SEN00309-00 10 Structure, function and maintenance standard

Fuel system 1
CRI system diagram 1

CRI is an abbreviation for common rail injection.

12 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-00

1. NE speed sensor
2. Engine controller
3. Injector
4. Fuel tank
5. Pre-fuel filter
6. Main fuel filter
7. Overflow valve
8. Fuel supply pump assembly
9. PCV
10. High-pressure pump
11. Feed pump
12. Relief valve
13. G speed sensor
14. Common rail
15. Flow damper
16. Pressure limiter
17. High-pressure injection pipe
18. Priming pump (Main)

12V140E-3 Series 13
SEN00309-00 10 Structure, function and maintenance standard

Outline of CRI system 1

Outline 1. Fuel system
The CRI system checks the condition of the
engine (engine speed, accelerator angle, cool-
ant temperature, etc.) with sensors.
The microcomputer of the CRI system controls
the fuel injection rate, fuel injection timing, fuel
injection pressure, etc. totally to operate the
engine under the best condition.
The CRI system has a diagnosis function and
an alarm function, with which the computer of
the system checks the main component parts
and notifies the operator of detected failures.
In addition, the CRI system has a failsafe func-
tion which stops the engine when a certain
parts fail and a backup function which contin-
ues the operation by changing the control
method in such a case.

Configuration
The CRI system is divided by the function into
the fuel system and control system.

The fuel system distributes the high-pressure

fuel generated by the fuel supply pump to the
cylinders through the common rail.
The solenoid valve in the injector opens and
closes the nozzle needle valve to start and fin-
ish fuel injection.

14 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-00

2. Control system

To the ECU (engine control unit), the signals

are sent from the sensors installed to the
machine. Based on the signals, the ECU cal-
culates and controls the energizing timing and
energizing period of the injector to inject proper
quantity of fuel in proper timing.
The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.

12V140E-3 Series 15
SEN00309-00 10 Structure, function and maintenance standard

Structure and operation of CRI system

The CRI system consists of fuel supply pump, If the TWV is turned ON (energized), the fuel
common rail, injector, ECU which controls circuit is changed so that the high-pressure
these 3 units, and sensors. fuel in the control chamber will flow through the
The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
The fuel discharge rate is controlled by turning If the TWV is turned OFF (de-energized), the
on and off the PCV (pressure rate control fuel circuit is changed so that the high-pres-
valve) of the fuel supply pump according to the sure fuel will flow to the control chamber
electric signals from the ECU. through the orifice. As a result, the needle
The common rail receives the pressurized fuel valve lowers to finish fuel injection.
from the fuel supply pump and distributes it to Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
The fuel pressure in the common rail is applied
to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
The injector controls the fuel injection rate and
fuel injection timing by turning ON and OFF the
TWV (2-way solenoid valve).

16 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-00

Structure and operation of component parts 1

1. Fuel supply pump

1. 3-thread type cam 6. No. 2 high-pressure pump

2. Overflow valve 7. Priming pump
3. Drive gear 8. Feed pump
4. No. 1 high-pressure pump 9. Gear for G speed sensor
5. PCV (Discharge rate control valve)

Outline Since the number of the times of feeding fuel

The fuel supply pump consists of priming to the common rail is the same as the number
pump (7), feed pump (8), and high-pressure of the times of fuel injection, the common rail
pumps (4) and (6). fuel pressure is smooth and stable.
The function of the fuel supply pump is to gen- The fuel fed by high-pressure pumps (4) and
erate common rail fuel pressure by controlling (6) to the common rail is divided as follows.
the fuel discharge rate. No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
Structure rail fuel pressure caused by fuel injection into
High-pressure pumps (4) and (6) have the the No. 1, 3, and 5 cylinders.
pressure feed systems similar to those of the No. 2 high-pressure pump (on the feed pump
conventional in-line fuel injection pump and the side) (6) compensates for drop in the common
PCVs (pressure control valves) for each cylin- rail fuel pressure caused by fuel injection into
der to control the fuel delivery. the No. 2, 4, and 6 cylinders.
By employing the 3-head cam, the necessary
number of the cylinders of high-pressure
pumps (4) and (6) is reduced to 1/3 of the
engine cylinders.

12V140E-3 Series 17
SEN00309-00 10 Structure, function and maintenance standard

Operation

(A): The PCV is open when the plunger is in

lowering stroke, through which low-pres-
sure fuel is sucked in the plunger chamber.
(B): While the PCV is not energized and is open
after the plunger starts the rising stroke, the
sucked fuel is returned through the PCV
without being pressurized.
(C): If the PCV is energized and closed in the
timing for the necessary delivery, the return
passage is closed and the pressure in the
plunger chamber rises. Accordingly, the
fuel is fed through the delivery valve (check
valve) to the common rail. That is, the
quantity of the fuel corresponding to the
plunger lift after the PCV is closed is deliv-
ery. The delivery is changed and the com-
mon rail fuel pressure is controlled by
changing the opening timing of the PCV.
(D): After the cam passes the maximum lift
point, the plunger starts the lowering stroke
and the pressure in it lowers. At this time,
the delivery valve closes to stop feeding the
fuel. Since the PCV is de-energized, it
opens and the low-pressure fuel is sucked
in the plunger chamber, or the state of (A)
starts again.

18 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-00

1) PCV (Pressure control valve) 2) Feed pump

The PCV adjusts the fuel delivery from the fuel The feed pump built in the fuel supply pump
supply pump to adjust the common rail fuel assembly draws the fuel from the fuel tank and
pressure. It means that the delivery from the sends it through the fuel filter to the high-pres-
fuel supply pump to the common rail is decided sure pump chamber.
by the timing of energizing the PCV. The outer and inner rotors of the feed pump
are rotated by the camshaft.
The fuel is sucked in on the suction side and
discharged on the delivery side according to
the increase and decrease of the spaces
between the outer and inner rotors.

12V140E-3 Series 19
SEN00309-00 10 Structure, function and maintenance standard

2. Common rail

Structure
Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injec-
tors of the cylinders.
Common rail (4) is equipped with common rail
fuel pressure sensor (2), flow dampers (1), and
pressure limiter (3).
The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
the injectors.
The piping of the pressure limiter (3) is
returned to the fuel tank.

1) Flow damper

Function
The flow dampers damp the pressure pulses in 2) Pressure limiter
the high pressure piping and supply the fuel to If abnormally high pressure is generated, the
the injectors with stable pressure. pressure limiter opens to release that pres-
If excessive fuel flows out, the flow dampers sure.
block the fuel passage to prevent abnormal If the common rail fuel pressure reaches about
outflow of the fuel. 140 MPa {1,430 kg/cm2}, the pressure limiter
If the fuel flows out abnormally, high pressure operates (Opens).
is applied to the piston, which moves to the If the common rail fuel pressure lowers to 30
right until it reaches the seat to stop the fuel. MPa {310 kg/cm2}, the pressure limiter resets
itself (close) to maintain the pressure.

20 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-00

3) Common rail fuel pressure sensor

The common rail fuel pressure sensor is
installed to the common rail to sense the fuel
pressure.
This sensor is a semiconductor pressure sen-
sor, which utilizes the phenomenon that the
electric resistance of silicon changes according
to pressure applied to it.

12V140E-3 Series 21
SEN00309-00 10 Structure, function and maintenance standard

3. Injector

Outline
The function of the injector is to inject the high
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
The nozzle sprays the fuel.

22 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-00

Structure

1. Inlet connector 7. Orifice (in)

2. Terminal 8. Pressure control chamber
3. Upper body 9. Command piston
4. Solenoid 10. Spring
5. Valve body 11. Pressure pin
6. Orifice (out) 12. Nozzle assembly

The injector consists of the nozzle section, ori-

fice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve sec-
tion.

12V140E-3 Series 23
SEN00309-00 10 Structure, function and maintenance standard

A: No fuel injection C: Finish of fuel injection

B: Start of fuel injection D: From common rail

1. Nozzle 5. Valve body

2. Control piston 6. Solenoid
3. Orifice (in) 7. Spring
4. Orifice (out) 8. Pressure control chamber

Operation
1) No fuel injection (A) 3) Finish of fuel injection (C)
While solenoid (6) is not energized, valve body If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber Since the high-pressure fuel in the common
(8), nozzle (1) is closed and the fuel is not rail is applied to pressure control chamber (8)
injected. suddenly at this time, nozzle (1) is closed
quickly and fuel injection is finished sharply.
2) Start of fuel injection (B)
If solenoid (6) is energized, valve body (5) is
raised by electromagnetic power to open the
fuel passage.
Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and the fuel injection pump starts.
The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
Continuing energization to solenoid (6) pro-
vides the maximum fuel injection rate.

24 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-00

Electric circuit diagram

Since high voltage (65V) is applied to the

wiring harnesses connected to the ECU,
COMMON1 and COMMON2 of ECU, and
TWV#1 – #6 of the injector, take care not to
get an electric shock.

12V140E-3 Series 25
SEN00309-00 10 Structure, function and maintenance standard

4. Various sensors and relays

1) Fuel temperature sensor 2) NE speed sensor (Crank angle sensor)

The fuel temperature sensor senses the fuel If the signal hole made on the flywheel passes
temperature and sends it to the engine control- the sensor, the magnetic line of force changes.
ler. The sensor unit is a thermistor the resis- If the magnetic line of force changes, the out-
tance of which changes according to the put of the hall element sensor changes linearly
temperature. and it is converted into pulse of 0 - 5 V by the
The engine controller applies voltage to the wave form shaping circuit in the sensor, and
thermistor and senses the temperature by the then output.
voltage divided by the resistance in the com-
puter and the resistance of the thermistor.

26 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-00

3) Atmospheric pressure sensor 4) Common rail pressure sensor

This sensor is used to correct altitude.
5) Oil pressure sensor

A: Pressure inlet
B: Mounting screw: M5
Tightening torque:
4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}
The following graph shows the output charac-
teristics of the atmospheric pressure sensor.

12V140E-3 Series 27
SEN00309-00 10 Structure, function and maintenance standard

6) Bkup speed sensor (G sensor) 7) Charge pressure sensor

(Cylinder No. sensor) This sensor is used to sense the charge pres-
Similarly to the NE speed sensor, this sensor sure (boost pressure).
utilizes the pulses of 0 – 5 V generated by the
change of the magnetic line of force crossing
the sensor unit.
The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 120°.
In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are gener-
ated every 2 revolutions of the engine.
The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.

A: Mounting screw: M6
Tightening torque:
5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}

1. Sensor
2. O-ring

The following graph shows the output charac-

teristics of the charge pressure sensor.

28 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-00

8) Charge temperature sensor 9) Coolant temperature sensor

The charge temperature sensor senses the The coolant temperature sensor senses the
intake air temperature (boost temperature) and coolant temperature and sends it to the engine
sends it to the engine controller. controller.
The sensor unit is a thermistor the resistance The sensor unit is a thermistor the resistance
of which changes according to the tempera- of which changes according to the tempera-
ture. The engine controller applies voltage to ture. The engine controller applies voltage to
the thermistor and senses the temperature by the thermistor and senses the temperature by
the voltage divided by the resistance in the the voltage divided by the resistance in the
computer and the resistance of the thermistor. computer and the resistance of the thermistor.

12V140E-3 Series 29
SEN00309-00 10 Structure, function and maintenance standard

Various controls

30 12V140E-3 Series
10 Structure, function and maintenance standard SEN00309-00

The CRI system controls the fuel injection rate

and fuel injection timing more properly than the
mechanical governor or timer of the conven-
tional fuel injection pump.
For the control of the system, calculations nec-
essary to the ECU are performed from the sig-
nals sent from the sensors installed to the
engine and machine.
The energizing timing and energizing period of
the injector are so controlled that the optimum
quantity of fuel will be injected in the optimum
timing.

1. Fuel injection rate control function

The fuel injection rate control function is
employed instead of the function of the con-
ventional governor. It controls the fuel injection
according to the signals of engine speed and
accelerator angle so that the fuel injection rate
will be most proper.

2. Fuel injection timing control function

The fuel injection timing control function is
employed instead of the function of the con-
ventional timer. It controls the fuel injection tim-
ing most properly from the engine speed and
fuel injection rate.

3. Fuel injection pressure control function

(Common rail fuel pressure control
function)
The fuel injection control function (common rail
fuel pressure control function) controls the fuel
discharge rate of the fuel supply pump by mea-
suring the fuel pressure by the common rail
fuel pressure sensor and feeding it back to
ECU.
This function performs pressure feedback con-
trol so that the fuel injection pressure will be
the same as the optimum value (command
value) set according to the engine speed and
fuel injection rate.

12V140E-3 Series 31
SEN00309-00 10 Structure, function and maintenance standard

Fuel piping 1
Left bank

The shape is subject to machine models.

1. Main fuel filter

2. Pre-fuel filter
3. Priming pump (Main)
4. Fuel pipe (From pre-fuel filter)
5. Fuel pipe (To feed pump)
6. Drain pipe

32 12V140E-3 Series