Professional Documents
Culture Documents
Chapter 19 - Common Rail PDF
Chapter 19 - Common Rail PDF
Title, Edition
Author(s)
Title, Edition
Author(s)
emissions, improved
power and fuel economy !
This chapter!
Solenoids
ECM
Fuel Pressure
Regulator
Injectors
Title, Edition
Author(s)
The latest high pressure common rail systems are capable of different
injection events in one combustion cycle.
Title, Edition
Author(s)
The quantity of fuel injected per degree of crank angle rotation is referred to as the fuel
rate.
Injection rate affects emissions, performance, fuel economy and even engine noise levels.
A specific injection rate will correspond to any given engine speed and load condition as
well as operating condition (i.e. oil, fuel and air temperature, boost pressure etc..)
Title, Edition
Author(s)
Title, Edition
Author(s)
Common rail has the capability to inject fuel very late during the power
stroke or exhaust stroke.
The fuel is used to raise the temperature of the filter during active
regeneration. (Burning away trapped soot)
Title, Edition
Author(s)
10
Title, Edition
Author(s)
Injectors
High pressure pump
Fuel rail
Relief valve
Rail pressure sensor
Fuel pressure regulator
11
Relief
Valve
High-Pressure Fuel
Rail
Return
Fuel
Injectors
Title, Edition
Author(s)
12
Title, Edition
Author(s)
13
CR Injectors
Title, Edition
Author(s)
14
CR Injectors - Types
Piezo-Electric
Actuator
Electromagnetic
Solenoid
These DMAX injectors
1. Electromagnetic
solenoids
2. Piezoelectric inline
actuators
Title, Edition
Author(s)
15
CR Injector Comparisons
Title, Edition
Author(s)
16
Title, Edition
Author(s)
17
Solenoid CR Injection
Title, Edition
Author(s)
18
Solenoid CR Injection
Sequence
Title, Edition
Author(s)
19
Solenoid CR Injection
1. The injector at rest
High pressure fuel is at
the bottom and top of the
needle valve but no
injection takes place since
the larger surface area on
top of the needle valve
hold the nozzle against its
seat.
Title, Edition
Author(s)
20
Fuel Return
Solenoid CR Injection
2. Injection
The solenoid is energized and lifts
the pilot needle or check ball from its
seat above the needle valve.
Fuel pressure above the needle valve
drops and fuel pressure below the
valve forcing the nozzle from its seat.
Restriction
Title, Edition
Author(s)
21
Solenoid CR Injection
3. End of Injection
The solenoid is de-energized and the
check ball return to its seat.
Fuel at rail pressure builds-up quickly
above the needle valve forcing it
against its seat thus ending injection
Title, Edition
Author(s)
22
23
Pilot Injection
24
Solenoid
Inline Piezo
Actuator
Title, Edition
Author(s)
25
Title, Edition
Author(s)
26
Title, Edition
Author(s)
27
Piezo-electric Principles
Title, Edition
Author(s)
28
Piezo-electric Principles
29
30
Title, Edition
Author(s)
31
Title, Edition
Author(s)
32
Title, Edition
Author(s)
33
Title, Edition
Author(s)
34
Exiting
Fuel
Title, Edition
Author(s)
35
The injection event can end quickly by changing the direction of current
flow through the stack of piezo crystals.
Without pressure from the piezo crystals, hydraulic force closes the
mushroom valve and pressure returns to the top of the control piston
Title, Edition
Author(s)
36
37
Title, Edition
Author(s)
38
CR Injector Failure
39
CR Injectors Lines
High Pressure
Lines
Injectors
Fuel Return
Lines
The injector and lines on the 2006 6.6L DMAX engine are all located
outside the scalloped valve covers to prevent fuel leaks into the engine
Title, Edition
Author(s)
40
CR Injectors Lines
Quill Tube
High
Pressure
Connection
These Cummins B series injectors use a quill tube to connect an external injector line
with the injector.
These tubes must be carefully tightened and the high-pressure connection cleaned
during assembly to prevent leakage!
Title, Edition
Author(s)
41
CR Injectors Lines
This early 6.6l DMAX has line fitting clamps to prevent loosening
and leakage of lines.
Title, Edition
Author(s)
42
CR Injector Lines
High
Pressure
Lines
Rail
Pressure
Sensor
Fuel Rail
Title, Edition
Author(s)
43
44
Title, Edition
Author(s)
45
Characteristics of CR injectors
cause fuel delivery variations over
a wide range of operation
(pressure & actuation time)
Trim codes
Trim codes or injection quality adjustment (IQA) codes for each injector
are entered in the ECM module and used to compensate for delivery
quantity variations
Title, Edition
Author(s)
46
High pressure pumps take low transfer fuel pressure and pressurize the fuel to
the for injection.
Title, Edition
Author(s)
47
Radial Plungers
Low Pressure
Gear Type
Transfer Pump
Fuel Return
Inlet/Outlet
Check Valve
High Pressure
Outlet
Title, Edition
Author(s)
48
Fuel Pressure
Regulator
49
Bosch CP-3
High
Pressure
Pump
50
High Pressure
Pump
51
Title, Edition
Author(s)
52
Radial plunger pumps use three lobed cams to driven by the engine to pressurize fuel.
Check valves in the end of the plunger pistons operate to control flow of fuel in and
out of the pumping chambers
Title, Edition
Author(s)
53
A fuel pressure regulating valve controls fuel pressure using a PWM signal sent from the
ECM.
With no signal, all pressurized fuel is sent to the fuel rail.
Increasing the PWM signal lowers fuel pressure to the rail
Title, Edition
Author(s)
54
Title, Edition
Author(s)
55
Title, Edition
Author(s)
56
Fuel Rail
Fuel Rail
Fuel Rail
Inlet
Fuel Rail
Pressure Sensor
57
Fuel Rail
Fuel Rail
Title, Edition
Author(s)
58
Title, Edition
Author(s)
59
Pressure Protection
60