卡特彼勒高壓共軌C64

1、C6.4 ENGINE OVER VIEW高壓共軌系統(tǒng)被世界內(nèi)燃機(jī)行業(yè)公認(rèn)為20 世紀(jì)三大突破之一,將成為21世紀(jì)柴油機(jī)燃油系統(tǒng)的主流。C6.4 ENGINE OVER VIEWWhat is a C6.4?C : Current nomenclature for CAT branded engines6.4 : Engine displacement in Liters 1.06 Liter per Cylinder, 6 cylinder Inline Bore : 102 mm, Stroke : 130 mm Piston Displacement : 6.373 liter Rate

2、d Power : 110 117 kW (148-157 hP) 1800 rpm Compression ratio : 17.7 Turbocharged - ATAAC Replaces the 3066 mechanical engineC6.4 ENGINE OVER VIEW高壓共軌系統(tǒng)利用較大容積的共軌腔將油泵輸出的高壓燃油蓄積起來，并消除燃油中的 壓力波動(dòng)，然后再輸送給每個(gè)噴油器，通過控制噴油器上的電磁閥實(shí)現(xiàn)噴射的開始和終止。其主要特點(diǎn)可以概括如下： 共軌腔內(nèi)的高壓直接用于噴射，可以省去噴油器內(nèi)的增壓機(jī)構(gòu)；而且共軌腔內(nèi)是持續(xù)高壓，高壓油泵所需的驅(qū)動(dòng)力矩比傳統(tǒng)油泵小得多。 通過

3、高壓油泵上的壓力調(diào)節(jié)電磁閥，可以根據(jù)發(fā)動(dòng)機(jī)負(fù)荷狀況以及經(jīng)濟(jì)性和排放性的要求對(duì)共軌 腔內(nèi)的油壓進(jìn)行靈活調(diào)節(jié)，尤其優(yōu)化了發(fā)動(dòng)機(jī)的低速性能。 通過噴油器上的電磁閥控制噴射定時(shí)，噴射油量以及噴射速率，還可以靈活調(diào)節(jié)不同工 況下預(yù)噴射和后噴射的噴射油量以及與主噴射的間隔。C6.4 ENGINE OVER VIEW高壓共軌系統(tǒng)由五個(gè)部分組成，即高壓油泵、共軌腔及高壓油管、噴油器、電控單元、各類傳感器和執(zhí)行器。供油泵從油箱將燃油泵入高壓油泵的進(jìn)油口，由發(fā)動(dòng)機(jī)驅(qū)動(dòng)的高壓油 泵將燃 增壓后送入共軌腔內(nèi)，再由電磁閥控制各缸噴油器在相應(yīng)時(shí)刻噴油。C6.4 ENGINE OVER VIEWOverhead view

4、of C6.4 engine cylinder head with rocker cover removed Integrated Cylinder head 4 valves Centrally located InjectorsC6.4 ENGINE OVER VIEWDesigned with most major service points located on the right side of the engine. Fuel Injection pump (1), Secondary Fuel Filter (2), Fuel priming pp (3), Oil fill

5、cap (4), Dip stick (5),Engine breather (6), ECM (7) C6.4 ENGINE OVER VIEWAir Inlet heaterInlet heater relayC6.4 ENGINE OVER VIEWSystem capacity : 30 ltr Including filter Oil pump delivery : 66 L / min 1800 rpmC6.4 ENGINE OVER VIEWWater pump centrifugal type - Belt driven together with alternatorSeal

6、ed bearing- no greasing requiredCoolant capacity (engine water jacket 9 L) Total : approx. 25 ltrThermostat - Opens at 71 deg C 10 mm lift at 85 deg CC6.4 ENGINE OVER VIEWC6.4 Fuel System Caterpillar designed and Developed High Fuel Injection pressures Fully Electronically controlled Multiple Inject

7、ion- reduce NOx and PMC6.4 ENGINE OVER VIEWFuel system Overview Fuel system using common rail technology High pressure pump up to 160 MPA Hardened Fuel lines External fuel manifoldC6.4 ENGINE OVER VIEW Fuel Manifold High quality steel component Designed to withstand 23,000 psi Relief Valve Replace L

8、ines if fitting is loosened Pump Pressurizes Fuel Transfer pump is serviceableC6.4 ENGINE OVER VIEWLow pressure fuel 43-58PSI 16000 PSIC6.4 ENGINE OVER VIEWLOW pressure fuel system Low pressure fuel circuit system pressure : 43-58 psi 300 - 400 kPA) Low pressure fuel utilized to cool engine ECM Cons

9、ists of Primary fuel filter / water separator (10 micron) Secondary Fuel filter (2 micron) Tertiary fuel filter (2 micron) in series 321C6.4 ENGINE OVER VIEW Driven by High Pressure Pump Draws Fuel through Primary Filter Output Pressure 300 to 400 kPa 43 to 58 PSI Transfer Pump Primed by Priming Pum

10、p Hand or Electric No Lift Pump RequiredTransfer PumpC6.4 ENGINE OVER VIEWHigh pressure circuit Components High pressure Fuel Injection pump Fuel Manifold High pressure fuel lines Normal fuel rail pressure : 11000- 16000 psiHIGH PR PP CRM INJECTORSC6.4 ENGINE OVER VIEWFuel Pump Function Pump Raises

11、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!C6.4 ENGINE OVER VIEW Transfer pump Gear type High pressure pum

12、p Speed timing sensor Fuel pump solenoid- control injection pump output pressure to common rail Injection pump Solenoid is not serviceable Transfer pump and the secondary speed/timing sensor are the only serviceable componentsC6.4 ENGINE OVER VIEWC6.4 ENGINE OVER VIEWHigh Pressure Relief Valve Fuel

13、Pressure Relief Valve Protects System from Over-Pressure Opens at Constant Pressure of 160 MPa (23,000 PSI) Withstands Spikes to 190 Mpa (27,500 PSI) Returns fuel to TankThe primary function of the fuel pressure sensor is to constantly monitor rail pressure.The high pressure relief valve protects th

14、e high pressure fuel system from excessive pressures. C6.4 ENGINE OVER VIEW Each Injector has a solenoid. The solenoid receives current from ECM & actuates the Injector.When no Injection :No current to solenoid- control valve closed -fuel from the rail stops at the injector control valveInjectio

15、n :Solenoid is energized- armature plate moves up- valve is opened-High pr fuel flows to nozzle area Injection begins (no of orifice : 6 ) When the current to solenoid is stopped, armature plate pushed down- valve seat is closed . Any remaining high pressure fuel exits through drain portC6.4 ENGINE

16、OVER VIEWTo nozzleSolenoid energizedValveInjector FunctionECM Energizes InjectorValve LiftsFuel Flows to NozzleSolenoid de-energizedInjector De-energizesValve ClosesUnused fuel flows back to Transfer Pump via passage in the HeadC6.4 ENGINE OVER VIEWWhen replacing injector,replace all of the followin

17、gO ringWasher copper Injector pipeRubber boot that seals valve cover openingNote : When removing a pipe and reusing an Injector, Always cap the injector Immediately until ready to install.Do not over tighten the solenoid connection terminals. C6.4 ENGINE OVER VIEWFuel Injector Trim code Do Write dow

18、n 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 Trim file can be found in sis webC6.4 ENGINE OVER VIEWPrimary and secondary speed/timing sensor are of same

19、part numberC6.4 ENGINE OVER VIEWFuel Injection Serviceability NEVER loosen high pressure pipes when engine is running! 23,000 PSI Use Electronic Service Tool to Troubleshoot Injector Problems Injectors have no serviceable parts. Pump Solenoid is non serviceable. If the solenoid is removed the whole

20、pump assembly must be replaced. Transfer pump is a serviceable item, separate from High Pressure pump. Speed sensor is serviceable.C6.4 ENGINE OVER VIEW GENEARAL SERVICE PROCEDURES w Common rail fuel technology requires a high degree of cleanliness. w Before attempting any work on the fuel system en

21、sure that the engine is cleaned of any dirt that might contaminate the fuel system.w Parts must be inspected prior to use to ensure capping is intact and parts are clean and undamaged.w Any fuel system components that are removed or exposed should be capped with new, clean caps to prevent dirt ingre

22、ssw Use anti contamination kit part No 278-4138C6.4 ENGINE OVER VIEWGENEARAL SERVICE PROCEDURES CONTw Do not pre fill the filters. Install filter dry and use priming to fill with fuelw Common rail fuel system is a self bleeding fuel system and does not require air to be purged from the system. w Onc

23、e a fitting has been loosened, the entire fuel pipe must be replaced with a new part to ensure proper seating and leak-free performance. Due to the unique “internally hardened” manufacturing process, high pressure pipes are single usew Common rail fuel systems operate at extremely high pressures (20

24、000 psi). Never loosen or open a high pressure fuel line while cranking or running a common rail fuel system. C6.4 ENGINE OVER VIEWGENEARAL SERVICE PROCEDURES CONTw FUEL tank drain : Drain water and sediments from Fuel tank daily, Keep fuel tank breather filter clean.w Ensure, once the engine is shu

25、t down, fuel rail pressure is reduced to zero, before any repair. If a leak is suspected, do not check / repair the fittings unless the engine is OFF and pressure is neutralized.C6.4 ENGINE OVER VIEWENGINE MAINTENANCE INTERVALSw Engine Oil SOS250 Hoursw Coolant SOS250 Hoursw Oil and Filter Change500 Hours (SOS to determine this)w Fuel Filter 500 Hours w Engine valve l