NANYANG NANTAI TEST EQUIPMENT

FULL-AUTOMATIC COMMON RAIL INJECTOR TEST BENCH CRI-NT816 Instruction Manual

Nanyang Nantai Test Equipments Co., Ltd Brief Introduction Installation instruction Computer system Operation & Attentions Defaults diagnostic and repair

1.Functions: CRI-NT816 is a full-automatic common rail injector test bench designed and developed by Nanyang Nantai, with following functions: 1.1.Test application BOSCH.DENSO.DELPHI.SIEMENS injectors Controlled by Industrial computer with High precise, measure the fuel quantity and display on computer automatically, test the seal performance of injectors, test fuel injection and return under different working conditions: rating, idling, pilot injection. 1.2.Industrialized computer with linux XP system,humanized operation system to enable easy operation. User can add data,customer information and data can be printed and save, with 12 touch-screen . 1.3.Equipped with original Bosch CP1 pumps, and Bosch rail pipe with DRV 1.4.Constant temperature controlling system, setting the oil to be 402 degree make sure the test precision

2. Installation 2.1.Environment A.Test bench must be placed in the draught, dry room being far away from corrosive gas, temperature is between 5-35. B. Test bench must placed on solid and plane ground, level test are required, put shock-absorbing rubber under the four base, make sure enough space for the operation. 2.2.Electricity distribution A. 4*6mm 2 four core cable is needed for 7.5KW, null line protection for outer shell. B. Test bench must be connected with specialized circuit, connecting with domestic load is forbidden. The distance between switchboard and test bench should not exceed 5 meters, remove the unnecessary electric wire, coiling them is forbidden. C voltage standard: three phase 380V10%, imbalance 3%, if voltage fluctuation is largely,the stabilized voltage supply should be connected, and keep design margin. 2.3. Wiring steps: Make sure the power is cut off, open the switchboard, drill the compatible three phases four wire from the bottom of test bench, find unconnected four terminals of R, S, T,O below the right wiring terminal on the switchboard, R, S, T are live wire, O is naught wire, make sure correct connection, tight the bolt with the necessary tool. 2.4.Grounding protection (option) The power supply is three phases four wires, If electric leakage exists when power supply is properly connected, this certifies the naught is not working well or not connect into ground. Naught protection is needed then. Steps as follows: A.Find a moist place indoor or outdoor being away 1.5 meter of test bench, embed the ground

connector (steel rod, steel angle, flat steel, iron angle) into the earth, 1.5-2 meter under the earthground. B.To make sure the effect, the grounding connector should be with certain mechanical hardness, and Longer than 2 meter. It should have the hole location or bolt on the end coming out of ground, for use of cable connecting if needed. C. Dismantle the short wires in the switchboard, from O position to the wiring points of shell. D. The grounding wire is 4 mm2 strand, one end should connect with the earthing point of switchboards shell, and another end should be fixed the grounding body with 6 --10 mm2 bolts. E. Grounding resistance is 4 ohm 3. Oil input To ensure the test precision and steadiness, input the DIN ISO04113 oil which is special for testing to the oil tank, the volume should not be less than two thirds of oil tank. 4. Computer operation system After fixing power supply and inputing test oil, connect the common rail wire properly, fix the oil pump and injector. 4.1 Turn on the power supply, The working light turns on and computer starts. Screen surface as follows

4.2 Click Automatic common rail system

Notice: The motor begins to run now and the oil supply starts, observe the oil supply pressure gauge, it is showing 0.03M. 4.3 Click system setup as below

Motor rotation speed 1 is the rotation speed of pump testing0-3000rpm Motor rotation speed 2 is the rotation speed when testing injector at rated condition 0-3000rpm Motor rotation speed 3 is the rotation speed when testing injector at idling condition 0-3000rpm Motor rotation speed 4 is the rotation speed when testing injector when leak test 0-3000rpm Oil temperature range and tolerance can be set up. Testing unit can be added by users. 4.4 After checking the parameter, click confirm, then turn back to this interface:

4.5 Click injector testing

4.6 Firstly need to choose the injector typeclick injector code as blow surface

Input the injector code in search option, and confirm, pls firstly choose the manufactory if needed, then choose injector model. Data setup: input injector code in the numbering column, input parameter in the new parameter, choose the high and low pressure, then click save. If need to delete the parameter, click delete. 4.7 Click confirm, entering the testing surface as follows:

Click start, the testing will be running step by step (total 5 steps) automatically, the testing results will be showing in the result column automatically. 4.8. Click save or Print when finished . Click stop to turn off the system. If single test are needed, click single test and choose the test step which are needed. Click "ON" to test electromagnetic valve of the injectors Click ESC when finish.

5.Test Bench Maintenance 5.1 Fuel injection system maintenance. A.Generally the test oil should be changed after running of 600 hours, or after completion testing of 300 injectors(exact situation based on oil quality). B.Check the connector of oil pipe timely, to avoid oil leakage or air in. C.Check the filter element and change timely; D.Check the connection between common rail pipe and pump, ensure the machine operate safely 5.2 Common rail pressure regulation valve - DRV and ZME are the main parts for common rail pressure, attentions as below: A.After working constantly 8-10 hours, Check whether DRV/ZME is contaminated by impurity, and clean them timely. B.Pls use the oil dispersant to clean them, ultrasonic cleaner is forbidden to use. 5.3 ZME & DRV valve should be fixed correctly and keep tightly 5.4 Flow sensor is imported form abroad, do not open it by yourself. Make sure the test oil clean when operating the machine. Check and maintain the inverter timely, to ensure the machine run steadily and safely. Pls note the electric should be cut off when checking the inverter, and do not touch the electricity 5.Usual defaults code default s Reason Removal methods

1Wrong power connection

check the wire

2.Single phase test bench outer shell make sure the grounding protection should be connected with earth. correctly 3.naught wire connection is not correct, grounding protection is needed or without grounding protection 4.contamination or oil impurity exist on Lamp surface, compressor switchboard, clean the impurity compressor switch, power cable connector 5.cable connector loose transaction and operation. during the check and tight the bolt

Electricity exists on outshell

5.1

1.start or stop keystroke are damaged mainframe of machine do not work

exchange

2.connector plugs on the backboard of tight the connector plug the control unit loose. 3.press the stop(brake)button by accident

5.2

press the button to be upper

4.the control line10VAVIEF5V Check and recover the line 10V VRFGND inside the inverter cut off AVIEF 5VVRFGND keep the machine closed for seconds, if the maintenance 5.other electric on the spot interferes machine still does not work, cause the inverter to be self-protection contact manufactory, do assembly by yourself 1. Shortage of power phases, 2.low Check the power distribution voltage, 3. phase imbalance 2.Left & right resistor malfunction, or exchange damaged 3.Fixture is not used properly, pump is choose the correct fixture to brace not fixed steadily the pump. 1.mainframe machine rotates, red LED sensor damaged and exchange beside the sensor is off 2.sensor LED flicker, rotation speed replace meter damaged heck and recovery, make sure good 3.Circuit connected with sensor rupture, connection,tight plug and, fix the plug or pin malfunction. bolt. 4.the distance between sensor and the distance between sensor and magnetic steel which is on the backside magnetic steel is 3-5MM , and be of dial is longer than normal same core. 15 of pls not

rotation speed not steady

5.3

rotation speed meter do nor work

5.4

1.temperature controller is damaged

exchange

oil temperature control failure pump motor does not start or stop no display on computer lamp off magneti c valve does

2.temperature sensor (at oil tank board) exchange is damaged. 3.temperature sensor connector, check and tight the plug, welding controller, signal plug loose, connection the signal wire again. line rupture or loose, reset the low and upper limit data, 4.temperature low limit preset is not make sure upper limit data higher correct than the low limit data. 5.heating contact damaged exchange

5.5

2.output current inside the switchboard check the 24V output , check the AC malfunction. safety tube

5.6

3.pump motor connection malfunction, damaged.

wire

check the line, and change

1.power supply open,but switch is off

check the circuit, open the switch

5.7

1.controller,safety tube(0.5A)damaged 2.Display device monitor damaged

replace

1.abnormal voltage 5.8

Overhaul

2.lamp damaged, block damaged

replace

5.9

1.electromagnetic valve circuit turn off

Overhaul

2.electromagnetic valve damaged

replace

3.check whether the 24V voltage normal Check & replace or not. 4. Check whether the injection connection is identical with the option on the computer Pump starts ,but no oil supply oil supply pressure abnormal . common rail pressure unsteady .injector does not work cut off the power supply, exchange pump motor rotation direction is not any two of R.S.T line in the identical with standard direction of pump. switchboard.

5.10

1.air exists in the oil line

Overhaul

5.11

2.Damping screw inside the pressure Adjust meter loose 3. test oil dirty or shortage 4. oil line blocked Input the test oil Clean the oil line

1. voltage unsteady 2. sensor plug contact is not good 3. oil line is dirty, blocked,impurities, air-in. 4. pressure safety cut off. 1.measure the voltage 2.check the 5.ZME valve is dirty or blocked oil line, 3.check and exchange 6. ZME valve damaged 7. DRV valve is dirty and blocked 8. DRV damaged 9. check whether the pump body pressure-regulation valve blocked or stagnation. 1.check the safety 2.check the connection line or plug loose or not Overhaul or exchange 3.whether injector data is correctly set up.

5.12

5.13

6. Maintenance: 6.1. If quality issue incurred under normal operation, we take the liability of maintenance for one year. The maintenance do not include DRV, ZME valve, rail pressure sensor which are imported from Bosch company, pls use these parts correctly 6.2.The free maintenance do not apply for the damages incurred by incorrect operation or other equipments fault. User should be responsible for maintenance costs. 6.3. Users should bear maintenance charges if it happens after one year.

NanYang NanTai Test Equipments Co., Ltd. Address: 368 NanTai Road, Nanyang City, Henan Province, China Tel037762080656 Fax0377-62080658 Web:www.nynt.net Email: nynt01@foxmail.com Tiger03821@sina.com