Full-Automatic Common Rail Test Bench

CR-NT915

Instruction manual
 Brief Introduction
 Installation instruction
 Input oil into tank
 Overall structure
 Computer operation system
 Test Bench Maintenance
 Warranty and maintenance

1. Brief Introduction:
CR-NT915 is a full-automatic common rail test bench designed and developed by Nanyang
Nantai, with following functions:
1.1 Test application：BOSCH.DENSO.DELPHI.SIEMENS injectors and pumps.
1.2. Industrial computer controls the operation high precisely, measure the fuel delivery and
display on computer automatically, test the sealing of injectors, test fuel injected and return
quantity under different working conditions: full-loaded, idling, pilot injection. Equipped with
original BOSCH flow sensor for monitoring fuel delivery, judge the single and whole function of
the injector.
1.3Industrialized computer with XP system and 19’LCD, humanized handling system to enable
easy operation. The data can be added by users, and printed and saved, with 19’LCD.
1.4. Full-automatically detect common rail pumps, injection volume, return volume, pump
chamber pressure, oil supply pressure, sealing performance, measuring unit ZME and DRV
valve performance, flow also can measure by imported flow sensor, pursuant to initial data, judge
whether single index and overall property are qualified or not.
1.5. Injector and pump use separate sensor ensure the accuracy of the test and the life time of
the sensor
1.6. Equipped with original Bosch CP3 pumps, Bosch rail pipe with DRV to make sure the rail
pressure precision ±5bar.
1.7. Electronic unit injector and Electronic unit pump (EUI/EUP)Caterpillar HEUI. VP37 VP44 ,
can be tested by installation of additional system and adapters.
1.8. Constant temperature equipment used, setting the oil to be 40±2 degree，make sure the test
precision.
1.9. Feeding pressure can be adjusted 0-20Mar. And it can meet the feeding pressure needs of
different electronic-controlled pump for oil demand.
1.10. Self-protection: over-heated, oil mist, over-pressure, insufficiency oil volume are all
alarmed by indicator light, to avoid any accidents.
1.11. All injector drive channel with short circuit protection function.
1.12. Compact universal test bench and various fixture for different pumps are used together to
make the efficient maintenance.
1.13 Optional function: lubrication system.
1.14. Remote control and multi-networked is convenient for service and software upgrading.
2.Installation instruction
2.1. Environment
A. Test bench must be placed in the draught, dry room being far away from corrosive gas,
temperature is between 5-28℃.
B. Test bench must placed on solid and plane ground, level test are required, put
shock-absorbing rubber on the foursquare.
2.2. Electricity power distribution requirement
A. 4*6mm 2 four core cable is needed for 11KW, null line protection for outer shell.
B. Test bench must be connected with specialized circuit, connecting with domestic load is
forbidden. The distance between switchboard and test bench should not exceed 5 meters,
remove the unnecessary electric wire, coiling them is forbidden.
C. voltage standard: three phase 380V±10%, imbalance ≤3%, the regulated power supply should
be connected if voltage fluctuation is largely, and keep design margin.
2.3. Wiring steps
Make sure the power is cut off, open the switchboard, drill the compatible three phases four wire
from the bottom of test bench, find unconnected four terminals of R, S, T,O below the right wiring
terminal on the switchboard, R, S, T are live wire, O is naught wire, make sure correct connection,
tight the bolt with the necessary tool.
2.4. Grounding protection (option):
The power supply is three phases four wires, If electric leakage exists when power supply is
properly connected, this certifies the naught is not good or not connect into ground. Naught
protection is needed then. Steps as follows:
A. Be away 1.5 meter of test bench, find a moist place indoor or outdoor, embed the ground
connector (steel rod, steel angle, flat steel, iron angle) into the earth, 1.5-2 meter under the earth
ground.
B. To make sure the effect, the grounding connector should be with certain mechanical hardness,
and longer than 2 meter. It should have the hole location or bolt on the end coming out of ground,
for use of cable connecting if needed.
C. Dismantle the short wires in the switchboard, from O position to the wiring points of shell.
D. The grounding wire is ≥ 4 mm2 strand, one end should connect with the earthing point of
switchboard’s shell, and another end should be fixed the grounding body with 6 --10 mm2 bolts.
E. The earth resistance is 4 ohms

3. Input oil into tank

To ensure the test precision and steadiness, input the DIN ISO04113 oil which is specialized for
testing to the oil tank, the volume should not be less than two thirds of oil tank.
4.Overall structure

Control Cable
Industrial SERIAL PORT232 Meter
computer Test
(single bench
Mainboar
d chip)

Monitor,keyboard
5.Computer operation system
5.1.After connecting power supply and inputting test oil, connect the common rail wire properly,
fix the oil pump and injector. Turn on the power supply, The working light turns on and computer
starts. Screen surface as follows：

5.2 Click “common rail test system ”Screen surface as follows：

Notice: The motor begins to run now and the oil supply starts, observe the oil supply pressure
gauge, it is showing “≥0.03M”.
 5.3.Click ‘system setup’,Screen surface as follows：

Choose the testing pump code, then click “pump type” to confirm the pump equipped, click 'Edit'
to set up or add pump data, Screen surface as follows：

5.3.1First to set up the pump model and manufacturer

5.3.2Choose the pump rotation direction: Forward or reverse.
Four steps needed for setting up pump parameter: rotation.electricity,rail pressure,test time
 Setup pump cleaning
 Start up testing
 Zero diesel provide testing
 Max diesel provide testing
 Best efficiency testing
 ZME different electricity testing
Up all steps can be added,delete,move up
5.3.3 When edit HPO pump data,pls remember when you choose DENSO,it must be on operating
mode.
Note:change any steps,must update first, then to save.
Motor rotation speed 1 is the rotation speed when pump testing（0-3000rpm）
Motor rotation speed 2 is the rotation speed when testing injector at full-loaded condition
（0-3000rpm）
Motor rotation speed 3 is the rotation speed when testing injector at idling condition（0-3000rpm）
Motor rotation speed 4 is the rotation speed when testing injector when pre-injection
（0-3000rpm）
 Oil temperature range and tolerance can be set up
 Motor rotation direction (forward/reverse) can be selected.
 Test results of the injector and pumps show on the computer or judge by user.
 Testing unit can be added by users
5.4 After checking the parameter, Click 'save' to be back to:

5.5.Click 'injector test', it comes to the following interface:

5.6.Click “injector type“ to choose the injector type：

Input the “injector type” in the “search” , and confirm, Please firstly choose the manufactory if
needed, then choose injector type.
5.6.1 If need to edit the injector date,please input the injector type in the injector type,input the
parameter in the injector parameter and choose the Voltage mode.
When you change any injector parameter,must click “enter ” on the keyboard, then click
“save”.(if need to add Piezo injector parameter ,pls choose Piezo voltage 180V, then save,but
this need add Piezo control system )
If need to delete the parameter ,just to choose the parameter ,click “delete”
 Notice:When add injector data,
Solenoid valve resistance between 0.7-1.5Ω ,the injector voltage should choose 28V-1.5,
resistance between "1.5-2.5Ω"voltage should choose 28V-2.5.

5.7.After confirming the injector code, click “confirm”, entering the testing surface as follows:
5.7.1 Click ”start”, the testing will be running by 5 steps, the results will be showing step by step
automatically.
Click “Print” and “save” to keep the results. Click “stop” to stop the system.
If single test are need, click “single test”, then choose the test step which are needed,
click"1.2.3.4.5.6” to test 6 injectors at once.
Click"ON" to test the electromagnetic valve.
5.8 Click ”Exit ” when finish.

5.9 Pump test:

Click ” pump test”
Entering the testing surface as follows:
5.10 Click “start”,

5.10.1 The computer will be running and test results will be showing automatically, print and
save.
5.10.2 "Self-supply" is the simulation of the pump to self-feeding the fuel when equipped on the
vehicle.
5.10.3"ZME"is pump measuring unit switch.
Click"ZME on" to clean ZME separately.
When test finished,click Exit.

6.Instruction manual for optional functions

6.1 VP37 operating introduction: Open “system setup”, choose VP37 setup, make sure oil supply
pressure reach 0.03Mar

Turn on data Edit, you can set the parameter for VP pump
You can set the rotate speed for VE pump at different conditions: 0-3000
Throttle position voltage: 0-4000mv
Click Exit

Click start to make testing for VE pump at different conditions, finally save and print the testing
result.

6.2 Simply introduction for EUI EUP testing system

Make sure the oil supply pressure of the test bench reach 0.2MPa
Note: When you test Cummins . Celect EUI, oil pressure pressure should be >0.6Mpa
When you test Cummins ISX EUI, oil pressure pressure should be > 2Mpa
Open “system setup”, choose UPI
Click data edit, you could add and save new data by yourself.

In the working model,you can choose:

A. Common driving signal is used for most types EUI EUP; Cummins driving signal is used for
driving Cummins . celect EUI
B. Simens piezo EUI
C. Delphi E3 EUI
D. Cummins ISX EUI

You can choose to edit and save data

Choose proper adaptors and proper data to make testing, finally print and save the testing result.

6.3 Simply instruction for HEUI testing function

Make sure the oil supply pressure of the test bench reach 0.35Mar, open “system setup”, pls
choose the proper HEUI data in the pump model

If you need to edit data, you can edit the data by yourself.
In data edit, you can set the rotate speed at different injection condition 0-3000
Injection time: 0-6000us

Injection times: 0-2000/min

Pressure: 0-30Mar
When you add and save new data, for HEUI with different discharge capacity, pls choose 7.3L or
6.0L working model.
Edit and save, finally exit

When you finish testing, you can print and save testing result.
7.Test Bench Maintenance
7.1 Fuel injection system maintenance.
A.Generally the test oil should be changed after running of 600 hours, or after completion testing
of 300 injectors, exactly based on oil quality.
B.Check the connector of pipe timely, to avoid oil leakage or air in.
C.Check the filter element and change timely;
7.2.Check the common rail pipe and pump joint in time, ensure that the host security operation
7.3.Common rail pressure regulation valve DRV and ZME valve are the main parts for common
rail pressure, attentions as below:
A. After working constantly 8-10 hours, Check whether DRV/ZME is contaminated by impurity
and clean them timely.
B. Pls use the oil dispersant to clean them, ultrasound cleaner are forbidden.
C. ZME DRV valve should be installed correctly and keep tightly.
7.4.Flow sensor is imported form abroad; do not open it by yourself. Make sure the test oil
clean when operat the machine.
7.5.Check and maintain the inverter timely, to ensure the machine run steadily and safely. Please
note the electric should be cut off during checking the inverter, and do not touch the electricity
8. Common defaults:
Default
code

Reasons Met Methods of elimination

1.wrong power distribution check the wire

2.Single phase test bench outer

Electricity leaks on outershell

shell should be connected with make sure the grounding correctly

earth.
3.three phase four wire,naught
wire connection is not
grounding protection is needed
1 correctly,or without
grounding protection
4.Lamp surface, compressor
switchboard, compressor
clean the impurity
switch, power cable connector
are contaminated by oil impurity
5.cable connector loose during the
check and tight the bolt
transaction and operation.

1.'Start' and 'stop' keystroke are

exchange
damaged
2.Press the “stop”button by
mainframe does not work

press the button to be upper

accident
3.The control line(10V、AVI、EF、
Check and recover the line ＋10V、
＋5V、VRF、GND)inside the
2 AVI、EF、（＋5V、VRF、GND）
inverter cut off

keep the machine closed for 15

4.other electric on the spot seconds, if the maintenance of
interferes cause the inverter to machine still does not work, pls
be self-protection contact manufactory, do not assembly
by yourself
 1.Shortage of power phases,

Rotation speed not steady

2.low voltage, 3. phase check the power distribution
imbalance

3
2.Left & right resistor
exchange
malfunction, or damaged

3.Adapter is not used properly, choose the correct fixture to brace the
pump is not fixed steadily pump.

1.mainframe machine rotates,

rotation speed meter do nor

sensor damaged and exchange

red LED beside the sensor is off

2.Circuit connected with sensor check and recovery, make sure good
work

4 rupture, plug or pin malfunction. connection,tight plug and, fix the bolt.

3.the distance between sensor

the distance between sensor and
and magnetic steel which is on
magnetic steel is 3-5MM , and be
the backside of dial is longer
same core.
than normal
1.temperature sensor (at oil
change
tank board) is damaged.
oil temperature control failure

2.temperature sensor
connector, controller, signal check and tight the plug, welding the
plug loose, connection line signal wire again.
5 rupture or loose,

reset the low and upper limit data,

3.temperature low limit preset is
make sure upper limit data higher
not correct
than the low limit data.

4.heating contact damaged change

pump motor does not start or

1.If pressure pump on/off button Check

2.24V output current inside the check the 24V output , check the AC
switchboard malfunction. safety tube
stop

3.pump motor connection wire

check the line, and change
malfunction, damaged.
 1.power supply open,but switch

no display on
check the circuit, open the switch
is off
7 computer
1.controller, safety
tube(0.5A)damaged Change
2.Display damaged

1.abnormal voltage check

lamp off

8
2.lamp damaged, block
change
damaged

1.electromagnetic valve circuit

electromagnetic valve does not work

check
turn off

2.electromagnetic valve
Change
damaged

9 3.check whether the 24V

voltage normal or not, Safety
tube(6A)damaged.
check and exchange
4.Check whether the injection
connection is identical with the
option on the computer.
Pump starts ,but
no oil supply

pump motor rotation direction is

cut off the power supply, exchange any
10 not identical with standard
two of R.S.T line in the switchboard.
direction of pump.

1.air exist in the oil line Check and maintain

oil supply pressure abnormal

2.Nylon screw inside the

tight
pressure meter loose
11
3. Test oil shortage, or
Add fuel or change
contaminated

4.Oil line is blocked clean it

 1.check whether fuel leaks from

No fuel shows on the injector

flow sensor

2.whether flow sensor lamp

alternately work

12 3.whether injector works Contact the manufacturer

properly
4.Flow sensor blocked by
anything
5.Small filter if blocked,dirty

1.voltage unsteady

2.sensor plug contact is not

good
common rail pressure unsteady

3.oil line is dirty, blocked,

impurities, air-in.

4.ZME valve is dirty or blocked 1.Check the voltage

13 2.Check the fuel line
5.ZME valve damaged 3.overhaul
6.DRV valve is dirty and
blocked
7.DRV damaged
8.check whether the pump body
pressure-regulation valve
blocked or stagnation.
1.Check the fuel supply
whether normal. Pump whether
turn reversed.
2.check connection line
No common rail pressure

between ZNE and DRV

whether good, the insurance
whether good
14 3.Check 36V ON/OFF power Check or change, contact manufacture
whether work and output
4.Turn the pump measuring
DRV plug whether have
24V-36V voltage output.
5.Use a multimeter to measure
the resistance DRV valve
whether about 0.4 Euro.
9. Warranty and Maintenance
 If quality problem incurred under normal operation, we take the liability of maintenance for
one year.
 The maintenance do not include DRV, ZME valve, rail pressure sensor which are imported
from Bosch company, pls use these parts correctly
 The free maintenance do not apply for the damages incurred by incorrect operation or other
equipment’s fault. User should be responsible for maintenance costs.
 Users should bear maintenance charges if it happens after one year.