238286736-Diesel-Common-Rail (1).ppt

Common-rail Diesel Diagnosis Training

High-tech Diagnosis Course for Common-rail  Goals – Reduce unnecessary unnecessary replacing of parts (NTF parts reaches 70% in some cases) – Reduce troubleshooting time – mpro!e o!erall o!erall customer satisfaction

High-tech Diagnosis Course for Common-rail  Goals – Reduce unnecessary unnecessary replacing of parts (NTF parts reaches 70% in some cases) – Reduce troubleshooting time – mpro!e o!erall o!erall customer satisfaction

High-tech Diagnosis Course for Common-rail  "b#ecti!es – mpro!e system $noledge – &earn 'T detection conditions – mplement structured and logic troubleshooting procedures

History of Common-rail System  'ifferent !ariations on ommonrail – * Generations

'iesel +F

ommonrail

1st-generation 1st-generation ,, ommonrail ommonrail ,, -.3 /uppl pply yy .um ..um pp -.3 /u /uppl /up ply .ump ump ,, /ol /oleno enoid id n#e n#ector n#ect ctor or /olenoid

135 MPa Max. Commonrail Pressure

2nd-generation 2nd-generation ,, -.* -.* /upply /upply .ump .ump ,, 'isc 'i scha harge rge al  al!e !e 'isc 'i scha harge rge al al!e !e ,, n#ector ompensation n#ector ompensation ode ode

135 - 160 MPa

3rd-generation 3rd-generation ,, N/R N/ R 1 '. NR N/R 1 '.NR '.NR ,, .ie2o .ie2o n#ector n#ector

160 - 180 MPa

System Overv Overview  iew  ommonraill /ystem 'iagram (for 4) ommonrai N+ /ignal G /ignal arious /ignals Fuel .ressure /ensor

+ngine +5

+'5

Other Injectors .ressure &imiter Common-rail

n#ector .ressure /itch

Fuel ooler Fuel / Fuel /ystemFilter /upply .ump 6arning &ight

Fuel Tan$

System Overview  4ain omponents for ommonrail /ystem – /hon for the 8'FT engine on the 4 Engine Front 

n#ection .ipe

n#ector

Fuel nlet .ipe

ommonrail /upply .ump ,/ (/uction ontrol al!e) ,Fuel Temp9 /ensor

,Fuel .ressure /ensor ,.ressure &imiter

System Overview  Features of ommonrail /ystem

n#ection pressure: !olume and timing are controlled electrically

-igh accuracy engine control

-igh pressure fuel

-igher atomi2ation of fuel

/tores high pressure fuel

-igh pressure in#ection in all engine speed range

, -igh performance and fuel economy , &o noise and !ibration , lean emission

System Overview  /ensors and ;ctuators

;ir Flo 4eter

Intake Restrictor Valve (Step Motor)

;tmospheric Temp9 /ensor

nta$e ;ir Temp9 /ensor

&-VRV (#or &R Valve Control)

Turbo .ressure /ensor

VSV (#or &R Valve Close) amshaft .osition /ensor Injector  ran$shaft .osition /ensor

VSV (#or $ur%o Pressure Sensor) lo! Plu" 6ater Temp9 /ensor

llustration is for 'FT on '+30

ECD System Components  /upply .ump – /upplies the high pressure fuel to the commonrail HP2

HP3

Type

-.3 ("uter am)

-.* (nner cam)

Generation

st

3nd'elta n#ection?

>.ilot n#ection?

/mall .remiCture ombustion

Common-rail Control Systems  n#ection Rate ontrol – .ilot in#ection

;ccelerator .edal .osition /ensor (.;)

ran$shaft .osition /ensor (Ne)

asic Pilot $iming

nta$e ;ir Temp9 /ensor (T-;) Turbo .ressure /ensor (.4) Correction

Pilot 'n(ection .+olume8 $iming8 'nterval/

Engine ECU

6ater Temp9 /ensor (T-6)

+'5 n#ector

Common-rail Control Systems  n#ection Rate ontrol – 4ain in#ection timing

amshaft .osition /ensor /ignal (G) n#ection Timing

.ilot n#ection

Fuel Duantity

4ain n#ection

Common-rail Control Systems  "ther /ystem "peration – +GR control system nta$e Restrictor al!e .osition /ensor

nta$e Restrictor al!e

nta$e Restrictor al!e ontrol 4otor

+GR al!e .osition /ensor

Engine ECU acuum .ump

acuum 'amper +GR al!e

+R (for +GR !al!e control)

Engine

;tmospheric .ressure /ensor

ran$shaft .osition /ensor ;ccelerator .edal .osition /ensor 6ater Temp9 /ensor Turbo .ressure /ensor nta$e ;ir Temp9 /ensor

Common-rail Control Systems  "ther /ystem "peration – nta$e restrictor !al!e control system

;ir "ut Reduction Gears

nta$e Restrictor al!e

;ir N /tep 4otor Throttle al!e Fully "pened /itch

Common-rail Control Systems  "ther /ystem "peration – nta$e restrictor !al!e control system

nta$e Restrictor al!e ontrol 4otor

Engine ECU nta$e Restrictor al!e .osition /ensor

ran$shaft .osition /ensor (Ne) 6ater Temp9 /ensor (T-6) nta$e ;ir Temp9 /ensor (T-;) ;ccelerator .edal .osition /ensor (.;)

nta$e Restrictor al!e

Turbo .ressure /ensor (.4) gnition /itch (/T;)