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S6K FUEL SYSTEM

FUEL FILTER FUEL INJECTION NOZZLES

FUEL
OVERFLOW
LINE

CHECK
FROM
VALVE
FUEL TANK

TO
FUEL TANK FUEL INJECTION PUMP

FUEL RETURN LINE

FUEL TRANSFER
AND PRIMING PUMPS

24

Fuel Pump Operation

• Fuel system diagram

This slide shows the flow through the fuel system. The fuel transfer pump
delivers fuel from the tank to the fuel filter. The fuel filter cleans the fuel
before it enters the main pump. The main pump contains six individual
fuel pumps. Each individual fuel pump delivers high pressure fuel to a
fuel injection nozzle through a fuel line. The fuel nozzles spray atomized
fuel into the cylinders.

• Excess fuel returns to The fuel transfer pump supplies more fuel to the main fuel pump and the
tank through fuel individual cylinder fuel pumps supply more fuel to the injector nozzles
return line than the engine needs. The excess fuel delivered to the main pump and
injection nozzles serves a lubrication, cooling and cleaning function
before returning to the tank through the fuel return line.
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FUEL TRANSFER
AND PRIMING PUMPS
PRIMING PUMP
SUCTION

CHECK VALVE
CHECK VALVE

SUCTION DISCHARGE

PISTON TAPPET
CAMSHAFT

25

• Camshaft drives the The camshaft drives the transfer pump. A tappet and pushrod assembly
transfer pump converts the rotational motion of the camshaft to reciprocating motion.
The pushrod moves the piston. The reciprocating motion of the piston
creates alternating suction and discharge cycles. As the tappet moves
down the cam lobe, the piston chamber spring returns the piston to the
• Piston chamber bottom position. The returning motion of the piston forces the fuel in the
spring returns piston bottom of the piston chamber into the fuel injection pump supply line and
to bottom also creates decreased pressure in the piston spring chamber. The
• Discharge check valve
pressure in the discharge line is now higher than the pressure in the piston
closes and suction spring chamber, and the discharge check valve closes. The decreased
valve opens pressure in the piston spring chamber also allows the suction check valve
to open allowing fuel from the tank to fill the chamber.
STMG 622 - 30 -
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FUEL TRANSFER
AND PRIMING PUMPS
PRIMING PUMP DISCHARGE

CHECK VALVE
CHECK VALVE

SUCTION DISCHARGE

PISTON TAPPET
CAMSHAFT

26

• Tappet motion forces As the cam lobe pushes the tappet up, the piston compresses the piston
piston to compress chamber spring. As the piston raises, the motion creates an increased
spring
pressure in the piston spring chamber. The increased pressure in the
• Suction valve closes
piston spring chamber closes the suction check valve and opens the
and discharge valve discharge check valve. Fuel flowing by the discharge check valve fills the
opens chamber under the piston (some fuel also enters the fuel injection pump
supply line) until the tappet reaches the peak of the cam lobe. As the
• Piston spring tappet starts to descend the cam lobe, the piston spring returns the piston
returning action
pumps the fuel
to the bottom of the chamber and forces the fuel in the chamber out the
discharge port into the fuel injection pump supply line.
STMG 622 - 31 -
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FUEL TRANSFER
AND PRIMING PUMPS
PRIMING PUMP REGULATING

CHECK VALVE
CHECK VALVE

SUCTION DISCHARGE

PISTON TAPPET
CAMSHAFT

27

• Transfer pump If the fuel discharge pressure increases abnormally, the fuel pressure in the
provides a regulating chamber under the piston can counteract the piston chamber spring force.
function
When the fuel pressure in the chamber under the piston and the spring
force reach the equilibrium point, the piston will not continue to descend
the cam lobe with the tappet, the fuel pressure inside the spring chamber
closes the suction check valve, and the fuel discharge pressure keeps the
discharge check valve closed. In this condition, the fuel transfer pump
provides a regulating function.
STMG 622 - 32 -
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TO NOZZLE

FUEL INJECTION PUMP

DELIVERY VALVE HOLDER
DELIVERY VALVE SPRING

DELIVERY VALVE
SUCTION AND
PLUNGER BARREL
DISCHARGE PORT

PUMP HOUSING

FUEL CHAMBER

CONTROL PINION
CONTROL RACK

PLUNGER CONTROL SLEEVE

PLUNGER SPRING

TAPPET

CAMSHAFT

28

• Sectional view of The fuel from the transfer pump flows through a filter to the main fuel
individual fuel pump injection pump. This slide shows a sectional view of an individual fuel
pump within the main fuel injection pump. The plunger spring and tappet
• Spring and tappet
force the plunger to follow the contour of the rotating camshaft lobe. As
force plunger to follow the camshaft rotates, the tappet moves up the cam lobe, compresses the
camshaft lobe spring, and forces the plunger upward. As the plunger moves up, fuel
pressure in the chamber above the plunger overcomes the delivery valve
• Fuel pressure spring force and delivers fuel to the fuel injection nozzle.
overcomes delivery
valve spring
The control rack position determines the amount of fuel that the pump can
• Control rack controls deliver to the injection nozzles. The governor controls the control rack
fuel injection quantity position (discussed later). Each individual fuel pump is connected to the
control rack through the control pinion. The control pinion clamps to the
control sleeve. Slots inside the control sleeve allow the plunger to slide
• Plunger rotates with
the sleeve up and down in the sleeve and in the plunger barrel. The slots in the
control sleeve will not allow the plunger to rotate within the sleeve, but
• Control rack force the plunger to rotate with the sleeve. Movement of the control rack,
movement rotates therefore, causes the plunger to rotate with the control sleeve while the
plunger
plunger barrel remains fixed.
STMG 622 - 33 -
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FUEL INJECTION PLUNGER

EFFECTIVE STROKE EFFECTIVE
STROKE

HELIX

SUCTION AND
DISCHARGE PORT
PLUNGER
BARREL

PLUNGER

DELIVERY STARTS DELIVERY ENDS

29

• Effective stroke As the governor moves the control rack, the movement changes the
definition effective stroke of the plunger which changes the amount of fuel injected.
The effective stroke is the distance the plunger moves up from the point
where the top of the plunger closes the suction and discharge port to the
• Injection ends after point where the scroll opens the suction and discharge port. After the
scroll is open to scroll opens the suction and discharge port, pressure above the plunger
discharge port decreases. The decreased pressure above the plunger allows the delivery
valve spring to close the delivery valve and end fuel injection, even if the
plunger continues to move up.
STMG 622 - 34 -
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FUEL INJECTION NOZZLE

NOZZLE BODY

SHIM PRESSURE SPRING

PRESSURE PIN

TIP PACKING
PIN

NOZZLE TIP

RETAINING NUT

30

• Main pump supplies The main fuel injection pump supplies high pressure fuel to the fuel
fuel to fuel injection injection nozzle through the injection lines. When the pressure in the
nozzles
injection lines reaches 22065 to 23046 kPa (3200 to 3342 psi), the nozzle
will inject fuel into the combustion chamber. Injection pressure can be
• Injection pressure is changed by changing the thickness of the shim behind the pressure spring
shim adjustable in the fuel injection nozzle. A 0.1 mm (0.004 in.) change in shim
thickness causes a 1373 kPa (200 psi) change in the injection pressure.
STMG 622 - 35 -
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GOVERNOR OPERATION
NO LOAD MAXIMUM SPEED
CONTROL LEVER FLOATING LEVER

CONTROL RACK LOW IDLE STOP

IDLING
GOVERNOR SPRING SUB-SPRING

SWIVEL LEVER

TENSION LEVER

TORQUE
CAMSHAFT CONTROL SPRING
FULL LOAD
SHIFTER
FLYWEIGHTS ADJUSTMENT SCREW
AND SLEEVE
SHUTOFF LEVER

31

Governor Control System Operation

• Engine starts to
This illustration shows governor operation when the engine speed starts to
overspeed
exceed the speed that the throttle control lever specifies. As the engine
• Flyweights move out starts to overspeed, the centrifugal force of the flyweights causes the
flyweights to move out. As the flyweights move out, the shifter and
• Sleeve and shifter sleeve move to the right until contacting and compressing the torque
compress torque control spring. After the sleeve and shifter compresses the torque control
control spring
spring, the tension lever moves to the right. Moving the tension lever to
• Tension lever moves the right stretches the governor spring. Stretching the governor spring
right increases the tension of the spring. The spring tension and the centrifugal
force of the flyweights will eventually reach an equilibrium point and the
• Spring and flyweight tension lever will stop moving.
force equalizes
STMG 622 - 36 -
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• Floating lever moves At the same time that the flyweights, shifter, and sleeve are moving the
to right tension lever, they are also moving the floating lever to the right. The
mechanical linkage connecting the floating lever to the control rack
• Control rack moves to
right until spring and moves the control rack to the right. Moving the control rack to the right
flyweight force decreases the amount of fuel that the fuel injection pump supplies to the
equalizes fuel injection nozzles. The control rack will continue to move to the right
until the governor spring and the flyweights reach the equilibrium point.

• Tension lever
If engine speed continues to increase, the tension lever continues to move
contacts idling sub- to the right until it contacts the idling sub-spring. After the tension lever
spring compresses the idling sub-spring, the control rack is in the NO LOAD
MAXIMUM SPEED condition.

The function of the torque control spring is to limit the amount of black
• Torque control spring smoke the engine produces during acceleration. When the engine speed is
limits black smoke low, the torque control spring force is larger than the centrifugal force of
the flyweights. The spring force moves the shifter and sleeve to the left.
Moving the shifter and sleeve to the left moves the guide and floating
levers to the left causing the control rack to move toward the FUEL ON
• Moving rack to left is direction. As the engine speed increases, the centrifugal force of the
FUEL ON flyweights compresses the torque control spring. The shifter will then
contact and move the tension lever to decrease the fuel injection quantity.
In this governor, pushing the rack in decreases fuel and pulling the rack
out increases fuel.

NOTE: The control lever and shutoff lever in this illustration are not
the actual mechanisms on the 3066 engine in the 320 Hydraulic
Excavator. The actual throttle control mechanism on the 3066 engine
in the 320 Hydraulic Excavator is not a lever, but rather, a pulley and
cable system. The shutoff lever is a solenoid operated control.