Vp44 Electronic Inj Pump2
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VP44 Electronic Inj Pump
DodgeRam.org > Main > Diesel Index > ISB 24 Valve - VP44 General Information
VP44 Injector Pump System Visit Geno's Garage for Truck accessories. The VP44 injection pump was introduced on the Cummins ISB as a stop gap measure to meet 1998 emissions standards before a common rail fuel system was ready for production. For Dodge Ram pickups, the ISB engine was used in all trucks built after January 1, 1998. A common rail system is being road tested now, and reliable rumors say the the VP44 will be replaced by a common rail in 2003 models. For those with 1998-2002 Rams, here are some details about the VP44 pump. To meet environmental regulations for a variety of engine applications, Cummins designed an ECU to which they could download different engine control programs without making any physical changes to the engine. This electronic engine control unit (ECU) is installed in a sealed box that is mounted directly to the cylinder block of the engine. The ECU communicates with the VP44 fuel injection pump through a high-speed 2-way CAN-BUS data-link. There is no direct connection from the throttle to the injector pump. Inputs from engine sensors and the throttle position are used by the ECU to determine how much fuel is injected, and when. The ECU uses sensor and throttle position inputs to compute the appropriate "load", then the controller obtains the fueling rate information from look-up tables, sometimes called maps, stored in ROM. From these a value is determined that represents the desired amount of fuel to be delivered to the engine. This value is then communicated to the injector pump. The VP44 injection pump uses a set of mechanical plungers to pressurize the fuel, and a mechanical distributor to route the fuel to the correct injector. An electronic controller converts the fuel information sent from the ECU into mechanical control of the fuel delivery by opening and closing fuel spill ports inside the pump mechanism. The pump returns information to the ECU regarding its current operating state.
Bosch VP44 Injector Pump
Cummins ECU
General Information from the ZEXEL site: The VP44 systemwas developed to meet emission standards and reduce fuel consumption. VP44 is a directinjection type fuel-injection system for small- to mediumsize diesel engines. To generate the high injection pressures
file:///Z:/Manuals/injection%20pumps/Vp44.htm[8/13/2010 12:41:23 AM]
VP44 Electronic Inj Pump
needed for direct-injection, The VP44 uses an internal cam disk and radially opposed plungers to pressurize the fuel from two directions. The VP44 controls the injection rate and injection timing using two electromagnetic valves. Also, the electronic control unit is divided into two, with a compact control unit mounted directly on the pump and a larger Engine Control Module mounted on the engine block. Fuel System - General Information from Cummins The VP44 is an electronic fuel injection pump manufactured by Bosch®, that can vary fueling and injection timing based on input from the electronic control module (ECM). This pump has its own electronic control unit, the fuel pump control module (FPCM), which contains fueling, timing, and diagnostic data. The fuel pump control module (FPCM) communicates with the engine controller (ECM) to obtain information on desired fueling and timing. The fuel pump control module (FPCM) responds to the ECM's commands by consulting the fueling data and timing in its memory and actuating the fueling and timing solenoids. A fuel temperature sensor is located inside the VP44 pump to compensate for changes in the temperature of the fuel. The pump also contains a speed sensor (IAT) that gives the fuel pump control module (FPCM) data on the position and speed of the pump shaft. A reference pulse that marks top dead center (TDC) of cylinder No. 1 is sent from the ECM once every pump revolution. By comparing this reference pulse from the ECM to the position signal from the speed sensor (IAT), the fuel pump control module (FPCM) can reference the pump's position in relation to the engine's position. This allows the fuel pump control module (FPCM) to adjust the pump timing to compensate for minor position differences between the fuel pump shaft and the engine camshaft. If the difference between the pump position and engine position becomes too great, then a fault will be logged in the fuel pump control module (FPCM). In addition to the engine position reference pulse, the fuel pump control module (FPCM) also receives timing and fueling commands from the ECM. The fuel pump control module (FPCM) controls the timing and fueling through two solenoids located in the pump. The timing solenoid controls the position of a cam ring inside the pump by varying internal transfer pump pressure. The cam ring has evenly spaced lobes around its inner diameter. The pumping plungers ride on rollers that rotate inside this cam ring. The rollers follow the inner diameter of the cam ring and push the pumping plungers inward whenever a cam lobe is encountered, thus file:///Z:/Manuals/injection%20pumps/Vp44.htm[8/13/2010 12:41:23 AM]
VP44 Electronic Inj Pump
building injection pressure. By rotating the cam ring with the timing solenoid, the fuel pump control module (FPCM) is able to advance and retard the injection timing by making the rollers contact the cam lobes either earlier or later. The second solenoid in the pump is used to meter fuel to the injectors. The solenoid opens the fuel metering valve to allow fuel from the supply pump to flow into the pumping chamber. Once the pumping chamber is charged with fuel, the solenoid valve closes. This traps the fuel in the chamber and allows injection pressure to build. The fuel is routed to the correct injector by the pump distributor. The distribution port on the distributor aligns with one of the six outlet ports to distribute fuel to a given injector. Once the desired amount of fuel has been injected, the solenoid valve opens, causing the pressure in the pumping chamber to bleed down, which ends injection. The cycle then begins again for the next cylinder. The fuel injection pump (VP44) is an electronic rotary distributor pump. The pump performs four basic functions: 1. 2. 3. 4.
Producing the high fuel pressure required for injection Metering the exact amount of fuel for each injection cycle Distributing the high-pressure, metered fuel to each cylinder at the precise time Varying the timing relative to engine speed.
A cam ring with three plungers, a rotor, and an electronically controlled fueling solenoid valve is used to develop and distribute the high pressure required for injection. A worn or damaged internal transfer pump, plunger, or fueling valve can affect the pressure and the amount of fuel injected, thus reducing the power from the engine. Generally, if the fuel-injection pump is injecting fuel from one outlet, it will deliver from all outlets. VP44 Timing Principles Timing in the VP44 is controlled by an internal timing piston coupled to a cam ring inside the pump. The timing piston is moved by fuel pressure. The amount of fuel pressure in the timing piston assembly housing is controlled by an internal transfer pump and a pulsating timing solenoid valve. As the pump speed increases, the fuel pressure to the timing piston assembly also increases. Based on the inputs from the fuel pump control module (FPCM), the timing solenoid valve pulses to vary the pressure to move the timing piston, which results in the cam ring moving to the desired position to achieve the commanded timing. The more pressure created by the internal transfer pump and timing solenoid valve, the more the timing will advance; therefore, timing range capability is increased at higher rpms. The ISB engine is equipped with an electric-powered lift pump. Fuel flow begins as the fuel lift pump pulls fuel from the supply tank. This electric lift pump supplies low-pressure fuel (10 to 12 psi) to the filter head, through the filter, and then to the electronic distributor injection pump. The electronic distributor pump builds the high injection pressures required for combustion and routes the fuel through individual high-pressure fuel lines to each injector. When the high-pressure fuel reaches the injector, the pressure lifts the needle valve against the spring tension to let the fuel enter the combustion chamber. Any leakage past the needle valve enters the fuel drain manifold in the cylinder head. The fuel in the manifold exits at the rear of the cylinder head and is routed to the fuel tank. The fuel that is returned from the fuel injection pump is also routed back to the fuel tank.
What other engines use the VP44 Injection Pump?
file:///Z:/Manuals/injection%20pumps/Vp44.htm[8/13/2010 12:41:23 AM]
VP44 Electronic Inj Pump
BMW 320d Ford Focus td Opel dti Saab VAG V6 tdi John Deere 6.8L diesel Case tractors and construction equipment Subject: [TD] VP44 & P7100 Date: Fri, 11 Jun 1999 08:19:36 -0700 From: Josh Berman [email protected] To: TurboDiesel, cummins > I was told the rotary pump on the ISB's does not have near the capacity of the > older in line pumps. One cylinder versus six. Just does not have the ability > to move as much fuel apparently. The VP44 that we use actually has 3 pistons arranged in a radial pattern (think of the "star" logo on a line of German luxury cars :-). BOSCH makes VP44s with different #'s of pistons, depending on how many cylinders the engine has. The pistons ride inside a cam ring (think of a doughnut with a lumpy hole). As the pump shaft rotates, the pistons rotate inside the cam ring, and the ramps on the cam ring press the pistons inward, pressurizing the fuel (which is then directed through the fueling solenoid and distributor which sends the fuel to the correct cylinder). The P7100 can pump a lot of fuel: it went to 230 HP on the B-Series automotive engine, 325 on the C-Series automotive engine, even higher on the marine versions. Currently, the highest rating we sell the ISB (and thus the VP44) at is 275 HP. That rating is restricted to RVs and fire trucks. I don't think the VP44 is max'd out at 275 HP, but I honestly don't know what its limit is. -Josh B.
TOP HOME
file:///Z:/Manuals/injection%20pumps/Vp44.htm[8/13/2010 12:41:23 AM]
DodgeRam.org > Main > Diesel Index > ISB 24 Valve - VP44 General Information
VP44 Injector Pump System Visit Geno's Garage for Truck accessories. The VP44 injection pump was introduced on the Cummins ISB as a stop gap measure to meet 1998 emissions standards before a common rail fuel system was ready for production. For Dodge Ram pickups, the ISB engine was used in all trucks built after January 1, 1998. A common rail system is being road tested now, and reliable rumors say the the VP44 will be replaced by a common rail in 2003 models. For those with 1998-2002 Rams, here are some details about the VP44 pump. To meet environmental regulations for a variety of engine applications, Cummins designed an ECU to which they could download different engine control programs without making any physical changes to the engine. This electronic engine control unit (ECU) is installed in a sealed box that is mounted directly to the cylinder block of the engine. The ECU communicates with the VP44 fuel injection pump through a high-speed 2-way CAN-BUS data-link. There is no direct connection from the throttle to the injector pump. Inputs from engine sensors and the throttle position are used by the ECU to determine how much fuel is injected, and when. The ECU uses sensor and throttle position inputs to compute the appropriate "load", then the controller obtains the fueling rate information from look-up tables, sometimes called maps, stored in ROM. From these a value is determined that represents the desired amount of fuel to be delivered to the engine. This value is then communicated to the injector pump. The VP44 injection pump uses a set of mechanical plungers to pressurize the fuel, and a mechanical distributor to route the fuel to the correct injector. An electronic controller converts the fuel information sent from the ECU into mechanical control of the fuel delivery by opening and closing fuel spill ports inside the pump mechanism. The pump returns information to the ECU regarding its current operating state.
Bosch VP44 Injector Pump
Cummins ECU
General Information from the ZEXEL site: The VP44 systemwas developed to meet emission standards and reduce fuel consumption. VP44 is a directinjection type fuel-injection system for small- to mediumsize diesel engines. To generate the high injection pressures
file:///Z:/Manuals/injection%20pumps/Vp44.htm[8/13/2010 12:41:23 AM]
VP44 Electronic Inj Pump
needed for direct-injection, The VP44 uses an internal cam disk and radially opposed plungers to pressurize the fuel from two directions. The VP44 controls the injection rate and injection timing using two electromagnetic valves. Also, the electronic control unit is divided into two, with a compact control unit mounted directly on the pump and a larger Engine Control Module mounted on the engine block. Fuel System - General Information from Cummins The VP44 is an electronic fuel injection pump manufactured by Bosch®, that can vary fueling and injection timing based on input from the electronic control module (ECM). This pump has its own electronic control unit, the fuel pump control module (FPCM), which contains fueling, timing, and diagnostic data. The fuel pump control module (FPCM) communicates with the engine controller (ECM) to obtain information on desired fueling and timing. The fuel pump control module (FPCM) responds to the ECM's commands by consulting the fueling data and timing in its memory and actuating the fueling and timing solenoids. A fuel temperature sensor is located inside the VP44 pump to compensate for changes in the temperature of the fuel. The pump also contains a speed sensor (IAT) that gives the fuel pump control module (FPCM) data on the position and speed of the pump shaft. A reference pulse that marks top dead center (TDC) of cylinder No. 1 is sent from the ECM once every pump revolution. By comparing this reference pulse from the ECM to the position signal from the speed sensor (IAT), the fuel pump control module (FPCM) can reference the pump's position in relation to the engine's position. This allows the fuel pump control module (FPCM) to adjust the pump timing to compensate for minor position differences between the fuel pump shaft and the engine camshaft. If the difference between the pump position and engine position becomes too great, then a fault will be logged in the fuel pump control module (FPCM). In addition to the engine position reference pulse, the fuel pump control module (FPCM) also receives timing and fueling commands from the ECM. The fuel pump control module (FPCM) controls the timing and fueling through two solenoids located in the pump. The timing solenoid controls the position of a cam ring inside the pump by varying internal transfer pump pressure. The cam ring has evenly spaced lobes around its inner diameter. The pumping plungers ride on rollers that rotate inside this cam ring. The rollers follow the inner diameter of the cam ring and push the pumping plungers inward whenever a cam lobe is encountered, thus file:///Z:/Manuals/injection%20pumps/Vp44.htm[8/13/2010 12:41:23 AM]
VP44 Electronic Inj Pump
building injection pressure. By rotating the cam ring with the timing solenoid, the fuel pump control module (FPCM) is able to advance and retard the injection timing by making the rollers contact the cam lobes either earlier or later. The second solenoid in the pump is used to meter fuel to the injectors. The solenoid opens the fuel metering valve to allow fuel from the supply pump to flow into the pumping chamber. Once the pumping chamber is charged with fuel, the solenoid valve closes. This traps the fuel in the chamber and allows injection pressure to build. The fuel is routed to the correct injector by the pump distributor. The distribution port on the distributor aligns with one of the six outlet ports to distribute fuel to a given injector. Once the desired amount of fuel has been injected, the solenoid valve opens, causing the pressure in the pumping chamber to bleed down, which ends injection. The cycle then begins again for the next cylinder. The fuel injection pump (VP44) is an electronic rotary distributor pump. The pump performs four basic functions: 1. 2. 3. 4.
Producing the high fuel pressure required for injection Metering the exact amount of fuel for each injection cycle Distributing the high-pressure, metered fuel to each cylinder at the precise time Varying the timing relative to engine speed.
A cam ring with three plungers, a rotor, and an electronically controlled fueling solenoid valve is used to develop and distribute the high pressure required for injection. A worn or damaged internal transfer pump, plunger, or fueling valve can affect the pressure and the amount of fuel injected, thus reducing the power from the engine. Generally, if the fuel-injection pump is injecting fuel from one outlet, it will deliver from all outlets. VP44 Timing Principles Timing in the VP44 is controlled by an internal timing piston coupled to a cam ring inside the pump. The timing piston is moved by fuel pressure. The amount of fuel pressure in the timing piston assembly housing is controlled by an internal transfer pump and a pulsating timing solenoid valve. As the pump speed increases, the fuel pressure to the timing piston assembly also increases. Based on the inputs from the fuel pump control module (FPCM), the timing solenoid valve pulses to vary the pressure to move the timing piston, which results in the cam ring moving to the desired position to achieve the commanded timing. The more pressure created by the internal transfer pump and timing solenoid valve, the more the timing will advance; therefore, timing range capability is increased at higher rpms. The ISB engine is equipped with an electric-powered lift pump. Fuel flow begins as the fuel lift pump pulls fuel from the supply tank. This electric lift pump supplies low-pressure fuel (10 to 12 psi) to the filter head, through the filter, and then to the electronic distributor injection pump. The electronic distributor pump builds the high injection pressures required for combustion and routes the fuel through individual high-pressure fuel lines to each injector. When the high-pressure fuel reaches the injector, the pressure lifts the needle valve against the spring tension to let the fuel enter the combustion chamber. Any leakage past the needle valve enters the fuel drain manifold in the cylinder head. The fuel in the manifold exits at the rear of the cylinder head and is routed to the fuel tank. The fuel that is returned from the fuel injection pump is also routed back to the fuel tank.
What other engines use the VP44 Injection Pump?
file:///Z:/Manuals/injection%20pumps/Vp44.htm[8/13/2010 12:41:23 AM]
VP44 Electronic Inj Pump
BMW 320d Ford Focus td Opel dti Saab VAG V6 tdi John Deere 6.8L diesel Case tractors and construction equipment Subject: [TD] VP44 & P7100 Date: Fri, 11 Jun 1999 08:19:36 -0700 From: Josh Berman [email protected] To: TurboDiesel, cummins > I was told the rotary pump on the ISB's does not have near the capacity of the > older in line pumps. One cylinder versus six. Just does not have the ability > to move as much fuel apparently. The VP44 that we use actually has 3 pistons arranged in a radial pattern (think of the "star" logo on a line of German luxury cars :-). BOSCH makes VP44s with different #'s of pistons, depending on how many cylinders the engine has. The pistons ride inside a cam ring (think of a doughnut with a lumpy hole). As the pump shaft rotates, the pistons rotate inside the cam ring, and the ramps on the cam ring press the pistons inward, pressurizing the fuel (which is then directed through the fueling solenoid and distributor which sends the fuel to the correct cylinder). The P7100 can pump a lot of fuel: it went to 230 HP on the B-Series automotive engine, 325 on the C-Series automotive engine, even higher on the marine versions. Currently, the highest rating we sell the ISB (and thus the VP44) at is 275 HP. That rating is restricted to RVs and fire trucks. I don't think the VP44 is max'd out at 275 HP, but I honestly don't know what its limit is. -Josh B.
TOP HOME
file:///Z:/Manuals/injection%20pumps/Vp44.htm[8/13/2010 12:41:23 AM]
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