HA NM I POW ER HDFD-1100

ISO 9001 MANUAL NO : HDFD-1100-0.12(2009.04)

INSTRUCTION MANUAL
FUEL VALVE TEST DEVICE
MODEL : HDFD-1100

HANMI HYDRAULIC MACHINERY CO., LTD.

#715-14, Mora-dong, Sasang-ku, Pusan, Korea
Tel. +82 51 305 2512~4 / Fax. +82 51 301 1721
E-mail : hm131@kornet.net / Hm132@kornet.net
 PAGE : 1

HA NM I POW ER HDFD-1100
ISO 9001
FUEL VALVE TEST DEVICE

CONTENTS

A. SPECIFICATIONS PAGE 2

B. OPERATION INSTRUCTIONS PAGE 3

C. TROUBLE-SHOOTING FOR THE HDFD-1100 TEST RIG PAGE 7

D. OUTLINE OF THE HDFD-1100 PAGE 8

E. OIL CHART PAGE 9

APPENDIX

- GENERAL ASSEMBLY (DWG NO. M12-7100-0)

- CIRCUIT DIAGRAM (DWG NO. M12-7100-1)

- ASSEMBLY DRAWING (DWG NO. M12-1100-0)

- TOOLS (DWG NO. M12-7112-0)

- SPARE PARTS (DWG NO. 1M12-7113-0)


HA NM I POW ER
ISO 9001
A. SPECIFICATIONS
1. MODEL NO
2. OUTPUT PRESSURE
3. AIR CONSUMPTION
4. MAX. FLOW AT NO PRESSURE
5. DISPLACEMENT PER CYCLE
6. PUMP SPEED
7. OIL TANK CAPACITY
8. WEIGHT
9. DIMENSION
10. POWER SUPPLY
11. CLASSIFICATION
PAGE : 2
HDFD-1100
FUEL VALVE TEST DEVICE
: HDFD-1100
: 0~1300BAR AT 10BAR AIR INPUT
.0~900BAR AT 7BAR AIR INPUT
: 60.5LITERS/CYCLE AT 10BAR INPUT
.44LITERS/CYCLE AT 7BAR INPUT
: APPROX. 1.2LITERS/MIN AT 7BAR AIR INPUT
. : 17.2㎤
: APPROX. 60 CYCLES/MIN. AT 7BAR AIR INPUT
: 6 LITERS
: ABT. 115kg AT EMPTY
: 885mm X 638mm X 1700mm
: SINGLE PHASE 115~230VAC
: GAUGE-CLASS 1.0, DISPLAY 0.2
PERFORMANCE CURVES
 PAGE : 3

HA NM I POW ER HDFD-1100
ISO 9001
FUEL VALVE TEST DEVICE

B. OPERATION INSTRUCTIONS

The HDFD-1100 ensures the correct testing of MAN B&W Diesel slide fuel valve.

The atomizing test cannot be executed.

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.
All numbers in the text refer to the numbers found on the HDFD-1100 front panel
(see the figure 1, Unit Layout illustrated overleaf.)

Pre-testing preparations :
Before performing any of the tests, the slide-valve must be completely filled with test-oil :
! CAUTION
"A coupling is separately packed when a product is supplied"
When a product is supplied, the coupling is separately packed under an unassembled state.
Assemble the coupling packed in tool box to the product.
(see the figure of page 8, No 10 " fuel outlet" coupling)

„ Turn Switch g to position RESET

„ Close Pressure Release Valve d by turning clockwise

„ Turn Pressure Control Valve e clockwise, until the WORKING PRESSURE Display j shows a
pressure above zero
„ The valve is now filled with oil. When clear oil without air-bubbles tickles from the venting hole
through the breathing-pipe, the valve is full
! Please connect vent hose to valve venting hole in advance. ( See next page picture:
vent hose)
But in case of O-ring seal test, remove the vent hose, then block vent hole to use plug.
„ Turn Pressure Control Valve e counter-clockwise to switch off air supply

„ Open Pressure Release Valve d by turning counter-clockwise

 PAGE : 4

HA NM I POW ER HDFD-1100
ISO 9001
FUEL VALVE TEST DEVICE

VENT HOSE

! In case of following function test

please make sure to connect vent hose
to fuel valve.
- Venting function.
- Opening pressure.
- Leak test.

! If fuel valve vent hole is blocked

by plug Oil is not spray.

( Figure. VENT HOSE)

Test A : Venting function

Before performing any of the tests, the slide-valve must be completely filled with test-oil, as
described
in the section "Pre-testing preparations".

z Turn Switch g to position RESET position

z Close Pressure Release Valve d

z Slowly adjust Pressure Control Valve e until WORKING PRESSURE j is around 200bar

z Turn Switch g to VENTING PRESSURE position

z Turn Pressure Control Valve e quickly counter-clockwise to switch off air supply

z The pressure will slowly decrease on the WORKING PRESSURE Display j. When the internal
leak slide valve opens, the opening pressure is shown on OPENING + VENTING PRESSURE
Display i. The pump stops automatically

z Open Pressure Release Valve d - turn it counter-clockwise

 PAGE : 5

HA NM I POW ER HDFD-1100
ISO 9001
FUEL VALVE TEST DEVICE

VENT HOSE

t
s
r
o p
n

( Figure 1, Unit Layout )

.ⓛ Full Stroke Push Button

② Pressure Release Valve
③ Pressure Control Valve
⑤ Switch (OFF / VENTING / RESET / OPENING)
⑥ Air Pressure Gauge (0~10bar)
⑦ Pressure Display (VENTING + OPENING PRESSURE)
⑧ Pressure Display (WORKING PRESSURE)
 PAGE : 6

HA NM I POW ER HDFD-1100
ISO 9001
FUEL VALVE TEST DEVICE

Test B : Opening pressure The atomizing test cannot be executed.

z Turn Switch g to RESET position.

z Close Pressure Release Valve d
z Slowly adjust Pressure Control Valve e until WORKING PRESSURE j is around 200bar
z Press FULL STROKE Push Button c
z Turn Switch g to OPENING PRESSURE position
z Increase pressure using Pressure Control Valve e until opening pressure is reached
z The opening pressure is shown on the OPENING + VENTING PRESSURE Display i
.the pump stops automatically
z Close Pressure Control Valve e - turn it counter-clockwise
z Open Pressure Release Valve d - turn it counter-clockwise

Test C : Leak Test

z Turn Switch g to RESET position
z Close Pressure Release Valve d
z Slowly adjust Pressure Control Valve e until WORKING PRESSURE j is around 200bar
z Press FULL STROKE Push Button c
z Turn Switch g to OPENING PRESSURE position
z Slowly Adjust pressure using Pressure Control Valve e until displayed WORKING PRESSURE
j is .10-20bar below the opening pressure measured in Test B
z Close Pressure Control Valve e - turn it counter-clockwise
z Open Pressure Release Valve d - turn it counter-clockwise

Test D : O-ring Seal Test

z Turn Switch g to RESET position
z Close Pressure Release Valve d
z Dismantle breathing pipe from the venting hole in the fuel-injection valve head/fixture
z Plug venting hole with plug supplied with the valve holder
z Slowly adjust Pressure Control Valve e until WORKING PRESSURE j is around 100bar
z Decrease air pressure using Pressure Control Valve e until manometer ⑥ reads 0bar
z Read pressure from WORKING PRESSURE Display j. The displayed pressure should remain
.stable for a few minutes
z Close Pressure Control Valve e - turn it counter-clockwise
z Open Pressure Release Valve d - turn it counter-clockwise
 PAGE : 7

HA NM I POW ER HDFD-1100
ISO 9001
FUEL VALVE TEST DEVICE

C. TROUBLE-SHOOTING FOR THE HDFD-1100 TEST RIG

Problem Possible solution Explanation Remark

No tests can be preformed Switch g to position When the electronic

Inlet pressure reads 0bar "RESET" and try again blocking
at all times (air pressure system in the HDFD-1100 is
gauge ⑥ although air activated, air supply to the
supply is working unit is blocked. The magnet
valve is"released" by
resetting the unit.

Make sure that the valve is Air inside the fuel valve
Air supply is turned off
filled with oil (clear oil is tickling results in malfunction of the
almost immediately after
from venting hole when electronic pressure
test is started
Pressure Control Valve e is transmitter.
turned a few times(clockwise)
before attempting to run a test.
Follow instruction above test
A before attempting to run the
desired test again

Air supply is turned off Reset the unit, and start the
when Full Stroke Button test again. press the
is pressured "FULL STROKE" Button c
while the Switch g is in RESET
position

The HDFD-1100 is plugged 1.Make sure the Switch g is Consult with Maker
in and turned on, but air pointing at either " OPENING HANMI for
supply is never blocked PRESSURE"or"VENTING FUNCTION" maintenance advice.
2.If the Switch is pointing at either
"OPENING PRESSURE"or"VENTING
FUNCTION",and a sudden pressure
drop doesn't result in a blocking
of the air inlet, the unit needs
further trouble-shooting

The display on the HDFD-1100 Check power supply

box is not working
 PAGE : 8

HA NM I POW ER HDFD-1100
ISO 9001
FUEL VALVE TEST DEVICE

D. HDFD-1100의 외부 명칭

tu s
r
n v

Pos. 1 Full Stroke Valve (Push Button) . (HM-FD01-01)

Pos. 2 Pressure Release Valve .. (HM-FD04-02)
Pos. 3 Pressure Control Valve / pneumatic reducing valve . (HM-FD04-03)
Pos. 4 Pressure transducer (inside HDFD unit) . . .(HM-FD04-04)
Pos. 5 Switch (OFF/VENTING PRESSURE/RESET/OPENING PRESSURE) . . (HM-FD04-05)
Pos. 6 Air Pressure Gauge for "Inlet air pressure"(0~10bar) . (HM-FD04-06)
Pos. 7+8 Pressure Display with two displays . . ..(HM-FD04-07)
Pos. 9 Adapter "air inlet"M42x2
Pos. 10 High Pressure Outlet "fuel outlet" .(HM-FD04-10)
Pos. 11 Filler cap with strainer (inside HDFD unit) .. (HM-FD04-11)
Pos. 12 Oil filter (inside oil tank) .(HM-FD04-12)
Pos. 13 2-Way pneumatic valve(inside HDFD unit) ..(HM-FD04-13)
Pos. 14 Pump AHP-1100(inside HDFD unit) . . . (12-1100-0.0)
 PAGE : 9

HA NM I POW ER HDFD-1100
ISO 9001
FUEL VALVE TEST DEVICE

E. OIL CHART

1. Recommendable Oil for Testing

Rust-preventing hydraulic oil with viscosity of 7-10 cST at 50 ℃.

2. Initial Filling Quantity

Fill the oil until the level gauge indicates between High and Low.
No further replenishment of the oil is required thanks to the close circuit.
(see figure 2, Oil level gauge)

3. Draining oil
(see figure 3, Oil tank)

Filter cap with

strainer
(Filling oil)

Drain plug
(Draining oil)
( figure 2, Oil level gauge ( figure 3, Oil tank )