Configuration

1. 1. Installation and configuration.

Connect the Common Rail Pump Tester to the current network (220 Volt – 50 Hz).
Connect the Pressure Regulator (type Bosch on CP1) located on the test rail to the Common Rail
Pump Tester by a “Cable R” enclosed into the kit.
Connect the Pressure Sensor (Bosch type) to Common Rail Pump Tester by a “Cable P” enclosed
into the kit.
Switch on the Common Rail Pump Tester box by relative switcher.

Dismount the common rail pump from the vehicle. Install the pump to the injection pump test bench
and the pressure sensor to the test rail.

In the picture below you can see the installation of the various elements for testing:

1. The pressure regulator of CP1 pump should be installed on the rail enclosed into the kit.
2. Connection for regulator refusal measurement. It is possible to measure fuel quantity in the
burette.
3. High pressure fuel sensor (Bosch Type).
4. Injectors output. It is possible to test up to 4 injectors simultaneously. In case of test without
injectors, it is possible to put the stoppers enclosed into the kit.
5. The Stopper of regulator refusal.

Remove the fuel temperature sensor and on its place screw the connection to join the pump and
the test bench for transfer pressure measurement test.
 Setting

Test Bench setting:

Switch on the test bench.
Feeding pressure of calibration liquid appr. 0.2/0.3 bar (7 psi).
Rotation direction of the test bench corresponds to the rotation direction of the pump (read carefully
the label on the pump).
Do not use the heater of the test bench to rise the temperature of calibration liquid.

Clearing:
Test bench rotation: 1000 rpm
Feeding pressure of calibration liquid appr. 0.2/0.3 bar (7 psi).
Duration: appr. 1 min.
Electroinjectors: (if presents) not feeded
 Test

Pumping elements state control

First test:
Feeding pressure of calibration liquid: 0.2/0.3 bar
Test bench rotation: 1000 rpm
Electroinjectors: not feeded
Pressure regulator (REG PWM) : increase the value clicking on the "+" button until 1350 bar in
the “P section” is displayed in case value overcoming, adjust pressure by clicking on the "-"
button.
In-line pressure (P section): 1350 bar
Verify pressure hold

Second test:
Feeding pressure of calibration liquid: 0.3 bar
Test bench rotation: 1000 rpm
Electroinjectors: Not feeded
Pressure regulator (REG PWM) : increase the value clicking on the "+" button until 500 bar in the
“P section” is displayed in case value overcoming, adjust pressure by clicking on the "-" button.
In-line pressure (P section): 500 bar
Verify transfer pressure (appr. 5 - 6 bar)
Pump total delivery control
First test:
Feeding pressure of calibration liquid: 0.3 bar
Test bench rotation: 1000 rpm
Electroinjectors: not feeded
Oil spray counter: 200 pulse
Pressure regulator (REG PWM) : increase the value clicking on the "+" button until 500 bar in the
“P section” is displayed in case value overcoming, adjust pressure by clicking on the "-" button.
In-line pressure: 500 bar

Delivery values:

Pump Delivery (cm³) Tolerance

R9044Z013A 160 (+/-) 10%

The above mentioned values were found at 37°C of temperature of calibration liquid ISO4113.

Second test:

Feeding pressure of calibration liquid: 0.3 bar

Test bench rotation: 1000 rpm
Oil spray counter: 200 pulse
Electroinjectors: not feeded
Pressure regulator (REG PWM): increase the value clicking on the "+" button until the value
arrives to 1000 bar in the “ P section” , in case of overcoming, reduce the value by clicking on the
"-" button.
In-line pressure (P section): 1000 bar

Delivery values:

Pump Delivery (cm³) Tolerance

R9044Z013A 140 (+/-) 10%

The above mentioned values were found at 37°C of temperature of calibration liquid ISO4113.

.
IMV valve test (pumping elements feeding):

If the Common Rail Pump Tester is used in cooperation with a Common Rail Pressure
Regulator Tester it is possible to check the magneto-proportional valve.
Disconnect the “P cable” from the Pressure Regulator located on the test rail.
Connect the Common Rail Pressure Regulator Tester to the “P cable”.
(REG PWM): increase the value by clicking on the "+" button until it arrives to 60.0 (%) value.
Connect the Common Rail Pressure Regulator Tester to the IMV valve located on the pump and
check the correspondence of the Duty Cycle (Duty section).

Test:
Feeding pressure of calibration liquid: 0.3 bar
Test bench rotation: 1000 rpm
Electroinjectors: Not feeded
Pressure regulator on the rail: Not feeded
IMV valve (REG PWM) : reduce the value by clicking on the"-" button until the value arrives to
100 bar in the “P section”.
In-line pressure (P section): 100 bar

Verify the IMV valve absorption (Section - Curr. (A) on the Common Rail Pressure Regulator
Tester):
Delivery min: 0.90 Ampère
Delivery max: 0.12 Ampère

If delivery value is near the min, the pump is quite ineffective.