Cummins Service Training School

Daventry
Fuel System
Fuel System
 Fuel System
Modular Common Rail System (MCRS)
Electric Lift Pump for Engine Fuel Supply
Fuel Delivery Pump (Gerotor)
Mechanical Dump Valve (MDV)
Fuel Pump Pressurizing Assembly (FPPA)
 Fuel System
•The Q50 pump is called a 5 X 2; 5 pumping plungers and a 2 lobe profile
per plunger camshaft.
•The pump has retracting plungers unlike the Pegasus pump that has
floating plungers.
•The pumping plungers are not ceramic rather, they are metal with a 3
micron wear resistant coating. The coating process is quite common to
other Bosch components.
•The Gerotor drive shaft is a spline drive. It is lubricated by fuel.
There are back to back oil and fuel seals with a weep hole between
them, like we have done on the PT fuel pump.
 Fuel System
Fuel Delivery Pump (Gerotor)
Accumulator (Produces 5-7 bar fuel pressure)

Fuel Pump
Pressurizing
Assembly

Fuel Pump
(Produces 1600 bar Electric Lift Pump
nominal maximum (Produces 3-5 bar
fuel pressure) fuel pressure)

Stage 1
Stage 2
Fuel Filter Fuel Filters
(15 micron) (5 micron)
 Fuel System

Fuel Pressure Sensor

Measures fuel
pressure after stage 1
& before stage 2

Stage 2 filtration:-
3 x 5 micron filters
Fuel Temperature
Fuel Injectors
Modular Common Rail Arrangement
Fuel Flow
New-current fuel flow logic
Fuel Flow
 Fuel Flow

Fuel from tank

into stage 1 filter

Fuel out of stage 1 filter

(lift pump or suction loop)
to fuel delivery pump

15 micron
 Fuel System
Check valve
open
(lift pump
not running)
 Fuel System
Check valve
closed Lift pump runs for 2 minutes or
(lift pump until 200 bar accumulator pressure
running) is detected

Lift pump produces

3-5 bar supply pressure
Fuel System

Stage 2
New filter FF5607
934 media (3 micron)
Fuel System

Stage 1
Industrial pro filter media
(7 micron) Water drain
WIF sensor with resistor.
Fuel System

Stage 1
Industrial pro filter outer
casing removal tool.

This part of tool used to

remove smaller cap on top
of first stage filter.
 Fuel Flow

Water drain fitting

WIF sensor w/83K ohm resistor

Fuel Flow

Fuel into fuel delivery pump

 Fuel Flow

Fuel delivery pump

Fuel delivery pump produces

5-7 bar fuel pressure

Fuel to fuel delivery pump

 Fuel Flow

Fuel out of fuel delivery pump

to stage 2 fuel filters
 Fuel Flow

Fuel from fuel delivery pump

to stage 2 fuel filters
 Parallel flow

Fuel from stage 2

fuel filters to fuel Fuel to
pump pressurizing stage 2
assembly (FPPA) fuel filters

5 micron 5 micron
Stage 2 fuel filters
are in parallel
 Fuel Flow

Fuel delivery pressure sensor

(pressure after fuel delivery
pump, before stage 2 fuel
filters)

Fuel temperature sensor

(after stage 2 fuel filters)
Fuel Flow

Fuel from stage 2 fuel filters

to fuel pump pressurizing
assembly (FPPA)
 Fuel into FPPA

Fuel pump pressurizing assembly

(controls amount of fuel delivered
to high pressure pumping
chambers)
 Fuel Flow

5 pumping plungers

1600 bar nominal maximum

fuel pump pressure, 300 bar
minimum for engine to start

Fuel enters HP pump

 Fuel Pump Identification

To identify the fuel pump, you need to record the following:

1. Serial Number
2. Date Code - This is a number like 587 for July 2005, the year is the 5, the month is 80 +month, so 87
for July
3. Cummins part number
 Fuel Flow

Mechanical dump valve

(fuel to return manifold when open)

Air bleed
(fuel to return
manifold)
Recirculation line
(fuel back to fuel delivery pump)
 Fuel Flow

Air bleed line contains a 5 bar one way

check valve
 Fuel Flow

5 bar air bleed

check valve
 Fuel Flow

Mechanical dump valve,

opens at 1950 bar

Should not be open, only opens

when fuel pressure is above system
design limits
 Fuel Flow

Injector metering rail

pressure sensor
 Fuel Flow

Fuel to LB injectors

Fuel to RB injectors
 Fuel Flow
All high pressure fuel lines are double wall.
Inner tube is high pressure fuel to injectors.
Outer tube is for fuel from a leaking high pressure
fuel line or high pressure fuel line fitting.
Warning! Do Not Reuse Any of the High Pressure
Fuel Lines Under Any Circumstances. Whenever a
High Pressure Fuel Line Fitting is Loosened, the
High Pressure Fuel Line Must be Replaced.
 Fuel Flow
Fuel to LB injectors
 Fuel Flow

Fuel to RB injectors
 Fuel Flow

Fuel to RB injectors
 Fuel Flow

Fuel pressure is common

to all injectors

Modular common rail system, fuel from

injector to injector

Each injector contains an accumulator

HP Line Between Injectors
HP Line Between Injectors

5 1

1. Outerwall Pipe
2. Vibralock Nut
3. Seal
8 4. Connector Fitting
3
5. O-Ring Groove
6. Sealing Cone
4
7. Innerwall Pipe
7 8. Pressurized Fuel

2
6
HP Line Between Injectors
T-connector

•Double walled pipe threads into T-

connector.
•3.5mm I.D.
•Green – fuel drain line
•Yellow – fuel inlet path
•When removing fuel line, (before
complete detachment) if some
Pressure still in line, fuel will go thru
drain path (Green)

O-ring
HP Line Between Injectors

•Double walled pipe threads into T-

connector.
•3.5mm I.D.
•Green – fuel drain path
•Yellow – high pressure fuel inlet path
•When removing fuel line, (before
complete detachment) if some
Pressure still in line, fuel will go thru
drain path (Green)
End of Line Plug

•M24 x 1.5 with 27mm Hex head

•0.799” x 0.103” viton o-ring

• Not just any Nut!

• Has a conical shaped end to

seal against Injector
 Fuel Flow

Return fuel out of injector

15–18 % of fuel delivered to injectors returns through drain lines

 Fuel Flow

RB return fuel

Fuel travels through drillings in

cylinder block and joins with return
fuel from LB injectors
 Fuel Flow

Return fuel from

LB injectors

Return fuel
from LB & RB
injectors
 Fuel Flow

Fuel return line check valve

Return fuel to fuel tank

 Fuel Flow

Vent hoses for double wall fuel lines

Fuel will only be present leaking

from these hoses if there is a
high pressure fuel line leak
 Fuel Injector
Operational Concept
 Fuel Injector
Identification
To identify a unique individual injector, you need to record the following:

1. Serial number
2. Date Code - This is a number like 587 for July 2005, the year is the 5, the month is 80 +month, so 87
for July
3. Cummins part number
 Fuel Injectors
How do they operate?
• The injection nozzle is being opened and closed by movements of a nozzle needle.
• The needle is balanced by pressures at the nozzle seat and at the needle control
chamber, at the opposite end of the needle.
• When the solenoid valve is energized (48 VDC) by the ECM, it opens the chamber to the
return fuel line.
• The pressure in the needle control chamber drops, the needle is lifted, the nozzle opens
and the injection begins.
• When the current in the solenoid valve drops to zero, the control valve returns to
its seat.
• The pressure in the needle control chamber increases and becomes equal to the
pressure at the nozzle seat.
• The needle closes due to a nozzle spring force and stops the injection.
• Optimal control of the system is achieved by calibrating several orifices in the hydraulic
assembly of the injector
• A flow limiter (check ball, seat, and spring) is used to prevent large volumes of fuel from
entering the cylinder, thus providing engine protection.
 Fuel Injectors
• What makes fuel inject is not the High Pressure
Fuel Pump Plunger, but the accumulated pressure
inside the accumulator. The fuel actually compresses
by about 7%.
 Fuel Injectors
Fuel to accumulator
and remaining injectors Fuel line outer wall
on that bank passages
Flow Limiter
This is a cutout view of what the injector flow limiter looks like
Injector Fuel Flow

Fuel enters the flow limiter region of the injector

Fuel fills up the area above the flow limiter’s check ball
Fuel flow pushes down on the check ball compressing the spring slightly
Fuel then enters the accumulator section of the injector
Fuel fills up the accumulator section of the injector
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

The needle is balanced by pressures at the

nozzle seat and at the needle control
chamber, at the opposite end of the needle.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

When the solenoid valve is energized by the

ECM, it opens the chamber to the
return fuel line.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

The pressure in the needle control chamber

drops, the needle is lifted, the nozzle opens and
the injection begins.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

The pressure in the needle control chamber

drops, the needle is lifted, the nozzle opens and
the injection begins.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

The pressure in the needle control chamber

drops, the needle is lifted, the nozzle opens and
the injection begins.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

When the current in the solenoid valve

drops to zero, the control valve returns to
its seat.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat

The pressure in the needle control chamber

increases and becomes equal to the
pressure at the nozzle seat. The needle closes
due to a nozzle spring force and stops the
injection.
 Flow Limiter
The flow limiter (check ball, seat, and spring) is used to prevent large volumes of fuel
from entering the cylinder, thus providing engine protection. If large volumes above
normal are suddenly demanded due to an injector malfunction, the check ball
compresses the spring to a point where it seals against the seat, thus cutting fuel
supply to the injector.
Injector Electrical Connector

Bosch connector.
Injectors operate with
24 - 48 VDC
INJECTOR DRIVER MAPPING
60 pin ECM Q50/60 source Q50/60 source Q50/60 source
Conn Driver address 00 address 01 address 144
Cylinder # BANK # Cylinder # BANK # Cylinder # BANK #
45 Drv 1+ 2 1R 6 3R 1 1L
53 Drv 1-

54 Drv 2+ 10 5R 7 4L 15 8L Share same

51 Drv 2- Vboost supply

55 Drv 3+ 11 6L 14 7R
52 Drv 3-

56 Drv 4+ 8 4R 4 2R 3 2L
58 Drv 4-

46 Drv 5+ 16 8R 12 6R 13 7L Share same

60 Drv 5- Vboost supply

57 Drv 6+ 5 3L 9 5L
59 Drv 6-