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Manual for 502

CRDi

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Ready and Directions Before OperationReady and Directions Before Operation

Cautions: Failure to observe the following warnings could result in a risk while operating 502.

Please read and observe the following warnings.

1. Do plug the device into a standard 220V socket.

2. Do not disassemble nor convert this device on your own.

3. Do not install this device in a humid place.

4. Do use designated test oil (Diesel or Castrol 4113) for the device.

5. Do operate the device on ground connection.

6. Prepare the air higher than (3kgf/㎠) and attach the connector

Fix at 3kgf/㎠

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1. Testing various injectors (Bosch, Delphi, Piezo)

2. Measuring injection quantity of an injector and quantity of the returning.

3. Controlling injection time and pressure etc. at your option.

4. Controlling channel can be set independently for each injector.

5. Measuring 4 injectors accurately at one time.

6. Cleaning fuel line with a vehicle.

7. Checking clogging of the hole in a nozzle.

8. Injection state of an injector could be confirmed under the various conditions(Pressure and

pulse).

9. Satisfying normal pressure of 1,350 bar, maximum allowable working pressure of 1,600 bar.

10. Injection time can be controlled by 10㎲ as a unit and measured accurately.

11. Formed under the identical condition with a vehicle, the accurate measured value can be

calculated.

IntroductionIntroduction

PowerPower Single phase/ AC 220VSingle phase/ AC 220V

Pressure ScalePressure Scale 100 ~ 1,600 bar100 ~ 1,600 bar

Normal PressureNormal Pressure 1,350 bar (CRDi High Pressure Pump Installed)1,350 bar (CRDi High Pressure Pump Installed)

Size (mm)Size (mm) 550(L) X 600(D) X 1550(H)/150kg550(L) X 600(D) X 1550(H)/150kg

Basic SpecBasic Spec

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Basic FeaturesBasic Features

Beaker Emptying Lever

Injector Fixing LeverCleaning Line for fuel line

(Yellow: In, Transparent: Out)

Cleaning Line Pressure Gauge

Cleaning Line Pressure Controlling Lever

Opening Lever(for the inner side)

Low Pressure Gauge

Low Pressure Controlling Lever

Injection Embodier ON/OFF Switch

Piezo Return Hose Adapter

Cooling of thermometer

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Setting Up

1.Power Connection – Ph1/AC220V (Do use grounded receptacle.)

2. Put test oil in. (Use Diesel Oil or Castrol 4113(recommandation)

(Inject over ⅔ of the oil lever gauge – over 7ℓ

Cleaning Chemical Tank

3 . Connect the injector Cable. (On the back side.)

Bosch Cable Piezo Cable

PiezoBosch/Delphi

Delphi Cable

Evil Oil TankInjector Test Oil Tank(Diesel)

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502 Control Panel / How to Use

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2 3 4 5 6

7

8

9

10

11

12

13

14

15

16

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No.No. NameName

1 Channel

2 Channel Store

3 Injector Check

4 Low Pressure Pump

5 High Pressure Pump

6 Nozzle Injection Test

No.No. NameName

7 Power

8 Fuel line Cleaning

9 Bosch

10 Delphi

11 Piezo

12 Rail Pressure

13 Set Pressure

14 Injector Pulse

15 Counter

16 Controlling Dial

17 Cleaning Time

18 Select

18

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Names and Features for Each Part.

1.Chennel - Each injection (Bosch, Delphi, and Piezo) can input injection time, pressure, and counter into each

channel button; 1 ~ 5.

2.Chennel Store - Push the button twice in a row then you can save the present state of a chosen channel.

Push the button once then the injector speed increases.

3.Check - Checks injection quantity and leakage quantity of the chosen channel.

4.Low Pressure Pump - Sets Low pressure.

5.High Pressure Pump - Sets High pressure of the chosen channel.

6.Nozzle Injection Test - After disassembling a nozzle from the injector and connecting test oil supply line to the

nozzle, you can test injection condition of the nozzle.

7. Power - Power of the control panel.

8. Cleaning – By connecting a vehicle to the cleaning line on side (Refer to p.4), it cleans the fuel line.

9.Bosch - Measures injectors made by Bosch.

10.Delphi - Measures injectors made by Delphi.

11.Piezo - Measures injectors made by Piezo.

Names and Features for 502 Control Panel

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Names and Features for Each Part.

12 Rail Pressure Screen - Shows the current operating pressure.

13 Pressure Screen - Shows the input pressure on each channel. (Input by 10bar as a unit)

14 Pulse Screen - Shows the time permitted to an injector. (Input by 10us as a unit)

15 Counter Screen - Shows the check time of an injector.

16 Control Dial - Controls target rail pressure, pulse and counter.

17 Cleaning/Nozzle Test Time - Shows cleaning time(40 min) and nozzle injection test time(10

sec) with a vehicle.

18 Select Button - Push the button and then push the control dial, the figures of 13,14,15,17

change.

Names and Features for 502 Control Panel

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Before You Install an Injector

1 Install a suitable connecter – Install only Bosch/Delphi connecters

2 Install a suitable pipe for each

injector.

3 Remove the carbon of nozzle and

insert an O-Ring.

Cylinder Switch

5. Using cylinder switch, place the cylinder to the top

This is a Install only Piezo connecters

Piezo

4. Press the injector and close the lever

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How To Install An Injector

1 Insert an injector.

2 Lock the nut with your hand.

3 Press the upper side of the injector to fix it tightly.

4 Locate a connecter and a hose.( Back-Leak).

5 Tighten with a spanner.

Cautions: Do check whether

the hole is clogged.

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Injector Test Order for 502

1

3

4

5 6 7 8 9 10 11

12

13

14

15161718

19

20

21

22

Step 1 – Push 15.Step 2 – Push 11,12, or 13 to select the injector.

ex) Push 13 for Bosch.Step 3 – Push 1,2,3,4, or 5 to select the pressure.

ex) Push 3 for the pilot.(1:Low pressure,2:Middle pressure,4:High pressure.)

Step 4 - Push 8. At this time, dial 22 that 21 to be 3kfg/㎠. Step 5 – Push 9.Step 6 – Push 7.For testing other injectors under different pressure, repeatthe upper process in order.

Fix at 3kgf/㎠

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Injection Shape

3. check the injection

shape of Injector

Must to using CH1(250bar), CH2(800bar),CH3(800bar).

1 The channel with selector 2. Cylinder Switch selector

★★ warningwarningDo not use in high pressure(1350bar)Do not use in high pressure(1350bar)

If you use high pressure(1,350bar) there is possibility that Cylinder is damaged

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How to Change the Measurement Value

1. Press Selection Switch

2. Change the measurement value by using the control dial- Left: Decrease, Right: Increase- When the dial is pressed and rotated to the left and the right, it is changed by the hundreds

3. In case that the set value is to be changed, press Store twice to store the set value

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Parameter

BrandBrand ChannelChannel Pressure (bar)Pressure (bar) Pulse(Pulse(㎲㎲)) CounterCounter

B

O

S

C

H

Ch1 (LOW) 250 730 1000

Ch2 (Middle) 800 600 500

Ch3 (Pilot) 800 180 500

Ch4 (High) 1350 800 500

Ch5 0 0 0

DD

EE

LL

PP

HH

II

Ch1 (LOW) 250 400 1000

Ch2 (Middle) 800 450 500

Ch3 (Pilot) 800 120 500

Ch4 (High) 1350 680 500

Ch5 0 0 0

PP

II

EE

ZZ

OO

Ch1 (LOW) 250 650 1000

Ch2 (Middle) 800 700 500

Ch3 (Pilot) 800 200 500

Ch4 (High) 1350 750 500

Ch5 0 0 0

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How to Piezo injector Tester

2. Connect the supply line hose of Piezo to the air supply line on the left side

3. Connect the supply hose to the injector and fix a holder

4. Connect the injection and back-leak line

※ There is no back leak line at Piezo Injector

1. Attach the high pressure pipe and coupling suitable to Piezo Injector type

Piezo

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Cleaner wire (option)

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Accessory

Bosch/Delphi Injector Cable

Fuel line cleaning Adapter

coupling Adapter

High-pressure coupling Pipe

Piezo injector connector

injector fix O-ring

Rail stopper