Component Orientation – CR Injector

Common Rail Injector

A brief overview by

Prashanth S, Mico/ECC11

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector

Contents:

¾ Overview

¾ Injector Function

¾ Mounting of Injector on Engine

¾ Injector handling and identification

¾ Testpoints & Measurement

¾ Summary

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector

Contents:

¾ Overview

¾ Injector Function

¾ Mounting of Injector on Engine

¾ Injector handling and identification

¾ Testpoints & Measurement

¾ Summary

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Component Orientation – CR Injector
Common Rail System Overview

Pressure Control Valve Rail Pressure

(DRV) Common Rail Sensor
(RDS)

High
Pressure
Pump Metering Unit

Fuel Filter
Injector

ECU

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector

Contents:

¾ Overview

¾ Injector Function

¾ Mounting of Injector on Engine

¾ Injector handling and identification

¾ Testpoints & Measurement

¾ Summary

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Component Orientation – CR Injector
Injector Overview

High pressure fitting

Body
Magnet group
Armature group
Valve group

Nozzle

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Component Orientation – CR Injector
Injector function

Low Pressure

High Pressure

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Component Orientation – CR Injector
Injector function
Electro Magnet

Valve spring

Armature plate

Stopper plate

Armature spring

Armature bolt

Ball guidance

Ball
MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Component Orientation – CR Injector
Injector function
Electro Magnet

Valve spring

Armature plate

Stopper plate

Armature spring

Armature bolt

Ball guidance

Ball
MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Component Orientation – CR Injector
Injector function

Nozzle needle

Ball

A-throttle

Valve piston
Nozzle
MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Component Orientation – CR Injector
Injector function
Nozzle needle

Ball

A-throttle

Valve piston
Nozzle

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector

Contents:

¾ Overview

¾ Injector Function

¾ Mounting of Injector on Engine

¾ Injector handling and identification

¾ Testpoints & Measurement

¾ Summary

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Component Orientation – CR Injector
Injector Mounting

• Injector guided at two different diameters (Ød1

& Ød2)
• Ød1 = Guidance diameter at the Nozzle
retaining nut
• Ød2 = Guidance diameter at the Injector body.
As high as possible, below clamping but
minimum of 57.0mm between two guidance.
d2

5min
• An axial force of 7000 – 9000N to be ensured
on injector clamping by customer.

57 min

12min
d1

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector

Contents:

¾ Overview

¾ Injector Function

¾ Mounting of Injector on Engine

¾ Injector handling and identification

¾ Testpoints & Measurement

¾ Summary

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Component Orientation – CR Injector
Injector Handling – Key points

• Clamping saddle – Not to be removed

• Caps – To be removed only shortly before assembly process

• HP Connector – Hold during disassembly / assembling of HP pipe.

• Magnet head – No tool (wrench) should be used.

• Copper washer – Replace even when injector is loosened.

• Nozzle shaft – Not to be cleaned by wire brush. Only by Ultrasonic

bath
MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector

Identification of Injector:

Shfit/Line/Clamping
Daily Production Amount station

Manufacturing date
Production plant code

IQA - Data Matrix Code

(for EOL use)
IQA – Alpha Numeric
Code (for field use)
Bosch part number

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector

Contents:

¾ Overview

¾ Injector Function

¾ Mounting of Injector on Engine

¾ Injector handling and identification

¾ Testpoints & Measurement

¾ Summary

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Component Orientation – CR Injector
Characteristic Map - Representative
120
10

100 7
Quantity( mm3/stroke)

80 3
Quantity( mm3/stroke)

2
VE2 1200bar ~240µs VE1 600bar ~290µs
1

0
0.1 0.15 0.2 0.25 0.3 0.35 0.4
60 Energising Time (ms) VL 1600bar ~800µs

40
1450 bar
1300 bar
1200 bar
1100 bar
1000 bar
900 bar
20 800 bar
700 bar EM 600bar ~630µs
600 bar
500 bar
400 bar
300 bar LL 300bar ~620µs
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
Energising Time (ms)

Main Injection test points Additional Injection test points

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector

Contents:

¾ Overview

¾ Injector Function

¾ Mounting of Injector on Engine

¾ Injector handling and identification

¾ Testpoints & Measurement

¾ Summary

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
 Component Orientation – CR Injector
Benefits of CRI

Î Electronically controlled device

Î Better control of Injection quantity
Î Possibility of multiple injections
Î Injection pressure is independent of Engine speed
Î Possibility of Software correction function like IQA

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.
Component Orientation – CR Injector

Thank You

MICO/ECC1
Confidential | 786001_C_MR | 04.06.2007 | This is the exclusive property of Motor Industries Co. Ltd.
Without their consent, it may not be reproduced or given to third parties.