DPA-240_User_s_Manua..
Contents
1. ADJUST 17 Now injector should start working and it starts to deliver oil that plays the fuel role in the back area of the test tubes as shown in picture NOTE NOTE When testing for the very first time perform the test with clean and pre checked working injector 18 Leave working the injector for about 20 seconds before checking fuel delivery this is for the injector to eliminate air bubbles from its mechanism 19 Press the Start Test button in the Pulse Box panel to check the fuel delivery in the test tube for the desired pre set time then drain the oil from the test tube 20 Repeat step 19 as many times as required until the fuel delivery reading gets stable NOTE NOTE Take note of the fuel delivery readings and testing parameters and compare between them This is the main purpose of the tester This tester does not fix injectors just compares between them DIESEL PARTS OF AMERICA 42 13150 Leadwell Street N Hollywood California 91605 U S A Turn off sequence 21 After all testing has been performed we proceed to turn off the tester First decrease the fuel pressure with the fuel pressure valve moving counter clockwise to almost 0 PSI then move the Fuel Pressure switch to OFF position As shown in picture Pha 5SURE PRESSURE ADJUST 22 Turn OFF CAM BOX switch then Turn OFF pulse box switch 14 Unplug Harness take out the injector starting with the CAM B2. 7 with a less distance 1 linear millimeter or less until the CAM has freely rotary injector linear movement and then follow step No 9 11 Then place the CAM BOX nozzle catcher to the Celect N 14 M 11 EUI Injector nozzle and give a normal strength tighten to the nozzle catcher as shown in picture too much strength tighten in the nozzle catcher could cause injector to pull out from its adapter and injector will not work ee PILL 12 Now plug the fuel pressure hose and fuel return hose if available to the Celect N 14 M 11 EUI Injector adapter DIESEL PARTS OF AMERICA 32 13150 Leadwell Street N Hollywood California 91605 U S A 13 Plug the Injector with the provided GREEN TAG wire and cover them with the acrylic protection as shown in the picture Also make sure that the BLUE TAG Harness the RED and YELLOW TAG harnesses wires are not connected so as in Short Circuit 14 Turn on the Pulse Box and set the testing mode to EUI mode then open the CAM BOX side door and spindle by hand the CAM Shaft pulley several times this is for the operator to hear the sound of the Injector Poppet Valve working with the solenoid RPM tachometer must mark RPM 000X10 Then set the test tube delivery time to the desired time then close the CAM BOX side door 15 Move the CAM BOX switch to ON position as shown in picture then CAM BOX motor will start working CAUTION Keep out from all moving parts when ins
3. Every step must be chronologically followed in order to get the best possible results 1 Make sure that the 6 Dummy injectors are placed in its correct positions adapter spaces and verify that they are strongly clamped to the adapter base with the Injector retaining adapters as shown this is to avoid pressure loose in the oil piping Remember always to perform this step before testing any EUI injector IMPORTANT Before testing make sure that all the injectors are cleaned in its inside outside parts this is to avoid oil contamination 2 Cover the external O ring s with yellow or green automotive grease and place the Cummins Celect Injector in its correct adapter N 14 or M 11 type as shown in picture Si FUEL w PRESSURE ADJUST 2 HHIH DIESEL PARTS OF AMERICA 29 13150 Leadwell Street N Hollywood California 91605 U S A 3 Place the EUI injector with its adapter in the CAM BOX and strongly tighten the retaining screws as shown in picture mi E a 4 i 5 Spindle by hand the CAM shaft with the CAM shaft pulley in order to find the LOWEST CAM PROFILE POINT in other words the roller part of the CAM BOX where the link is placed should be as far as possible from the Injector follower part as shown in the pictures DIESEL PARTS OF AMERICA 30 13150 Leadwell Street N Hollywood California 91605 U S A 6 Then assembly the Cummins Celect N 14 M 1
4. PSI and press the Hydraulic pump switch to OFF As shown in picture r_ sSURE PRESSURE ADJUST DIESEL PARTS OF AMERICA 26 13150 Leadwell Street N Hollywood California 91605 U S A 12 Decrease the fuel pressure with the fuel pressure valve moving counter clockwise to almost 0 PSI then move the Fuel Pressure switch to OFF position As shown in picture Pha 5SURE PRESSURE ADJUST 13 Turn OFF the pulse box 14 Unplug Harness take out the injector the hose Oil Supply Injector and then place the Dummy Injectors in the adapter spaces and cover them with the acrylic protection This is for avoiding dust or contamination in the internal piping system 15 Testing cycle finished DIESEL PARTS OF AMERICA 27 13150 Leadwell Street N Hollywood California 91605 U S A EUI Injector Tests Cummins Celect N 14 M 11 EUI Injector MODE Hydraulic Fuel Test Tube Pulse Box EUI Pressure Pressure Time RPM s Reguired YES YES AUTO Parameter Parameter 60 to 28 to 900 RPM Values 150 PSI 32 Sec Fixed Recomended 900 RPM 100 PSI 30 Sec Fixed Value Accessories to be used for testing these injectors Able to test injectors at a time 1 1 Cummins Celect N 14 M 11 1 Cummins Celect N 14 M 11 EUI Injector Adapter EUI Injector Link screw concaves head DIESEL PARTS OF AMERICA 28 13150 Leadwell Street N Hollywood California 91605 U S A Testing Sequence IMPORTANT
5. Take out the dummy injectors from the HEUI testing adapters IMPORTANT Before testing make sure that all the injectors are cleaned in its inside outside parts this is to avoid oil contamination 2 Place the 6 0 L amp 4 5 L HEUI Adapter in the first HEUI adapter space from right to left position then place the 6 0 L or 4 5 L injector over it and press it until it reaches its final position place also the hose oil supply injector in the last adapter space Place the oil supply plug from the hose oil supply injector to the top of the 6 0 L or 4 5 L injector and make sure that they are strongly clamped to the adapter base with the Injector retaining adapters Also place the Dummy injectors in the 2 3 4 5 positions from right to left as shown in the pi R d za y r A ZB o A 4 7 f i x sE lt Tam 7 N A P gt F ea 4 a P as we 2 1 Plug the injector with the provided BLUE TAG wires as shown in the picture and cover it with the acrylic protection Also make sure that the RED TAG Harnesses the GREEN and YELLOW TAG wires are not connected so as in Short Circuit i j e DIESEL PARTS OF AMERICA 19 13150 Leadwell Street N Hollywood California 91605 U S A 3 Turn on the Pulse Box and set the testing parameters HEUI mode Test tube delivery time and RPM s Now you will hear the sound of the Injector Poppet Valve working at the specified RPM s 4 Move th
6. contamination in the internal piping system 15 Testing cycle finished DIESEL PARTS OF AMERICA 22 13150 Leadwell Street N Hollywood California 91605 U S A CAT 3126A HEUI 3116 Injector MODE Hydraulic Fuel Test Tube Pulse Box HEUL Pressure Pressure Time RPM s Ba YES YES YES YES Parameter Parameter 750 to 60 to 28 to 300 to Values 1000 PSI 150 PSI 32 Sec 2000 RPM Recomended Low 300 RPM Value 750 PSI 100 PSI 30 Sec Mid 900 RPM High 1200 RPM Able to test injectors at a time 1 Accessories to be used for testing these injectors 4 Dummy Injectors 6 Injector Retaining Adapters N Ya y eS TAT wa l a gt TEAT if ca gt TAT 7 i 1 Hose Oil Supply Injector ha S a i ait a ij A j 3 Sagy On n t i pi Tib i Yi gt DIESEL PARTS OF AMERICA 23 13150 Leadwell Street N Hollywood California 91605 U S A Testing Sequence IMPORTANT Every step must be chronologically followed in order to get the best possible results 1 Take out the dummy injectors from the HEUI testing adapters IMPORTANT Before testing make sure that all the injectors are cleaned in its inside outside parts this is to avoid oil contamination 2 Place the CAT 3126A HEUI 3116 Injector in the first HEUI adapter space from right to left position place also the hose oil supply injector in the last adapter space Place the oil supply plug from the hose o
7. pump switch to OFF As shown in picture r_ sSURE PRESSURE ADJUST 12 Decrease the fuel pressure with the fuel pressure valve moving counter clockwise to almost 0 PSI then move the Fuel Pressure switch to OFF position As shown in picture Pha 5SURE PRESSURE ADJUST 13 Turn OFF the pulse box 14 Unplug Harnesses take out the injectors and then place the Dummy Injectors in the adapter spaces and cover them with the acrylic protection This is for avoiding dust or contamination in the internal piping system 15 Testing cycle finished DIESEL PARTS OF AMERICA 17 13150 Leadwell Street N Hollywood California 91605 U S A 6 0 L amp 4 5 L HEUI Ford Power Stroke International Injector HEUL Pressure Pressure Time RPM s Parameter Values 1000 PSI 150 PSI 32 Sec 2000 RPM Recomended Low 300 RPM Value 750 PSI 100 PSI 30 Sec Mid 900 RPM High 1200 RPM Able to test injectors at a time 1 Accessories to be used for testing these injectors 6 Injector Retaining Adapters Li j y i eey 3 i i 4 Dummy Injectors J 1 pply Injector mag d i 4s YUL vs ah gt Ohya y 20 E aL per AA ee ee mbai ia dia Ol ku heiii aid baasi 18 DIESEL PARTS OF AMERICA 13150 Leadwell Street N Hollywood California 91605 U S A Testing Sequence IMPORTANT Every step must be chronologically followed in order to get the best possible results 1
8. the test tubes as shown in picture DIESEL PARTS OF AMERICA 20 13150 Leadwell Street N Hollywood California 91605 U S A NOTE NOTE When testing for the very first time perform the test with clean and pre checked working injector 7 Leave working the injector for about 20 seconds before checking fuel delivery this is for the injector to eliminate air bubbles from its mechanism 8 Press the Start Test button in the Pulse Box panel to check the fuel delivery in the test tubes for the desired pre set time then drain the oil from the test tubes 9 Repeat step 8 as many times as required until the fuel delivery reading gets stable 10 Change the RPM s in the Pulse Box panel as desired Low mid or high RPM s and re arrange the fuel and oil pressures to the desired parameters this helps us to get steady fuel delivery readings moving the pressure valves clockwise or counter clockwise and repeat step 8 as many times as required until the fuel delivery readings gets stable in each desired RPM Parameter NOTE NOTE Take note of the fuel delivery readings and testing parameters and compare between them This is the main purpose of the tester This tester does not fix injectors just compares between them Turn off sequence 11 After all testing has been performed we proceed to turn off the tester First decrease the oil pressure with the oil pressure valve moving counter clockwise to almost 0
9. 1 EUI Injector Link screw to the roller till it slightly touches the injector follower part as shown in picture Slight Contact only 7 Then screw the Cummins Celect N 14 M 11 EUI Injector Link until the follower part of the injector diminish 2 linear millimeters more less 2 screw rounds after the link screw slightly touches the injector follower part and tighten the lock nut to the roller as shown in picture 8 Spindle by hand the CAM shaft with the CAM shaft pulley to verify that the CAM has free rotary movement and free Injector linear movement It can happens that the Injector is too much tightened with the link screw that it is not able to move or to rotate and gets clogged as in the extreme right diagram as shown in picture ae CAM BOX Link Injector Spring Follower DIESEL PARTS OF AMERICA 31 13150 Leadwell Street N Hollywood California 91605 U S A IMPORTANT If the CAM DOES NOT HAVE FREELY ROTARY INJECTOR LINEAR MOVEMENT after CAM BOX switch is turned ON it could cause several damage to the CAM BOX electrical motor pulleys bands 9 If the CAM has freely rotary injector linear movement close the CAM BOX side door in order to continue IMPORTANT Risk of death or serious injury can be caused if the CAM BOX side door is not closed before the CAM BOX switch Is turned ON 10 If the CAM DOES NOT HAVE FREELY ROTARY INJECTOR LINEAR MOVEMENT repeat step No
10. DIESEL PARTS OF AMERICA 13150 Leadwell Street N Hollywood California 91605 U S A Tel 818 765 3344 818 765 3345 Fax 818 765 1412 DPA 240 USER S MANUAL DPA 240 Worldwide approved entities FIDE TABLE OF CONTENTS MOON CHON Aaa page 2 General a ee nawa page 4 Testing Parameters Block Diagram mwwaamanamana page 5 WASIA NGUO wA ate eres eee Serene he waa page 6 Pulse Box Generator FUNCtiIONS wwamamanamwnanwamanawa page 10 DPA 240 Testing Method and Parts wwanaman page 11 7 3 L HEUI Ford Power Stroke international 1444 DT 466E 1530E CAT Injector TeSt w awwnaamamananwnnanananza page 14 6 0 L amp 4 5 L HEUI Ford Power Stroke International Injector TeSt wwwmmmwanamana mana wwa page 18 CAT 3126A HEUI 3116 Injector TeSst ws page 23 Cummins Celect N 14 M 11 EUI Injector Test page 28 Detroit Diesel Series 60 EUI Injector Test page 36 CAT 3406E EUI Injector Test wwaamananamana page 44 FRECOMMENGATONS oa s ccnsocuvsniuetdorsaitecstumsvseientcesttuwededenerstebededen page 52 Limited Warranty 0 cece cece cece ee eee eee eeeeeeeeeeeeeeeeeeenenanaas page 53 NA en AI page 54 DIESEL PARTS OF AMERICA 13150
11. Leadwell Street N Hollywood California 91605 U S A Introduction Thank you for your recent DPA 240 purchase We appreciate your business and are pleased to add your name to our growing list of customers You have invested in the highest quality equipment available Now please take a few minutes and read this booklet This will familiarize you with the benefits you will receive from the equipment you just purchased and help you understand the testing routine that will be required This manual has been prepared especially for use in familiarizing personnel with the design installation and operation of this equipment All information presented herein should be given careful consideration to assure optimum performance of this equipment All information illustrations photographs and specifications contained in this manual are based on the latest product information available at the time of publication Due to improvements or other changes there will be some discrepancies in this manual We reserve the right to make product changes at any time without notice and without incurring any obligation to make the same or similar changes to the tester previously built or sold Safety The following definitions apply to CAUTION IMPORTANT and NOTE blocks found throughout this manual CAUTION Under this heading installation and operating procedures or practices will be found that if not carefully followed may create a hazard to personnel IMPOR
12. O RESELLER IS AUTHORIZED TO EXTEND DIESEL PARTS OF AMERICA WARANTIES TO ANY CONSUMER DIESEL PARTS OF AMERICA 55 13150 Leadwell Street N Hollywood California 91605 U S A NOTES DIESEL PARTS OF AMERICA 13150 Leadwell Street N Hollywood California 91605 U S A 54
13. OX nozzle catcher then the screw link and at the end with the Injector Adapter 23 Testing cycle finished DIESEL PARTS OF AMERICA 43 13150 Leadwell Street N Hollywood California 91605 U S A CAT 3406E EUI Injector MODE Hydraulic Fuel Test Tube Pulse Box EUI Pressure Pressure Time RPM s Reguired Parameter Parameter 60 to 28 to 900 RPM Values 150 PSI 32 Sec Fixed Recomended 900 RPM 100 PSI 30 Sec Fixed Value Accessories to be used for testing these injectors Able to test injectors at a time 1 1 CAT 3406E EUI Injector Adapter 1 CAT 3406E EUI Injector Link screw Planar Head same as Series 60 Link Screw iihi AU samaisa DIESEL PARTS OF AMERICA 44 13150 Leadwell Street N Hollywood California 91605 U S A Testing Sequence IMPORTANT Every step must be chronologically followed in order to get the best possible results 1 Make sure that the 6 Dummy injectors are placed in its correct positions adapter spaces and verify that they are strongly clamped to the adapter base with the Injector retaining adapters as shown this is to avoid pressure loose in the oil piping Remember always to perform this step before testing any EUI injector IMPORTANT Before testing make sure that all the injectors are cleaned in its inside outside parts this is to avoid oil contamination 2 Cover the external O ring s with yellow or green automotive grease and place the CAT 3406E EUI Inj
14. TANT Under this heading installation and operating procedures or practices will be found that if nor carefully followed may result in damage to equipment NOTE Under this heading explanatory statements will be found that need special emphasis to obtain the most efficient operation of this equipment DIESEL PARTS OF AMERICA 3 13150 Leadwell Street N Hollywood California 91605 U S A General The DPA 240 is a standard alone machine designed to test HEUI Hydraulically activated electronically mechanically controlled injectors and EUI electronically activated mechanically controlled injectors It features a graduate metering system and a comprehensive electronic control enabling a full range of tests to be performed The machine incorporates a single test oil supply with fuel and hydraulic pressures controlled individually Injector Control Features Auto pulse width control from 0 05 to 3 Ms equivalent to injection duration Shot count control up to 1000 shots and continuous operation HEUI Variable simulated RPM s in a wide range of tests from 300 to 2000 RPM Test tube time control from 1 sec to 60 sec Information Table Power Supply 210 220 Volts 60 Hertz Fuel Pump Motor power Hydraulic Pressure Motor power 7 5 HP Cam Box Motor power 5 HP po P Tank Capacity 200 Liters DPA 240 injectors capable to test 3 L HEUI Ford Power Stroke International T444 DT 466E 1530 E CAT In
15. ading gets stable 10 Change the RPM s in the Pulse Box panel as desired Low mid or high RPM s and re arrange the fuel and oil pressures to the desired parameters this helps us to get steady fuel delivery readings moving the pressure valves clockwise or counter clockwise and repeat step 8 as many times as required until the fuel delivery readings gets stable in each desired RPM Parameter NOTE NOTE Take note of the fuel delivery readings and testing parameters and compare between them This is the main purpose of the tester This tester does not fix injectors just compares between them Turn off sequence 11 After all testing has been performed we proceed to turn off the tester First decrease the oil pressure with the oil pressure valve moving counter clockwise to almost 0 PSI and press the Hydraulic pump switch to OFF As shown in picture r_ sSURE PRESSURE ADJUST DIESEL PARTS OF AMERICA 21 13150 Leadwell Street N Hollywood California 91605 U S A 12 Decrease the fuel pressure with the fuel pressure valve moving counter clockwise to almost 0 PSI then move the Fuel Pressure switch to OFF position As shown in picture Pha 5SURE PRESSURE ADJUST 13 Turn OFF the pulse box 14 Unplug Harness take out the injector the hose Oil Supply Injector and then place the Dummy Injectors in the adapter spaces and cover them with the acrylic protection This is for avoiding dust or
16. ath or serious body injury such as electrical damage to the tester DIESEL PARTS OF AMERICA 7 13150 Leadwell Street N Hollywood California 91605 U S A Power supply must be connected as shown in the next electrical diagram Phase 1 re a ae a Wye Connected A Transformer Secondary Wiring Phase 2 VOGOUOG Neutral Grounded at Three Phase 4 Wire 110 220 Volt System 60 Hertz Transformer i Phase 3 service Disconnecting Means Main Switch Earth Electrical Plug Electrode ka system eo oN a Electrical Plug s DPA 240 properly We can check this with this singles steps After we have connected the DPA 240 tester to the electrical supply we have to check that the electrical motors are correctly spindle orientated in order for the tester to work 1 Open the CAM BOxX side door and turn on the CAM BOX with the sliding switch in the ON direction and Immediately slide the switch to OFF position as shown in the picture DIESEL PARTS OF AMERICA 13150 Leadwell Street N Hollywood California 91605 U S A 2 Verify that the spindle direction of the CAM BOX is clockwise as shown and close de CAM BOxX side door CAUTION Keep out from all moving parts when installing or testing with the machine If the spindle direction of the CAM BOX is correct the DPA 240 is ready to start testing Injectors if not disconnect the main switch and correct t
17. ch strength tighten in the nozzle catcher could cause injector to pull out from its adapter and injector will not work 12 Now plug the fuel pressure hose and to the Detroit Diesel Series 60 EUI Injector adapter DIESEL PARTS OF AMERICA 40 13150 Leadwell Street N Hollywood California 91605 U S A 13 Plug the Injector with the provided YELLOW TAG wire and cover them with the acrylic protection as shown in the picture Also make sure that the BLUE TAG Harness the RED and GREEN TAG harnesses wires are not connected so as in Short Circuit 14 Turn on the Pulse Box and set the testing mode to EUI mode then open the CAM BOX side door and spindle by hand the CAM Shaft pulley several times this is for the operator to hear the sound of the Injector Poppet Valve working with the solenoid RPM tachometer must mark RPM 000X10 Then set the test tube delivery time to the desired time then close the CAM BOX side door 15 Move the CAM BOX switch to ON position as shown in picture then CAM BOX motor will start working CAUTION Keep out from all moving parts when installing or testing with the machine DIESEL PARTS OF AMERICA 41 13150 Leadwell Street N Hollywood California 91605 U S A 16 Move the Fuel Pressure switch to ON position and rise the fuel pressure with the fuel pressure valve moving clockwise to the desired fuel pressure we recommend 100 PSI as shown in picture PR SURE PRESSURE
18. d a link that must be connected to the EUI Injector EUP pump Link Roller CAM NOTE NOTE In this DPA 240 version this CAM BOX only works at 900 RPM s DIESEL PARTS OF AMERICA 13 13150 Leadwell Street N Hollywood California 91605 U S A HEUI Injector Tests 7 3 L HEUI Ford Power Stroke International T444 DT 466E I530E CAT Injector MODE Hydraulic Fuel Test Tube Pulse Box Pressure Pressure Time RPM s hecho YES YES YES YES Parameter Parameter 750 to 60 to 28 to 300 to Values 1000 PSI 150 PSI 32 Sec 2000 RPM Recomended Low 300 RPM Value 750 PSI 100 PSI 30 Sec Mid 900 RPM High 1200 RPM Able to test injectors at a time 6 Accessories to be used for testing these injectors 6 Dummy Injectors 6 Injector Retaining Adapters ji 3 i Testing Sequence IMPORTANT Every step must be chronologically followed in order to get the best possible results 1 Take out the dummy injectors from the HEUI testing adapters DIESEL PARTS OF AMERICA 14 13150 Leadwell Street N Hollywood California 91605 U S A NOTE You can test 6 injectors at a time or less number of injectors placing in NOTE the missing adapters the Dummy injectors these injectors will play as a plug for not loosing hydraulic pressure Never leave an empty adapter space when testing IMPORTANT Before testing make sure that all the injectors are cleaned in its inside outside parts th
19. e Fuel Pressure switch to ON position and rise the fuel pressure with the fuel pressure valve moving clockwise to the desired fuel pressure we recommend 100 PSI as shown in picture PR SURE ADJUST 5 Press the Hydraulic pump switch to ON and rise the oil pressure with the oil pressure valve moving clockwise to the desired oil pressure we recommend 750 PSI as shown in picture Ph SURE PRESSURE ADJUST 6 Now injector should start working You will see how the injector releases oil pressure in the adapters area and it start to deliver oil that plays the fuel role in the back area of the test tubes as shown in picture c i lt a n gt 4 Efa Ta 3 i aa ia Cen WA ole he r s E wn o oe 1 To LI WA es A os j 5 5 A N K a ee a gt gt g be i aa di Vey v DIESEL PARTS OF AMERICA 20 13150 Leadwell Street N Hollywood California 91605 U S A NOTE NOTE When testing for the very first time perform the test with clean and pre checked working injector 7 Leave working the injector for about 20 seconds before checking fuel delivery this is for the injector to eliminate air bubbles from its mechanism 8 Press the Start Test button in the Pulse Box panel to check the fuel delivery in the test tubes for the desired pre set time then drain the oil from the test tubes 9 Repeat step 8 as many times as required until the fuel delivery re
20. ease Value SYSTEM RESET Starts to fill the Test tubes with the predeterminated delivery time NOTE The test tubes filler button is independent from all the other pulse box functions and once the delivery time starts running it is not possible to stop this function until the delivery time finishes DIESEL PARTS OF AMERICA 10 13150 Leadwell Street N Hollywood California 91605 U S A DPA 240 testing method and Parts For testing EUI HEUI injectors this is the main methodology IMPORTANT Every step must be chronologically followed in order to get the best possible results 1 Clean the injector injectors in its internal external parts before testing to avoid oil contamination 2 Place the injector injectors in its testing place CAM BOX or HEUI adapters with its accessories if necessary 3 Turn on the Pulse Generator Box and set its parameters HEUI or EUI mode RPM s lt just in the HEUI mode Test tube times etc then check that the solenoid is really working you can check this by the sound it generates when opening and closing the poppet valves 4 Turn on the Hydraulics and fuel pump or just the fuel pump depending on the testing system EUI or HEUI and rise to the desired pressure value 5 Turn on the CAM BOX only when testing EUI systems NOTE NOTE Remember that the EUI injector systems only works with a CAM and Fuel pressure 6 Check the fuel delivery in the
21. eck the fuel delivery in the test tube for the desired pre set time then drain the oil from the test tube 20 Repeat step 19 as many times as required until the fuel delivery reading gets stable NOTE NOTE Take note of the fuel delivery readings and testing parameters and compare between them This is the main purpose of the tester This tester does not fix injectors just compares between them DIESEL PARTS OF AMERICA 50 13150 Leadwell Street N Hollywood California 91605 U S A Turn off sequence 21 After all testing has been performed we proceed to turn off the tester First decrease the fuel pressure with the fuel pressure valve moving counter clockwise to almost 0 PSI then move the Fuel Pressure switch to OFF position As shown in picture Pha SSURE PRESSURE ADJUST 22 Turn OFF CAM BOX switch then Turn OFF pulse box switch 14 Unplug Harness take out the injector starting with the CAM BOX nozzle catcher then the screw link and at the end with the Injector Adapter 23 Testing cycle finished Turn off the Main Switch after all the testing has been performed These names are used for reference purpose only and do not imply that we represent these brands DIESEL PARTS OF AMERICA 51 13150 Leadwell Street N Hollywood California 91605 U S A Recommendations If the operator finds something wrong with the DPA 240 tester when working for example Fuel delivery pan d
22. ector in its correct adapter as shown in picture DIESEL PARTS OF AMERICA 45 13150 Leadwell Street N Hollywood California 91605 U S A 3 Place the EUI injector with its adapter in the CAM BOX and strongly tighten the retaining screws as shown in picture A i k 44 ai Wa 4 Open the CAM BOX side door where the CAM shaft pulley is located 5 Spindle by hand the CAM shaft with the CAM shaft pulley in order to find the LOWEST CAM PROFILE POINT in other words the roller part of the CAM BOX where the link is placed should be as far as possible from the Injector follower part as shown in the pictures DIESEL PARTS OF AMERICA 46 13150 Leadwell Street N Hollywood California 91605 U S A 6 Then assembly the CAT 3406E EUI Injector Link screw to the roller till it slightly touches the injector follower part as shown in picture Slight Contact only 7 Then screw the CAT 3406E EUI Injector Link until the follower part of the injector diminish 2 linear millimeters more less 2 screw rounds after the link screw slightly touches the injector follower part and tighten the lock nut to the roller as shown in picture 8 Spindle by hand the CAM shaft with the CAM shaft pulley to verify that the CAM has free rotary movement and free Injector linear movement It can happens that the Injector is too much tightened with the link screw that it is not able to move or to rotate and gets cl
23. f warranty or any other duty with respect to the quality of any foods the exclusive remedies therefore shall be at Diesel Parts of America options 1 repair or 2 replacement or where authorized in writing Diesel Parts of America in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Diesel Parts of America service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Upon recipe of notice of apparent defect of failure Diesel Parts of America shall instruct the claimant on the warranty claim procedures to be followed ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFOMACE AND ANY REMEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY DIESEL PARTS OF AMERICA IS EXCLUDED AND DISCLAIMED BY DIESEL PARTS OF AMERICA EXCEPT AS EXPRESSLY PROVIDED BY DIESEL PARTS OF AMERICA IN WRITING DIESEL PARTS OF AMERICA PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND TESTING OF HEUI OR EUI INJECTORS DIESEL PARTS OF AMERICA WARRANTIES DO NOT EXTEND TO AND N
24. he electrical supply diagram connections as shown then connect the main switch and repeat the last 2 steps service Disconnecting Means Earth Electrode system Electrical Plug Electrical Plug DPA 240 S Change the wire position Between 2 lines only DIESEL PARTS OF AMERICA 9 13150 Leadwell Street N Hollywood California 91605 U S A Pulse Box Generator Functions The pulse box generator has 3 main selectable parameters but in order to understand them first of all we have to recognize the Pulse Box panel functions and block diagram gt Selecting arrow is powered by the button and it select between menus RPM lt Just when HEUI function is slected Mode HEU or EUI and Test tubes delivery time When the arrow selects a menu you can increase or decrease its value with the Increase or decrease arrows RPM Selection This function can only be used when the HEUI function is selected in the HEU EUI Menu and its limit values are from 300 to 2000 RPM PULSE GENERATOR Test Tubes Delivery time on sec time where the test tubes will be reciving oil Recomended Value from 28 to 32 Sec re TEST TUBES Turns ON or OFF Navigation between Menus FILLER the Pulse Box Increase Value HEU EUI Menu select between this 2 systems as shown in page 5 TEST TUBES DELIVERY TIME Resets the Pulse box Stroke Counter Decr
25. il supply injector to the top of the CAT 3126A HEUI 3116 Injector and make sure that they are strongly clamped to the adapter base with the Injector retaining adapters Also place the Dummy injectors in the 2 3 4 5 positions from right to left as shown in the picture 2 1 Plug the Injector with the provided RED TAG harness and cover them with the acrylic protection as shown in the picture Also make sure that the BLUE TAG Harness the GREEN and YELLOW TAG harnesses are not connected so as in Short Circuit DIESEL PARTS OF AMERICA gt 24 13150 Leadwell Street N Hollywood California 91605 U S A 3 Turn on the Pulse Box and set the testing parameters HEUI mode Test tube delivery time and RPM s Now you will hear the sound of the Injector Poppet Valve working at the specified RPM s 4 Move the Fuel Pressure switch to ON position and rise the fuel pressure with the fuel pressure valve moving clockwise to the desired fuel pressure we recommend 100 PSI as shown in picture PR URE ADJUST 5 Press the Hydraulic pump switch to ON and rise the oil pressure with the oil pressure valve moving clockwise to the desired oil pressure we recommend 750 PSI as shown in picture Ph SURE PRESSURE ADJUST 6 Now injector should start working You will see how the injector releases oil pressure in the adapters area and it start to deliver oil that plays the fuel role in the back area of
26. is is to avoid oil contamination 2 Place the injector s in the HEUI adapter spaces and make sure that they are strongly clamped to the adapter base with the Injector retaining adapters Also Dummy injector s if placed plug them with the provided RED TAG harnesses where available and cover them with the acrylic protection as shown in the picture Also make sure that the BLUE TAG Harness the GREEN and YELLOW TAG harnesses are not connected so as in Short Circuit 3 Turn on the Pulse Box and set the testing parameters HEUI mode Test tube delivery time and RPM s Now you will hear the sound of the Injector s Poppet Valves working at the specified RPM s 4 Move the Fuel Pressure switch to ON position and rise the fuel pressure with the fuel pressure valve moving clockwise to the desired fuel pressure we recommend 100 PSI as shown in picture i PR SURE ADJUST ww DIESEL PARTS OF AMERICA 15 13150 Leadwell Street N Hollywood California 91605 U S A 5 Press the Hydraulic pump switch to ON and rise the oil pressure with the oil pressure valve moving clockwise to the desired oil pressure we recommend 750 PSI as shown in picture Ga Ph SURE PRESSURE ADJUST 6 Now injectors should start working You will see how the injector s releases oil pressure in the adapters area and they start to deliver oil that plays the fuel role in the back area of the test tubes as shown i
27. jector 6 0 L amp 4 5 L HEUI Ford Power Stroke International Injector CAT 3126A HEUI 3116 Injector Cummins Celect N 14 M 11 EUI Injector Detroit Diesel Series 60 EUI Injector CAT 3406E EUI Injector DIESEL PARTS OF AMERICA 4 13150 Leadwell Street N Hollywood California 91605 U S A Testing Parameters Block Diagram DPA 240 oe ia HEUI Injector Test Hydraulic Electronic Unit Injector Works with Hydraulic Pressure 7 3 L HEUI Ford Power Stroke International T444 DT 466E I530E CAT Injector Hydraulic Press 750 to 1000 PSI 6 0 L amp 4 5 L HEUI Ford Power Stroke International Injector CAT 3126A HEUI 3116 Injector Testing Speed 300 to 2000 RPM Hydraulic Press 750 to 1000 PSI Fuel Press 60 to 150 PSI Test Tube Time 28 to 32 sec DIESEL PARTS OF AMERICA D 13150 Leadwell Street N Hollywood California 91605 U S A Installation For your safety and to maximize the service life of your equipment it is very important to take a few moments before you operate the tester to check its condition Be sure to take care of any problem you find before you operate the tester IMPORTANT Every step must be chronologically followed in order to get the best possible results The DPA 240 basically needs three main conditions to work Hydraulic oil for the 200 liter tank gear transmissio
28. n oil for the CAM BOX and Electrical Power Supply 1 Fill the oil tank with 180 liters with any of the next Hydraulic oil Brand specifications NOTE NOTE In order to maintain always the same oil temperature it is necessary to fill the tank with at least 180 oil liters check with DIP STICK Remove the acrylic protection and fill the Hydraulic oil in the tank as shown in the picture v YA s E ell a a S Fill the oil in this Area i DIESEL PARTS OF AMERICA 6 13150 Leadwell Street N Hollywood California 91605 U S A 2 Fill the CAM BOX with 2 liters of gear transmission oil with next gear transmission oil Brand specifications GENERAL OIL SAE 250 Quaker State Green Oil SAE 250 Thuban SAE 250 Shell Dentax SAE 250 The gear transmission Oil must be filled in the CAM BOX as shown in the picture IMPORTANT Do not overfill the CAM BOX with the gear transmission oil if there is too much oil it can cause oil leakage from the CAM BOX at work 3 Now we proceed to connect the DPA 240 to the electrical power supply The DPA 240 power supply specification is 210 220 Volts 60 Hertz With NO ground neutral connection all the motors from the pumps and CAM BOX such as the pulse box generator are 3 phases electrically wired and does not need an electrically ground neutral connection as in accordance with the National Electrical Code CAUTION Risk of electric shock may cause de
29. n picture NOTE NOTE When testing for the very first time perform the test with clean and pre checked working injectors 7 Leave working this injector s for about 20 seconds before checking fuel delivery this is for the injector s to eliminate air bubbles from its mechanism 8 Press the Start Test button in the Pulse Box panel to check the fuel delivery in the test tubes for the desired pre set time then drain the oil from the test tubes 9 Repeat step 8 as many times as required until the fuel delivery reading gets stable 10 Change the RPM s in the Pulse Box panel as desired Low mid or high RPM s and re arrange the fuel and oil pressures to the desired parameters this helps us to get steady fuel delivery readings moving the pressure valves clockwise or counter clockwise and repeat step 8 as many times as required until the fuel delivery readings gets stable in each desired RPM Parameter DIESEL PARTS OF AMERICA 16 13150 Leadwell Street N Hollywood California 91605 U S A NOTE NOTE Take note of the fuel delivery readings and testing parameters and compare between them This is the main purpose of the tester This tester does not fix injectors just compares between them Turn off sequence 11 After all testing has been performed we proceed to turn off the tester First decrease the oil pressure with the oil pressure valve moving counter clockwise to almost 0 PSI and press the Hydraulic
30. nesses wires are not connected so as in Short Circuit 14 Turn on the Pulse Box and set the testing mode to EUI mode then open the CAM BOX side door and spindle by hand the CAM Shaft pulley several times this is for the operator to hear the sound of the Injector Poppet Valve working with the solenoid RPM tachometer must mark RPM 000X10 Then set the test tube delivery time to the desired time then close the CAM BOX side door 15 Move the CAM BOX switch to ON position as shown in picture then CAM BOX motor will start working CAUTION Keep out from all moving parts when installing or testing with the machine DIESEL PARTS OF AMERICA 49 13150 Leadwell Street N Hollywood California 91605 U S A 16 Move the Fuel Pressure switch to ON position and rise the fuel pressure with the fuel pressure valve moving clockwise to the desired fuel pressure we recommend 100 PSI as shown in picture PR JURE PRESSURE ADJUST 17 Now injector should start working and it starts to deliver oil that plays the fuel role in the back area of the test tubes as shown in picture NOTE NOTE When testing for the very first time perform the test with clean and pre checked working injector 18 Leave working the injector for about 20 seconds before checking fuel delivery this is for the injector to eliminate air bubbles from its mechanism 19 Press the Start Test button in the Pulse Box panel to ch
31. oes not returns to its initial place after the test tubes delivery times has ended or when pressing the Start test button the fuel pan does not react usually what the operator only has to do is to press the System Reset Button located in the Pulse Box panel and everything should be corrected If the DPA 240 does not starts please check the service disconnecting means fuses or electricity connections in the electrical power supply NEVER LEAVE THE DPA 240 TESTER WORKING IN 2 OR 1 ELECTRIC PHASES ONLY This could cause several damage to the electric motors wiring It is recommendable not to take the tester to its parameter limits excessive oil fuel pressure during long operating times It is recommendable to change the oil from the tank every 300 hours of operation about 1 year DIESEL PARTS OF AMERICA 392 13150 Leadwell Street N Hollywood California 91605 U S A Limited Warranty Diesel Parts of America North Hollywood CA warrants to Customer that all new and unused Equipment furnished by Diesel Parts of America is free from defect in workmanship and material as of the time and place of delivery by Diesel Parts of America such electric motors electric equipment accessories or other items manufactured by others are subject to the warranty of their respective manufacturers At the present time the manufacturer s warranty on the DPA 230 test equipment is limited to 1 year In the case of Diesel Parts of America breach o
32. ogged as in the extreme right diagram as shown in picture CAM BOX Link Injector Spring Follower DIESEL PARTS OF AMERICA 47 13150 Leadwell Street N Hollywood California 91605 U S A IMPORTANT If the CAM DOES NOT HAVE FREELY ROTARY INJECTOR LINEAR MOVEMENT after CAM BOX switch is turned ON it could cause several damage to the CAM BOX electrical motor pulleys bands 9 If the CAM has freely rotary injector linear movement close the CAM BOX side door in order to continue IMPORTANT Risk of death or serious injury can be caused if the CAM BOX side door is not closed before the CAM BOX switch is turned ON 10 If the CAM DOES NOT HAVE FREELY ROTARY INJECTOR LINEAR MOVEMENT repeat step No 7 with a less distance 1 linear millimeter or less until the CAM has freely rotary injector linear movement and then follow step No 9 11 Then place the CAM BOX nozzle catcher to the CAT 3406E EUI Injector nozzle and give a normal strength tighten to the nozzle catcher as shown in picture too much strength tighten in the nozzle catcher could cause injector to pull out from its adapter and injector will not work DIESEL PARTS OF AMERICA 48 13150 Leadwell Street N Hollywood California 91605 U S A 13 Plug the Injector with the provided YELLOW TAG wire and cover them with the acrylic protection as shown in the picture Also make sure that the BLUE TAG Harness the RED and GREEN TAG har
33. t decrease the fuel pressure with the fuel pressure valve moving counter clockwise to almost 0 PSI then move the Fuel Pressure switch to OFF position As shown in picture Pha SURE PRESSURE ADJUST 22 Turn OFF CAM BOX switch then Turn OFF pulse box switch 14 Unplug Harness take out the injector starting with the CAM BOX nozzle catcher then the screw link and at the end with the Injector Adapter 23 Testing cycle finished DIESEL PARTS OF AMERICA 39 13150 Leadwell Street N Hollywood California 91605 U S A Detroit Diesel Series 60 EUI Injector MODE Hydraulic Fuel Test Tube Pulse Box EUI Pressure Pressure Time RPM s Required Parameter Parameter 60 to 28 to 900 RPM Values 150 PSI 32 Sec Fixed Recomendad 900 RPM 100 PSI 30 Sec Fixed Value Accessories to be used for testing these injectors Able to test injectors at a time 1 1 Detroit Diesel Series 60 1 Detroit Diesel Series 60 EUI Injector Adapter EUI Injector Link screw Planar head lt o oa DIESEL PARTS OF AMERICA 36 13150 Leadwell Street N Hollywood California 91605 U S A Testing Sequence IMPORTANT Every step must be chronologically followed in order to get the best possible results 1 Make sure that the 6 Dummy injectors are placed in its correct positions adapter spaces and verify that they are strongly clamped to the adapter base with the Injec
34. talling or testing with the machine DIESEL PARTS OF AMERICA 33 13150 Leadwell Street N Hollywood California 91605 U S A 16 Move the Fuel Pressure switch to ON position and rise the fuel pressure with the fuel pressure valve moving clockwise to the desired fuel pressure we recommend 100 PSI as shown in picture PR JURE PRESSURE ADJUST 17 Now injector should start working and it starts to deliver oil that plays the fuel role in the back area of the test tubes as shown in picture NOTE NOTE When testing for the very first time perform the test with clean and pre checked working injector 18 Leave working the injector for about 20 seconds before checking fuel delivery this is for the injector to eliminate air bubbles from its mechanism 19 Press the Start Test button in the Pulse Box panel to check the fuel delivery in the test tube for the desired pre set time then drain the oil from the test tube 20 Repeat step 19 as many times as required until the fuel delivery reading gets stable NOTE NOTE Take note of the fuel delivery readings and testing parameters and compare between them This is the main purpose of the tester This tester does not fix injectors just compares between them DIESEL PARTS OF AMERICA 34 13150 Leadwell Street N Hollywood California 91605 U S A Turn off sequence 21 After all testing has been performed we proceed to turn off the tester Firs
35. test tubes pressing the Start Test button After finishing the test tests turn off the Hydraulics and fuel pump or just the fuel pump depending on the testing system EUI or HEUI 8 Turn off the CAM BOX only when testing EUI systems 9 Turn off the Pulse Generator Box and Main Switch after all the testing has been performed 10 Place their accessories protective case acrylics dummy injectors etc DIESEL PARTS OF AMERICA 11 13150 Leadwell Street N Hollywood California 91605 U S A Recognize the main DPA 240 controls panel Hydraulic Pressure switch Hydraulic Pressure Regulator and Manometer PRESSURE PRESSURE ADJUST Fuel Pump Pressure Regulator and Manometer PRESSURE PRESSURE ADJUST CAM BOX switch Pulse Box switch DIESEL PARTS OF AMERICA 12 13150 Leadwell Street N Hollywood California 91605 U S A ji A CAM BOX Description The CAM BOX works with a universal CAM capable to test virtually all EUI Injectors and EUP Electronic Unit Pumps available on the market If you need more testing adapters for other types of injectors or EUP pumps please ask for more information with your local DPA Dealer this eliminates the assembly and disassembly job of changing CAMS since 1 CAM works with all EUI injectors and EUP pumps The diagram of the CAM BOX is as shown A CAM is dragged by the electrical motor which is in contact with a roller this roller on the top has attache
36. tor retaining adapters as shown this is to avoid pressure loose in the oil piping Remember always to perform this step before testing any EUI injector IMPORTANT Before testing make sure that all the injectors are cleaned in its inside outside parts this is to avoid oil contamination 2 Cover the external O ring s with yellow or green automotive grease and place the Detroit Diesel Series 60 Injector in its correct adapter as shown in picture DIESEL PARTS OF AMERICA 37 13150 Leadwell Street N Hollywood California 91605 U S A 3 Place the EUI injector with its adapter in the CAM BOX and strongly tighten the retaining screws as shown in picture 4 Open the CAM BOX side door where the CAM shaft pulley is located 5 Spindle by hand the CAM shaft with the CAM shaft pulley in order to find the LOWEST CAM PROFILE POINT in other words the roller part of the CAM BOX where the link is placed should be as far as possible from the Injector follower part as shown in the pictures DIESEL PARTS OF AMERICA 38 13150 Leadwell Street N Hollywood California 91605 U S A 6 Then assembly the Detroit Diesel Series 60 EUI Injector Link screw to the roller till it slightly touches the injector follower part as shown in picture Slight Contact only 7 Then screw the Detroit Diesel Series 60 EUI Injector Link until the follower part of the injector diminish 2 linear millimeters more less 2 scre
37. w rounds after the link screw slightly touches the injector follower part and tighten the lock nut to the roller as shown 8 Spindle by hand the CAM shaft with the CAM shaft pulley to verify that the CAM has free rotary movement and free Injector linear movement It can happens that the Injector is too much tightened with the link screw that it is not able to move or to rotate and gets clogged as in the extreme right diagram as shown in picture ps CAM BOX Link Injector Spring Follower DIESEL PARTS OF AMERICA 39 13150 Leadwell Street N Hollywood California 91605 U S A IMPORTANT If the CAM DOES NOT HAVE FREELY ROTARY INJECTOR LINEAR MOVEMENT after CAM BOX switch is turned ON it could cause several damage to the CAM BOX electrical motor pulleys bands 9 If the CAM has freely rotary injector linear movement close the CAM BOX side door in order to continue IMPORTANT Risk of death or serious injury can be caused if the CAM BOX side door is not closed before the CAM BOX switch Is turned ON 10 If the CAM DOES NOT HAVE FREELY ROTARY INJECTOR LINEAR MOVEMENT repeat step No 7 with a less distance 1 linear millimeter or less until the CAM has freely rotary injector linear movement and then follow step No 9 11 Then place the CAM BOX nozzle catcher to the Detroit Diesel Series 60 EUI Injector nozzle and give a normal strength tighten to the nozzle catcher as shown in picture too mu
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