Technical Information

Bulletin No. 195/33

Hartridge Limited, The Hartridge Building, Network 421,
Radclive Road, Buckingham, MK18 4FD, United Kingdom
Tel: +44 (0) 1280 828 420 Fax: +44 (0) 1280 828 421
E-mail: sales@hartridge.com Web: www.hartridge.com

Product: HF1153 Bosch CP4 Common Rail Pump Test Kit

Subject: Installation & Operation

1. Introduction
This bulletin describes the Bosch CP4 Common Rail pumps, and how they can be tested using the All Makes
Pump Test Kit (HF1130) along with the specific mounting parts.

NOTE: This bulletin should be read in conjunction with manual ref HL025 which gives overall information about
using the All Makes Pump Test Kit (HF1130), and manual ref HL024 which describes the HB378 CR
Base Kit.

2. CP4 Principle of Operation

There are two variants of Bosch CP4 pump. The CP4.1
which has a single pumping cylinder and the CP4.2
which has 2 pumping cylinders.
For the CP4.2 variant (pictured) the pumping cylinders
are offset by 90 degrees. A double lobed cam on the
shaft drives both cylinders. The lobes on this cam are
offset by 180 degrees. This allows each cylinder to
pump twice per revolution. This pump variant has two
HP outlets of delivering half of the total output over one
revolution.
The CP4 control valve is a proportional valve (“inlet
flow control” type); it is situated on the input side of the
pump and varies the amount of fuel going into the
pumping chambers, therefore varying the output flow.
A typical curve of flow versus current applied is given in
Figure 1.
NOTE: Inlet flow control valves can work in different
senses depending on the vehicle application.
This is shown by the solid and dotted lines in
cc/min

the figure, i.e. either “energise for no flow” or

“energise for maximum flow”. It is important
to establish which sense the valve operates
before running at high speeds or high
pressures.
On the vehicle, rail pressure is controlled closed loop
as for other Bosch CR pumps, however in this case
varying the inlet solenoid demand in order to achieve
the required pressure and flow conditions.

I
Figure 1: CP4 Current vs. Flow Relationship

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3. Pump Type Codes
The type code on the pump serial plate gives some 1: Common Rail designation
useful information such as the drive direction and
2: Pump Family
theoretical output, e.g.
3: Drive direction (L or R)
3
4: Theoretical pump output in mm /rev divided by
CR / CP4HS2 / R90 / 40 3
10, e.g. 90 means 900mm /rev.

1 2 3 4

4. Kit Installation
4.1 Tank Return Hose
Route the open end of Tank Return Hose ALP372 under the bedplate mounting bar and into the return tank.
Refit the covers so that the connector end of the hose is accessible at the front of the machine (route through
front table semi-circular cut-out). This hose can remain permanently fitted to the machine.

5. Test Setup
5.1. Pump Mounting and Low Pressure Connections
The mounting parts required for each application are shown in the table below:

Pump Ref. App. Mounting Plate Inlet & Return Drive / Coupling Cable
Hyundai APB333
0445 010 511 R 2 off ALP388 25mm Taper FP383 A086E928
Kia 3 off M8 x 35
APB333
0445 010 622 Ford R 2 off ALP366 25mm Taper FP383 A086E928
3 off M8 x 35
APB333 ALP366 (10mm) &
0445 010 669 VW R 25mm Taper FP383 A086E928
3 off M8 x 35 ALP389 (12mm)

Connect the supply and return pipes to the AVM2 bulkhead connections. Arrows indicate the inlet and outlet on
the pump body; follow these to ensure correct connection to the facia of the AVM2-PC.

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 5.2. Test System Connections

AVM2-PC
Console

RPM EXT1
EXT2 – A086E913
Guard
AE31 – CR Pump Controller

Bosch Pump Cable

A086E928
Rail Pressure HP Pipe – A079B114

QR Pipe – A069B013
HP Hose – A079B112
Drive Coupling CP4.2
FP383
Pump Plate HP Hose – A079B115
DV Bottom Port Adaptor & Seal
APB333
A069B263 & 8557121
AVM2-PC
See Detail A Metering Unit
AVM2-PC
Facia

Supply/Return Fitting
ALP366 or
ALP388 or
ALP389

CR Guard Area – Rated to 2000 Bar

NOTE: When testing a 2 cylinder pump (0445 010 622/669), It is possible for the operator to measure one
cylinder at a time using the following method:
 Remove A069B263 port adaptor from the underneath of the Dump Valve
 Replace with A069B261 M14 blanking plug
 Connect ALP373 to HP port of the cylinder that is not to be measured
 Connect ALP373 to the ALP372 tank return house installed earlier (Section 4.1)

0445 010 669 ONLY

HP Pipe Assy
AHP5245

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All Listed Pumps

Pump HP Connection HP Seal Insert HP Outlet Adaptor

M16x1 AHP178 AHP177

NOTE: HP SEAL INSERT AHP178 IS TREATED AS A CONSUMABLE. ITS CONDITION SHOULD BE

MONITORED OVER TIME
Detail A - Pump HP Outlet

5.3. Test Parameters/Limits

Supply Temperature - 40°C (+/- 2°C)
Supply Pressure - 4.5 Bar (+/- 0.5 Bar)
Engine/Pump Speed Ratio - 2:1

6. Software
When the AE31 is switched on, the software will detect that a Bosch pump is fitted and ask you to select the
pump type; select CP4. Please note only versions of Magmah beyond and including v40.07 are compatible with
testing Bosch CP4 pumps.

The pump setup window for CP4 is shown in Figure 2. The common features of the screen are explained in
manual HL025. The parts/settings specific to CP4 are explained below:

FCV Use the “Ω” button to check the FCV resistance.

Set the required current demand and monitor the actual value (feedback). The range of
operation of the particular pump under test should be established during the warm up phase.
NOTE: keyboard shortcut F2 can be used to edit the current demand.

Supply Voltage Set to 12V.

PWM Frequency Set to 250Hz.

NOTE: Solenoid resistance checks can only be done with the drive stationery. Changes to the Supply Voltage,
PWM Frequency, and FCV demand are only implemented when Apply (F1) is pressed.

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 Figure 2: Pump Setup Dialog Box

7. Example Testplan
Users can set up individual test conditions manually as required, or create a semi-automatic testplan in Testplan
Editor to run through a series of different test steps.

Pump
Pump/Engine Output IMV Current
Test Step Result
Speed (RPM) Pressure (Amps)
(Bar)
1. Resistance Test 0 RPM 0 Bar 0.0 Ω
2. Cranking 200 RPM 300 Bar 0.0 mm3/st
3. Idle 800 RPM 500 Bar 0.0 mm3/st
4. Peak Torque 1600 RPM 2000 Bar 0.0 mm3/st
5. Max Power 2800 RPM 2000 Bar 0.0 mm3/st
1000 Bar 0.0 mm3/st
1.0 mm3/st
6. IMV Shut Off 1600 RPM
1.5 mm3/st
2.0 mm3/st

Step 1 is a resistance check on the FCV solenoid (this can be done on the vehicle before the pump is removed).
Steps 2 - 5 are tests of output flow across the range of engine conditions.

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It is also important during this phase, if it is a pump model that you have not tested before, to establish the sense
and range of operation of the FCV, i.e. is it “energise for maximum flow” or “energise for no flow”? Refer to
Section 4.4 in manual HL025.
CAUTION: The FCV current settings in this testplan are given for an “energise for no flow” valve. If the
valve is an “energise for maximum flow” type then the demand values should be inversed,
i.e. where this testplan calls for 0A, this is to give maximum flow, and so this should be
replaced by 1.5 to 2A, depending on the range of operation.
Step 6 is to test the function of the IMV. This is carried out by gradually increasing the current to the valve. As
more current is provided the flow should be restricted. These test conditions should cause a full closure of the
IMV giving close to zero output flow.
NOTE: The backpressure at step 6 is not important; set the pressure at the initial condition and allow the
pressure to fall as the IMV valve is closed.
Before stopping the bench, run at a reduced speed and pressure for a couple of minutes to allow the pump to
ease down.
The estimated time for completing a pump test like this is 20 minutes.

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