Engine Works & Wears

• Engine Wear
• Combustion Process
• Internal Components
• External Components
• Cooling System
• Lubrication System
• Fuel System
• Air System
• Electronics

Single Fuel System

 Function of Fuel System
• Meters the amount
of fuel to achieve
desired power

• Regulates engine
speed and timing
sequence

• Helps control
emissions
Fuel System Operation
 Types of Fuel Systems
• Pump & Line • Unit Injection
 Current Scroll Fuel System  MUI
 New Scroll Fuel System  EUI
 Sleeve Metering Fuel System (SMFS)  HEUI
 Program Electronic Engine Controls (PEEC)  Common Rail
(Single Fuel)
1973 1981 1983 1988E 1994
CSFS MUI NSFS UI HEUI

Pre 1970 1970 1975 1980 1985 1990 1995 2000 2005

Timeline
1974 1987 2004
SMFS PEEC Rail
 Fuel Delivery - History
• Pre-Combustion (PC)
• Direct Injection (DI)
Fuel Line Fuel Line

Fuel Injector
Electrical Wire Fuel Injector
Mechanically
Glow Plug Nozzle Controlled
Fuel Injector Unit Injector
Housing Assembly
Pre-Combustion

Piston Piston
Heat Plug

Pre-Combustion Direct Injection Direct Injection

Pencil Style Unit Injector
 Sleeve Metering Fuel System

Barrel

Fill Port
Plunger

Sleeve

Spill Port

Filling Begin Continue End

Injection Injection Injection
 Scroll Metering Fuel System

• Pump & line governor

• Few moving parts
• Simple mechanical governor
• Easy starting & service
• More tolerant of dirt
• Economical
MUI System
• A unit injector is
positioned above each
cylinder

• A mechanically actuated
governor controls fuel rate
(scroll metered) with
flyweights and springs

• Timing is fixed
EUI System
• A unit injector is
positioned above each
cylinder

• An Electronic Control
Module (ECM) controls
fuel rate and timing

• Injectors are
mechanically actuated by
a camshaft
EUI - Injector Fill
• Without pressure from
the rocker arm, a
spring keeps the
plunger retracted

• Fuel flows into the

injector through the
fill / spill port, past the
solenoid valve and into
the barrel
EUI - Injection
• On a signal from the
ECM, the solenoid
closes the fuel valve
• Pressure elevates at
the tip to the 5,500 psi
needed to unseat the
valve
• Injection begins
EUI - Injection
• Fuel continues to inject
until the ECM signals the
solenoid to open the valve

• Injection timing and

duration is controlled by the
ECM
HEUI System

• A unit injector is positioned

above each cylinder

• An Electronic Control Module

(ECM) controls fuel rate,
timing, and injection pressure

• The injector is hydraulically

actuated
Cat Fuel System – Single Fuel

Fuel Manifold

Pump

C6.6 Injector
 Fuel System Wear & Failure Causes
• Short unit injector life due to excessive abrasive particles in
the fuel
 Abrasive particles damage sealing surfaces causing leakage of
high pressure fuel and low engine power
 Abrasive particles are inherent in most fuels
 Most particles can be removed by using High Efficiency filters

• Injector seizure due to excess water in the fuel

 Always small amounts of water in fuel, which is harmless
 Excess water in fuel reduces the lubricating film strength of fuel
and causes seizure of the injector plunger and barrel
 Maximum amount of allowable water in fuel is 0.1%
Fuel System Wear & Failure Causes
• Injector sticking or seizure due to fuel overheating
 Fuel in the injector “cooks” and produces varnish which
causes components to stick or seize
 Viscosity of hot fuel is inadequate and the fuel film
thickness will not provide adequate protection against
scuffing or seizure of the plunger and barrel
 Fuel overheating can be caused by operating in extreme
ambient temperatures. An auxiliary fuel cooler installed in
the fuel supply line to the cylinder heads may be required
to limit fuel temperatures
 Running fuel tank too low, or running out of fuel causes
the fuel to cycle through the engine too frequently and
becomes very hot. This can be avoided by keeping the
fuel tank levels at ¼ full or above
Fuel System Wear & Failure Causes
• Poor quality oil
 Fuel may be low in viscosity or lubricity. Fuel which is old
or oxidized often contains excessive gums or resins which
promotes injector sticking or seizure.
Effect of Work Environment
• Dust
• Temperature/Climate
• Hours of continuous operation
• Terrain
System Improvement
• Reduce system damage caused by fuel
 Water Separator
 Primary Fuel Filter
 Bypass Flow

• Minimize tip failure caused by aeration

 Maintain fuel supply pressure
Stripping Out Water
• Water Separator
 Second line of defense
• All free water
• 87% emulsified water
 Injector damage
Removing Larger Debris
• Primary Fuel Filter
 10+ micron particle retention
• prevents premature secondary
fuel filter plugging
• protects fuel transfer pump
 Remove Fine Abrasives
• Secondary Fuel Filter
 2 micron and larger
• 98% efficient
 Reduces wear on fuel injectors and pumps
• Essential for higher pressure systems
• Extends life of older systems as well
Double Filter/Double Life
• Series filtration
 Second filter “safety net”
• Second filtering pass
• Filter failure
- Double injector wear life
Engine Works & Wears
• Engine Wear
• Combustion Process
• Internal Components
• External Components
• Cooling System
• Lubrication System
• Fuel System
• Air System
• Electronics
 Air Intake & Exhaust System Functions
Boost air at 300
Inlet air from air º- 400º
cleaners Inlet air from air
cleaners

Exhaust out
Air manifold

From exhaust ports

at cylinder heads

• Provide adequate
quantities of clean • Compresses the
filtered intake air intake air into the
cylinders in order to
• Removes exhaust gases from the product more power
cylinders and reduces exhaust noise
Air System
Air System Components

• Precleaner
• Air Filters
• Filter Service
Indicator
• Turbochargers
• Aftercooler
• Intake & Exhaust
Manifolds
• Muffler
Air System Operation
• Flow
1. Precleaner
2. Air Filters
3. Turbocharger
4. Intake Manifold &
Cylinder Head(s)
5. Combustion
Chamber
6. Exhaust Manifold
• Wear
 Turbocharger
• Bearings
• Seals
Air System Wear & Failure Causes
• Single most common problem – dust ingestion
 Causes accelerated abrasive wear of piston rings & liners
 Most often caused by inlet leaks around flexible joints in
air inlet piping
 May also be caused by defective/damaged air filters, or
poor maintenance practices
• Plugged air filters
• Turbo failures
• Coolant to air leaks in the aftercooler
• Hydraulic lock