hus-1000 heui system test bench user`s manual
Contents
1. 4 2 2 HYDRAULIC CIRCUIT 8 2 3 HEUI CONTROL MODULE ccccecescacsicncsasocostxehostoaseudenstuancaaavsasaceniexeineinenendenssuadoabaceaneqnstevahnddosewlensteahesnncsadacastiens 9 2 4 FUEL DELIVERY MEASUREMENT cccccccsseeeeecccccccccseeccccccccussceecccccceuseeeecceccccuussecececceuuuatsesecesseuaaaeseecess 12 PE YS PW RN ETE 12 2 6 DEVICE TO DETECT INJECTOR LEAKAGE sicsscoccsssnavecdcascesadendsonndaasananaseganoedsaasanadieeensaddahaantonascamsaiascencduaiaases 13 D V SEV 15 JTESTBENCH OPERATION 2 eeu sua PESE es poe 17 4 1 INJECTOR K A xNSMSK 17 4 2 POWER ON THE TEST BENGHL iet apretar 17 4 3 START THE TEST OIL HEATER 17 4 4 SET TEST OIL TARGET TEMPERATURE cccccsecccccccecececcusccececccsecccccusucececccausececcusucecceceaececcecuauceececuaees 18 4 5 START LOW PRESSURE SUPPLY PUMP ro e ap ce cua Pape E rac ua Cox Da Fea 18 4 6 START ACTUATION PUMP cccscccacsesssesceacsenecianenadesensinesdavacedetevuacnetaeanecateuseun clans Fede vus SPEEDS OPEENS PEPEES 18 4 7 SET ACTUATION PRESSUR2. Regulation gt knob clockwise gradually to increase the main motor speed and in turn to increase the actuation pressure which can be monitored by the corresponding analog pressure gauge on the front panel 4 7 Set Actuation Pressure Maximum Limit After the actuation test oil passage being purged the user may turn ON the actuation pump adjusting the Actuator Regulation hand wheel to reach the maximum 18 HUS 1000 HEUI System Test Bench http www chinahanji com actuation pressure of current setting Adjust the pressure relieve valve inside of the bench if necessary to obtain the adequate test oil actuation pressure up limit Warning Before switching ON the test oil actuation pump secure all HEUI injectors or dummy injectors in the test head to prevent pressurized test oil and injectors shot up to cause personal injury HUS 1000 HEUI System Test Bench 19 http www chinahanji com 5 INJECTOR TESTS 5 1 Injector Delivery Test Place clean injectors with testing O rings into the injector test head Make sure that the injectors are held in place by bolts Connect the wires to the injectors check the fluid level and close the lid Using the three function keys of the mini keypad lt Pulse Width gt lt Engine Speed gt and lt Set Counter gt to move the editing cursor on the LCD screen Using the lt A gt and V gt keys to adjust the values for the parameters W N and C with
3. Target Temperature The required temperature of the test oil is controlled by the temperature control module The detailed operation to set the target temperature refers to the user s manual of the control module The top half of the module LCD screen displays the actual temperature of the test oil The lower half displays the lower limit of the target temperature When the test oil temperature is lower than the target temperature and the heater switch is at ON position the heater in the test oil tank is working and the low pressure fuel pump is running to ensure the circulation of the test oil in the tank When the temperature of the test oil is higher than the target the heater stops working regardless the heater switch at ON position and the solenoid valve is ON to let cooling water flow through the heat exchanger to cool the test oil to maintain test oil close to the target temperature 4 5 Start Low Pressure Supply Pump To turn the Supply Pump switch to ON position starts the low pressure fuel pump The analog pressure gauge on the front panel shows the actual supply pressure The required supply pressure can be reached by adjusting the pressure relieve valve 4 6 Start Actuation Pump Before switch ON the actuation pump the supply pump has to be running and the Actuator Regulation knob is in the Min position To turn the Actuator Pump switch to ON position starts the actuation pump Adjust the lt Actuator
4. on the fuel supply pump adjust the supply pressure to the required reading Turn on the actuation pump adjust the pressure and the 6 0L injector starts fuel injection 22 HUS 1000 HEUI System Test Bench http www chinahanji com 5 3 3 Remove 6 0L injector fixture Loose the actuation oil hose from the 6 0L injector fitting and connect it to the inlet port of actuation oil on the test head block An O ring P N 920243 is required for the hose connection Using the removing tool P N 920261 to pull out the injector from the adapt sleeve e Using the removing tool P N 920260 to pull out the adapt sleeve HUS 1000 HEUI System Test Bench 23 http www chinahanji com 6 MAINTENANCE AND SERVICE Two filters are applied in the test oil circuit one at down stream of the supply pump and the other at the inlet of the actuation pump The filters should be changed in a period of six months The filter in test oil tank is Chinahanji P N 920098 The filter for fuel supply circuit is Fleetguard FF5485 The filter for actuation circuit is Chinahanji P N 920101 Periodically check the level of the test oil in the tank The oil level should not below the red line on the observation side tube 7 WARRANTY Chinahanji will replace free of charge HEUI system test bench HUS 1000 which fails in use within a time period of one year from the date of delivery due to faulty material or workmanship as determined by Chinahanji p
5. the Cursor After setting the three parameters press lt Inject ON OFF gt key to start fuel injection The user is still able to change the values of three parameters while fuel injection is ON The user may press lt Inject ON OFF gt again to stop fuel injection and the LCD screen will displays OFF The test oil actuation pressure may have a sudden change after changing of injection parameters or injection being turned ON or OFF The user needs to re adjust the actuation pressure after each parameter setting When the actuation pressure exceeds the preset maximum limit the pressure relieve valve will open to spill out excessive test oil Once the parameters and the test oil actuation pressure meet the test requirement pressure lt Counter gt key on the front panel to start fuel delivery measurement The solenoid driven fuel direction plate is turned to the position to let the fuel injection flow into the metering graduates Once the count down counter is reaching zero the solenoid driven plate is turned to the position to let fuel injection flow to the test oil tank The fuel delivery test is completed The user may press lt gt to abort an on going fuel delivery test Note that the parameters should not be changed during the fuel delivery test 20 HUS 1000 HEUI System Test Bench http www chinahanji com The fuel in the graduates can be emptied by turning over the carrying board with the K
6. to replace the original O rings on the HEUI body Apply small amount of grease on the O ring to help placing the O ring into the grooves Place four clean injectors with the test O rings into the cavities of the injector test head in the testing chamber Make sure that the injectors are held in place by bolts The injector and some fluid will be forcefully ejected from the cavity if the injector is not secured causing injury to the operator and or damage to the equipment Connect the wires to the injectors and close the chamber cover lid NOTE When less than four injectors are tested the dummy injectors should be installed to the unused injector cavities 4 2 Power on the Test Bench The AC power of the HUS 1000 is ON by turning the main power switch on the left panel to position ON The power indicator on the front panel will be lightened once the power is ON 4 3 Start the Test Oil Heater switch Heater on the front panel to ON position The electrical heater in the test oil tank will ON automatically once the test oil temperature below the preset temperature on the temperature control module The heater will be OFF once the test oll temperature exceeds the preset target temperature switch lt Heater gt to OFF position The electrical oil heater will not ON even the test oil temperature is below the preset target temperature HUS 1000 HEUI System Test Bench 17 http www chinahanji com 4 4 Set Test Oil
7. 0 package This device has a potentiometer and an analog amperage gauge meter for adjusting and monitoring the electrical current amperage to drive a solenoid of a HEUI injector When the leakage test is needed simply connect the 36VDC on the side board of the HUS 1000 test bench to this unit and connect the output cable of this unit to the target HEUI and then turn on the test bench to the required actuation pressure by adjusting the driving current the user may observe the sealing condition of the HEUI being tested The photo below is the device to detect injector leakage HUS 1000 HEUI System Test Bench 13 http www chinahanji com B Power switch B Socket for 36VDC power supply and injector drive B Cooling fan 44 HUS 1000 HEU System Test Bench http www chinahanji com 3 INSTALLATION Unpack the HUS 1000 package Carefully place the HUS 1000 test bench on a solid and leveled floor The water needs to be connected using locally available hardware The 3 phase 4 conductor AC power needs to be connected by a qualified electrician The procedure to connect the 3 phase AC power Warning The 3 phase AC power needs to be connected by a qualified electrician to prevent any accident Open the back panel to expose the electrical wire chamber Let the AC power wires go through the hole below the wire chamber The 3 phase 4 conductor AC power connection terminals are located at the lo
8. DC Power supply 2 3 1 LCD screen The LCD screen shows the fuel injector setting parameters and injection status Initial LCD screen after power ON 0100 7 3L OFF W 1 0 N 0608 C HlBH 3L ON W 1 H8 M H6BHH 10 HUS 1000 HEUI System Test Bench http www chinahanji com B 6 0L Injector is running Cz Fuel injection cycle count down counter for fuel delivery measurement Range 1 9999 W Pulse width of fuel injection In terms of milli seconds ms Range 0 6 0 N Fuel injection frequency In terms of injection minute Range 0 2000 7 3L or 6 0L 7 3L Injector or 6 0L Injector ON or OFF Fuel injection or Cursor to indicate the parameter currently being edited 2 3 2 Mini keypad The mini keypad of the HEUI control module on the front panel shown below has five function keys Inject ON OFF gt lt Pulse Width gt lt Engine Speed gt lt Set Counter gt and lt 7 3L 6 0L gt and two value changing keys lt A gt and lt gt Once a function key is pressed the editing cursor will move to the corresponding parameter on the LCD screen for editing its value e Press lt Inject ON OFF gt to start or stop fuel injection Press lt Pulse Width gt to move the cursor _ to Wz and ready to edit the value HUS 1000 HEUI System Test Bench 11 http www chinahanji com Press lt Engine Speed gt to
9. E MAXIMUM LIMIT c ccccccccccseeeecccccccccesceeccccccccacceecceccccauecceeccecesuaaseeecceseeuas 18 WIN UC EO 20 S MIE TO IN TEST 20 5 2 INJECTOR SEALING ML 21 LETO OLINE TOR 22 6 MAINTENANCE AND SERVICE eee eee eee eee eee sees 24 1 INE YY 24 HUS 1000 HEUI System Test Bench http www chinahanji com This USER S MANUAL allows you to exploit all the functions of the HUS 1000 test bench We strongly suggest you to read this manual with attention before using the equipment and retain it for future reference 1 PREFACE 1 1 Symbols The following symbols are used throughout this manual Safety warnings must be strictly observed during operation Caution Cautions describe conditions activities operations which could result in danger E Note Notes provide important supplementary information 1 2 Application The HUS 1000 test
10. HUS 1000 HEUI SYSTEM TEST BENCH USER S MANUAL CHINAHANJI POWER CO LTD Http www chinahanji com Address comments concerning this document to Copyright 2010 All rights reserved No part of this publication may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or computer language in any form or by any means electronic mechanical magnetic optical chemical manual or otherwise without prior written consent of CHINAHANUI HUS 1000 HEUI System Test Bench http www chinahanji com Table of Contents sca 1 INESilebmM 1 1 2 APPLICATION cccccccccsseeeeccccccccsccsecccccccucesecccceccaussececcccesuuseeeccccccuaussesececccuuaesesecesceuauseesesecessuaaceeeceseceuaaeess 1 1 3 FUNCTION 1 lU SPEOIBICATION MM M M MEM 2 1 5 MAIN FEATURES OF CONTROL MODULE sssececccccccccseececceccccucceeccceccccauseecccccesausccesceeeceaaaeess 3 2 HUS 1000 TEST BENCH DESCRIPTION ee eee e eee eee rene eee eee see eese eese esses oe eoee 4 2 1 TEST BENCH PANEL DESCRIPTION cssseeeccccccccccsececccccccacsceccccccccusssececcececaueseescceccesuaeceeeccesseuaaeeececeeeaas
11. actor T m3 0 Contactor E ERE Intermediate Relay Therma cma 11 0 Motor Figure2 The circuit schematic drawing of the electrical system HUS 1000 System Test Bench
12. bench is designed to test up to four HEUI injectors equipped on the following engines e Navistar T444E as Ford 7 3L PowerStroke Engines e Navistar DT466E e Navistar I530E Caterpillar 3126B Add on kits to test injectors of Ford 6 0L PowerStroke engines 1 3 Function The HUS 1000 test bench is designed to perform the following tests e Measure fuel deliveries of up to four injectors HUS 1000 HEUI System Test Bench 1 SHJ http www chinahanji com Check sealing for injector upper seat of the solenoid control valve of individual injector Check needle opening pressure and nozzle spray pattern analysis with optional POP test adapting kits 1 4 Specification Items Parameters AC Power Supply 3 Phase 230V 380V 460V 50 60Hz Temperature Control module 30 C50 C 1C LCD display Inductive divider control motor speed Max Power Supply 7 5kW Test Oil The HUS 1000 is designed to be run on single test oil for both the low and high pressure actuation supplies to the injector The test oil used therefore needs to have proper lubricating properties and for this purpose Chinahanji recommends Rock Valley C 3112 Type 2 Calibration Fluid Test oil filtration Full Flow fuel filter Fleetguard FF5485 WidthxDepthxHeight 1200x700x1700 mm Weight Net 450kg Gross 500kg 2 HUS 1000 HEUI System Test Bench http www chinahanji com 1 5 Main Features of HEUI Control Module Range of fuel injectio
13. ead the test head block has two galleries to connect the four injector cavities The upper gallery provides actuation test oil and the lower one provides low pressure fuel supply for each injector There is a bleeding valve at the end of the actuation oil gallery for purging the trapped air in the gallery A hose to test oil tank is connected to the bottom of the test head chamber for test oil returning flow Because of this flow passage the user can pure test oil into the test chamber to fill test oil 2 2 2 Actuation pressure control The actuation pump output pressure is controlled by varying the pump speed A potentiometer knob on the control panel is used to adjust the actuation pressure which is monitored by an analog pressure gauge on the front panel A pressure relieve valve inside of the bench at the up left corner of the electrical chamber is used to limit the maximum actuation pressure Adjustment of the maximum actuation pressure can be done by a hand wheel of the pressure relieve valve clockwise to Increase and count clockwise to decrease the maximum actuation pressure 2 2 3 Supply pressure control A pressure regulation valve with a hand wheel on the front panel is used to adjust oil supply pressure To turn the hand wheel clockwise or counter clockwise will increase or decrease supply pressure The supply pressure is monitored by an analog pressure gauge on the front panel 8 HUS 1000 HEUI System Test Bench htt
14. move the cursor _ to N and ready to edit the value Press lt Set Counter gt to move the cursor _ to C and ready to edit the value Press lt 7 3L 6 0L gt to choose 7 3L injector 6 0L injector lt A 0r V gt increase or decrease the value for the parameter with cursor 2 4 Fuel Delivery Measurement Fuel injection quantity is measured by using 2 groups of 4 glass graduates 45ml and 150ml and a solenoid driven plate to direct fuel flow to the fuel tank or to the glass graduates The On OFF of the solenoid is controlled by the HEUI control module The user sets the injection cycle counter using the button Set Counters The user pushes the button Countersto start the measurement The board to carry the graduates can be turned over to empty the fuel in the graduates 2 5 Electrical System The electrical system of the HUS 1000 test bench consists of a divider an inductive motors and electrical wiring chamber By varying the frequency of the AC power the divider controls the speed of the main motor to drive the pump which boosts actuation oil pressure A smaller electrical motor is used to drive the low pressure pump to feed the HEUI s fuel inlets Figure 2 shows the schematic drawing of the electrical system circuit 12 HUS 1000 HEUI System Test Bench http www chinahanji com 2 6 Device to Detect Injector Leakage The leakage detection device is a separate box as part of the HUS 100
15. n frequency 0 2000 Range of Injection Pulse Width 0 6 0ms Range Fuel Delivery Measurement Counter 1 9999 Simple User Friendly Display and Mini Key Pad HUS 1000 HEUI System Test Bench 3 http www chinahanji com 2 HUS 1000 Test Bench Description 2 1 Test Bench Panel Description Front view of the HUS 1000 test bench A Control HEUISYSTEMTESTBENCH Panel gt N oN ane Fuel Delivery ad Emm Measurement Graduates Injector Test Chamber 4 HUS 1000 HEUI System Test Bench http www chinahanji com 2 1 1 Front Panel There are display meters switches buttons a hand wheels to regulate pressures oil temperature control module and HEUI control module on the front panel of the HUS 1000 test bench The photo below is the front panel of the test bench The followings list the devices and their functions on the front panel B lt Supply Pressure Analog pressure gauge to display the supply pressure B Pressure HUS 1000 HEUI System Test Bench 5 http www chinahanji com Analog pressure gauge to display the test oil actuation pressure Injector Controller gt HEUI injector control module Temperature Controller gt Test Oil Temperature displayed and Test oil temperature control module Test Bench Controller gt lt Power gt Indication light of AC Power lt Supply Pump gt Switch for supply pump ON OFF lt Actuator Pump gt switch for te
16. nob on the side board To avoid personal injury do not remove any injector from the test head until the actuation test oil becomes atmosphere pressure Caution The injector and some fluid will be forcefully ejected from the test head if the injector is not secured causing injury to the operator and or damage to the equipment Note When injector number less four other positions in the test head must have a dummy injector in them 5 2 Injector Sealing Test This test will check the sealing condition of the upper seat of the injector and the injector solenoid control valve by using a separate device The maximum ON time for this test is 2 minutes otherwise the solenoid may burn out The followings are the procedure e Place the device on the top of the test bench ensure the current adjusting knob at the minimum current position counter clock turn to the end Connect 36 VDC wire on the bench side panel to the device and the injector driving wire to the target injector Turn equipment power ON e Turn supply pump ON Turn actuation pump ON e Adjust supply pressure to 40 50psi e Adjust actuation pressure to 1000psi Turn the current adjusting knob clockwise slowly The amp meter will start to rise HUS 1000 HEUI System Test Bench 24 http www chinahanji com Fluid should be escaping from the injector s return port Continue to turn the knob When approximately 3 4 amps is indicated on the amp meter
17. p www chinahanji com 2 2 4 Test oil temperature control The HUS 1000 test bench equipped with an automatic oil temperature control system which consists of a temperature controller an oil to water heat exchanger cooling water flow solenoid regulator and an electrical heater The target test oil temperature is set by the user The electrical heater is ON when the test oil temperature is lower than the target temperature and the cooling water flow solenoid regulator is ON when the test oil temperature is higher than the target temperature The test oil temperature can be controlled within 1 C at the target temperature 2 2 5 Test oil tank The volume of the test oil tank is 11 US gallons The oil level in the tank can be observed via the transparent tube at the back of the bench The electrical heater is installed in the tank 2 2 6 Test Oil Filtration Two test oil filters are applied 2 3 HEUI Control Module The HEUI control module box is installed on the front panel of the test bench A LCD screen and on the control module displays injector setting and operational parameters A mini keypad on the front panel is used to edit the parameters The photo below is the front panel of the module The photo below is the back panel of the module HUS 1000 HEUI System Test Bench 9 http www chinahanji com The sockets on the back panel are HEUI injector Mini keypad solenoid to control the plate to direct fuel flow 36V
18. rovided that the HUS 1000 is returned prepaid to Chinahanji within one month from the date of failure with an APPLICATION FOR REPLACEMENT UNDER WARRANTY signed by a responsible engineering representative of the customer This warranty does not cover any coincidental or consequential damages of the HUS 1000 During the warranty period Chinahanji is not liable for any losses or damages of any kind resulting from the improper use of this product and user charges for the repair cost After the warranty period user charges for the repair cost 24 HUS 1000 HEUI System Test Bench http www chinahanji com Pressure gauge Pressure m reservoir Test chamber for four injectors Lube filter Pressure gauge D Mounting base of pressure reservoir Pressure relieve valve Actuator pump Pressure regulation valve Fuel filter Water in 2 FF5485 Water out 3 phase motor Heat exchanger LIE EZ Supply pump Temperature sensor Heater Figure1 The hydraulic circuit of the HUS 1000 Test bench HUS 1000 HEUI System Test Bench http www chinahanji com MO ground vire 201 neutral wire 3 Phase Mp W 1 4 conductor id AC Power Input 123 jj 1133 LE 1 Lola Water Valve PA Je E amp Fuse Re O O Hips trae kr E ntact _ 5 no a Cont
19. st oil actuation pump ON OFF lt Heater gt Switch for test oil heater ON OFF lt Actuator Regulation gt Knob of potentiometer to adjust actuation pressure lt Counter gt Push button to start fuel injection quantity measurement Stop the measurement during the fuel delivery test by pushing the button again Supply Regulation Hand wheel to adjust fuel supply pressure Turn it clockwise to increase fuel supply pressure lt E Stop gt Button for emergency stop 6 HUS 1000 HEUI System Test Bench http www chinahanji com 2 1 2 Left Side Panel The red turning switch on the left panel is the main power switch The AC power of the HUS 1000 is ON when the switch is turned to position ON The power indicator on the front panel will be lightened once the AC main power is ON The photo below is the left side panel of the test bench The 36VDC power output banana terminal sockets below the main AC power switch provide DC power for the leakage testing device Cooling water inlet and outlet ports are mounted on the lower left side panel HUS 1000 HEUI System Test Bench 7 http www chinahanji com 2 2 Hydraulic Circuit Figure 1 shows the hydraulic circuit of the HUS 1000 Test bench 2 2 1 Injector test chamber A special designed test head block is installed in the chamber The test head block has four HEUI injector mounting cavities for injector installation Similar to an engine cylinder h
20. the upper seat should snap shut and fluid should stop flowing 5 3 Test a 6 0L PowerStroke Engine Injector 5 3 1 Preparation 6 0L injector add on fixture The following procedure should be applied to prepare the test bench for testing a HEUI injector for Ford Power Stroke 6 0L engine Place the two O rings of the sealing kits P N 920240 to the adapt sleeve for 6 0L injector P N 920115 Insert the adapt sleeve into one of the injector mounting holes Insert the fitting P N 920213 or 920313 into the top cavity of the 6 0L injector Place the restrainer plate for adapter sleeve P N 920214 on the fitting and fasten the parts to the head block by the two M6 80 bolts P N 920217 Remove the actuation oil hose from the test heat block and connect it to 6 0L injector fitting P N 920213 or 920313 The sealing washer P N 920244 is needed for the connection Connect the 4 pin connector of the bench harnesses to the 6 0L injector The dummy injectors with O rings sets P N 920229 or 7 3L injectors should be installed into the other three unused injector mounting holes 5 3 2 Run 6 0L injector test Turn on the power switch of the test bench set the parameters for injector control the same as those for test 7 3L injectors Press lt 7 3L 6 0 L gt the LED screen becomes 6 0L OFF from 7 3L OFF press Inject ON OFF gt then LED screen changes to 6 0L ON and the solenoid of 6 0L injector starts to klick Turn
21. west terminal rack and labeled as 111 112 113 and 201 100 Terminals 111 112 and 113 are for power connection and 100 is for ground connection The neutral wire should be connected to terminal 201 Test the rotation direction of the fuel supply pump after the AC wire connection Switch any two input AC power wires if the rotation direction of the supply pump is incorrect Copper wires with 4mm cross section area should be applied for the 3 phase AC power connection e Place approximately 11 US gallons of suitable calibration fluid in the main tank by pouring it in over the test head The recommended calibration fluid is Viscor If you are using a different calibration fluid it should meet 1504113 standard DO NOT USE DIESEL FUEL Diesel fuel will not provide consistent or accurate measurements Use of diesel fuel may void warranty HUS 1000 HEUI System Test Bench 15 http www chinahanji com Warning DO NOT USE DIESEL FUEL Diesel fuel will not provide consistent or accurate measurements Use of diesel fuel may void warranty Caution Electrical heater is installed in the test oil tank the oil level should be higher than the red line on the level observation tube HUS 1000 HEUI System Test Bench http www chinahanji com 4 TEST BENCH OPERATION 4 1 Injector Installation Clean the injectors thoroughly to prevent contaminate the expensive test oil Install three testing O rings Chinahanji P N 920229
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