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 Common Rail
 
 
 
 
We have a complete assortment of Common Rail high pressure pumps Bosch CP1 – CP1H – CP3 – CP4 in addition to many other types, such as Delphi, Denso and Siemens. We offer you the new original pump or an overhauled and guaranteed version. Immediate availability of all parts for the common rail system such as:

ELECTRONIC PUMPS FOR TANKS 
HIGH PRESSURE PUMPS 
PARTS FOR HIGH PRESSURE PUMPS
FUEL FILTERS
FUEL ADDITIVES
PRESSURE REGULATORS (DRV)
RAIL – HIGH PRESSURE ACCUMULATOR
CONNECTION PIPES
ELECTRONIC INJECTORS
PRE-HEATING GLOW PLUGS
TESTERS AND DIAGNOSIS TEST BENCH AND COMMON RAIL REPAIR
  
 TECHNICAL INFORMATION ABOUT COMMON RAIL
 
WHAT IS COMMON RAIL
Common rail refers to a small accumulation tank called Rail where the pressure of the fuel remains almost constant and always available in order to supply the electronic injectors and therefore for an optimum injection. The protection of the environment, the need to reduce the consumption of fuel and to make the diesel engines more silent and better performing are the key factors that determined the study and development of the Unijet common rail system. Born as a project from Marelli in 1987, it was afterwards acquired by Fiat’s research centre in Bari who set it up and tested it on a vehicle in 1992. The project was transferred to Bosch Group for the final industrialisation process in 1994. The first vehicles with Unijet Common Rail installation were introduced into the market in 1997. 
 
 
WHAT IS COMMON RAIL
 
 
ITS FUNCTION
A pump inhales the fuel from the tank (ELECTRONIC PUMP) and continuously sends the quantity of requested fuel towards a second pump (HIGH PRESSURE PUMP) by making it pass first through the fuel filter that purifies it from any impurity which would cause a premature wear of its components. The high-pressure pump compresses the fuel at a pressure of 1350 bar and transfers it through a connection pipe to the high-pressure accumulation duct (Rail). This tank develops the function of mitigating the pressure oscillations caused by the opening and closing of the injectors and by the continuous discharges of the pump. The fuel is then transferred from the Rail through some connection pipes to the electronic injectors, which - instructed by an electromagnetic valve –inject the correct amount of fuel directly into the combustion chamber of the engine.

The fuel in excess, required for the opening of the nozzles, is sent back to the tank along with the leakages of fuel coming from the pressure regulation valve and from the high pressure pump itself. In this type of system, the quantity of injection is being established by the driver through the accelerator pedal while the initial stage and the pressure of injection are calculated and controlled by the electronic control unit (EDC). Through the accelerator pedal’s sensor, the electronic control unit registers the driver’s intention while, thanks to other sensors, it registers the exercising conditions of the engine and vehicle and – according to the information acquired – it carries out the intervention for the engine regulatio

The power supply of the fuel is divided into low-pressure circuit and high-pressure circuit. The low-pressure circuit is made of: 
- auxiliary immersed electronic pump
- diesel filter; 
- leakage manifold
The high-pressure circuit is made of:
-pressure pump;
- repair collector
 
 
WHAT IS COMMON RAIL
 
 
1. fuel tank
2. overall immersed pump complete with level indicator command
3.fuel introduction pipe
4. multifunctional valve
5. cartridge for diesel filter
6. pressure pump
7. high pressure connecting pipe
8. allotment collector
9. electronic injectors
10. electronic injectors recycle
11. return collector (low pressure)
12. pressure regulator
13. fuel temperature sensor
14. fuel pressure sensor
15. diesel heater 
16. heat switch

The sketch below identifies the various flows. The light arrows indicate the diesel at high pressure (discharges), the dark arrows indicate the diesel at low pressure (return to tank and discharges from primer pump).

 
 
WHAT IS COMMON RAIL
  
  ELECTRONIC PUMP TANK
 
The main trigger pump of fuel is situated in the tank inside a sump containing a filter with and a sensor for the level of fuel. It is a volumetrically type with a roller impeller and its function is to fill up the circuit and to supply the high-pressure pump. It has two valves: a non-return one in order to prevent the emptying of the circuit and a safety one which limits the pressure to a maximum value of 5 bar in case of obstruction of the diesel circuit. The electronic pump is feeded at 12V from the special relay, which is instructed – at its turn – from the EDC control unit. It guarantees a minimum flow of 0.5 litres/minute and with lot pressure of about 0.5 bar.
  
 HIGH PRESSURE MECHANICAL PUMP
 
The high-pressure pump is used for compressing the fuel at high pressure and sending it at pressurized stage towards the rail. 

The high pressure is obtained from the action of three small pistons being arranged in radial position (radialjet) at an angular distance of 120° and thanks to their action; they generate a pressure from a minimum of 150 bar to 1350 bar and even more among the pumps of latest generation.



The pump is dragged by the engine through the toothed distribution belt at about half speed. The pump does not require the phasing since the instant and time of injection are being entrusted to the control unit, which manages the opening of the injectors. The alterning movement of the three small pistons is assured by a triangular cam connected to the pump’s shaft and every pumping group is characterised by a suction valve and by a discharging one, the first having a clay shape and the second a spherical one.

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 SPARES FOR HIGH PRESSURE PUMPS
 
At our premises, we have available the original spares for the repair of high-pressure pumps such as: 
elements
valves
heads
seals kit
toggle shaft
incoming and outgoing connections

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SPARES FOR HIGH PRESSURE PUMPS
     
 FUEL FILTERS
 
The fuel could contain impurities or combined water (emulsion) or non-combined water (for example: condensation formation due to an change of temperature), which may cause corrosion and wear damages to the components of the pumps and injectors. For this reason, the system needs a fuel filter with a water-collecting compartment, which must be periodically emptied. FUEL FILTERS
    
 FUEL ADDITIVES
 
HP INJECTOR COMMON RAIL

SPECIFIC TREATMENT FOR INJECTION SYSTEMS TO HIGH PRESSURE: COMMON RAIL AND INJECTOR PUMP (PDE)

NEW FORMULA FOR DIESEL DIRECT INJECTION PLANT TO HIGH PRESSURES

The most careful researches on the formulations of the new diesel fuels to low way of sulphur and their use in the new injection systems to high pressure, “common rail” and “injector pump (PDE)” that use pressures from 1.300 to over 2.000 bar, have made necessary the introduction of new products to provide for three fundamental problems that arise from there:

1° high percentage of water in the tank caused by condensation.

2° very high temperatures with consequent excessive wear of the injection.

3° formation of deposits and sludges on the electroinjettors and on the head of the piston.

The triplex effectiveness of HP INJECTOR expressly formulated for the new systems of high pression injection through the synergy of its components: 

1. It absorbs and breaks up the water of condensation present in the tank and in the system of injection.
2. It improves the lubricity of the diesel oil reducing notably the temperature of exercise and the wear of the mechanical components.
3.It cleans the injection plant, the electroinjettors and the combustion chamber from deposits, sludges and rust. 
HP INJECTOR besides optimizes the combustion of the diesel-oil, improving the performance, the elasticity of march and reducing the consumptions and the pollution substances.

INSTRUCTIONS:
Professional use: every 5.000 km or every car serviced pour in the tank the whole content of the bottle (500 ml).

Daily use: divide the content of the bottle in two or three full of diesel-oil (around 150 ml x 60 lt of diesel-oil).

BOXES OF:
- 24 bottles of ml.500
FUEL ADDITIVES
    
 PRESSURE REGULATOR (DVR)
 
The regulating valves for the pressure is fixed on the body of the high pressure pump or Rail and has the function to regulate and maintain the pressure in the Rail according to the loading condition of the engine. In case the pressure is too high, the valve will open in order to make part of the fuel flow from the Rail to the tank; in case of too much low pressure in the Rail, the valve will close itself separating in this way the high pressure side from the low pressure one. 
It deals with a solenoid electronic valve instructed electronically by the central unit (EDC). The control unit instructs the valve only after it elaborates the signals coming from the various sensors connected to the peripheral system of the engine: engine speed, load, mass of extracted air, air pressure, engine temperature and fuel temperature. The variation of pressure is carried out by regulating the flow of fuel going back to the tank.

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PRESSURE REGULATOR (DVR)
    
 RAIL – HIGH PRESSURE ACCUMULATOR
 
This tank develops the function of accumulating the fuel at high pressure, mitigating the pressure oscillations caused by the opening and closing of the injectors and by the constant discharges of the pump. 
The pressure remains almost constant in the rail even in case there is an injection of a remarkable quantity of fuel. On the rail it is possible to fit a capacity limit valve, a rail pressure sensor, a valve regulating and limiting the pressure. RAIL – HIGH PRESSURE ACCUMULATOR
    
 CONNECTING PIPES
 
The connecting pipes of high pressure fuel must have a long life and resistance at the system’s maximum pressure and at the remarkable oscillations of pressure that occur. 
They are made of steel pipes with an external diameter of 6mm and inside hole of about 2.4mm. Attempts have been made in order to reduce as much as possible the length of the pipes.

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CONNECTING PIPES
   
 ELECTRONIC INJECTORS
 
The injectors of the Common Rail system are composed of a top part which includes an electromagnetic valve and electric control device; and a low part including a mechanical injection device and the nozzle. 
The initial phase of injection and the quantity are programmed by the control unit through an electronic instruction towards the electronic injectors. Download stock list.

ELECTRONIC INJECTORS
    
 PRE-HEATING GLOW PLUGS
 
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Tel +39 080.5368586 - Fax +39 080.5357579
Tel +39 080.5367468 - Tel +39 080.5357615
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