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CATERPILLAR
Common Rail Fuel System

CATERPILLAR Common Rail Fuel System

CATERPILLAR Common Rail Fuel System
CATERPILLAR Common Rail Fuel System
 Orifice

CATERPILLAR Common Rail Fuel System

 Electronic Control Module
(ECM)
• ECM Controls:
– Fuel Pressure
– Speed Governing
– Air/Fuel Ratio
– Start/Stop Sequence
– Engine Protection
Devices/ Diagnostics

CATERPILLAR Common Rail Fuel System

 Fuel Pump Function
• Pump Raises Pressure
• ECM tells Injector to Fire
• Rail Pressure Drops
• ECM Detects Pressure Drop
–Sensed by Fuel Rail
Pressure Sensor
• ECM tells Pump Solenoid to
Increase Volume
–Also tells Pump Solenoid
to Spill fuel once pressure
is reached
• Do it Again!

CATERPILLAR Common Rail Fuel System

 Oil lubrication
Fuel Leak off to Tank Fuel in from
Secondary Filter

To Fuel HP
Manifold

To
Secondary
Pump Speed
Filter
Position Sensor

From
Primary
Locks the Pump Filter

CATERPILLAR Common Rail Fuel System

 Transfer Pump
Driven by High Pressure Pump
Draws Fuel through Primary
Filter
Output Pressure
300 to 600 kPa
Transfer Pump Primed by
Priming Pump
Hand or Electric

CATERPILLAR Common Rail Fuel System

 High Pressure Fuel System
Do’s & Don’ts Fuel Manifold Injector Lines

Do Check for leaks

Do Not Loosen HP Connection
with Engine Running
Do Replace HP Pipes After they
are Loosened
Do Replace ALL Hp Pipes if new
manifold is Installed High PRV
Do Not Force Pipes to Fit
Do Cap Manifold and Injector
Connections Immediately when
HP Pipe is removed Rail Pressure Sensor
CATERPILLAR Common Rail Fuel System
 Fuel Pressure Relief Valve
High Pressure
Protects System from Over- Relief Valve

Pressure
Opens at Constant Pressure of 160
MPa (23,000 PSI)
Withstands Spikes to 190 Mpa
(27,500 PSI)
Returns fuel to Tank

CATERPILLAR Common Rail Fuel System

 Fuel Return from Head
Excess Fuel Returned to Fuel
Transfer Pump Return
from
Not High Pressure Head
LIne

CATERPILLAR Common Rail Fuel System

 Injector Function
Injector De-energizes
Valve Closes
Unused fuel flows back to
Transfer Pump via passage
in the Head

CATERPILLAR Common Rail Fuel System

 Fuel Injector
Do’s and Don’ts
Do Write down the Injector
Serial Number
and Confirmation Code before
you install the Injector
Do use Cat ET to Program ECM
with proper Injector Trim File
Do Look for the Trim File CD in
the Injector Box

CATERPILLAR Common Rail Fuel System

 Injector Adaptive TRIM
Fuel System Optimization Routine
Runs every hundred hours or so
Audible changes when engine is running
NO performance or Power Changes
Everything’s OK
Similar to HD ACERT engines

CATERPILLAR Common Rail Fuel System

CATERPILLAR Common Rail Fuel System
 Cat Common Rail Fuel System
Advantages
C175
Meets emissions High Pressure Rail

Lower fuel consumption

Better transient response

High Pressure
Primary Fuel Filter/
Pump Cooler
Water Separator

Secondary Fuel Filters

Fuel Tank
Electric Priming
Pump

CATERPILLAR Common Rail Fuel System

 Cat Common Rail Fuel System

Low Pressure Fuel System

 FTP
 Electric Priming
 Filtration
CATERPILLAR Common Rail Fuel System
 Cat Common Rail Fuel System

Fuel System
 HP Pump
 Double Wall Lines
 Double Wall Rails
 Flow Limiter
 Injector
CATERPILLAR Common Rail Fuel System
 Cat Common Rail Fuel System - HP Rail
HP Rail

Low Pressure
Injector return Pressure Sensor

Double Wall Double Wall

Crossover Line Lines From HP Pump
To Rail

CATERPILLAR Common Rail Fuel System

 High Pressure Fuel System Hardware
PRV

PRV Outlet
HP Outlet

Oil Supply

Camshaft
FTV Drive
Oil Return Flow Control
Valve

CATERPILLAR Common Rail Fuel System

 Flow Limiter

• Flow Limiter
 Protection Device
Against Cylinder Over
Fueling
 Piston Moves With
Every Injection
 Trips at Set Point To
Prevent Continuous
Injection and Remains Spring
Shut
Piston

CATERPILLAR Common Rail Fuel System

CATERPILLAR Common Rail Fuel System
CATERPILLAR Common Rail Fuel System