Fuel System: Systems Operation

D7R SERIES II TRACK-TYPE TRACTOR /FINGER TIP CONTROL/ BRP00001-U...
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Product: TRACK-TYPE TRACTOR
Model: D7R II TRACK-TYPE TRACTOR BRP
Configuration: D7R SERIES II TRACK-TYPE TRACTOR /FINGER TIP
CONTROL/ BRP00001-UP (MACHINE) POWERED BY 3176C ENGINE

Systems Operation
3176C and 3196 Engines for Caterpillar Built Machines
Media Number -RENR1222-07 Publication Date -01/09/2007 Date Updated -27/09/2007

i02593986
Fuel System
SMCS - 1250

Illustration 1 g00647085
(1) Crankshaft position sensor
(2) Camshaft position sensor
(3) Injectors
(4) Retarder solenoid
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 9/12/2011
D7R SERIES II TRACK-TYPE TRACTOR /FINGER TIP CONTROL/ BRP00001-U... Page 2 of 15
(5) Rail for fuel supply
(6) Boost pressure sensor
(7) 2 Micron secondary fuel filter
(8) Atmospheric pressure sensor
(9) Fuel pump
(10) Primary fuel filter
(11) Fuel tank
(12) Fuel pressure regulator
(13) Engine oil pressure sensor
(14) Engine coolant temperature sensor
(15) Inlet air temperature sensor
(16) Fuel temperature sensor
(17) Ambient air temperature
(18) Engine coolant level sensor
(19) Accelerator pedal
(20) Accelerator pedal position sensor
(21) Batteries
(22) Engine Control Module (ECM)
(23) SAE J1587/J1708 Data link
(25) SAE J1939 Data link
(26) Warning and check engine lamps
(27) 2 Lamp outputs
(28) Timing calibration connector
(29) 6 Programmable outputs
(30) Cooling fan relay or solenoid
(31) Engine retarder switch
(32) PTO on/off & set/resume switches
(33) Cruise on/off & set/resume switches
(34) 7 Programmable inputs
(35) Vehicle speed sensor
(36) Speedometer & tachometer
(37) Service brake pedal position switches.
(38) Neutral & clutch pedal position switches
(39) keyswitch
The Electronic Unit Injector system consists of the following systems: the mechanical system and the
electronic system. The mechanical system is made up of the low pressure fuel supply system and the
electronic unit injectors. The electronic system provides complete electronic control of all engine functions.
The electronic control system consists of the following three types of components: input, control and output.
Most changes to engine horsepower or to the performance are accomplished by installing new electronic
software or upgrading mechanical components.
There are five major components of the Electronic Unit Injector fuel system:
 Electronic Unit Injectors
 Fuel transfer pump
 Engine Control Module (ECM)
 Sensors
 Actuators
The Electronic Unit Injectors produce fuel injection pressures up to 207000 kPa (30000 psi). The Electronic
Unit Injectors also fire up to 19 times per second at rated speed. The fuel transfer pump supplies the
injectors by drawing fuel from the tank and by pressurizing the tank between 60 and 125 PSI. The ECM is a
powerful computer which controls all major engine functions. Sensors are electronic devices which monitor
engine performance parameters. Engine performance parameters measure pressure, temperature and speed.
This information is sent to the ECM via a signal voltage. Actuators are electronic devices which use
electronic currents from the ECM to change engine performance. An example of an actuator is the Injector
solenoid.
Low Pressure Fuel System


(1) Crankshaft position sensor
(2) Camshaft position sensor
(3) Injectors
(4) Retarder solenoid
(5) Rail for fuel supply
(6) Boost pressure sensor
(7) 2 Micron secondary fuel filter
(8) Atmospheric pressure sensor
(9) Fuel pump
(10) Primary fuel filter
(11) Fuel tank
(12) Fuel pressure regulator
(13) Engine oil pressure sensor
(14) Engine coolant temperature sensor
(15) Inlet air temperature sensor
(16) Fuel temperature sensor
(17) Ambient air temperature
(18) Engine coolant level sensor
(19) Accelerator pedal
(20) Accelerator pedal position sensor
(21) Batteries
(22) Engine Control Module (ECM)
(25) SAE J1939 Data Link
(26) Warning and check engine lamps
(27) 2 Lamp outputs
(28) Timing calibration connector
(29) 6 Programmable outputs
(30) Cooling fan relay or solenoid
(31) Engine retarder switch
(32) PTO on/off & set/resume switches
(33) Cruise on/off & set/resume switches
(34) 7 Programmable inputs
(35) Vehicle speed sensor
(36) Speedometer and tachometer
(37) Service brake pedal position switches.
(38) Neutral & clutch pedal position switches
(39) keyswitch
The low pressure fuel system supplies fuel from the fuel tank to the injectors. The low pressure fuel system
has three basic functions:
 The low pressure fuel system supplies fuel to the injectors for combustion.
 The low pressure fuel system supplies fuel to the injectors for cooling.
 The low pressure fuel system supplies fuel to the fuel system in order to remove air.
The major parts in a low pressure fuel system consist of the following components:
 Fuel tank
 Fuel transfer lines
 Primary fuel filter or water separator
 Fuel transfer pump
 Secondary fuel filter
 Fuel priming pump
 Fuel pressure regulator valve
The electronic unit injectors, the fuel transfer pump, the engine control module, sensors, and actuators are
part of the low pressure fuel system.
In the low pressure fuel system, the fuel is pulled from the fuel tank to the primary fuel filter or to the water
separator. The primary fuel filter removes large debris from the fuel before the fuel flows into the transfer
pump. The fuel transfer pump is a gear pump that contains a pressure relief valve. Fuel flows from the outlet
port of the transfer pump to the secondary fuel filter. All 1999 and newer engines use a 2 micron fuel filter.
The 2 micron filter removes small abrasive contaminants from the fuel system, which can cause damage to
the unit injectors.
The fuel filter base contains a hand operated fuel priming pump. The fuel priming pump removes air from
the system when a fuel filter has been changed or a unit injector has been changed. The priming pump pulls
fuel from the tank, around the transfer pump and into the filter. The transfer pump pushes fuel through the
supply passage in the cylinder head and back to the tank.
The fuel pressure regulator consists of a check valve that is spring loaded. The pressure relief valve opens at
approximately 60 to 125 PSI. When the engine is in the off position and the fuel pressure drops below 60
PSI, the check valve closes. The check valve closes in order to prevent the fuel in the cylinder head from
draining back into the fuel tank. Retaining the fuel in the head maintains a supply of fuel for the injectors
during start-up requirement.
The engine control module controls major engine functions. Sensors are electronic devices that monitor
engine performance parameters. The pressure sensor, the temperature sensor and the speed sensor provide
information to the electronic control module by a signal voltage. Actuators are electronic devices which use
electrical currents from the engine control module to change engine performance. An example of an actuator
is an injector solenoid.
Electronic Controls
The electronic control system provides complete electronic control of all engine functions. The electronic
control system consists of the following three types of components: input, control and output. Sensors
monitor engine operating conditions. This information is sent to the Engine Control Module (ECM). The
ECM has three main functions. The ECM provides power for the engine electronics and monitors input
signals from the engine sensors. The ECM also acts as a governor to control engine rpm. The ECM stores
active faults, logged faults, and logged events. The Personality Module is the software in the ECM which
contains the specific maps that define power, torque, and RPM of the engine. The ECM sends electrical
current to the output components in order to control engine operation. The ECM has the following
connectors: two 70 pin harness connectors, one engine harness connector and one vehicle harness connector.
The vehicle harness connects the ECM to the engine control portion of the vehicle harness. The engine
control portion includes the following components.
 Accelerator pedal position sensor
 Vehicle speed sensor
 Transmission
 Brake
 Clutch switches
 Cruise control
 PTO switch
 Data links
 Check engine light
 Warning light
 Engine retarder switch
 Speedometer
 Tachometer
 Cooling fan solenoid
The following list of features are part of the electronic control system:
 Cold start strategy
 Oil pressure
 Coolant temperature warning indicator
 Automatic altitude compensation
 Variable injection timing
 Electronic engine speed governing
These features result in the following items: precise engine speed control, very little smoke, faster cold
starting and built-in engine protection.
The engine control module consists of the following two main components: the electronic control module
and the personality module.
The ECM is a computer and the personality module is the software for the computer. The personality
module contains the operating maps. The operating maps define the following characteristics of the engine:
 Horsepower
 Torque curves
 Rpm
 Other characteristics
The ECM, the personality module, the sensors, and the unit injectors work together in order to control the
engine. The ECM, the personality module, the sensors, and the unit injectors can not control the engine
alone.
The ECM determines a desired rpm that is based on the following criteria:
 Throttle signal
 Certain diagnostic codes
 Vehicle speed signal
The ECM maintains the desired engine rpm by sensing the actual engine rpm. The ECM calculates the fuel
amount that needs to be injected in order to achieve the desired rpm.
Fuel Injection Timing and Delivery
The ECM controls the injected fuel amount by varying the signals to the unit injectors. The unit injectors
will inject fuel ONLY if the unit injector solenoid is energized. The ECM sends a 90 volt signal to the
solenoid for energizing the solenoid. By controlling the timing of the 90 volt signal, the ECM controls
injection timing. By controlling the duration of the 90 volt signal, the ECM controls the injected fuel
amount.
Injection timing is determined by engine rpm, and other engine data. The ECM senses the top center
position of cylinder number 1 from the signal that is provided by the engine speed sensor. The ECM decides
when the injection should occur relative to the top center position. The ECM provides the signal to the unit
injector at the desired time.
Unit Injector Mechanism

Typical examples of Electronic Unit Injector fuel systems.
(1) Adjusting nut
(2) Rocker arm assembly
(3) Unit injector
(4) Pushrod
(5) Camshaft
Injection Actuation System

The unit injector pressurizes the fuel. The correct amount of fuel is then injected into the cylinder block at
precise times. The ECM determines the injection timing and the amount of fuel that is delivered. The unit
injector is operated by a camshaft lobe and a rocker arm. The camshaft has three camshaft lobes for each
cylinder. Two lobes operate the inlet and exhaust valves, and the other lobe operates the unit injector
mechanism. Force is transferred from the unit injector lobe on the camshaft (6) through the lifter to the
pushrod (4). The force of the pushrod is transferred through rocker arm assembly (2) and to the top of the
unit injector. The adjusting nut (1) allows setting of the unit injector adjustment. Refer to Systems
Operation/Testing and Adjusting, "Unit Injector Adjustment" for the proper setting of the unit injector
adjustment.
Unit Injector

(1) Solenoid
(2) Tappet
(3) Plunger
(4) Barrel
D7R SERIES II TRACK-TYPE TRACTOR /FINGER TIP CONTROL/ BRP00001... Page 10 of 15
(5) Nozzle Assembly
Operation of the Fuel Injector

The operation of the Electronic Control Unit (EUI) consists of the following four stages: Pre-injection,
Injection, End of injection and Fill. Unit injectors use a plunger and barrel to pump high pressure fuel into
the combustion chamber. Components of the injector include the tappet, the plunger, the barrel and nozzle
assembly. Components of the nozzle assembly include the spring, the nozzle check, and a nozzle tip. The
cartridge valve is made up of the following components: solenoid, armature, poppet valve and poppet spring.
The injector is mounted in an injector bore in the cylinder head which has an integral fuel supply passage.
The injector sleeve separates the injector from the engine coolant in the water jacket. Some engines use a
stainless steel sleeve. The stainless steel sleeve fits into the cylinder head with a light press fit.

Pre-injection
(A) Fuel supply pressure
(B) Injection pressure
(C) Moving parts
(D) Mechanical movement
(E) Fuel movement.
Pre-injection metering starts with the injector plunger and the injector tappet at the top of the fuel injection
stroke. When the plunger cavity is full of fuel, the poppet valve is in the open position and the nozzle check
is in the open position. Fuel leaves the plunger cavity when the rocker arm pushes down on the tappet and
the plunger. Fuel flow that is blocked by the closed nozzle check valve flows past the open poppet valve to
the fuel supply passage in the cylinder head. If the solenoid is energized, the poppet valve remains open and
the fuel from the plunger cavity continues flowing into the fuel supply passage.

Injection
(A) Fuel supply pressure.
(C) Moving parts
(E) Fuel movement.
To start injection, the Engine Control Module (ECM) sends a current to the solenoid on the cartridge valve.
The solenoid creates a magnetic field which attracts the armature. When the solenoid is energized, the
armature assembly will lift the poppet valve so the poppet valve contacts the poppet seat. This is the closed
position. Once the poppet valve closes, the flow path for the fuel that is leaving the plunger cavity is
blocked. The plunger continues to push fuel from the plunger cavity and the fuel pressure builds up. When
the fuel pressure reaches approximately 34500 kPa (5000 psi), the force of the high pressure fuel overcomes
the spring force. This holds the nozzle check in the closed position. The nozzle check moves off the nozzle
seat and the fuel flows out of the injector tip. This is the start of injection.


End of injection
(C) Moving parts
Injection is continuous while the injector plunger moves in a downward motion and the energized solenoid
holds the poppet valve closed. When injection pressure is no longer required, the Engine Control Module
(ECM) stops current flow to the solenoid. When the current flow to the solenoid stops, the poppet valve
opens. The poppet valve is opened by the fuel injector spring and the fuel pressure. High pressure fuel can
now flow around the open poppet valve and into the fuel supply passage. This results in a rapid drop in
injection pressure. When the injection pressure drops to approximately 24000 kPa (3500 psi), the nozzle
check closes and injection stops. This is the end of injection.


Fill
(C) Moving parts
(E) Fuel movement.
When the plunger reaches the bottom of the barrel, fuel is no longer forced from the plunger cavity. The
plunger is pulled up by the tappet and the tappet spring. The upward movement of the plunger causes the
pressure in the plunger cavity to drop below fuel supply pressure. Fuel flows from the fuel supply passage
around the open poppet and into the plunger cavity as the plunger travels upward. When the plunger reaches
the top of the stroke, the plunger cavity is full of fuel and fuel flow into the plunger cavity stops. This is the
beginning of pre-injection.
Copyright 1993 - 2011 Caterpillar Inc. Mon Sep 12 08:28:04 UTC+0700 2011
All Rights Reserved.
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D7R SERIES II TRACK-TYPE TRACTOR /FINGER TIP CONTROL/ BRP00001-U...

Low Pressure Fuel System

Fuel Injection Timing and Delivery

Unit Injector Mechanism

Injection Actuation System

Operation of the Fuel Injector

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