Configuration 1. 1. Installation and configuration. Connect the Common Rail Pump Tester to the current network (220 Volt – 50 Hz). Connect the Pressure Regulator (type Bosch on CP1) located on the test rail to the Common Rail Pump Tester by a “Cable R” enclosed into the kit. Connect the Pressure Sensor (Bosch type) to Common Rail Pump Tester by a “Cable P” enclosed into the kit. Switch on the Common Rail Pump Tester box by relative switcher. Dismount the common rail pump from the vehicle. Install the pump to the injection pump test bench and the pressure sensor to the test rail. In the picture below you can see the installation of the various elements for testing:
1. The pressure regulator of CP1 pump should be installed on the rail enclosed into the kit. 2. Connection for regulator refusal measurement. It is possible to measure fuel quantity in the burette. 3. High pressure fuel sensor (Bosch Type). 4. Injectors output. It is possible to test up to 4 injectors simultaneously. In case of test without injectors, it is possible to put the stoppers enclosed into the kit. 5. The Stopper of regulator refusal. Connect the feeding of the high pressure pump, coming from the transfer pump, with a tube of the output to be connected to the test bench transfer pressure measurement test.
Setting Test Bench setting: Switch on the test bench. Feeding pressure of calibration liquid appr. 0.2/0.3 bar (7 psi). Rotation direction of the test bench corresponds to the rotation direction of the pump (read carefully the label on the pump, ex. Rotation left xxx-CP3-110L-xx). Do not use the heater of the test bench to rise the temperature of calibration liquid.
Clearing: Test bench rotation: 1000 rpm Feeding pressure of calibration liquid appr. 0.2/0.3 bar (7 psi). Duration: appr. 1 min. Electroinjectors: (if presents) not feeded
Test Pumping elements state control First test: Feeding pressure of calibration liquid: 0.2/0.3 bar Test bench rotation: 1000 rpm Electroinjectors: not feeded Pressure regulator (REG PWM) : increase the value clicking on the "+" button until 1350 bar in the “P section” is displayed in case value overcoming, adjust pressure by clicking on the " -" button. In-line pressure (P section): 1350 bar Verify pressure hold Second test: Feeding pressure of calibration liquid: 0.3 bar Test bench rotation: 1000 rpm Electroinjectors: Not feeded Pressure regulator (REG PWM) : increase the value clicking on the "+" button until 500 bar in the “P section” is displayed in case value overcoming, adjust pressure by clicking on the " -" button. In-line pressure (P section): 500 bar Verify transfer pressure (appr. 4 - 5 bar)
Pump total delivery control First test: Feeding pressure of calibration liquid: 0.3 bar Test bench rotation: 1000 rpm Electroinjectors: not feeded Oil spray counter: 200 pulse Pressure regulator (REG PWM) : increase the value clicking on the "+" button until 500 bar in the “P section” is displayed in case value overcoming, adjust pressure by clicking on the " -" button. In-line pressure: 500 bar Delivery values:
70
130
(+/-) 10%
80
160
(+/-) 10%
95
180
(+/-) 10%
110
220
(+/-) 10%
The above mentioned values were found at 37°C of temperature of calibration liquid ISO4113. The cam rise can be identified from the pump label (ex. Cam rise 110-CP3-110L-xx). Second test: Feeding pressure of calibration liquid: 0.3 bar Test bench rotation: 1000 rpm Oil spray counter: 200 pulse Electroinjectors: not feeded Pressure regulator (REG PWM): increase the value clicking on the " +" button until the value arrives to 1000 bar in the “ P section” , in case of overcoming, reduce the value by clicking on the "-" button. In-line pressure (P section): 1000 bar Delivery values:
70
110
(+/-) 10%
80
140
(+/-) 10%
95
170
(+/-) 10%
110
190
(+/-) 10%
The above mentioned values were found at 37°C of temperature of calibration liquid ISO4113. The cam rise can be identified from the pump label (ex. Cam rise 110-CP3-110L-xx). .
Magneto-proportional valve test (pumping elements feeding):
If the Common Rail Pump Tester is used in cooperation with a Common Rail Pressure Regulator Tester it is possible to check the magneto-portional valve. Disconnect the “P cable” from the Pressure Regulator located on the test rail. Connect the Common Rail Pressure Regulator Tester to the “P cable”. (REG PWM): increase the value by clicking on the " +" button until it arrives to 60.0 (%) value. Connect the Common Rail Pressure Regulator Tester to the Magneto-proportional valve located on the pump and check the correspondance of the Duty Cycle (Duty section). Test: Feeding pressure of calibration liquid: 0.3 bar Test bench rotation: 1000 rpm Electroinjectors: Not feeded Pressure regulator on the rail: Not feeded Magneto-proportional valve (REG PWM) : reduce the value by clicking on the"-" button until the value arrives to 100 bar in the “ P section”. In-line pressure (P section): 100 bar Verify absorption (Section - Curr. (A) on the Common Rail Pressure Regulator Tester): Delivery min: 1.50 Ampère Delivery max: 0.60 Ampère If delivery value is near the min, the pump is quite ineffective.
