FUEL INJECTION PUMP

Fig 1 Fuel injection pump

FUNCTION
Mico Bosch Fuel injection pumps are being used by kazipet diesel loco shed in construction of the diesel engine block. These are of single acting, constant stroke and plunger type with the effective working stroke, however, being adjustable. The pump consists primarily of a housing, delivery valve and spring, delivery valve holder, element ( plunger and barrel assembly ), plunger spring, a geared control sleeve and control sleeve and control rack assembly. The pump element comprises a barrel and a plunger, which are match assembled to a very close tolerance.

The primary functions of fuel injection pump is

To raise the fuel oil pressure to a value, which will efficiently atomise the fuel To supply the correct quantity of fuel to the injection nozzle commensurate with the power and speed requirement of the engine To accurately time the delivery of the fuel for efficient and economical operation of engine

OPERATION

Fuel oil enters pump from the fuel oil header and fills the sump surrounding the plunger barrel. When the plunger is at the bottom of its stroke (position1), fuel flows through the barrel ports filling the space above the plunger and the cut away area of the helix. As the plunger moves upward, fuel is pumped back to the sump until barrel ports are closed. Further upward movement of plunger (position2) raises the pressure of the trapped fuel. When pressure is sufficient to overcome the force exerted on the delivery valve by the valve spring, the delivery valve opens and the fuel is discharged into the high pressure pipe, leading to the injector. Further upward movement of the plunger increases fuel pressure to enable the injection to occur. Delivery of fuel ceases when the plunger helix opens the barrel ports (position3). During the remaining movement of plunger, fuel spills into the sump. This termination of fuel delivery by the helix controls the quantity of fuel delivered per stroke. The angular position of the plunger, with respect to the barrel ports, determines the effective stroke and therefore, the quantity of fuel injected. The total length of the plunger stroke remains constant regardless of engine speed or load. When the plunger is rotated to a position where the vertical groove is aligned with the control port, no pressure can build up and consequently, no fuel will be delivered. The angular position of the plunger, with respect to barrel, is altered by a control sleeve, the lower end of the sleeve being slotted to engage the flange of the plunger. The upper end of the control sleeve has an integral gear ring, which engages with the control rack. Movement of the control rack by the engine governor rotates the plunger, thereby varying the quantity of fuel delivered by the pump. When the plunger helix first uncovers the barrel ports, the lower edge of the relief piston slides into the valve body and taps all fuel in the injection tube. Further movement of the valve to its seat increases the space available for fuel in the tube and therefore reduces the fuel pressure.

The metered quantity of fuel from the injection pump passes through snubber valve and high pressure line, entering the nozzle holder at the pressure tube inlet connection. Drilled passages in the nozzle holder conduct fuel to the pressure chamber of the nozzles. When the pressure of fuel acting on the pressure chamber exceeds the spring pressure, the nozzle valve is forced from its seat. Fuel then flows through the nozzle spray holes until the fuel pump ceases to deliver fuel. Fuel flow is then instantaneously and positively cut off, as the spring snaps the valve shut. The delivery valve prevents excess draining of fuel from the discharge line. As the plunger helix uncovers the barrel ports, there is a sudden pressure drop in the barrel resulting in the closure of the valve due to higher pressure in the delivery pipe and delivery valve spring force. As the valve snaps into its seat, the pressure is reduced in the injection tubing to lower the opening pressure of the nozzle. This action of the valve eliminates the possibility secondary injection from the nozzle.

The following figure below shows different parts of the fuel pump with their part no. 1. 2. 3. 4. 5. 6. 7. 8. 9. Pump housing (1) Element (2) Regulating sleeve (4) Upper spring plate(5) Plunger spring(6) Plunger guide cup(7) Lower spring plate(9) Spring ring(10) 27. Gasket(33) 28. Banjo bolt for fuel unit(39)

Oring(11) 10. Oring(12)

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Screw(14) Nut(18) Delivery valve spring(19) Delivery valve holder(20) Delivery valve(21) Baffle ring(22) Screw(24) Pointer(25) Latch(26) Screw(27) Shims(28) Control rack assembly(29) Control rack bushing(29) Screw(30) Washer(31) Inspection cover(32)

The sudden drop in pressure in the injection tubing is achieved by providing an accurate relief piston at the end of the delivery valve pin.

Snubber valve
Function: A Snubber valve assembly is fitted on the fuel injection pump at the top of the delivery valve holder using a tubing union sleeve and nut. It is basically a check valve that restricts fuel flow in the reverse direction through a small orifice. Its function is to dampen shock waves travelling through the high pressure line resulting from sudden closure of the delivery valve and the nozzle valve .

Snubber valve

Nozzle Holder and Nozzle

Nozzle Holder
The fuel injection nozzle holder conducts fuel from pump, Snubber valve and high-pressure discharge tubing to fuel injection nozzle and provides a means of adjusting the nozzle valve opening pressure. The nozzle atomises the fuel and directs it in a definite spray pattern into the combustion chamber. The major components of nozzle holder are nozzle holder body, pressure adjusting spring, shims(components washers), guide bush, intermediate disc and nozzle capnut. To adjust nozzle valve opening pressure, shims are used between nozzle holder body and guide bush above the spring. The lower end of nozzle holder is ground to provide leak-proof and pressure-tight seal with the upper surface of intermediate disc.

The lower surface of intermediate disc is provide a pressure tight sealing with the surface of nozzle body. Nozzle holder and nozzle assembly will be referred as injector.

Nozzle
The fuel injection nozzles are closed, hydraulically operated, differential type closing of two parts-nozzle body and nozzle valve (pin). Both these parts should not be exhausted individually but replaced only as an assembly. At the tip of the nozzle body are 9 spray holes through which fuel passes into the combustion chamber. The spring loaded nozzle valve controls the flow.

Injection nozzle

Operation
The metered quantity of fuel from the injection pump enters the nozzle holder through the high pressure inlet tube connection and flows through the drilled passages of nozzle holder and nozzle body to the nozzle pressure chamber when fuel acting on the differential area exceeds the spring force to which the opening pressure is set, the valve is lifted off its seat. Fuel flows through the nozzle spray holes until fuel pump ceases to deliver fuel. The fuel flow is then instantaneously and positively cut off as the spring pressure forces the nozzle valve to its seat. Leakage of fuel between the nozzle valve and nozzle body is

necessary for lubrication. The leakage fuel accumulates in spring compartment. From the spring compartment, fuel drains out of the nozzle holder through a leak off passage, thus preventing the nozzle valve from becoming hydraulically locked.

The following are th parts of injection body 1. 2. 3. 4. 5. 6. 7. 8. Nozzle holder body Compensating washer Spring seat Spring Spindle with guide bush Intermediate disc Nozzle capnut Nozzle