Structure & Function

Fuel System & Pump

 3. fuel filter 1. Fuel tank
2. Fuel supply pump assembly 5. common rail
2A. PCV ' 6. Pressure limiter
28. High-pressure pump 7. flow damper
2 C. Priming pump 8. Injector assembly
2D. feed pump 9. fuel cooler
2E. bypass valve 10. ECU (Engine Control Unit)
2F. G revolution sensor 11. NE revolution sensor
4. Overflow valve
*5533333335*552533

51E015B9
 Fuel System Summary
CRI
SUMMARY
The CRI system detects engine conditions (revs, throttle angle, water
temperature etc.) from various sensors and uses a micro-computer
to carry out full control of fuel quantity, injection time and injection
pressure to operate the engine in optimal conditions. The computer
also carries out a self-diagnosis of the main components and if any
abnormality is found, the diagnosis is carried out and an alarm
signal is sent to the operator. There is also a fail-safe function to
stop the motor depending on where the abnormality is located and a
safety function to change the control method to make it possible to
continue operation.
 CRI Fuel System Overview
1. Fuel System
High pressure fuel generated by the supply pump goes from the
common rail and is distributed to each cylinder. The start and end of
the injection is controlled by the opening or closing of the nozzle
needle valve, using an electromagnetic valve located inside the
injector.

electronic
control

• Needle hit control

Discharge volume with solenoid valve
control
I ejection common
fuel tank rail
 CRI System Overview
The CRI system consists of a fuel supply pump, common rail,
injectors, sensors and the ECU control unit.
Structure & Function of the CRI System

The supply pump generates fuel pressure inside the CR. Fuel
pressure is controlled by the amount of fuel discharged from
the supply pump. The amount of fuel discharged is controlled
by sending an electrical signal from the ECU to the ON-OF
supply pump PCV (discharge control valve) switch. The CR
accepts pressurized fuel generated by the fuel supply pump.
And distributes it to the cylinders. Fuel pressure is sensed by
the fuel pressure sensor located in the CR. This performs
feedback to ensure that the current pressure values match the
set values for the load and engine revolutions.
Structure & Function of the CRI System

The pressurized fuel from

the CR reaches each
cylinder through the
injection pipes and is sent
to the control chamber
and the injector nozzles.
Structure &
Function of the CRI
System
The injector controls the amount of fuel injected and the
timing of the injection. This is controlled by the ON-OFF
position change of the TWV valve (2-way electromagnetic
valve). When TWV is in the ON position (current flows), the fuel
circuit is changed so that high pressure fuel in the control
chamber passes through the orifice and flows out. The needle
valve rises because the nozzle burst pressure is actuated by
the high pressure at the end of the nozzle and injection begins.
When TWV is OFF (no current flowing), it becomes the fuel
circuit with high pressure circuit applied through the orifice,
so the needle valve goes down and injection ends.
 Structure & Function of the CRI
Systemthe injection timing is
Therefore,
electronically controlled by the time that
electricity passes through TWV, and the
amount of fuel injected is controlled by
the amount of time that current passes
through TWV.
Fuel system
Fuel Pump
PCV replace
with
primary pump
assembly
 plate valve

delivery valve

barrel
overflow valve
plunger

replace with a
game
Cylinder NO sensor
adjustment of (2.5±0.5 μ
ｍ)
transfer pump

eccentric spring cranksh

aft
eccentric

roller bearing
(inside of the )
9. Gear
 Fuel Pump
1. 3 protrusion type chamber
2. Overflow valve
3. drive gear
4. High pressure pump No.1
5. PCV (delivery control valve)
6. High pressure pump No 2
7. Primary pump
8. Feed pump
 Fuel Pump - Pump
Feeder

To pump chamber

Rotor
Pressure
chamber

drive shaft

From fuel tank

Fuel Pump - PCV Control Valve
Fuel System - Valve Operation
With the high pressure pump, pump control valves
(discharge quantity control valves) are installed to
each cylinder to control the force of the fuel supply
system and the discharge quantity of fuel in the same
way as a fuel pump. conventional in-line injection.

With the use of 3-prong chambers, the necessary

number of high-pressure pumps (cylinders) is reduced
to 1/3 of the number of engine cylinders. In addition,
the feeding force in the CR is the same number of
times as the number of times of fuel injection, this
makes it possible to obtain a smoother and more
stable pressure in the CR.
Fuel System -Valve Operation
The fuel feed force from the high pressure pump to the
CR is divided as follows for each pump.

High pressure pump No. 1 (drive gear side) (4) covers

the pressure drop within the CR due to fuel injection
into the No. cylinders. 1, no. 3 and No.5, while high
pressure pump No. 2 (feed pump side) (6) covers the
pressure drop of cylinders No.2, No.4 and No.6 of the
CR in the same way.
 Fuel System - Valve Operation

Suction process Force feed process

operation arge

cam lift

Open valve
PCV operation
close valve
ECM - Power Off PCV

PCV

To common rai Ri

Delivery valve
Plunger

STEP
Fuel System - Valve Operation
Operation

A. During the downward stroke of the plunger, the PCV is

open, so low pressure fuel passes through the PCV and is
sucked into the plunger chamber.

B. Even when the plunger enters the upstroke while there is

no electricity flowing to the PCV and it remains open, the
fuel taken passes through the PCV, so the pressure does
not increase and it is returned.
operation Fuel System - Valve Operation

Suction process Force feed

cam lift
 Open valve
PCV operation

ECN PCV
ECM - Power ON PCV
To common rail

PCV
OFF

Plunger
Fuel System - Valve Operation
Operation

C. When electricity is sent to PCV to close the valve

just in time for the required discharge amount, the
return passage is closed, and the pressure in the
plunger increases. Therefore, fuel passes through the
delivery valve (check valve) and is forced to feed the
CR. In other words, when the PCV is closed, the
plunger rises making the discharge amount, and by
changing the time of closing the PCV (plunger before
stroke), the discharge amount changes and the fuel
pressure in it is controlled.
Fuel System - Valve Operation
Operation

D. When the cam passes the maximum height, the plunger

enters the downward stroke and the pressure inside the
plunger chamber drops. When this happens, the delivery
valve closes and stops the fuel supply force. Additionally,
current flow to the PCV is stopped, so the PCV opens and
low-pressure fuel is sucked into the plunger chamber. In
other words, it returns to the condition in A.
CRI - Valve Operation
CRI - Valve Operation

KEY/SW

NDE
CRI- Fuel Pipes

1.
Fuel System Summary.......................................................................................................4
CRI.....................................................................................................................................4
Fuel Pump........................................................................................................................14
Fuel System - Valve Operation.......................................................................................17
Fuel System -Valve Operation........................................................................................18
Fuel System - Valve Operation.......................................................................................20
Fuel System - Valve Operation.......................................................................................23
Fuel System - Valve Operation.......................................................................................24
CRI- Fuel Pipes...............................................................................................................28
CRI- Fuel Pipes...............................................................................................................33
CRI - Limiter...................................................................................................................37
CRI - Normal Flow..........................................................................................................39
CRI - Abnormal Flow......................................................................................................40
CRI - Pressure Limiter.....................................................................................................41
2.
3. CR (Common Rail)
4. Fuel return pipe
5. Main Pump
6. Feed pump
7. Oil inlet tube (for pump lubrication)
8. high pressure pump
9. Fuel supply pump drive gear
(No. of teeth: 48)
10. Overflow valve
11. PCV
CRI- Fuel Pipes

MENU
CRI - Fuel Pipes
1. Mounting bracket Specifications
2. Core
• Method: Air cooled
TO. From the fuel
tank • Core type: AL-CFT-1
b. To supply pump • Heat dissipation surface:
3.31m 2
CRI- Fuel Pipes
The CR acts to distribute the high-pressure fuel generated by the high-pressure pump
and send it to the injectors of each cylinder. The CR is equipped with a fuel pressure
sensor, flow limiter, and pressure limiter. The flow restrictor is equipped with a fuel
injection tube and sends high pressure fuel to the injector. The pressure limiter line is
located to return fuel to the tank.
CRI - Components
 CRI - Limiter
The flow restrictor reduces pressure pulses
within the high pressure lines and acts to
supply fuel at a stable pressure to the injector.
If any excess fuel flows, it acts to close the fuel
passage and prevent any abnormal fuel flow.
If any overflow is generated, the high pressure
hits the piston, the piston and ball move to the
right as shown in the diagram and contact the
seat. As a result the fuel passage is closed.
CRI - No Flow
- Normal Flow
The flow restrictor reduces pressure pulses within
the high pressure lines and acts to supply fuel to
the injector at a constant pressure.

Piston Ball
 CRI - Abnormal Flow
As we said previously, if any abnormal flow is generated, the high pressure hits the
piston, so it and the ball move to the right and come into
contact with the seat, as shown in the figure. As a result the
fuel passage is closed.

seat
common rail Injector

Piston Ball Spring

 CRI - Pressure Limiter

The pressure limiter opens if any abnormal high pressure is generated, and acts to
release the pressure. This is actuated (opens) if the pressure in the CR reaches
approximately 140 MPa {1,430 kg/cm 2 }, and when the pressure drops to
approximately 30 MPa {310 kg/cm 2 }, it returns to the previous position (closes) thus
maintaining the pressure.
CRI - Pressure Limiter
 RI - CR Pressure Sensor

VPC

4.0v
160Mpa

50 100 150
Provides a pressure reading for
Pressure PC (Mpa)
the ECM supply
 CRI- CR pressure sensor
The CR fuel pressure sensor is installed on the CR and detects fuel pressure. The sensor
is a semi-conductive pressure sensor. This uses the characteristics of silicon, which
changes its electrical resistance if pressure is applied to it.

ECU
CRI- Related electrical circuit diagram

VPC
A-VCC

VPC

A-GND

150

Pressu PC (MPa 1 ke/cm]

engine controller re
pressure sensor PFL
EC2 (HD30-31) (DENSO-3)
common rail pressure

Power sensor (5V)

Analog GND

BJE00314