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 ..1
uses ..1
CONSTRUCTIVE FEATURES .2
Main body 2
Injection measuring system .. 3
TRANSMISSION SYSTEM ...4
Dragging head .....4
Inverter controlling motor .5
FUEL SYSTEM 6
Technical data 6
Principle and drawing 6
Operations ..7
ELECTRONIC SYSTEM 8
Principle and drawing 8
List of electronic components .10
PNEUMATIC SYSTEM 11
Principle and drawing ..11
Use of pneumatic system ..11
COMPUTER CONTROLLER OPERATION MANUAL12
INSTALLATION ..21
Environment 21
Laying ..21
Electric supply 21
Compressed air .21
Test oil .21
OPERATION AND ADJUSTMENT .22
Preparation .22
Un-load testing ..22
Full-load testing .22
MAINTANCE ..23
ACCESSORIES 24
TROUBLE AND CORRECTIVE ACTIONS .26
PACKING AND TRANSPORTATION 27
SOLE AGENT/DISTRIBUTORS & MANUFACTURERS 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 pumps tightness
capacity measure of each cylinder in different revolution, with pre-selection of the stroke
number
check of each lines 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 pumps body internal pressure
check of the solenoid valve (DC 12/24V)

1
ai r v al ve

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.

ai r v al ve

Main body including (see fig. 1)

fig. 1

2
USER MANUAL EPS619
1) stand
2) lubricating system
3) feed pump and motor
4) dirty oil tank
5) heater
6) oil tank
7) sideway
8) gathering oil tank
9) dragging disc
10) indicator arm
11) main motor
12) control panel
13) inverter
14) switch
15) electric box
16) electric board
17) vacuum valve
18) air holder
19) vacuum holder
20) feeding holder

21) return oil holder

22) oil pressure adjusting valve
23) oil inlet holder
24) oil return holder
25) flow meter holder
26) inside pressure holder
27) flow meter
28) couple
29) low-pressure gauge
30) emergency button
31) feed pump stop button
32) feed pump start button
33) internal pressure gauge
34) air pressure valve
35) barometer
36) vacuum gauge
37) feeder pump stop button
38) feeder pump start button
39)emergency stop button
40) high pressure gauge

Injection measuring system including (see fig. 2)

fig. 2

3
USER MANUAL EPS619
1) rotation arm axle
2) rotation arm
3) gather oil tank
4) graduate board
5) graduate
6light

7) oil fender
8) gather oil cup
9) electromagnet
10) fixture seat
11) vertical shaft
12,13) handle

TRANSMISSION SYSTEM

Dragging head (see fig.3)

fig. 3
It is constituted by:
Main engine
Flywheel 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 pressure
Index mobile of reference for the angular number of the rotation of the engine.

4
USER MANUAL EPS619
Concerning the follow figure:

1) pressure gauge 0-0.6Mpa for the low pressure feeding

2) pressure gauge 0-1.6Mpa for the body pump pressure
3) pressure gauge 0-0.25Mpa for the feeder pump pressure
4) pressure gauge 0.1-0Mpa for the vacuum pressure
5) pressure gauge 0-6Mpa for the high pressure feeding
6) temperature digital display
7) flow meter
8) vacuum valve
9) flow meter(13)
10)insider pressure(14)
11) oil supply(15)
12)oil return(16)

Inverter controlling motor

Principle
There 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 speed
F: valve of supplied frequency to motor
S: valve of slip
P: number of motor pole
Obviously there is a direct ration between N and F because P is a constant and S is

almost a constant.

5
USER MANUAL EPS619
Connecting the inverter
The 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 inverter
Moment power-off protection
Lower voltage protection
Over voltage protection
Over load protection

FUEL SYSTEM
Technical data
Volume of oil tank: 60 liter
Pressure of feeding test oil
Low pressure: 0~0.4 Mpa
High pressure: 0~4 Mpa
Feeding capacity of test oil: 8 mm3/r
Stabilization temperature: 40+2
Heater: 1.5kW, 380V
Cooling: water or compressor cooling
Principle
The drawing shown its principle(see Fig.4)
1) tank
2) heater
3) cooler
4) absorb filter
5) feed pump
6) motor
7) filter

8) pressure adjusting valve

6
USER MANUAL EPS619
9) temperature meter
10)high pressure meter
11) under tested pump
12)standard injector
13)injection measurement system
14)over flow valve

Fig. 4

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

Radiator fan

heater

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 thermoregulator 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)

8
USER MANUAL EPS619

L1

- D-

- D-

see fig.5

L3

USER MANUAL EPS619

List of electronic components as bellows:
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

Code

Name
Stop switch
Transformer
Fuse
Fuse
Fuse
Starting capacitor
Ballast
Working light
Electronic heater

Model
VC-2
JRK4-400

FR
M2
M1
KM1,
KM2,KM3
SB1
SB2, SB4
SB3,SB5,SB6
SA2
YA1,YA2

Thermo switch
Main motor
Feed pump motor
Relay

LR2-D1306N

ST
SR

Temperature sensor
Speed sensor
Inverter
Electric potential

QF
TC
FU1,FU4
FU2
FU3
C
L
EL1
JR

RP1,RP2

Emergency button
Stop button
Start button
2-position button
Electromagnet

Y90S-4
LC1-D0910

XB2-EA141
XB2-EA131
XR2-ED21
MQ0.7/AC220

WXD4-24

Spec.
40A
380/220
6A
10A
2A
2uF
220V/20W
220V/20W
220V/1.5k
W
5.5-18.5kW
1.1kW

220/50HZ

Qty
1
1
2
1
1
1
1
1
1
1
1
1
3
1
2
3
2
2
1
1
1
2

10
USER MANUAL EPS619
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

see fig. 6
remarks:
1 pressure adjusting valve
2 air pressure output

3 pressure digital indicator

4 air sensor

Use
It is constituted by:
Rapid attachment for the connection of the compressed air of the workshop
Security 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 test
Regulator of the accuracy pressure

Pressure/de-pressure transducer
Pumps for the empty
Pneumatic cylinder for the starting of the interceptor
Pneumatic cylinder for the driving of the emergency brake
Electro pneumatic valve for the control of the logic functionement

11
USER MANUAL EPS619
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/50-60Hz
Voltage 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 252-64
Capacity: 40-50 L
Note: before testing, please check the oil tank

12
USER MANUAL EPS619

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 pumps 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 light
The 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.

13
USER MANUAL EPS619
MAINTENANCE
The test bench does require a complex periodical maintenance with view to simplify as far
as possible the operators 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 substitution
3. Substitution of the oil filter after about 200 tests on the injection pump
4. Periodical checking (after about 200 tests) of the injectors and the connection tubes
5. Periodical checking of the intervention at the S dimension of pad brake with pneumatic
plate
6. Periodical checking the main motor, usually every half a year

14
USER MANUAL EPS619
ACCESSORIES
Standard accessories for EPS600 series
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Name
Standard nozzle
Assembly
Mounting
High pressure pipe
High pressure pipe
High pressure pipe
High pressure pipe
Inlet pipe
outlet pipe
Holder
Holder
Holder
Driving shaft spanner
Bronze washer
Bronze washe
Bronze washe
Coupling
Coupling
coupling
coupling
Clip

Specification
Z12J1
A,AD,K,P,PD,VE
M14X1.5/M14X1.5X600
M14X1.5/M12X1.5X840
2X6X600XM14XM14
2X6X450 M14
M18X1.5-14.5-1000
M18X1.5-14.5-1000
M14X1.5
M12X1.5
M16X1.5
12.5
14.5
16.5
17
20
25
30

P 1.
Qty
12

Unit
Set

1
12
12
12
12
1
2
2
2
2
1
3
3
2
1
1
1
1
2

Set
Pc
Pc
Pc
Pc
Pc
Pc
Pc
pc
Pc
pc
pc
pc
pc
pc
pc
pc
pc
set

Remarks

15
USER MANUAL EPS619
ACCESSORIES
Standard accessories for test bench EPS600 series
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Graduator
Graduator
block
Spanner
Spanner
Washer
Washer
washer
Plate spacer
Plate spacer
Are spacer seat
Are spacer seat
Plastic seat
Plastic reducer
12/24V wire
fuse
fuse
fuse
Air pipe
Pressure holder
Dial gauge
Gauge holder
Initial pressure holder
Initial pressure holder

45ML
150ML
45ML/150ML
S10
S6
12
14
16
H80
H87
R45
R56
H71
80X60
1M
2A
6A
10A
2M
8 10 12

M12X1.5
M14X1.5

P 2.
12
12
10
1
1
4
8
4
2
2
2
2
2
4
1
2
2
2
1
1
1
1
1
1

pc
pc
pc
pc
pc
pc
pc
pc
set
set
set
set
set
pc
pc
pc
pc
pc
pc
pc
Pc
Set
Pc
pc

16
USER MANUAL EPS619
TROUBLE AND CORRECTIVE ACTIONS
This chapter describes the main problem will be met and list their corrective actions,
No.

Troubles

Causes

1)
2)
The main motor 3)
can not run
4)

Speed
error

3-phase power 380V+5%

main motor over-loaded
whether press control panel
start or running key
not the above problem

1) Test bench not touch the

ground
display 2) The tolerance between speed
sensor and wheel is big
3) Voltage waves
4) Speed sensor coil short circuit

Temperature
display error

Check the connecting

Release
Read menu carefully
Firstly
power
off,
restart in 2 minutes
Touch the ground
Adjust to 0.5mm to
1mm
Check the power
Use multimeter to
check

1) whether
the
temperature Check the shielded
sensor touch the ground safety cable
touch
the
ground or not
2) whether
the
temperature Open
the
sensor
sensor loosened
housing
check
if
loosened
3) whether
the
temperature Measure and make
sensor damaged
sure if the sensor
damping
value
is
107.79(20)
1) leakage

Pressure
adjusting
incorrect

Corrective actions

2) low pressure, can not up

Replace the O sealing

seat
Re-install

valve
3) barometer indicator can not up

Barometer oil pipe

blocked up, clean or
change the pipe

17
USER MANUAL EPS619
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, dont let sling
and transporting tools touch the faces of the test stand.

SOLE AGENT/DISTRIBUTORS

CODIPA COMERCIAL DIESEL PARAGUAY

CALLE TEN. EUGENIO AGERO C/ ITURBE
FONO : 595-331-243126
CONCEPCION
PARAGUAY

18