Diesel Engine Fuel Supply System

Diesel Engine Fuel Supply System

Function of the diesel engine file supply system :

• Storing of fuel

• Filtering of fuel

• Delivery of Fuel to Injection Pump

• Injecting the fuel in to engine cylinders

• Controlling the engine speed

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Requirements of Diesel Engine Fuel Supply System

• Fuel supply should be in a defined period of cycle

• Fuel should be metered very accurately

• Quantity of fuel should vary to meet changing speed

and load.

• Fuel must be broken in to very fine droplets

9A304.65 3
Diagram of Diesel Engine Fuel Supply System

4
Diagram of Diesel Engine Fuel Supply
System

Fig 2

9A304.65 5
Diagram of Diesel Engine Fuel Supply
System

Fig 2

9A304.65 6
Diagram of Diesel Engine Fuel Supply
System

Fig 2

9A304.65 7
Diagram of Diesel Engine Fuel Supply
System

Fig 3
9A304.65 8
FIP Mounted On An Engine

Fig 4

9A304.65 9
Components of Diesel Engine Fuel System

• Fuel tank: To store the diesel usually made of pressed steel

• Feed Pump: To supply fuel from the fuel tank to the fuel injection pump through fuel filters

• Fuel Filters: To filter fuel before supplying to Fuel Injection Pump. Usually two filters are
used; Primary and Secondary

• Fuel Injection Pump (FIP): To deliver diesel under pressure to the injectors.

• Hand Primer: A hand priming pump to feed fuel from tank to FIP for starting the engine and
to bleed air from the system.

• Fuel Injector: To inject fuel into the combustion chamber in atomised state and with high
pressure.

• Governor: To regulate the input fuel supply in accordance with engine load

• Fuel lines: To carry fuel through different components of the fuel system
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Fuel Feed Pump
• What is Fuel Feed Pump ?

It is a device to supply fuel from the tank to Fuel

filters and in turn to the FIP.

9A304.66 12
Fuel Feed Pump Function

• It feeds the fuel from the fuel tank to the injection

pump as per engine requirement

• It is driven from an eccentric or cam on the injection

pump cam shaft

• It is usually a part of injection pump assembly

• Feed pump is also called transfer pump or pump

9A304.66 13
Types of Fuel Feed Pumps

• Diaphragm type

• Gear type

• Vane type

• Plunger type

9A304.66 14
Diagram of Plunger Type Pump

Fig(1)

9A304.66 15
Operation

16
Fuel feed Pump Construction

Fig 3
9A304.67 17
Plunger Type Pump
• It is used in Ashok Leyland vehicles
• The main parts of the pump are
1. Barrel
2. Plunger
3. Spindle
4. Plunger return spring
5. Hand primer
6. Roller tappet
7. Suction and delivery valves

9A304.66 18
Working of Plunger Type Pump

• Plunger is driven from the eccentric on the cam shaft of the injection pump
• The return stroke of the piston is effected by means of a plunger return spring
• With the eccentric, the plunger moves inwards by the pressure of return spring

• This creates a suction which lifts the suction valve

• Draws fuel from the fuel tank to the front side of the plunger

• Eccentric rotation, moves the plunger against spring force

• Then suction valve is closed and the fuel is forced through delivery valve

19
 Hand Primer
It is a device to supply fuel from Tank up to the fuel
filters and in turn to the FIP manually during air-
bleeding.

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Fuel Filter Assembly

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 Fuel filters - Necessity
• Dirt carried in the fuel is recognized as a prime source of

trouble and inefficiency of diesel engine operation.

• Dust entering the fuel injection pump and injectors will

lead to severe wear of FIP element, delivery valve and

nozzle element

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 Fuel filters - Necessity

• Fuel Injection Equipment (Feed Pump, FIP and Injectors) are designed
accurately to close tolerances to provide trouble-free service, on the
condition that it receive clean, dirt free fuel at all times of engine running.

• Therefore it is very important to filter the fuel before it is allowed to enter

the Fuel Injection Pump and Fuel Injectors.

23
 Types of Fuel Filters

Generally two types of fuel filters are used in Diesel Engine Fuel system:

• Primary Filters

• Secondary Filters

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Fuel Filters
▪ Primary fuel filter removes water and coarse specks of dust.

▪ Secondary filter does not allow even fine dust specks to go through it.

•The filter assembly comprises of a filter bowl, an element and a cover with rubber gasket.

• The filter element may be of cloth, felt, metal or paper.

• Usually primary filters are made of cloth while secondary filters are of paper

•The fuel passes through the annular space of the into the primary fuel element and then to the secondary filter.

• Fuel is further filtered in the secondary filter and then passed into the fuel injection pump.

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Fuel Filters
• The mesh filter is between 100 and 200 mesh size.

• The efficiency of the filter depends upon fuel velocity and sediment chamber

design.

• Such screen filter requires regular cleaning.

•Element filters have elements of impregnated paper, ceramic, metal disc and fiber.
• Diesel fuel filters must have good particle retention and water separation
efficiency.
• Such filters are arranged on the pressure side of the feed pump.

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Fuel Filter

9A304.68 27
Fuel Filter

9A304.68 28
• What is Fuel Injection?

Injecting diesel at high pressure into the high pressure and high temperature
compressed air in the cylinder at the end of compression stroke.
• Diesel engines compress pure air during the compression stroke.
• Diesel must be introduced into this high pressure and high temperature compressed air.
• This requires that Diesel must be injected at a higher pressure than that is prevailing in
the cylinder

• Fuel Injection system is designed to supply diesel at a pressure which is higher than that
of compression pressure.

• Different methods of fuel injection are adopted to achieve this.

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What is the necessity of Fuel Injection System?

30
Requirements of Fuel Injection System

Requirements of A Fuel Injection System can be

summarized as:
• Meter
• Time
• Pressurize
• Atomize
• Distribute
• Control, start and Stop Injection

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TYPES OF INJECTION SYSTEM
• AIR INJECTION
• SOLID INJECTION
AIR INJECTION SYSTEM

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 Working Principle of Air Injection system

• In this system, the air is first compressed to a very high pressure.

• A blast of this air is then injected carrying the fuel along with it
into the cylinder.
• The rate of fuel injection is controlled by varying the pressure of
air.
• This method of fuel injection is expensive and complicated.

34
Advantages
• It obtains good atomization
• Heavy and viscous fuels can be injected
• Only small pressure need to develop by fuel pump

Disadvantages
• It requires high pressure air compressor
• Air compressor consumes lot of engine power
• A separate mechanical linkage is required
• Reduced power of engine

35
 SOLID INJECTION
• In this system the fuel under high pressure is injected directly in to the
combustion chamber with out atomization
• It burns due to the heat of compression of the air.
• It is also called air less mechanical injection
• It employs a fuel injection pump and injector

The Solid Injection is mainly classified into the following types

• Common rail System

• Individual Pump System

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Common rail System

37
Common Rail Fuel Injection System

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Common Rail Fuel Injection System

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Common Rail Fuel Injection System

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Common Rail Fuel Injection System

41
Common Rail Fuel Injection System V-8 Engine

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Lay Out of Common Rail Fuel Injection
System

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Diagram of Common Rail system

44
Working Principle of Common Rail system

• In this system fuel is pumped by a multi cylinder pump

in to a common rail.

• The pressure in this rail is controlled by relief valve.

• A metered quantity of fuel is supplied to each cylinder

from the common rail.

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Unit Injector system

46
Diagram of Unit Injector

47
Unit Injector fitted on Engine

48
Parts of Unit Injector

Fig.5
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Line diagram of Unit Injection system

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 Working Principle of Unit Injector
• In this both the pump and injector are combined in to one unit.

• Each cylinder has one such unit injector.

• This arrangement requires push rod and rocker arm to operate the unit injector.

• As shown in figure the system being a 6-cylinder engine has 6 unit injectors.

• Each of this is operated from a Cam operated Rockers.

• Fuel from filters enters into the gallery.

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 Working Principle of Unit Injector
• The Unit injector is fitted into the engine cylinder head, where the fuel is supplied via
integral ducts machined directly into the cylinder head.
• Each injector has its own pumping element.
• In case of electronic control, each injector will have an electronic fuel solenoid valve.

• A low pressure fuel pump supplies fuel from tank to the cylinder head fuel ducts

through filters.

• This fuel is injected into engine cylinder by constant stroke plunger injector which is

operated by overhead cam shaft.

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 Working Principle of Unit Injector

• A low pressure fuel pump supplies fuel from tank to the

cylinder head fuel ducts through filters.

• This fuel is injected into engine cylinder by constant stroke

plunger injector which is operated by overhead cam shaft.

9A304.73 53
 Advantages
• Design of Unit Injector eliminates the need for high pressure fuel pipes and with
that their associated failures.

• It allows much high injection pressures.

• This system allows accurate injection timing and quantity of fuel delivered as in
Common rail system.

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Individual pump fuel injection system

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Individual pump fuel injection system

Fig. 2

A304.74 56
Fig 3

A304.74 57
Individual pump fuel injection system

1. Injection pump
2. Governor
3. Feed pump
4. Timing device

Fig. 4

A304.74 58
Working Principle of Individual Pump and Injector

• A jerk pump is a reciprocating fuel pump

• It meters the fuel and provides injection pressure

• There is a separate pump element and a separate injector

for each cylinder

• Fuel is supplied by multi unit fuel pump

A304.74 59
Diagram of Distributor system

Fig.4

9A304.75 60
Layout of Distributor type fuel injection
system

Fig.5

9A304.75 61
Working of Distributor type fuel injection

Fig.5
9A304.75 62
 Working Principle of Distributor system

• Unlike the jerk pump this pump has a single pumping

element.

• Fuel from this single pumping element is distributed to

each of the cylinder by means of a rotor.

• The rotor has a central longitudinal passage and a set of

radial holes (suction ports) equal to number of cylinders.

9A304.75 63
 Working Principle of Distributor system

• Outer sleeve has a set of equal number of holes (delivery

ports) at a different level BB.

• Besides there is a metering port in the sleeve for the fuel

intake at level AA.

• A distribution port is located in the rotor at level BB.

• Distribution port is connected to the central passage in

the rotor.

9A304.75 64
Working of Distributor type fuel injection

Suction Delivery

9A304.75 65
Working Principle of Distributor system

• Each delivery ports is connected to the high pressure

delivery lines leading to the injectors.

• As the rotor revolves, the suction ports align with the

intake metering port one by one.

• Distribution ports align with deliver ports in turn.

• The alignment of suction and distribution ports takes

place at different instants of time.

9A304.75 66
Working Principle of Distributor system

• The lower end of the central passage in the rotor

opens into a chamber in which two opposed pumping
plungers are housed.

• As the rotor rotates, a stationary ring with internal

cams operates the plungers through rollers and shoes
which are placed in slots into the rotor base.

9A304.75 67
Working Principle of Distributor system
• The number of lobes on the cam ring is equal to the
number of engine cylinders and these are evenly
spaced around the ring.
• As the pump plunger move away from each other, the
fuel is drawn into the central rotor passage from the
inlet port through suction ports
• The fuel thus charged is delivered to each cylinder in
turn at high pressure when distribution port coincides
with the delivery port of any cylinder

9A304.75 68
Fuel Injection Pump Function

To supply equal quantity of fuel to all cylinders

• At equal intervals

• Under extremely high pressure

• According to firing order

9A304.77 69
Fuel Injection Pump

Fig 1

9A304.77 70
Construction of Fuel Injection Pump

• It consists of a barrel in witch a plunger reciprocates when

driven by a cam shaft.

• The plunger has a constant stroke and is single acting.

• Pump barrel and plunger have small clearance between

them ie 3/1000 of mm.

9A304.77 71
Pump Element Construction

Fig 2
9A304.77 72
Injection Volume Control Mechanism

Fig 3

9A304.77 73
Control of Injection Volume

• After the fuel flows from the fuel chamber into the
pressure chamber (above the plunger head) the pump
element pumps the fuel to the nozzle

• However, the volume of fuel that is injected must be

controlled according to the engine load.

• The injection volume is regulated by varying the length of

the time between the beginning and the ending of the fuel
delivery process.

9A304.77 74
• This is accomplished by enabling the control rack to rotate
the plunger, in order to vary the control groove position
(plunger's effective stroke), thus varying the volume of fuel.

• Also, because the control rack rotates all the plungers

simultaneously for the same amount, the injection volume
to all cylinders can be varied simultaneously.

• The longer the effective stroke, the larger is the injection

volume.

9A304.77 75
Zero delivery

Fig 4
9A304.77 76
Partial delivery

Fig 5
9A304.77 77
Full delivery

Fig 6

9A304.77 78
Construction of Fuel Injection Pump

• Low clearance provides a perfect sealing at very high

pressure.

• Pump barrel has two radially opposing holes.

• These are inlet and out let ports.

9A304.77 79
Construction of Fuel Injection Pump

• To vary the quantity of the fuel delivered per stroke.

• A vertical channel, extending from top face of the plunger

to an annular groove is provided on the upper part of the

plunger.

9A304.77 80
Construction of Fuel Injection Pump

• The top edge of the upper end is milled in the form of a

helix.

• At the top of the barrel is provided with a spring loaded

delivery valve.

• A delivery pipe connects the delivery valve with the

respective nozzle on the cylinder.

9A304.77 81
Working of Fuel Injection Pump

• When the plunger is at the bottom of its stroke the fuel

flows through the inlet port in to barrel.

• It fills the space above the plunger, vertical grove and space

below the helix.

• When the plunger starts moving up, fuel goes out of the

chamber to delivery valve witch leads to injector.

9A304.77 82
• What is the function of FIP?

9A304.78 83
Phasing Of Fuel Injection Pump

• It is a process of adjustment of the pump elements to

ensure that inject at

• Equiangular intervals

• In the sequence of firing order

9A304.78 84
Phasing:

• This is the procedure for checking and adjusting the intervals

between successive Injectors.

• The Pump is mounted on a machine that is bitted with a

degree plate and the plunger of No.1 pumping element is set
at spell cut–off.

9A304.78 85
Phasing :

• At this point, the timing mark on the pump flange should

align with the pointer.

• The degree plate should be set to zero and the shill pipe

transferred to the next pumping element.

• So that when the pump is rotated slowly, shill cut–off can

be identified and checked against degree plate.

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Phasing :

• This should occur at 900

• This procedure is repeated for the remaining two pumping

elements.

• Adjustment to the Phase angle can be made by changing

the tappet spacers.

• To cause plunger action to start earlier of later as required

to correct the Phase angle.

9A304.78 87
Calibration Of Fuel Injection Pump

It is the process where the quantity of fuel delivered is

regulated to suit the

• Varying speed of the engine

• Varying load of the engine

9A304.78 88
Calibration:

• The pump is calibrated so that same volume of fuel is delivered from each pumping element.

• This ensures that all cylinders will produce equal process.

• Adjustments are made by attiring the positions of gear segments on sleeves.

• Loosening the clamp an adjusting the gear segment turns the plunger in its barrel.

• This alters the Quantities of Fuel that it delivers

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Calibration :
• The injection Pump is mounted on the testing machine.

• It is their run at speeds shown in the specification data for particular pump.

• The delivery of test oil into the calibrated test tubes is their checked for a

specified number of shots.

• All pumping elements should deliver the same volume of test oil during the

period of the Test.

• This can be checked by comparing the level of oil in the graduated test tubes.

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• Do you know function of an injector?

91
 Injector
• The purpose of injector is to inject a small volume of fuel in a fine spray.

• Assist in bringing each droplet into contact with sufficient oxygen to give quick and

complete combustion.

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Injector

93
Injector

94
Fuel Injector

• This is also known as nozzle, atomizer or fuel valve.

• This injects the fuel in the cylinder in atomized form

and in proper quantity

9A304.79 95
Types of Fuel Injectors

1. Blast type injector

2. Mechanically operated

3. Automatic fuel injector

9A304.79 96
 Fuel Injector

Fig. 6
9A304.79 97
Automatic Injector

Fig.7
9A304.79 98
Working Principle of Automatic Injector

It consists of two main parts

1. Nozzle

2. Nozzle holder

9A304.79 99
 Working Principle of Automatic Injector
• The nozzle is connected to holder by means of a screw cap.

• A spring loaded spindle in the nozzle holder keeps the nozzle valve
in the nozzle body.

• Till the fuel supplied by the fuel injection pump enters with
sufficient pressure.

• To lift the nozzle valve against the spring.

• This makes a spray of atomized fuel in to cylinder.

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• The fuel spray continues till the delivery from Injection
pump is continued.

• When the fuel delivery is stopped the pressure falls back

closing nozzle valve back on its seat.

• Over flow is drained back to the fuel tank through the

leak off connection.

9A304.79 101
 FUEL INJECTION NOZZLES
• The main function of nozzle is to deal with many hundreds of fuel charges per minute with widely

varying conditions of pressure and temperature.

FOLLOWING TYPES :

1. Single hole nozzle

2. Multi hole nozzle

3. Long stem nozzle

4. Pintle nozzle

102
Injection Nozzles

A - Hole type Nozzle

B - Pintle type nozzle

103
Single Hole Nozzle :

• It has one hole drilled centrally through its body which

is closed by the nozzle valve.

• The hole can be of any diameter from 0.2 mm up wards.

9A304.79 104
Multi Hole Nozzle :

• A multi hole nozzle can have a varying number of holes

drilled in its bulbous and under the valve seating.

• Their actual number, size depends upon the engine

requirement.

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 Long Stem Nozzle :

• These nozzles are mainly used, where limited space between the valves

in the cylinder head.

• It is used where it is not possible to provide adequate cooling for the

short stem.

106
Hole Type Nozzle

1. Nozzle body
2. Exposed annular area
3. Pressure chamber
4. Nozzle needle
5. Blind hole
6. Spray orifices

9A304.79 107
Pintle Nozzles
• This mainly used in engine combustion chambers of the air cell, swirl chamber.

• The valve stem is extended to form a pin which protrudes through the mouths of the
of the nozzle body.

a) Closed
b) Slightly open (pre spray)
c) Fully open (main spray)

108
Objectives

• Governing system

• Mechanical governor

109
• What is governor?

• What is the function of FIP?

110
 Fuel Injection Pump Function

To supply normal quantity of fuel to all cylinders

• At equal intervals

• Under extremely high pressure

• According to firing order

111
Governors

• A governor is necessary in case of diesel engines.

• To control the fuel injected.

• To ensure optimum conditions at all speeds and loads with

in the range specified.

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 Governor
1. Control rack
2. Link fork
3. Play compensating spring
4. Adjusting nut
5. Governor spring
6. Fly weight
7. Bell crank
8. Sliding bolt
9. Slider
10. Guide pin
11. Control lever
12. Fulcrum lever
13. Guide block
Fig 7 14. Linkage lever
9A304.81 113
Mechanical Governor

Fig 8
9A304.81 114
Working of Mechanical Governor
• Two spring loaded weights are mounted on the governor shaft which gets driven by the engine
• These are driven by the engine
• At one end the bell crank levers carry balls
• Other end touch the lower surface of the flange of a sleeve on the governor shaft

• At the engine speed increases, the centrifugal force due to the weights acts against spring tension

• The weights fly apart, causing the other ends of the bell crank levers to rise the sleeve

• Hence operating the control lever in the downward direction

• It actuates the control rack on the injection pump in a direction

• Thus reduces the amount of fuel delivered

• Hence decreases the engine speed

• The amount of fuel delivery is increased when the engine speed tends to decrease

115
 Objectives

On completion of this session you would be able to

know about :

• Governing system

• Pneumatic governors

9A402.82 116
Pneumatic Governor

117
 Pneumatic Governor

1. Accelerator pedal
2. Air filter
3. Max. Speed stop
4. Venturi lever
5. Venturi control unit
6. Idling screw
7. Idling Spring
8. Diaphragm
9. Control Rod
10. Idling Screw
118
 Working of Pneumatic Governor

• This is a variable speed governor used with in-line FIPs.

• It is also called as vacuum operated governor.

119
Working of Pneumatic Governor
It has the following parts

1. Venturi Control Unit with butterfly valve and control lever

2. Diaphragm unit having a diaphragm, spring, auxiliary idling spring with idling set

screw

• This unit as (i) Atmospheric Chamber and (ii) Vacuum Chamber

3. Control Rod connected to diaphragm.

4. Maximum and idling stop screws.

120
 Working of Pneumatic Governor
• At the stationary position of the engine the diaphragm is controlled by its spring at such a
position that the control rod allows maximum amount of fuel.

• The control lever remains in contact with the idling screw situated at the top of the Venturi
unit.

• The difference of pressure on both sides of the diaphragm keeps it in a position where the
control rod controls the fuel supply.

• When the accelerator pedal is depressed to increase the fuel supply, air rushes into the
Venturi unit as the throttle is fully open.

• Such as action reduces the vacuum and the diaphragm moves towards left increasing the fuel
supply.

121