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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
Product: INDUSTRIAL ENGINEModel: 3054E INDUSTRIAL ENGINE 304Configuration: 3054E Industrial Engine 30400001-UP
ystems Operation54E Industrial Enginedia Number -RENR7568-01 Publication Date -01/12/2003 Date Updated -08/12
i027
uel Injection
MCS - 1251; 1252; 1253; 1254; 1281
ustration 1 g01140556
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Shutdown S
Previous Screen
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ow diagram of the fuel system
Fuel injection nozzles
Electronic fuel priming pump and secondary fuel filter
Fuel injection pump
Primary fuel filter/water separator
Fuel tank
Fuel return line
Fuel supply line
e 3054E engine is equipped with a Bosch VP30 fuel injection pump. This pump is an axial piston distributor injection pu
t is controlled by the Electronic Control Module (ECM).
e axial piston distributor injection pump generates injection pressure for all cylinders in a single pump. The injection pumponsible for the distribution of fuel to the fuel injection nozzles. The injection pressure is generated by an axially moving
ton. The movement of the piston is parallel to the fuel injection pump shaft.
hen the engine is cranking, the fuel is pulled from fuel tank (5) through primary fuel filter/water separator (4) by fuel prim
mp (2). When the fuel passes through the water separator, any water in the fuel will go to the bottom of the bowl. The fue
ming pump is equipped with a secondary fuel filter. From the fuel priming pump, the fuel passes through the fuel supply
fuel injection pump (3). The fuel injection pump sends fuel through the high pressure fuel lines to fuel injection nozzles (
e fuel injection nozzles spray atomized fuel into the cylinder.
e fuel injection pump needs fuel for lubrication. The precision parts of the pump are easily damaged. The engine must no
rted until the fuel injection pump is full of fuel. The system must be primed when any part of the system is drained of fuee fuel system needs priming when a fuel filter is changed, and/or when a fuel line is removed, and/or when the fuel inject
mp is replaced.
uel Injection Pump
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 2 g01140815
hematic of the Bosch VP30 fuel injection pump
ECM
Electronic Control Unit (ECU) for the fuel injection pump
Fuel priming pump
Speed/timing sensor
Cam ring
Fuel solenoid valve
Pressure regulator
Distributor plunger
Fuel transfer pump
0) Fuel injection nozzle
1) Timing solenoid valve
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
2) Timing advance mechanism
3) Roller
4) Cam plate
5) Delivery valve
e fuel injection pump has the following operations:
q Delivery
q Generation of high pressure
q Distribution and injection
q Timing
q Shutoff
q Control
elivery
ustration 3 g01140827
nter view of the Bosch VP30 fuel injection pump
Fuel transfer pump
el is supplied by the head pressure of the priming pump. The fuel enters fuel transfer pump (9) of the fuel injection pump
l transfer pump is a vane pump. The transfer pump is driven by the fuel injection pump shaft. The pump supplies a const
ount of fuel to the interior of the fuel injection pump. The revolution of the transfer pump is directly related to the speed
l injection pump shaft.
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 4 g01140857
el transfer pump for the Bosch VP30 fuel injection pump
Cam ring
6) Pump housing
7) Outlet passage
8) Rotor
9) Vane
0) Inlet passage
tor (18) rotates inside cam ring (5). The ring is firmly attached to pump housing (16). Vanes (19) are pressed against the
centrifugal force. The fuel flows through inlet passage (20) then into a recess in the pump housing.
e eccentric position of the rotor is relative to the cam ring. A volume is created between the vanes, the rotor, and the cam
e fuel is transported by the eccentric position. The eccentric position is relative to the rotor and outlet passage (17). The f
nsfered to the outlet passage into the distributor plunger. The volume of the fuel is reduced between the inlet passage and
let passage. This creates pressure before the delivery to the distributor plunger.
e quantity of fuel increases as the speed of the engine increases. Increased engine speed increases the delivery pressure of
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l. The pressure inside the pump is limited by a pressure regulator (7). The pressure regulator controls the fuel pressure. T
l forces the valve spring open and the fuel flows back into the inlet passage from the inside of the fuel injection pump.
eneration of High Pressure
ustration 5 g01140929
e distributor rotor and the cam plate of the Bosch VP30 fuel injection
mp
Cam ring
3) Roller
4) Cam plate
Distributor plunger
1) Head of the distributor
2) Springs
e fuel comes from the outlet passage of the fuel transfer pump (9). The high pressure is generated by the axial movement
distributor plunger (8). The cam plate (14) is driven by the fuel injection pump shaft. The cam plate (14) has four cams.
mber of cams corresponds to the number of cylinders of the engine. The cams on the cam plate (14) run on the rollers (13
e rollers (13) are fixed on the cam ring (5). The rotating movement and the lifting movement of the cam plate (14) genera
h pressure.
e cam plate (14) moves the distributor plunger (8) toward the head of the distributor (21). The high pressure is created by
crease in the volume between the distributor plunger (8) and the head of the distributor (21). The cam plate (14) is pressed
cam ring (5) by two springs (22). This brings the distributor plunger (8) back to the original position. The fuel solenoid v
closes the high pressure volume.
stribution and Injection
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 6 g01140974
e rear view of the Bosch VP30 fuel injection pump
Fuel solenoid valve
5) Delivery valve
1) Timing solenoid valve
e distribution of fuel to the fuel injection nozzles (10) takes place through the rotating movement of the distributor plunge
e fuel solenoid valve (6) meters the amount of fuel by the following operations:
q Time of closure
q Duration time
q Start of injection
q Amount of fuel
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 7 g01140988
livery of fuel from the delivery valve
ustration 8 g01141216
osing of the delivery valve
e delivery valve (15) ensures that the pressure waves do not allow a reopening of the fuel injection nozzle (10). The press
ves are created at the end of the injection process. The valve cone is lifted by the fuel pressure.
e fuel is forced through the fuel line to the fuel injection nozzle (10). The delivery ends and the fuel pressure drops. The v
ing presses the valve cone onto the valve seat. The reopening of a fuel injection nozzle (10) has a negative effect on
issions.
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ming
tarding of the fuel injection is the direct relationship between the start of injection and the position of the piston. The timi
mpensates for the higher RPM of the engine by advancing the start of injection.
ustration 9 g01141217
ming advance for timing mechanism (side view and top view)
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 10 g01366794
ming retard for timing mechanism (side view and top view)
e timing advance or the timing retard of the fuel injection pump is shown in the following steps:
1. The ECU (2) sends a signal to the timing solenoid valve (11).
2. The timing mechanism is triggered by the timing solenoid valve (11) .
3. The timing solenoid valve (11) changes the pressure in the timing advance mechanism (12) .
4. The timing advance mechanism (12) changes the position of the cam ring (5) .
5. The cam ring (5) changes the position of the rollers (13) .
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
6. The rollers (13) change the position of the cam plate (14) .
7. The cam plate (14) changes the timing of the fuel delivery.
hutoff
e engine shuts off by interrupting the fuel supply. The engine Electronic Control Module (ECM) (1) specifies the amount
l. The fuel solenoid valve (6) is switched by the ECU (2) on the fuel injection pump to zero.
ontrol
ustration 11 g01141220
ectronic control for the fuel system (typical example)
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
e ECU (2) for the injection pump uses the command from the ECM (1) and the measured values from the secondary spee
ming sensor (4) to actuate the fuel solenoid valve (6).
ustration 12 g01141235
e timing wheel and the secondary speed/timing sensor
Secondary speed/timing sensor
3) Timing wheel
e ECU (2) for the fuel injection pump is mounted on the top of the pump. The ECU has a connection to the engine ECM
d a connection to the speed/timing sensor (4). The ECU has a connection for the two solenoid valves (6). The ECM funct
a control computer. The ECU calculates the optimal parameters from the ECM data. The fuel solenoid (6) actuates the va
ordingly.
e secondary speed/timing sensor (4) in the fuel injection pump determines the precise angular position and the speed of th
l injection pump shaft. Timing wheel (23) is permanently connected to the fuel injection pump shaft. The secondary spee
ming sensor (4) gets information from the timing wheel (23). The sensor then sends electrical impulses to the ECU (2). Th
U also uses the information to determine the average speed of the pump and momentary speed of the pump.
te: The engine will not run if the secondary speed/timing sensor (4) fails.
e signal of the speed/timing sensor (4) is constant. Power command signals are routed over the CAN data link from the en
M (1) to the ECU (2) on the fuel injection pump.
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 13 g01141251
perating principle
4) Angle of fuel delivery
5) Lift of the cam
6) Stroke
7) Pulse for actuating the fuel solenoid
8) Valve lift
9) Angle of the speed/timing sensor
e amount of fuel is proportional to the stroke of the piston. The effective stroke is proportional to the angle of fuel deliver
mperature compensation takes place in the ECU (2). The compensation takes place in order to inject the precise amount of
uel Injection Nozzles
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 14 g01144089
el injection nozzle
ch fuel injection nozzle is held into the cylinder head by a clamp around the fuel injection nozzle. The fuel injection nozz
not serviceable but the nozzles can be removed in order to clean the orifice.
e fuel injection pump forces the fuel to flow under high pressure to the hole in the fuel inlet. The fuel then flows around a
edle valve within the nozzle holder which causes the nozzle to fill with fuel. The pressure of the fuel pushes the needle va
d a spring. When the force of the fuel pressure is greater than the force of the spring, the needle valve will lift up.
hen the needle valve opens, fuel under high pressure will flow through the nozzle orifices into the cylinder. The fuel is inj
o the cylinder through the orifices in the nozzle end as a very fine spray. When the fuel is injected into the cylinder, the fo
the fuel pressure in the nozzle body will decrease. The force of the spring will then be greater than the force of the fuel
ssure that is in the nozzle body. The needle valve will move quickly to the closed position.
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
e needle valve has a close fit with the inside of the nozzle. This makes a positive seal for the valve.
pyright 1993 - 2012 Caterpillar Inc.
Rights Reserved.
vate Network For SIS Licensees.
Sat Aug 25 19:37:54 UTC+1100
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
uel Injection
MCS - 1251; 1252; 1253; 1254; 1281
ustration 1 g0114
ow diagram of the fuel system
) Fuel injection nozzles
) Electronic fuel priming pump and secondary fuel filter
) Fuel injection pump
) Primary fuel filter/water separator
) Fuel tank
) Fuel return line
) Fuel supply line
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
e 3054E engine is equipped with a Bosch VP30 fuel injection pump. This pump is an axial piston distributor
ection pump that is controlled by the Electronic Control Module (ECM).
e axial piston distributor injection pump generates injection pressure for all cylinders in a single pump. The
ection pump is responsible for the distribution of fuel to the fuel injection nozzles. The injection pressure is
nerated by an axially moving piston. The movement of the piston is parallel to the fuel injection pump shaft.
hen the engine is cranking, the fuel is pulled from fuel tank (5) through primary fuel filter/water separator (4)
el priming pump (2). When the fuel passes through the water separator, any water in the fuel will go to the bo
the bowl. The fuel priming pump is equipped with a secondary fuel filter. From the fuel priming pump, the fu
sses through the fuel supply line to fuel injection pump (3). The fuel injection pump sends fuel through the hi
essure fuel lines to fuel injection nozzles (1). The fuel injection nozzles spray atomized fuel into the cylinder.
e fuel injection pump needs fuel for lubrication. The precision parts of the pump are easily damaged. The eng
ust not be started until the fuel injection pump is full of fuel. The system must be primed when any part of the
stem is drained of fuel. The fuel system needs priming when a fuel filter is changed, and/or when a fuel line is
moved, and/or when the fuel injection pump is replaced.
uel Injection Pump
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 2 g0114
hematic of the Bosch VP30 fuel injection pump
) ECM
) Electronic Control Unit (ECU) for the fuel injection pump
) Fuel priming pump
) Speed/timing sensor
) Cam ring
) Fuel solenoid valve
) Pressure regulator
) Distributor plunger
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
) Fuel transfer pump
0) Fuel injection nozzle
1) Timing solenoid valve
2) Timing advance mechanism
3) Roller
4) Cam plate
5) Delivery valve
e fuel injection pump has the following operations:
q Delivery
q Generation of high pressure
q Distribution and injection
q Timing
q Shutoff
q Control
elivery
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 3 g01140827
enter view of the Bosch VP30 fuel injection pump
) Fuel transfer pump
el is supplied by the head pressure of the priming pump. The fuel enters fuel transfer pump (9) of the fuel
ection pump. The fuel transfer pump is a vane pump. The transfer pump is driven by the fuel injection pumpaft. The pump supplies a constant amount of fuel to the interior of the fuel injection pump. The revolution of t
nsfer pump is directly related to the speed of the fuel injection pump shaft.
ustration 4 g01140857
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
uel transfer pump for the Bosch VP30 fuel injection pump
) Cam ring
6) Pump housing
7) Outlet passage
8) Rotor
9) Vane
0) Inlet passage
otor (18) rotates inside cam ring (5). The ring is firmly attached to pump housing (16). Vanes (19) are pressed
ainst the ring by centrifugal force. The fuel flows through inlet passage (20) then into a recess in the pump
using.
e eccentric position of the rotor is relative to the cam ring. A volume is created between the vanes, the rotor, a
e cam ring. The fuel is transported by the eccentric position. The eccentric position is relative to the rotor and
tlet passage (17). The fuel is transfered to the outlet passage into the distributor plunger. The volume of the fu
duced between the inlet passage and the outlet passage. This creates pressure before the delivery to the distrib
unger.
e quantity of fuel increases as the speed of the engine increases. Increased engine speed increases the delivery
essure of the fuel. The pressure inside the pump is limited by a pressure regulator (7). The pressure regulator
ntrols the fuel pressure. The fuel forces the valve spring open and the fuel flows back into the inlet passage froe inside of the fuel injection pump.
eneration of High Pressure
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 5 g01140929
he distributor rotor and the cam plate of the Bosch VP30 fuel injection
mp
) Cam ring
3) Roller
4) Cam plate
) Distributor plunger
1) Head of the distributor
2) Springs
e fuel comes from the outlet passage of the fuel transfer pump (9). The high pressure is generated by the axiaovement of the distributor plunger (8). The cam plate (14) is driven by the fuel injection pump shaft. The cam
ate (14) has four cams. The number of cams corresponds to the number of cylinders of the engine. The cams o
e cam plate (14) run on the rollers (13). The rollers (13) are fixed on the cam ring (5). The rotating movement
e lifting movement of the cam plate (14) generates high pressure.
e cam plate (14) moves the distributor plunger (8) toward the head of the distributor (21). The high pressure i
eated by a decrease in the volume between the distributor plunger (8) and the head of the distributor (21). The
ate (14) is pressed to the cam ring (5) by two springs (22). This brings the distributor plunger (8) back to the
ginal position. The fuel solenoid valve (6) closes the high pressure volume.
stribution and Injection
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 6 g01140974
he rear view of the Bosch VP30 fuel injection pump
) Fuel solenoid valve
5) Delivery valve
1) Timing solenoid valve
e distribution of fuel to the fuel injection nozzles (10) takes place through the rotating movement of the
stributor plunger (8). The fuel solenoid valve (6) meters the amount of fuel by the following operations:
q Time of closure
q Duration time
q Start of injection
q Amount of fuel
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 7 g01140988
elivery of fuel from the delivery valve
ustration 8 g01141216
osing of the delivery valve
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
e delivery valve (15) ensures that the pressure waves do not allow a reopening of the fuel injection nozzle (10
e pressure waves are created at the end of the injection process. The valve cone is lifted by the fuel pressure.
e fuel is forced through the fuel line to the fuel injection nozzle (10). The delivery ends and the fuel pressure
ops. The valve spring presses the valve cone onto the valve seat. The reopening of a fuel injection nozzle (10)
negative effect on emissions.
ming
tarding of the fuel injection is the direct relationship between the start of injection and the position of the pist
e timing compensates for the higher RPM of the engine by advancing the start of injection.
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 9 g01141217
ming advance for timing mechanism (side view and top view)
ustration 10 g01366794
ming retard for timing mechanism (side view and top view)
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
e timing advance or the timing retard of the fuel injection pump is shown in the following steps:
1. The ECU (2) sends a signal to the timing solenoid valve (11).
2. The timing mechanism is triggered by the timing solenoid valve (11) .
3. The timing solenoid valve (11) changes the pressure in the timing advance mechanism (12) .
4. The timing advance mechanism (12) changes the position of the cam ring (5) .
5. The cam ring (5) changes the position of the rollers (13) .
6. The rollers (13) change the position of the cam plate (14) .
7. The cam plate (14) changes the timing of the fuel delivery.
hutoff
e engine shuts off by interrupting the fuel supply. The engine Electronic Control Module (ECM) (1) specifies
mount of fuel. The fuel solenoid valve (6) is switched by the ECU (2) on the fuel injection pump to zero.
ontrol
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 11 g01141220
ectronic control for the fuel system (typical example)
e ECU (2) for the injection pump uses the command from the ECM (1) and the measured values from the
condary speed/timing sensor (4) to actuate the fuel solenoid valve (6).
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054E Industrial Engine 30400001-UP(SEBP3645 - 38) - Document Structure
ustration 12 g01141235
he timing wheel and the secondary speed/timing sensor
) Secondary speed/timing sensor
3) Timing wheel
e ECU (2) for the fuel injection pump is mounted on the top of the pump. The ECU has a connection to thegine ECM (2) and a connection to the speed/timing sensor (4). The ECU has a connection for the two solenoi
lves (6). The ECM functions as a control computer. The ECU calculates the optimal parameters from the ECM
ta. The fuel solenoid (6) actuates the valve accordingly.
e secondary speed/timing sensor (4) in the fuel injection pump determines the precise angular position and th
eed of the fuel injection pump shaft. Timing wheel (23) is permanently connected to the fuel injection pump s
e secondary speed/timing sensor (4) gets information from the timing wheel (23). The sensor then sends elect
pulses to the ECU (2). The ECU also uses the information to determine the average speed of the pump and
omentary speed of the pump.
ote: The engine will not run if the secondary speed/timing sensor (4) fails.
e signal of the speed/timing sensor (4) is constant. Power command signals are routed over the CAN data link
om the engine ECM (1) to the ECU (2) on the fuel injection pump.
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ustration 13 g01141251
perating principle
4) Angle of fuel delivery
5) Lift of the cam
6) Stroke
7) Pulse for actuating the fuel solenoid
8) Valve lift
9) Angle of the speed/timing sensor
e amount of fuel is proportional to the stroke of the piston. The effective stroke is proportional to the angle of
livery. A temperature compensation takes place in the ECU (2). The compensation takes place in order to inje
e precise amount of fuel.
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uel Injection Nozzles
ustration 14 g01144089
uel injection nozzle
ch fuel injection nozzle is held into the cylinder head by a clamp around the fuel injection nozzle. The fuel
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ection nozzles are not serviceable but the nozzles can be removed in order to clean the orifice.
e fuel injection pump forces the fuel to flow under high pressure to the hole in the fuel inlet. The fuel then flo
ound a needle valve within the nozzle holder which causes the nozzle to fill with fuel. The pressure of the fuel
shes the needle valve and a spring. When the force of the fuel pressure is greater than the force of the spring,
edle valve will lift up.
hen the needle valve opens, fuel under high pressure will flow through the nozzle orifices into the cylinder. T
el is injected into the cylinder through the orifices in the nozzle end as a very fine spray. When the fuel is inje
o the cylinder, the force of the fuel pressure in the nozzle body will decrease. The force of the spring will then
eater than the force of the fuel pressure that is in the nozzle body. The needle valve will move quickly to the
osed position.
e needle valve has a close fit with the inside of the nozzle. This makes a positive seal for the valve.