Common_Rail_Manual.pdf

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TM
COMMON RAIL MANUAL
PRINCIPLES OF OPERATION
2007
DDGX200(EN)
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TABLE OF CONTENTS
OBJECTIVES
I
THE COMMON RAIL SYSTEM
II
CONTROL STRATEGIES
III
ABBREVIATIONS
IV
Produced and published by:
Delphi France SAS
Diesel Aftermarket
12 - 14 Boulevard de l’industrie
41042 Blois Cedex
Tel: (+33) (0) 2 54 55 39 39
France
Fax: (+33) (0) 2 54 55 39 12
DDGX200(EN) - Issue 1 of 09/2007
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I
OBJECTIVES
TABLE OF CONTENTS
1.1
REDUCING NOISE.........................................................................................................................................................1-1
1.2
REDUCING POLLUTING EMISSIONS..........................................................................................................................1-2
1.2.1
COMBUSTION..............................................................................................................................................1-2
1.2.2
STANDARDS.................................................................................................................................................1-3
1.2.3
POLLUTANTS...............................................................................................................................................1-4
1.3
REDUCING FUEL CONSUMPTION...............................................................................................................................1-5
1.4
INCREASING PERFORMANCE.....................................................................................................................................1-6
ii
DDGX200(EN) - Issue 1 of 09/2007
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THE COMMON RAIL SYSTEM
II
TABLE OF CONTENTS
2.
SYSTEM MAKE-UP
2.1
DESCRIPTION................................................................................................................................................................2-7
2.2
COMMON RAIL HYDRAULIC CIRCUIT.........................................................................................................................2-9
3.
HP PUMP
3.1
TRANSFER PUMP........................................................................................................................................................3-11
3.1.1
DESCRIPTION.............................................................................................................................................3-11
3.1.2
OPERATING PRINCIPLE.............................................................................................................................3-11
3.1.3
TRANSFER PUMP CHARACTERISTICS....................................................................................................3-12
3.2
DFP1 COMMON RAIL PUMP .....................................................................................................................................3-13
3.2.1
DESCRIPTION.............................................................................................................................................3-13
3.2.2
OPERATION................................................................................................................................................3-14
3.2.3
CHARACTERISTICS....................................................................................................................................3-17
3.3
DFP3 COMMON RAIL PUMP .....................................................................................................................................3-19
3.3.1
DESCRIPTION.............................................................................................................................................3-19
3.3.2
OPERATION................................................................................................................................................3-20
3.3.3
SPECIFICATIONS........................................................................................................................................3-23
3.4
IMV...............................................................................................................................................................................3-24
3.4.1
OPERATION................................................................................................................................................3-24
3.4.2
DESCRIPTION.............................................................................................................................................3-25
3.4.3
OPERATION................................................................................................................................................3-26
3.4.4
SPECIFICATIONS........................................................................................................................................3-27
3.5
Pressure limiter...........................................................................................................................................................3-28
3.6
Venturi..........................................................................................................................................................................3-28
4.
INJECTOR DFI 1.X
4.1
OPERATION.................................................................................................................................................................4-29
4.2
TECHNOLOGY.............................................................................................................................................................4-29
4.2.1
Valve............................................................................................................................................................4-30
4.2.2
Crosspiece...................................................................................................................................................4-30
4.2.3
Specifications.............................................................................................................................................4-31
4.3
DESCRIPTION..............................................................................................................................................................4-33
4.4
OPERATING PRINCIPLE..............................................................................................................................................4-33
4.4.1
Pressure propagation.................................................................................................................................4-33
4.4.2
Injector at rest.............................................................................................................................................4-34
4.4.3
Coil control..................................................................................................................................................4-34
4.4.4
Injection start..............................................................................................................................................4-34
4.4.5
Injection end...............................................................................................................................................4-34
4.5
INJECTOR OPERATION..............................................................................................................................................4-36
4.6
DISCHARGE THROUGH INJECTORS.........................................................................................................................4-36
4.7
C2I: INJECTOR INDIVIDUAL CORRECTION...............................................................................................................4-37
4.7.1
Description..................................................................................................................................................4-37
4.7.2
Procedure....................................................................................................................................................4-37
4.7.3
Development: C3I.......................................................................................................................................4-38
4.7.4
Read/Write..................................................................................................................................................4-40
5.
RAIL ASSEMBLY
5.1
RAIL..............................................................................................................................................................................5-41
5.1.1
GENERAL....................................................................................................................................................5-42
DDGX200(EN) - Issue 1 of 09/2007
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