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VP44 Service Manual
VP44 Service Manual
EE14E-11130
SERVICE MANUAL
VP44
CONSTRUCTION
& OPERATION
FOREWORD
This service manual describes the construction
and operation of the VP 44 (Radial plunger
distributor type fuel injection pump).
This manual is intended for use by vehicle
maintenance technicians or persons with an
adequate knowledge of injection pumps.
Tokyo, Japan
CONTENTS
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
1.
2.
3.
4.
5.
Page
COMPONENT OUTLINE ........................ 1
OUTLINE ................................................ 1
FEATURES ............................................. 2
SPECIFICATIONS .................................. 3
FUEL SYSTEM ....................................... 4
SYSTEM CONTROL DIAGRAM ............. 7
CONTROL UNIT SYSTEM
CONTROL DIAGRAMS ......................... 8
CONSTRUCTION ................................... 9
EXTERNAL VIEW ................................... 9
CROSS-SECTIONAL VIEW ................. 10
EXPLODED VIEW ................................ 11
CONSTRUCTION ................................. 12
OPERATION ........................................ 21
LOW PRESSURE FUEL CIRCUIT ....... 21
HIGH PRESSURE FUEL CIRCUIT ...... 23
TIMING CONTROL ............................... 29
ANGULAR ENCODER ......................... 34
PUMP CONTROL UNIT........................ 35
COMPONENT OUTLINE
1. OUTLINE
Pump control unit
Driveshaft
-1-
COMPONENT OUTLINE
2. FEATURES
[1] High pressure injection
The radial plunger distributor type injection
pump can generate pressure of 100 MPa
{approx 1,000 kgf/cm2} demanded by the small,
fuel efficient, high pressure, high speed direct
injection diesel engines.
[2] High pressure atomization of fuel
injected from the nozzle
Through high pressure injection of fuel, the fuel
injection from the nozzle is atomized at high
pressure with a high penetrating force (the fuel
droplets penetrate further) and with greater
dispersion and distribution (mixing with air is
improved) so that combustion is improved. This
contributes to cleaner emissions.
[3] Optimum fuel injection system
High speed control of fuel injection quantity and
fuel injection timing suitable for the engine is
performed by the control unit, enabling lower
fuel cost and high output.
[4] Improved endurance
The components used in the pump are very
resistant to high pressure, ensuring improved
endurance.
[5] Improved engine matching
As fuel injection to the engine can be controlled
for each cylinder, matching to the engine is
improved.
[6] Improved reliability
As a dual control unit system with both an engine
control unit and a pump control unit is used, the
control system is extremely reliable.
-2-
COMPONENT OUTLINE
3. SPECIFICATIONS
Item
Injection pump type
Applicable vehicles
Specifications
VP44
Passenger vehicles, recreational vehicles, small and
medium sized trucks (less than 1 / cylinder)
Applicable number of engine cylinders 4 cylinders, 6 cylinders
Direction of rotation
Clockwise / counter clockwise
Drive method
Toothed belt, gear, chain
Injection performance
Maximum pump pressure
100 MPa {approx 1000 kgf/cm2}
Plunger diameter x number
4 cylinder: 6.5 mm x 2, 7 mm x 2, 7.5 mm x 2
6 cylinder: 7 mm x 3, 7.5 mm x 3
Maximum lift
3.5 mm
Maximum plunger speed
1.9 m/second: 1000 r/min
Maximum allowable drive torque
200 N.m {20.4 kgf.m}: 3 holed flange
260 N.m {26.5 kgf.m: 4 holed flange
(Maximum drive torque necessary under actual usage
conditions: 150 N.m {15.3 kgf.m} limit)
System
6V
Minimum drive voltage
Maximum high pressure solenoid 20 A
valve current
Control unit type
Engine control unit, pump control unit
(dual control unit system)
Battery specification
12V specification, 24V specification
Standard performance
Standard control method
Fuel injection quantity control: high pressure solenoid
valve, time control
Injection timing control: TCV duty solenoid system,
hydraulic timer
Cam position feed back
Timing feed back
Compensation for variation between Pump EPROM, multi point compensation
pump fuel injection quantities
Maximum advance angle: 15
Timer advance angle range
Identical to COVEC-F
Pump size
Approx 8.0 kg
Weight
-3-
COMPONENT OUTLINE
4. FUEL SYSTEM
[1] Fuel system schematic
Overflow valve
Fuel tank
Feed pump
P-VP4C-002
-4-
COMPONENT OUTLINE
[2] Injection pump fuel intake system
Regulating valve
Overflow valve
Fuel intake
Feed pump
P-VP4C-003
Distributor head
High pressure
solenoid valve
Constant
pressure
valve
Radial plunger
high pressure pump
P-VP4C-004
-5-
COMPONENT OUTLINE
[4] Fuel pressurization control
High pressure
solenoid valve
Constant
pressure
valve
Valve needle
Accumulator
diaphragm
Diaphragm
chamber
High pressure
passage
Radial plunger
Overflow valve
Timer piston
TCV
Timer piston
drive fuel return
Hydraulic
stopper
Timer piston
drive fuel
charge
Feed pump
Ser vo valve
Regulating valve
P-VP4C-005
-6-
COMPONENT OUTLINE
5. SYSTEM CONTROL DIAGRAM
Pump control unit
Engine speed
(crank shaft)
Accelerator pedal
Idle switch
Boost pressure
CAN
DZG
MAB
Power supply
Air flow volume
LGS
Atmospheric pressure sensor
Signal input
Signal evaluation
EPC
EGR valve
EPC
Turbo charger
Air temperature
Signal processing
Fuel injection quantity
Beginning of pressure feed
EGR
Boost pressure
Vehicle speed
Engine load
Monitor
Minimum function
maintenance
Calibration
Cooling water
temperature
Vehicle speed
Cruise control
operation panel
A/C compressor
Diagnostic lamp
Diagnostic
requirement
Brake
Service tester
Clutch
Power output
Signal output
Air conditioner
Interface
Diagnosis
Beginning of
injection
Option
CAN
CAN:
DZG:
MAB:
LGS:
Automatic
transmission
Engine control unit
-7-
COMPONENT OUTLINE
6. CONTROL UNIT SYSTEM CONTROL DIAGRAMS
[1] Block diagram
Sensors
Engine speed
Injection timing
Fuel temperature
High pressure
solenoid valve
Accelerator pedal
Air temperature
Injection quantity
Engine control unit
(ECU)
Boost pressure
Response signal
Additional
signals
Pump
control unit
(PCU)
Others
Fuel injection
pump
(mechanical
section)
Timer control
device
To timer control device
Additional
operations
Injection timing
CAN
High pressure
solenoid valve
Injection quantity
MAB
High pressure
solenoid valve
DZG
Pump speed
P-VP4C-007
-8-
CONSTRUCTION
1. EXTERNAL VIEW
Fuel inlet
Overflow valve
Regulating valve
Top view (drive side on right)
P-VP4C-008
-9-
CONSTRUCTION
2. CROSS-SECTIONAL VIEW
Pump control unit
Distributor head
Angular encoder
High
pressure
solenoid
valve
Driveshaft
Constant
pressure
valve
Constant pressure
valve holder
Feed pump
Radial plunger
high pressure pump
Timer
P-VP4C-009
Barrel
Annular
passage
Annular
passage
Fuel return
Valve needle
Rotor shaft
Barrel
Radial
plunger
High pressure
solenoid valve
Valve
needle
High pressure passage
Distributor slit
Diaphragm chamber
Distributor slit
High pressure outlet
P-VP4C-010
- 10 -
3. EXPLODED VIEW
35/5
123
39
35/6
38
471
35/3
42
37
41
30
35/2
32
480
34
67
35/1
31
36
50/13 35/4
109
33
213
50/14
51
50/4
424
54
206
59
127
207
135/2
58
271
135/1
50/16
50/15
50/5
107
135/4
135/3
135/5
134
133
111
50/7
- 11 -
104
105
63
59
270
49
1/1/2
12
62
61
19
22
50/10
50/9
21
7/3
9
20
50/3
50/12
23
7/4
10
105
1
50/8
50/11
50/1
400
50/6
7/2
50/2
17
7/1
425
424
104
P-VP4C-011
CONSTRUCTION
25
CONSTRUCTION
4. CONSTRUCTION
[1] Fuel injection pump body
Feed pump
Angular encoder
Driveshaft
Distributor head
Constant pressure
valve holder
Radial plunger
high pressure pump
High pressure
solenoid valve
TCV (duty solenoid)
Timer
P-VP4C-001
Distributor head
Angular encoder
- 12 -
CONSTRUCTION
Casing ring
Rotor
Outlet
Chamber
Vane
Driveshaft
Inlet
Vane
Spring
P-VP4C-012
Valve holder
Spring
Valve piston
Por t
To inlet
From outlet
P-VP4C-013
Regulating valve
Fuel intake
To radial plunger
high pressure
pump
Feed pump
Timer
P-VP4C-014
- 13 -
CONSTRUCTION
[4] Radial plunger high pressure pump (high pressure section)
Plunger chamber
Cam ring
Driveshaft
Driveshaft guide slit
Rotor shaft
Roller shoe
Radial plungers
Roller
Ball pin
Timer
P-VP4C-015
Radial plunger
high pressure pump
High pressure
solenoid valve
Constant
pressure valve
holder
P-VP4C-016
- 14 -
CONSTRUCTION
Radial plungers: 2
Radial plungers: 3
For 6 cylinders
For 4 cylinders
P-VP4C-017
Plug
Spring
Ball
Seat
Ball suppor t
Valve
Orifice
Spacer
Holder
Valve spring
P-VP4C-018
- 15 -
CONSTRUCTION
[6] Distributor head
Barrel
Annular passage
Annular passage
Fuel return
Head
Valve needle
Rotor shaft
Barrel
Radial
plunger
High pressure
solenoid valve
Valve needle
High pressure passage
Distributor slit
Accumulator diaphragm
Diaphragm chamber
Distributor slit
High pressure outlet
P-VP4C-010
Overflow valve
Diaphragm chamber
To fuel tank
Accumulator
diaphragm
High pressure
solenoid valve
Valve needle
P-VP4C-019
- 16 -
CONSTRUCTION
[7] Overflow valve
The overflow valve consists of a valve holder, a
spring and a ball valve, and is installed on the
side of the injection pump.
The valve holder is equipped with a port and an
orifice port. The orifice port assists in automatic
air bleeding.
When the excess fuel returned from the
distributor heads fuel return exceeds a specified
pressure, the fuel pressure pushes the ball valve
up so that the fuel can return to the fuel tank.
The overflow valve maintains the returned fuel
at a specified pressure, and also works to cool
the injection pump body.
Valve holder
Por t
Spring
To fuel tank
Orifice por t
Ball valve
From fuel return
P-VP4C-020
Overflow valve
P-VP4C-021
Valve closing
direction
Valve needle
Coil
Magnet
Valve seat
Rotor shaft
Magnet anchor
(movable iron core)
P-VP4C-022
High pressure
solenoid valve
P-VP4C-023
- 17 -
CONSTRUCTION
[9] Timer
Timer piston
drive pressure chamber
(high pressure chamber)
Timer piston
Ball
Cam ring
Hydraulic stopper
Annular chamber
Servo valve
Hydraulic stopper
return spring
Timers low
pressure chamber
P-VP4C-024
High
pressure
chamber
Timer piston
Servo valve
Return channel
Side view of the timer
Low pressure
chamber
P-VP4C-025
- 18 -
CONSTRUCTION
High
pressure
chamber
Check valve
Inlet channel
Ser vo valve
Timer piston
Low
pressure
chamber
P-VP4C-027
Valve body
Magnet anchor
(movable iron core)
Coil
Orifice por t
Valve needle
Valve casing
Connector
[10] TCV
The TCV consists of a valve body, a valve
needle, a valve casing, a magnet anchor (a
movable iron core), a coil, a flange plate (for
installation) and a connector. The valve body
is equipped with an orifice port.
The TCV is installed on the pump housing at
right angles to the timer s axial orientation, and
controls the pressure of the annular chamber
of the timers hydraulic stopper.
P-VP4C-028
TCV
P-VP4C-029
- 19 -
CONSTRUCTION
Angular encoder
Flexible connecting
harness
Sensor wheel
Driveshaft
Angular encoder
retaining ring
P-VP4C-030
Flexible connecting
harness
Angular
encoder
Driveshaft
Angular encoder
retaining ring
Sensor wheel
Cam ring
P-VP4C-031
P-VP4C-001
- 20 -
OPERATION
1. LOW PRESSURE FUEL CIRCUIT
Overflow valve
Regulating valve
Fuel suction
To fuel tank
Feed pump
P-VP4C-003
Casing ring
Fuel supply
Rotor
Outlet
Fuel suction
Chamber
Inlet
Vane
Driveshaft
P-VP4C-032
OPERATION
Spring
Valve piston
Por t
To inlet
From outlet
P-VP4C-013
Pump chamber
pressure
Beginning of regulating
valve operation
Pump speed
Valve holder
Por t
Spring
To fuel tank
Orifice por t
Ball valve
- 22 -
OPERATION
2. HIGH PRESSURE FUEL CIRCUIT
Distributor head
High pressure
solenoid valve
Constant
pressure
valve
Radial plunger high pressure pump
P-VP4C-004
Radial plunger
Internal cam
Cam ring
Rotor shaft
Roller
Roller shoe
Plunger chamber
P-VP4C-034
- 23 -
OPERATION
(1) Fuel suction
Plunger chamber
Radial plunger
Fuel suction
Radial plungers
top dead center position
Radial plungers
bottom dead center position
P-VP4C-035
Radial plungers
bottom dead center position
Radial plungers
top dead center position
P-VP4C-036
- 24 -
OPERATION
Valve needle
Rotor shaft
Constant
pressure valve
holder
Barrel
Distributor slit
P-VP4C-037
Barrel
Annular passage
Annular passage
Fuel return
Head
Valve needle
Rotor shaft
Barrel
Radial plunger
High pressure
solenoid valve
Valve needle
High pressure passage
Distributor slit
Accumulator diaphragm
Diaphragm chamber
Distributor slit
High pressure outlet
P-VP4C-010
- 25 -
OPERATION
(2) Fuel pressure delivery process
Barrel
Annular passage
Fuel return
Head
Valve needle
Rotor shaft
Annular passage
Barrel
Radial plunger
High pressure
solenoid valve
Valve needle
High pressure passage
Low pressure inlet
Distributor slit
Low pressure inlet
Accumulator diaphragm
Diaphragm chamber
Distributor slit
High pressure outlet
P-VP4C-038
Accumulator
diaphragm
Diaphragm chamber
P-VP4C-039
- 26 -
OPERATION
[3] High pressure solenoid valve
The high pressure solenoid valve has a valve
needle, and this valve needle is opened and
closed by the control current from the pump
control unit.
This results in the switching of the fuel outflow
passage to control fuel injection quantity.
Valve needle
P-VP4C-022
Valve needle
Magnet anchor
Coil
High pressure
passage
Constant pressure
valve
P-VP4C-040
Valve needle
Coil
P-VP4C-041
Radial
plunger
High
pressure
solenoid
valve
Open
Closed
Open
P-VP4C-042
- 27 -
OPERATION
[4] Constant pressure valve (CPV)
The constant pressure valve decreases the
reverse pressure wave (ie, the reflected wave)
generated at nozzle valve closing to prevent the
nozzle from reopening (ie, secondary injection).
Valve spring
Valve
To nozzle holder
assembly
P-VP4C-043
Ball suppor t
From high
pressure
passage
Ball
Valve
Valve spring
To nozzle holder
assembly
Orifice
Seat
P-VP4C-044
Spring
Ball
Valve
To nozzle holder
assembly
P-VP4C-018
- 28 -
OPERATION
3. TIMING CONTROL
[1] Timer operation
Ball pin
Cam ring
Annular chamber
Servo valve
Hydraulic stopper
Timer piston
Return passage
Outlet
Feed pump
TCV
Inlet
Fuel suction
P-VP4C-045
Engine
load
Engine
speed
Engine
control
unit
Pump
control
unit
Engine
cooling
water
temperature
Angular
encoder
TCV
- 29 -
OPERATION
Ser vo valve
Hydraulic stopper
Return
channel
Annular chamber
Hydraulic stopper
return spring
Inlet channel
Return channel
Inlet channel
High
pressure
chamber
Open
Closed
Timer piston
Top view of timer
P-VP4C-046
Ser vo valve
Hydraulic stopper
Annular
chamber
Hydraulic stopper
return spring
Return
channel
Inlet channel
High
pressure
chamber
Inlet channel
Timer piston
Top view of timer
P-VP4C-047
- 30 -
Closed
Open
OPERATION
Servo valve
Cam ring
Hydraulic stopper
Return
channel
Annular
chamber
Hydraulic stopper
return spring
Inlet channel
Closed
Open
Timer piston
Top view of timer
P-VP4C-048
Servo valve
Hydraulic stopper
Return
channel
Annular chamber
Hydraulic stopper
return spring
Inlet channel
High
pressure
chamber
Timer piston
Top view of timer
P-VP4C-049
- 31 -
Return channel
Closed
Inlet channel
Closed
OPERATION
Servo valve
Hydraulic stopper
Return
channel
Annular chamber
Hydraulic stopper
return spring
High
pressure
chamber
Inlet channel
Timer piston
Open
Closed
Servo valve
Cam ring
Hydraulic stopper
Return
channel
Annular
chamber
Hydraulic stopper
return spring
Inlet channel
Inlet channel
High
pressure
chamber
Open
Timer piston
Top view of timer
Low
pressure
chamber
P-VP4C-051
- 32 -
Closed
OPERATION
Annular chamber
Hydraulic stopper
Return
passage
TCV
P-VP4C-045
Open
Open
Control signal
Time
Closed
Closed
t
T
Coil
To feed pump
Orifice
Valve needle
P-VP4C-052
Valve needle
P-VP4C-053
- 33 -
OPERATION
4. ANGULAR ENCODER
Flexible connecting
harness
Angular
encoder
Sensor wheel
Driveshaft
Angular encoder
retaining ring
P-VP4C-054
Sensor
wheel
Angular
encoder
Pulse count
Closed
Open
Valve lift
Beginning of
pressure delivery
Cam lift
End of pressure
delivery
Pressure delivery
angle
Effective stroke
P-VP4C-055
- 34 -
OPERATION
5. PUMP CONTROL UNIT
Accelerator pedal
Cooling water
temperature
Injection quantity
Response
signals
Boost pressure
Pump
control unit
(PCU)
Fuel injection
pump
(mechanical
section)
Additional
signals
Timer control
device
To timer control device
Additional operations
- 35 -
WPGES-01