HCR708 Common rail integrated machine multi-functional type

HCR708

Common Rail Test Bench Instruction Manual

CONTENTS

Safety rules:

The user must carefully read the safety instructions before using the equipment, and the user should warn the operator of unsafe operations.

1 ) The operation, maintenance and repair personnel of the equipment must be professionally

trained, capable of meeting risks and safety-conscious personnel to operate the equipment.

2 ) Operators and maintenance personnel must carefully read and master the operating instructions.

Strictly follow the safety instructions and safety warnings on the equipment, and ensure that they are complete and clear.

During operation, operators must wear glasses to protect their eyes and wear masks.

5 ) The operation, maintenance and adjustment of the equipment must be carried out by professionals, and other personnel are not allowed to start the equipment at will.

If the equipment is abnormal, it should be shut down immediately and inspected and repaired by professional maintenance personnel in time.

Unless the equipment is maintained, be sure to close all protective covers and electrical box doors.

Turn off the power before servicing the machine.

Please leave a space of 600mm outside the limit position of the machine, mark the working range with a yellow line, and prohibit others from entering during operation.

The maximum pressure of this test bench can reach 2000bar when testing the common rail injector, so the safety door of the operating room must be closed when in use! !

Precautions

The power cord of this equipment is three-phase five-wire, which is connected to the power supply of 380V/3PH/50Hz, please ensure reliable grounding;

If the power supply voltage is unstable, please use a power supply regulator for power supply;

Regularly check whether the AC power cord is in good condition, and whether there is dust accumulation on the power plug or power socket;

If the controller appears abnormal, or emits an abnormal sound or smell, or the controller becomes too hot to touch, please stop using it immediately and unplug the AC power cord and all other connections from the power socket.

If the controller fails, please contact the after-sales service personnel to get the necessary help.

Operators must operate in accordance with the fuel pump repair industry and related diesel

electronic control system maintenance safety regulations. Pay special attention to environmental factors such as acid and alkali, poisonous gas, high-pressure heavy objects, and items that are prone to sparks to prevent equipment damage or personal injury.

It is strictly forbidden to splash corrosive liquids such as water and diesel into the LCD screen,

the inside of the test bench and the electrical connection parts.

There are precision electronic instruments inside this test bench, please do not drop it.

Do not touch the terminals of the AC power cord with wet hands.

When using the wiring harness and plug, please use screws as far as possible to prevent

failure due to improper connection. If the display is flickering or blue, the program is interrupted or the screen is blurred, please turn off the power, check the external power supply and restart the test.

It is strictly forbidden to turn on the main power switch when the fuel tank is not filled with fuel

to prevent damage to the heater from dry burning!

It is strictly forbidden to stand on the front of the operating room when the test bench is

running for the first time, to prevent high pressure leakage from causing danger. When the equipment is running, the operator is not allowed to stand on the front of the operating room every time the tested fuel injector is installed and started! ! !

Shut down the computer strictly in accordance with the computer shutdown procedure. Turn

off the main power after the computer is turned off.

Do not allow dust or foreign objects to accumulate around the terminals of the AC power

supply. Dust and foreign objects accumulated on the AC power terminals may cause fire or electric shock;

Please unplug the power cord when cleaning the controller

Test bench function introduction and instruction

Brief introduction of comprehensive performance test bench for common rail system

The function of the HCR708 high pressure common rail electronic control comprehensive performance test bench is to provide control signals for common rail systems such as Bosch and Delphi according to the working conditions of the diesel engine ECU (Engine Control Unit) to drive the high pressure common rail oil pump and the high pressure common rail The fuel injector is working; the user can set and save the driving signal parameters according to their actual conditions, which is convenient for maintenance personnel to judge and repair the working status of the high pressure common rail system.

Operating environment, conditions and specifications of common rail injector test bench

Temperature (runtime)*********************-10～50 C(14～122°F) Temperature (non-operating)*************-20～70 C(-4～158°F)

Relative humidity (runtime)***************** 40 C:15%～95%(No condensation) Relative humidity(non-operating)******* 65 C: 90%(No condensation)

Technical Parameters

Preparation

Check the machine and accessories

When you receive the machine, please open the package and check whether the contents of the packing box are consistent with the packing list. If any items are missing, please contact the after-sales service personnel in time.

Open the door of the equipment box, then check whether any parts are loose or falling off, and check whether the connecting cables are falling off or loose.

If the test system is in good condition and the accessories are complete, follow the steps below.

Check the input power of the device before connecting to the power source. The power cord of this equipment is three-phase five-wire 380V.

Please ensure reliable grounding;

If the voltage is unstable, please use a power supply regulator.

Filling the fuel injection pump special test and calibration fluid (ISO4113)

Remove the fuel tank cap, and fill the fuel injector special JB-1 test calibration fluid (or ISO4113) into the fuel tank.

Fuel tank capacity is about 40L.

Function Introduction

Function area Introduction

cavity 9.Negative pressure gauge b10.Common rail pump to be tested 11.Common rail unit

12. Fuel pressure adjustment valve 13.Drive wiring harness unit

14. Return fuel back pressure valve 15. Inlet pipe line interface 16.Pump nozzle test unit 17. Common rail injector universal clamp 18. Common rail injector to be tested

Control interface function area

The corresponding function options can be selected according to the actual test items

Operation station

1. Fuel pump start switch 2. Fuel pump stop switch 3. Heating switch

4. Heating indicator light 5. Cooling indicator light 6. Lack fuel alarm(fuel level low )

7. USB interface 8. Input AC power indicator

9. DC 24V of the machine output indicator 10. Emergency stop switch

Operation room panel 1

Diesel pressure regulating valve:

When the diesel pump is forced to supply fuel, it is used to adjust the pressure, 0-1.6MPa;

Back pressure regulating valve:

When debugging the oil pump, if there is no back pressure, use this valve, 0-1.6MPa;

Oil supply interface; 4.Self-priming interface; 5. Fuel-feed pump inlet filter;

Fuel filter outlet; 7. Fuel return interface

Schematic diagram of operation room drive interface

Panel:

INJECTOR: Common rail injector drive interface (various common rail injectors, pump nozzle injector interfaces)

2/3.PCV1/PCV2 high pressure common rail pump PCV drive interface

PIEZO: Piezo injector drive interface

METERING UNIT: high pressure common rail pump metering unit interface

TDC(G): Cam timing signal interface

320D: CAT320D cam timing signal interface

BIP: Common Rail Injector Response Time Test Interface

MEASURING INJECTOR: Injector injection measurement interface

MEASURING BACKFLOW: Injector return flow measurement interface

CLEANING INJECTOR: Injector injection cleaning interface

CLEANING BACKFLOW: Injector oil return cleaning interface

Schematic introduction of each operation function connection

The fuel injector test connection

Lock the interface of common rail pipe assembly 1 tightly,

Select the appropriate injector adapter 2, connect the common rail pipe and the injector with high pressure pipe, Connect the fuel injector solenoid valve drive line 2, select the suitable fuel injector connecting line 4, Select the suitable oil nozzle sealing ring assembly 5 and lock it tightly.

Injector adapter 2 Oil nozzle sealing ring assembly 5 injector connecting line 4 Attention:

The injector cleaning area is used for testing under the condition that the injector is not disassembled and cleaned to prevent unclean test oil from entering the main oil circuit circulation system. When the injector injection and return fuel are connected to this interface, the flow measurement system of the test bench does not work

Connect the fuel injection interface and oil return interface of the injector with 11/12 first. After the fuel injection of the injector is clean, insert the joint of the cleaning area 11/12 into the measuring area 9/10 of the injector

Common rail pump test connection

Bosch CP2/CP3 connections

1. Common rail pump fuel return 2. Common rail pump fuel feed

3. Pump high pressure fuel supply interface 4. Metering unit

5. Interface of metering unit 6. Fuel suction by fuel pump

7. Fuel supply pump 8. Injector measuring interface

9. Fuel self-priming interface 10. Fuel from the fuel transfer pump enters the filter

11. The filter fuel into the common rail pump 12. Fuel return interface

CAT320D connection

1.320D pump fuel return 2. Metering unit

3. Pump high pressure fuel supply interface 4. 320D CAM timing signal

5. Fuel suction interface of fuel pump 6. Metering valve drive interface

7. Injector measuring interface 8. Fuel return interface

9. The filter fuel enters the common rail pump 10. Fuel feed pump fuel inlet filter

11. Fuel self-priming interface

Connection diagram of EUI and EUP

1.EUI cam box unit 2. EUI

3. Adapter 4. Fuel collector

5. EUI fuel injection interface 6. EUI fuel inlet interface

7. EUI fuel return interface 8. Fuel supply interface

9. Fuel return interface 10. TDG (CAM timing signal interface)

11. Injector solenoid valve drive wire