INSTRUCTIONS FOR USE OF FUEL VALVE TESTER WOO AM MACHINERY CO.

FUEL VALVE TESTER FOR MAN B&W

MODEL : WBTD-1100 (F)

#634 , SONGHYEON-RI , JILLYE-MYEON , KIMHAE-SI , KYUNGNAM , KOREA

TEL. +82-55-346-6900
FAX. +82-55-346-6789
E-MAIL : jsg2580 @unitel.co.kr

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 INSTRUCTIONS FOR USE OF FUEL VALVE TESTER WOO AM MACHINERY CO.

1. Description

4 8

10
7

3
5
9
1

Automizing test cannot be executed.

(re‐testing button)

(oil pump)

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 INSTRUCTIONS FOR USE OF FUEL VALVE TESTER WOO AM MACHINERY CO.

2. Operation Instruction

The WBTD-1100 (F) ensures the correct testing of MAN B&W Diesel slide fuel valve.

The below procedure for fuel-valve testing is to be in compliance with the MAN B&W Diesel A/S'
guidelines for testing of fuel injection valves. Please refer to the MAN B&W manual for general
fuel valve maintenance as well as possible derivations from the below procedure. All numbers
in the text refers to numbers found on the WBTD-1100 (F) front panal

Pre-testing preparations :

Before performing any of the tests, the slide-valve must be completely filled with test-oil :

■ Close pressure relief valve (2) by turning clockwise

■ Turn switch (5) to position OPENING or VENTING
■ Turn pressure control valve (3) clockwise, untill the WORKING PRESSURE display (7)
shows a pressure above "15 bar "
■ The valve is now filled with oil. When clear oil without air-bubbles tickles from the venting hole
throught the breathing-pipe, the valve is full
■ Turn pressure control valve (3) counter-clockwise to cut off air supply
■ Open pressure relief valve (2) by turning counter clockwise
counter-clockwise
■ Turn switch (5) to position NORMAL

Test A : Opening Pressure

■ Air vent until no oil bubble at drain hose.

■ Close pressure relief valve (2) by turning clockwise
■ Turn switch (5) to position OPENING
■ Rapid Increase pressure using the pressure control valve (3) until opening pressure is reached
■ The opening pressure is shown on the OPENING + VENTING PRESSURE display (7).
( After the fuel valve injects test oil from its outlet, the test oil is automatically drained to the
oil tank, while the oil pump(12) still operate without stopping )

Repeat test

■ Press switch (re-testing button) (1).

■ The opening pressure is shown on the OPENING + VENTING PRESSURE display (7).
(Merely pushing the re-testing button(1) makes the flow of the test oil while is draining to the
oil tank, switch toward the fuel valve,thus,it is possible to swiftly execute the re-testing
of the fuel valve.)

After test

■ Close pressure control valve (3) - turning it counter-clockwise

■ Open pressure relief valve (2) - turning it counter-clockwise
■ Turn switch (5) to position NORMAL

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 INSTRUCTIONS FOR USE OF FUEL VALVE TESTER WOO AM MACHINERY CO.

Test B : Venting function

■ Close pressure relief valve (2) by turning clockwise

■ Turn switch (5) to position VENTING
■ Adjust pressure control valve (3) untill WORKING PRESSURE (8) is around 150 bar
■ Turn pressure control valve (3) quickly counter-clockwise to cut off air supply
■ The pressure will slowly decrease on the WORKING PRESSURE display (8). when
the internal leak slide valve opens, the opening pressure is shown on
OPENING + VENTING PRESSURE display (7).
■ Open pressure relief valve (2) - turning it counter-clockwise
■ Turn switch (5) to position NORMAL

Test C : Sealing Test

■ Close pressure relief valve (2) by turning clockwise

■ Turn switch (5) to position VENTING
■ Adjust pressure using the regulator valve (3) untill displayed WORKING PRESSURE (8) is
50 bar below the opening pressure measured in " Test A "
■ Maintain
M i t i pressure and d check
h k that
th t there
th is
i no leak
l k att the
th valve
l nozzle
l
■ Close pressure control valve (3) - turning it counter-clockwise
■ Open pressure relief valve (2) - turning it counter-clockwise
■ Turn switch (5) to position NORMAL

Test D : O-ring Seal Test

■ Close pressure relief valve (2) by tuning clockwise

■ Turn switch (5) to position VENTING
■ Dismantle breathing pipe from the venting hole in the fuel-injection valve head / fixture
■ Plug venting hole with plug supplied with the valve holder
■ Adjust pressure control valve (3) untill WORKING PRESSURE (8) is around 100 bar
■ Decrease air pressure using the regulator valve (3) until manometer (6) reads 0 bar
■ Read pressure from WORKING PRESSURE display (8). The displayed pressure
should remain stable for a few minutes
■ Close pressure control valve (3) - turning it counter-clockwise
■ Open pressure relief valve (2) - turning it counter-clockwise
■ Turn switch (5) to position NORMAL

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 INSTRUCTIONS FOR USE OF FUEL VALVE TESTER WOO AM MACHINERY CO.

Caution

■ After the test of fuel valve, turn pressure relief valve (2) and pressure control valve (3)
working pressure (8) 0 bar.
■ Remove and clean oil filter in the outlet of oil tank often, and replace it when needed
(this is equipped inside of the fuel valve tester).
Replacement should be within every 6 months. Extra filter is included as spare part
at the purchase of this fuel valve tester.
■ When you need to reassemble booster (12), grease inside of cylinder, plunger,and o-ring
with the best quality grease for the smooth operation between cylinder and piston.
■ Regular check is important for the maintenance of this fuel valve tester.

3. Trouble-shooting the WBTD-1100 (F) Test Rig

■ No tests can be performed. Inlet pressure reads 0 bar at all times(manometer(6))

althought air supply is working

Turn
T switch
it h (5) to
t position
iti OPENING or VENTING and
d try
t again
i

■ The display on the WBTD-1100 (F) box is not working

Check power supply.

The WBTD-1100 (F) for testing of MAN B&W Diesel slide valves requires 220V power-supply.

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 INSTRUCTIONS FOR USE OF FUEL VALVE TESTER WOO AM MACHINERY CO.

4. Circuit diagram

5. Booster assembly

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INSTRUCTIONS FOR USE OF FUEL VALVE TESTER WOO AM MACHINERY CO.

■ Description of the Booster ( WBTD-1100 (F) )

NO DESCRIPTION MATERIAL Q"TY (EA) SPARE CODE NO. REMARKS
1 CYLINDER STKM 1 WBTD2001
2 TOP COVER SS400 1 WBTD2002
3 BOTTOM COVER SS400 1 WBTD2003
4 PISTON SS400 1 WBTD2004
5 LOAD S45C(H) 1 WBTD2005
6 PLUNGER S45C(H) 1 WBTD2006
7 CHECK VALVE S45C(H) 1 WBTD2007
8 SLEEVE SS400 1 WBTD2008
9 CHECK VALVE S45C(H) 1 WBTD2009
10 BUSH SS400 1 WBTD2010
11 SLEEVE SS400 1 WBTD2011
12 SLEEVE BC 1 WBTD2012
13 PACKING TEFLON 1 WBTD2013
14 BUSH BC 1 WBTD2014
15 TOP COVER CAP SS400 1 WBTD2015
16 O-RING NBR 2 WBTD2016
17 O-RING NBR 2 WBTD2017
18 O-RING NBR 1 WBTD2018
19 O-RING NBR 1 WBTD2019
20 O-RING NBR 1 WBTD2020
21 BACK UP RING TEFLON 2 WBTD2021
22 O-RING NBR 3 WBTD2022
23 BACK UP RING TEFLON 6 WBTD2023
24 O-RING NBR 2 WBTD2024
25 U-PACKING MAKER 1 1 WBTD2025
26 WEAR RING MAKER 1 WBTD2026
27 WEAR RING MAKER 1 WBTD2027
28 BALL MAKER 1 WBTD2028
29 BALL MAKER 1 WBTD2029
30 SUPPORT BOLT S45C(H) 2 WBTD2030
31 SUPPORT BOLT S45C(H) 2 WBTD2031
32 WRENCH BOLT 10.9 8 WBTD2032
33 WRENCH BOLT 10.9 6 WBTD2033
34 NUT 10.9 4 WBTD2034
35 SOLENOID VALVE MAKER 1 WBTD2035
36 SILENCER MAKER 2 WBTD2036

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INSTRUCTIONS FOR USE OF FUEL VALVE TESTER WOO AM MACHINERY CO.

■ Description of the Booster ( WBTD-1100 (F) )

NO DESCRIPTION MATERIAL Q"TY (EA) SPARE CODE NO. REMARKS

37 FITTING STEEL 1 WBTD2037

38 ONE TOUCH MAKER 1 WBTD2038
39 ONE TOUCH MAKER 2 WBTD2039
40 ONE TOUCH MAKER 3 WBTD2040
41 ONE TOUCH MAKER 2 WBTD2041
42 ONE TOUCH MAKER 1 WBTD2042
43 SPRING SWP 1 WBTD2043
44 SPRING SWP 1 WBTD2044
45 SPRING SWP 1 WBTD2045
46 OIL FILTER MAKER 1 1 WBTD2046

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