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C&I stage 2
K u r b e lg e h ä u s e
System cost
Electronics on A u s g le ic h s c h e ib e
R o lle n s tö ß e l
Fuel consumption
demand N o c k e n w e lle Cold start
Electronic functions (EMR variant)
Common-Rail
Almost every • Pressure flexibility
passenger car • Multiple injection
RVI, JohnDeere, • Silent gear train
Cummins, CAT
DCR - System
ECU
1 Heater (optional)
2 Pressure sensor
Injector
3 MProp
FCU
Supply Main
pump filter
Thermostatic
Hand- valve
primer
ECU: Electronic Control Unit
TE-TM1 05.02.04
Magnet coil
Magnet core Armature Control chamber High pressure channel Pressure piece
Features:
• Injector just opens when current is on
• A leakage occurs during opening which is systematically caused (dependend on rail pressure and
injection duration)
• Spring is just applied to keep the injector closed against compression pressure
TE-TM1 05.02.04
in combustion chamber
• Exchange of nozzles is not permitted ! The whole injector has to be removed !
• Service concept is in progress
Rail
• High pressure storage of injection system
• Rail contains pressure relieve valve (DBV) and rail pressure sensor (RDS)
Pressure sensor
• The system is adjusted that after each injection a corresponding fuel quantity is delivered by
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Features:
• If opened the rail pressure remains in the range of 650 - 850 bar (dependend on speed
and load). The engine keeps running but if necessary with decreased performance (limp
home mode)
• Under usual conditions the DBV will not open during engine operation
TE-TM1 05.02.04
Rail Pressure Sensor (RDS)
• Input variable for rail pressure controller
• If any malfunction is detected the ECU may force the DBV to open by putting over
pressure onto the system
Signal voltage
5V
4,5 V
0,5 V
0V Pressure
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I/O-Valve
(integrated)
ND-connector
back to tank
Fuel Control Unit (FCU)
Inlet 3,5
Outlet 1,5
0,5
• Supplier: BOSCH
0
• FCU for all DCR systems usable 300 500 700 900 1100 1300 1500
TE-TM1 05.02.04
Current [mA]
• Tested Part from Supplier
Characteristic of Overflow Valve
Low Pressure vs. Engine Speed
8
7,5
Pressure [bar, absolute]
6,5
5,5
4,5
4
0 500 1000 1500 2000 2500 3000
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• Prefiltration of Particle 30 m