bosch common rail catalogue.pdf

7/23/2019 Bosch Common Rail Catalogue.pdf

1/12

Common Rail injectorsTesting, dismantling, and now-precision repair


2/122

1998 2001 2004 2007 2010 2013 2016

Rapid developments in diesel technology

Technical innovations are bringing change to the world

of diesel at an ever accelerating pace. The main drivers

of this trend are new legal requirements, more stringent

emissions standards and also new system functionality,

such as pre-injection.

Bosch boosting diesel popularity

State-of-the-art diesel systems from Bosch, featuring

Common Rail high-pressure pumps and injectors, have

not only set the standard for modern-day diesel vehicle

performance. They have also made diesel more popular

thanks to the fuel economy and smoother drive they

offer. Bosch has to date fitted more than 50 million

diesel injection systems as original equipment world-

wide. And that means an incredible total of over

350 million injectors.

Diesel success as a service opportunity

There are large numbers of diesel-powered vehicles onthe roads, and so more and more vehicles with high-

pressure injection systems are being brought into

service centers for diagnostics, testing and repair.

In order to provide diesel customers with professional,

cost-effective repair solutions, it is becoming ever more

vital for vehicle service centers to have expertise in the

latest fuel injection systems.

CRI (Common Rail injectors for passenger cars) and

CRIN (Common Rail injectors for commercial vehicles)

on the diesel service market

Testing and replacement of injectors is becoming an ever

more vital part of diesel service. Emissions are subject

to increasingly tight controls. Engine performance and

fuel efficiency have to be balanced. Consequently, CRI /

CRIN servicing is becoming a benchmark for customer

satisfaction.

Benefits from the complete injector servicing package:

What began in 2005 as merely a nozzle replacement

service has since grown into a complete backup package.

Immediately you can:

Interchange all injector components Service all current Bosch solenoid-controlled

injectors till up to 1800 bar (CRI 1.0-2.2; CRIN 1-3)

to factory standard

Take on practically any repair job

350 million Common Rail sales figures

injectors in Europe

Com.veh. (CRIN)

Cars (CRI)

Trend on the diesel market

Common Rail injector repair:Opportunities for service centers


3/123

2

3

Tools for complete repairof Common Rail injectors


4/124

Complete tool set

Repair toolsfor Common Rail injectors

The right tools for efficient repair

To ensure professional repair of Common Rail injectors

for cars and commercial vehicles (CRI / CRIN) by service

centers, Bosch provides a set of precision tools specially

tailored to the demands of modern-day diesel products.

Digital dial gage CRR 420

Bosch service equipment is subject to the same

standards as are applied in injector manufacture.

As one illustration, the digital dial gage measures

to an accuracy of 1 / 1000 mm.

Assembly and measurement fixture

The data recordings by the digital dial gage and measurement

adapters are reliably and accurately saved to the service program.

Digital angle / torque wrench CRR 320

The unit's integrated database enables it to handle any

tightening torques and angles, such as on measuring tools,

nozzle retaining nuts and valve clamping screws.

Measurement adapters and calibration tools

The package of measurement heads, adapters, calibration

fittings and component fixtures enables all injector

components to be precisely calibrated.

Assembly and measurement fixture

Digital dial gage with pneumatic damper Measurement adapters and calibration tools Digital angle / torque wrench


5/125

Armature stroke control unit CRR 220 /

Pneumatic control unit CRR 120

A pneumatic control unit and defined application of

measurement forces ensure reproducibility of measured

values and conformance to tolerances within the m range.

The repair software CRR 920

For efficient calibration of functional parameters,

data recording and calculation of shim thicknesses

for the respective processing step.

Pneumatic fitting tool CRR 130

Depending on the injector type, solenoid assemblies

may be fitted with a stop sleeve. To remove and refit it,

a defined force needs to be applied, with a short press

time, activated by the pneumatic control unit CRR 120.

CRI / CRIN shims

A wide range of options (shim graduations from

2 to 10 m) are available for injector adjustment.

The color coding simplifies finding the appropriate

washer(s).

Armature stroke and pneumatic control units Repair software CRI / CRIN shims

Pneumatic fitting tool


6/126

Optimal repair sequence

The various individual steps must follow one another

exactly for the repair:

Measurement "Armature stroke, electric"

For a time-saving receiving inspection

Measured value NOK, injector faulty

Start of repair: Clean thoroughly in ultrasonic bath,

disassemble injector

Measured value OK

Hydraulic test on test stand

Visual inspection(based on fault illustration diagrams

from the service manual). If defective parts are

identified, they are replaced.

Calibration of functional parametersand step-by-

step assembly of the injector.

Interim check: Electrical armature stroke measure-

ment, revealing possible assembly errors (e.g. valve

ball forgotten).

Measured value OK, repair completed

Test on the EPS 815 / EPS 708, determine code as

necessary.

Armature stroke / pneumatics control unit measurementDial gage, measurement adapter and angle / torque wrench

The systematic approach to repair:Sequence outlined briefly


7/127

Servicing systemsdelivering genuine benefit

The software indicates which shim is needed Shim fitting

Repair software with user guidance CRR 920

Simple sequencing of complex repair procedures

Software calculates required shim thickness for

precision calibration without rework

Tightening torques and angles directly from a database

No need for time-consuming manual adjustment of

torque and rotation angle disk.

Upgraded fitting tool

No need for time - consuming switching to different

fixture during assembly.

Groundbreaking full repair package

Replacement of injector body, all component

assemblies and single parts

Repair options for defects which were until now not

repairable

Efficient servicing based on coordinated tooling and

user guidance

Optimum injector setting based on use of specially

graduated shims


8/128

Protecting investment:Reuse of repair tools

Injector fitting tool, stage 1 Case with special tools for stage 2

Previous repair stages still in operation

Carrying out repairs to diesel components is nothing

new to you, and you have already invested in the first

stages of the CRI /CRIN repair package. You can continue

to use the stage 1 fixture for removal. The stage 2 fixture

will serve in future as a fitting and measuring tool. This

approach is a practical aid in attaining the essential

degree of cleanliness. The dismantling and assembly

processes are strictly separated.

Stage 1: Nozzle replacement

Stage 1 of the CRI and CRIN repair package comprises

the tool set for replacement of the diesel injector nozzles.

Stage 2: Replacement of the high-pressure sealing ring

The stage 2 procedure can also be applied to replace the

high-pressure ring on the Common Rail injector.

Stage 1: Nozzle replacement Stage 2: Replacement of the high-pressure sealing ring


9/129

7

3

2

1

4

5

67

Cleanliness is essentialto diesel repair

1 Washing station with component washing machine

and ultrasonic cleaner

2 Airlock access for material

3 Airlock access for personnel with dust-binding mat

4 Dismantling station

5 Component washing station with Bekanol bath, ultrasonic

cleaner (replacement parts) and drying trough

6 Assembly station

Parts store

A work bench for professionals Practical layout of a service area

Ultrasound bath: thorough cleaning

High-efficiency pressure jets from state-of-the-art ultra-

sonic systems ensure that all parts, including the fine

nozzle holes of the injectors, are cleaned without damage.

A work bench that assures top quality

The diesel work bench is the essential basis for

professional, error-free repair of all diesel

components, from conventional systems to state-of-

the-art diesel injection technology. It may be fitted outwith different tool boards depending on the repair case.

Cleanliness, cleanliness, cleanliness!

Cleanliness is vital when working on diesel equipment.

The electrical and mechanical components of modern-

day diesel systems are subject to the highest quality

demands. That is true especially of high-pressure pumps

and injectors in Common Rail systems. Even the tiniest

contaminants can cause them to malfunction.

Divided room concept

Spatial separation of the preliminary cleaning step out-side the "closed room" from the disassembly, cleaning

of the individual parts and assembly steps inside the

"closed room" is important. Appropriate furnishing of

the work room optimizes these operations.

State-of-the-art diesel work benchEverything exact: the workshop magnifierCleaning in an ultrasonic bath


10/12

Accessory set CP1

Accessory set CP2

Accessory set CP3

Supplementary set

CRI 846 H for cars

Supplementary set

CRI / CRIN 848 H

CRIN for

comm. veh.

CRI Delphi /

Denso

CRI

Piezo

CRI 2.5(CRI 2-18, 2-20)

Accessory set CP4

Accessory set CB18

Accessory set CB28

Accessory set CP

Delphi/Denso/Siemens

Adapter set for newinjector generation

10

Bosch testing systemsfor Common Rail injectors

ESI[tronic] 2.0 softwareEPS 815: The professional test rig for diesel components

Precision testing after full service

The latest Bosch field service concept (designated FIS)

for solenoid-controlled injectors now expands the

possibilities of diesel servicing even further. After

servicing, the injection quantities of the injectors are

tested in the tried and proven way.

Precision is the key

Common Rail injectors are high-tech components which will

work properly only if they are kept within the tightest tole-

rances. That is demonstrated by the check using the EPS 815

and the corresponding supplementary equipment sets.

EPS 815

Dieselinjection pump

test rig

CRS 845

Common Railpump

supplementary

equipment set

Test kit for EPS 815 for the testing of Common Rail overview of components


11/1211

ESI[tronic] 2.0, training and hotline:Complete service support

Service training: the ideal tuition for the full range of repair procedures

Technical hotline and knowledge databaseESI[tronic] 2.0: Modular workshop software Training: for field repair procedures

ESI[tronic] 2.0: Software for diesel service

The entire diesel testing and repair procedure is soft-

ware-controlled. ESI[tronic] 2.0 from Bosch provides the

service center with the necessary target and actual value

data.

ESI[tronic]-K:Component repair instructions

ESI[tronic]-D: Diesel replacement parts

ESI[tronic]-W: Test values for in-line and distributor

injection pumps and software for injector repair

TestData CD

Test and setting values for VP29/30/44 and test values

for CR pumps, CR injectors, UI and UP products.

Know - how built on diesel training is the basis

A key prerequisite for the correct use of injector repair

tools is an induction course at a Bosch Training Center.

It is particularly important to take the course when

preparing to handle complex servicing procedures such

as CRI / CRIN.

Technical hotline provided by the diesel specialists

Saving you both time and money, the Hotline will help

you deal with any problems in repair and repair work.

Advice is on hand from experts with years of experience

in automotive engineering, backed by all the original

equipment know-how and comprehensive strength that

only Bosch can offer.

Bosch diagnostics: the full package

Bosch offers diesel service centers a full range of

equipment and comprehensive backup in all workshop

matters:

Testing systems

ESI[tronic] 2.0 software

Special tools

Service training

Technical hotline


12/12

What drives you,drives us.

Technology from Bosch is used in practically every vehicle in the world.For us, the focus is on people and helping them to stay mobile.

We have been dedicated to people for more than 125 years with our

pioneering spirit, research, production and expertise.

Our dedication is an unwaivering commitment to providing themwith a unique combination of parts, diagnostics, workshop equipmentand services:

state-of-the-art solutions for efficient vehicle repairs

innovative workshop equipment and software also available onfavorable lease terms

the worlds largest range of new and remanufactured spare parts

fast, reliable delivery service

expert customer care via our hotline

extensive range of training courses

specific sales and marketing support

plus many other services

Bosch products and services

Diagnostics

Diesel systems

Gasoline systems

Brake systems

Spark plugs

Energy systems

Batteries

Filters

Wiper systems

Light technology

Comfort electronics

Hybrid/e-mobility

Technical hotline

Knowledge database

Service training

Workshop concepts

Bosch electronic repair service

Fair repair: repairs in line with the market

value

Fast and reliable: most work completed

within 48 hours

Quality remains priority: Bosch is committed

to this as a globally leading original equiment

manufacturer

Find out more at:

https://www.bosch-repair-service.com/

Robert Bosch GmbH

Automotive Aftermarket

Business Unit Automotive Service Solutions

73201 Plochingen

Germany

www.bosch-workshopworld.de

AA-AS/MKCF026P02825/201408

Subjecttotechnicalandp

rogramc

hanges.

bosch common rail catalogue.pdf

Documents