Configuration 1. 1. Installation and configuration. Connect the Common Rail Pump Tester to the current network (220 Volt – 50 Hz). Connect the Pressure Regulator 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. Connect the Shut-off Valve to Common Rail Pump Tester by a “Cable S” enclosed into the kit. Switch on the Common Rail Pump Tester box by relative switcher. Dismount the common rail pump from the vehicle and the pressure sensor from the rail. Install the pump to the injection pump test bench and the pressure sensor to the test rail. Remove the pressure regulator from the pump and substitute it by a special stopper enclosed into the kit.
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. 4. Injectors output. It is possible to test up to 4 injectors simultaneously (kit rail optional). In case of test without injectors, it is possible to put the stoppers enclosed into the kit.
Setting Test Bench setting: Switch on the test bench. Feeding pressure of calibration liquid appr. 1.5 bar (22 psi). Rotation direction of the test bench corresponds to the rotation direction of the pump (read carefully the label on the pump, ex. Rotation right xxx-CP1-55R-xx) or base on the feeding connection position. Do not use the heater of the test bench to rise the temperature of calibration liquid.
Clearing: Test bench rotation: 1000 rpm Pressure in-line: 500 bar Duration: appr. 1 min. Electroinjectors: (if presents) feeded (make sure that the tubes in rilsan are filled up while connected with the burettes).
Test Pumping elements state control First test: Feeding pressure of calibration liquid: 1.5 bar Test bench rotation: 200 rpm Electroinjectors: not feeded Pressure regulator (Duty Cycle) : 00.0 % In-line pressure (bar): da 50 a 80 bar Second test: Feeding pressure of calibration liquid: 1.5 bar Test bench rotation: 1000 rpm Electroinjectors: not feeded Pressure regulator (Duty Cycle) : 00.0 % In-line pressure (bar): da 80 a 110 bar
Pump total delivery control First test: Feeding pressure of calibration liquid: 1.5 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: Cam rise
Delivery (cm³)
Tolerance
45
77
(+/-) 10%
55
102
(+/-) 10%
60
111
(+/-) 10%
65
120
(+/-) 10%
70
130
(+/-) 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 55-CP1-55R-xx). The size of the puming element of the high pressure pumps with complexive volume 75 and 85 mm3 (e.g. code pump xxx-CP1-75x-xx) is 7.2 mm. Volume / cam rise
Delivery (cm³)
Tolerance
75 mm3 / 6.5 mm
145
(+/-) 10%
85 mm3 / 7.0 mm
160
(+/-) 10%
For the pumps with shut-off valve of the third pumping element: Feeling pressure of calibration liquid: 1.5 bar Test bench rotation: 1000 rpm Oil spray counter: 200 pulse Electroinjectors: not feeded In-line pressure: 500 bar Shut-Off valve: Click on the ITEM button the “SH section” visualize ON Delivery values: (values reduced 33%) Cam rise
Delivery (cm³)
Tolerance
45
51
(+/-) 10%
55
69
(+/-) 10%
60
75
(+/-) 10%
65
80
(+/-) 10%
70
87
(+/-) 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 55-CP1-55R-xx). The size of the puming element of the high pressure pumps with complexive volume 75 and 85 mm3 (e.g. code pump xxx-CP1-75x-xx) is 7.2 mm. Volume / cam rise
Delivery (cm³)
Tolerance
75 mm3 / 6.5 mm
97
(+/-) 10%
85 mm3 / 7.0 mm
107
(+/-) 10%
Second test: Feeding pressure of calibration liquid: 1.5 bar (22 psi) 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: Cam rise
Delivery (cm³)
Tolerance
45
70
(+/-) 10%
55
92
(+/-) 10%
60
100
(+/-) 10%
65
110
(+/-) 10%
70
117
(+/-) 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 55-CP1-55R-xx). The size of the puming element of the high pressure pumps with complexive volume 75 and 85 mm3 (e.g. code pump xxx-CP1-75x-xx) is 7.2 mm. Volume / cam rise
Delivery (cm³)
Tolerance
75 mm3 / 6.5 mm
138
(+/-) 10%
85 mm3 / 7.0 mm
152
(+/-) 10%
Lubrication valve control Feeding pressure of calibration liquid: 1.5 bar (22 psi) Test bench rotation: 1000 rpm Electroinjectors: not feeded Pressure regulator (REG PWM): increase the value by clicking on the "+" button until it arrives to 1350 bar in the “P section”, in case of overcoming reduce the value by clicking on the "-" button. In-line pressure (P section): 1350 bar Reduce feeding of calibration liquid to the pressure value inferior to 0.5 bar (7 psi), in-line pressure will be reduces because of high pressure stage of the pump closing. Pay attention to immediate restore of feeding pressure to a value superior to 0.8 bar (12 psi) to escape pump seizing.
Pressure regulator test: Feeding pressure of calibration liquid: 1.5 bar (22 psi) Test bench rotation: 1000 rpm Electroinjectors: not feeded Pressure regulator (Duty Cycle): 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 After the pumping elements state checking with pressure regulator disabled, make sure that pressure remains constant during regulator piloting with a fixed value of Duty Cycle. If the Common Rail Pump Tester is used in cooperation with a Common Rail Pressure Regulator Tester check regulator absorption (Section - Curr. (A)) should be constant , oscillation should vary for some milliampère (mA) only because of solenoid heating.
