נוהל טיפול באחריות – פריטי דיזל 1 department | 11.07.2006 | © all...

דיזל – פריטי באחריות טיפול נוהל

1 Department | 11.07.2006 | © All rights, including patent applications, reserved by Robert Bosch GmbH. All rights of disposal, including copyright and right of distribution, reserved.


2 AA/ASA | 11.07.2006 | © All rights reserved by Robert Bosch GmbH, including patent applications. All rights of disposal, including copyright and right of distribution, reserved.

. אחריות מלאה תינתן לשנה אחת ממועד החשבונית1

. לצורך בדיקת הזכאות להכרה בתביעת אחריות, חובה על הלקוח 2

לצרף לחלק

התקול את המסמכים הבאים:

ח-ן רכישה של הלקוח מחברת לדיקו

דו"ח מחשב/סורק אבחון תקלות עם קוד התקלה שמתייחס לפריט

התקול

3תיאור התקלה בטופס המצ"ב בעמוד



Test Procedure

Indication of incompletevehicle information

In warranty period

CRI/CRIN

Product information complete

1

Vehicle information complete

NoYes Reject

NoYes Reject

NoYes Reject

Indication of incomplete product information

Indication of expired warranty period

Bosch product

NoYes Reject Indication of third-party

product

Page 3


5 AA/ASA | 11.07.2006 | © All rights reserved by Robert Bosch GmbH, including patent applications. All rights of disposal, including copyright and right of Distribution, reserved.

Test Procedure

Visual check

Dismantling

Test bench audit

Further test steps:

1



Product Information

Part number

Complete product

FD

Purchase date

Failure date



Vehicle Information

Chassis numberEngine number

First registrationDate of sale

Vehicle fault code(if available)

Vehicle manufacturerEngine manufacturer

Vehicle model

Mileage



Visual Inspection

Indication of mechanical damage

Visual inspection for mechanical damage

Visual inspection for outside intervention

RejectionYes

No

Yes

No

RejectionIndication of outside

intervention

2



Visual Inspection

Visual inspection for mechanically cleaned,

brushed injectors

Indication of incorrect service center procedure

Yes

No

Rejection

Visual inspection for thermal overload of

injector

Yes

No

RejectionIndication of thermal

Overload, check engine forconsequential damage

Ultrasonic cleaning

of injector

2



Test Bench Audit

Test with Bosch test values on Bosch

EPS 815 test bench

Ultrasonic cleaning

of injector

DismantlingNo

Yes

Injector OKNo warranty case



Dismantling

Diagnosis of individual parts Evaluation against fault

symptoms catalogue

Acknowledge warranty

Observe storage periods for spare parts

Dismantle injectorin line with ESI instructions

Ultrasonic cleaning of

individual part

No

Yes

Warranty caseRejection

Reference to fault symptoms catalogue


12 Abteilung | 18.09.2006 | © Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

Automotive Aftermarket

Common Rail Injector (Passenger Car + Commercial Vehicle)

Complaint Poor performance Black smoke

Symptoms Combustion residue on outside of

injector

Possible cause Injector incorrectly installed (tightened

or twisted on one side) No sealing ring Inadequate tightening torque when

installed

Warranty decision: No warranty claim. No material or manufacturing fault







injector Sealing ring compressed on one side


or twisted on one side) No sealing ring Inadequate tightening torque when

installed








injector Escaping gas


or twisted on one side) No sealing ring Inadequate tightening torque angle







injector


or twisted on one side) No sealing ring Inadequate tightening torque angle








Symptoms Combustion residue on one side of

copper sealing ring Sealing ring compressed


or twisted on one side) Injector incorrectly installed (tightening

torque too high)


New Not OK OK





Complaint Poor performance Idling problems (vibration) Combustion noise (diesel knock)

Symptoms Thermal overload Combustion residue (coking) on tip of

nozzle

Possible cause Diesel tuning Incorrect or non-approved additives in

fuel Engine oil in intake system Oil thinning Biodiesel







Symptoms Thermal overload Injection bore burnt out Some combustion residue on nozzle

cone and shaft


fuel Engine oil in intake system, sealing

problems Oil thinning






Symptoms Thermal overload Injection bore burnt out











Symptoms Thermal overload Nozzle does not seal Nozzle tip melted










Symptoms Thermal overload Nozzle tip melted










Symptoms Thermal overload Nozzle tip melted Aluminum deposits on nozzle shaft









Symptoms Thermal overload Aluminium deposits on nozzle shaft











Symptoms Thermal overload Surface severely scarred Blue tarnish on nozzle shaft








Complaint Poor performance (vehicle)

Symptoms Injection nozzle hole diameter

constricted

Possible cause Injector cleaned improperly

(mechanically, wire brush)








Symptoms Mechanical damage to injector

Possible cause Injector cleaned improperly, evidence of

brushing on nozzle body and union nut







Symptoms Mechanical damage to injector

Possible cause Foreign parts in combustion chamber





Complaint Poor performance Start problems

Symptoms Thermal overload Nozzle needle seat worn Marked impression of injection holes on

nozzle needle

Possible cause Incorrect or non-approved additives in


problems Oil thinning Bio-diesel







Complaint Poor performance Start problems

Symptoms Thermal overload Nozzle needle broken off Nozzle needle melted

Possible cause Incorrect or non-approved additives in


problems Oil thinning Bio-diesel






Complaint Idling problems (vibration) Combustion noise (diesel knock)

Symptoms Wear on one side of nozzle needle shaft.


or twisted on one side) Ultra fine particles in fuel Incorrect assembly sequence (CRIN)







Symptoms Wear on one side of nozzle needle shaft

combined with sealing ring compressed on one side









Symptoms Circumferential wear on valve piston

Possible cause Poor, abrasive fuel (particles) Poor, inadequate filtration







Symptoms Circumferential wear on distributor

piston







Complaint Poor performance Engine running out of true Combustion noise (diesel knock)

Symptoms Oil deposits in interior of CRI Valve piston or nozzle needle sluggish

Possible cause Engine oil in fuel system Leak in engine oil lubricated CP Leak on fuel return side of cylinder head

(CRIN)







Symptoms Oil deposits in edge type filter Valve piston or nozzle needle sluggish

Possible cause Engine oil in fuel system Leak in engine oil lubricated CP Leak on fuel return side of cylinder head

(CRIN)







Symptoms Deposits in interior of CRI Valve piston or nozzle needle sluggish

Possible cause Engine oil in fuel system Poor fuel Incorrect or non-approved additives in

fuel








Possible cause Engine oil in fuel system Poor fuel Incorrect or non-approved additives in

fuel






Complaint Poor starting performance Poor performance Engine running out of true


Possible cause Water in fuel Poor fuel Inadequate filtration, poor filter quality

or filter service life exceeded







Symptoms Edge type filter corroded Nozzle needle corroded








Complaint Poor performance

Symptoms Nozzle needle corroded Edge type filter corroded








Complaint Start problems Engine cuts out during journey Poor performance

Symptoms High-pressure sealing ring worn Return quantity too high

Possible cause Old sealing ring design, modification

introduced at beginning of 2004 Support ring assembly error

Warranty decision: Warranty case

Medium

Severe





Complaint Harsh combustion noise (diesel knock) Start problems

Symptoms Foreign particles in interior of injector

(blocked inlet hole, cellulose, filter particles)

Possible cause Poor, inadequate filtration Filter element contaminated with

loose particles Incorrect filter installation







Symptoms Foreign particles in interior of injector

(packing film in inlet hole)

Possible cause Poor, inadequate filtration Filter element contaminated with

loose particles Incorrect filter installation Dirt present when installing injector or

lead







Symptoms Steel particles or high-pressure

sealing ring splinters in interior of injector

Possible cause Splinters sheared off from high-

pressure sealing ring (assembly error) Field repair concept error

Warranty decision: Warranty for new and BX items. For repaired injector, workshop is responsible.





Complaint Poor performance Start problems No injection to this cylinder

Symptoms Steel particles in interior of injector

Possible cause Assembly error Field repair concept error

Warranty decision: Warranty for new and BX items. For repaired injector, workshop is responsible.





Complaint Poor performance Start problems Idling problems (vibration) Engine cuts out during journey Return quantity too high

Symptoms Erosion wear on valve piece ball seat



נוהל טיפול באחריות – פריטי דיזל 1 department | 11.07.2006 | © all...

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