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Innovative diesel fuel injection products

 

Bosch in India, is committed to developing innovative diesel fuel injection products, apart from providing services that will help meet the stringent emission norms of the future. The in-line fuel injection pumps of Bosch could cater to the full spectrum of diesel engines till BSII. They are used in a range of engines starting from small fixed installations to large earth movers.
By increasing pressure capability, improving timing control along with combustion optimization, the in-line pump is able to meet the next level of emission norms of BSIII in major parts of the country, thereby reducing carbon monoxide (CO) emissions by 50%.
With the introduction of Bharath Standard IV (BS IV) in 13 cities across India, the need for reduced emissions, and quieter engines are making greater demands on the engine and the fuel-injection systems. These demands can be met by the Common Rail fuel injection system that delivers fuel at a high pressure, precise quantity, precise timing, and split in to multiple injections. Moreover, electronic control in the Common Rail diesel fuel injection system increases flexibility making the vehicles less polluting, more fuel efficient and capable of meeting future emission norms for a host of end applications like: Load carriers, Passenger cars, Light & Medium duty Commercial vehicles.
For the low price vehicle segment, second generation Common Rail System based on single plunger pump with the very efficient inlet fuel metering control system for the single and two cylinder engines was introduced. The first generation Common Rail system based on the principle of high pressure control system is presently in Series production for this segment.
In line with its practice of developing and producing state of the art technology for the market, Bosch began production of the A4000 pump in 2010. The A4000 meets the requirements, which is in accordance with BSIII & TREM emission norms. This has contributed significantly in changing the landscape of the commercial vehicle and off-highway segments in India.
These unique products are a clear testimony to the Company’s strong innovative culture and its focus on providing value to the customers.

Areas of operations

• Electronic Diesel Control (EDC)
• Air management
• Injection management
• Exhaust-gas management

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Diesel Systems

Multi-cylinder Pumps – PE

• Over 300 varieties in inline, catering to the requirements of 2 to 12-cylinder engines
• Catering to engines with 25 hp to 540 hp power output (20 kW to 400 kW)
• Speed range up to 3500 rpm (engine speed)
• Upgraded version (A3500) to meet Euro I emission standards

Add-on features include:

• Turbo-charger pressure-dependent management
• Torque-dependent fuel shaping
• Timing lock to ensure exact injection timing on the engine, enabling quick mounting
• Mechanical timing advance mechanism (Timer)
• Part load advance features to combat white smoke
• Part load retard to meet emission
• Timing advance through pumping element
• Pneumatic shut-off device for stopping the engine

 Distributor Pumps - VE

• Designed to achieve lower exhaust emissions
• Highly compact and lightweight
• Modular design for add-on devices
• Several add-on devices for emission control and driving comfort
• Speed range up to 5000 rpm engine speed
• Built-in timing device
• Electrical shut off
• Enhanced driving comfort
• Easy adaptability to a variety of engine requirements
• Capable of working up to 950 bar peak line pressure at pump end
• Add-on devices include Cold start accelerator, Fast idle device, Load-dependent start of injection and Boost compensator for turbo-charged engine.

 Single-cylinder Pumps – PF

• Wide variety of pumps to suit diverse engine needs (A, B, K, Q, W, PF30, PF37, PF41, PF43)
• Varied pressure capabilities from 400-1050 bar
• Suitable for 3 to 200 hp/ cylinder diesel engines from 2 kW to 2300 kW
• Modular design
• Easier adaptation for different types of engines (1, 2, 3, 4,..16 cylinders)
• Easy maintenance

New Generation Fuel Injection Systems 
The Distributor Type Injection Pump with Electronically Controlled Injection Timing

• Equipped with Electronically Controlled Injection Timing
• The ECU with stored data maps enables closed loop control of injection timing by sensing injection begin with the help of a Needle Movement Sensor
• A solenoid valve is installed on the injection-timing device at the base of the pump
• Improves performance, while reducing emissions
• Exhaust Gas Recirculation (EGR) aids further reduction in emissions

The Distributor Type Injection Pump with Electronic Diesel Control (VE-EDC)

• Relies on program maps to regulate operation according to an array of parameters
• The catalogue of variables embraces engine load and speed, coolant temperature and the volume of the induction-air charge
• Self-monitoring and diagnostic functions . Injection pressures extending up to 1200 bar at the nozzle
• Fast and efficient starts along with smooth, quiet running
• Cuts fuel consumption and exhaust emissions

Common Rail System (CRS)

• Designed for injection pressures of up to 1350 bar
• An inlet metered pump
• Reduction of fuel consumption
• Lowers fuel temperature
• Suitable for installation in passenger cars and commercial vehicles

Unit Pump System (UPS)

• Single Cylinder Pump Module driven by the engine camshaft
• Connected to the injection nozzle by a short high-pressure pipe

Unit Injector System (UIS)

• Single Cylinder Pump Module in which the pump element and injection nozzle are combined into one unit
• Installed in the engine cylinder head and driven by the engine camshaft
• Wide range of applications
• For heavy trucks up to 80 kW per cylinder
• Tractors / industrial, marine and Locomotive applications
• High Injection Pressures up to 1500 bar
• Variable start of injection
• Possibility of pilot injection
• Easier adaptation for different types of engines (1,2,3,4,...16 cylinders)

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Lubricants

 

Lubricants

• Conforms to prevalent standards (API, SAE, JASO, ISO-E GC, as relevant)
• Complete range of engine and gear oil

2T / 4T Engine Oil

• Improves engine performance
• Reduces wear of engine parts
• Protects against rusting
• High resistance to piston scuffing
• Lower emission levels

Monograde / Multigrade Engine Oil

• Reduces friction, dissipates heat - minimises wear
• Protects against sludge - maximises engine life
• Multigrade Engine oil has optimal viscosity - reliable for all-weather operation.

Gear Oil

• Anti-wear properties - minimises metal to metal contact.
• Stable viscosity - reliable for all weather operation
• Oxidation resistance - prevents formation of sludge

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Batteries

Batteries
Passenger car batteries
BOSCH Silver Perfect Maintenance Free (PMF) Battery comes with breakthrough Silver alloy technology. This means it offers greater electrical conductivity and better corrosion resistance, substantial increase in service life, and a totally maintenance-free battery experience.  Features

• Factory charged and sealed; so, no charging or topping required
• Consistent power output
• Withstands heavy loads
• Greater acid volume above the plates (safety reserve)
• Charge-eye indicator
• Side wall ribbing
• Polyethylene envelope separators

 The sealed maintenance-free battery has optimised grid geometry and contains calcium silver alloy that offers excellent cold start performance, improved power consumption during charging, greater starting power and longer service life. The water consumption is much less than conventional batteries because the labyrinth for gas condensation and return to the battery minimises the loss of water.
Benefits

• Faster charging
• Better short-trip resistance
• Long-life
• Improved cyclic loading
• 30% higher starting power
• Minimises the danger of ignition from external sources

Truck and tractor batteries: Bosch Ustad and Kranti

• Longer life
• Higher cranking power
• Leak resistant
• Low on maintenance. Special hybrid alloy minimises water loss
• Extreme vibration resistance. Ribbed container withstands temperature extremes and shocks/ vibration damages
• Factory filled and wet shipped
• Better corrosion resistance with superior plate design and weld systems
• No electrical shorts, with glass matt lined enveloped PE separators

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Horns

Horns

Great construction and consistent performance - that’s what Bosch Ltd. and BOSCH Horns have to offer. Disc horns and Fanfares can be used for 2-wheelers, 3-wheelers, cars, MUVs, LCVs and tractors.

•  Exclusive designs
• Compact size
• Superior quality
• Covered under warranty

The horns come with sturdy brackets, designed for specific vehicle models so it can be conveniently mounted internally or externally. What’s more, Bosch Ltd. and BOSCH Horns are tested under rigorous operating conditions, including vibration and corrosion resistance, continuous blast test, endurance, dust, water and dampness test, temperature stability test etc. With Bosch Ltd. and BOSCH Horns and Fanfare, get heard and get ahead on city roads and highways.
BOSCH Europa Horns: World-class super-tone horns

• Bosch design
• Teflon filter technology
• Corrosion resistant
• Premium quality
• For passenger cars and MUVs

BOSCH Europa Horns come in three variations
Standard Horn - 125 mm

• Standard horn for concealed mounting
• Housing, tone disc and diaphragm black, resi-coated

Decorative Ring Horn - 140 mm

• Decorative ring for visible mounting
• Housing and diaphragm black resi-coated
• Tone disc and ring shiny matt

Grilled Horn - 140 mm

• Grilled horn for visible mounting
• Housing and decorative cover resi-coated in black or chrome-plastic

BOSCH FC4 Horns

• Penetrating, strong sound even at long distances
• Galvanised steel for protection against corrosion, dust and humidity
• Pressure compensation through micro-porous Teflon filter

Impact Horns

• High quality construction
• Impactful sound output
• Attractive grills

100 Dia Horn

• Repairable
• Powerful tone
• High quality construction
• Consistent performance

Compact Horns

• Powder coated body
• Vibration resistant brackets
• Sealed, yet repairable
•  Compact design, ideal for concealed installations

Symphony Fanfare Horn

• Pleasant Tone
• Plastic trumpet - Fracture and corrosion resistant
• High quality construction - Consistent performance
• Sturdy yet flexible bracket
• Easy horizontal or vertical mounting
• Extremely resistant to vibrations

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Function of a Spark Plug

What is the function of a spark plug and why is it a vital engine component?

The function of the spark plug is to introduce the ignition energy into the combustion chamber and to initiate combustion of the compressed air-fuel mixture. It accomplishes this task by generating a spark between its electrodes, which then generates the required heat to ignite a smooth burn of the air/fuel mixture. The spark plug is an important factor in determining optimal performance and reliable functioning of an engine. It must permit reliable cold starting, it must guarantee that there is no misfiring during acceleration, and it must withstand the engine being operated for hours on end at maximum power. These requirements apply throughout the entire service life of the spark plug. For 100 years, Bosch Spark Plugs have been designed for optimal performance, reliable functioning, and to withstand extreme operating conditions. Today, the continuously developing spark plug is a key engine system component. It plays a major role in fuel economy, clean, efficient combustion, and the reliable operation of engines and catalytic converters.

What are the different types of spark plugs?

There is a large variety of different spark plug designs with more than 1,400 variations. Design variants and special materials such as platinum, silver, or yttrium allow Bosch spark plugs to be used in a wide variety of applications today. In all, Bosch has developed more than 20,000 different types of spark plugs over the last 100 years.

Why do we need to change spark plugs?

During operation, the spark plug is subjected to both wear and to fouling and should be replaced at regular intervals. In the course of its service life, the spark plug undergoes changes that increase the required ignition voltage. When the required voltage reaches a level that can no longer be compensated for by the voltage reserve, the result is misfiring. These changes can be caused by: Electrode wear Engine wear Abnormal operating conditions (pre-ignition, detonation, high oil consumption) Independent tests have shown that installing premium spark plugs such as Bosch’s Platinum+4 improves fuel mileage by as much as 4.8% over original equipment plugs. Platinum+4 uses race-tested technology including multiple electrode paths and more pure platinum to generate strong, consistent sparks.

How do I "read" a spark plug?

Reading the spark plugs provides valuable information on spark plug and engine operating conditions. See the Technical Info tab to review spark plug faces.

How should spark plugs be tightened for best performance?

Bosch recommends when installing spark plugs to use a torque wrench and the correct torque in ft.-lbs. As listed below:

	10mm With Gasket	12mm With Gasket	14mm With Gasket	14mm Tapered Seat	18mm With Gasket	18mm Tapered Seat
Torque Ft.-Lbs.	8-11	12-15	19-22	12-15	20-23	14-17

If a torque wrench is not available, hand tighten the plug until it is seated in the cylinder head. Spark plugs with gaskets should be tightened an additional 90°. Spark plugs with tapered seats should be tightened an additional 15°.

Are Bosch Spark Plugs pregapped at the factory?

Most Bosch Spark Plugs are factory pre-gapped for popular vehicle applications. The gap measurements are indicated either on the box, or by the part number located on the spark plug shell.

• X suffix = .044"
• Y suffix = .060"
• Z suffix = .080"

Gaps should never by adjusted on Platinum+4 or Platinum+2. Bosch Platinum+4 and Platinum+2 have factory pre-set gaps, and should never be gapped by the installer.
Bosch Platinum and Super Spark Plugs also have factory-set gaps. For most plugs, the setting is shown on the plug package. These gaps are correct for the most popular applications of these plugs. There are applications, however, for which the gap setting has to be adjusted according to the vehicle manufacturer’s specifications. To avoid damage to a spark plug in the process of adjusting the gap, it is important to follow these guidelines:

• To widen the electrode gap, use a tool that only pulls back the ground electrode, without applying pressure to the center electrode. The tool must not be wedged between the electrodes as that may cause damage to the insulator nose.
• To close the electrode gap, carefully tap the plug, electrode first, on a hard surface, as shown in the illustration.

What is detonation?

Detonation or "knocking" is uncontrolled combustion with a very steep rise in pressure. It is caused by spontaneous ignition of the fuel mixture, which has not yet been reached by the ignition spark. As the high-pressure waves hit the walls of the combustion chamber, their impact produces a metallic knocking sound. Failure to recognize and deal with knocking will inevitably lead to serious engine damage.

What is heat range?

The spark plugs’ heat range is an index of its capacity to dissipate thermal energy. The different characteristics of automotive engines regarding operating load, compression, engine speed, cooling, and fuel make it impossible to run all engines with a standard spark plug. The same spark plug may get very hot in one engine type, but may reach only a relatively low temperature in another. In the first case, the air-fuel mixture would ignite on the glowing parts of the spark plug projecting into the combustion chamber (pre-ignition) and, in the second case, the insulator tip would soon become so badly fouled by combustion deposits that misfiring would occur. To ensure that the plug runs between the desired temperatures, plugs with different heat capacities were developed. The so called “heat range”, which is assigned to each spark plug, is used to characterize these heat dissipation capacities. A plug with a low heat range number (e.g., 2-4) indicates a cold plug that quickly dissipates heat to the engine block and cooling system, while a high code (e.g., 7-10) indicates a hot plug that retains heat. By properly selecting the heat range of the plug, it ensures that the plug will operate between the plug’s designed operating range of 500-900 degrees Celsius. In this range, the spark plug will be self-cleaning, yet will not be hot enough to pre-ignite the air/fuel mixture.

How does Bosch test engines to determine the heat range and what heat range should I use?

To ensure optimal performance in your car, Bosch has tested each vehicle model and the various engines available for that model listed in the Spark Plug catalog or our web-page. Using a special spark plug with a thermocouple built in, Bosch engineers find the hottest cylinder in an engine and then test various spark plugs in that cylinder until the ideal plug is found. This ensures that you will always get the best performance possible.

I want to use Bosch Spark Plugs, but have modified my engine by adding a performance system. Can I still use the plug listed in the catalog for my vehicle?

If you have modified your engine with a performance system such as a turbocharger, supercharger, or nitrous, the recommended spark plug may not be correct. You may need to use a plug with a colder heat range to compensate for the additional heat generated by the engine. Bosch recommends that in these situations, you consult a qualified engine builder for assistance in determining the appropriate heat range

How often do I need to change my plugs?

As a rule, Bosch recommends that you follow the replacement interval listed in your vehicle owners manual, however we highly recommend that you inspect (read) your spark plugs annually and replace as required, to insure optimum engine performance

Do Bosch Spark Plugs meet original equipment requirements?

Yes! Bosch Spark Plugs meet or exceed warranty requirements of all vehicle and engine manufacturers, and when properly installed in accordance with the recommended application, will not adversely affect the emission control system of any vehicle.

What about vehicle manufacturer warranties?

Consumers are sometimes told by an automobile dealer’s service writer or mechanic that a brand of replacement spark plug cannot be used in the consumer’s vehicle during the warranty period. The claim is made that use of the brand will “void the warranty”, with the statement or implication that only the original equipment brand of spark plugs may be used. This, of course, tends to cast doubt on the quality of the replacement spark plug. That claim is not true. Under the Magnuson-Moss Warranty Act and general principles of the Federal Trade Commission Act, a manufacturer may not require the use of any brand of spark plug (or any other article) unless the manufacturer provides the item free of charge under the terms of the warranty.
So, if the consumer is told that only the original equipment spark plug will not void the warranty, they should request that the OE spark plug be provided free of charge. If they are charged for the spark plug, the manufacturer or dealer is in violation of the Magnuson-Moss Warranty Act.

Does the Bosch part number have meaning to help determine the specifications of the plug?

Yes! See the Technical Info tab for the list of designation codes.

How does platinum improve a spark plug?

Perhaps the greatest innovation in spark plug design over the years is “pure platinum” technology, combined with multiple electrodes. As early as the 1960’s engineers recognized the value that platinum added to automotive plugs: it provides improved corrosion and erosion resistance and imparts a longer performance life than the standard copper core center electrode plug design. The use of platinum not only broadens the heat range beyond that achieved with a copper core center electrode design, but also provides extremely consistent performance, a reliable spark and a longer performance life.

What are the advantages of surface air gap plugs such as Platinum+4 and Platinum+2?

To validate the improved performance of surface air gap plugs with a pure platinum core and multiple ground electrodes, extensive testing was conducted in the laboratory and in the field:

• The first test measured the energy transfer efficiency of the four-electrode platinum plug compared to conventional and other premium plugs with a single ground electrode. This certified laboratory test measured the additional pressure generated by the spark discharge in a pressure chamber. Higher pressure equals a higher energy transfer by the spark. The test showed that the four-electrode platinum plugs transferred more energy to the air/fuel mixture resulting in improved driveablility and lower emissions.
• As a spark plug wears via erosion and corrosion, the gap between the center electrode and ground electrode gets larger. The larger the gap, the more voltage is required to produce a spark, until the capability of the ignition system is exceeded and the plug misfires. It was found that the multiple ground electrode, pure platinum center electrode plug reduces gap erosion and increasing voltage requirements over time.
• Roush Industries, an independent test lab, measured the fuel consumption for the four-electrode platinum plug, as well as, that for original equipment and other premium single ground electrode plugs. Fuel savings up to 4.8% were found in the four electrodes, platinum core plugs. Tests were conducted in accordance with Federal Test Procedure 75FTP and HFE.
• Tests for carbon fouling were simulated in a cold cell by repeatedly cooling, starting and operating the engine without letting the spark plugs reach their self-cleaning temperature. This cycle does not let the spark plug reach its self-cleaning temperature and allows the formation of carbon deposits. The tests found that the four ground electrode spark plugs had up to 33% better cold restart reliability than conventional plugs.

Does technology used in racing plugs find its way into Bosch Premium plugs?

YES! Racing, as it has for 100 years, provides a great developmental impetus and test bed for spark plug durability and performance, and what is learned at Indy or Darlington, or Le Mans helps improve the spark plugs installed in today’s cars or trucks. From the first Indy 500 won by Ray Harroun’s Marmon Wasp to the last 17 Indy 500 winners, and many in between, each have used Bosch spark plugs. Many premium passenger car spark plugs use multiple ground electrodes and precious metals, such as platinum, which are a direct result of their development and testing in long distance racing.
See the Technical Info tab for more details on how racing improves the breed of passenger car spark plugs.

What if I do not feel a difference after I have Bosch Premium Spark Plugs installed?

Bosch guarantees that you will feel improved performance in your vehicle when using a spark plug of the Bosch Platinum Series (Platinum+4, Platinum2, and Platinum). However, if you do not experience quicker starts, smoother acceleration, and improved fuel efficiency, you can return the plugs with a dated sales receipt and Bosch will refund the purchase price of the spark plugs.
Glossary:
Multi Ground- Plugs with multiple ground electrodes are called multi ground. These plugs also use surface gap spark patterns and the multiple ground electrodes increase service life.
Surface Gap- Surface gap technology is when the ground electrode is to the side of the center electrode. There can be no ground electrode (racing applications), multiple ground electrodes (PT+4 and PT2), or a single ground electrode. These spark plugs have improved efficiency and a higher probability of igniting a lean air/fuel mixture.
Resistor- Many spark plugs have a special conductive glass seal between the center electrode and the terminal stud. This seal acts as a resistor in the plug which reduces the transmission of pulses of energy to the ignition cables. These pulses can cause Radio Frequency Interference (RFI) with electrical components in the car. For some newer cars, resistor plugs are required for effective communication between the plugs and the electronic ignition.
Radio Frequency Interference (RFI)- When the spark plug creates a spark, a high frequency burst of energy is created. If this energy was to travel through the ignition wires, it could cause interference with other sensitive electronic devices, such as the radio or electronic control units. The resistor in the spark plug reduces this energy before it causes interference with other electrical components.
Fouling- Fouling occurs when a plug becomes contaminated with fuel, oil, or other contaminates that prevent the plug from generating a spark. Most plugs today are designed to reduce fouling and become self-cleaning when they reach 500 degrees Celsius. However, short trips, low speed driving, improper spark plug heat range (too cold), improper timing, or an oil leak in the combustion chamber can cause a spark plug to become fouled.
Bridging- Over time, contaminants can build on the surface of the spark plug if it does not reach self-cleaning temperature often. These buildups can grow between the electrodes until they are actually connected by a bridge of contaminants. This will often cause misfire.
Flashover- Occurs when the spark does not jump between the electrodes within the combustion chamber, but instead jumps between the metal shell and the terminal on top of the plug. This will always cause a misfire since the air/fuel mixture will not be ignited. Bosch spark plugs have a ribbed insulator to prevent flashover.
Quenching- The purpose of a spark plug is to introduce enough heat into the combustion chamber to initiate a smooth burn of the air/fuel mixture. Quenching occurs when that heat generated by the spark is reabsorbed back into the ground electrode, the center electrode, and the ceramic insulation. To reduce quenching and ensure an efficient transfer of heat, Bosch Platinum+4 and Platinum2 spark plugs use surface gap technologies.

Spark Plugs
More than a century ago, in combination with a high-voltage magneto, Bosch presented the first spark plug. Bosch was awarded the patent for this ground-breaking system on 7 January, 1902. Manufactured using world-class Bosch technology, Bosch Ltd. Spark Plugs meets world-class standards of reliability and performance. A testimony to this is the fact that Bosch Ltd. is the preferred OE supplier for companies like Bajaj Auto, Hero Honda, Yamaha, T.V.S., Kinetic, Maruti, Hindustan Motors, PAL and M&M, to name a few.

Features - Highly effective anti-tracking barriers
Prevents arcing which would otherwise result in misfiring
- Suppression resistor
Reliable functioning of all electronic systems and interference-free radio reception
- Ground electrode
The number of electrodes, their configuration and their geometry have a decisive effect on ignition-spark techniques and service life
- Nickel-plated spark-plug shell and screw-in thread
Guards against corrosion and prevents seizure in the aluminum cylinder heads
- Heat-shrink assembly
Guarantees 100% gas tightness and precise heat rating
- Compound centre electrode
The copper core with high thermal-conductivity characteristics inside a non-wearing, chrome-nickel sheath ensures that the operating temperature is reached quickly. Protects against thermal overloading, conventional corrosion and spark erosion Range
Bosch Ltd. and BOSCH Super

• Centre electrode with non-corroding chrome-nickel sheath and copper core
  • Rapid burn-off and protection against thermal overload
  • Insensitive to shunts
  • Highly resistant to wear
• With interface suppression resistor - follows the Original Equipment trend
  • Reliable functioning of all electronic systems
  • Interference-free radio reception

BOSCH Super Plus

• The technology plus: Yttrium - the innovative alloy
  • Outstanding protection against corrosion
  •  Absolutely reliable ignition
• The Original Equipment plus: Tried and proven million times over
  • State-of-the-art technology from Original Equipment and motor racing
  • Installed by leading vehicle manufacturers at the factory
• Specially shaped ground electrode
  • Ever higher ignition reliability and better protection for the catalytic converter

BOSCH Super 4

• The technology combination which is unique throughout the world
  • Air-surface principle
  • Four, thin, ground electrodes
  • Pointed, silver-plated centre electrodes
• Optimum engine performance throughout the plug’s operating time, even under extreme operating conditions

BOSCH Super: pointed ground electrode for 2 / 3 wheelersThe ground electrode has a structured profile and is less vulnerable to wear than centre electrode. As a result, the advantages of this structured profile can be utilised throughout the entire service life of the spark plug.

• Higher ignition reliability due to faster flash-over of the spark and ignition of the mixture
• Additional cold-start reliability even when battery voltage is low
• Improved combustion protects the engine
• Since misfiring is avoided, fuel consumption drops even more

BOSCH Super: twin electrode for 2 wheelers

• Increased ignition reliability throughout the spark plug’s entire service life
• Improved cold-start characteristics
• Low ignition-voltage requirement
• Self-cleaning effects in case of sooting
• Two ground electrodes increase the plug’s service life

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