DIESEL FUEL SYSTEM

This system is employed in vehicles that run on Diesel Fuel. The function of fuel injection system is
to inject proper quantity of fuel into the engine cylinder at the correct time for a predetermined period.
The fuel injection system may be classified into two.
1. Solid Injection System
2. Air Injection System
Solid Injection system
In this system only fuel is injected.
Air Injection System
In this system fuel is injected along with compressed air. Out of the above solid fuel injection system is
most commonly used. It is again classified into two.
1. Common Rail Injection System
2. Individual Pump Fuel Injection System
Common Rail Injection System

In this type there is single injection pump with injector for each cylinder. The unit injectors are operated by
cam and springs. A linkage connect the control racks of all the unit injectors to control the quantity of fuel.
The fuel is taken from the fuel tank by the fuel pump and is supplied at low pressure to a fitter, and to all
injectors. This is not used commonly now.




Individual Pump Injection System

The fuel is drawn from the tank by means of fuel pump. This fuel is then passed through the filter
and reaches fuel injection pump. There it gets pressurized and send to the injector. There it injects definite
quantity of fuel into individual cylinder according to the firing order.
Components of Individual Pump System
1. Diesel Tank
2. Low pressure lines
3. Water Separator
4. Fuel Feed Pump
5. Fuel Filter
6. Fuel Injector Pump (H. P. Pump)
7. High Pressure Lines
8. Injector
9. Heater Plug
Fuel Feed Pump






This pump feeds fuel from tank to the fuel injection Pump through filter. It is driven from an
eccentric or cam on the injection pump camshaft. It consists of a Suction Valve, delivery Valve, a plunger
with return spring, a spindle with tappet and housing. As the cam rotates the tappet moves and its
movement is transmitted to the plunger through spindle. The return stroke of the plunger is done by
means of plunger return spring. When the eccentric is at minimum throw, the plunger moves inwards by
the pressure of the return spring, creating Suction, which lifts the suction valve and draws fuel from fuel
tank through the front side of plunger. When the eccentric rotates it moves the plunger against the spring
force. The suction valve is closed and the fuel is forced through the delivery valve. The cycle is repeated
and fuel discharges continuously. To permit manual feeding of fuel when the engine is stationary a priming
pump is fitted with the feed pump.
Fuel Filter
Since the clearance between the plunger and barrel is very low, the slightest dust particles can
damage the fine clearance between them. So to protect it from impurities like dust, metal particles etc. the
diesel oil should be very clean. For this purpose filters are used. In Indian vehicles mostly two filters are
used. One is primary filter with felt cloth as filtering element and other one is secondary filter with paper
as filtering element. The secondary filter with paper element should be replaced at 20000- to 25000 km,
while primary filter can be reused by cleaning it 2 to 3 times.
Fuel Injection Pump

The function of fuel injection pump s to deliver accurately, metered quantity of fuel under high
pressure, at the correct instant and in the correct sequence, to the injector fitted on each engine cylinder.
The injection pump is driven from the engines timing gears and its output is controlled by the driver
through accelerator pedal.
The main parts of the pump are the delivery valve, the plunger, the control sleeve, and the control rack.
The camshaft creates the plunger movement for each pumping element occurring in the firing
order and at the correct point in the engine's cycle of operation. As the plunger moves up, it first cuts off
the spill port. During its movement it pushes back a small quantity of fuel through the inlet port until the
top edge of the plunger cuts off this port from the space above the plunger, which is completely filled with
fuel. The rising plunger pressurizes the trapped fuel and forces open the delivery valve situated above the
plunger. The plunger then transmits rising pressure through the existing fuel in the pipeline to the injector-
nozzle needle. Eventually this pressure build-up lifts the needle off its seat, and fuel is sprayed out into the
combustion chamber.
Further upward movement of the plunger forces fuel past the delivery valve until the upper edge
of the plunger helical groove is exposed to the barrel spill port. As fuel escapes down the axial spill
passage, across to the helical groove, and out through the spill port the fuel pressure suddenly collapses.
The spring-loaded delivery valve is then closed, due to which fuel delivery and injection stop.

Calibration
Measurement of fuel delivered by each element of an Injection pump at a fixed control setting and
adjusting these setting so as to ensure that equal quantity of fuel per stroke of each plunger is supplied to
all the cylinders is known as calibration.
This is done by changing the relative position of both the quadrant of each pump element.
Phasing
The testing and adjusting of injection pump for the accuracy of its firing interval is known as
phasing. It is done by adjusting the height of tappet assembly or by adding or removing shims.
Governors
All diesel engines are equipped with governors to ensure that engine does not pick up speed when
there is no load on it as the speed of engine is depended on the quantity of fuel injected. Secondly, the
governors have also to supply enough fuel when engine is loaded so that the vehicle speed does not get
down. There are various types of governors used in diesel engine. These are follows.
1. Mechanical Governor
2. Pneumatic Governor
3. Combined (Mechanical and pneumatic)
4. Hydraulic Governor
Mechanical Governor





Mechanical Governor works on the centrifugal force principle. Two spring loaded weights are
mounted on the governor shaft which gets drive from the engine. At the one end, the bell crank levers
carry balls whereas their other ends touch the lower surface of the flange of a sleeve on the governor
shaft. As the engine speed increases, the centrifugal force due to the weights acts against the spring
tension. Once the former exceeds the latter, causing the other ends of the bell crank levers to raise the
sleeve and hence operating the control lever in the downward direction which further actuates the control
rack on the fuel injection pump in a direction which reduces the amount of fuel delivered and hence
decreases the engine speed. In this way, the amount of fuel delivery is increased when the engine speed
tends to decrease.
Pneumatic Governor



Pneumatic governors are having two parts
1. Venturi air flow control unit
2. Diaphragm unit
Venturi airflow control unit is fixed in inlet air manifold
under the air cleaner. In this unit a small venturi is fixed by the
side of butterfly valve, so that quantity of air can be increased
or decreased as desired. The butterfly valve is linked to the accelerator pedal with linkage from the venturi.
A suitable pipe is taken for fixing pipe connecting diaphragm unit.
The diaphragm unit if fitted at the end of the injection pump over the opening of control rod. This
unit consists of two chambers separated from each other by a diaphragm. The outer chamber is called
vacuum chamber and is connected to venturi unit while other unit is connected to atmospheric pressure.
As soon as the engine starts vacuum produced in the venturi acts on the diaphragm and pulling it
outward taking along with control rod. As the speed of engine increases or decreases the vacuum in the
venturi also increases and decreases, so the diaphragm is pulled out and speed is kept under control. To
stop the engine a stopper lever is placed in the atmospheric chamber which when pulled up the diaphragm
along with control rod comes to stop position. In some vacuum chamber a spring is placed in to the cover,
which is adjustable and is adjusted to run the engine without hinting idling speed.
Injectors
Injector is a device, which spray Diesel oil in a fine atomized form just before the piston reaches TDC in
compression stroke.
The main functions of Injectors are
1. It should inject in fine atomized form
2. The atomized fuel should mix up with hot air to form a uniform mixture for proper combustion.
3. Fuel injection and cut of should be rapid
4. It should not dribble











The main part of an Injector is a spring-loaded needle valve. It is held by a spring on its seat by
spring pressure, until high pressure fuel is applied through the injection pipe. The pressure increases and
nozzle valve gets shifted up from its seat and the fuel under pressure sprayed in to the combustion
chamber through holes provided on nozzle tip. The fuel spray continues till the delivery from injection
pump is stopped. Then the spring pressure again closes the nozzle valve back in its seat. A small quantity of
fuel is allowed to leak between the nozzle valve and guide for lubrication purpose. The fuel accumulated
around the spindle in this way get de-pressurized and drained back to the fuel tank through the leak off
connection. In injector needle valve lifting pressure can be adjusted by tightening or loosening the spring
tension by adjusting screw.
Types of Nozzle
There are three types of nozzles used. They are
1. Simple hole type
2. Pintle type
3. Pintaux type
Simple type nozzle are further classified as follows
Simple hole
Multi hole
In simple hole type there is only one hole, which is usually in the center of valve body, but in some
cases it is made at an angle also. While in multi hole type there can be two or four holes drilled at certain
angle. The diameter of hole drilled in the body is usually 0.45 mm. Both nozzle body and nozzle valve are
supplied as a pair and are not interchangeable.


Pintle nozzle

The construction of this nozzle is like simple hole nozzle except that the valve is extended and is projected
out of the body. The projected portion is known as Pintle.
Pintaux nozzle




Pintaux nozzle is like pintle nozzle except that needle valve is extended and another auxiliary hole is drilled
in the body. In the beginning of spray approximately 10% of the fuel is sprayed from this auxiliary hole.
Type of Combustion Chamber
1. Open Combustion Chamber or Direct injection type.
2. Pre-Combustion chamber
By considering different types of combustion chambers we gets better fuel burning so that engine
develops full power. For complete burning of fuel it is very necessary that atomized fuel should get mixed
up properly with the compressed air and engine should start quickly in cold condition.
Pre-Combustion chamber are again classified into various shapes and designs.
1. Turbulence chamber
2. Energy cell
Open Combustion Chamber
This is the simplest type of chamber where cylinder head is flat but on the piston crown are made
in various shapes. These shapes help in developing swirl action of hot compressed air. Injection pressure
used in this type is quiet high being simple in design and less cost.


Pre - Combustion chamber
Pre-combustion chamber are usually tubular in construction and fitted in the cylinder head. These
are connected to the main cylinder through a pre combustion chamber fitted at the upper end. Such
combination chamber considered well burning the fuel completely but it gives problem in cold starting.


Turbulence chamber
This type of chamber is also like pre combustion chamber the only difference is that these are
circular in construction and are placed in the cylinder head. There is a very little distance between the
cylinder head and the opening to turbulence chamber