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CATERPILLAR
Common Rail Fuel System

CATERPILLAR Common Rail Fuel

CATERPILLAR Common Rail Fuel

CATERPILLAR Common Rail Fuel

Orifice

CATERPILLAR Common Rail Fuel

Electronic Control Module

(ECM)
ECM Controls:

CATERPILLAR Common Rail Fuel

Fuel Pressure
Speed Governing
Air/Fuel Ratio
Start/Stop Sequence
Engine Protection
Devices/ Diagnostics

Fuel Pump Function

Pump Raises 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!

CATERPILLAR Common Rail Fuel

Fuel Leak off to Tank

Oil lubrication

Fuel in from
Secondary Filter

To Fuel HP
Manifold

Pump Speed

To
Secondary
Filter

Position Sensor

Locks the Pump

CATERPILLAR Common Rail Fuel

From
Primary
Filter

Transfer Pump
Driven by High Pressure Pump
Draws Fuel through Primary
Filter
Output Pressure
300 to 600 kPa

Transfer Pump Primed by

Priming Pump
Hand or Electric

CATERPILLAR Common Rail Fuel

High Pressure Fuel System

Dos & Donts

Fuel Manifold

Do Check for leaks

Do Not Loosen HP Connection
with Engine Running
Do Replace HP Pipes After they
are Loosened
Do Replace ALL Hp Pipes if new
manifold is Installed
Do Not Force Pipes to Fit
Do Cap Manifold and Injector
Connections Immediately when
HP Pipe is removed
CATERPILLAR Common Rail Fuel

Injector Lines

High PRV

Rail Pressure Sensor

Fuel Pressure Relief Valve

Protects System from OverPressure
Opens at Constant Pressure of 160
MPa (23,000 PSI)
Withstands Spikes to 190 Mpa
(27,500 PSI)

Returns fuel to Tank

CATERPILLAR Common Rail Fuel

High Pressure
Relief Valve

Fuel Return from Head

Excess Fuel Returned to
Transfer Pump
Not High Pressure

CATERPILLAR Common Rail Fuel

Fuel
Return
from
Head
LIne

Injector Function
Injector De-energizes
Valve Closes
Unused fuel flows back to
Transfer Pump via passage
in the Head

CATERPILLAR Common Rail Fuel

Fuel Injector
Dos and Donts
Do Write down 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

CATERPILLAR Common Rail Fuel

Injector Adaptive TRIM

Fuel System Optimization Routine
Runs every hundred hours or so
Audible changes when engine is running
NO performance or Power Changes
Everythings OK
Similar to HD ACERT engines

CATERPILLAR Common Rail Fuel

CATERPILLAR Common Rail Fuel

Cat Common Rail Fuel System

C175
Advantages
High Pressure Rail

Meets emissions
Lower fuel consumption
Better transient response

High Pressure
Pump

Primary Fuel Filter/

Water Separator

Cooler

Secondary Fuel Filters

Electric Priming
Pump
CATERPILLAR Common Rail Fuel

Fuel Tank

Cat Common Rail Fuel System

Low Pressure Fuel System

FTP
Electric Priming
Filtration
CATERPILLAR Common Rail Fuel

Cat Common Rail Fuel System

Fuel System
HP Pump
Double Wall Lines
Double Wall Rails
Flow Limiter
Injector

CATERPILLAR Common Rail Fuel

Cat Common Rail Fuel System - HP Rail

HP Rail

Low Pressure
Injector return

Double Wall
Crossover Line

CATERPILLAR Common Rail Fuel

Pressure Sensor

Double Wall
Lines From HP Pump
To Rail

High Pressure Fuel System Hardware

PRV
PRV Outlet
HP Outlet

Oil Supply

Camshaft
FTV Drive
Oil Return
CATERPILLAR Common Rail Fuel

Flow Control
Valve

Flow Limiter

Flow Limiter
Protection Device
Against Cylinder Over
Fueling
Piston Moves With
Every Injection
Trips at Set Point To
Prevent Continuous
Injection and Remains Spring
Shut
Piston

CATERPILLAR Common Rail Fuel

CATERPILLAR Common Rail Fuel

CATERPILLAR Common Rail Fuel