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Page 1: Diesel in-line fuel-injection pumpsinjectionpumps.co.uk/pdf/bosch_pe_pumps.pdfDiesel fuel-injection systems: An overview Fields of application 4 Technical requirements 4 ... Bosch

Combustion in the diesel engineThe diesel engine 2

Diesel fuel-injection systems: An overviewFields of application 4Technical requirements 4Injection-pump designs 6

PE in-line fuel-injection pumpsFuel-injection systems 8Fuel-injection techniques 9PE standard in-line fuel-injection pumps 16PE in-line fuel-injection pumps for alternative fuels 26PE in-line control-sleeve fuel-injection pumps 27Fuel supply and delivery 30Operation of the in-line fuel-injection pump 36Nozzles and nozzle holders 40

Single-plunger fuel-injection pumpsPF single-plunger fuel-injection pumps 48PF-MV solenoid-valve-controlled single-plunger fuel-injection pumps 52Innovative fuel-injection systems 54

Start-assist systems 56

Dieselin-line fuel-injection pumps

Mobility in this day and age is notleast of all a question of commonsense and economy.In future, the technology withoutwhich these considerations regard-ing individual mobility are meaning-less will continue to be of decisiveimportance.In the automotive sector, economi-cal and quiet-running diesel enginesare making history.Bosch in-line and distributor injec-tion pumps have played, andcontinue to play, a major role inthese developments. The introduc-tion of electronic controls (ElectronicDiesel Control/EDC), together withincreased injection pressures andeven more precise fuel metering,has made it possible to further in-crease the diesel engine’s servicelife, as well as reducing its exhaust-gas emissions, while at the sametime even further improving its fuel-economy figures.In this “Technical Instruction” man-ual, from the Diesel Fuel Injectionseries, you have access to a wealthof information on a variety of diffe-rent fuel-injection pumps, as well ason important components and theirfunctioning. These components in-clude for instance, the delivery-valve assemblies and the plunger-and-barrel assemblies.The appropriate governors for thePE in-line injection pumps are dealtwith in the Technical Instructionmanual “Governors for Diesel In-Line Fuel-Injection Pumps”.

Page 2: Diesel in-line fuel-injection pumpsinjectionpumps.co.uk/pdf/bosch_pe_pumps.pdfDiesel fuel-injection systems: An overview Fields of application 4 Technical requirements 4 ... Bosch

PE standard in-linefuel-injection pumps

Design and construction

The standard PE in-line injection pumpsincorporate their own camshaft, and aplunger-and-barrel assembly (pumpingelement) for each engine cylinder (Fig. 1).

The complete fuel-injection system iscomprised of:– A fuel-injection pump,– A mechanical (flyweight) or electronic

governor for control of engine-speedand injected fuel quantity,

– A timing device (if required) for varyingthe start of delivery as a function ofengine speed,

– A fuel-supply pump for delivering thefuel from the fuel tank, through the fuelfilter and the fuel line, to the injectionpump,

– A number of high-pressure fuel-in-jection lines, corresponding to thenumber of engine cylinders, connec-ting the injection pump and the injec-tion nozzles,

– The injection nozzles.

The injection pump’s camshaft is drivenby the diesel engine. Injection-pumpspeed and crankshaft speed are identicalfor 2-stroke engines. For 4-stroke engi-nes, pump speed is the same as enginecamshaft speed, in other words halfcrankshaft speed.The drive between injection pump andengine must be as torsionally rigid aspossible if today’s high injection pres-sures are to be generated.There are a number of different sizes ofin-line injection pumps for the various en-gine outputs.The injected fuel quantity depends uponthe swept volume of the injection-pumpbarrel, and maximum (pump-side) injec-tion pressures are between 400 and1,150 bar.

In-linefuel-injection

pumps

16

1

234567

89

10111213

14

15

Fig. 1

PES in-line fuel-injection pump

1 Delivery-valve holder, 2 Filler piece, 3 Delivery-valve spring, 4 Pump barrel, 5 Delivery valve, 6 Inletport and spill port, 7 Control helix, 8 Pump plunger, 9 Control sleeve, 10 Plunger control arm, 11 Plungerreturn spring, 12 Spring seat, 13 Roller tappet, 14 Cam, 15 Control rack.

UM

K04

09Y

Page 3: Diesel in-line fuel-injection pumpsinjectionpumps.co.uk/pdf/bosch_pe_pumps.pdfDiesel fuel-injection systems: An overview Fields of application 4 Technical requirements 4 ... Bosch

To lubricate the moving injection-pumpcomponents (e.g. camshaft, roller tap-pets etc.) there must be a certain amountof oil in the injection pump. The injectionpump is connected to the diesel engine’slube-oil circuit, and oil circulates throughthe pump during operation.Each pump type is allocated to a giventype series, which in some cases overlapwith respect to their power ranges. Thesewill be described in the following chap-ters.Two different construction principles areused for in-line injection pumps: The prin-ciple for the M and A pumps, and that forthe MW and P pumps.The power outputs of diesel enginesequipped with in-line injection pumpsrange from 10 to 70 kW per cylinder. Thisbroad power-output range is made possi-ble by the availability of a wide variety ofdifferent pump versions. The pump sizes

A, M, MW, and P are manufactured inlarge batches (Fig. 2).The pump sizes ZW, P9, and P10 areavailable for even higher cylinder poweroutputs.

Method of operation

Interaction between the componentsThe camshaft of the PE in-line injectionpump is integrated in the aluminum pumphousing. It is connected to the diesel en-gine either through a timing device,through a coupling element, or directly. Aroller tapper with spring seat is locatedabove each camshaft cam. The springseat provides a positive-drive connectionbetween pump plunger and roller tappet.The pump plunger moves up and down inthe pump barrel, and together these twocomponents form the plunger-and-barrelassembly (pumping assembly).

Standardin-linefuel-injectionpumps

17

In-line injection pumps. Size comparison (looking onto camshaft end)

Tab. 1

OverviewFeatures PE in-line injection pumps

M A MW P1...3000 P7100...8000Injection pressure 550 750 1100 950 1300in bar (pump side)Application Passenger Light to medium Heavy

cars commercial vehicles, commercialand tractors, vehicles, indus-vans industrial engines. trial engines.

Output per cylinder 20 27 36 60 160in kW/cylinder

M A MW P1…3000 P7100…8000

Fig. 2

UM

K08

03Y