FUEL SYSTEM
MCRS Fuel System
y
Totally Different
New Terminology
gy
• Modular Common Rail System (MCRS)
• Electric Lift Pump for Engine Fuel Supply
• Fuel Delivery Pump (Gerotor)
• Mechanical Dump Valve (MDV)
• Fuel Pump Pressurizing Assembly (FPPA)
Fuel Pump Notes
•The Q50 pump is called a 5 X 2; 5 pumping plungers and a 2 lobe profile
per plunger camshaft.
•The pump has retracting plungers unlike the Pegasus pump that has
floating plungers.
•The pumping plungers are not ceramic rather, they are metal with a 3
micron wear resistant coating
coating. The coating process is quite common to
other Bosch components.
•The Gerotor drive shaft is a spline drive. It is lubricated by fuel. There are
back to back oil and fuel seals with a weep hole between them, like we have
done on the PT fuel pump.
p p
Fuel System
y
Fuel Delivery Pump (Gerotor)
Accumulator (Produces 5-7 bar fuel pressure)
Fuel Pump
Pressurizing
Assembly
Fuel Pump
(Produces 1600 bar Electric Lift Pump
nominal maximum (Produces 3-5 bar
fuel pressure) fuel pressure)
Stage 1
St Stage 2
Fuel Filter Fuel Filters
(15 micron) (5 micron)
Fuel Injectors
Modular Common Rail Arrangement
Fuel Flow
New – Current Fuel Flow Logic
Fuel Flow
Fuel Flow
Fuel from tank
into stage 1 filter
Fuel out of stage 1 filter
(lift pump or suction loop)
to fuel delivery pump
15 micron
Fuel Flow
Check valve
open
(lift pump
not running)
Fuel Flow
Check valve
closed Lift pump runs for 2 minutes or
(lift pump until 200 bar accumulator pressure
running) is detected
Lift pump produces
3-5 bar supply pressure
Fuel Filters
Stage 1 Stage
g 2
• New filter FS1062 • New filter FF5607
• 906 media (15 micron) • 934 media (5 micron)
• W t drain
Water d i • Nutplate (currently used on the
• WIF sensor with resistor LF3000)
• FS1062 is similar to FS1007 • Shell (currently used on existing filter)
structurally, but with different
media
Fuel Filters Stage 2
• DO NOT fill this filter with fuel
Stage 1 when replacing/servicing.
• Fill with fuel when Install dry to prevent possible
replacing/servicing contamination to fuel system.
This Is Critical!!
Fuel Flow
Water drain fitting
WIF sensor w/83K ohm resistor
Fuel Flow
Fuel into fuel delivery pump
Fuel Flow
Fuel delivery pump
Fuel delivery pump produces
5-7 bar fuel pressure
Fuel to fuel delivery pump
Fuel Flow
Fuel out of fuel delivery pump
to stage 2 fuel filters
Fuel Flow
Fuel
F el from ffuel
el deli
delivery
er ppump
mp
to stage 2 fuel filters
Fuel Flow
Parallel flow
Fuell from
F f stage
t 2
fuel filters to fuel Fuel to
pump pressurizing stage 2
assembly (FPPA) fuel filters
5 micron 5 micron
Fuel Flow
Stage 2 fuel filters
are in parallel
Fuel Flow
Fuel delivery pressure sensor
(pressure after fuel delivery
pump, before stage 2 fuel
filters))
Fuel temperature sensor
(after stage 2 fuel filters)
Fuel Flow
Fuel from stage 2 fuel filters
to fuel pump pressurizing
assembly (FPPA)
Fuel Flow
Fuel into FPPA
Fuel pump pressurizing assembly
(controls amount of fuel delivered
to high pressure pumping
chambers)
h b )
Fuel Flow
5 pumping plungers
1600 bar nominal maximum
fuel pump pressure, 300 bar
minimum for engine to start
Fuel enters HP pump
Fuel Pump
Identification
To identify the fuel pump, you need to record the following:
1. Serial Number
2. Date Code - This is a number like 587 for July
y 2005, the yyear is the 5, the month is 80 +month, so 87
for July
3. Cummins part number
Fuel Flow
Mechanical dump valve
(fuel to return manifold when open)
Air bleed
(fuel to return
manifold)
Recirculation line
(fuel back to fuel delivery pump)
F l Flow
Fuel Fl
Air bleed line contains a 5 bar one way check valve
Fuel Flow
5 bar air bleed
check valve
Fuel Flow
Mechanical dump valve,
opens at 1950 bar
Should not be open, only opens
when fuel pressure is above system
design limits
Fuel Flow
Injector metering rail
pressure sensor
Fuel Flow
Fuel to LB injectors
Fuel to RB injectors
Fuel Flow
All high pressure fuel lines are double wall
wall.
Inner tube is high pressure fuel to injectors.
Outer tube is for fuel from a leaking high pressure
fuel line or high pressure fuel line fitting.
Warning! Do Not Reuse Any of the High
Pressure Fuel Lines Under Any
Circumstances. Whenever a High Pressure
Fuel Line Fitting
g is Loosened,, the High
g
Pressure Fuel Line Must be Replaced.
Fuel Flow
Fuel to LB injectors
Fuel Flow
Fuel to RB injectors
Fuel Flow
Fuel to RB injectors
Fuel Flow
Fuel pressure is common
to all injectors
Modular common rail system, fuel from
injector
j to injector
j
Each injector contains an accumulator
HP Line Between Injectors
HP Li
Line B
Between
t IInjectors
j t
5 1
1. Outerwall Pipe
2. Vibralock Nut
3
3. S l
Seal
8 4. Connector Fitting
3 5. O-Ring Groove
6
6. Sealing Cone
4
7. Innerwall Pipe
7 8. Pressurized Fuel
2
6
HP Line Between Injectors
T connector
T-connector
•Double walled pipe threads into T-
connector.
•3.5mm
35 II.D.
D
•Green – fuel drain line
•Yellow – fuel inlet path
•When removing fuel line, (before
complete
l t d detachment)
t h t) if some
Pressure still in line, fuel will go thru
drain path (Green)
O-ring
HP Line Between Injectors
•Double walled pipe threads into T-
connector.
•3.5mm I.D.
•Green – fuel drain path
•Yellow – high pressure fuel inlet path
•When removing fuel line, (before
complete detachment) if some
Pressure still in line, fuel will go thru
d i path
drain th (G
(Green))
E d off Li
End Line Pl
Plug
•M24
M24 x 1.5 with 27mm Hex head
•0.799” x 0.103” viton o-ring
• Not just any Nut!
• Has a conical shaped end to
seal against Injector
Fuel Flow
Return fuel out of injector
15–18 % of fuel delivered to injectors returns through drain lines
Fuel Flow
RB return fuel
Fuel travels through drillings in
cylinder
li d block
bl k and d joins
j i withith return
t
fuel from LB injectors
Fuel Flow
Return fuel from
LB injectors
Return fuel
from LB & RB
injectors
Fuel Flow
Fuel return line check valve
Return fuel to fuel tank
Fuel Flow
Vent hoses for double wall fuel lines
Fuel will only be present leaking
from these hoses if there is a
high pressure fuel line leak
Fuel Injector
Operational Concept
Fuel Injector
Identification
To identify a unique individual injector, you need to record the following:
1. Serial number
2. Date Code - This is a number like 587 for July 2005, the year is the 5, the month is 80 +month, so 87
for July
3. Cummins part number
F l Injectors
Fuel I j t
How do they operate?
• The injection nozzle is being opened and closed by movements of a nozzle needle.
• The needle is balanced by pressures at the nozzle seat and at the needle control
chamber, at the opposite end of the needle.
• When the solenoid valve is energized (48 VDC) by the ECM, it opens the chamber to the
return fuel line.
• The pressure in the needle control chamber drops, the needle is lifted, the nozzle opens
and the injection begins.
• When the current in the solenoid valve drops to zero, the control valve returns to
its seat.
• The pressure in the needle control chamber increases and becomes equal to the
pressure at the nozzle seat.
• The needle closes due to a nozzle spring force and stops the injection.
• Optimal control of the system is achieved by calibrating several orifices in the hydraulic
assembly of the injector
• A flow limiter (check ball, seat, and spring) is used to prevent large volumes of fuel from
entering
t i the th cylinder,
li d ththus providing
idi engine
i protection.
t ti
Fuel Injectors
• What makes fuel inject is not the High Pressure
Fuel Pump Plunger, but the accumulated pressure
inside the accumulator. The fuel actually compresses
by about 7%.
Fuel Injectors
Fuel to accumulator
and remaining injectors Fuell line
F li outer
t wall
ll
on that bank passages
Flow Limiter
This is a cutout view of what the injector flow limiter looks like
Injector Fuel Flow
F l enters
Fuel t the
th flow
fl limiter
li it region
i off the
th injector
i j t
F l fills
Fuel fill up the
th area above
b the
th flow
fl limiter’s
li it ’ check
h k ball
b ll
F l flow
Fuel fl pushes
h down
d on the
th check
h k ball
b ll compressing
i the
th spring
i slightly
li htl
Fuel then enters the accumulator section of the injector
Fuel fills up the accumulator section of the injector
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
The needle is balanced by pressures at the
nozzle seat and at the needle control
chamber at the opposite end of the needle
chamber, needle.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
When the solenoid valve is energized by the
ECM, it opens the chamber to the
return fuel line.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
The pressure in the needle control chamber
drops, the needle is lifted, the nozzle opens and
the injection begins.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
The pressure in the needle control chamber
drops, the needle is lifted, the nozzle opens and
the injection begins.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
The pressure in the needle control chamber
drops, the needle is lifted, the nozzle opens and
the injection begins.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
When the current in the solenoid valve
drops to zero, the control valve returns to
its seat.
Solenoid Control Valve Control Chamber
Injection Needle
Nozzle Seat
The pressure in the needle control chamber
increases and becomes equal to the
pressure at the nozzle seat. The needle closes
d tto a nozzle
due l spring
i fforce andd stops
t th
the
injection.
Flow Limiter
The flow limiter (check ball, seat, and spring) is used to prevent large volumes of fuel
from entering the cylinder, thus providing engine protection. If large volumes above
normal are suddenly demanded due to an injector malfunction, the check ball
compresses the spring to a point where it seals against the seat,
seat thus cutting fuel
supply to the injector.
Injector Electrical Connector
Bosch
B h connector.
t
Injectors operate with
24 - 48 VDC
INJECTOR DRIVER MAPPING
60 pin ECM Q50/60 source Q50/60 source Q50/60 source
Conn Driver address 00 address 01 address 144
Cylinder # BANK # Cylinder # BANK # Cylinder # BANK #
45 Drv 1+ 2 1R 6 3R 1 1L
53 Drv 1-
54 Drv 2+ 10 5R 7 4L 15 8L Share same
51 Drv 2- Vboost supply
55 Drv 3+ 11 6L 14 7R
52 Drv 3-
56 Drv 4+ 8 4R 4 2R 3 2L
58 D 4
Drv 4-
46 Drv 5+ 16 8R 12 6R 13 7L Share same
60 Drv 5- Vboost supply
57 Drv 6+ 5 3L 9 5L
59 Drv 6-
Fuel Pump
p R&I
• It is critical that all fuel system components
be keptp extremely y clean
• 30 micron is the smallest particle that can
be seen with the human naked eye
• The fuel pump is manufactured to
clearances as small as 6 micron
• Keep it clean!
Warning
Never R
N Remove th the FFuell D
Delivery
li P
Pump.
The End Plate May be Removed, But
N t th
Not the F
Fuell D
Delivery
li P
Pump ItItself
lf
Fuel Delivery Pump
Warning
Never Remove These Bolts
(10)
Fuel Pump
R&I Service Tool
Fuel Pump
Mounting Bolts (6)
Fuel Pump
Rear Support Bracket
There is a specific bolt
This bracket must be removed / tightening sequence for
installed with pump these bolts
Fuel Pump R&I
Service Tool Installed
Fuel Pump R&I
Fuel Pump R&I
Injector R&I
• It is critical that all fuel system components
be keptp extremely y clean
• 30 micron is the smallest particle that can
be seen with the human naked eye
• The injectors are manufactured to
clearances as small as 6 micron
• Keep it clean!
Clean the Injector Tee Fitting Connection
Area and Fuel Line Fittings.
g Clean the
Rocker Cover and Injector Cover Plate.
Loosen the Outer Tube Fittings and Pull
the Seals Away From the High Pressure
Fuel Line Fittings
Loosen the High Pressure Fuel Line
Fitti
Fittings and
dRRemove th
the F
Fuell Li
Line
Follow the Procedure to Carefully Clean
the Injector
j Tee Fitting
g and Immediately
y
Plug the Injector Tee Fitting Connectors
Discard the HP Fuel Line.
Do Not Reuse!
Disconnect the Injector Electrical Connector
Pry up on the Retaining Clip and Remove
the Injector Electrical Connector From the
Mounting Bracket
Remove the Retaining Capscrews and
Remo e the Wiring Harness Mo
Remove Mounting
nting
Bracket From the Rocker Cover
Remove the Two Capscrews Securing the
Injector Cover Plate to the Rocker Cover
Pry the Injector Cover Plate From the
Rocker Cover and Remove
Remove the Three Remaining Rocker
Cover Capscrews and Remove the Rocker
Cover
Using
g a 13mm,, 6 Point,, Flex Head Socket;;
Loosen the Injector Hold Down Capscrew
Install the Cylinder
Head Plug Service
Tool
Need
eed Picture
ctu e With
t Tool
oo Installed
sta ed
Remove the Injector Hold Down Capscrew
with a Magnet
Remove the Injector and Injector
Hold Down Clamp as an Assembly
Injector Hold Down Clamp
Cover the Exposed Overhead Components
Clean and Inspect the Injector, Tee
Connector and Wiring Harness
Replace the Two Injector O-Rings
and
d the
h Injector
I j S
Seall
Inspect the Injector O-Ring/Damper,
Replace if Damaged
Clean and Inspect the Injector Bore
Lubricate the Injector O-Rings and
Damper With Engine Oil
Install the Injector and Injector Hold
Down Clamp as an Assembly
Lightly Snug the Injector Hold Down
Capscrew
Injector Alignment Tool
Install the Injector Alignment Tool and Align
the Injector
Torque the Injector Hold Down Capscrew to 50 ft-
lb loosen
lb, loosen, tighten to 177 in
in-lb,
lb Rotate an
Additional 60 Degrees
Clean the O-Ring Groove in the Rocker
Co er and Install a Ne
Cover New Injector Co
Cover
er
Plate O-Ring
Install a New Rocker Cover Gasket and
Install the Rocker Cover
Cover, Torque the 3
Installed Capscrews
Do not install this
capscrew at this time
Install the Injector Cover Plate, Torque the
Two Capscrews
Install the Electrical Harness Bracket,
T
Torque the
h Capscrews
C and
dCConnect the
h
Injector Wiring Harness
Remove the Protective Plug From the
Injector
Inspect and Install the New Fuel Line,
Tighten the High Pressure Fuel Fittings
Alternately and Evenly, Torque to Specification
Start the Engine, Perform the Fuel System
Leakage Test With INSITE and Check for
Fuel Leaks
If no Fuel Leaks Were Observed; Push the Seals Into
Contact With the High Pressure Fuel Fittings and
Tighten the Outer Tube Fittings to Specification
Fuel System Vent Lines
If Fuel is Leaking From the Vent Lines,
There is a HP Fuel Line or HP Fuel Line
Fitting Leaking
The Fuel Leak Could be From any of the HP Fuel
Li
Lines F
From th
the F
Fuell P
Pump tto the
th IInjectors.
j t Loosen
L
the Outer Tube Fittings, Pull Back the Seals, Start the
Engine and Perform the Fuel System Leakage Test
with INSITE. Continue this Procedure Until the Leak
is Located.
Keep it Clean!
• It is Critical that no Contamination be
Allowed to Enter the Fuel System
y
• Use Appropriate Cleaning Procedures
Before Opening the Fuel System at any
Component
• This is Critical!
