AGP
 

Diesel Fuel Injection Equipment


A. Content
I. Purposesandtechnicalparameters of fuel injection pump test bench······························ 3
1. Content of test········································································· 3
2. Application scope······································································ 3
3. Main technical parameters······························································· 3
II. Introduction to thestructure of test bench··················································· 4
1. Integral structure of testbench···························································· 4
2.Structure of fuel measuringsystem························································· 5
III. Drive system of test bench······························································ 6
1. Components of drive system oftest bench··················································· 6
2. Variable-frequency speedregulation system of test bench······································· 6
IV. Fuel system of test bench······························································· 7
1. Technical parameters of fuelsystem of test bench············································· 7
2. Principle of fuel system oftest bench······················································· 7
3. Debugging and application offuel system of test bench········································ 8
V. Electrical system of fuelinjection pump test bench············································ 9
1. Electrical principle····································································· 9
2.List of electrical elements································································ 9
3. Instruction manual of electriccontrol box··················································· 9
VI. Pipeline system of testbench···························································· 12
VII. Installation of test bench······························································· 13
VIII. Debugging of test bench······························································ 14
1.Preparation for Debugging testbench······················································· 14
2. Items of Debugging····································································· 14
IX. Maintenance of test bench······························································ 16
1. Maintenance of fuel system······························································ 16
2. Inspection of Transducer································································· 16
3. Inspection of shaft coupling······························································ 16
4. Periodical inspection ofstandard fuel injector················································ 16
X. Packaging, hoisting and transportationof test bench··········································· 17
XI. List of wearing parts oftest bench························································ 18
XII. Fault analysis of testbench····························································· 19

一、 Purposes and main technical parameters of fuel injection pump testench

A. The fuel injection pump test bench is applied in adjusting the following aspects: Inspection of sealing property of fuel injection pump...
Diesel Fuel Injection Equipment (1) Fuel delivery and uniformity of each cylinder under different speed of fuel injection pump
(2) Starting point of fuel supply of fuel injection pump and interval angle of fuel supply between         cylinders
(3) Measurement of speed regulating performance of mechanical speed regulator
(4) Fuel supply pressure of fuel transmitting pump and measurement of fuel delivery
(5) Inspection of speed regulating performance of pneumatic speed regulator
(6) Measurement of internal pressure of distribution pump
(7) Test on electric performance of electromagnetic valve of distribution pump


B. Application scope
The test bench is mainly adapted in test and adjustment of the following fuel injection pumps in   professional manufacturers of fuel injection pump, servicing departments of fuel injection pump,  and   scientific research and education units.

Bosch types of in-line pump K ,M ,MW ,A ,B ,BV ,P(ZU ,ZW ,ZM)
Bosch types of distribution pump EP/VA ,EP/VM ,VE…F…


C. Main technical parameters of fuel injection pump test bench (see form I)

Order Power of test bench 18.5kw
1 Rotation speed range of output shaft 0-4000
2 Number of cylinders in test 12
3 Timesof measurement of fuel 0-9999
4 Pressure of fuel(Mpa) 0-0.04 0-4
5 Fuel delivery of fuel pump (L/m) 25
6 Height of center of main shaft(mm) 125
7 Type of electric motor Y180M-4
8 Return measurement (L/m) 10-100
9 DC power source 12V/24V
10 Drive coupling Several clutches without gap
11 Grease-box (special accessories) 12L
12 Pressure of lubricating oil (Mpa) 0-0.6
13 Degree of vacuum (Mpa) -0.1-0
14 Air pressure {Mpa) 0-0.25
15 Pressure of lubricating oil (Mpa) 0-1.6
16 Cooling methods Compressor or water cooling
17 Temperaturecontrol range 30-49(±2℃)
18 Output power (KW) 18.5
19 Cubage of measurement cylinder (ml) 45 150
20 Dimension of test bench (L*W*H)2.3*1.05*1.8
21 Weight (KG) 1800

 Introductionto the structure of test bench
1. Integral structure of test bench
The main frame of the test bench is combined with channel steel and angle iron by welding, with transducer and circuit board installed on the back of it, and main motor connected directly with transmission tray, tachometer wheel and coupling. Pressure gauge is installed on the panel, electric control instrument on the upper case and fuel supply motor and temperature control equipment on the bottom of motor. (see Diagram I)

Integral structure of test bench


Diagram I
(1) Frame
(2) Oil cooler
(3) Fuel supply pump and motor
(4) Dirty fuel cylinder
(5) Thermal cycling motor
(6) Oil lubricating system
(7) Guide rail
(8) Fuel sump tank
(9) Driving tray
(10) Shield of pointer arm
(11) Main motor
(12) Display control
(13) Transducer
(14) Switch-off box
(15) Electric box
(16) Electric installation board
(17) Air pressure connector
(18) Vacuum connector
(19) Test fuel supply connector
(20) Test fuel return connector
(21) Oil pressure adjusting valve
(22) Test oil pressure adjusting valve
(23) Oil supply connector
(24) Oil return connector
(25) Oil suction connector
(26) Internal pressure connector
(27) Coupling
(28) Pressure instrument
(29) Emergency stop switch
(30) Start switch of Fuel pump
(31) Stop switch of Fuel pump
(32) Vacuum air pressure valve
(33) Low pressure gauge
(34) Start switch of test fuel pump
(35) Stop switch of test fuel pump
(36) Electrical equipment control box

 Introduction to the structure of test bench
2. Fuel measuring system of test bench
Fuel measuring system is a structure in which fuel delivery of each cylinder of test fuel pump is measured and it is composed of fuel sump tank, pillar, rotating arm, measuring cylinder board, measuring cylinder and automatic break of Fuel measuring system etc. It is able to rotate 180°around the test bench. The fuel sump tank is able to move up and down along the pillar.

The channel to measuring cylinder is opened or closed by the oil cut-off tray to move back and forth with the help of electromagnet. Electromagnet is controlled by counting

mechanism which is control by counting instrument. Measuring cylinder board is able to overturn so as to measure fuel or empty the test fuel in the measuring cylinder. (See Diagram II)

Fuel measuring system of test bench


(1) Shaft of rotating arm
(2) Rotating arm
(3) Fuel sump tank
(4) Measuring cylinder board
(5) Measuring cylinder
(6) Daylight lamp
(7) Spit ring
8) Fuel collecting cup
(9) Electromagnet
(10) Fixed seat
(11) Pillar
(12) Big handle
(13) Small handle

III. Drive system of test bench

1. The system is composed of transducer, motor, transmission tray, tachometer wheel and coupling etc. The test fuel pump is driven through motor to drive transmission tray across coupling with non-gap shrapnel. Tachometer wheel through electromagnetic sensor on motor, and the signal is transferred to electric control box. Afterwards, output rotating speed and fuel quantity measurement digital display are showed out by control box. (See Diagram III).

Drive system of test bench

The rotating speed signalof test bench is collected on

(1) Guide rail
(2) Main motor
(3) Speed measurement sensor
(4) Pointer
(5) Transmission tray

2. Variable-frequency speed regulation system of test bench

(A) Variable-frequency speed-control and theory basis of induction-motor Induction-motor: rotating speed (N), voltage (V), frequency (F), magnetic flux density (F) and torque (T) have the following relations: (In the formulas, P as motor polo, S as slip, F as output frequency, I as rotor current and K1, K2, K3, K4 are constant) From formula (1), we can see that rotating speed (N) is in direct ratio with frequency (F) and in reverse ratio with motor polo (P). If motor polo does not change, rotating speed can be altered by changing frequency.

(2) Brief introduction to the work of transducer Three alternating currents are equipped with input terminals L1, L2 and L3. Output terminals U, V and W connect motor. External speed-control potentiometer connects with three terminals +10, AT1 and COM of transducer. External speed-control potentiometer is able to control the output of transducer by rotating potentiometer and then motor can run with different rotating speed.

(3) Protective function of transducer
A. Instantaneous protective function When power failure happens, transducer will go on with operation for 5 seconds; if power failure exceeds 5 seconds, output of transducer will be automatically cut off for the judgment of power cut.

B. Under voltage protective function
If the output voltage of transducer descends, the controlling circuit will run with abnormal conditions like super-heated motor and lack of torque. Therefore, when output voltage is lower than fixed value, protective circuit will function to cut off output of transducer and protect transducer.

C. Overvoltage protective function
When rectifier changes alternating current into direct current, the voltage of direct current of the rectifier will ascend for the state of generating electricity of motor. If the voltage of the rectifier ascends excessively, parts of the apparatus will be broken. Therefore, when voltage exceeds fixed value, protective circuit will function to temporarily stop speed-down in order to prevent voltage from ascending. If voltage exceeds fixed value, output of transducer will be cut off to protect transducer.

D. Overloading protective function
The performance of overloading protective function lies on the demand of overloading protection for accumulation of current between current and work. If big current is in the motor, time is limited and if time is too long, transducer will process over-current protection.

Ⅳ Hydraulic pressure system of test bench


(I) Technical parameters of test fuel system
1. Volume of fuel: 60L
2. Fuel supply pressure: low 0-0.4MpaHigh0-4Mpa
3. Fuel delivery: 19.2 mm?/r
4. Temperature scope of test fuel: 40±2°
5. Power of electric heater: 2.0 kw
6. Cooling method: water cooling or

Refrigerating compressor
(II) Principle of test fuel system
Test principle is as follows. (See Diagram IV)


Refrigerating compressor

V. ElectricalSystem of Test Bench for Fuel Injection Pump


The electrical system of test bench for fuel injection pump is made up of distribution board, transducer, motor & control element and display instrument.

1. Electrical Principle of Test Bench for Fuel Injection Pump
The main electric principle diagram of test bench (VI) and (VII)

2. The List of Electrical Elements for Fuel injection pump test bench (see Table (II)

No. Code Name Type Spec. Qty Remark
1 QF IsolatingSwitch VC-2 40A

1

2 TC Transformer JRK4-400 380/220.

1

3 FU1,FU4 Fuse 6A

2

4 FU2 Fuse 10A

1

5 FU3 Fuse 2A

1

6 C Starter 2μF

1

7 L Ballast 220V/20W

1

8 EL1 Fluorescentlamp 220/20W

1

9 JR Electricheater 220/1.5KW

1

10 FR Thermorelay LR2-D1306N

1

11 M2 Mainmotor 5.5-18.5KW

1

12 M1 Pumpmotor Y90S-4 1.1KW

1

13 KM1,KM2,KM3 ACcontactor L<

3

Import
14 SB1 Emergencystop button

1

15 SB2,SB4 Stopbutton XB2-EA141

2

16 SB3,SB5.SB6 Startbutton XB2-EA131

3

17 SA2 Two-position
button
XR2-ED21

2

18 YA1,YA2 Tractivemagnet MQ-0.7/AC220 220/50HZ

2

19 ST Temperaturesensor PT100

1

20 SR Speedsensor

1

21 INVERTER Transducer

1

Import
22 RP1,RP2 Multi-turnpotentiometer WXD4-24

2

23 M Compressorunit (option)

1

24 Two-positionTwo-way
magnet(option)

1



3. Instruction for Use of Electric control box See Instruction for Use of EPS619 Series Control Cabinet.

V.ElectricalSystem of Test Bench for Fuel Injection Pump



ElectricalSystem of Test Bench for Fuel Injection Pump

V. ElectricalSystem of Test Bench for Fuel Injection Pump


ElectricalSystem of Test Bench for Fuel Injection Pump

VI. GaspathSystem of Test Bench
1. Gaspath system of test bench sees Diagram (VIII).
2. Gaspath system of test bench is made up of pressure reducing valve, air service unit, vacuum generator, barometer, etc.
3. Base d on fuel injection pump to be adjusted, the user can connect the pump with air supply outlet by the plastic hose in fittings. At this time, the barometer displays the pressure and the fuel pump can be correctly debugged by air pressure reducing valve.

GaspathSystem

VII. Installationof Test Bench


1. Site if Installation
The test bench should be installed in the house with dry air, far away from corrosive gas and sheltering from wind and sands. The ambient temperature is generally between5? and 35?.

2. Installation
The test bench should be installed on a flat and firm ground, with four legs equipped with damping rubber boot. Some space should be left for operation.

3. Power Distribution for Test Bench
Power source: three-phase four-wire 380V/50Hz The allowable voltage fluctuation: -15?+10% Frequency fluctuation: 5%

4. Air Supply of Test Bench The 0.6Pma exterior air supply should undergo air-water separation and drying.

5. Fuel of Test Bench
The standard for fuel: inject No.0 diesel fuel conformable to GB252—64 or experimental fuel complying with the technical requirements of ISO4113—1978C. Volume: 40~50L.

6. Wiring of Test Bench
A. Cable:
The 18.5KW test bench may choose the 4×6mm5 four-core cable.

B. Steps:
Firstly lead the cables to the electric door of test bench across the trench or through flexible conduit, and then onto the terminals L1,
L2, L3 and N on the power distribution of test bench through the hole on the lower right of power distribution of test bench; and press
four cables onto the terminals L1, L2, L3 and N separately; note that “N” must be connected with earth wire, because this test bench
will be protected by earth wire. In this case, terminal “N” and “E” should be separated and “E” is grounded safely.

7. Fuel injection of Fuel Tank
Requirements:
(1) Clean fuel tank before injection;
(2) Filter the fuel strictly before injection; the particle size of mechanical impurity should be controlled below 0.05mm;
(3) The level of fuel exceeds the fuel scale over 2/3.

VIII Debuggingof Test Bench


(I) Preparation for Debugging Test Bench
1. Check of Shaft Coupler Once the shaft coupler of main shaft for output is removed, upon reinstalling, it is necessary for coaxiality to be
0.05mm, if not, the vibration will happen.
2. Check whether the shield is fixed properly.
3. Clamp the high-pressure fuel pump Clamp the high-pressure fuel pump onto the worktable of test bench with attached fitting properly,
connect it with shaft coupler of main shaft and connect the fuel pipe between test bench and fuel pump. If the used fuel pump is
distribution pump and needs 12V/24V power source, please use the specific connecting line to connect the 12V/24V jack in the front of
test bench onto the solenoid coil ofdistribution pump and choose the proper voltage for pump by switch .
4. Injection of Experimental Fuel Open the side doors under the test bench; Notice that fuel cannot flows out of display Tube; screw out
the fuel tank and inject 40L experimental fuel into tank.
5. Port of power wire Ensuring that the main power switch on the door under the test bench locates in “0” position, open the back door
at the bottom and draw the cold and proper three-phase four wire idistribution board through the bottom hole of test bench. if
possible,
the earth wire should be drawn
6. Elimination of anticorrosive oil Eliminate the dial on the test bench and anticorrosive oil on the workbench prior to use.

(II) No-Load Test
1. Preparation for Power on Recheck the tightness of each terminal on distribution board to ensure that they become flexible or dropped
off. In case of no fault, it can be put into trial run under power.

2. Test for Steering of Fuel Pump
Plug the fuel discharge outlet of test bench. Open the switch of outside distribution board and the main switch of test bench; if all
instruments on the instrument box work normally, it indicates that test bench is powered on. Pressing start switch of pump and
adjusting the fuel passage regulation valve to check whether the pressure gauge works normally, if not please shut down the main
switch, cut off external power source, open the electrical door and interchange the “L1” line and “L2” line of terminals. Finally recheck
the working condition of pressure gauge after the vane pump works normally.

3. Trail Running

(1) Opening the main power switch, if the lamp of controller is not light, open power switch in the back of controlling box to check the power supply.
(2) The rotation speed cannot exceed 600 under no-load running to prevent the danger due touniversal joint dropping
(3) Pressing the manual key on the controlling box and forward and backward buttons of main motor, when rotate the hand knob of right and left motors, the main shaft should rotate (if not, please turn the switch of right and left motors to the opposite direction).
(4) Pressing the operation key of controlling box and storing the rotation speed in need in presetting key of speed, if press the forward or backward button of main motor, the different rotation speeds can be obtained.
(5) If the test bench has Fuel pump, the test method is the same as that of fuel supply system of diesel.

VII. Debugging of Test Bench


(III) Load Running 1. Connect fuel intake port and the fuel return port of fuel injection pump to that on the test bench with high-pressure hose separately.
2. Putting the standard fuel injection pump into the antifogging shield on fuel sump tank, connect the fuel feeding port of fuel injection pump with assembly of standard fuel injection pump by high-pressure fuel pipe. At this time, it is required to adjust height of measuring tank to smooth the way to connect the fuel pump and high-pressure fuel pipe. If the thread of fuel delivery port is different from that of high-pressure fuel pipe, please add the transition joint.
3. Opening stop switch, starting fuel pump of experimental fuel and adjusting pressure regulating handle to make the fuel feedingpressure conform to the requirements, when the controlling box controls the heating or cooling of experimental fuel at one time, it is necessary to start the switch of tap water.
4. Start the main motor according to the instruction of controlling box, the main shaft of test bench will drive the fuel injection pump rotate (notice rotary direction). Upon adjusting it to the required speed, the debugging can be conducted on fuel injection pump.
5. Upon completion of debugging, it is necessary to make the speed control potentiometer back fog( ) , switch off main power source, brush away the oil stain on test bench, spread the anticorrosive oil and cover the dust-proof shield.
6. Notices for Operation
(1) When the speed control potentiometer of right and left motors stops running, it should be set at “0”. Upon rotating, it is forbidden to overexert force to prevent precision potentiometer destroying.
(2) Tighten the universal screw prior to running of test bench.
(3) Install the shield and clamp the fuel injection pump upon running of test bench.
(4) In case of voltage below level (undervoltage), fierce fluctuation and other causes, the test bench will automatically stop running and the transducer will point out the causes, which belongs to the automatic protection function of it. Cutting off power source of test bench and restoring it two minutes later, the test bench will return to normal.
(5) The transducer, belonging to high-tech electronic product, should be shockproof, dustproof and damp proof. The unit without repair ability mustn’t dismantle and adjusting transducer. It is forbidden to press and touch the surface to prevent disturbing procedure.
a. Prohibit to connect the power source onto the output terminals of inverter (u,v and w).
b. Prohibit part grounding of main circuit or control circuit.
c. Never use the megohmmeter to measure insulating resistance.

IX.Maintenance of Test Bench
1. The working environment:
Temperature: -5?and 40?;
Dry;
Enough light;
No dust;
2. Set on the flat and firm ground, shockproof.
3. Input voltage: not below 350v and stable.
4. The test bench must use the light diesel fuel (RC-10 or RC-20) precipitating over 48hrs with kinematic viscosity ( 20?) for 3 to 8 centistoke.
5. The experimental fuel is prohibited to be contaminated or mixed with lubricant oil. The grey and turbid fuel should be replaced immediately. Generally, theexperimental fuel should be replaced once 50 hours. It is necessary to check the sealing of each joint to prevent any linkages happening.
6. Maintenance of Standard Fuel Injection Pump To ensure the measuring accuracy of test bench, it is necessary to keep the fuel injection pump in good maintenance.Upon debugging 100 sets or non-use for 30 days, the following items should be checked: The open pressure of pin valve; Tightness of coupled pin valve;
Fuel volume;
The open pressure of standard fuel injection pump is 17.5Mpa.
The fuel volume of standard fuel injection pump is: when the rotation speed is 1000 revolution per minute, the rack bar for fuel control should be fixed on theposition of 100 mm3 per circulation. The flow rate of 1000 times is between 98 and 100ml. The grouping difference is over 1ML.
7. Maintenance of Motor In the process of use, the motor should be cleaned and overhauled once every half year. it s necessary to prevent it from damp and foreignmatter into the motor. The reasonable lubrication should be given on shaft when motor is running.
8. Upon completion, it is necessary to brush away residual fuel on workbench and motor t reduce the corrosion of diesel to workbench and paint flat.
9. The filter cleaner should be cleaned once every 250 working hours and replaced once every 1000 working hours.

X. Packing and Hoisting of Test Bench
Upon packing test bench, it is necessary to use the wood to support the fuel sump tank against the frame side.
The test bench should be enveloped with a plastic sleeve and the top of packing box should be coated with one piece of asphalt felt for rain protection.

XI. List of Wearing Parts
Big graduate: :V=150ML 12 pieces
Small graduate: V=45ML 12 pieces
Drip cup: :organic glass 12 pieces
Big sleeve :organic glass 12 pieces
Small sleeve :organic glass 12 pieces
O-ring 12 pieces


XII. Common Faults and Trouble Shooting
Although the test bench is assembled by high –reliability parts, some accidents still will happen due to certain cause. In this case, please eliminate the trouble according to “fault diagnosis”. The fault diagnosis can be classified into two kinds, that is, “Trouble shooting for protecting and displaying 7-segment LED character” and Trouble shooting for Abnormal Phenomenon.
Countermeasures for Abnormal Phenomenon”.
(1) To “Trouble shooting for protecting and displaying 7-segment LED character” , please refer to the instruction for use of transducer.
(2) Trouble shooting for abnormal phenomenon (see table III)

Abnormal phenomenon Check Trouble shooting
The starting engine fails Check whether three-phase
power source is connected
well and voltage falls 380V
±5%.
Check whether the
connection is right and
use the multimeter to measure
whether voltage is normal.
Whether the motor is jammed
(overload)
Eliminate the jam (reduce load)
Whether the manualkey or
operation key is pressed;
Operate properly according to instruction ofcontroller and operation instruction of test bench. 
Other conditions Firstly cut off the power and
restart it minutes later; if does not
work, please inquire our company.
The rotation speed is displayed inaccurately Whether the test bench is
grounded
Grounding
Whether the speed sensor has
a big gap with tachometer
wheel
Adjust it to 0.5mm-1mm
Whether voltage fluctuates dramatically Check power source
Whether the speed sensor is
in open circuit or grounded.
Use multimeter to check
The fuel volume is
displayed inaccurately
Whether the temperature
sensor is grounded
Check whether the screening wire is
grounded
Whether  thetemperature
sensor gets loose
Open the shell of sensor to check
Whether the temperature
sensor is broken
Measure whether the resistance of sensor
is 107.79Ω(20℃)
The pressure regulating
valve does not work
normally
Fuel leak Replace seal ring
Lower pressure The ring washer of shaft gets loose;
reinstall it
The pressure cannot go up The fuel pipe of pressure meter is
jammed


OperationInstruction
OperationInstruction of EPS619 Controller

I. General
EPS619 Multi-function Controller for frequency control fuel injection pump test bench adopts the advanced single-chip computer control technology. It can detect and display fuel temperature of three lines separately, control and display the rotation speed and control fuel injection frequency. It also functions over temperature indication and protection of senor dropping. It can adapt various different test benches of fuel pump and control of different gears. It is equipped with a series of measuring and control devices for air pressure measurement and digital display. EPS619 controller can meet the debugging of fuel injection pump with higher requirements. In the integral design, the operation of keyboard adopts direct digital input, simple and repair easy. In circuit design, it adequately considers the use environment on site. Therefore, various measures are taken to strengthen the anti-disturbing capability to make it controller work long and normally. Features:
• Setting and storage of rotation speed for ten groups of main shaft; direct rotation speed switch from digital;
• “+” and “-” key for vernier regulation of rotation speed in various gear;
• The digital of injection frequency is set according to gear of rotation speed;
• Self-correcting deviation of rotation speed;
• The air pressure adopts the imported sensor, digital display;
• Emergency stop protection and detector falling-off indication;
• Fuel temperature indication of three lines, error indication for fuel temperature of two lines and fuel return temperature indication of one line;

II. Technical Parameters
1. Voltage: AC AC220V ? 20?;
2. Power consumption: ?50 W;
3. Control temperature:0 ? 99.9?C double ways (resolution: 0.1?C, accuracy: 0.5?C);
4. Speed range: 40 ? 4000 r/min;
5. Presetting of rotation speed: 50 ? 4000 r/min (0, 1, 2……9 gear, total 10 gears);
6. Pressure display: 0 ? 1999 KPa (accuracy: ? 0.2 % );
7. Fuel injection frequency: 1 ? 3999 times.

III. Layout of Display Panel and Key Panel
Panel and Key Panel

IV. Introduction to Operation
1. Normal Work
Pressing “Count” key, the fuel injection baffle works and the number of fuel injection frequency displays reduction; when reducing to zero, the fuel injection baffle will automatically restore.
Pressing “Stop” key, the fuel injection baffle restores; pressing it again, the baffle will recount.
Pressing “Reverse” or “Forward” key, start the forward and reverse rotation of motor; pressing “Stop”, the motor stops working.
Pressing “Manual/Automatic” key, the automatic will turn into the manual and the rotation speed can be adjusted by potentiometer; pressing it again, the automatic will restore.
At automatic operation, pressing 0….9 key can directly the rotation speed of motor set on 0….9 gears.

2. Modification of Parameters
Pressing “Temperature Set” key, the temperature can be modified. The temperature value has upper limit and lower limit. The first pressing will be the upper limit (the indication light of temperature drop will be light), and then use the “+” and “-” key to set the required temperature. Pressing it again, confirm and exit the set. (Notice: the temperature upper limit should be bigger than the lower limit).
Pressing “Frequency Set” key, the required frequency of fuel injection can be se; pressing it again, confirm and exit the set state.
Pressing “Rotation speed” key, the value of rotation speed can be modified. Use the “+” and “-” key to set the required rotation speed value. if setting the rotation speed on other gears, directly press the digital key and then use the “+” and “-” key to set the required rotation speed value. Upon completion, press the “Rotation speed” key again for confirmation and exit the set state.

V. Automatic Adjustment of Instrument
When the instruments start to work and the motor runs (above 800r required), the instruments will enter the automatic adaption curse. About 10-seond stable running, the instrument will display a data (about twice prior to end), which represents the instrument finishes the automatic adaption, and at this time, the instrument will quickly reach the required rotation speed.

VI. Notices
1. Of single-chip product, the relevant technicians are not allowed to dismantle or remove the integrated circuit and socket connector and conduct welding work under current-carrying state, so as to prevent destroying the controller.
2. The grounding should be normal in the use of machine.
3. If the speed sensor is in open circuit, the speed of motor running within five seconds is still displayed for 0000, and the panel displays OFF, OFEr, which indicates that the sensor is in open circuit and will stop running at once. The user should solve the problem of sensor prior to returning to normal by pressing any key and then operate the motor according to normal steps.
4. Upon motor running, if the reverse rotation is required, it is necessary to press the “Stop” key and then “Reverse” Key. It is useless to directly press “Reverse” key at the time of forward rotation.

VII. Layout on the back of Instrument
back of Instrument

VIII. The concrete wiring is detailed in the graph below: (Seen from back)
The concrete wiring is detailed in the graph below
Description of C1 Pin 1: live wire
Pin 2: null line
Pin3: earth wire
Pin 4: Relay close contact of fuel injection

frequency
Pin 5: Relay’s moving point of fuel injection

frequency
Pin 6: Common point of transducer’s

forward and reverse rotation
Pin 7: Normal open of heating relay
Pin 8: Moving point of heating or cooling relay
Pin 9: Normal open of fuel injection frequency relay
Pin 10 Forward rotating point of transducer
Pin 11: Normal open of cooling relay
Pin 12: Reverse rotating point of transducer

Description of C2
Pin 1: IN+(terminal of original temperature sensor)
Pin 2: IN-(terminal of original temperature sensor)
Pin 3: F-(Negative terminal of transducer)
Pin 4: F+ (Positive terminal of transducer)
Pin 5: Signal F (Signal point of speed sensor)
Pin 6: Grounding (grounding terminal of speed sensor)
Pin 7: WM (side of potentiometer)
Pin 8: VCC (power source point of speed sensor
Pin 9: NC

Description of C3
Pin 1: IN+ (Terminal of fuel intake temperature sensor)
Pin 2: IN-(Terminal of fuel intake temperature sensor)
Pin 3: power source+ of pressure sensor (5V)
Pin 4: signal of pressure sensor

(0.5V-2.5V)
Pin 5: power source – of pressure sensor(0V)
Pin 6: IN+ (terminal of fuel return temperature sensor)
Pin 7: IN- (terminal of fuel return temperature sensor)

Specification for External Sensor
Rotation speed sensor: magnetoelectric speed sensor Temperature sensor: Pt100
Number of gears: 60
Pressure sensor: 4040PC100G5D

X. Standard Accessories
1. Instruction (Warranty Card)
                                                                          one
2. Aviation Plug (12 cores, 9 cores and 7 cores)                                              one for each
3. Pressure sensor imported from US                                                                 one


XI. Wiring Diagram of Transducer
Common point (10)                                                                                              COM
Forward rotating point (13)                                                                                 FWD
Reverse rotating point (14)                                                                                 REW
F-IN (4)                                                                                                                   13
WVI (7)                                                                                                                    12
ACM(3)                                                                                                                     11


Packing List of EPS619 Fuel Injection Pump Test Bench

No. Name Spec. Qty Unit Remarks
1 Fuel injectionpump test bench   1 Set  
2 Electricalcontrolling box   1 Set Upward side 3 ofworkbench

List ofAccessories

3 Fixed supportof
pump flange
 

1

Set  
4 Fuel feedingpipe

M18X1.5-14.5-1000

1

Length  
5 Fuel returnpipe

M18X1.5-14.5-1000

1

Length  
6 Fuelpumpconnector

M14X1.5

2

Piece Plastic bag
7 Fuel pumpconnector

M12X1.5

2

Piece Plastic bag
8 Fuel pumpconnector

M16X1.5

2

Piece Plastic bag
9 Dial lever

 

1

Piece  
10 Flat connector

12.5

2

Piece Plastic bag
11 Flat connector

14.5

2

Piece Plastic bag
12 Flat connector

16.5

2

Piece Plastic bag
13 Shaft couplingjoint of pump

17

1

Piece  
14 Shaft couplingjoint of pump

20

1

Piece  
15 Shaft couplingjoint of pump

25

1

Piece  
16 Shaft couplingjoint of pump

30

1

Piece  
17 Clamp

 

2

Piece  
18 Graduate

150ML

12

Piece Upward side 2 ofworkbench
19 Graduate

45ML

12

Piece Upward side 1 ofworkbench
20 Clip

150ML/45ML

5 for each

Piece Plastic bag
21 inner hexagonalwrench

S10

1

Piece  
22 inner hexagonalwrench

S6

1

Piece  
23 Bronze washer

φ12

4

Piece Plastic bag
24 Bronze washer

φ14

8

Piece Plastic bag
25 P7cuship blockseat

H80

2

block  
26 P7cuship blockseat

H87

2

block  
27 Positioning arcseat

R56

2

block  
28 Positioning arccushion block

R45

2

block  
29 Positioning arccushion block

R42

2

block  
30 Rubber shock absorptionblock

80X80

4

block  
31 12/24V powersource wire

1M

1

Length Plastic bag
32 Protective tube

2A

2

Piece Plastic bag
33 Protective tube

6A

2

Piece Plastic bag
34 Protective tube

10A

2

Piece Plastic bag
35 Air pipe

2M

1

Length  
36 Air pressureconnector

φ8 φ10 φ12

1 for each

Piece Plastic bag
37 PW cushionblock R45

R45

2

Piece  
38 PW 2000 flange

 

1

Piece  
39 PW cushionblock

H71

2

Piece  
40 PW cushion block

H80

2

Piece  



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