenoid closes the fuel valve Pressure elevates at the tip to the 5,500 psi needed to unseat the valve Injection begins

EUI - Injection
Fuel continues to inject until the ECM signals the solenoid to open the valve Injection timing and duration is controlled by the ECM

HEUI System
A unit injector is positioned above each cylinder An Electronic Control Module (ECM) controls fuel rate, timing, and injection pressure The injector is hydraulically actuated

Cat Fuel System Single Fuel

Fuel Manifold

Pump

C6.6

Injector

Fuel System Wear & Failure Causes

Short unit injector life due to excessive abrasive particles in the fuel Abrasive particles damage sealing surfaces causing leakage of high pressure fuel and low engine power Abrasive particles are inherent in most fuels Most particles can be removed by using High Efficiency filters Injector seizure due to excess water in the fuel Always small amounts of water in fuel, which is harmless Excess water in fuel reduces the lubricating film strength of fuel and causes seizure of the injector plunger and barrel Maximum amount of allowable water in fuel is 0.1%

Fuel System Wear & Failure Causes

Injector sticking or seizure due to fuel overheating Fuel in the injector cooks and produces varnish which causes components to stick or seize Viscosity of hot fuel is inadequate and the fuel film thickness will not provide adequate protection against scuffing or seizure of the plunger and barrel Fuel overheating can be caused by operating in extreme ambient temperatures. An auxiliary fuel cooler installed in the fuel supply line to the cylinder heads may be required to limit fuel temperatures Running fuel tank too low, or running out of fuel causes the fuel to cycle through the engine too frequently and becomes very hot. This can be avoided by keeping the fuel tank levels at full or above

Fuel System Wear & Failure Causes

Poor quality oil Fuel may be low in viscosity or lubricity. Fuel which is old or oxidized often contains excessive gums or resins which promotes injector sticking or seizure.

Effect of Work Environment

Dust Temperature/Climate Hours of continuous operation Terrain

System Improvement
Reduce system damage caused by fuel
Water Separator Primary Fuel Filter Bypass Flow

Minimize tip failure caused by aeration

Maintain fuel supply pressure

Stripping Out Water

Water Separator
Second line of defense All free water 87% emulsified water Injector damage

Removing Larger Debris

Primary Fuel Filter
10+ micron particle retention prevents premature secondary fuel filter plugging protects fuel transfer pump

Remove Fine Abrasives

Secondary Fuel Filter
2 micron and larger 98% efficient Reduces wear on fuel injectors and pumps Essential for higher pressure systems Extends life of older systems as well

Double Filter/Double Life

Series filtration
Second filter safety net Second filtering pass Filter failure - Double injector wear life

Engine Works & Wears

Engine Wear Combustion Process Internal Components External Components Cooling System Lubrication System Fuel System Air System Electronics

Air Intake & Exhaust System Functions

Inlet air from air cleaners

Boost air at 300 - 400

Inlet air from air cleaners

Exhaust out Air manifold From exhaust ports at cylinder heads

Provide adequate quantities of clean filtered intake air

Removes exhaust gases from the cylinders and reduces exhaust noise

Compresses the intake air into the cylinders in order to product more power

Air System

Air System Components

Precleaner Air Filters Filter Service Indicator Turbochargers Aftercooler Intake & Exhaust Manifolds Muffler

Air System Operation

Flow
1. 2. 3. 4. Precleaner Air Filters Turbocharger Intake Manifold & Cylinder Head(s) 5. Combustion Chamber 6. Exhaust Manifold

Wear
Turbocharger Bearings Seals

Air System Wear & Failure Causes

Single most common problem dust ingestion
Causes accelerated abrasive wear of piston rings & liners Most often caused by inlet leaks around flexible joints in air inlet piping May also be caused by defective/damaged air filters, or poor maintenance practices

Plugged air filters Turbo failures Coolant to air leaks in the aftercooler Hydraulic lock