Manual Stage 3

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TEST EQUIPMENTS
USER MANUEL
CR INJECTOR STAGE 3 SET
CRST 300
CONTENTS:
1. DESCRIPTION
2. CONTACT US
3. ABOUT TEST EQUIPMENT
4. TECHINACAL SPECIFICATIONS
5. SAFETY RULES
6. THE CARRIAGE,ACCEPTANCE
7. MONTAGE AND STARTING

8. OPERATION INSTRUCTION
9.TROUBLESHOOTING
10. ACCESORIES
11. GUARANTEE RULES
12.ELECTRICAL DIAGRAM
13. CE CERTIFICATE
USER MANUAL 2
USER MANUAL 3
2. CONTACT US
USER MANUAL 4
3.GENERAL INTRODUCTIONS ABOUT TEST DEVICE
Used for Bosch 0 445 110 XXX and 0445 120 XXX Type Injectors.
You can repair 4 injectors in 30 minutes as fabrication standart.Special program includes
measurements and spare part numbers
Adjustment and measurement of new CR injectors for cars and trucks.
After pilot injection AHE is very important. Bosch CRI ver2.1 ver 2.2, CRIN-2 and CRIN-3
need these adjustment and measurement.
USER MANUAL 5
3.1 DESCRIPTIONS
1
5
3
7
4
8
1. 19” LED SCREEN

2. PAN
3. CLAMPER 125 MM
4. TROLLEY
5. RACK PANEL
6. INJECTOR AHE KIT
7. PULSE GENERATOR
8. COMPUTER
USER MANUAL 6
9 13
10 14
11 15
12
9. AIR PISTON
10. REAR COLUMN
11. AIR CONTROL VALVE
12. DOWN PLATE
13. SLIDER AXLE
14. INDICATOR HOLDER
15. INJECTOR HOLDER
USER MANUAL 7
4.TECHNICAL PROPERTIES
CRST 300
WORKING VOLTAGE 220- 230 V
TOTAL POWER 0,5 Kw
SOUND EMISSION 65 Dba
DIMENSIONS 120X 160 X 55

FREQUENCY 60 Hz
CURRENT 2,5 (A)
PROTECTION CLASS IP 20
WEIGHT 120 KG.
USER MANUAL 8
5.SAFETY RULES
5.1.GENERAL INSTRUCTIONS
Machine must be used in its purpose it is designed for. DAYEL is not
resposible in cases of injuries and demages on machine.
All the safety instrutions must be applied for avoiding damages on machine
and any injuries.
Safety applications must well known by the operator.
In addition to these all other general safety rules must be be considered.
5.2. THE RESPONSIBILITY OF CUSTOMER/
Customer is responsible for educating operator about main safety instructions
Do not connect another type or brand equıpments to the machine.
5.3.THE RESPONSIBILITY OF OPERATOR

Before starting the machine for operations, operator must to educate himself/herself
about the subjects written below,
Changed with the DEMO
BasicVERSION ofand
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instructions
Safety precautions and periodical controls.
Do not start the test if the ventilating is defective
5.4.RISCS WHILE OPERATING
All electrical equipments are potentially dangerous.
Do not placeyour hands in working zone.There are tools for claping,cutting

and drilling in working zone.
Your slow motion may cause you a harm, like hand crushing, cutting.
We advise the use of helmets, ear protectors, glasses, protective gloves etc.
Consult to your manager for rules of protection and equipment
Before starting the machine, be sure that all potential dangers are removed or
eliminated
USER MANUAL 9
5.5.SAFETY PARTS/
Before starting any maintenance or spare part changing all electricity and pressured
air suplies must be shut down. All caution signs must be in sight. These precautions
are essential.
Periodically all checkings, controls and maintenances must be done by

operator.
Before any maintenance process operator must be informed.
After maintenance process all safety system be activated.
All improper parts must be changed immediateley. All new spare parts must
be originally manufacturer’s. Other spare parts supplied by others are out
warranty.
This text only5.6. SAFETY

appears in theRULES
demo version. This text can be removed with the full version.
Please keep this operating and maintenance manual close to the machine while its
operating.
Addition to the warnings in this operators manual, please obey local

envioremantal and security rules aganist accidents .
Please follow the maintenance instructions strictly given in this manual
5.7.THE SAFETY PROTECTIONS OF ON WORKING
Ø İf is there any problem while working shut down the machine by main switch
Ø Do not open any cover of the bench
USER MANUAL 10
5.8.DANGEROUS OF ELECTIRICITY
Do not contact the machine with water or another type of liquid
5.9. SAFETY SIGN EXPLANATION

İŞARET AÇIKLAMA
CHECK THE USER MANUAL BEFORE USING
CAUTION
CARE YOUR HAND BEHIND
USER MANUAL 11
6. CARRIAGE, ACCEPTANCE AND STORING

Ø The equipment is delivered after final test on the factory.
Ø The equipment is delivered after packing on the factory
Ø Our company isnot responsible from damages with customer transportations.
Ø The Costomer must control transportation conditions before acceptance.
Ø If the customer see any damage on the equipment , must write a damage
protocol with forwarder.
Ø The customer will keep the equipment a neat and closed area up to montage
from Dayel.
Ø If the equipment doesnot use along time the customer must keep it with
original box on free of moisture environment.
6.1 PACKING AND DIMENSIONS

B type package : it’s using in domestic and international dispatching.
At first, bench covered with air bubble nylon. After covered completely with wood
material on own base line measurements.
7. MONTAGE AND STARTING

ü You should keep Trolley on a flat floor after delivery.
ü Supply voltage should be the same with bench’s label voltage .
ü Power plug must be connected with ground plug.
ü Absolutely, security introductions should checked over before the bench switch on.
USER MANUAL 12
8 OPERATION INSTRUCTION
8.1. Before Start
Set the air pistons input pressure as shown on the Picture

· 1,5 bar
USER MANUAL 13
8.2 Program Descriptions
2 3
5 4
6 9
10 11 12 14 15 16 13
1. SERIAL NUMBER SECTOIN
2. SELECTED INJECTORS VEHICLE
3. INJECTOR SERIAL ENTERANCE(DON’T DELETE DOTS)
4. SELECTED INJECTORS TYPE SECTION
5. SELECTED INJECTORS PILOT SPACE SECTION
6. SELECTED INJECTORS MAGNET SPACE SECTION
7. SELECTED INJECTORS FUEL ADJ SPACE
8. SELECTED INJECTORS OPENING PRESSURE ADJ SPACE
9. SPACE TOLERANCES OF ALL ADJUSTMENTS
10. SEL. INJ. VALVE ORDER NUMBER
11. SEL INJ NOZZLE ORDER NUMBER
12. SEL INJ BALL ORDER NUMBER
13. SEL INJ BALL METARIAL AND SIZE
14. ALLEN FORCE TORQ VALUE
15. NOZZLE HOLDER FORCE TORQ VALUE
16. COIL FORCE TORQ VALUE
USER MANUAL 14
CR1.0 SERIES
MAGNET SPACE / AIRGAP MEASUREMENT
WITH DIGITAL GAUGES
Open the AHE program from PC.and select the repaired injector
number and see the Air gap measurement from 2. step like 0.08
+/- 0.01
Remove the coil from CR injector
Take one of digital gauges for airgap measurement.

And make it zero from reset button in a a smooth surface.
Connect it the calibrate tool and

reset zero and
see 0.00 mm
Connect one of them to body and the other to coil.

Note the values on the screen displayed 5.47 and 5.51
The difference is 0.04 mm it is less than 0.08.
Please find find 0.04 mm thicker shim and put there.
Note the values on the screen displayed 5.4 and 5.51

The difference is 0.07 mm
It is ok 0.08 +/- 0.01
USER MANUAL 15
CR1.0 SERIES
AHE MEASUREMENT
Open the AHE program from PC.and select the repaired injector
number and see the AHE measurement from 2. Step
like 0.040 +/- 0.002
Remove the coil and connect analog gauge and press the top button.
Measure it must be 0.04 but it shows here 0.07
please find a shim 0.03 mm thinner difference.

AHE Analog grob measurement.:

Change this new shim and by pressing top button , measure again
It shows 0.04 mm
AHE digital fine measurement:

Please put it for presecion measurement to AHE clamper.
Fix it from bottom lathe head as vertical and from top with air with 1.5
bar.
And give a pulse from simulator to measure it .
It shows 0.040 mm. That is OK.
USER MANUAL 16
CR1.0 SERIES
FUEL TABLET 2,3 mm
MEASUREMENT TYPE 1
Open the AHE program from PC.and select

the repaired injector number and see the
step 3 for fuel adjustment like 0.42 +/- 0.02
Open the the nozzle holder from bottom and

remove the nozzle.
Connect analog gauge to injector body.
Measure from reverse side (red scale)

Adjust with 2,3 mm tablet shim for 0.42 mm
USER MANUAL 17
CR1.0 SERIES
FUEL TABLET 8.40 mm
MEASUREMENT
TYPE 2
Open the AHE program from PC.and select

the repaired injector number and see the
step 3 for fuel adjustment like 0.20 +/- 0.01
This text only appears in the demo version. This text can be removed with
Open the the the full
nozzle version.
holder from bottom and
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the nozzle.
Connect analog gauge to injector body
Measure from reverse side (red scale)

Adjust with 8.40 mm tablet shim for 0.20 mm
USER MANUAL 18
CR2.1 SERIES
AHE MEASUREMENT
Open the AHE program from PC.and select the

repaired injector number and see the AHE
measurement from 1. Step
like 0.045 +/- 0.002

Please put it for presecion measurement to AHE
clamper.
Fix it from bottom lathe head as vertical and from top
with air with 1.5 bar.
Reset the value to 0.000 And give a pulse from
simulator to measure it .
It shows 0.079 mm. Change the shim
Please find find 0.79-0.45= 0.34 mm thiner shim (under

coil) and put there.
And give a pulse from simulator to measure it .

It shows 0.044 mm. That is OK.
USER MANUAL 19
CRIN-1 SERIES
AHE MEASUREMENT
WITH ANALOG GAUGES

like 0.050 +/- 0.003
Remove the coil from injector.
Make the gauge zero at the smooth surface and
connect to body.
Press the top button for analog AHE measurement
See from reverse side ( Red Panel) 0.05 mm
That is OK.
USER MANUAL 20
CRIN-1&2 SERIES
AHE MEASUREMENT
WITH DIGITAL GAUGES

like 0.050 +/- 0.003
Remove the plastic and ball holder allen nuts from top
of truck injectors for needle hole.
Please put it for presecion measurement to AHE

clamper.
Fix it from bottom lathe head as vertical and from top
This text only appears in the demo version. This text with
canair bewith
removed
1.5 bar. with the full version.
Change truck adapters and connect the proper cables.
Reset the gauges to 0.000 mm

Give a pulse from simulator to measure it .
It shows 0.061 mm. Change the shim 0.011 mm
thinner to bring it to 0.050 mm.
USER MANUAL 21
CRIN.1 SERIES
MAGNET SPACE
MEASUREMENT WITH
DIGITAL GAUGES

repaired injector number and see the Air gap
measurement from 2. step like 0.08 +/- 0.01
Digital gauge for body aparat:

Take one of digital gauges for airgap
measurement.
And make it zero from reset button in a a smooth
surface
Digital gauge for coil aparat:

This text only appears in the demo version. This text canConnect
be removedit the calibrate
with thetool
full version.
Changed with the DEMO VERSION of CAD-KAS PDF-Editor Reset(http://www.cadkas.com).
it to zero
And remove the tappet calibrate tool
Connect both digital gauges to coil and body.

Note the values on the screen displayed 5.74 and
5.93
The difference is 0.19 mm thicker than 0.08 mm.
Please find a 0.11 mm thinner shim to bring it 0.08
mm.
USER MANUAL 22
9.MAINTENANCE AND TROUBLESHOOTING
9.1 MAINTENANCE
DESCRIPTION MAINTENANCE TIME

1. DIGITAL GAUGES CALIBRATION PER 1 MONTH
2. ANALOG GAUGES CALIBRATION PER 2 MONTH
3. TORKMETER CALIBRATION PER 12 MONTH
This text only9.2 TROUBLESHOOTING

appears in the demo version. This text can be removed with the full version.
DEFECT AND COUSE SOLUTION
PROBLEM
Although the system · Electrical defect · cable and connection
switch is on but no control
energy on the system. · fuse control
Injector in not pulsing Electronical defect · Mainboard or swithmode

problem
Digital gauges in not Elecronic defect Battery empty

measuring Gauges damged
Computer is not Electrical defect · Software damaqed
opening · Power supply defect
· Screen damaged
USER MANUAL 23
10. ACCESORIES
DRAWING DESCRIPTION QUANTITY
AHE MEASUREMENT TOOL 1 PIECE
INJECTOR HOLDER 1 PIECE
AIR PISTON 1 PIECE
LKW INJECTOR AHE

1 PIECE
MEASUREMENT APARAT
PKW INJECTOR AHE

1 PIECE
MEASUREMENT APARAT
AHE PULSE SIMULATOR 1 PIECE
PULSE CABLE
1 SET
LKW-PKW
USER MANUAL 24
POWERCABLE FOR
1 PIECE
SILMULATOR
PC –LCD-MOUSE-
1 SET
KEYBOARD
USER MANUAL AND

PROGRAM INSTALLATION 1 PIECE
CD
TROLLEY WITH PANEL 1 SET

CLAMP 1 PIECE
DOUBLE HANGER 8 PIECES
SINGLE HANGER 6 PIECES
USER MANUAL 25
AHE MEASUREMENT
1 PIECES
GAUGE 0.001 TYPE
NEEDLE 2 PIECE
DIGITAL GAUGE TYPE1 1 PIECES
DIGITAL GAUGE TYPE2 1 PIECE
ANALOG GAUGE TYPE1 1 PIECE
USER MANUAL 26
ANALOG
1 PIECE
GAUGE TYPE2
ANALOG
1 PIECE
GAUGE TYPE3
This text only appears in the demo version. This text canANALOG
be removed with the full version.
Changed with the DEMO VERSION of CAD-KAS PDF-Editor (http://www.cadkas.com). 1 PIECE
GAUGE TYPE4
THIN GAUGE 1 PIECE
10 MM ALLEN 1 PIECES
INJ. CLAMP 1 PIECES
DOUBLE ENDED
1 PIECES
RING WRENCH
USER MANUAL 27
HENRYMETER 1 PIECES
DIGITAL
1 PIECES
MICROSCOBE
MICROSCOBE
1 PIECE
STAND
TORKMETER
This text only appears in the demo version. This text can be removed 1 PIECE
with the full version.
Changed with the DEMO VERSION of CAD-KAS PDF-Editor 20-100 NM
(http://www.cadkas.com).
TORKMETER
TOOL 2 PIECES
29-30 MM
SHIM AND 1 SET
EASY FIBER
1 SET
APARAT
USER MANUAL 28
11. GUARANTEE RULES
· The tester is to be under guarantee that you must use it like user manual
instructions , also maintenance is made by authorisized personel.
There is no guarantee as follows:

· If there is a repair or revision except Dayel.
· İf there is usıng an unoriginial spare part.
· İf there is changement on tester label or it’s guarantee papers.
· The waste spare parts belong to tester dont have any guarantee time.
· The necessary maintenance must be on time ,regularly.
USER MANUAL 29
12.ELECTRICAL DIAGRAM
USER MANUAL 30

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Manual Stage 3

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Changed with the DEMO VERSION of CAD-KAS PDF-Editor (http://www.cadkas.com).

CR INJECTOR STAGE 3 SET

3. ABOUT TEST EQUIPMENT

7. MONTAGE AND STARTING

11. GUARANTEE RULES

3.GENERAL INTRODUCTIONS ABOUT TEST DEVICE

Adjustment and measurement of new CR injectors for cars and trucks.

need these adjustment and measurement.

1. 19” LED SCREEN

DIMENSIONS 120X 160 X 55

Safety applications must well known by the operator.

In addition to these all other general safety rules must be be considered.

5.2. THE RESPONSIBILITY OF CUSTOMER/

Customer is responsible for educating operator about main safety instructions

Do not connect another type or brand equıpments to the machine.

5.3.THE RESPONSIBILITY OF OPERATOR

Safety precautions and periodical controls.

Do not start the test if the ventilating is defective

5.4.RISCS WHILE OPERATING

All electrical equipments are potentially dangerous.

Do not placeyour hands in working zone.There are tools for claping,cutting

Consult to your manager for rules of protection and equipment

Periodically all checkings, controls and maintenances must be done by

Before any maintenance process operator must be informed.

After maintenance process all safety system be activated.

This text only5.6. SAFETY

Addition to the warnings in this operators manual, please obey local

Please follow the maintenance instructions strictly given in this manual

5.7.THE SAFETY PROTECTIONS OF ON WORKING

Do not contact the machine with water or another type of liquid

5.9. SAFETY SIGN EXPLANATION

CHECK THE USER MANUAL BEFORE USING

CARE YOUR HAND BEHIND

6. CARRIAGE, ACCEPTANCE AND STORING

6.1 PACKING AND DIMENSIONS

7. MONTAGE AND STARTING

8.1. Before Start

Set the air pistons input pressure as shown on the Picture

8.2 Program Descriptions

Remove the coil from CR injector

Take one of digital gauges for airgap measurement.

Connect it the calibrate tool and

Connect one of them to body and the other to coil.

Please find find 0.04 mm thicker shim and put there.

Note the values on the screen displayed 5.4 and 5.51

please find a shim 0.03 mm thinner difference.

AHE Analog grob measurement.:

AHE digital fine measurement:

Open the AHE program from PC.and select

Open the the nozzle holder from bottom and

Measure from reverse side (red scale)

Open the AHE program from PC.and select

Measure from reverse side (red scale)

Open the AHE program from PC.and select the

AHE digital fine measurement:

Please find find 0.79-0.45= 0.34 mm thiner shim (under

And give a pulse from simulator to measure it .

Open the AHE program from PC.and select the

Remove the coil from injector.

Open the AHE program from PC.and select the

Please put it for presecion measurement to AHE

AHE digital fine measurement:

Open the AHE program from PC.and select the

Digital gauge for body aparat: