5 Cylinder engine PDE

Technical Training
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 Advantages with unit injector PDE

– Better possibility to control injection time and

volume.
• Results in:
– Lower fuel consuming
– Higher torque
– Lower emissions

Abbreviations with engine

Family name: EMS Engine Management System
Injection type: PDE Pumpe-Düse-Einheit others HPI and XPI
ECU Version: S 6 others MS6, S7 ,,,,,,

Technical Training
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 DC9

The new 9 litre engine has

5 cylinders.
It is essentially a
'shortened' 12 litre DC
engine.

Technical Training
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 Summary DC9

• The new 9-litre is a 5-cylinder Engine, with 230, 270

and 310 hp
• Higher exhaust brake output 180 kW
• Higher Power Take-Off torque 600 Nm
• EMS, 4-valve technique, combustion chamber and
PDE
• Long field test experience:
- It is strong, reliable and efficient. With power,
outstanding torque, drivability and low fuel
consumption

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 DC9

The rear engine brackets

are located at the same
coordinates, which
means that the engine is
further from the radiator.

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 DC9

The fuel system

comprises PDE injectors
and EMS/S6.

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 DC9

Note that the fan is fitted

with a radiator assembly
spacer.

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 General engine components / function

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What is the firing order 1-5-3-6-2-4
 General engine function
Crankshaft movement

Inlet valve Exhaust valve

opens closes

Inlet valve Exhaust valve

closes opens

Technical Training
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 PDE / HPI Fuel system
Differences

PDE
HPI

PDE HPI
Pumpe Düse Einheit High Pressure Injection

Unit injector Technical Training

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 Fuel system components

1 Feed pump
2 Hand pump
3 Engine control unit
4 Fuel filter
5 Unit injector, of PDE type
6 Fuel manifold,
7 Pressure relief valve
Technical Training
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 Water separating pre-filter
Shut – off cock

PDE engines can be fitted with a water

separating pre-filter and these filters are
also available with a heater.

Standard in SLA production

Option SSS production

Drain valve

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 Jarene wong australia sing
Unit injector tau ngukur nganggo
multimeter voltase ne 120
volt

• Electrical part
– Electromagnet
– Fuel valve

• Hydraulic part
– Pump element
– Nozzle

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 Fuel system components Mono Rail

1: Feed pump
2: Hand pump
3: Fuel filter
4: PDE unit injector Monorail
5: Fuel tank
6: Fuel channel for leak-off fuel
A: Check valve
B: Feed pump
C: Safety valve
D: Pressure relief valve

K bus

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 Fuel system components Dual Rail

4
D

Truck
E 6
3

1: Feed pump
2: Hand pump
3: Fuel filter
4: PDE unit injector Dual Rail
5: Fuel tank 1 T Bus
6: Fuel channel for leak-off and return fuel
A: Check valve 2 5
B: Gear pump (feed pump) Inside pump
C: Safety valve T: Truck
D: Pressure relief valve
E: Drain nipple
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 PUMP
Safety valve opens at 13 bar

If clogged overflow valve the

safety valve will open

Overflow valve

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 PUMP

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 PUMP

Leak indicator could be from

compressor / oil or pump /
fuel

If the indicator is clogged the

oil or fuel could go to between

Replace the complete pump

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 Truck fuel supply

Bleeder nipple
Pressure relief valve

Inlet

Outlet
1 Bleeder nipple
2 Intake
3 Outlet
4 Return to fuel tank
5 Return from fuel manifold
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 Bus / Coach fuel supply

Pressure relief valve

In and outlets of the fuel filter on buses

1 Bleeder nipple
2 Intake
Location of the hand pump on buses.
3 Outlet
4 Bleeder nipple (used when the fuel tank is
too high for draining the filter housing.)
That’s way the return fuel never goes to the filter
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 The fuel manifold on a 5 cylinder engine

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 NEWS ON K and N
Fuel system PDE
Cooler

lowers the temperature by 10 to 15°C down to 70-80°C

Pump
Filter

Fuel temperature up to 90ºC.

The maximum allowed temperature in main tanks is 60ºC.
The plastic pipes that are used are only specified up to 60°C.

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 NEWS ON K and N
Fuel system HPI – Buffer tank
Cooler

lowers the temperature by 10 to 15°C down to 70-80°C

Pump 45°C

Two fuel circuits, one that supplies the

buffer tank and one that supplies the engine

Fuel temperature up to 90ºC.

The maximum allowed temperature in main tanks is 60ºC.
The plastic pipes that are used are only specified up to 60°C.

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 Buffer tank on HPI
Gas ventilated Engine

HPI Cooler

Pump Fuel Tank

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 Variations on fuel filter
HPI PDE Truck PDE Bus/Coach

5 5 5

3 3
1 1 1

4 4

2 2 2
6 Drain nipple only on bus 6
1 in 2 out 3 return in 4 Return to tank 5 Bleeder nipple
6 Drain nipple Technical Training
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 Connector at rocket cover
5 Cylinder PDE engine

Firing order: 1 2 4 5 3
Component code: V14 V16 V15 V26 V28

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 2 types of injectors
PDE Dual Rail PDE Monorail EU3

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 Fuel system components
Dual rail Eu3

Leakage and
cooling fuel out

1: Feed pump
2: Hand pump
3: Fuel filter
4: PDE unit injector Dual Rail
5: Fuel tank The fuel is circulating
6: Fuel channel for leak-off and return fuel
A: Check valve
continuously in the injector
B: Gear pump (feed pump) Inside pump
C: Safety valve
D: Pressure relief valve
E: Drain nipple
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 Fuel system components
Monorail EU3

Leakage out

1: Feed pump
2: Hand pump
3: Fuel filter
4: PDE unit injector Dual Rail
5: Fuel tank
6: Fuel channel for leak-off and return fuel Only leakage fuel is returning continuously
A: Check valve
B: Gear pump (feed pump) Inside pump
C: Safety valve
D: Pressure relief valve
E: Drain nipple
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 Fuel system components 2 types of Dual rail
Dual rail Eu4

Leakage and
cooling fuel out

Dual Rail Eu 3 injector Dual Rail Eu 4 injector

The fuel is circulating continuously in

the injector

Middle o-ring is taken away to have

Fuel
some leakage to not have pressure
pikes when the valve is closing
O-rings O-rings

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 Fuel system components
Dual rail Eu4

B is taken away

Coolant
Leakage and coolant fuel out

Fuel intake

C is against coolant water

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 Measuring supply pressure

Start the engine and run it at idle speed, 550 rpm.

The fuel pressure should then be approximately 3.0 bar.

Rev up the engine to 1900 rpm and read the pressure.

The fuel pressure should then be approximately 4.0 bar

0,3 – 0,5 bar in difference between supply

and fuel manifold pressure is OK
Resistance in filter makes the different

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Checking overflow valve
- Mono Rail Euro 2 + 3, Series 4 (4.5 – 7.5 bar).
0,3 – 0,5 bar in difference between supply
and fuel manifold pressure is OK
- Dual Rail Euro 3 with a return and an overflow
Pressure is depending
channel, PGRT (3.0 – 6.5 bar).
on over flow valve type
Fuel - Dual Rail Euro 4 + 5 with a return and an
overflow channel, PGRT (3.5 – 4.5 bar).

Overflow valve

Measure point

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 Practical exercise what type of injector do we have?

How to se the difference!

1 Monorail unit injector

2 Dual Rail unit injector
3 Dual Rail Euro 3 unit injector
4 Dual Rail Euro 4 unit injector

2 versions of type 2
There is 2 versions on the
spring diameter a

Mono Rail “ no cooling of injector

valve” have 66,9 mm in diameter

Dual Rail “cooling of injector

valve” have 69,9 mm in diameter

Its not possible to se on the spring if it’s a

Euro 3 or 4 injector

4 types of PDE injectors when counted with Ethanol engine Technical Training
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 PDE injector Mono rail

A Valve housing
B Pump section
C Injector section

1 Fuel duct, inlet and outlet

2 Fuel valve
3 Pressure by pass
4 Solenoid valve
5 Pump plunger
6 Non-pressurised return
(leakage fuel) to fuel tank
7 Release hole for lubrication
fuel (lubricating the injection needle)
Technical Training
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 PDE injector Mono rail
Alpha and Delta
Alpha (A) injection timing Delta (B) quantity injected

Technical Training
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 PDE injector Mono rail

Filling phase
A Overflow valve
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 PDE injector Mono rail

Spill phase
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 PDE injector Mono rail

Opening pressure
283 +/- 5 is adjusted by
shims above the spring

Opening pressure
283 +/- 5

Injection phase
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 PDE injector Mono rail

Pressure reduction phase

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 PDE injector Mono rail

Technical Training
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 PDE injector Dual rail

Technical Training
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 Engine Sensors
Charge air pressure Engine speed 2 pieces
and temperature

Fuel manifold

E118 Fuel
temperature

T33

T5
Coolant level

Oil pressure T33 coolant temperature T8

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 5 Cylinder engine PDE
Checking injectors

Technical Training
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 Removing the unit injectors

Remove the rocker arm shaft Remove the fork clamp bolt Withdraw the unit injector
Detach the cables

Position the unit injector in Lift up the nozzle needle and Place the adapter 99 506 on the
a vice with a nut on each side rotate it several times and release. nozzle nut and tighten the nozzle nut
If the nozzle needle falls back under
its own weight, it is working correctly.

10mm

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 Testing the unit injectors
Gradually increase the pressure until Check the spray pattern
the gauge needle stops or until the
pressure drops ? OK
Read and note the
opening pressure
Shim

Measure the resistance on the

contact surfaces of the solenoid
valve for about 20 seconds until
a stable value is obtained.
The resistance should be between
0.4 - 0.6 ohms at room temperature
when the engine is cold

Technical Training
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 Testing leakage on cylinder head and injector

Cylinder head

Make a 10 mm thick support plate which will

be used together with the rocker arm on the cylinder head.

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 Order of adjustment for 9 litre engines
1. Turn the flywheel in the direction of engine rotation until TDC down (0°) is visible in the lower window
on the flywheel housing
2. Check whether there is a valve overlap on cylinder 1.
3. If there is valve overlap on cylinder 1: Start adjustment at the top of the table, otherwise turn the engine 1 turn more

The flywheel is also marked at 240°/600° and 120°/480°,

these markings apply to 6 cylinder engines

Flywheel seen from the rear of the engine

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* Direction of rotation of flywheel when adjusting
 Check what type of unit injector is fitted on the vehicle

Adjusting the injector

When adjusting, loosen the lock nut and adjust the unit
injector with adjusting screw 1. The unit injector is correctly
set when the small piston 2 is level with the flat upper
surface of the tool. Use a finger to check. It is possible to feel
differences of less than a millimetre. The setting dimension
is 66.9 +/ -0.1 mm or 69.9 +/-0.1 mm.

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 Tools to adjust the unit injector

Adjust

99 365 Euro 4 69,9±0,1

Should be even

Euro2 & 3
Euro4
99 414
99 442

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 My truck is very
tired
Practical work on removing,
checking and fitting injector

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 Practical exercise

Group 1 Group 2

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 5 Cylinder engine PDE
END

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