Yuchai BOSCH High-Pressure Common Rail System

Yuchai BOSCH High-pressure Common Rail System
Common rail direct fuel injection

-is a direct fuel injection system for diesel engines. On diesel engines, it
features a high-pressure (over 1,000 bar or 100 MPa or 15,000 psi) fuel rail
feeding individual solenoid valves as opposed to a low-pressure fuel pump
feeding unit injectors (or pump nozzles). Third-generation common rail
diesels now feature piezoelectric injectors for increased precision, with fuel
pressures up to 3,000 bar (300 MPa; 44,000 psi).
-In Common Rail Direct Injection, commencement of combustion takes place

directly into the main combustion chamber located in a cavity on the top of
the piston crown. Today, CRDi technology is being widely used to overcome
some of the deficiencies of conventional Diesel engines which were sluggish,
noisy and poor in performance when implemented especially in passenger
vehicles.
Features of Yuchai BOSCH Common Rail Engine

Yuchai common rail serial engines are low emission, energy saving and
environment protection diesel engine which are specially developed to
replace Euro-Ⅱ engine after the implement of Euro-Ⅲ and Euro-Ⅳ emission
standard. Major differences with Euro-Ⅱ engine include the electro-control
high-pressure common rail technology.
Description of the Principle of BOSCH Common Rail Electro-
control Engine

Common pressure feedback
High pressure fuel

of each cylinder
for each cylinder
Injection order
Common rail pressure

order
Input from other

sensors
Instruction
 According to the pulse order of fuel injection from ECU,
Electro Control injector begins to inject fuel.
 The initial point of injection is controlled by the beginning
point of pulse order.
 The injection volume is controlled by the width of pulse.
 Multi-injection is available.
 The injection pressure is equal to common rail pressure
 Common rail pressure can be controlled by the common rail
pressure order from ECU on high pressure fuel pump.
 Common rail pressure is a closed loop control.
Fuel Route Diagram
BOSCH CP3.3 pump, applicable for Yuchai 4E, 4G, 6J, 6A, 6G medium duty
series BOSCH common rail engine
Fuel route:
Fuel tank→Fuel strainer(mannual fuel pump)→Fuel distributor→Fuel
dilevery pump(at the rear end of high pressure fuel pump) →Fuel filter→High
pressure fuel pump→Common rail pipe→Fuel injector
inner diameter of allowable length of allowable

fuel pipe fuel pipe pressure
From fuel tank to ≥10 mm ≤3 mm 0.5—1.0bar
fuel inlet pipe ≥11 mm ≤6 mm
≥12 mm ≤9 mm
Fuel inlet and ≥9 mm ≤6 mm ≤1.2bar
return pipe of fuel ≥10 mm ≤9 mm
tank
Crankshaft/camshaft sensor
Connector
Main functions
Relative control strategy
1. Determine injection takes place in which cylinder

2. Transient rotation speed calculation
3. Injection time calculation
4. Injection pulse (fuel injected-quantity) calculation
Failures Causes and descriptions Relative repair suggestions
Hard to start. It can’t start, 1. Too large error of crankshaft, camshaft 1. Correct installation error according to
vibrate when running in signal panel or sensor installation phase instruction manual
high speed disenable to set up synchronization 2. Sensor that is out of the synchronous
2. Diagnose instrument shows faulty relationship error enables controller to enter
synchron signals, displaying fault code Limp Home mode to operate.
P0016, with fault blink code
correspondence.
1. Crankshaft/camshaft sensor signal is not 1. Check if sensor signal circuit for short-
presented circuit/open-circuit
2. Diagnose instrument shows no rotation 2. Replace dual sensor depending on sensor
speed and fault codes presented during characteristics
starting 3. Fit one sensor to enable controller to enter
Limp Home mode.
1. One sensor signal is intermittently not 1. Check if sensor is damaged or connections

presented are loose.
2. Diagnose instrument shows fault code 2. Check corresponding signal panel for dirt's
P0008 P0340 P0341 P0335 P0336. 3. Sensor that is out of the synchronous
fault blink code in correspondence: 141 、 relationship error enables controller to enter
142 、 143 Limp Home mode to operate.
Booster Pressure and Temperature Sensor
Booster pressure and Connector

temperature sensor
Booster pressure and temperature sensor
Main function
1. Intake flow calculation

2. Smoke control
3. Turbocharger protection
4. Intake temperature overheat protection
5. Altitude Compensation
Cooling water temperature sensor
Main function:
1. Injection quantity modification

2. Injection timing modification
3. Starting control(cold, heat)
4. Target idle-speed control
5. Overheat protection
Throttle position sensor
Accelerator pedal Accelerator pedal interface
Main function
1. Torque control(fuel quantity control)
2. Idle-speed control(high, low idle speed)
3. Deacceleration fuel shutoff control
4. Limp home control
Vehicle speed sensor
1. At present, we suggest using Hall
sensor of Shanghai Yaotong Electronic
Instrument Co., Ltd.
2. Model: YT316B
3. Installation: M22×1.5
4. Characteristics: 8 pulse per revolution
5. Reference voltage: DC 8V
THE END
Thank
You!!!!

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Yuchai BOSCH High-pressure Common Rail System

Common rail direct fuel injection

-In Common Rail Direct Injection, commencement of combustion takes place

High pressure fuel

Common rail pressure

Input from other

inner diameter of allowable length of allowable

Relative control strategy

1. Determine injection takes place in which cylinder

1. One sensor signal is intermittently not 1. Check if sensor is damaged or connections

Booster pressure and Connector

1. Intake flow calculation

1. Injection quantity modification

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