(Injector & High Pressure Pump Test)

Add: Bungmundaero 420 , 166, Gwangsangu, Gwangju, Korea Tel: 82-62-351-4200 Fax: 82-62-361-4200www.motortool.co.kr

(Injector & High Pressure Pump Test)

[Bosch, Delphi, Denso, Siemens, Piezo)


Caution

• Be aware of fire and electric shock.

• Do not connect or disconnect the plug with wet hands.

• Be sure to check the injection coupler and if the injector is tightened before the

operation(Auto and Manual mode).

There is a risk of injury If the coupler and injector are not tightened or loose.

• Using more than the specified pressure for each injector may damage the injector.

• It is dangerous to remove the injector’s coupler during operation

• Failure to comply with the specifications of the fitted pump or rail may result in

damage and explosion

• Keep out of reach of children.

• Wear earplug when working


Product I-CRDI

Model MT – 4600

Pressure 2000 bar (When changing set up: Max 2200bar)

Test Cylinder 4

Cooling Forced Cooling

Input Voltage380V 50/60Hz 3-Phase

220V 50/60Hz Single-Phase

Weight(Kg) 250Kgs + &

Dimension(mm) 1320 X 600 X 1590 (mm)

Specification

1. Power connection ( Circuit breaker / over 10A outlet required )

380V, 3PHASE

※ Grounding (Compulsory)If there is no grounding, install a grounding rod on the ground.

220V, 1PHASE

※ Rotation directionIf the direction of rotation is not correct, switch the R &S line(Switching the R&S lines changes the direction of rotation of the motor accordingly )

Installation

2. Fill the test oil into the oil tank(diesel oil, 15L)


A. Main Power Main Power ON / OFF Function (Emergency Stop)

B. Low-pressure Pump Supply Switch

Low-pressure ON / OFF Function

C. Low-pressure Test Oil Gauge

Display the pressure between test oil filter and high-pressure pump* You can check problem of filter or low-pressure pump according to the pressure.

D. Operation Monitor Select and display various test modes

Content

C. Low Pressure suction gauge

B. Low pressure pump supply

switch

A. Main Power (Emergency

button)

D. Operation MonitorPump

adaptor

• Fuel filter: every 6 months

• Test oil(diesel): every 6months

• Injection tip o-ring: When broken (Frequent check required)

• Replace the o-ring when oil leaks on injection tip

Consumable replacement

Solenoid cleaning

Enter the setting • Select the sole port • Blow air into the injection return hose of the selected sol port with 1 bar of air pressure. • Blow all the solenoids in the same way.


Preparation for operation

FUEL ON (Low-pressure pump)

Power ON Auto mode screen

Ready to operate

*** Fuel pump should be turned off when injector is mounted or removed.

Press the power icon (on program)

Power off the computer

Power off

Turn off the main switch

Injector connection

1. Pipe connection Connect the pipes according to the injector type

2. Connector Connect the connectors according to the injector type

* When assembling the nozzle tip on the nozzle, assemble it while moving the injection tip


Injector connection

Search

Compare measured volume with standard value

Start program

Injector Maker / Model / OK

STARTSelect Mode(Ex: MAIN)

Injector measurement ( Auto mode)

* When assembling the nozzle tip on the nozzle, assemble it while moving the injection tip

① MAKER

③ MODEL

② SEARCH

④ OK

standard value

measured value


Program operation (Auto mode)

1. Exit Finish the program and returns to Windows.

2. Setting

Change the settings of the equipment.* Do not change the default setting without consulting the manufacturer, as this may cause equipment may malfunction or failure if the user makes any changes.

3.CommunicationStatus

Checking communication status between PC and equipment(If it is ‘ON’ in yellow, it is normal, if it is ‘OFF’ in grey, no communication.)

4. Auto Convert to the mode that tests injector automatically(current mode).

5. Manual Convert to the mode that tests injector manually.

6. Device test(Option)

Convert to the mode that test coil, piezo actuator and circuit inspection.

7. Pump Convert to the mode that tests pump and IMV.

8. Start/Stop Start & Stop the test

9. Print Print out injector report tested by the equipment.

10. InjectorInformation

*Display micro resistance value and connection status of injector- NON(gray): Disconnection- Numerical value(green): Normal (Piezo type is displayed as ‘Conn.’)

- SHORT(Red): Failure (defective)

3 12

4

5

6

7

8

9

10

11

12

13

14

15

1617 18 19 20 21

22

23

25

24


11. Operationinformation

Display rail temperature / tank temperature / target pressure/ current pressure/ Pump RPM/ Rail value

12. Waveform Graph

Display the waveform of injector that is currently injecting in graph.General injector type shows current wave and piezo injector type shows voltage wave.Graph display is turned on/off by pressing the number.

13. Search• Able to create new injector number or retrieve saved injector DB in this menu.* Below picture is screen displayed when pressing search button.

14. Injector Manufacturer

Display injector manufacturer information

15. Injector Number

Display injector number

16. Air deflation Remove air inside injector

17. Maximum Injection

A mode that checks maximum injection volume and changed operation parameter values are applied.

18. Main Injection

A mode that checks main injection volume and changed operation parameter values are applied.

19. IDLEA mode that checks cranking injection volume and changed operation parameter values are applied.

20. PilotA mode that checks pre-injection volume and changed operation parameter values are applied.

21. Back Leak Check noticeably hot area of injector using back leak volume

22. Injection volume

Automatically record measured volume by flowmeter

23. Measured volume

Check and compare measurement results by injector or measurement mode. 1) No. Selected: View measurement results by cylinder 2) Mode Selected: View measurement results by measurement mode

24. Piezo seating

Piezo injector automatic seating

25. Temperature Display the current temperature of the rail


Operation (Search)

1

2

3

1. Type of Injector

Select injector manufacturer.

2. SearchSearch selected injector manufacturer.

3. OK

After selecting one out of following injector number, click “OK” It goes to auto mode and selected injector DB values are applied to Auto Mode.

Select injector type Manual mode

screenSet target pressure/ injection time/Count

START Check measured volume

Injector measurement (Manual mode )


Program operation ( Manual mode )

1. Start/Stop Start or stop after adjusting pressure/injection count /injection time.

2. Types of InjectorBosch, Bosch Piezo, Delphi, Delphi Piezo, Denso, Denso PiezoSelect type of injector by injector manufacturer.*You need to select type of injector first to drive the equipment.

3. Target Pressure Set setting value of pressure by unit of bar.

4. Injection countInjection count can be adjusted freely from 0 to 999 times in units of 10 times.

5. Injection TimeInjection time of injector can be adjusted freely from 0 to 1600 us in units of 10 us

6. Adjustment button

: Adjust by 10 : Adjust by 100

7. Graph Display target pressure/ current pressure/ Rail value in graph

8. Temperature Display the current temperature of the rail

9. Waveform GraphDisplay waveform of injector that is currently injecting in graph.(auto mode reference)

10. Injector Information

Display micro resistance value and connection status of injector (auto mode reference)

11. Back-leak Record back-leak volume by flowmeter

12. Injection Record injection volume by flowmeter

6

1

2

3 4 5

7

8

9

10

1112


Program operation : Device test (OPTION)

Determine the deterioration in solenoid by inspecting the magnetic force of the

solenoid

Indicate the deterioration of piezo injector actuator by numerical value

and color

Coil Magnetic force test Bosch piezo actuator test

Injector circuit test

Check for short circuit or poor circuit of piezo injector or Delphi injector

When checking circuit, make sure that the claws are firmly attached to the rail as shown in the picture on the left, and remove all connectors except the connector of the injector to be inspected.


High pressure pump IMV test

Pump mode Auto mode

STARTPump flow check

Pressure change check

Pump test (Auto mode)

Pump mounting

IMV Auto mode IMV connectionIMV duty check by

the graph

IMV Manual mode

Select pressure Check the changes

in operation

Search pump


Program operation: Pump auto mode

2

10

4

3

1

11

9

1. Start/Stop Start or stop after adjusting pressure/injection count

2. Measurement /Empty

Measurement: Measuring injector’s injection volume after placing cylinder to measuring location.Empty: Emptying the oil by turning the cylinder upside down.

3. Rotating Direction

Set rotation direction of motor as LEFT / RIGHT

4. IMV Type Select IMV type: Normal/Open(N/Open) or Normal/Close(N/Close)

5. Graph Display target pressure/ current pressure/ Pump RPM/ Rail value in graph.

6. Pump flow Record pump flow.

7. Auto A mode to test high-pressure pump in fixed condition

8. ManualA mode to test pressure of high-pressure pump / pump rpm /rail value / IMV value using own set value

9. SearchSearch for Pump manufacturer and part no. Same as Injector Auto Mode No.13 (Search)

10. Pump 1 Test pump volume at 500BAR (Low pressure)

11. Pump 2 Test pump volume at 1000BAR (High-pressure)

12. IMV AutoCheck if IMV installed in high-pressure pump controls the pressure properly at each pressure section (300/500/700 bar).

13. IMV Manual Select the pressure range to test among 300bar, 500bar, 700bar and then test

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56

7

8


Program operation: Pump manual mode

2

3

1

1. Pressure Auto/Manual

Auto: Hold the rail duty & IMV and pressure is adjusted automatically Manual: Able to adjust set bar manually (target pressure)

2. Rail duty Auto/Manual

Auto: Hold the pressure & IMV and rail duty is adjusted automatically according to the target pressure Manual: Able to adjust the rail duty manually

3. IMV Auto/Manual

Auto: Hold the rail and IMV is adjusted automatically according to the target pressure Manual: Able to adjust the IMV manually

4. Target PressurePressure generated in rail can be adjusted freely from 0 to 2000 bars in units of 10 or 100 bars

5. Rail ValueYou can set duty value of valve that adjusts pressure of rail from 0 to 100% in units of 0.1/1%.

6. IMVIt is used to test separate control valve or inlet valve of pump and duty value can be applied by fixing from 0 to 100% in units of 0.1/1%.

7. RPMRPM of high-pressure pump can be set from 0 to 1100 RPM in units of 10 or 100RPM.* When you drive in high RPM for a long time, it may damage the pump

8. Injection count Injection count of high-pressure pump can be adjusted freely from 0 to 999 times in units of 1 or 10 times.

9. IMV Frequency Set IMV frequency

10. Adjustment button Change the value for no. 4~9

11. Initialization Change to default: Target pressure, rail duty, IMV, RPM, count, IMV frequency

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5

6

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8

9


Program operation: Settings

1

2

34

5

6

7

8

9

1. Language Select language (Korean, English, Russian, Spanish)

2. Temperature Set the time when the cooling fan runs based on the rail temperature

3. Rail setting Change it according to the specification of the rail mounted to the equipment

4. IMV setting Default value recommended

5. RPM Motor rotation setting

6. Sole portUsed to remove foreign substances inside by adjusting the opening and closing of the sole arbitrarily.

7. Resistance Calibration of injector’s resistance.

8. Save Save changed values

9. Default Returns all settings to factory default value

2. Click button ② after connecting the tongs as shown picture

3. Click button ③ after connecting to the resistor for 0 setting

※ Calibration: 0 setting

①

②

③

1. Click button ① after connecting to the injector port as shown picture


Quality Warranty

We would like to guarantee as below.

1. This product is the one manufactured passing through strict quality control and inspection

process.

2. When needs repair, never fail to present the warranty.

3. The warranty shall not be re-issued so keep with care.

4. In case that something is wrong within the warranty period in a normal use state

according to the Operating Manual (within 12 months after purchase), it shall be repaired

free for account of this company.

However, indemnity of the damage occurred secondarily and trouble corresponding to the

following shall not be guaranteed.

(1) Trouble and damage occurred owing to wrong use, failure of maintenance check and

custody obligations

(2) Alteration or remodeling is made that affects the instrument of the product so when

trouble and damage thereby was occurred

(3) A case that needs exchange as all naturally-consumed components and consumables

get damaged

(4) Trouble and damage caused by external factors such as fire, earthquake, damage from

storm and flood and other natural calamity, etc

(5) Trouble and damage occurred for not using a designated genuine component

Product name Date of sale 20 . . .

Model name Serial Number

Warranty article by article Warranty period

Main body base board part 1 year

PC control partThe pc is not covered by warranty and is one-time service item when purchasing a

test bench

High pressure pump 6 months

Rail3 months (not available when neglects

administration and enters an alien substance)

Accessories (wiring, pipe) Consumables

Name Contact number

Address

Documents

(Injector & High Pressure Pump Test)