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CRS3 Common Rail Injector and Pump Tester Users Manual V3.

1.1 Introduction..................................................................................3 1.2 Characteristics..............................................................................4 1.2.1 This tester not only support high-speed solenoid valve type common rail injector, but also support piezoelectric crystal common rail injector which is the third generation high pressure common rail technology.................................................................4 1.2.2 Six channel common rail injector..........................................4 1.2.3 Support various common rail pressure sensors.....................4 1.2.4 It adopts intelligent PID algorithm, and makes pressure controlling more accurate...............................................................4 1.2.5 Short-circuit protection is by hardware and software, and makes this tester more reliable.......................................................4 1.2.6 Various languages can be choose, Chinese/ English/ Russia.4 1.2.7 It adopts safety protection design, to prevent operator misoperating. So it used more safe.................................................4 1.3 Safety............................................................................................4 1.3 Usage and Maintenance................................................................5 Preparation..................................................................................................5 1.4 Connector.....................................................................................5 Operating Instruction..................................................................................6 1.5 Keyboard settings.........................................................................6 1.6 Basic operation.............................................................................6

Preface 1.1 Introduction IAT-CRS3 High Pressure Common Rail Injector Tester imitates the function of diesel engine ECU (Engine Control Unit) and supplies common rail system control signals such as Bosch, Denso, and Delphi to drive high pressure common rail injector to work. To be convenient for the serviceman to judge and repair high pressure common rail working state, the parameter of driving signal can be set and stored according to users practical situation.

1.2 1.2.1

Characteristics This tester not only support high-speed solenoid valve type common rail injector, but also support piezoelectric crystal common rail injector which is the third generation high pressure common rail technology.

1.2.2 1.2.3 1.2.4

Six channel common rail injector. Support various common rail pressure sensors. It adopts intelligent PID algorithm, and makes pressure controlling more accurate.

1.2.5

Short-circuit protection is by hardware and software, and makes this tester more reliable.

1.2.6 1.2.7

Various languages can be choose, Chinese/ English/ Russia. It adopts safety protection design, to prevent operator misoperating. So it used more safe.

1.3

Safety

To make sure safe operation, please conform to the following regulation: 1. Operation staff should wear safety glass in operating process. 2. Please use independently private socket and make sure reliable grounding. Power line of this tester is three line plugs. So please connect this tester with standard three line plug and guarantee connect ground reliably. 3. If the voltage is not stable, please connect the tester with voltage stabilizer to use. 4. Please check AC power line to make sure its good and check power plug and power socket to make sure no dust periodically. 5. If this tester appears abnormal condition including gives out abnormal voice and odor or too hot to touch, please stops using and pulls up AC power plug and all other connecting lines in power socket.

6. Please contact with after service personnel to get timely help if this tester has any fault. 1.3 Usage and Maintenance 1. No throwing, dropping, treading on the tester. Prevent the tester from strong outside force bump. 2. No foreign matters is inserting into the connecting part of tester. 3. No water or other liquid flow into or onto tester. 4. No with wet hand touching the AC power line wires terminals. 5. Please dont make dust or foreign matter pile up around the AC power line wires terminals, which maybe lead to fire hazard or electric shock. 6. Please prevent from stepping on or squeezing AC power line. 7. Please pull up power line when cleaning tester. Preparation 1.4 Connector

Injector7needles Function Injector1 Injector2 Injector3 Injector common port Injector4 Injector5 Injector6 Aviation Socket End 1needle 2needles 3needles 4needles 5needles 6needles 7needles

Common rail pump3needles Function Common rail pump Common rail pump Null Aviation Socket End 1needle 2needles 3needles

Common rail pressure sensor 4needles Function pressure sensor GND Aviation Socket End 1needle

pressure sensor signal pressure sensor +5V Null

2needles 3needles 4needles

Counting control5needles Function Relay closed Relay common port Relay open Null Null Operating Instruction 1.5 Keyboard settings Aviation Socket End 1needle 2needles 3needles 4needles 5needles

1.6

Basic operation

1. When tester power is on, its initial display is as following:

F1: Switch in Chinese and English F2: For help F3: PID setting ENTER: Access control program.

2. Press F3 enter Setting Up Program


Setting up Program divides into three sections: 1) PID setting

2) Pressure sensor setting


3) Pre-injection A. PID setting:

1) Press F0 to choose Common Rail Pump, modify PID parameter values


correspondingly

2) Press F1 to set Percentage Value, reference value is 2.5 3) Press F2 to set Integral Value, reference value is 0 4) Press F3 to set Differential Value, reference value is 4.78
B. Pressure sensor setting

1) Press F5 to set Zero Value, Bosch sensor is 0.44, Denso sensor is 1.04 2) Press F6 to set Full value, Bosch sensor is 4.04, Denso sensor is 3.65
The above value is reference. It can be set according to actual situation.

Press ESC goes back to main interface.

3. Press ENTER to control program.

Page Up/Down: choose parameter list

1) Press F0 to choose model number of fuel pump, and press it continually to


choose the exact pump model number you need. The fuel pump is divided into 2 kinds including Delivery Valve and Spill Valve. Please make an accurate choice. It must be used in closed loop.

2) Press F1 to choose Injector type, and press it continually to choose BOSCH,


DENSO, DELPHI and SIEMENS. Siemens is a selectable function.

3) Press F2 to set Pulse Width. It can be set by inputting number key directly or by
pressing UDLR (Up, Down, Left, Right) key to choose.

4) Press F3 to set Frequency. It can be set by inputting number key directly or by


pressing UDLR (Up, Down, Left, Right) key to choose.

5) Press F4 to set Counting. It can be set by inputting number key directly or by


pressing UDLR (Up, Down, Left, Right) key to choose.

6) Press F6 to Start control system or Close control system. Press F6 continually to


choose.

Note: Before starting control system, the following inspection must be done:

1. Check the set of parameter such as model number of fuel supplying


pump, controlling type, setting pressure and so on 2. Output value of current PWM

3. Whether the motor has stable travel speed and the current speed value 4. Fuel supply and fuel return will form a stable fuel cycle 7) Press F7 to choose control type. Choose open loop and close loop by pressing F7
continually.

8) Press F8 to set PWM in the state of open loop 9) Press F5 to set Initial PWM and Given Pressure Value in the state of closed
loop. Set PWM first and then press TAB to switch to set pressure value.

10) Press F9 to Store current parameter


11) Dynamic adjustment: Press F6 to start system, then Pulse width, Frequency and Given Pressure value can be adjusted dynamically. Operation as following: 1.Left and Right adjust Pulse width 2.Up and Down adjust Frequency 3. Page Up and Page Down adjust Given Pressure Value.

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