CR Injector PkW Ps

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 (DRV)

High Pressure Pump

Common Rail

Rail Pressure Sensor (RDS)

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

5min

• Ød2 = Guidance diameter at the Injector body. As high as possible, below clamping but minimum of 57.0mm between two guidance.

12min

57 min

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

d2

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.

d1

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:

Daily Production Amount

Manufacturing date

Shfit/Line/Clamping station

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

9

8

100 Quantity( mm3/stroke)

7

Quantity( mm3/stroke)

80

6

5

4

3

2

VE2 1200bar ~240µs

VE1 600bar ~290µs

1

0 0.1

60

0.15

0.2

0.25

0.3

0.35

0.4

VL 1600bar ~800µs

Energising Time (ms)

40

1450 bar 1300 bar 1200 bar 1100 bar 1000 bar 900 bar 800 bar 700 bar 600 bar 500 bar 400 bar 300 bar

20

0 0

EM 600bar ~630µs LL 300bar ~620µs 0.2

0.4

0.6

0.8

1

1.2

1.4

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.

1.6

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.