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InlineFuelInjectionPumps
In1927RobertBoschproducedthefirstpracticaldieselpump.Thisdesignenabledthenewlydeveloped
dieselenginetobecomeaviableengineformanyapplications.Themethodoffuelmeteringonthisinitial
pumpwasportandhelix,(highpressuremetering).Thismethodofmeteringwasstillbeingusedonmost
moderninjectionpumpsintol990's.Boschhaslicensedmanycompaniestobuildthesepumpsbutthey
allretainthebasicBoschdesignprinciples.Boschdesignedpumpsareusedonmanymanufacturers
engines.OneofthelargerpumpsintheBoschline,thePE/Sserieshasmanyheavydutyfeatures,making
itsuitableforhighoutputenginesThesepumpshavebeenusedonMack,NavistarandCumminsand
countlessothersthroughouttheworld.Largercamshafts,plungers,andnonadjustablerollertappets
enablethispumptobeusedwithnozzleopeningpressuresof1,350Bar,(10,000to20,000psi).The
hydromechanicalversionsofthesepumpshadmanyaddonfeaturesandcontrolssuchasafuellift
pump,smokelimiter,(aneroid),injectionadvanceunit,andseveraldifferentgovernors.ThePsizepump
isgenerallyusedonengineshavingmorethan200hp(149Kwh).Tomeetincreasinglystringent
emissionsrequirements,manufacturersofinjectionequipmentareusingmuchhighernozzleopening
pressuresthanpreviously.Importantinformationaboutthepumpisstampedonaplatemountedtothe
sideofthepump.Thisplatewilllistamongotheritems,pumpserialnumber,pumpmodel,and
partnumber.
ComponentPartsandtheirFunction
Thepumpshownatrightistypicalofmostinlinepumps.Thepumphousinghasalowpressurefuel
gallerysurroundingthepumpingelements.Thisgalleryissealedfromtherestofthepumphousingsofuel
isavailableonlytotheinlet/spillportsofthepumpbarrels.Anexcesssupplyoffuelissuppliedtothe
gallerybythetransferpumpinmostapplicationsandareturnlinereturnsunusedfueltothetank.This
excessflowremovesanybubblesthatforminthefuelcausedbyvibrationoraerationandalsokeepsthe
pumpcool.Thecamshaft,(14),iscoupledtotheenginedrivetrainthroughvariousmethodsbut
mostcommonlyageartrainarrangementisused.Thecamshaftcausesreciprocatingmovementoft

hepumpingplungers.Thepumpingplungerandbarrelassembly,(8+4)performstwofunctions.It
forcesfuelpastthedeliveryvalve,intotheinjectionline,andtothenozzlebywayofitsreciprocating
action,italsocontrolsthequantityoffuelbyrotatingaction.Therollertappets,(13),ridedirectlyon
thecamshaftandtransmititsmotiontothepumpingplungers.Theplungersprings,(11),keepthe
rollertappetsincontactwiththecamshaft.Thecontrolrackorrod,(15),transmitstheactionof
thegovernortothepumpingplungerthroughthecontrolsleeves,(9).

Thedeliveryvalve,(5),sealsoffthehighpressurelinefromthebarrelduringtheplungers
downwardstrokeandalsoreducespressureinthelinetoapredeterminedleveltopreventsecondary
injectionsinthecombustionchamber.
PumpOperation
Theheartoftheinlineinjectionpumpistheplungerandbarrelassembly,(atleft).Thisiswherefuelat
supplypumppressureispressurizedtoinjectionlevelsrangingfrom140to1,350Bar,(2,000to20,000
PSI)andtheprecisecontroloffueldeliveryisaccomplishedbychangingthepointofregisterofthe
helicalcontroledgeoftheplunger,(thehelix),withthespill/fillport.Becausetheplungerfitssoprecisely
inthebarrel(approximateclearanceisonly2to4microns),therearenosealingringstoretaintheinjection
pressureastheplungerpumpsfueltheysealbytheviscosityofthefuelonly.Pumpingplungers
andbarrelsarelappedtogethertoprovidethisseal.Neverinterchangeaplungerfromonebarreltoanother.
Eventhewarmthcausedbyholdingaplungerinyourhandcancauseitnottofitinitsbarrel.Plungerand
barrelsaresoldasamatchedset.Thepumpcamshaftlobeprovidesaconstantmechanicalstrokelengthof
thepumpingplunger.Theplungerisrotatedindirectlybythegovernortoprovidechangesinfueldelivery.
Theupperedgeofthepumpingplungerhasaverticalgroovewhichconnectsthehydraulicpressure
abovetheplungertothemilledrecessesbelow.Nearthetopisahelix(orcontroledge)thisedgeprovides
precisecontroloffueldeliverybycoveringanduncoveringthefill/spillportsastheplungerisdriven
upwardsinthebarrel.Thebarrelmayhaveeitheroneortwocontrolports,alsocalledfill/spillports.Any
fuelthatdoesleakbytheplungerisusuallycollectedinanannulargroovecutintothebarrelortheplunger
andacorrespondingductinthebarrelprovidesameansofreturningthisleakagefueltothecharging
gallery.Withoutthismethodofreturningtothecharginggallery,anyfuelthatleaksbytheplungerwould
endupintheenginesoilsupplyandcauseittodiluteandleadtoenginedamage.Thedesignofthese
pumpsissoprecisethatfuelleakagebytheplungersisveryrarelythecauseofdilutedengineoilandifthis
occursallotherleakagepossibilitiesshouldbeeliminatedbeforesuspectingthepumpasthecause.When
thepumpingplungerisatitsbottomposition,fuelfromthepumpgalleryentersthroughthefill/spill
port/sandfloodstheareaabovetheplungeranddowntheverticalgroovetothemilledrecesses.The
plungerisnowforcedupwardbythecamshaft.Initiallythisupwardmotionmerelydisplacesfuelbackto
thecharginggallerybecausethefill/spillports/sis/arestilluncovered.

Afterashortperiodofupwardtravel,theplungerleadingedgecoverstheinletorfill/spillport/s.This
isknownasportclosureandiscriticaltothetimingoftheinjectionevent.Continuedupwardmovement
willraisethepressureandthenforcefuelpastthedeliveryvalveintothehighpressureline,open
theinjectionnozzle,andinjectfuelintothecombustionchamber.Injectionwillcontinueuntiltheplunger
hasrisenfarenoughtoenablethelowercontroledgeofthehelixtouncovertheinletorfill/spillport/s.At
thistime,pressurizedfuelwillrushdowntheverticalgrooveontheplungerandexitthroughthenow
openport/s.Thisisknownasspillandistheendofpressurization;thepressurewillcollapsebackfromthe
nozzlethroughtheopenportinthebarrelandwillcontinuetodropuntilthedeliveryvalveclosingpressure
isreached,typically2/3ofnozzleopeningpressure,(NOP).Thedeliveryvalvewillthenclosesealingthe
barrelchamberfromthehighpressureline.Thisclosingmaintainsaresidualpressureinthehighpressure
linesothesystemisreadyforthenextinjectiontothatcylinder.Aftertheendoffueldelivery,theplunger
willcontinuetobeforcedupwardbythecamshaft,butthismovementwillnotcauseanyfurtherinjection
itmerelydisplacesfuelthroughtheopenfill/spillport/sbacktothecharginggallery.Theplungerstrokecan
bedividedintofourstages.Prestroke;thisisthemovementoftheplungerfromitsbottomdead
centrepositiontothepointofportclosurefuelismerelydisplacedbacktothecharginggalleryduring

thisportionofthestroke.Retractionstroke;thisisthesmallportionofthestrokerequiredtoraisethefuel
pressuretonozzleopeningpressureorNOP.Effectivestroke;thisistheplungerstrokewhilefuelisactually
beingdeliveredtotheinjectornozzle.Residualstroke;thisistheremainingupwardtraveloftheplunger
afterthespillporthasbeenuncoveredbythehelixuntiltheplunger reachesitstopdeadcentreposition.