Ships, locomotives, power generators, mining trucks, construction and agricultural machinery can all run in an economical, powerful and reliable way on diesel engines. No other combustion engine is used as widely as the diesel. Its high efficiency and associated fuel economy make it the preferred propulsion system for off-highway vehicles.
Why Bosch Diesel systems?
Bosch is a leading manufacturer of components for diesel engines in both the on-highway and off-highway segments and continually sets new standards with its diesel innovations. Bosch offers a comprehensive portfolio of high-quality components and systems for both segments. A large proportion of off-highway diesel engine and generator manufacturers take advantage of this and benefit from excellent power dynamics, low emissions and low fuel consumption.
Bosch, your reliable partner for diesel systems
Bosch is a constant, reliable partner throughout the lifecycle of Off-Highway and large engines: from the design and development of powertrain technology, through to large-scale production, all the way to spare parts supply and replacement solutions. Hence, Bosch consistently further develops diesel drive systems for use in on-highway as well as off-highway applications. These include components for fuel injection and fuel supply as well as the engine and air control and exhaust-gas treatment.
As a provider of complete systems, Bosch is familiar with the various technical requirements and offers the right injection system for each segment. Our experts support customers in finding the appropriate design for their specific application in terms of function, robustness, and economic efficiency. Thanks to its global presence, Bosch also appreciates the specific requirements of each market.
Classification of Off-Highway diesel engines
Bosch divides Off-Highway applications according to their engine power output in two segments.
One of the segments is the Off-Highway diesel engine segment, with engine power outputs between 19 kW and 560 kW.
The Off-Highway Large Engine (LE) segment is characterized by engine power outputs above 560 kW (inspired by the Stage V nonroad mobile machinery emission limits, source: Dieselnet). Large engines are typically characterized by engine displacements between 15 l and several 100 l, bore sizes between 150 mm to 500 mm and configurations from L8 to V20. Hence, the large engine segment includes a very broad variety of set-ups.
Bosch started producing inline injection pumps back in 1927. The distributor injection pump (1962), the electronic diesel control (1987) and the control-sleeve inline fuel injection pump (1993), marked important milestones at the development of conventional diesel systems.
Original-equipment diesel competence
No matter whether common-rail or unit injector system, inline or distributor injection pump, Bosch innovations ensure powerful performance and efficient fuel combustion of and in millions of diesel engines. Bosch products and spare parts are based on the system know-how gained over decades. They need to meet high quality expectations. Workshops can thus be sure, they will always install modern and robust spare parts featuring well-known Bosch quality.
Global production of reliable spare parts
Bosch produces globally conventional and modern diesel systems and a comprehensive range of spare parts in case they need any repair. High-quality spare parts are a prerequisite for the high functionality of these systems. Bosch spare parts stand out for their high quality and reliability.
Hence, Bosch supplies workshops with a comprehensive range of parts for diesel injection systems; genuine spare parts as well as spare parts of equivalent quality for various OHW applications:
1) Pump elements
2) Injection nozzles
3) Pressure valves and valve sets
4) Rail-pressure sensors
5) Sealing kits
Further product portfolio and services for Off-Highway diesel engines:
-Innovative workshop equipment and software
-Practice-oriented service trainings
Big engines mean big opportunities
Market forecasts predict worldwide demand over the coming years in the segment of new and efficient large engines. One major driver of this phenomenon is the demand in growth markets. Manufacturers and dealers have the opportunity to open up new market segments and expand existing ones. However, conventional powertrain systems can help vehicles meet emissions limits only in conjunction with exhaust-gas treatment. Electronically controlled powertrain systems with common-rail injection are the key to greater cost effectiveness, reliability, and performance – both in the commercial vehicle segment as well as for large engines.
Bosch is systematically refining powertrain systems for large engines and offers comprehensive system know-how with consulting services and components that have proved their worth in large-scale production (Hallein, Austria - LE headquarters and biggest site). This includes control units and sensors for engine management as well as complete systems and components for fuel injection, gas ignition, gas injection, dual-fuel operation and exhaust-gas treatment. In addition, the Bosch portfolio includes marine-certified versions of injection components, sensors and control units.
Customer benefits with Bosch LE parts
-Global presence: Bosch provides injection equipment and system control for large engines in many regions and for the key players in the large-engine business.
- Long-term partnership: Bosch is a constant, reliable partner throughout the lifecycle of large engines.
- Ensuring quality and reliability: To ensure reliable operation even under adverse environmental conditions and in difficult situations, Bosch designs its components – from injectors to pumps – to be particularly robust.
- System and network competence: As a provider of complete systems for large engines – from injection to exhaust-gas treatment – Bosch is familiar with their various technical requirements. Bosch understands the need for coordinated system design that takes into account all interrelationships, and meets this need with integrated solutions
- Comprehensive portfolio and know-how: Bosch offers the full span of injection systems and components – from the smallest one-cylinder engine with an output of a few kW up to large 20-cylinder engines with over 10000 kW. The portfolio covers a wide range of operating types that run on various fuel types.
Conventional - Inline pump
Conventional - PF pump
Conventional - VE/VP pump
Conventional - Nozzle-and-holder assemblies (NHA)
Modern - Common Rail System
Modern - CRIN
Modern - Common Rail pump CPN
Service parts - Injection nozzle
Bosch products for your diesel engines below 560 kW
Conventional
Bosch is a supplier of OEM products and replacement parts for conventional systems.
Bosch is producing conventional systems since more than 90 years. These systems comprise of nozzleholder assemblies and mechanically/electronically controlled inline pumps or distributor pumps. Conventional systems are particularly robust. This is why they are often used in a range of off-highway applications. The injected fuel quantity can be quickly, evenly and simply varied.
Modern - Common-Rail systems
Bosch offers a broad spectrum of common-rail systems that delivers state-of-the-art answers to typical requirements. Bosch common-rail injectors for the off-highway segment work with pressures between 1400 and 2700 bar. The various types of common-rail pumps are suitable for use in a wide range of applications.
Customer benefits
-Same product in aftermarket as in OEM series, thus ensuring quality and longer maintenance intervals
-Fair-value-oriented customer solutions with new or remanufactured goods or replacement parts for repairs
-Worldwide production network
Designed for high cylinder outputs, inline injection pumps are used for 2- to 12-cylinder engines – mainly engines of commercial vehicles, construction and agricultural machinery and stationary engines.
As this type of pump is lubricated by means of the engine oil circuit, it even copes with lower-quality fuels. Nevertheless, lasting reliability and a long service life can only be ensured in case of regular maintenance and proper installation of Bosch spare parts.
Inline injection pumps allow high cylinder outputs. Their name is based on the pump cylinders arranged in lines. At engines equipped with this pump, each cylinder is supplied with fuel by an own pump element and via a pressure valve and a high-pressure line.
Advantages at a glance:
- Due to the top fitting accuracy of the pump pistons, no special seal is required – not even in case of high pressures and low rotational speeds
- Can also be operated with lower-quality fuels due to lubrication via engine oil circuit
- Lasting reliability and a longer service life in case of regular maintenance and use of the proper Bosch spare parts
Single cylinder PF pumps are used in small offroad applications such as small construction machinery, small tractors or generator sets.
The operating mode of PF pumps is similar to inline pumps. PF pumps are particularly suitable for small engines.
- Very good compromise between price and performance
- PF pumps allow the use of very short injection lines, with one pump assigned to each cylinder of the engine
Thanks to their compact design, distributor pumps can be used for diverse application purposes e.g. in stationary engines as well as construction and agricultural machinery (off-highway).
Axial-piston distributor injection pumps (VE) for engines with indirect injection (IDI) generate pressures of up to 250 bar at the nozzle. Used for engines with direct injection (DI), they generate peak pressures of approx. 1950 bar.
Axial-piston distributor injection pumps are used for engines with a power output of approx. 30 kW per cylinder
Used for direct injection (DI) engines, radial-piston distributor injection pumps (VP) generate peak pressures of approx. 1950 bar. Radial-piston distributor injection pumps (VP) are used for engines with a power output of up to 45 kW per cylinder.
- Accurate fuel dosing by means of variable injection pressures and injection timing due to electronically controlled injection with electric supply pump
- Long service life due to high robustness
- Wide-spread application in vehicles due to its space-saving design
- Maintenance-free due to lubrication by fuel
A nozzle-and-holder assembly (NHA) consists of a nozzle holder, an injection nozzle, a nozzle clamping nut and different smaller bits and pieces (e.g. spring, pressure bolt, shim washer).
Nozzle-holder assemblies are needed to inject fuel into the combustion chamber of diesel engines.
Nozzle-and-holder assemblies are robust components. They work with injection pressures of up to 1800 bar. For the fuel injection, a nozzle-and-holder assembly is assigned to each of the cylinders of an engine. Thanks to their resilient design, nozzle holders can be operated with a large variety of different fuels. The selection of the matching nozzle-and-holder assembly is based on the required supply volume, spray pattern and injection pressure.
- Optimization of engine performance, exhaust-gas and noise development due to major influence on both mixture formation and combustion
- Different types of Bosch nozzle-and-holder assemblies suitable for all conventional systems and types of engines
- Accurate injection into the combustion chamber
Modern common-rail systems
By means of products such as unit pumps, unit injectors or even the common-rail system, Bosch made a significant contribution to the development of modern diesel systems. Bosch technology stands for the powerful performance and the efficient fuel combustion of modern diesel engines.
In 1997, Bosch launched the first common rail system onto the market. The system’s name is based on the common rail supplying all cylinders with fuel. At conventional diesel injection systems, the fuel pressure for each injection cycle has to be generated separately. At common-rail systems, however, pressure build-up and injection are separated from each other. Fuel is thus always available at the required injection pressure.
Bosch offers a broad spectrum of common-rail systems that delivers state-of-the-art answers to typical requirements. Bosch common-rail injectors for the off-highway segment work with pressures between 1400 and 2700 bar. The various types of common-rail pumps are suitable for use in a wide range of off-highway applications.
Modular common-rail system for commercial and Off-Highway vehicles
The modular common-rail system CRSN for commercial vehicles and off-highway applications ensures efficient fuel supply and fuel injection in diesel engines. It is scalable for pressure levels between 1800 bar and 2500 bar and can be used variably in engine sizes with up to eight cylinders. The system is suitable for displacements of 4 to 17 liters and engine powers of up to 850 kW. High nozzle flow rates enable optimization of the combustion strategy as well as high engine performance. The system is designed for the electrification of the powertrain.
The system consists of a high-pressure pump, a high-pressure rail, a leakless injector for each cylinder and an electronic engine control unit.
System components and modules can be combined in different configurations to meet the engine manufacturer’s specific requirements.
Features
- No. of cylinders: up to 8
- Available system pressure levels: 1800/ 2000/ 2500 bar
- Max. 5-8 injections per cycle
- 12 V and 24 V operating voltage
- For 6 cylinder engine power up to 850 kW
- Contribution to Euro VI and comparable standards
- Modular combination of various system components and modules
- Scalable for available pressure levels
- Oil and fuel lubricated pumps possible
- High hydraulic nozzle flow rates for improved combustion and high engine performance
- Start-stop and hybrid capability
Solenoid valve injector CRIN Specialist for long lifetime and high performance
The rapidly switching solenoid valve injectors are a central component of the CRSN modular system and inject a specific quantity of fuel into the cylinders to match the driving situation and ensure economical combustion. The leakless solenoid valve injectors allow a high degree of freedom for the injection rate shaping. The high efficiency of the injector contributes towards reducing fuel consumption and CO₂ emissions. The solenoid valve of the injector is controlled by the electronic control unit. The control unit causes the nozzle needle lift. Thus, the fuel can be injected directly into the engine's combustion chamber.
The injector is permanently supplied with fuel from the rail via the high-pressure connection. The injection is initiated by the control unit via the electrical connection. The backflow quantities arising during the injection flow back to the tank via the fuel-return line.
Solenoid valve injectors for commercial vehicles made by Bosch are available for pressure levels between 1800 bar and 2500 bar. They are highly successful in the market and are used for all on and off-highway applications in medium-duty through to heavy-duty commercial vehicles. The injectors have a modular design and can be adapted to the customer's needs. The variants tailor-made for each application vary among others concerning lifetime, nozzle design, injector length, exterior injector design and compatibility with different fuels.
Features (CRIN Baseline with ball valve )
- Solenoid injector with ball valve
- Two piece armature leads to excellent dynamics due to reduced armature bouncing
- Available system pressure levels: 1600/1800/2000 bar
- Max. 5 injections per cycle
- Market-specific solution for medium duty, heavy duty and off-highway for emerging markets
- Functionality and lifetime adapted to market requirement
- Compatibility of injector design allows same mounting and engine assembly as previous generation
- Robust ball-valve solenoid injectors
- Start-stop capability
- Robust design for selected standardized fuel qualitites
CRI is a diesel fuel injector for medium duty and off-highway derived from PC/LD-system with additional robustness packages and additional lifetime packages.
Features (CRI2 OHW )
- Solenoid injector with ball valve at 1600 bar or pressure balanced valve ≥ 1800 bar
- Available system pressure levels: 1600/ 1800/ 2000 bar
- Max. 5 injections per cycle (1600 bar), max. 8 injections per cycle ≥ 1800 bar
- Robust solution for all 4-6 cylinder diesel engines in medium duty and off-highway applications world wide
- Contribution to BS6,CN6, EU Stage V and comparable standards
- Robust design for selected standardized fuel qualities
- Single governor concept possible
Various types of common-rail pumps are available for a wide range of off-highway applications.
The high-pressure pump CPN6 delivers the fuel into the connected rail under high pressure. The pump camshaft is driven by the engine and moves the pump piston to generate the required high pressure.
The CPN6 high-pressure pump is based on the heavy-duty Bosch common-rail pumps, which have been produced in millions of units. Designed for heavy-duty applications, the pump handles pressure levels from 1800 to 2500 bar and is used for both on and off-highway. The variants tailor-made for each segment differentiate themselves regarding lubrication concept, fuel pre feed, fuel metering and maximum delivery quantity.
Demand-based delivery from tank to rail
Typically, the feed pump is connected to the fuel tank via a feed connection and delivers the fuel via a low-pressure outlet in the pressure-side filter. From the filter, the fuel is routed back into the high-pressure pump via a further low-pressure connection, before reaching the metering unit. The metering unit is connected electrically to the control unit and ensures the requirement-driven supply of the pump with fuel. The fuel lines lead from the high-pressure connectors on both high-pressure elements to the rail. Fuel which is no longer needed flows back into the tank via a further low-pressure connection.
Features (CPN6-family)
- For engines up to 16l high heavy duty
- Available pressure levels: 1800 / 2000 / 2500 bar
- Cam drive
- Two plungers in line
- Fuel or oil lubrication
- Improved energetic efficiency with fuel lubrication concept
- Improved robustness with oil lubrication concept
- Weight reduced design compared to previous generation
- Pressure upgrade without change of outer shape of the pump
- Modular concept supports customer specific requirements
High pressure rail for common-rail systems
Precise fuel injection and reduced emissions
The high-pressure rail gives its name to the common-rail system and binds the pump and injectors together as the central hydraulic component. It stores the compressed fuel and supplies this to the injectors. A rail pressure sensor and - independent of the system configuration - an additional pressure control valve or pressure limiting valve are always fitted on the high-pressure rail as rail assembled components.
The rail consists of a forged steel tube into which the rail pressure sensor (RPS) and pressure control valve (PCV) are screwed. Independent of the high-pressure pump used, the rail has one or two fuel lines to connect to the high-pressure pump. Corresponding to the number of cylinders, further high-pressure connections for the fuel lines leading to the injector are present. The PCV-controlled fuel is conveyed back to the tank via the low-pressure connection.
Customized variants for every segment
High-pressure rails made by Bosch are available for pressure levels between 1400 bar and 2700 bar. They are used for all on-highway applications in cars up to heavy duty vehicles and for all off-highway applications. The rails have a modular construction and can be specifically adapted to the customer's needs or adjusted to the application specifications. The variants tailor-made for each application scenario differentiate themselves with regard to, for example, the rail assembled components, rail length, number of high-pressure connections, installation concept on the motor, and lifetime.
Various rail assembled components are fitted on the high-pressure rail depending on the system configuration. The rail pressure sensor (RPS) installed on the high-pressure rail communicates with the control unit. The transmitted pressure values serve to regulate the system pressure and control the injectors. The pressure control valve (PCV, PCVN) sets the system pressure supplied by the control unit in the rail. The pressure limiting valve (PLV) reduces the system pressure in case of overload and thus protects the other injection components from damage.
Features (Hot Forged Rail HFR )
-No. of cylinders: 1 to 8
-Available pressure levels: 1600 / 1800 / 2000 bar
-Length adaptable between 160 and 600 mm; min. length 120 mm for short rails up to 1800 bar with RPS only
-Market specific solution for 1 to 8 cylinder diesel engines for small medium duty (IN, CN, ASEAN) and off-highway applications
-Flexible modular concept allows easy adaption on customer packaging requirements with standardized customer interfaces
-Improved design reduces weight
-Robust design for selected standardized fuel qualities
-Start-stop and hybrid capability
-Identical basic design for all pressure levels
Each cylinder of an inline injection pump is supplied with fuel by an own pump element and via a pressure valve and a high-pressure line. The engine drives the pump’s camshaft by means of either gears or a chain. The pump runs synchronously with the pistons – that is, half as fast as the engine. To ensure this performance throughout hundreds of thousands of kilometers of operation, Bosch pump elements feature a particularly high material and production quality.
Pump elements consist of a pump piston and a pump cylinder. They work with overflow principle and beveled-edge control. Thanks to the high fitting accuracy of the pump piston, no special seal is required –not even in case of high pressures and low rotational speeds.
No matter whether contact surfaces, bores or threads, pump elements need to be processed thoroughly and with top precision to prevent pump damages affecting the operation of the engine. Bosch pump elements are produced according to a clearly defined quality guideline.
- As human eyes hardly see the details involved in the production of pump elements, being a Bosch product provides certainty and safety at the product selection
- Production with high precision prevents increased fuel consumption, loss of power and a shortened service life of both pump and engine as well as breakdowns and engine damage
Valves are among the most strained components of conventional and modern diesel injection systems. Therefore, the high quality of Bosch valves is particularly important. Especially valve pistons and pieces have to fit into one another accurately. As one of the world’s largest OE suppliers and diesel system developer, Bosch provides pressure valves with excellent quality both as original equipment and on the aftermarket.
- Low friction losses due to valve pistons and pieces perfectly fitting into one another
- Reduced surface roughness of valve sets due to accurate processing
- Increased service life and consumption benefits due to the use of high-tenacity materials – in part even with additional tempering or hard chromium plating
- Particularly high manufacturing precision due to stringent checks and permanent monitoring of the dimensional accuracy throughout the production
Injection nozzles are used in conventional and modern diesel systems to precisely atomize the fuel spraying it into the combustion chamber for an optimum combustion. Concomitantly, the nozzle also seals off the fuel system against the combustion chamber in a reliable manner. The versatile and broad range of Bosch nozzles covers all common applications. It includes comprehensive know-how Bosch bears as an important partner of international vehicle manufacturers.
- Production with very high precision due to moving parts’ guide clearance amounting to 0.002 mm and fuel pressures of up to 2000 bar
- Particularly long service life of Bosch nozzle needles due to their carbon coating
- Bosch injection nozzles prevent increasing smoke formation – especially after cold starting – as well as combustion noises with a cold engine, uneven engine performance and even loss of power or increased consumption
Conventional - NHA
Modern - Modular Common-Rail System MCRS
Modern - MCRS CRIN-LE injector
Modern - MCRS CP9 inline high-pressure pump
Modern - Modular Common-Rail System MCRS (engine)
Modern - HFRN hot forged rail
Modern - PLV6 pressure limiting valve
Denoxtronic - dosing module
Denoxtronic - supply module
Bosch products for your diesel engines bigger than 560 kW
The huge variety of worldwide large engine requirements leads to a broad portfolio of Bosch products. The Bosch Large Engine (LE) portfolio includes mechanical/conventional solutions like PF pumps with NHA (Nozzle Holder Assemblies), electronically controlled single cylinder solutions like UP (Unit Pump) and UI (Unit Injector) as well as scalable Modular Common Rail systems (MCRS) with 1600 bar and 2200 bar system pressure.
Bosch can draw on over 40 years of experience with mechanical fuel-injection systems for large engines. The Bosch PF single injection pump with a nozzle holder assembly for each engine cylinder is a particularly successful example among these. Due to the robust design, the PF pump can be operated with a large selection of fuel types.
Please visit the Bosch Mobility Solutions Website for further information and interactive graphics.
In comparison with conventional fuel-injection systems, the modular common-rail systems (MCRS) from Bosch reduce the fuel consumption with a simultaneous reduction of running noise. They are designed for pressures between 1600 and 2200 bar and engines with up to 20 cylinders. The injection pressure is independent of engine speed.
- Stringently fulfills the OEM specifications
- Product options for use with different fuel types
- Robust and reliable, thanks to proven series-production technology
- Worldwide production network
The inline pump system consists of a nozzle holder assembly and a mechanically controlled pump / pump element for each cylinder for fuel injection.
The inline pump system is mainly used for maritime and stationary applications.
- Injection pressure: up to 1800 bar
- Specific power output engine: up to 600 kW/cyl.
- Robust and reliable through proven series technology
- Contribution to emission standards like EPA TIER 1/2, IMO 1&2, or world bank emission limits - fulfilment of more stringent limits in combination with exhaust gas treatment possible
- Design to cover to a wide range of multi-cylinder engine applications
- Robust design for selected and standardized specific fuel qualities
- Wide range of spare parts available
The single-cylinder pump system ensures excellent mixture preparation and combustion of fuel with specific high performance, which can support compliance with emission guidelines and a reduction in fuel consumption.
The single-cylinder pump system has been a proven injection system for many years. It comprises nozzle holder assemblies with injection pressures up to 1800 bar and mechanically controlled single pumps which are powered by the camshaft for the engine's valve controller and are therefore referred to as "Pumps with external drive“(PF). Each engine cylinder is equipped with a PF pump fitted with a pump element that can be used to regulate the injection quantity via a control edge. The nozzle holder assembly is selected to match the delivery rate, spray form and injection pressure. Due to robust design, the single-cylinder pump system can be operated with a large selection of fuel types.
Each engine cylinder is equipped with a PF pump fitted with a pump element that can be used to regulate the injection quantity via a control edge. The PF pump system can be adapted to different engine sizes and outputs. Delivery volumes, drive, housing and injection pressure of the pump element can be variably designed.
- Max. injection pressure: up to 1800 bar
- Max. engine speed: up to 1200 rpm
- Designed to cover a wide range of multi-cylinder engine applications
- Wide range of spare parts available allows sustainable product use
The nozzle-and-holder assembly is made up of nozzle holder and nozzle. The compression spring inside the nozzle holder acts on the nozzle needle via the pressure pin. During the injection process, the nozzle needle is lifted upwards by the pressure of the fuel. The fuel passes through the injection orifices into the combustion chamber. The injection process comes to an end when the fuel pressure drops to a point where the compression spring is able to push the nozzle needle back against its seat. Start of injection is thus controlled by fuel pressure. The injected fuel quantity depends essentially on how long the nozzle remains open.
The nozzle holder assembly is selected to match the delivery rate, spray form and injection pressure. In the single-cylinder pump system, the nozzle holder assembly can be adapted to different engine sizes and outputs.
- Specific power output engine: up to 1000 kW/cyl.
- Robust and reliable through proven series technology, easy maintenance
- Improved spray hole design supports compliance to emission regulations and reduction of fuel consumption
- Wide range of spare parts allow sustainable product use
The unit pump injection system (UPS) injects the fuel into the engine cylinder. It consists of an electronically controlled unit pump and a nozzle holder assembly connected via a precisely adapted high-pressure line, which is proven for many years.
The unit pump system is a modular, time-controlled single-pump injection system. Each engine cylinder is supplied by a separate module consisting of a high-pressure plug-in pump with integrated, fast-switching solenoid valve and nozzle holder assembly. The unit pump is integrated in the diesel engine block and powered directly by an injection cam on the engine camshaft via a roller plunger.
A fuel pump (injection pump) is fitted for each engine cylinder. The pump piston is fitted in the pump cylinder with such precision that high injection pressure is guaranteed, even at low speeds. A 2/2-way valve provides the full range of functions. The valve closes against the high-pressure circuit with the fuel feed or outlet. The injection start and duration determined by the camshaft profile can be adapted as required. As a result, the injection pressures and delivery rates required for efficient combustion are available, even at low speeds. The nozzle holder assembly is selected to match the delivery rate, spray form and injection pressure.
The unit injector system (UIS) is a nozzle holder assembly with integrated high-pressure pump.
- Engine speed: up to 1200 rpm
- Specific power output engine: UPS up to 350 kW/cyl. , UIS up to 210 kW/cyl.
- Robust and reliable through proven series technology, therefore suitable for many applications
- Contribution to emission standards like EPA Tier 1/2, IMO 1/2, world bank emission limits - fulfillment of more stringent limits in combination with exhaust gas treatment possible
- Electronically control feasible with Large Engine- tailored engine control unit MD1CE200. Quick and variable adjustment of the injection quantity.
- Robust design for selected and standardized fuel qualities
- Remanufacturing established with wide range of spare parts
The robust unit injector has an integrated high-pressure pump and injects the right amount of fuel required for efficient combustion into the cylinder. The electronically controlled, camshaft-driven unit injector generates a high fuel pressure using the integrated piston pump and injects exact quantities of fuel into the combustion chamber. The advantage of the unit injector system is that there is no high-pressure line between the high-pressure pump and injection nozzle.
The electronically controlled unit injector is a single-cylinder injection pump with integrated injection nozzle and solenoid valve that is installed directly in the cylinder head of the diesel engine. A separate injector is assigned to each engine cylinder. The unit injectors are powered by an injection cam on the engine camshaft via a rocker lever.
The injection start and quantity are determined by the fast switching solenoid valve, although these variables can be freely selected in the program. The solenoid valve is opened when not energized. This ensures a free passage from the fuel feed of the low-pressure system through the pump area and back into the low-pressure system in the cylinder head of the engine, which allows filling of the pump chamber during the suction stroke of the pump piston. This bypass is closed when the solenoid valve is energized during the delivery stroke of the pump piston. This causes pressure to build up in the high-pressure area and the injection of fuel into the engine's combustion chamber when the nozzle opening pressure is exceeded.
- Injection pressure: up to 1350 bar
- Max. engine speed: up to 950 rpm
- Specific power output engine: up to 210 kW/cyl.
- Contribution to emission standards like e.g. EPA Tier 0/1, world bank emission limits
- Electronically controlled - quick and variable adjustment of the injection quantity
- Long service life allows sustainable product use
- Retrofit of mechanical UI equipped engines to reduce fuel consumption feasible
With high pressure, the unit pump ensures excellent mixture preparation and combustion of fuel with specific high performance, which contributes towards compliance with emission guidelines and a reduction in fuel consumption. The camshaft driven unit pump (UP) delivers fuel to the nozzle holder assembly, which injects the fuel directly into the combustion chamber.
If the solenoid valve is open, the pump cylinder can be filled during the suction stroke of the pump piston and return flow is possible during the delivery stroke. If the solenoid valve is energized and therefore closed, a pressure in the high-pressure range builds up between the pump piston and injection nozzle during the delivery stroke of the pump piston. If the nozzle opening pressure is exceeded, fuel is injected into the engine's combustion chamber. Closure of the solenoid valve determines the start of the injection process, while opening of the valve determines the injection quantity.
Please visit the Bosch Mobility Solutions Website for further information and interactive graphics
- Specific power output engine: up to approx. 450 kW/cyl.
- Electronically controlled. Quick and variable adjustment of the injection quantity.
- The UPS system can be tailored to various engine sizes and power output levels. Users can select the pump element as well as the drive, housing, and injection pressure as required.
- Design to cover to a wide range of multi-cylinder engine applications; typically locomotives, marine and gensets with 6, 8, 12 or 16 cylinders
- Long service life
- Remanufacturing allows sustainable product use
The MCRS is a modular common-rail system with injectors, high-pressure pump, and a ECU tailored for large engines.
The Modular Common-Rail System (MCRS) for large engines supports compliance with emissions standards and also offers savings potential. It ensures excellent mixture preparation and combustion of fuel with specific high performance to help reduce emissions and fuel consumption. The right injection system can be provided for all power outputs within a range of 50 to 450 kW/cylinder.
In high-speed and medium-speed large engines, the modular common-rail system MCRS is applied, mainly used for high and medium speed engines in stationary, construction & industry, maritime and railway applications.
For compact large engines, the common rail system CRSN for commercial vehicles can be used.
For special applications, mixed systems of CRSN and MCRS products can be provided.
The MCRS is a modular common-rail system. The electronically controlled, oil-lubricated type CP9 inline high-pressure pump is used to generate high pressure. The fuel is injected into the combustion chamber by a CRIN-LE injector. High-pressure accumulators are integrated into the pump and the injectors, which are damping pressure oscillations and ensure highly precise metering of the fuel. A separate rail is not required. The heart of the injection system is the electronic engine management that links the individual functions to form an overall system.
Better efficiency, lower emissions:
The MCRS offers all the benefits of Common Rail injection. It injects fuel at 1600 bar/ 2200 bar. Hydraulic pulsations in the high-pressure system are minimized thanks to the fuel storage volume in the high-pressure pump and injectors, which is specific to the MCRS. The fuel accumulator in the injector also ensures a nearly constant pressure, even during injection, as well as maximum flexibility during multiple injection. This means that the MCRS reduces fuel consumption and contributes to the compliance with stricter exhaust gas limits. The system is also very robust in every detail and boasts impressive service life.
In use around the world
The MCRS from Bosch is suitable for large diesel engines. It is the first fully modular Common Rail system for this kind of engine and is used by vehicle and engine manufacturers around the world. Thanks to its modular construction, it is extremely flexible and is used in large diesel engines from 4-cylinder inline engines up to 24-cylinder V engines.
- No. of cylinders: up to 24
- System pressure levels: 1600/ 2200 bar
- Injector with integrated accumulator volume, edge filter, flow limiter, and inline magnet valve
- Multi injection capability: up to 6 inj./cycle
- Pump (L2 – L5 type) with integrated accumulator volume and gear pump; single pump available for 1600 bar, too
- Control unit: MD1CE200, LE-specific
- Fully modular design in injector, pumps and ECU, which can be tailored to various engine sizes and power outputs
- Power range: 500 kW to 5000 kW
- Contribution to emission standards up to EPA TIER 4, IMO 3 or Euro Stage V
- Ability for dual fuel operation: pilot injection for gas ignition feasible by MCRS
- Supports improvement of TCO by increased fuel efficiency and subsequently reduces CO2 output
- Provides flexibility to improve combustion strategy with high torque / power output, allows high dynamic engine operation
- High injection pressure independent of engine speed
- Sustainable product use by remanufacturing and long service life
MCRS components
The robust CRIN-LE common-rail injector injects exactly the right amount of fuel required for efficient combustion into the cylinder. The injector is permanently supplied with fuel via the high-pressure connection. The injection process is initiated by the control unit via the electrical connection. The high-pressure accumulator integrated in the injector allows a flexible engine design. The right injector can be provided for every power output within a range of 50 to 450 kW/cylinder.
The fast switching CRIN-LE injectors are a central component of the modular Common-Rail System (MCRS) and inject fuel into the cylinders for efficient combustion. Up to five individual injections are possible per injection cycle. The engine's fuel consumption as well as CO2, pollutant and noise emissions can be reduced using high injection pressure and multiple injections. A pressure accumulator integrated in the CRIN-LE injector ensures a consistently high injection pressure and reduces pressure fluctuations.
The solenoid valve with durable ball valve located near to the nozzle is actuated by the electronic control unit. The actuation causes the nozzle needle of the injector to open, allowing the fuel to be injected directly into the engine's combustion chamber.
- Available pressure levels: 1600 / 2200 bar
- Available in three nozzle flow-rate categories: T1 and T1+, T
- Up to 5 injections per injection cycle
- Supply voltage 24 V
- Up to 450 kW/cyl. power output feasible
- Integrated accumulator volume reduces fuel pressure peaks, which results in a high mean effective injection pressure
- Integrated pressure wave damper enables multiple injection capability and reduces nozzle seat wear
- Variable injector length
- Multiple injection w/ small pilot injection quantities
- No leakage / high efficiency
- Ability for dual fuel operation: pilot injection for gas ignition feasible
The oil-lubricated CP9 high-pressure pump delivers the fuel into the piping system leading to the injector under high pressure. The CP9 consists of up to five high-pressure elements, each integrated in a housing with separate camshaft. The pump camshaft is driven by the engine and moves the pump piston to generate the required high pressure.
A pre-feed pump integrated in the high-pressure pump supplies fuel from the low-pressure side to the high-pressure pump. The volume is controlled by a metering unit installed on the suction side, which is regulated by the control unit and is responsible for supplying the pump with the required amount of fuel.
The camshaft is the central drive component. It drives the pump elements that generate the high pressure and delivers the fuel. The robust pump elements consist of pistons, cylinders, corresponding suction and pressure valves, including a seal element and a roller plunger that transfers the drive forces from the camshaft to the piston. The high-pressure accumulator integrated in the high-pressure pump allows for a flexible engine design, minimizes overpressure and guarantees a consistently high pressure in the injection system.
The CP9 is a highly successful common-rail pump on the large engine market. It has a modular construction and can be adapted to meet the engine's requirements. The CP9 is suitable for pressure levels ranging from 1600 to 2200 bar and is used for applications in the stationary engine, surface mining, marine and locomotive sectors, for example.
- High-pressure pump can be scaled via the number of plungers
- Inline pump family from two up to five plungers (L2 - L5) with integrated fuel metering unit and gerotor (gear pump)
- Covers engine power of up to 5000 kW- depending on application using single or dual pump configuration
- Oil lubricated pump
- Modular design offers greater flexibility
- Integrated accumulator volume reduces pressure peaks, which results in high mean effective injection pressure
- Economical and versatile due to modular design, which allows flexibility to engine layout
The basic configuration of the hot forged rail (HFRN) includes a rail pressure sensor (RPS).
Depending on the system/application and other specific requirements a pressure control valve (PCVN/PCVN2) or a pressure limiting valve (PLV4/PLV5) can be used additionally.
- No. of cylinders: 4 to 8
- Available pressure levels: 1600 / 1800 / 2000 / 2500 bar
- Length adaptable between 160 and 600 mm
- Market specific solution for 4 to 8 cylinder diesel engines in medium duty, heavy duty off-highway and large engine applications
- Flexible modular concept allows easy adaption on customer packaging requirements with standardized customer interfaces
- Improved design reduces weight
- Identical basic design for all pressure levels
Pressure Control Valve PCVN2
- Magnetic valve for rail pressure control and active rail pressure ramp down
- Current-less closed
- Allows pressure control and limp home functionality in one valve
- Available pressure levels: up to 2500 bar
- PCVN25 designed for battery energy management (BEM)
- Usage of PCVN25 or PCVN2-25 also depending on required max. flow rate and pressure characteristic in limp home operation
- Standardized hydraulic interface to rail for all pressure levels
- Market specific solution for diesel engines in medium duty, heavy duty, off-highway and large engine applications
- Applicable in all CRSN FIE
Pressure Limiting Valve PLV4-6
- Mechanical security valve to avoid improper FIE pressure levels in failure case.
- In failure case system pressure level will be reduced to limp home pressure level
- Available pressure levels: 1400 / 1600 / 1800 bar
- Designed for max. 50 operation sequences over lifetime
- Limp home functionality allows to reach the garage in failure case with reduced power
- Limp home pressure depending on nominal pressure level
- Available pressure level: 2000 bar
- Limp home functionality allows to reach the repair shop in failure case with reduced power
- Limp home pressure depending on nominal system pressure level
- Identical outer dimensions for all pressure levels
- Available pressure level: 2200 bar
- Max. flow rate: 1200 l/h
- Limp home functionality allows to reach the service in failure case with reduced power
- Standardized hydraulic interface of all PLV generations to rail for all pressure levels
- Applicable in all CRSN FIE and CRS off-highway FIE
- Increase of system security
- Avoidance of overload of FIE-components in failure case
- Applicable in all MCRS fuel injection systems
Rail Pressure Sensor RPS4
- Electric sensor to measure the rail pressure level
- Stainless steel sensing element with metals thin film strain gauges
- Digital circuit concept with analogue output signal
- Available pressure levels: 1800 / 2000 / 2500 bar (2700 bar for PC/LD)
- Variants for different voltage outputs available
- Fault diagnostic using signal range check
- Variants with dual sensing element concept available to meet OBD II requirements
- Standardized hydraulic interface of all RPS4 versions to rail for all pressure levels
- Cost optimized design
- Product design for selected standardized fuel qualities
- Applicable in all CRS(N) FIE and CRS off-highway FIE
- Resistant to media, hermetic sealing against measured media
- Vibration resistant, high thermal stability
Exhaust Treatment Technology - Selective Catalytic NOx (SCR) reduction - Dosing System for Urea Injection
The Denoxtronic LE system injects a aqueous of 32.5 % urea solution into the exhaust-gas stream upstream of the SCR catalytic converter for NOx-reduction.
Hence, it contributes to achieve off-road emissions standards for large engines.
- Supply module: 9 bar operating pressure, flow rate of 20 kg/h, electronically or water heated
- Two airless dosing module, water cooled
- Control unit: Off-highway based EDU, operating voltage 24 V
- Power range: up to 1000 kW with single system,up to 4000 kW using multiple systems
- Simplifies or eliminates engine-internal methods for emissions reduction
- Enables improvement of diesel engine fuel consumption
- Contributes to emission standards: EPA Tier 4, IMO 3 or Euro Stage V
- Modular approach: Up to five LE DNOX systems can cover a wide engine range
- Flexibility: One system concept can be adapted to different power ranges of the same engine type series
- High quality: LE DNOX system is based on proven DNOX 2.2 components for on- and off- highway applications
- Optionally, a system integration for exhaust gas treatment is possible
For all information, presented on this webpage, applicable:
No legal advice - provided for informational purposes strictly on a non-reliance basis.
For further and detailed information about diesel and gas fuel injection equipment, please visit the Bosch Mobility Solutions Website.