⑧BOT EN

BTE-618
INJECTION PUMP TEST BENCH MANUAL

Installation and Operation Manual

BL03 (HZ ）version，2020年8月

⑧ BOT EN Boten Testing Equipment (suzhou）ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

（一 ） Preparation for test bench

1. Once the flexible coupling was removed from the main shaft, In order to fix the flexible cou­
piing again, dial indicator have to be used to ensure the coaxality between the flexible coupling
and the main shaft is within 0.05mm, or else it will cause vibration.
2. Check whether the protective cover is fixed properly.
3. Install the high pressure pump.
Using the fixture shipped together with the machine to install the high-pressure fuel injection
pump tightly onto the working table of the test bench, and connect with the spindle coupling,
and then connect the oil pipe between the test bench and the pump. If the pump is a distribution
pump, it is necessary to connect the 12V I 24V power socket to the solenoid valve coil of the
distribution pump, and select the appropriate voltage by the switch.
4. Inject test oil
Open the two side doors on the lower part of the test bench. Fill the diesel tank with 40 liters of
special test oil or No. 0 diesel oil. Fill the oil tank with 30 liters of engine oil or hydraulic oil.
5. Connect the power line
Ensure that the main power switch of the test bench is in the "off" position, open the back door,
and lead the three-phase four wires into the distribution board from the bottom hole of the test
bench. If you have good ground wire , please lead in the ground wire together. Please connect
the first empty terminal from right which is on middle of the distribution board with the neutral
line, and then connect the other three empty terminal blocks with the fire wire in order to ensure
that there is no short circuit connection. Users with good ground wire shall connect the intro­
duced ground wire to the ground wire terminal reliably.

BTE-618
⑧ BOT EN Boten Testing Equipment (suzhou）ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

Fuel tank Oil tank

。
Oil radiat r fan

。
Fuel radiat r fan

。
Fuel utlet 。
Oil utlet
• Oil pump

Fuel pump
Air pump

。
Temperature c ntrol suitch
。
Waste ii tank

BTE-618
 ⑧ BOT EN Boten Testing Equipment (suzhou）ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

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cr
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。

电阻
F
F』

Relay

- Distribuition box diagram -

I Fire wire

川 Fire wire

BTE-618
⑧ BOT EN Boten Testing Equipment (suzhou ） ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

（二） Commissioning test bench with power on

1. Connect the other end of the three-phase four wire cable (with three-phase four wire plug) to
the power grid through the automatic protection switch, close the automatic protection switch
and power-on the test bench.
2. Electrified observation

Turn the main power switch on the back door to 、 n". Now test bench is powered on, and the

nixie tube on the instrument is on, indicating that the system is working .
3. Commissioning of oil system
Press the start button of the fuel pump motor in the instrument, the fuel pump motor starts to
work. Now observe whether the rotation direction of the fuel pump motor is consistent with the
direction marked on the fuel supply pump. If not, press the stop button of the fuel pump motor,
and then turn off the main power switch at the rear of the test bench (set to "Off" position, and
disconnect the three-phase four wire cable that supplies power to the test bench from the power
grid (i.e. disconnect the automatic protection switch). Then open the electric control door of the
test bench, find the three terminals connected with three phase lines, exchange the terminals of
any two lines(i.e. phase change) and connect them reliably to ensure no short circuit connection.
Close the electric control door, and then repeat the work of 1, 2 and 3. In this way, the rotation
direction of the fuel pump motor is consistent with the direction marked on the fuel supply
pump. Find the fuel regulating valve in the side of the test bench and rotate it clockwise. The
pressure gauge will indicate the fuel pressure, which proves that the fuel supply motor works
normally.
4. Commissioning of gas system
On the front panel of the test bench, there are positive pressure air source output socket--Air
out, air source regulating valve--Air ADJ, air source power selection socket--DC12V/DC24V, Posi­
tive pressure air source ga uge--Air Pressure . Plug the air out port by hand and rotate the regula­
ting valve clockwise. There should be a sense of air outlet at the air outjoint and the Air pressure
gauge has the display value.

BTE-618
⑧ BOT EN Boten Testing Equipment (suzhou）ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

（三） Work after commissioning

Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor inci­
didunt ut labore et dolore magna aliqua. Quis ipsum suspendisse ultrices gravida.
Risus commodo viverra maecenas accumsan lacus vel facilisis.

（四） Failure analysis list

No Fault phenomenon Faull 『eason T『oubleshooting.
Main moter can’ t start 1.F『equency convertor is damaged 1.Contact with manufactu『e『

2. Self protection of frequency converto『 2.Sea『ch in fault list o『 contact manufactu『e 『

3.Eme『gency stop switch is damaged 3.Check and 『eplace
2 The rotation speed is not stable 1. 1. The distance of speed sensor is not prope『 Adjust distance
2. 2.potentiometer is damaged Replace
3 Fuel pump moto 『 doesn’t WO『k O『 have 1.motor is damaged 1.overhaul
big noise 2.potentiometer is damaged 2 overhual and 『eplace
3.The power is lack of phase 3.check 3 phase powe『
4.No 24V powe『 4.Check
4. Measuring and counting doesn’t WO『k No speed display Check speed senso『
’
5 Ret『actable oil baffle doesn t move or 1.counting mete『 is damaged 1.ove『h aul
only move to one di『ection 2.No 110V powe『 2. Check transforme『 output and 『elay
6 The lamp doesn't work 1.No 220V powe『 1.0verhaul
2.The lamp is damaged 2.Replace
7 No output fo『 DC12V /24V 1 1.Fuse is damaged 1.Replace
2.Regulated powe『 supply failu『e 2.Replace
3.No power input 3.Check power supply
8 Pressure guage are not stable with big 1.There is ai『 in oil ci『cuit 1.0verhaul
v1brat1on 2.Less fuel/oil in the tank 2. inject fuel/oil
3.The filter is blocked 3.Clean filter element or 『eplace filter
5.The vane pump is worn 4.Replace or 『epai『
9 Fuel supply p「essu 「e can’ t adjust higher 1.The pressure regulating sc『ew of overflow 1.Adjust the pressu『e 『egulating screw of
valve is loose overflow valve
2.The movement of ove 『flow valve spool is not 2.Clean overflow valve
flexible

BTE-618
⑧ BOT EN Boten Testing Equipment (suzhou）ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

（三） Work after commissioning

Lorem ipsum dolor sit amet, consectetur adipiscing elit, sed do eiusmod tempor inci­
didunt ut labore et dolore magna aliqua. Quis ipsum suspendisse ultrices gravida.
Risus commodo viverra maecenas accumsan lacus vel facilisis.

（四） Failure analysis list

No Fault phenomenon Faull 『eason T『oubleshooting.
Main moter can’ t start 1.F『equency convertor is damaged 1.Contact with manufactu『e『

2. Self protection of frequency converto『 2.Sea『ch in fault list o『 contact manufactu『e 『

3.Eme『gency stop switch is damaged 3.Check and 『eplace
2 The rotation speed is not stable 1. 1. The distance of speed sensor is not prope『 Adjust distance
2. 2.potentiometer is damaged Replace
3 Fuel pump moto 『 doesn’t WO『k O『 have 1.motor is damaged 1.overhaul
big noise 2.potentiometer is damaged 2 overhual and 『eplace
3.The power is lack of phase 3.check 3 phase powe『
4.No 24V powe『 4.Check
4. Measuring and counting doesn’t WO『k No speed display Check speed senso『
’
5 Ret『actable oil baffle doesn t move or 1.counting mete『 is damaged 1.ove『h aul
only move to one di『ection 2.No 110V powe『 2. Check transforme『 output and 『elay
6 The lamp doesn't work 1.No 220V powe『 1.0verhaul
2.The lamp is damaged 2.Replace
7 No output fo『 DC12V /24V 1 1.Fuse is damaged 1.Replace
2.Regulated powe『 supply failu『e 2.Replace
3.No power input 3.Check power supply
8 Pressure guage are not stable with big 1.There is ai『 in oil ci『cuit 1.0verhaul
v1brat1on 2.Less fuel/oil in the tank 2. inject fuel/oil
3.The filter is blocked 3.Clean filter element or 『eplace filter
5.The vane pump is worn 4.Replace or 『epai『
9 Fuel supply p「essu 「e can’ t adjust higher 1.The pressure regulating sc『ew of overflow 1.Adjust the pressu『e 『egulating screw of
valve is loose overflow valve
2.The movement of ove 『flow valve spool is not 2.Clean overflow valve
flexible

BTE-618
⑧ BOT EN Boten Testing Equipment (suzhou）ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

（五） Maintenance

1. Maintenance of fuel system:

(1) The fuel in the fuel tank should be replaced with new oil every 800 hours or after
commissioning 500 pumps;
(2) The oil pipe clamp at each connection part must be correctly set and clamped to pre­
vent oil leakage and air entering.
(3) Clean the coarse filter every 800 hours or after commissioning 500 pumps;
(4) After the pressure regulating valve is rotated to the bottom, it is not allowed to
rotate it with force to avoid damaging the pressure regulating valve.
2.Adjustment of standard fuel i时ector
2.1 Pintle standard injector
In order to ensure the test accuracy of the test bench, PJ-40 nozzle tester is used to cali­
brate the standard injector regularly to check whether the opening pressure is correct.
The standard pressure is 17.5 + 0.2MPa, and the flow uniformity of the fuel injector need
to be checked.
2.2 Low inertia standard injector
In order to ensure the test accuracy of the test bench, PJ-40 nozzle tester is used to cali­
brate the standard injector regularly to check whether the opening pressure is correct.
The standard pressure is 17.5 + 0.2MPa, and the flow uniformity of the fuel injector need
to be checked.
3. Check the coupling regularly
Due to long-term operation, it is necessary to regularly check whether the universal joint
connecting screw and spring piece are loose or broken, so as to ensure the safe operati­
on of the main engine.

BTE-618
⑧ BOT EN Boten Testing Equipment (suzhou）ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

- Controller panel Introduction -

一 ， Technical parameter
1.Six spindle speed setting and storage
2. Speed switching directly by digital
3. In the automatic mode, rotate the speed control knob to set the speed of each gear
4. Galloping protection (emergency stop button)
5. Automatic control of oil temperature
6. Power consumption: < 20W
7. Temperature control range: 0 ～ 99.9 °ζ （accuracy: 0.5 °ζ ）
8. Speed measurement range: 20-4000r I min
9. Speed range: 20-4000r I min (1. 2,.3.4.5.6 , 6 gears in total)
10. Fuel i时ection times: 1～5000 times

BTE-618
⑧ BOT EN Boten Testing Equipment (suzhou ） ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

⑤ ⑤ ⑦ ③ ③

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ZME POWER ⑦⑦

① ② ＠
- Controller panel Introduction -
-, Introduction of digital display part
①Power switch

②Emergency stop switch: Used for galloping protection

③Diesel pump switch

④Oil pump switch

⑤Oil measuring times knob/count setting: Setting from Oto 5000

⑥ count Oil measuring times knob: 0-5000 times

rn Diesel temperature : 0-99.9℃

m Return oil temperatu陀：0-99.9。 c

抄 1 Oil temperature : 0-99.9℃

⑦Speed setting button: setting range: 25-4000r I min (1.2.3.4.5.6, six gears in total)

③Speed meter: display the speed range : 25-4000r I min

⑨PWM knob: 12-24 V PWM adjustment (adjustment range 5% - 95%)

⑩RED4 output port: drive RED4 electric governor

@ZME output port: drive ZME I SCV I IMV valve

BTE-618
⑧ BOT EN Boten Testing Equipment (suzhou ） ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

④

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ZME POWER

③ ② ①

- Controller panel Introduction -

-, Operation for digital display part

(1) 。
N rmal 。 perati。n:
①oil-measuring button:Press Count Start: the fuel cut-off baffle acts, and the fuel i时ection times
show positive count. When the count reaches the preset number, the fuel cut-off baffle will reset
automatically.
②Turn (FWD-forward) or (REV-reverse) knob: start the positive and negative rotation of the
motor. Turn the knob to the (OFF) to stop the motor.
③Turn (Man I Auto) knob: turn from automatic to manual, and adjust the speed with potentio­
meter.
④speed regulator : In the automatic mode, rotate the speed control knob to set the speed of
each gear,

①Display: spindle speed, oil measuring times, Fuel temperature

②Six speed preset setting, automatic control of fuel temperature, arbitrary setting of count

value.

③There are Stop, forward rotation, reverse rotation, temperature control, oil pumping, count,

gear operation and mark indication on the controller interface. User can complete all debugging

for i时ection pump according to the main control interface.

BTE-618
⑧ BOT EN Boten Testing Equipment (suzhou ） ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

－、 Controller wiring instructions

A. Controller fuse

B. Power socket

C. 3-pin 485 communication socket (definition: 1.485A 2. Shielded wire 3.485b)

D. 4-pin temperature sensor socket (definition: 1.SV 2. 18b20 signal 3. GND 4. Shielded wire)

E. 5-pin frequency convertor socket (definition: 1. GND 2. PWM motor speed regulation 3.

Motor reverse I 4. Motor forward 5. GND 24v negative pole)

F. 7 pin (definition: 1. Diesel heating 2. Oil heating 3. Diesel heat dissipation 4. Engine oil coo­

ling 5. Oil pump 6. Diesel pump 7. 24 negative pole)

G. 7 pin (definition: 1. Baffle extension 2. Baffle retraction 3. 24 V negative 4. 12 V positive speed

sensor 5. Speed signal 6. 12 V negative GND 7. Shield wire)

。
Precauti ns:

1. This product is a high-tech product, please let the professional person do the maintenance. It

is not allowed to open the cabinet to remove the integrated circuit and connector and carry out

various operations under the condition of power on, so as to avoid damaging the controller.

2. When the instrument is used, the grounding must be good.

3. After the motor runs forward, if you need to run in reverse direction, you should turn knob to

(OFF) to stop running and then turn knob to (REV) .

BTE-618
 ⑧ BOT EN Boten Testing Equipment (suzhou）ζo.,L TD.

INJECTION PUMP TEST BENCH MANUAL

Air pressure Internal pressure Diesel pressure Oil pressure Return pressure

Pointer

Air outlet

Air ADJ

Oil pump
Oil return

Diesel pump
Internal
Diesel return
pump
chamber

- Operating room diagram -

BTE-618