Diesel

2.2.
Engine Fuel systems with Distributor

type injection pump
• Contents
– Fuel system outline,
– Fuel filters and water sedimenter,
– BOSCH VE pump:
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only
Fuel system outline with distributor
injection pump
...cont
• Diesel fuel is drawn from the fuel tank through the
sedimentor/water separator and fuel filter by the
feed pump, which is incorporated in the front of
the injection pump. The feed pump not only
supplies fuel to the injection pump, but also
circulates fuel to lubricate the moving parts of the
pump. The single pump plunger meters and
distributes the fuel (under pressure) through the
nozzle to the combustion chamber, and does so in
the correct combustion order.
• Excess fuel from the pump and nozzles returns to
the tank by way of the overflow valve and
pipeline. This system of fuel circulation cools and
lubricates the injection pump while warming
the fuel in the tank to help prevent fuel waxing in
Components
• Injection pump
– high-pressure mechanical pump
– meters fuel to each injector nozzle at the proper
time
• Injection lines
– high-strength steel tubing
– carry fuel to each injector nozzle
Components
• Injector nozzles
– spring-loaded valves
– spray fuel into each combustion chamber
• Glow plugs
– electric heating elements
– warm air in the cylinder precombustion
chambers
– aid starting of a cold engine
Components
• Diesel fuel supply system
– feeds fuel from the fuel tank to the injection
pump
– components
• inline electric pump or engine-driven
mechanical pump
• filters and water separator to clean the fuel
• fuel return lines to carry unused fuel back to
the tank
Fuel filters & water sedimenters
• Since the injection pump and the injectors are
manufactured to very high standards of precision
(1 /1000 mm (1 /40 in.)), even the smallest
particle of dirt or other foreign body would cause
severe wear or damage within a short time, and
reduce the item concerned unserviceable. It is
therefore a more economical proposition in the
long run to keep the fuel filter in good working
order than to be obliged to renew expensive pump
elements or injectors
Box type fuel filters and replaceable filter element
type filters
• Box type filter • Filter Element:
– In addition to filters – Paper is the material
with replaceable mostly used for filter
elements, box-type elements.
filters are being used – Wrapped filter
increasingly today. – Star shaped filter
Water Sedimenter
• The water sedimenter separates water
from the diesel fuel by using the
difference in specific gravities
between it and the diesel fuel. When
the water level and the float rise
beyond a specified limit, a magnet
inside the float closes a reed switch.
This lights an indicator lamp on the
combination meter to warn the driver
that water has accumulated in the
water sedimenter. The sedimenter has
a cock underneath.
• Water can be removed by un
tightening the cock and operating the
priming pump. Water is heavier than
the diesel fuel and so sinks to the
bottom.
Cont...
• The float is lighter than
water but heavier than the • Water level detection
diesel fuel. Therefore, the
float rises as the water
level under the fuel
increases. When it reaches
the water level detection
switch (a reed switch), the
magnet inside the float
turns the switch on to issue
a warning.
Priming pump
Priming pump
• Pumping • Suction
Cont...
Cont...
• Two stage fuel filter

– In the two-stage
fuel filter the fuel
first passes through
the course filter to
the fine filter.
Diesel Injection Pumps
• Bolted to the top or side of the engine

• Purpose
– Meter correct amount of fuel to the injectors
– Time fuel injection
– Control idle speed and maximum speed
– Provide a means of shutting off the engine
Distributor Injection Pumps
• Only one plungers supply fuel for all the

cylinders
• Most common type of pump used on passenger
cars
Single Plunger Pumps
(the BOSCH VE pump)
• Components
• Operation
– Pumping
– Metering
– Timing
– Governing
Fuel system with VE pump
Note the system fuel flow
Components
Feed Pump
• Purpose: suck fuel from the
tank and deliver it to the
pump hosing under pressure.
• Rotor is connected to the
driveshaft by a woodruff key,
• As the rotor spins, centrifugal
force holds the vanes against
the wall of the concentric ring
(pressure chamber) that is
held stationary against the
pump housing.
• Due to the off center location
of the concentric ring, with
respect to the rotor, fuel
becomes trapped between the
vanes and is pressurized and
forced
...cont
• The pressure regulating
valve is located in the
upper portion of the
injection pump housing
on the drive end.
• The fuel pressure
regulation valve is
designed to regulate
pressure in proportion to
engine rpm to operate
the automatic timer.
Pumping and Distribution
• All the things shown on
the right in the pump
section have to do with the
pumping, metering, and
distribution of fuel
delivery,
• The distributor plunger
and the face cam are held
against the roller ring
assembly by the
distributor plunger return
springs.
Pumping and Distribution
• As the face cam and the distributor plunger rotate,
they reciprocate back and forth over the rollers.
• With one turn of the cam plate, the plunger makes
one complete turn and reciprocates four times
• With an interval of 90 degrees,
• During each stroke the delivery port (distributive
port) in the middle of the plunger is connected to
a particular delivery valve (distribution passage).
• For each revolution the plunger will pump four
times.
• It is the reciprocating motion that performs the
high pressure pumping, while the rotation is
responsible for metering and sending the fuel to
the correct cylinder.
...cont
• The coupling connects the
drive shaft & cam plate,
• A pin on the other side of
the cam plate fit with a
groove on the base of the
plunger and the plunger
receives rotational motion
from the drive shaft
• Cam plate:
– Rotating lobed disc
– Operates plunger
– Forces plunger to move
and develop injection
pressure
Fuel Metering Sleeve
• Can be slid sideways on the plunger to
change effective plunger stroke
• Surrounds the plunger
Distributive Head
Housing around the plunger
Contains passages for filling the barrel
and injecting fuel into the delivery
valves
Pumping and distribution Operation
• Inlet • Injection
• End of injection • Pressure equalization
Anti-reverse rotation
• Timing of intake and outlet
port opening
– The pump plunger
movement and the
opening and closing of
each port are as
illustrated below. If the
engine should happen to
rotate in reverse, the
suction ports will open
and the distribution port
will close when the
pump plunger moves to
upward. Therefore,
there will be no fuel
injection and the engine
will stop
• Fuel cut off solenoid
– Engine cut-off is
accomplished by stopping the
fuel supply. The passage from
the pump housing is closed
and delivery of pressurized
fuel is terminated by the fuel
cut-off solenoid, which is
designed to close the passage
when the engine starter
switch is turned off (to the
lock position).
Single Plunger
Pump Parts
Injection Timing
• As speed increases, injection must occur sooner
• Transfer pump turns faster, increasing pressure
output
• Increased pressure moves an injection advance
piston
• Cam plate ramps engage plunger sooner
Automatic injection timer construction and
operation
Injection Timing
Vane pump pressure can be used to control
injection timing
Centrifugal Governor
• Controls amount of fuel injected and
engine speed
• Flyweight action moves the metering
sleeve to limit top speed
• All speed governor • Min-Max speed governor
• Starting • Idling
• Full load • Max-speed
Min-max speed governor
VE pump accessory units
• Load sensing timer (L.S.T.)
– The load-sensing timer was created to retard
the injection timing as the load decreases at a
certain speed.
High altitude compensator
• Purpose:
• Low altitude • High altitude
Turbocharger boost compensator
• Principle of operation
Turbocharger boost compensator
• Principle of operation

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2.2.

Engine Fuel systems with Distributor

• Two stage fuel filter

• Bolted to the top or side of the engine

• Only one plungers supply fuel for all the

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