Electronic Axial & Radial Pumps(bosch pump)

Electronic Axial & Radial Pumps(bosch pump)

Explain the structure and mode of action and set the time when  
remove and installation

Main components of the VP30 injection pump

Angle-of-rotation sensor often referred to as DWS system which is a German abbreviation roughly translated to  Debug Winkel Sensor

Note 1: In the event of an engine crankshaft position failure the engine will still run using the Angle of Rotation Sensor.

Note 2: Be aware on certain models it is necessary to couple the VP30 pump with the engine controller via the Electronic Service Tool (EST)

1. Drive Shaft                                    

2. Housing

3. Vane Pump

4. Bearing Ring

5. Roller Ring

6. Cam Disc

7. Distributor Piston

8. Snubber Valve

9. Pressure Fitting                                                                                                           10. Electronic Control Module (PCU)

11. Angle of rotation Sensor (DWS)
      or (IAT)

12. Incremental Wheel

13. Solenoid (Injection Rate)

14. Proportional Solenoid (variable
       timing)

15. Timing Actuator

16. Connector

 17. Conducting Foil 

1. Drive shaft

 2. housing

 3. Vane pump

 4. Bearing ring

 5. Roller ring

 6. Cam disc

 7. Distributor piston

 8. Snubber valve

 9. Pressure Fitting

10. Pump Control Unit (PCU)

11. Angle of rotation Sensor (DWS) or (IAT)

12. Incremental wheel

13. Solenoid (injection rate) 

14 Proportional - Solenoid (variable timing) 

15. Timing Actuator

17. Conducting foil

18. Timing mark

20. Pressure regulator

21. Nozzle holder

22. Pump case pressure regulator

23. Pressure regulator (filter)

24. Tank

25. Pre filter (with water drain)

26. Electric lift pump

27. Fuel filter

28. Fuel pressure switch

 A primer pump (26) supplies fuel to the injection pump, an overflow valve (22) ensures permanent bleeding and cooling of the injection pump. The low pressure vane pump (3) creates a pressure feeding the high pressure pump and also as a control pressure for the timing device (15). High pressure is produced by injection pump means of the cam lobes on the roller ring (5) and the lift disc (6) in connection with the axial pistion. The injection pump is lubricated solely by fuel, making proper bleeding essential.

The electronic Pump Control Unit (PCU) (10) is located at the top of the injection pump. The PCU controls the proportional solenoid valve, which varies the control pressure for the timing device.

The Incremental Advance Time system (IAT) sensor (11) attached to the bearing ring, signals the real angle of increment wheel as well as the pump speed and the commencement of fuel delivery.

The fuel-quantity solenoid valve (13) is positioned concentrically with the distributor body. When the PCU energises the valve, it‘s needle closes a port and delivery commences. When the valve is de-energised, delivery ceases. During the time the fuel quantity valve is energised the piston (7) moves a specific distance of its total stroke, this also determins the quantity of fuel delivered to the injector (21). One revolution of the driveshaft runs through six cycles of opening and closing the needle (related to number of cyclinders).

The incremental wheel (12) rotates together with the pump drive shaft (1). The IAT sensor (11) moves together

with the bearing ring(4) and the roller ring (5).

• When in the timing device (15) the timing advance is altered by the proportional solenoid valve , the bearing

ring (4) together with the roller ring (5) and the IAT sensor (11) is moved in the direction „advance“ or „retard“

either.

• At the circumference of the incremental wheel (12), there are six notches (18) (one notch for each cylinder of

the engine), arranged by symetric division. The sequence of teeth and notches is scanned by the IAT sensor

(11).

• The signal is transmitted to the PCU (10) by means of a conductive foil (17). The signal is utilised as follows:

- to determine the present angle position

- to determine the present timing advance in connection with the engine speed signal

- to sense the speed of the pump drive shaft

• The present angle position determines the trigger point for energising the fuel-quantity solenoid valve (13)

by the PCU (10). This will ensure the correct timing for closing and opening of the valve needle (valve lift) in

accordance with the cam lift 

1.Engine ECU

(Note There is a CAN Bus connection between engine ECU and Pump Control Unit (PCU). The CAN

Hi voltage and CAN Lo voltage are both measured as 2.5Volts on a standard multi meter.)

2. Low pressure control valve

3. Pump Control Unit (PCU)  - The pump ECU receives information from the angle-of-rotation sensor (2) (DWS/IATsystem) and the engine ECU (1) . Using this information it calculates the triggering signal for the high-pressure solenoid valve (6).

4. Vane-type supply pump (Turned though 90º for clarity)

5. Angle-of-rotation sensor (DWS) or (IAT) - Measures the increment wheel angle which results between the driveshaft and cam ring during driveshaft rotation. These are used to calculate the current pump speed, timing device (7) position and the angular setting of the driveshaft.

6. Cam ring. NOTE: THIS IMAGE SHOWS A RADIAL PUMP AND NOT AN AXIAL PUMP AS USED ON VP!  (Turned though 90º for clarity)

7. Overflow throttle valve

8. High-pressure solenoid valve – Controlled by the pump ECU (2) , regulates the entry of fuel to the high-pressure piston pump, meters the injected fuel quantity and the instant of injection for each injection process.

9. Injector

10. Timing device solenoid valve (pulse valve) – Controlled by the pump ECU (2) .  The fuel flow quantity is varied to move the timing device (7) to its desired position.

11. Timing device - Adjusts the start of delivery

This diagram shows in detail, all the components that control the advance and retard timing

1. Cam ring

2. Ball pivot

3. Timing-device piston

4. Inlet passage/outlet passage

5. Control collar

6. Vane-style supply pump

7. Pump outlet (pressure side)

8. Pump inlet (suction side)

9. Input from fuel tank

10. Control plunger spring

11. Return spring

12. Control plunger

13. Ring chamber of the hydraulic stop

14. Throttle (restrictor)

15. Timing-device solenoid valve

Retiming Pump

1.Slacken Pump lock bolt (5)

2.Align pump timing holes and insert locking pin (1)

3.Tighten pump locking bolt (5)