Beacon Machine Manufacturing Co., Ltd.

EPS208 high pressure common rail

injector test bench

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Welcome to buy Beikun Machinery Equipment Co., Ltd.

EPS028 high pressure common rail injector test bench. Before
use, please read the instruction manual carefully.

The appearance, structure, function, etc. of the product

involved in this manual are for reference only. The products
provided are subject to the actual product, and the final
interpretation right belongs to Kechuang.

Contents
Chapter 1 Overview ………………………….4
Chapter 2 Characteristic ………………….....4
Chapter 3 Features…………………................5
Chapter 4 Technical parameter……………....5
Chapter 5 Structure introduction…………….5
Chapter 6 Drive and safety system……….......6
Chapter 7 Oil road system………………….....7
Chapter 8 Install ................…………………....7
Chapter 9 Maintenance and precautions …....8
Chapter 10 Packing and lifting…………….......8

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Chapter 1 Overview

The EPS208 high-pressure common rail test bench imitates the

diesel engine ECU (Engine Control Unit), and provides common rail

system control signals (CP1/ CP2/ CP3/ HP3/ HP4/ DELPHI), such as

Bosch, Denso, Delphi, and Siemens, to drive the high-pressure common

rail. The oil pump and the high-pressure common rail injector are

working, and the driving signal parameters can be set by the user

according to their actual conditions, and can be grouped and saved, which

is convenient for maintenance personnel to judge and repair the working

state of the high-pressure common rail system.

The power of the EPS208 high-pressure common rail test bench is

2.6KW.
Chapter 2 Characteristic
（一） While supporting high-speed solenoid valve type common rail
injectors, it also supports piezoelectric crystal common rail injectors of
the third-generation high-pressure common rail technology;
（二）Single-channel common rail injector;
（三）Support multiple rail pressure sensors (BOSCH/DEOSN/DELPHI);
（四）Intelligent PID algorithm, more precise pressure control;
（五） Short-circuit protection in both software and hardware makes the
machine more reliable;
（六） Multiple language options;
（ 七 ） Safety protection design to prevent misoperation by operators,
making it safer to use
（八）Not only can the flow sensor be used to display the flow from the
computer, but also the flow can be displayed from the graduated cylinder.

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Chapter 3 Features
（一）Test the sealing performance of the common rail injector

（二）Test the full load performance of the common rail injector

（三）Test the mid-load performance of common rail injectors

（四）Test the idling performance of the common rail injector

（五）Test the pre-injection performance of the common rail injector

Chapter 4 Technical parameter

（一）Measuring motor speed: 0 ～ 3000rpm; oil pump speed:

0--1500rpm

（二）Working pressure: 0-200MPa

（三）Fuel tank volume: 10L;

（四）Test oil filtering accuracy: 3μ;

（五）Oil measuring method: flow meter

（六）Power supply: 220V/50HZ;

（七）Common rail pump type: CP1H;

（十）Output power: 2.6KW

（十一）Overall dimensions (mm):; 830*750*900

（十二）Net weight: 150Kg.

Chapter 5 Structure introduction

The whole structure of the test bench

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（1）The product is welded and assembled by steel plates, with a compact

overall structure and strong shock resistance.

（2）The shell is made of high-voltage electrostatic spray, which has the

characteristics of scratch resistance and wear resistance, and the shell is

beautiful.

（ 3 ） The servo motor and the common rail pump are connected by a

synchronous belt transmission, and the output power is highly accurate.

（4）The test bench is equipped with test fuel tank, transmission timing

belt wheel, servo motor, servo drive, LCD touch screen display, mouse,

keyboard, flow meter, temperature sensor, etc.

（5）The test bench is equipped with a power control switch, a power

jack socket and a power cord.

（6）The operation part of the test bench is all controlled by an industrial

computer, and the operation interface is very convenient.

Operation method: First connect the 220V lighting power, turn on the

main power switch, wait for the system to start and enter the system

interface, select the injector test and click start, enter the injector test

interface, select the injector model, and click start (if selected For

automatic test, after clicking start, the system will automatically test all

working conditions. After the test is completed, it will automatically stop

and give a test report; if you choose manual testing, you can choose the

test conditions at will, wait for the pressure and speed to stabilize, and

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then click test, test Click Stop when finished, the motor will stop running.

After all the items to be tested are tested, turn off the main power

manually.

Chapter 6 Drive and safety system

（一）Transmission system

The system is mainly composed of servo drives,

synchronous motors, synchronous belt wheels, common rail

pumps and other components.

（二）Security system

（Ⅰ）Instantaneous power failure protection

In the event of an instantaneous power failure, the servo drive

will continue to run within about 5MS; when the power failure time

exceeds 5MS, the drive's output will be automatically cut off to determine

it as a power failure.

（Ⅱ）Under and over voltage protection

If the input voltage drops or rises, the control circuit cannot perform

its normal functions, and the drive or motor will be damaged. Therefore,

when the input voltage is lower or higher than the specified value, the

protection circuit will act to cut off the output of the driver and protect the

driver and motor.

（Ⅲ）Over-oil pressure protection

When the rail pipe pressure exceeds the set pressure or is higher

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than 220MPa, the protection circuit will act to cut off the output of the

driver to protect the pipeline and personnel safety.

Chapter 7 Oil road system

（一）The working cycle path of the oil supply system of the test bench

Fuel tank → filter → common rail pump → common rail pipe → fuel

injector → filter → radiator → solenoid valve → flow meter → fuel tank

（二）The working principle of the oil supply system of the test bench

When the main motor is started, the common rail oil pump starts to work

under the drive of the motor. At this time, the test oil begins to enter the

fine filter through the filter in the fuel tank, and then enters the common

rail fuel pump, and supplies fuel to the tested fuel injector through the

common rail fuel pump and the common rail pipe. The fuel injection and

return flow of the fuel injector pass The filter, radiator, and solenoid valve

arrive at the flow meter and return to the fuel tank after being measured

by the flow meter.

Chapter 8 Install
（一）Test bench installation environment

After the test bench is transported to the user, first remove the

package and place the test bench on a flat foundation. There must be a

certain space around the test bench to facilitate operation and work. The

test bench is installed in a room where the air is dry, away from

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flammable and explosive and other dangerous goods and not easily

attacked by wind, sand and dust. The room temperature is generally

5℃～35℃.

C h e c k i t e m Check the content m e t h o d

Whether there is noise or

External terminals,
vibration during operation
drive fixing screws, Fixed tightening
(generally after 20,000 hours
connection connectors
of cumulative operation)

A printed circuit Whether there is conductive

Carefully remove
board metal or oil accumulation

Whether there is Clear with a spray gun

Power components accumulation of dust and with a pressure of 4～

impurities 6Kg/cm2

Blow into the flow

Flow Sensors Flow cannot be displayed sensor with appliance

cleaner

Blow the filter of

DRV Unregulated pressure DRV with compressed

air

（三）Power supply for the test bench

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Power requirements: 220V/50HZ lighting power, the power must be

connected to the test bench through the external triangular jack.

Chapter 9 Maintenance and precautions

（一）Maintenance and maintenance of the test bench

（ 1 ） The oil in the oil tank should be replaced with new oil every 200

hours of work or after 50 injectors are debugged;

（2）The tubing clamps of all connecting parts must be properly installed

and clamped to prevent oil leakage and air entry;

（3）The coarse oil filter should be cleaned every 200 hours of work or

after 50 injectors are debugged;

（ 二 ） The driver program shall not be changed without authorization

except the factory staff.

（三）The four screws fixing the main motor must not be disassembled

at will.

Chapter 10 Packing and lifting

（ 一 ） When packing the test bench, the protective cover should be

separated with foam to prevent crushing.

（二）The test bench should be covered with a plastic gown to prevent

rain.

（三）The test bench shall be strictly prevented from inverted vibration

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during transportation. When lifting after unpacking, the rope should not

directly touch the body to avoid damage to the paint.

（ 四 ） The accessories included with the test bench are subject to the

packing list.

Our product and details:

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 Beacon Machine Manufacturing Co., Ltd.

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 Beacon Machine Manufacturing Co., Ltd.

Email：
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 Beacon Machine Manufacturing Co., Ltd.

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 Beacon Machine Manufacturing Co., Ltd.

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