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  • Common Rail Injector Repair Procedure

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    SoeAye
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    1. Common rail injector repair involves measuring lift, stroke, and air gap values and replacing parts if deviations from standards are found. Adjustment shims of specific thicknesses are used to adjust values. 2. The document provides repair steps and specifications for three common rail injector types (CRIN1, CRIN2, passenger car) involving measuring, disassembling, replacing parts if needed, reassembling, and adjusting with shims. 3. Injector testing involves leak and fuel quantity tests at various operating points to check for issues like smoking, power loss, or emissions; quantity should be controlled and is adjusted with different shims. Proper adjustment requires all stroke measurements to be within

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    common rail injector repair procedure

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    1. Common rail injector repair involves measuring lift, stroke, and air gap values and replacing parts if deviations from standards are found. Adjustment shims of specific thicknesses are used to adjust values. 2. The document provides repair steps and specifications for three common rail injector types (CRIN1, CRIN2, passenger car) involving measuring, disassembling, replacing parts if needed, reassembling, and adjusting with shims. 3. Injector testing involves leak and fuel quantity tests at various operating points to check for issues like smoking, power loss, or emissions; quantity should be controlled and is adjusted with different shims. Proper adjustment requires all stroke measurements to be within

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    © All Rights Reserved
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    652 views4 pages

    Common Rail Injector Repair Procedure

    Uploaded by

    SoeAye
    1. Common rail injector repair involves measuring lift, stroke, and air gap values and replacing parts if deviations from standards are found. Adjustment shims of specific thicknesses are used to adjust values. 2. The document provides repair steps and specifications for three common rail injector types (CRIN1, CRIN2, passenger car) involving measuring, disassembling, replacing parts if needed, reassembling, and adjusting with shims. 3. Injector testing involves leak and fuel quantity tests at various operating points to check for issues like smoking, power loss, or emissions; quantity should be controlled and is adjusted with different shims. Proper adjustment requires all stroke measurements to be within

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    of 4

    Common rail injector repair steps

    1: CRIN1 (first generation of commercial vehicle) injector


    Common types currently available in the market; Cummins 0 445 120 ***007 121 122 123
    Komatsu excavator 0 445 120 0 Mitsubishi 6M70 engine: 0 445 120 006
    Iveco; 0 445 120 002, Dongfeng Renault; 0 445 120 084 085 and so on!
    Before replacing the valve assembly
    1, in order to do a good job in the maintenance process, when the fuel injector is
    decomposed and then decomposed, sometimes the valve components can be saved!
    The injector can be repaired only by adjustment.
    2, remove the solenoid valve to measure the armature lift (standard value: 45-50um)
    3, measuring the total stroke of the armature (standard value: 85-95um)
    4, measure the remaining air gap (standard value: 35-55um)
    5, if the deviation is not large, the injector replacement valve assembly
    6, when the nozzle is removed, the nozzle of the nozzle is measured by the way
    (depending on the horsepower)
    After replacing the valve assembly
    1. Measure the lift of the nozzle needle valve and determine the thickness of the
    needle valve gasket (the horsepower is not the same size)
    2, measure the total stroke of the armature, determine the thickness of the circlip
    3, measure the armature stroke, determine the thickness of the hexagonal gasket below
    4, measure the remaining air gap, determine the thickness of the above hex gasket
    After assembling the injector
    Pre-spraying is not suitable to adjust the solenoid valve spring force adjustment gasket
    Idle speed is not suitable to adjust the needle needle valve spring force washer

    1, armature lift adjustment pad B12 0.900-1.500 each piece difference 0.01
    2, the remaining air gap adjustment gasket B11 0.900-1.500 each piece difference 0.01
    3, nozzle lift adjustment gasket B16 0.910-1.400 each piece difference 0.01
    4, nozzle needle valve spring force adjustment gasket B13 1.000-1.960 each piece difference 0.02
    5, solenoid valve spring force adjustment washer B14 1.000-1.860 each piece difference 0.02
    6, circlip
    7, armature total stroke adjustment circlip B37 1.155-1.265 each piece of difference 0.01

    2, CRIN2 injector (second generation of commercial vehicle cart), common injectors are as
    follows
    Xichai; 081 078 215, etc.
    Weichai: 086 170 169 149 159 213 214 224 265 etc.
    Yuchai: 110, etc. There are also Cummins 289, etc.
    Before replacing the valve assembly
    In order to be aware of the repair process, when decomposing the injector, first measure and
    then decompose, sometimes save the valve components! The injector can be repaired only by
    adjustment.
    1. Remove the injector insulation board, remove the solenoid valve, remove the spring and
    gasket, and install the solenoid valve to measure the armature lift (standard value: 45-50um)
    2, measuring the lift (standard value: 35-50um)
    3. Check the remaining air gap of the solenoid valve (standard value: 35-55um)
    5, if the deviation is not large, consider replacing the valve assembly
    6, by the way, measure the nozzle needle lift
    After changing the valve assembly
    1, measuring the nozzle needle lift, determine the needle lift gasket (depending on the
    horsepower)
    2, measuring the lift, determine the thickness of the lift pad
    3, measuring the armature lift, determine the armature lift gasket
    4, confirm the remaining air gap of the solenoid valve
    After assembling the injector
    If the pre-spray is not suitable to adjust the thickness of the solenoid valve gasket
    If the idle speed is not suitable to adjust the needle valve spring force pad thickness

    1: Armature lift adjustment pad B26, thickness 1.340-1.760mm, each piece is 0.01mm, 43 levels
    2, over-lift adjustment pad B22, thickness: 0.980-1.440mm, each piece difference 0.02mm, 24 levels
    3, nozzle needle lift adjustment gasket B16, thickness: 0.910-1.400mm, each piece of difference
    0.01mm, 50 grade
    4, nozzle needle valve spring force adjustment gasket B13, thickness: 1.200-1.960, each piece
    difference 0.02mm
    5, solenoid valve spring force adjustment washer B14, thickness: 1.200-1.860mm,each piece
    different 0.02mm

    CRI (passenger car injector) 0 445 110 *** type, usually 4-cylinder engine
    Before replacing the valve assembly
    为了维修过程中做到心中有数，在分解喷油器时先测量再分解，有时可以省下阀组件！ 只调
    整就能修好喷油器。
    1,拆下电磁阀测量衔铁升程（标准值：40-45um）
    2，测量衔铁总行程（标准值：55-70um）
    3，测量电磁阀的剩余气隙（标准值：35-55um）
    7， 如果偏差不大就考虑更换阀组件
    8， 顺便测量油嘴针阀升程
    换阀组件之后
    5， 测量油嘴针阀升程， （根据马力大小不同）
    6， 测量衔铁总行程，决定衔铁总行程卡簧厚度
    7， 测量衔铁升程，决定衔铁升程垫片
    8， 测量电磁阀剩余气隙，决定剩余气隙垫片厚度
    装配好喷油器后
    如果预喷不合适调整电磁阀垫片厚度
    如果怠速不合适调整针阀弹簧力垫片厚度

    1， 衔铁行程调整垫片 B31，1.20-1.300，每片相差 0.01


    2， 剩余气隙调整垫片 B25，0.900-1.140，每片相差 0.01
    3， 衔铁总行程调整卡簧，1.155-1.265，每片相差 0.01
    4， 电磁阀弹簧力调整垫片，1.200-1.960，每片相差 0.02
    5， 油嘴弹簧力调整垫片，1.200-1.860,每片相差 0.02
    电装喷油器只能测量和调整衔铁升程，标准为：45-55um，其他行程出厂

    已经固定无法调整

    共轨喷油器测试步骤以及对发动机造成的影响

    LEAK TEST 泄漏测试，通过此项测试可验证阀组件、高压密封环、油嘴压

    帽部分的泄漏情况

    VL 最大喷油量，过大冒烟油耗大，过小无力提速慢，调整时每只喷油

    器误差应该控制在 6mm3/HH，主要由油嘴升程垫片调整。

    TL/EM 中速/排放点油量，喷油特性验证点，过大冒烟排放超标，过小加

    速无力。由油嘴弹簧力垫片，衔铁行程，过升程垫片、电磁阀

    弹簧力垫片决定。

    LL 怠速油量，过大怠速冒烟、过小丢油门熄火，启动困难，油量不

    均匀度超标时游车，噪声大、加速过程中发动机摆动。不均匀

    度应该控制在 2mm3/HH 以内，主要由油嘴弹簧力垫片调整。

    VE 预喷油量，过大敲缸冒烟，过小噪音大、不好启动，加速无力！

    不均匀度应该控制在 0.5mm3/HH 以内，主要由电磁阀弹簧力垫

    片调整。

    说明：以上调整方法前提是各种行程都调整在范围之内！

    调整垫片在维修中起着关键作用，请在选购垫片时购买博世垫片或者耐驰垫片。
    耐驰垫片销售专线：18815256017 [email protected]

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