User Manual

Diesel Engine
Electronic Control
System Training Panel
(Bosch System)

User Manual
 User Manual

Contents
I. Preface............................................................................................................3
1.1 About the product..................................................................................3
1.2 Basic configuration and technical parameters......................................3
1.3 Main function.........................................................................................4
1.4 Precautions for use of products.....................................................4

1.5 Experiments...........................................................................................5
1.6 Components..........................................................................................6
 User Manual

I. Preface

1.1 About the product

The training panel adopts the real components of Bosch’s common rail fuel
electronically-controlled diesel engine electronic fuel injection system to
illustrate the structure and working process of electronic control diesel
common rail injection system which with high pressure fuel pump and electric
injector.

1.2 Basic configuration and technical parameters

A. Components of the product including:

Main Relay ， EGR Control Valve ， Glow Plug Relay ， Diagnostic
Socket ， ECU ， Air Flow Meter, Intake Air Temperature Sensor,Electronic
Accelerator Pedal Position Sensor,Fuel Rail Pressure Sensor,Coolant
Temperature Sensor, Crankshaft Position Sensor,Camshaft Position
Sensor,Fuel Metering Valve,4 injectors, Ignition Switch, Diagnostic
Socket,Emergency Stop Switch

B. Technical parameter：
1) Size: 1600mm x 700mm x 1700mm (length x width x height)
2) External power supply: A.C. 110/220V±10% 60Hz

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3) Operating voltage: 12V DC

4) Operating temperature: -40℃～+50℃

1.3 Main function

1. Real and operable electronic control diesel common rail injection system to
illustrate the structure and working process. Rolling crankshaft position
signal wheel, common rail diesel sequential simultaneous injection.
2. Never fade color circuit diagram and working principle diagram are painted
on the board whose surface coating with varnish. The trainees can learn
and analyze the working principle of the control system by referencing the
diagram and the real object.
3. Detection terminals are installed on the training panel. On the bench,
operators can detect resistance, voltage, current, and signals of
components of the electronic control system.
4. The training panel is installed with diagnosis socket connecting dedicated
or universal automobile decoder, The diagnosis socket reads fault codes,
clears fault codes, and reads data stream from the engine electronically-
controlled system.
5. Lockable casters are installed for fixing and moving the panel.
6. The training panel connects to 110V AC voltage which changes to 12V DC
voltage for panel use. The three phase driving motor connects to 220V AC.
7. Equipped with wireless fault setting and appraisal system, the fault setting
plate is used for wireless fault setting for the equipment.
8. The acceleration pedal can control the step motor to suck in or come out.
It also can control the throttle valve open or not.

1.4 Precautions for use of products

1) When the equipment is running, do not disconnect the power switch.
2) 110/220V AC power supply is required for training panel and driving
motor. The power connection should be operated by a professional
electrician in high voltage.
3) Do not touch any moving parts or components when doing
experiments to avoid injury.
4) After using the equipment, disconnect the power supply and keep it
from water and dust.

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1.5 Experiments

This equipment is available to do the following line open circuit

experiments.
No. Malfunction Description Malfunction Phenomenon

1 Air Flow Meter Intake Air The engine is shaking and hard to

Temperature Sensor Line 3 star

2 Electronic Accelerator Pedal
With fault code
Position Sensor Line 4
3 Electronic Accelerator Pedal
With fault code
Position Sensor Line 6
4 Fuel Rail Pressure Sensor Line Four injectors do not inject fuel

2
5 Coolant Temperature Sensor With fault code

Line1
6 Crankshaft Position Sensor Line With fault code

1
7 Camshaft Position Sensor Line Hard to start

8 Fuel
2 Metering Valve Control Can’t start

9 Injector
Line 4 Control Line Cylinder 4 does not inject fuel

10 Injector 3 Control Line Cylinder 3 does not inject fuel

11 Injector 2 Control Line Cylinder 2 does not inject fuel

12 Injector 1 Control Line Cylinder 1 does not inject fuel

13 Diagnostic Socket Line 7 Can’t do diagnose

14 EGR Control Valve Line 1 With fault code

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15 Main Relay Line 86 Can’t start and does not inject fuel.

1.6 Components
15 13
14

1
12
5
17

16
5
2 11
5

10

5 6 7 8
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1. Main relay and fuse: used for control and protect the power supply of
engine ECU or other components.
2. Air flow meter intake air temperature sensor: it is the device for transfer
the air flow data into electric signal.
3. Accelerator pedal, diagnostic socket, ignition switch, USB port.

Accelerator pedal: In the process of driving, the driver controls the engine's air
intake by controlling the press strength of the pedal, so as to control the
speed of the engine.

Diagnostic socket used for connecting the

decoder.
USB port is used for connecting power supply.
SD card slot is used reading fault codes.

5. Fuel tank
6. Main power switch: used for control the power on or off of this equipment.
7 & 8.

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High pressure fuel pump

Oil-water separator

Fuel filter

Camshaft Position Sensor

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Crankshaft Position Sensor

10. Injector, Oil return valve switch, Fuel pressure sensor.

11. Throttle body, emergency switch.

Throttle body control intake air.

Press the emergency switch the

equipment will stop working
immediately, clockwise rotate the
switch to make it work normally.

12. Glow plug: during severe winter, the electric plug provides heat
energy to improve start-up performance
13.Engine control unit: special microcomputer controller for automobile.
14.Preheating relay: used for heating the air when cold starts.
15. EGR control valve: to make appropriate amount of waste gas into the
combustion in cylinder, reducing NOX emissions
16. Step motor: controlled by the throttle electronic accelerator pedal

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17. Fuel flow control valve: used to control the volume of oil into the cylinder
combustion