ISBN-3-934584-68-3 Order Number 1 987 722 137 AA/PDT-09.03-En The Bosch Yellow Jackets Edition 2003 Expert Know-How on Automotive Technology Diesel-Engine Management 2003 Diesel In-Line The Bosch Yellow Jackets Fuel-Injection Pumps The Program Order Number ISBN Diesel In-line Fuel-Injection Pumps Automotive Electrics/Automotive Electronics Motor-Vehicle Batteries and Electrical Systems 1 987 722 143 3-934584-71-3 Automotive Technology Alternators and Starter Motors 1 987 722 128 3-934584-69-1 Automotive Lighting Technology, Windshield and Rear-Window Cleaning 1 987 722 176 3-934584-70-5 Automotive Sensors 1 987 722 131 3-934584-50-0 Automotive Microelectronics 1 987 722 122 3-934584-49-7 Diesel-Engine Management Diesel-Engine Management: An Overview 1 987 722 138 3-934584-62-4 Electronic Diesel Control EDC 1 987 722 135 3-934584-47-0 Diesel Accumulator Fuel-Injection System Expert Know-How on Automotive Technology Common Rail CR 1 987 722 175 3-934584-40-3 Diesel Fuel-Injection Systems Unit Injector System/Unit Pump System 1 987 722 179 3-934584-41-1 Distributor-Type Diesel Fuel-Injection Pumps 1 987 722 144 3-934584-65-9 • Injection pump designs Diesel In-Line Fuel-Injection Pumps 1 987 722 137 3-934584-68-3 • Governor designs • Workshop technology Gasoline-Engine Management Emissions-Control Technology for Gasoline Engines 1 987 722 102 3-934584-26-8 Gasoline Fuel-Injection System K-Jetronic 1 987 722 159 3-934584-27-6 Gasoline Fuel-Injection System KE-Jetronic 1 987 722 101 3-934584-28-4 Gasoline Fuel-Injection System L-Jetronic 1 987 722 160 3-934584-29-2 Gasoline Fuel-Injection System Mono-Jetronic 1 987 722 105 3-934584-30-6 Ignition Systems for Gasoline Engines 1 987 722 130 3-934584-63-2 Gasoline-Engine Management: Basics and Components 1 987 722 136 3-934584-48-9 Gasoline-Engine Management: Motronic Systems 1 987 722 139 3-934584-75-6 Safety, Comfort and Convenience Systems Conventional and Electronic Braking Systems 1 987 722 103 3-934584-60-8 ESP Electronic Stability Program 1 987 722 177 3-934584-44-6 ACC Adaptive Cruise Control 1 987 722 134 3-934584-64-0 Compressed-Air Systems for Commercial Vehicles (1): Systems and Schematic Diagrams 1 987 722 165 3-934584-45-4 Compressed-Air Systems for Commercial Vehicles (2): Equipment 1 987 722 166 3-934584-46-2 Safety, Comfort and Convenience Systems 1 987 722 150 3-934584-25-X Audio, Navigation and Telematics in the Vehicle 1 987 722 132 3-934584-53-5 The up-to-date program is available on the Internet at: www.de/aa/de/fachliteratur/index.htm Robert Bosch GmbH Imprint Published by: Reproduction, duplication and translation of this © Robert Bosch GmbH, 2003 publication, either in whole or in part, is permis- Postfach 11 29, sible only with our prior written consent and D-73201 Plochingen. provided the source is quoted. Automotive Aftermarket Business Sector, Illustrations, descriptions, schematic diagrams Department of Product Marketing Diagnostics & and the like are for explanatory purposes and Test Equipment (AA/PDT5). illustration of the text only.
They cannot be used as the basis for the design, installation, or speci- Editor-in-Chief: fication of products. We accept no liability for Dipl. the accuracy of the content of this document in respect of applicable statutory regulations. Editorial team: Robert Bosch GmbH is exempt from liability, Dipl.
(FH) Thomas Jäger, Subject to alteration and amendment. Karl-Heinz Dietsche. Printed in Germany. Authors: Imprimé en Allemagne.
Hans Binder (Nozzle testing), 1st edition, September 2003. Henri Bruognolo English translation of the 1st German edition (System overview, presupply pumps, dated: April 2002 Standard in-line fuel-injection pumps, Governors, (1.0) Control-sleeve in-line fuel-injection pumps), Dipl. Thomas Kügler (Nozzles, Nozzle holders), Dipl. Felix Landhäusser (EDC), Albert Lienbacher (Customer Service Academy), Dr.
Ulrich Projahn (Fuel supply system), Dipl. Rainer Rehage (Overview of workshop technology), Dr. Ernst Ritter (Presupply pumps, Standard in-line fuel-injection pumps, Governors, Control-sleeve in-line fuel-injection pumps), Kurt Sprenger (High-pressure delivery lines), Dr. Theodor Stipek (Injection pumps for large engines), Rolf Wörner (Fuel-injection pump test benches, Testing in-line fuel-injection pumps) and the editorial team in cooperation with the responsible technical departments of Robert Bosch GmbH.
Unless otherwise indicated, the above are employees of Robert Bosch GmbH, Stuttgart. Robert Bosch GmbH Diesel In-Line Fuel-Injection Pumps Robert Bosch GmbH Robert Bosch GmbH Contents 4 Overview of diesel fuel-injection 58 Mechanical governors systems 84 Calibration devices 4 Requirements 97 Type PNAB pneumatic shutoff device 6 Overview of in-line fuel-injection 98 Timing device pump systems 100 Electric actuator mechanisms 6 Areas of application 102 Semi-differential short-circuit ring 6 Types sensors 7 Design and construction 7 Control 104 Control-sleeve in-line fuel-injection pumps 10 Fuel supply system 105 Design and method of operation (low-pressure stage) 10 Fuel tank 108 Nozzles 10 Fuel lines 110 Pintle nozzles 11 Diesel fuel filter 112 Hole-type nozzles 12 Supplementary valves for in-line 116 Future development of the nozzle fuel-injection pumps 118 Nozzle holders 14 Presupply pumps for in-line 120 Standard nozzle holders fuel-injection pumps 121 Stepped nozzle holders 14 Applications 122 Two-spring nozzle holders 15 Design and method of operation 123 Nozzle holders with needle-motion 17 Manual priming pumps sensors 17 Preliminary filters 17 Gravity-feed fuel-tank system 124 High-pressure lines 124 High-pressure connection fittings 18 Type PE standard in-line 125 High-pressure delivery lines fuel-injection pumps 19 Fitting and drive system 128 Electronic Diesel Control EDC 19 Design and method of operation 128 Requirements 28 Design variations 128 System overview 38 Type PE in-line fuel-injection 129 System structure pumps for alternative fuels 130 In-line fuel-injection pumps 39 Operating in-line fuel-injection pumps 132 Service technology 132 Overview 40 Governors and control systems 134 Fuel-injection pump test benches for in-line fuel-injection pumps 136 Testing in-line fuel-injection pumps 40 Open and closed-loop control 140 Nozzle tests 42 Action of the governor/control system 142 Index of technical terms 42 Definitions 142 Technical terms 43 Proportional response of the 144 Abbreviations governor 44 Purpose of the governor/control system 47 Types of governor/control system 52 Overview of governor types Robert Bosch GmbH Since the first in-line fuel-injection pump was produced by Bosch in 1927, countless numbers of them have reliably kept diesel engines in motion. These “classics of diesel fuel-injection technology” are still in use today on large numbers of engines. Their particular strengths are their durability and ease of maintenance.
Type PE in-line fuel-injection pumps cater for virtually the full spectrum of diesel engines. They are used on small fixed-installation engines, car engines, truck engines and even large marine diesels that produce several thousand kilowatts of power. Familiarity with this type of fuel-injection pump is therefore an important foundation for anyone with an interest in diesel engines. In combination with an Electronic Diesel Control (EDC), increasingly high fuel- injection pressures and high-precision fuel metering, these pumps can continue to achieve improvements in durability, exhaust-gas emission levels and fuel consumption.
This publication is part of the “Technical Instruction” series on diesel fuel-injection technology. It explains every significant aspect of a variety of in-line fuel-injection pump designs and their components, such as pump units and delivery valves, as well as providing interesting insights into their methods of operation. There are also chapters devoted to pump governors and control systems, outlining functions such as intermediate-speed and maximum-speed limiting, design types and methods of operation. Nozzles and nozzle holders – important components of the fuel-injection system – are also explained.
The chapter on workshop technology describes the tests and adjustments that are performed on fuel-injection systems. The principles of electronic diesel engine management and the Electronic Diesel Control EDC are explained in full detail in separate publications. Robert Bosch GmbH 4 Overview of diesel fuel-injection systems Requirements Overview of diesel fuel-injection systems Diesel engines are characterized by high fuel Requirements economy. Since the first volume-production fuel-injection pump was introduced by Bosch Ever stricter statutory regulations on noise in 1927, fuel-injection systems have experi- and exhaust-gas emissions and the desire for enced a process of continual advancement.
more economical fuel consumption contin- ually place greater demands on the fuel-in- Diesel engines are used in a wide variety of jection system of a diesel engine. design for many different purposes (Figure 1 and Table 1), for example Basically, the fuel-injection system is required to inject a precisely metered amount of fuel at to drive mobile power generators high pressure into the combustion chamber (up to approx. 10 kW/cylinder) in such a way that it mixes effectively with the as fast-running engines for cars and air in the cylinder as demanded by the type of light commercial vehicles (up to approx. engine (direct or indirect-injection) and its 50 kW/cylinder) present operating status.
The power output as engines for construction-industry and and speed of a diesel engine is controlled by agricultural machinery (up to approx. means of the injected fuel volume as it has no 50 kW/cylinder) air intake throttle. as engines for heavy trucks, omnibuses and tractor vehicles (up to approx. Mechanical control of diesel fuel-injection 80 kW/cylinder) systems is being increasingly displaced by to drive fixed installations such as emer- Electronic Diesel Control (EDC) systems.
gency power generators (up to approx. All new diesel-injection systems for cars 160 kW/cylinder) and commercial vehicles are electronically as engines for railway locomotives and controlled. 1 Applications for Bosch diesel fuel-injection systems M M M A/P P/H ZWM ZWM MW MW MW MW CW CW PF PF PF PF PF PF Fig. 1 M, MW, VE VE VE VE VE VE A, P, H, ZWM, CW In-line fuel-injection VR VR VR VR VR pumps of increasing size PF Discrete fuel- UIS UIS UIS UIS UIS injection pumps VE Axial-piston pumps UPS UPS UPS UPS VR Radial-piston PF(R) PF(R) æ UMK1563-1Y pumps UPS Unit pump system CR CR CR CR CR CR UIS Unit injector system CR Common-rail system Robert Bosch GmbH Overview of diesel fuel-injection systems Requirements 5 1 Properties and characteristic data of the most important fuel-injection systems for diesel engines Control Fuel-injection system Type of use Injection parameters Engine-related data method O Off-road vehicles 1) Max.
power output Electromechanical light commercials N Trucks and buses Max. rated speed Max. permissible IDI Indirect injection Injected volume DI Direct injection Solenoid valve pressure at jet injection cycle PO Post-injection PI Pre-injection S Ships/trains per cylinder Mechanical per stroke/ Number of Hydraulic P Cars and cylinders Type h m em Mv bar mm3 (0.1 MPa) rpm kW In-line injection pumps M P, O 60 550 – m, em IDI 4. 8 2,200 70 P10 S, O 800 1,200 – m, em, h DI/IDI 6.
12 2,400 140 ZW (M) S, O 900 950 – m, em, h DI/IDI 4. 12 2,400 160 P9 S, O 1,200 1,200 – m, em, h DI/IDI 6. 12 2,000 180 CW S, O 1,500 1,000 – m, em, h DI/IDI 6. 10 1,800 200 Axial-piston pumps Table 1 VE.
6 4,800 25 1) Fixed-installation VE.F N, O 125 800 – m DI 4, 6 3,800 30 construction VP37 (VE.EDC) P 70 1,250 – em7) DI 3. 6 4,400 25 and agricultural VP37 (VE.EDC) O 125 800 – em7) DI 4, 6 3,800 30 machinery VP30 (VE.MV) P 70 1,400 PI Mv7) DI 4. 6 4,500 25 2) Larger numbers of VP30 (VE.MV) O 125 800 PI Mv7) DI 4, 6 2,600 30 cylinders are also Radial-piston pumps possible with two VP44 (VR) P 85 1,900 PI Mv7) DI 4, 6 4,500 25 control units VP44 (VR) N 175 1,500 – Mv7) DI 4, 6 3,300 45 2a) EDC 16 and above: Discrete/cylinder-pump systems 6 cylinders 3) PI up to 90° BTDC, PF(R)… O 13. – m, em DI/IDI Any 4,000 4.
120 1,150 30 PO possible 4) Up to 5500 rpm PF(R)… large-scale P, N, O, S 150. – m, em DI/IDI Any 300. diesel 18,000 1,500 2,000 1,000 when overrunning 5) PI up to 90° BTDC, UIS P1 P 60 2,050 PI Mv DI 52, 2a) 4,800 25 UIS 30 N 160 1,600 – Mv DI 82) 4,000 35 PO up to 210° UIS 31 N 300 1,600 – Mv DI 82) 2,400 75 ATDC 6) PI up to 30° BTDC, UIS 32 N 400 1,800 – Mv DI 82) 2,400 80 UPS 12 N 180 1,600 – Mv DI 82) 2,400 35 PO possible 7) Electrohydraulic UPS 20 N 250 1,800 – Mv DI 82) 3,000 80 UPS (PF.MV) S 3,000 1,600 – Mv DI 6 .