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2015-10-20
|
Robert Bosch GmbH
28 | Diesel Set 3.1 | Testing
en
4.1.2
Connecting the pressure sensor
module to the CP 4.2 common rail
high-pressure pump
1.
Connect the high-pressure connections on the
CP 4.2 (fig. 14, item 1) and the combining rail
(fig. 14, item 5) by means of black 60 MPa hoses
(fig. 14, item 2) and attach using the appropriate
connection adapter, angle, nut and compression ring
(left-hand thread).
2.
Use M16x1, M16x1.5 or M16x2.0 union nut to con-
nect to the high-pressure connections.
i
Note the thread dimensions on the common rail
high-pressure pump.
3.
Connect the combining rail (fig. 14, item 5) to the
pressure sensor module (fig. 14, item 3) by means
of a black 60 MPa hose (fig. 14, item 4).
Abb. 14: Example of connecting to a CP 4.2 common rail high-
pressure pump
1 CP4.2 common rail high-pressure pump
2 60 MPa hose assemblies, 600 mm long
3 Pressure sensor module
4 60 MPa hose assemblies
5 Combining rail
4.1.3
Pressure buildup –
Performing the test
!
The vehicle battery must be fully charged for this
test.
1.
Switch on ignition.
2.
Start the engine for 10 to 15 seconds and observe the
display on the digital pressure display unit.
i
Pressure buildup is delayed slightly, since the hose
assembly must first be filled.
Pressure is
greater than 25 MPa
:
"
The low-pressure circuit and the common rail high
pressure pump are OK in terms of pressure buildup
during start-up.
Pressure is
less than 25 MPa
:
¶
Check whether the low-pressure circuit is at the set
pressure or may have bubbles.
i
Bubbles in the test oil and insufficient pressure in
the low-pressure circuit of the common rail high-
pressure pump have a considerable effect on pressu-
re buildup in the common rail high-pressure pump.
If the low-pressure circuit is OK, the common rail
high-pressure pump and its attached components
(pressure control valve, metering device, overflow
valve) must be checked.
"
If the problem is not resolved by checking the common
rail high-pressure pump and its attached components,
continue on the basis of the vehicle-specific SIS trou-
ble-shooting instructions (e.g. for Bosch ESI[tronic]).
4.1.4
Disconnecting the pressure sensor module
!
The ignition must be switched off before the pressu-
re sensor module is connected or disconnected.
!
The display on the digital pressure display unit must
not show any pressure.
!
Loosen the first hose assembly connection slowly in
order to relieve any potential pressure spikes. Place
a lint-free cloth around the connection and tool
when doing this.
1.
Disconnect the hose assembly from the common rail
high-pressure pump.
2.
Disconnect the pressure sensor module.
3.
Disconnect the digital pressure display unit.
4.
Attach a new high-pressure hose assembly to the rail
and common rail high-pressure pump.
!
Follow the assembly instructions and observe the
tightening torque in the manufacturer's documenta-
tion.
5.
Allow the engine to run and check the line connec-
tions for leaks.
6.
Inspected visually for leaks after the test run.
