operating manual-eps600.doc

OPERATING MANUAL

TEST BENCH FOR DIESEL FUEL INJECTION PUMPS

Model EPS619

© 2003Copyrights ITM Co — All rights reserve

USER MANUAL EPS619

INDEX Pag.EPS600 SERIES TEST BENCH USES AND TECHINICAL FEATURES…………….………………. 1

performances ………………………………………………………………………..…………………1uses ……………………………………………………………………………………………………..1

CONSTRUCTIVE FEATURES …………………………………………………………………………….2Main body ………………………………………………………………………………………………2Injection measuring system ……………………………………………………………………….. …3

TRANSMISSION SYSTEM ………………………………………………………………..……………….4Dragging head .…………………………………………………………………………..……………..4Inverter controlling motor …………………………………………………………………………….5

FUEL SYSTEM ………………………………………………………………………………………………6Technical data …………………………………………………………………………………………6Principle and drawing …………………………………………………………………………………6Operations ……………………………………………………………………………………………..7

ELECTRONIC SYSTEM ……………………………………………………………………………………8Principle and drawing …………………………………………………………………………………8List of electronic components ……………………………………………………………………….10

PNEUMATIC SYSTEM ……………………………………………………………………………………11 Principle and drawing ……………………………………………………………………………… ..11

Use of pneumatic system ……………………………………………………………………………..11COMPUTER CONTROLLER OPERATION MANUAL……………………………………………………12 INSTALLATION ……………………………………………………………………………………………..21

Environment ……………………………………………………………………………………………21Laying …………………………………………………………………………………………………..21Electric supply …………………………………………………………………………………………21Compressed air ……………………………………………………………………………………….21Test oil ………………………………………………………………………………………………….21

OPERATION AND ADJUSTMENT ……………………………………………………………………….22Preparation …………………………………………………………………………………………….22Un-load testing ……………………………………………………………………………………..…22Full-load testing ……………………………………………………………………………………….22

MAINTANCE ………………………………………………………………………………………………..23

ACCESSORIES ……………………………………………………………………………………………24TROUBLE AND CORRECTIVE ACTIONS ……………………………………………………………….26PACKING AND TRANSPORTATION ……………………………………………………………………27SOLE AGENT/DISTRIBUTORS & MANUFACTURER’S INFORMATION ………..………………….27

USER MANUAL EPS619

EPS600 SERIES TEST BENCH USES AND TECHNICAL FEATURES

Performances

The test bench is used for the calibration and the testing conforming to the exercise condition of the pumps regulators, advanced variations and carburetors feeding pumps. Any other use not conforming to the test bench is not allowed.

The EPS600 series test bench available in 3 version 7.5kW, 11kW and 15kW, has been realized in observance of the ISO 4008 regulations actually in force for the test and the calibration of the in line and rotative diesel fuel injection pumps.

Used for BOSCH in line pumps of size K, M, MW, A, B, BV, P(ZU,ZW,ZM) and BOSCH rotor distributor injection pumps EP/VA, EP/VM, VE,…F…, also used for Chinese pumps size I, II, III, K, P7, BQ etc.

Uses

The EPS600 allows to carry out the following checks,· check of the injection pump’s tightness· capacity measure of each cylinder in different revolution, with pre-selection of the stroke

number· check of each line’s injection timing and starting point of injection· check of the intervention of the speed regulators· measurement of the pressure of the feed pump· check of the pneumatic regulators of the in line and distributor injection pumps· measurement of rotative distributor pump’s body internal pressure· check of the solenoid valve (DC 12/24V)

1 USER MANUAL EPS619

CONSTRUCTIVE FEATURES

Built in high sturdiness plate and structural steel, is equipped a set of door that access in his internal on which they are installed: the electronic operation of the motor, the pneumatic system and the electrical board. The top of the basement constitute the floor of work of the test bench. It substain the support of fastener of the injection pump, the dragging head, the measurement group and the panel of control.

Main body including (see fig. 1)

fig. 1


1) stand 21) return oil holder 2) lubricating system 22) oil pressure adjusting valve3) feed pump and motor 23) oil inlet holder4) dirty oil tank 24) oil return holder5) heater 25) flow meter holder6) oil tank 26) inside pressure holder7) sideway 27) flow meter8) gathering oil tank 28) couple9) dragging disc 29) low-pressure gauge10) indicator arm 30) emergency button11) main motor 31) feed pump stop button12) control panel 32) feed pump start button13) inverter 33) internal pressure gauge14) switch 34) air pressure valve15) electric box 35) barometer16) electric board 36) vacuum gauge17) vacuum valve 37) feeder pump stop button18) air holder 38) feeder pump start button19) vacuum holder 39)emergency stop button20) feeding holder 40) high pressure gauge

Injection measuring system including (see fig. 2)

fig. 2

3 USER MANUAL EPS619 1) rotation arm axle 7) oil fender2) rotation arm 8) gather oil cup3) gather oil tank 9) electromagnet4) graduate board 10) fixture seat5) graduate 11) vertical shaft

6）light 12,13) handle

TRANSMISSION SYSTEM

Dragging head (see fig.3)

fig. 3It is constituted by:Main engineFlywheel of inertia keyed in the shaft of the engine and equipped with goniometry for angular measurement (0~360 )℃

Pneumatic cylinder for the braking of the flywheel in emergency case and during the timing operation of the in line injection pump with the overflow system in high pressureIndex mobile of reference for the angular number of the rotation of the engine.


Concerning the follow figure:

1) pressure gauge 0-0.6Mpa for the low pressure feeding2) pressure gauge 0-1.6Mpa for the body pump pressure3) pressure gauge 0-0.25Mpa for the feeder pump pressure4) pressure gauge –0.1-0Mpa for the vacuum pressure5) pressure gauge 0-6Mpa for the high pressure feeding6) temperature digital display7) flow meter8) vacuum valve9) flow meter(13)10)insider pressure(14)11)oil supply(15)12)oil return(16)

Inverter controlling motorPrincipleThere is a relationship between motor speed and supplied frequency to motor. The relationship is as following:

N = 120F(1-S)/P

N: valve of rotary speedF: valve of supplied frequency to motorS: valve of slipP: number of motor poleObviously there is a direct ration between “N” and “F” because “P” is a constant and “S” is almost a constant.


Connecting the inverterThe 3-phase electrical supply was connected to the terminals(L1, L2, L3) of inverter through switch. The exterminable(U,V,W) of inverter were connected to the main motor. The terminals(+10, A11, COM) of inverter were connected to the speed adjusting potentiometer.Turning potentiometer clockwise/anti-clockwise rotation to control the output of inverter, and the main motor will run accordingly.

Protection function of inverterMoment power-off protectionLower voltage protectionOver voltage protectionOver load protection

FUEL SYSTEM

Technical dataVolume of oil tank: 60 literPressure of feeding test oil

Low pressure: 0~0.4 MpaHigh pressure: 0~4 Mpa

Feeding capacity of test oil: 8 mm3/rStabilization temperature: 40+2℃Heater: 1.5kW, 380VCooling: water or compressor cooling

Principle

The drawing shown its principle(see Fig.4)1) tank2) heater3) cooler

4) absorb filter5) feed pump6) motor7) filter8) pressure adjusting valve


9) temperature meter10)high pressure meter11)under tested pump12)standard injector13)injection measurement system14)over flow valve

Fig. 4

Operations

Test oil

Pour 60L test oil in the test oil tankThe test oil should be ISD 411401978C or GB252-64The level of test oil should be lower by 30-40mm than the top of the tank.Pay attention to the rotation of the pump motorThe rotation must be in the same direction as indicator by the arrow on the feeding

pump’s body.

Test oil temperature

Press the “START” button, the warning lamp will light up to signal that the controlling

7 USER MANUAL EPS619 system is beginning to work. Set the thermo regulator at the temperature of 40 or on℃ the request of tested pump. The thermo regulator will show the current temperature. Sensor of temperature will automatically control the oil temperature to continue the pump testing. Please see the processing figure as below,

Sensor of temperature thermo regulator heater

Radiator fan test oil

Adjusting

The adjusting valve could adjust not only the low pressure, bust also the high pressure.Regulation group of temperature of the test oil. The device is constituted by a heater immersed in the test oil, by an exchanger of heat electric fan, by a temperature sensor and by an electronic thermo-regulator for the thermo-station. Feeding pump conveys the oil test from the tank through the filter and the radiator of the heat exchanger. The thermo-regulator placed on the control panel, connected to the sensor, realize the pilotage of the resistance of the heating of the heating of the electric fan stabilize the temperature of the fixed level.

ELECTRONIC SYSTEM

Principle and drawing

ITM700 test bench electronic system is mainly including electronic board, inverter, motor, controlling components and indicator.

Electric principle (see fig.5)

see fig.5


List of electronic components as bellows:

No Code Name Model Spec. Qty1 QF Stop switch VC-2 40A 12 TC Transformer JRK4-400 380/220 13 FU1,FU4 Fuse 6A 24 FU2 Fuse 10A 15 FU3 Fuse 2A 16 C Starting capacitor 2uF 17 L Ballast 220V/20W 18 EL1 Working light 220V/20W 19 JR Electronic heater 220V/

1.5kW1

10 FR Thermo switch LR2-D1306N 111 M2 Main motor 5.5-18.5kW 112 M1 Feed pump motor Y90S-4 1.1kW 113 KM1,

KM2,KM3Relay LC1-D0910 3

14 SB1 Emergency button 115 SB2, SB4 Stop button XB2-EA141 216 SB3,SB5,SB6 Start button XB2-EA131 317 SA2 2-position button XR2-ED21 218 YA1,YA2 Electromagnet MQ-0.7/

AC220220/50HZ 2

19 ST Temperature sensor 120 SR Speed sensor 121 Inverter 122 RP1,RP2 Electric potential WXD4-24 2


PNEUMATIC SYSTEM

Principle and drawing

It must be connected to the air compressed net of the workshop. It work for the control of the pneumatic super charging(LDA) of the injection pump, for the check of the pneumatic regulators and it guarantee the emergency stop through pneumatic actuators. Drawings (see fig. 6) 3

2

1

4

see fig. 6remarks:1 pressure adjusting valve 3 pressure digital indicator2 air pressure output 4 air sensor

UseIt is constituted by:Rapid attachment for the connection of the compressed air of the workshopSecurity pressure switch for the test bench stop, when the air pressure do not guarantee

the intervention of the emergency pneumatic braking(<4bar)Rapid attachment for the connection of the injection pump during the testRegulator of the accuracy pressurePressure/de-pressure transducerPumps for the emptyPneumatic cylinder for the starting of the interceptorPneumatic cylinder for the driving of the emergency brakeElectro pneumatic valve for the control of the logic functionement


INSTALLATION

Environment

The environment around the test bench should be dry and without dust and corrosion gases.The temperature of environment should be in the range from 5℃ to 35℃

Laying

Take care that all the sides should be easily accessible.Between the test bench and floor put the four vibration dampers which is supplied as standard accessories.

Electrical supply

Power: 3-phase, 4 poles, 380v/50-60HzVoltage allowed: -15∽+10%Frequency allowed: 5%

Compressed air

Input air pressure should be 0.6Mpa by connecting the pipe union.Dry air or water strictly separated.

Test oil

Standard: ISO 4113-1978c or GB 252-64Capacity: 40-50 LNote: before testing, please check the oil tank


OPERATION AND ADJUSTMENT

Preparation

Check the flexible coupling

Once the flexible coupling was removed from the main shaft, in order to fix the flexible coupling again a set of special tools should be used, because the coaxality between the flexible coupling and the main shaft must be within 0.05mm.On connecting the fuel injection pump’s coupling to the flexible coupling, make sure that the faces of the two joints do not make contract in order avoid preloading or dangerous strains on the flexible disks of the flexible coupling. Do not run the test stand if the flexible coupling is not connected to the pump.

For distributor pump, connect 12V/24V DC power using the wire attached to the test bench.

Feed test oil

Main switch on

Set the main switch on, this operation should light up the following: The current power lightThe indicators placed on the control board

Un-load testing

In the case of the test bench works empty, it does not exceed the rotation regime of 600rpm. On the contrary the dragging joint bump against its cover and suffer damage.

Full-load testing

Connecting the high pressure pipe and standard injector.Put on fuel injection pump.Press power switch, start feeder pump, adjust feeding pressure.Start main motor, adjust the speed at your requirement to finish the testing.


MAINTENANCE

The test bench does require a complex periodical maintenance with view to simplify as far as possible the operator’s work.The ordinary maintenance intervention suggested are:

1. Test oil substitution when it have vivid yellow color(indicating the mixing with lubricant oil) or when have a turbid grey color(indicating the presence of impurity that can damaging the pump and the nozzle in test)

2. Carefully clearing of the oil tank during the oil substitution3. Substitution of the oil filter after about 200 tests on the injection pump4. Periodical checking (after about 200 tests) of the injectors and the connection tubes5. Periodical checking of the intervention at the S dimension of pad brake with pneumatic

plate6. Periodical checking the main motor, usually every half a year


ACCESSORIES

Standard accessories for EPS600 series P 1.

No Name Specification Qty Unit Remarks

1 Standard nozzle Assembly Z12J1 12 Set

2 Mounting A,AD,K,P,PD,VE 1 Set3 High pressure pipe M14X1.5/M14X1.5X600 12 Pc4 High pressure pipe M14X1.5/M12X1.5X840 12 Pc5 High pressure pipe 2X6X600XM14XM14 12 Pc6 High pressure pipe 2X6X450 M14 12 Pc7 Inlet pipe M18X1.5-Ø14.5-1000 1 Pc8 outlet pipe M18X1.5-Ø14.5-1000 2 Pc9 Holder M14X1.5 2 Pc10 Holder M12X1.5 2 pc11 Holder M16X1.5 2 Pc12 Driving shaft spanner 1 pc13 Bronze washer Ø12.5 3 pc14 Bronze washe Ø14.5 3 pc15 Bronze washe Ø16.5 2 pc16 Coupling Ø17 1 pc17 Coupling Ø20 1 pc18 coupling Ø25 1 pc19 coupling Ø30 1 pc20 Clip 2 set


ACCESSORIES

Standard accessories for test bench EPS600 series P 2.

21 Graduator 45ML 12 pc22 Graduator 150ML 12 pc23 block 45ML/150ML 10 pc24 Spanner S10 1 pc25 Spanner S6 1 pc26 Washer Ø12 4 pc27 Washer Ø14 8 pc28 washer Ø16 4 pc29 Plate spacer H80 2 set30 Plate spacer H87 2 set31 Are spacer seat R45 2 set32 Are spacer seat R56 2 set33 Plastic seat H71 2 set34 Plastic reducer 80X60 4 pc35 12/24V wire 1M 1 pc36 fuse 2A 2 pc37 fuse 6A 2 pc38 fuse 10A 2 pc39 Air pipe 2M 1 pc40 Pressure holder Ø8 Ø10 Ø12 1 pc41 Dial gauge 1 Pc42 Gauge holder 1 Set43 Initial pressure holder M12X1.5 1 Pc44 Initial pressure holder M14X1.5 1 pc


TROUBLE AND CORRECTIVE ACTIONS

This chapter describes the main problem will be met and list their corrective actions,

No. Troubles Causes Corrective actions

1 The main motor can not run

1) 3-phase power 380V+5%2) main motor over-loaded3) whether press control panel

start or “running” key4) not the above problem

Check the connecting ReleaseRead menu carefully

Firstly power off, restart in 2 minutes

2 Speed display error

1) Test bench not touch the ground

2) The tolerance between speed sensor and wheel is big

3) Voltage waves4) Speed sensor coil short circuit

Touch the ground

Adjust to 0.5mm to 1mmCheck the powerUse multimeter to check

3 Temperature display error

1) whether the temperature sensor touch the ground safety

2) whether the temperature sensor loosened

3) whether the temperature sensor damaged

Check the shielded cable touch the ground or notOpen the sensor housing check if loosenedMeasure and make sure if the sensor damping value is 107.79Ω(20 ) ℃

4Pressure adjusting valve incorrect

1) leakage

2) low pressure, can not up

3) barometer indicator can not up

Replace the O sealing seat Re-install

Barometer oil pipe blocked up, clean or change the pipe


PACKING AND TRANSPORTATION

The injection measurement group must be supported on the bottom stand of the packing box, by a supporter.

Use a plastic dustcoat to pack the test stand, and use some pieces of asphalt felt or the same things on the faces of the packing box inside, so as to protect the test stand against raining.

Protect the test stand against quake violently, during transporting.

After opening the packing box, in order to protect the paint of the test stand, don’t let sling and transporting tools touch the faces of the test stand.

SOLE AGENT/DISTRIBUTORS

CODIPA COMERCIAL DIESEL PARAGUAYCALLE TEN. EUGENIO AGÜERO C/ ITURBE FONO : 595-331-243126 CONCEPCION - PARAGUAY

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