5/7/22, 22:45 SIS 2.

1995/10/01 Systems Operations (SENR6572-01)

SMCS - SENR65720001 

Fuel Injection Pump

Fuel Injection Pump

The Zexel fuel system consists of the fuel injection pump, housing, timer, governor, feed pump, fuel filter, delivery valves, and injection nozzles.

The feed pump draws fuel from the fuel tank and forces it through the fuel filter, into the fuel injection pump. The delivery valves and injection
nozzles deliver high-pressure fuel into the combustion chambers.

If the fuel leakage occurs, the overflow pipe returns the excess fuel to the fuel tank. An overflow valve is installed above the fuel filter. This valve
prevents the fuel pressure of the injection nozzles from exceeding the maximum allowable by opening and returning excess fuel to the fuel tank.

The engine lubricant system provides adequate lubrication for Zexel fuel system. A pressure line and pump inlet port provides filtered engine oil to
the cam chamber. The outlet port returns engine oil to the chamber.

Feed Pump

Feed Pump
The feed pump is mounted on the side of the fuel system housing. The cam shaft drives the feed pump. The feed pump draws fuel from the fuel
tank and forces it through the fuel filter, into the fuel injection pump. A priming pump allows manual operation when starting the engine or venting
air.

While the cam is at its lowest position, suction pressure opens the suction check valve, filling the suction chamber with fuel. When the chamber is
full, the suction check valve closes. The cam then moves to its highest position, pushing the plunger into the suction chamber and forcing fuel out
into the pressure chamber. As the cam moves back to its lowest position, the spring force on the piston forces the piston to follow the cam. The
compression of the pressure chamber pushes fuel out of the pressure chamber into the delivery valve. Simultaneously, fuel enters the suction
chamber through the suction check valve.

When the fuel discharge pressure exceeds 245.5 kPa (35.6 psi), the piston remains in the intermediate stroke position, compressing the piston
spring and disabling the feed pump.

Delivery Valve

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5/7/22, 22:45 SIS 2.0

Delivery Valve
The delivery valve receives fuel from the pressure chamber and sprays it into the combustion chamber.

Fuel is forced out of the pressure chamber into the delivery valve when the camshaft is at its lowest point in its stroke. At this point, the delivery
valve is open, allowing the fuel to enter the high pressure pipe. This narrow pipe sprays the fuel into the combustion chamber.

During the highest point in the cam stroke, the delivery valve closes and a relief plunger slides into the bore of the valve housing. The high
pressure pipe is sealed from the pressure chamber, preventing backflow.

RSV Governor

RSV Governor
The RSV-type mechanical governor has a flyweight attached to the camshaft of the injection pump.

When the flyweight opens outward, the flyweight roller pushes the sleeve in an axial direction.

The sleeve is connected to the shifter via bearings, and will move only in an axial direction.

The shifter is connected to the guide lever which is mounted on a pin incorporated with the governor cover.

The floating lever is attached to the guide lever by a pin at the lower end of the guide lever, which acts as a fulcrum.

The floating lever is connected to the control rack by a link.

The start spring is attached to the top of the floating lever so that the control rack is always pulled towards the fuel-increase direction.

Speed Control Spring

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5/7/22, 22:45 SIS 2.0

Speed Control Spring

The governor spring for the RSV-type mechanical governor is attached to the tip of the swivel lever at point B and to the tension lever at point A.
When the control lever is operated, the swivel lever will rotate around the control lever shaft. The full-load stopper bolt is installed at the lower end
of the tension lever to limit tension lever movement.

When the control lever is moved in the "speed increase" direction, distance A-B will increase, and therefore the governor spring tension will also
increase.

However, with an increase in speed, the centrifugal force of flyweights increases, moving the tension lever further and increasing the tension of the
governor spring. Therefore, the actual controlled revolution range of the engine will increase, without a change of governor spring.

The RSV-type governor, then, enables changing of the controlled revolution range through control lever movement only.

1CS1-UP, 1ES1-UP, 1KL1-UP, 1XM1-UP, 2DL1-UP, 2LS1-UP, 2MS1-UP, 2NS1-UP, 2WZ1-UP, 3ES1-UP, 3FS1-UP, 3MR1-UP, 4FS1-UP, 4MR1-UP,
4XW1-UP, 5BR1-UP, 5CS1-UP, 5GW1-UP, 6CR1-UP, 6GK1-UP, 6LS1-UP, 7ZZ1-UP, 8ES1-UP, 8GR1-UP, 8GZ1-UP, 8HR1-UP, 8JR1-UP, 8LK1-UP,
9CS1-UP, 9CZ1-UP, 9GR1-UP, 9HR1-UP, 9JS1-UP, 9KK1-UP, 9KR1-UP, 9LJ1-UP, 9MR1-UP, AED1-UP, AKG1-UP, AKR1-UP, ALF1-UP, ALX1-UP,
AMC1-UP, ANB1-UP, APA1-UP, BBG1-UP, BDB1-UP, BDC1-UP, BDE1-UP, BEA1-UP, BER1-UP, BKK1-UP, BPR1-UP, BRX1-UP, BTG1-UP, CAE1-
UP, CBA1-UP, CKE1-UP, CLK1-UP, CLM1-UP, CLZ1-UP, CWP1-UP, DAX1-UP, DBG1-UP, EGA1-UP, EGL1-UP, FBA1-UP, FBB1-UP, FDS1-UP,
GAA1-UP, GAB1-UP, GAC1-UP, GLA1-UP, GPA1-UP, HGF1-UP, JPL1-UP, JTG1-UP, KBB1-UP, KHB1-UP, KJA1-UP, MAA1-UP, MAB1-UP, MAC1-
UP, MCF1-UP, MDY1-UP, PAA1-UP, PAB1-UP, PAC1-UP, PCA1-UP, RAW1-UP, SAH1-UP, SBN1-UP, TBR1-UP, WSA1-UP

PIP-11174098

2022/07/06

02:59:26-05:00

SENR65720001

© 2022 Caterpillar Inc.

Caterpillar:

Confidential Green

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