T-TEX CRI330 BOSCH COMMON RAIL INJECTOR MATCHING SET MANUAL (Stage3) Ertur Pazarlama Sanayi Ticaret Co. 2014-Konya/TURKEY Second Edition : February 2014 Publication Project: Assoc. Prof. Dr. Recai KUS Composition-Graphic Design: Ertur Pazarlama Sanayi Ticaret Co. Cover Design: Hanefi Turgut © The printing, publication, and sales rights of this book belong to Ertur Pazarlama Sanayi Ticaret Company without the permission of the mentioned institution, the whole or the parts of the book, and cover design cannot be reproduced, printed and distributed with the mechanical, electronic, photocopy, magnetic, recording or other methods. Ertur Pazarlama Sanayi Ticaret Co. Fatih Mahallesi, Karatay Sanayi Cebeci Sokak No: 1 42300 Selcuklu/KONYA/TURKEY Tel : +90 332 235 39 10 Fax :+ 90 332 236 08 43 Web : http://www.erturpompa.com http://www.erturdiesel.com/ E-mail : ttex@erturpompa.com - erturpompa@gmail.com Konya, Turkey - 2014 I PRESENTATION My dear colleagues, The demands that are expected from the modern engines gradually increase more. Today at the focal point, the demand not only to the environmental consciousness, but also to better fuel savings and developed driving comfort with the gradually increasing exhaust emissions also takes place. The new generation diesel engines are mainly electronic injection control Common Rail system engines. In the Common Rail system engines, there are low pressure pump transmitting the fuel in the fuel depot to the high pressure pump. The fuel coming to the high pressure pump is stored there in the rail under 1350- 1800 bar pressure. Due to the usage of the fuel which is not appropriate to the system having such high working pressure, there are breakdowns in the injectors. The common rail injector produced with the high technology work in the narrow tolerances. While the tolerances are at the level of 0,10 mm in the mechanic order fuel systems, it is at 0,001 mm sensitivity at the high technological productions. Due to the wearing of the operating parts and the falling of the tensions of the springs ensuring the operation of the injector nozzles, the operation deformations and performance losses happen in the engines. For the regular operation of the engine and the prevention of the performance losses, it is required that the injectors should be readjusted and the pairing should be realized after certain operation hours. Also, to making adjustments in the sensitivity of 0,001, the special sets and equipments are needed. The adjustment method of the Common Rail injectors which has been known till this time is that the machines and installations are tried to be adjusted by observing the spraying values. By considering the data in the control devices and the values in the software of the devices, the spraying values are tried to be balanced. The TTEX CRI330 CR injectors that we have produced is a set that provide you to make pairing in a shorter time period compared to its precedents and at the full adjustment value. TTEX CRI 330 pairing set is composed of 7 parts.        Montage set that makes the demounting and mounting of all kinds of injectors easier Calibration set for reading and adjusting the injector measurement values Electronic unit for triggering the injector coil Shim set to be used in the injector adjustment Digital microscope for clearly observing the injector part damages Torque meter for tightening of screw the injectors at the accuracy values TTEX CRI330 Software in which spare parts and adjustment values are available TTEX CRI 330 provides the following to you, dear users,  Possibility to change all components including the injector body (valve set, armature set, meme…vb.)  Possibility to make armature stroke measurement (0,001 mm)  Possibility of problem-free repair and adjustment at the optimum time by working with the special sets  Possibility of sensitive adjustment with the high quality shim set  Possibility to reach to the part numbers and adjustment values with the TTEX CRI330 software Consequently, TTEX CRI330 will provide gain to you, our dear colleagues, in the below mentioned issued.  Increased customer satisfaction with the correct adjustment operations  High performance and fuel economy of the engine  Decreasing of the emission values  Time saving ( adjusting of 4 injectors in approximately 30 minutes) This manual has been prepared with the aim of learning the usage of the TTEX CRI330 matching set step by step. Mainly, the visual issues have been given importance and each stage has been explained by being supported with the pictures. With the hope of being beneficial, I kindly present my sincere regards and respects to all of my colleagues. Mustafa TURGUT General Manager Ertur Pompa Pazarlama Sanayi Ticaret Co. erturpompa.com ttex@erturpompa.com erturpompa@gmail.com II CONTENTS I. PRESENTATION II. CONTENTS 1. INSTALLATIONS ………………………………………………………………………………1 1.1. Assembly Disassembly Set Installation …………………………… …………….2 1.2. Installation of the T-TEX software …………………………………………………6 1.3. Installation of the Microscope software …………………………………………...9 2. INJECTOR DISASSEMBLY ………………………………………………………………...11 3. DIAGNOSTICS WITH MICROSCOPE …………..………………………………………...15 4. ADJUSTMENT AND MATCHING…………………………………………………………..21 4.1. CRI – Spring Armature Group Adjustment and Matching ………………………… …22 4.1.1. Last control (spring armature)…………………………………………………… …33 4.2. Non-spring Armature Group Adjustment and Matching ………………………………37 4.3 CRIN – Commercial Vehicle Injectors Adjustment and Matching…………………48 4.4. Thrust Pin Type Injector Adjustment and Matching ………………………………..55 5. Important Torque Values …………………………………………………………………….58 6. General Last Control (CRI, CRIN)…………………………………………………………..59 erturpompa.com ttex@erturpompa.com erturpompa@gmail.com