Emissions & Fuel Systems

Advanced Power Train

Clean Air Act

Date
1970

Congress Creates Environmental Protection Agency (EPA)

1990

Clean Air Act Amendments

Mandated Regulation for Nonroad Equipment

1996

Nonroad Regulations Become Effective

- US and its territories (Puerto Rico, Guam, District
of Columbia, the Virgin Islands, American Samoa,
and the Commonwealth of the Northern Mariana
Islands)
- Engines must be Certified
- Machines must be equipped with Certified
Engines

Environmental Regulations
CO2

BACT
9
LAER

72

ppm

NOX

PM

MW-hr
2
5

145

42

96

Tons/yr

48

215
UHC

Technology of Power
HP/L

Emissions

HP/Liter

40

Particulates (?/HP-HR)

50

2X

30
20
10
0
1970

1980

1990

10
8

5X

6
4
2
0
1970

2000

1978

1988
Nox

Part.

50

0.40

Efficiency %

BS FC-LB-HP-HR

2004

60

0.50

0.20

1998

Thermal Efficiency (Diesel)

Fuel Economy

0.30

1991

2X

0.10

40
30
20

2X

10

0.00
1930 1940 1950 1960 1970 1980 1990 2000
Production

Research

0
1930 1940 1950 1960 1970 1980 1990 1998 2000

Technology Drivers

EMISSIONS

Sociability

Customer
TARGET

OWNING & OPERATING COSTS

Regulated Diesel Emissions

Particulate Matter (PM)
Carbon from incomplete combustion
Soluble organic fractions from the fuel &
lubricating oil
Sulfates formed from the sulfur in the fuel

Nitrogen oxides (NOX)

Composed of nitric oxide (NO) and nitrogen
dioxide (NO2)

Hydrocarbons (HC)
Regulated either as total hydrocarbon
emissions (THC) or as non-methane
hydrocarbons (NMHC)

Carbon Monoxide (CO)

Non Road Emissions Limits - USA

Tier 1

Tier 2

Tier 3

<25 hp
25-50 hp
50-100 hp (3054&6)
100-175 hp (3116)
175-300 hp (3306)
300-600 hp (3406)
600-750 hp (3408)
>750 hp (3500)

Year

96

97

98

99

00

01

02 03

04

05 06 07 08

PM g/hphr

Non Road Emission Limits - USA

NOx (+HC) g/hphr

12

1.2
1

10
8

0.8

Unregulated

Tier 1

0.6

Tier 2

1990

0.4

Tier 3

0.2
0

1995

2000
Year

2005

09 10

2010

NOx (+HC)
PM

Environmental Benefit & Cost

EPA estimates that by 2010, NO X emissions will be reduced
by about 1 million tons per year; the equivalent of taking 35
million passenger cars off the road.

Emission Reduction Building Blocks

Combustion
Systems
Increase
Injection
Pressure
Increase
Fuel/Air
Control
Improve
Oil Control
Air
Motion

Cooler
Inlet Air
Increase
Timing
Control

Turbos

Fuels

After
Treatment

Increase
Cylinder
Pressure
Inlet
Tuning

Electronics

Heat
Rejection

Exhaust Gas
Recirculation

Emissions R & D
Piston Crown

Modeling Simulation

Improve
Fuel efficiency
Emissions
Reliability

Laser Cutting Injector Holes

Casting Core

Engine Research & Development

What % of Engine R&D is spent on emissions?

66%

Development - Alternate Fuels

Utilize diesel cycle with range of fuels.
Methanol

Diesel or
Biodiesel

Ethanol

Water-Fuel
Emulsions

Coal Gas

"Flex Fuel"
Methanol-Diesel
or
Gasoline-Diesel

Hydrogen

Propane
Natural
Gas

Focus On Fuel

Co develop low emission diesel fuel

Complementary fit between leaders in diesel engine and
chemical technologies
New low emission diesel fuel/water blends & blending
technology called - PuriNOx
No modifications to fuel systems or engine hardware required
Estimated reductions of NOx by 5 to 30% & PM by 20 to
50%
Currently being tested in a variety of Cat engines and
different machine applications

Major Development Programs

EMISSIONS

Sociability

Diesel technology

Alternative fuels

Development process

New concepts
Customer

TARGET

OWNING & OPERATING COSTS

The Works And Wears of Fuel Systems

What We Are Going to Talk About

History
Types of Fuel Systems
Fuel System Applications
Differentiation
Works & Wears
Reman
Additional Resources

Caterpillar Products
Solar
Turbines

Track-Type
Tractors

Track-Type
Loaders
Wheel
Loaders

Engines
Wheel Tractors
and Compactors

Integrated
Toolcarriers

Forest
Machines

Excavators

Agricultural
Equipment

Mining
Shovels
Fuel
Systems

Paving
Products
Backhoe
Loaders

Trucks
Scrapers
Motor Graders

What does a Fuel System do?

Meters the amount of

fuel to achieve desired
power
Regulates engine
speed and timing
sequence
Helps control
emissions

Fuel System History

Electronic Unit Injectors
(Hydraulic)
Electronic Unit Injectors
(Mechanical)
Electronic Engine Controls
3600 UI- Worlds Largest
15,000 PSI Pump & Line
Unit Injector
7000 Series Nozzle
Sleeve Metering System
Direct Injection
Auto-Timing Advance
En-Bloc System
Fuel/Air Ratio Control
Capsule Nozzle
First Cat Fuel System

1930

1940

1950

1960

1970

1980

1990

2000

The Combustion Process

Air Compressed 1/16 original volume

Heats up to 1,000 degrees Fahrenheit
Cylinder pressures up to 2200-2700 psi
Air volume constant- fuel variable

Intake

Compression

Combustion

Exhaust

The Combustion Process

Types of Fuel Systems

Direct Injection- Pump & Line

Sleeve

Metering
Current Scroll Fuel System
New Scroll Fuel System

Unit Injection
MUI
EUI
HEUI

Pre Combustion & Gas

Fuel Systems Applications

Engine
Engine 3600 3500 3408
3408 3406 3176 3300 3200 3100 3064
3064 3054
3054 3046 3003
3003
3600
3500
3406
3176
3300
3200
3100
3046 3034
YEAR
3412
3066
3056
YEAR
3412
3066 3056
3034
1993
1993
1994
1994

MUI
MUI

MUI CSFS NSFS EUI NSFS P&L 3116 Zexel Stana- Nipp- Zexel
MUI CSFS NSFS EUI NSFS P&L 3116 Zexel Stana- Nipp- Zexel
NSFS
SMFS MUI In-line dyne
ond.
NSFS
SMFS MUI In-line dyne
ond.
Lucas
Lucas
EUI
3126
EUI
3126
HEUI
All Pump & Line Systems
HEUI
All Pump & Line Systems

1995
1995
1996
1996

EUI
EUI

HEUI
HEUI

1997
1997
1998
1998

3196
3196
EUI
EUI

Fuel System Service Strategy

Past Strategy:
If Caterpillar makes it, dealers can service it.

CCE Engine Strategy:

Caterpillar will provide systems that dealers
can service cost effectively. This may not
include service at the piece part level on inexpensive
components.

Fuel System Differentiation

Pump
Pump&&Line
Line
CSFS
CSFS
NSFS
NSFS
Sleeve
Sleeve
Stanadyne
Stanadyne
Nippondenso
Nippondenso
Zexel
Zexel
Lucas
Lucas
Unit
UnitInjector
Injector
MUI
MUI
EUI
EUI
HEUI
HEUI

INJECTION
INJECTION
PRESSURE
PRESSURE
(psi)
(psi)

INJECTION
INJECTION
TIMING
TIMING

INJECTION
NOISE
FUEL
INJECTION EMISSION
EMISSION
NOISE
FUEL
RATE
CAPABILITY
EMISSIONS
CONSUMPTION
RATE
CAPABILITY EMISSIONS CONSUMPTION
SHAPE
SHAPE

14,000
14,000
18,000
18,000
10,000
10,000

Mechanical
Mechanical
Mechanical
Mechanical
Mechanical
Mechanical

Fixed
Fixed
Fixed
Fixed
Fixed
Fixed

TIER
TIERII
TIER
TIERII
None
None

Low
Low
Low
Low
Low
Low

Med
Med
Med
Med
Med
Med

14,000
14,000

Mechanical
Mechanical

Fixed
Fixed

TIER
TIERII

Low
Low

Med/High
Med/High

30,000
30,000
30,000
30,000
23,000
23,000

Mechanical
Mechanical
Electronic
Electronic
Electronic
Electronic

Ramp
Ramp
Ramp
Ramp
Variable
Variable

TIER
TIERII
TIER
TIERIIII
TIER
TIERIIII

High
High
Med-high
Med-high
Low
Low

Med-low
Med-low
Low
Low
Med-low
Med-low

Sleeve Metering Fuel System

Direct Injection - Scroll Metering

Features
Pump & line govenor
Few moving parts
Simple mechanical govenor
Fuel lubricates

Benefits
Easy starting
Easy to service
More tolerant of dirt
Economical
Easily replaced

New Scroll Fuel System

New Scroll vs. Current Scroll (Old)

Old

New

New Scroll vs. Current Scroll (Old)

Old

New

Unit Injection - MUI

Features
Mechanically
actuated/controlled
Mechanical governor
connected to unit injectors via
mechanical linkage
Unit injectors deliver fuel at
20,000 psi

Benefits
High reliability
Long life

Unit Injection - EUI

Features

Mechanically actuated
Electronically controlled
Variable fuel delivery
Virtually adjustment free
Serviceable components
injectors
electronic sensors
harnesses
connectors
ECM

Benefits

Improved engine starting

Precise engine speed control
Reduced exhaust black smoke
Faster cold starting
Improved fuel economy

Unit Injection - HEUI

Features

Hydraulically
actuated
Electronically
controlled
Injection pressure
independent of RPM

HEUI Injector

Unit Injection - HEUI

Benefits
Higher performance
Faster cold starts
Lower exhaust emissions
Lower engine noise
Better fuel economy
Higher serviceability
Increased reliability

HEUI System Operation

HEUI Nozzle Tip Splitting Due to Tip Fatigue

Improved tip
processing 12/96
Reduced check lift
3/97
Thicker wall to
increase tip
strength 6/97
Dampened check
reduces check
impact loads
5/98

Nozzle Tip Breakage Due to Installation Side Load

Improved tip
processing 9/98
Injector tip bore
cleaning 7/98
New gauge and brush
Instruction wrapper
Improved packaging
12/97
Special instructions
REHS0116-02
included 9/97

Broken Tips are normally

retained in injector

Solenoid Post Loosening Due to Vibration

Added epoxy matrix to terminal posts 3/99

Rubber washers no longer required
Added Material

NEW

OLD

Solenoid Failure Due to Internal Shorting

Frayed wire
insulation vibration
Bondable wire
implemented
3/98

Bondable Wire

Cavitation Erosion of the Poppet Valve Seat

New software during low delivery, low load

operating conditions 7/97
Typical Cavitation Erosion

Major Improvements for the 3408E and 3412E

Service Magazine Article, April 1999
Seal kits for HEUI pump groups available
Troubleshooting hard starting
129-0372 primary fuel filter/water separator
assembly
New o-ring seal improves engine initial
combustion gas sealing
Improved fuel injectors reduce carryover
Correct procedure for installation of HEUI
New Injector now available

Proper Fuel System Maintenance

Repair fuel systems in a protected environment

Always install new fuel filter

Do not pre-fill filter, use priming pump

Do not remove injector from package until ready for

installation

Return failed injector in replacement injector packaging

Always buy clean fuel

Transport clean fuel in clean containers

Use Caterpillar high efficiency (2 micron) fuel filters

Proper Fuel System Maintenance

Plunger Wear

Stay-Clean Valve

Prevents Pre-Filling

Eliminates Entry of
Unfiltered Fuel Into
the Fuel System

Fuel Water Separator

Benefits
Best-in-Market Water
Separation
Debris Retention
Extends Secondary
Filter Life

3054
3056
3114
3116
3126
3176
3204
3208
3304
3306
3406
3408
3412
3508
3512
3516
3606
3608

HEUI

Timing
Advance

Fuel/Air
Ratio
Controls

EUI

MUI

DIFN

Governors

Fuel P & G

Fuel
Transfer
Pumps

Remanufactured Fuel System Components

X
X
X
X

X
X

X
X
X
X
X
X
X

X
X
X
X
X
X
X
X
X

X
X
X
X
X

X
X
X
X
X

X
X
X

X
X
X

X
X
X

Reman - Value

High Quality Remanufactured products

Priced at 50% of corresponding new
7000 Series Fuel Nozzles - No price
adjustment since 1997
Higher direct purchase program pricing

Additional Resources
CDs

Cat Power Pro

Sleeve Metering Fuel System :LERV9802 (CD)
Caterpillar HEUI HI300 Fuel System
Fuel System and Electronic System Operation and Troubleshooting:
RENR1390-01 (CD)
Caterpillar EUI Fuel System
Fuel System and Electronic System Operation and Troubleshooting:
RENR1391-01 (CD)

Videos

Datasheet
The New Caterpillar 3408E and 3412E Engines

HEUI Fuel Systems

LEVN3547 (Video)
PEHP9526-01
The HEUI Fuel System
LEVN3545 (Video)
Caterpillar Intranet site: http://www.pont.cat.com/
Caterpillar Power Train Customer Meeting Package
PEKP6026-01