Contents

4 Overview of diesel fuel-injection systems 4 Requirements 6 Overview of in-line fuel-injection pump systems 6 Areas of application 6 Types 7 Design and construction 7 Control 10 Fuel supply system (low-pressure stage) 10 Fuel tank 10 Fuel lines 11 Diesel fuel filter 12 Supplementary valves for in-line fuel-injection pumps 14 Presupply pumps for in-line fuel-injection pumps 14 Applications 15 Design and method of operation 17 Manual priming pumps 17 Preliminary filters 17 Gravity-feed fuel-tank system 18 Type PE standard in-line fuel-injection pumps 19 Fitting and drive system 19 Design and method of operation 28 Design variations 38 Type PE in-line fuel-injection pumps for alternative fuels 39 Operating in-line fuel-injection pumps 40 Governors and control systems for in-line fuel-injection pumps 40 Open and closed-loop control 42 Action of the governor/control system 42 Definitions 43 Proportional response of the governor 44 Purpose of the governor/control system 47 Types of governor/control system 52 Overview of governor types

58 Mechanical governors 84 Calibration devices 97 Type PNAB pneumatic shutoff device 98 Timing device 100 Electric actuator mechanisms 102 Semi-differential short-circuit ring sensors 104 Control-sleeve in-line fuel-injection pumps 105 Design and method of operation 108 110 112 116 118 120 121 122 123 Nozzles Pintle nozzles Hole-type nozzles Future development of the nozzle Nozzle holders Standard nozzle holders Stepped nozzle holders Two-spring nozzle holders Nozzle holders with needle-motion sensors

124 High-pressure lines 124 High-pressure connection fittings 125 High-pressure delivery lines 128 128 128 129 130 132 132 134 136 140 Electronic Diesel Control EDC Requirements System overview System structure In-line fuel-injection pumps Service technology Overview Fuel-injection pump test benches Testing in-line fuel-injection pumps Nozzle tests

142 Index of technical terms 142 Technical terms 144 Abbreviations

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 fuelinjection 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.

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Control-sleeve in-line fuel-injection pumps

Design and method of operation

Operating cycle of control-sleeve in-line fuel-injection pump

1
Fig. 4 a Bottom dead center b Start of delivery c End of delivery d Top dead center 11 Delivery valve 12 Plunger chamber 13 Pump barrel 14 Control sleeve 15 Helix 16 Control port (start of delivery) 17 Pump plunger 18 Plunger spring 19 Roller tappet 10 Drive cam 11 Spill port h1 Plunger lift to port closing h2 Effective stroke h3 Residual travel

2 3 4 5 6 7 8 9 11 h1 h2 h3

10

Start of delivery Assoon asthe pump plunger (Figure4b, Item7) has completed the preliminary phase (h1) of the delivery stroke, the control sleeve (4) closes off the control port (6) in the pump plunger. From this point on, the pressure inside the plunger chamber (2) increases and fuel delivery begins. The point at which fuel delivery, and therefore fuel injection, begins is altered by moving the control sleeve vertically relative to the pump plunger. When the control sleeve is closer to the piston top dead center, the plunger lift to port closing is longer and the start of delivery is therefore later.When the control sleeve is closer to the pistons bottom dead center position, the plunger lift to port closing is shorter and the start of injection is earlier. The cam shape used determines the delivery velocity and the fuel-delivery rate (theoretical amount of fuel delivered per degree of cam rotation) as well as the injection pressure.

Spill The pistons effective delivery stroke (h2) ends when the helix (Figure 4c, Item 5) in the pump plunger overlaps the spill port (11) in the control sleeve and allows pressure to escape. Rotating the pump plunger by means of the control rack changes the point at which this occurs and, therefore, the quantity of fuel delivered in the same way as on a standard in-line fuel-injection pump. Electronic control system From the input data received from the sensors and desired-value generators described in the chapter Electronic Diesel Control EDC, the control unit (Figure 5, Item 5) calculates the required fuel-injection pump settings. It then sends the appropriate electrical signals to the actuator mechanisms for start of delivery (1) and injected fuel quantity (4) on the fuel-injection pump.

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Control-sleeve in-line fuel-injection pumps

Design and method of operation

107

Controlling start of delivery Start of delivery is adjusted by means of a closed control loop. A needle-motion sensor in one of the nozzle holders (generally on no. 1 cylinder) signals to the control unit the actual point at which injection occurs. This information is used to determine the actual start of injection in terms of crankshaft position. This can then be compared with the setpoint value and the appropriate adjustment made by sending a current signal to the electrical start of delivery actuator mechanism. The start of delivery actuator mechanism is structurally rigid. For this reason, a separate travel feedback sensor can be dispensed with. Structurally rigid means that the lines of action of solenoid and spring always have a definite point of intersection. This means that the forces are always in equilibrium. Thus, the travel of the linear solenoid is proportional
5

to the signal current. This is equivalent to feedback within a closed control loop. Controlling injected fuel quantity The required injected fuel quantity calculated by the microcontroller in the control unit is set using the position control loop: The control unit specifies a required control-rack travel and receives a signal indicating the actual control-rack travel from the control-rack travel sensor (3). The control unit repeatedly recalculates the adjustment needed to achieve the required actuator mechanism setting, thereby continuously correcting the actual setting to match the setpoint setting (closed control loop). For safety reasons, a compression spring (2) moves the control rack back to the zero delivery position whenever the actuator mechanism is de-energized.

Control-sleeve in-line fuel-injection pump Type H1 (RP43) with control unit

10 1 2 3 9 8

7 6

5 cm

Fig. 5 11 Fuel delivery actuator mechanism 12 Compression spring 13 Control-rack travel sensor 14 Control-rack actuator mechanism (injected fuel quantity) 15 ECU 16 Connection to engine 17 Camshaft 18 Control sleeve 19 Pump plunger 10 Delivery valve

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