PT2012b PDF

FUEL INJECTION PUMP
TEST BENCH
PT2012-PT1012-PT1008
USER MANUAL
PT01E
İzmir-Ankara Yolu No:12/1 Ulucak/İzmir -35170
Tel : (+90-232) 877 08 35 Fax : (+90-232) 877 07 82
www.maktest.com.tr
PT01E
USER MANUAL, PumpTester 2012-1012-1008
Foreword
The equipment has been designed and manufactured to give maximum performance. Regular maintenance and
servicing will ensure maximum service life.
Service and support facilities are provided by MAKTEST MAKİNA SAN. ve TİC. A.Ş, , İzmir-Ankara Yolu,
No:12, Kemalpaşa – Ulucak / İzmir which may be contacted if any difficulty is experienced.
It is essential to quote the MODEL and SERIAL NUMBER of the machine in all communications.
Maintenance
To ensure continued, trouble-free operation of the equipment, it is important that periodic servicing is carried out
in accordance with the information contained in this publication.
Use only the replacement parts recommended by MAKTEST MAKİNA SAN. ve TİC. A.Ş when carrying out
routine maintenance, overhaul or repair.
When handling, operating and/or performing maintenance or repair, personnel are expected to use safe
engineering practices and to observe all relevant national and local safety regulations.
Work requiring electrical and mechanical competence must be carried out by suitably skilled personnel.
Ref. No. PT01E i

Safety Information
Most accidents involving equipment operation and maintenance are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognising potentially hazardous situations
beforehand. The equipment is designed to be intrinsically safe whenever possible. Guards are fitted to afford
optimum operator protection.
Read and understand all warning, caution, prohibition and mandatory notices and labels on the equipment
before operation or carrying out any maintenance or servicing.
If in doubt - ASK!
Warnings, Cautions and Notes

The precautionary notes in this publication, indicated by the words WARNING, CAUTION, or NOTE provide
information about potential hazards to personnel or equipment. Ignoring these notes may lead to serious injury
to personnel and/or damage to equipment. These notes appear as follows:
WARNING!
INDICATES THAT A SITUATION MAY BE HAZARDOUS TO PERSONNEL. INSTRUCTIONS ARE
PROVIDED FOR AVOIDING PERSONAL INJURY.
CAUTION!
Indicates that conditions exist that could result in damage to equipment. Instructions are
provided to prevent equipment damage.
NOTE:
Indicates additional information for clarification where there may be confusion.
ii Ref. No. PT01E

Warning Symbols
Isolate the electrical supply before performing any maintenance operations. Do

not work on electrical equipment while voltage is supplied. If such cannot be
avoided, e.g. for measurements, tests or adjustments, have the action carried
out by qualified personnel only.
Safety glasses must be worn when working on this equipment for the following
reasons:
1. The test equipment is capable of producing high pressure fluid jets or
sprays which can cause severe eye injury in the event of a malfunction.
2. The test stand uses calibration fluid which is harmful to the eyes.
Ensure the coupling guard is fitted over the coupling during operation. Ensure
the guard sleeve is fully extended to completely cover the drive coupling.
Make sure any rotary machinery is stationary before opening any access
panels or removing fixed panels.
Use extreme care to avoid being drawn in to the test stand. Check that all
clothing, especially sleeves and ties, and hair is safe and cannot be caught in
revolving parts. Check that hoses connected to the injection pump cannot chafe
or become entangled in the drive, thus causing a hazard.
Do not adjust any test stand components (including pumps under test) while
they are moving.
Make sure there is adequate ventilation. Oil vapour may be released from hot
fixtures or high pressure leaks. The specific directions in Health & Safety Data
Sheets must be adhered to.
Keep hands and the body away from fluid sprays, especially injectors, leaking
high pressure pipes and seals. High pressure injection through the skin can
result in fatal injury. In the event of injection into the skin, seek urgent medical
attention. Refer to the Health & Safety Data Sheets.
Ref. No. PT01E iii

Impervious gloves and overalls should be worn if regular contact with ISO4113
test fluid is likely. Gloves should also be worn when handling fixture parts or
injectors after testing which may be hot. Refer to the Health & Safety Data
Sheets.
Burns will occur to the hands if certain parts of the test stand or equipment
under test are touched. Keep hands away from the calibration fluid heater
element and injector or high pressure pipes after periods of extended running.
Safety footwear must be worn in the test area at all times. Injury to the feet may
be sustained in the event that equipment under test (during loading or
unloading) or test stand covers, are dropped.
Severe injury can be caused by slipping on spilt oils or fluids. All spillages of
fluids in the test area must be dealt with immediately. These can be mopped
up and mineral absorbent material spread over the affected area.
Use calibration fluid and lube oil of the correct specification only. Obtain the
manufacturers Health & Safety Data Sheets and follow the advice given therein.
Prolonged and repeated contact with oil products, ingestion or excessive and
prolonged inhalation of oil mists can be detrimental to health. Use an
appropriate barrier cream.
Ensure that the servicing requirements and intervals as set out in the
Maintenance section are adhered to. Operate and service this equipment only if
competent to do so. Carry out regular inspections to make sure all high
pressure connections are tight and safe.
Remove any tools, cleaning rags or other debris from the test stand before
starting up. Make sure the inching bar is not fitted to the test stand before
starting up.
There must be no naked flames. Potentially flammable vapours are present in

the test stand and ignition is possible although unlikely. Smoking whilst
operating the equipment is strictly forbidden.
Accidents can occur to unauthorised personnel during testing. Untrained

person(s) must not be present in the test area when the equipment is operating.
Only qualified personnel are to operate this equipment.
iv Ref. No. PT01E

Ensure good levels of lighting for safe, efficient equipment operation.
This equipment uses Viton (fluoroelastomer) seals. If these seals are exposed
to high temperatures, they decompose into a corrosive substance which is
extremely harmful and will contaminate skin. Do not touch Viton seals or the
sealing surfaces if they have been burnt or exposed to temperatures in excess
of 400ºC.
Take care to ensure only recommended equipment is connected to the test

stand auxiliary power socket and that it is correctly earthed.
Ear defenders or ear plugs must be worn by all personnel in the test area. Low
frequency noise may damage the inner ear and cause deafness.
CAUTION
Care must be taken to ensure that the correct speed and the correct rotation
are selected for the pump under test. Always return the speed control to
minimum before switching off the test stand.
This equipment contains electrostatic sensitive devices. Observe the necessary

precautions for handling electrostatic discharge sensitive devices. Do not touch
printed circuit boards and associated electronic connections and components.
Arc welding equipment must not be operated within 5 metres of the test stand.
The electrical supply to welding equipment must be provided from a remote
isolating transformer. Arc welding can disturb the measuring circuit.
Ref. No. PT01E v

CONTENTS LIST
Foreword ....................................................................................................................... i
Safety Information ...........................................................................................................ii
1. Introduction.......................................................................................................................1
1.1 Test Bench Dimensions and Layout ........................................................................1
1.2 Specifications ...........................................................................................................2
1.3 Health and Safety Data Sheet for Calibration Fluid (ISO 4113) ..............................3
2. Installation ........................................................................................................................5
2.1 Positioning the Test Bench ......................................................................................5
2.2 Connecting the Air Supply .......................................................................................6
2.3 Connecting the Cooling Water .................................................................................6
2.4 Filling the Test Oil Tank ...........................................................................................6
Electrical Installation..............................................................................................................6
2.5.1 Connect the Test Bench ..............................................................................................6
2.6 Installation Checklist ................................................................................................8
3. Systems ............................................................................................................................9
3.1 Pressure Controllers and Facia Connections ..........................................................9
3.2 Electrical Equipment ................................................................................................10
3.2.1 Electrical Circuit Description........................................................................................14
3.3 Test Oil and Pneumatic Equipment .........................................................................17
3.4 Metering System ......................................................................................................20
3.5 Cooling System ........................................................................................................21
3.6 Emergency Stop Braking System ............................................................................23
3.7 Central Conrol Unit ..................................................................................................24
4. Operating the Test Bench.................................................................................................25
4.1 Before Start ..............................................................................................................25
4.2 Pump Delivery..........................................................................................................26
4.3 Auxiliary Voltage Supply ..........................................................................................26
4.4 Pump Mounting Table..............................................................................................28
4.5 Mounting Pumps to the Test Stand .........................................................................29
4.5.1 In-Line Pump Mounting Brackets (Part Numbers AA1991 and AA1992)....................29
4.5.2 Quick-Action Clamps for In-line Pumps (Part No. AA1999) ........................................29
4.5.3 Bosch P Flange Adapter Plate (Part No. AA1592)......................................................30
4.5.4 Rotary Pump Mounting Bracket (Part No. AA1996)....................................................30
4.5.5 Pump Mounting Adapter Plate with 4 Pump Fixing Holes (Part No. AA1188) .......................... 31
4.5.6 Rotary Pump Adapter Plate with 9 Pump Fixing Holes (Part No. AA1187) ................31
4.5.7 Rotary Pump Adapter Plate with 3 Pump Fixing Holes (Part No. AA1186) ................31
4.5.8 Antibacklash Coupling And Coupling Cover ...............................................................32
5. Maintenance .....................................................................................................................33
5.1 Daily Checks ............................................................................................................33
5.1.1 Check the Tank Test Oil Level ....................................................................................33
5.1.2 Check the Air Supply ...................................................................................................33
5.2 Every 300 Running Hours........................................................................................33
5.2.1 Drain the Test Oil Tank................................................................................................33
5.2.2 Change the Test Oil Tank Filter ..................................................................................33
5.2.3 Empty the Waste Oil Tank...........................................................................................34
5.2.4 Change the Waste Oil Tank Filter ...............................................................................34
5.2.5 Check the Test Injectors..............................................................................................34
5.3 Every 500 Running Hours........................................................................................34
5.3.1 Check the Motor Brushes............................................................................................34
5.4 Fault Finding ............................................................................................................35
6. Spares List........................................................................................................................38
6.1 Electrical Spares ......................................................................................................38
6.2 Test Oil & Pneumatic System Spares......................................................................39
6.3 Metering System Spares..........................................................................................39
6.4 Cooling System Spares ...........................................................................................39
6.5 Braking System Spares ...........................................................................................40
6.6 Central Control Unit Spares .....................................................................................40
6.7 Standard Accessory Set for PT2012-B.....................................................................40
6.8 Standard Accessory Set for PT2012-H ...........................................................41
6.9 Standard Accessory Set for PT1012-B ...........................................................42
6.10 Standard Accessory Set for PT1008-H ...................................................................43
7. Circuit Diagrams ...................................................................................................45
7.1 Pneumatic Circuit Diagram..............................................................................45
7.2 Hydraulic Circuit .............................................................................................46
7.3 Hydraulic Circuit (Lube) ..................................................................................47
7.4 Electrical Equipment Enclosure Layout ......................................................................48
7.5 Electrical Circuit Diagram (1/2)....................................................................................49
7.5 Electrical Circuit Diagram (2/2)....................................................................................50
7.6 Electrical Relay Control...............................................................................................51
1. Introduction
This manual provides information about the safety, installation, operating and routine maintenance of
the Pumptester PT2012,PT1012 and PT1008. Troubleshooting information is also provided to assist
the user to solve simple problems.
Make sure you have read and understand the information contained in this manual before attempting
to install and use the test stand.
1.1 Test Stand General Arrangement

Figure 1.1 shows the general arrangement of the PT2012,PT1012 and PT1008 test stand. The
PT2012 is fitted with a 20 h.p. a.c. drive motor and twelve graduates.The PT1012 and the PT1008 are
fitted with a 10 h.p. a.c. drive motor.The PT102 is fitted twelve gaduates,The PT1008 is fitted eight
graduates.
3
1 2
2 4
40 20
30
10
60
0 40
20 0 3
1 5 200 10
50
80 20
400
0 30 60
600
0 6 4
30
1 1,5
20 40
20 400
600
10
0,5 2 200
30 50
10
800
0 0
0 2,5 0 60
4b ar 60bar
2.5bar
1 4bar 60bar
l / min.
1843 (PT2012) 1703 (PT1012-PT1008)
1912 (PT2012) 1772 (PT1012-PT1008)
Figure 1.1 Test Stand General Arrangement
1
USER MANUAL, PumpTester 2012-1012-
1008
1.2 Specifications
ÖZELLİKLER PT2012 PT1012-PT1008
380 V A.C. 380 V A.C.

Standard: 3 phase 50 Hz 3 phase 50 Hz
(no neutral required) (no neutral required)
Electrical Supply
Current: 55 A. 40A
Gross: 1030 kg 955 kg
Weight
Net: 875 kg 800 kg
Width (W): 764 mm 764 mm
Dimensions
Length (L): 1772 mm 1772 mm
(Refer to Fig 1.1)
Height (H): 1871 mm 1871 mm
Type: ISO4113 ISO4113
Calibration Fluid Capacity: 48 litres (tank) 48 litres (tank)
Refer to Health and Safety Data Sheet for Calibration Fluid (ISO 4113)
Clean, dry Clean, dry
Air Supply minimum 5.5 bar minimum 0 bar
Pressure:
maksimum 7 bar maksimum 7 bar
Clean Clean
Water Supply
Temperature: maximum 20°C (68°F) maximum 20°C (68°F)
2
1.3 Health and Safety Data Sheet for Calibration Fluid (ISO 4113)
HEALTH & SAFETY DATA SHEET DATE Pub. No.
Information regarding the safe handling & storage of the named product. MAR 97
Applicable to employees and customers.
PRODUCT WARNING
CALIBRATION FLUID (ISO 4113) SEEK IMMEDIATE MEDICAL ATTENTION
IF INGESTED
USE CLASSIFICATION
TEST FLUID FOR DIESEL INJECTORS, FLAMMABLE
INJECTION PUMPS & OTHER DIESEL EQUIPMENT
PRODUCT DESCRIPTION - COMPOSITION

THESE FLUIDS ARE PETROLEUM BASED PRODUCTS CONTAINING SIGNIFICANT PROPORTIONS OF
THE MORE VOLATILE PETROLEUM FRACTIONS AND OTHER SOLVENTS USED FOR LUBRICATION,
ANTI-CORROSION AND DERMATITIC INHIBITION.
SAFE HANDLING ADVICE (Protection - Usage, Storage & Transport)

USAGE: 1) Avoid eye splashes and extended skin contact.
2) Do NOT take internally.
3) Keep mist generated by machinery to a minimum, also avoid where possible vapours
caused by elevated temperatures.
4) Protective clothing to be regularly laundered.
STORAGE: These are flammable products which should be stored in closed containers away from
heat in a well ventilated area.
EMERGENCY & FIRST AID PROCEDURE (Eyes, skin, ingestion, inhalation)

INGESTION: Do NOT induce vomiting. Give a glass of water and get immediate medical attention at
Hospital.
EYES: Flush with large amounts of water for 15 minutes. Seek medical help if irritation persists.
SKIN: Wash thoroughly with soap & water. Seek medical help if irritation or skin rashes occur.
Remove any contaminated clothing.
INHALATION: Inhalation includes oil mists or vapours. Remove victim to fresh air. Seek medical help if
affliction persists.
FIRE HAZARDS & PROTECTION (Flash point, spillage)

SPILLAGE: Contain spillages with sand or mineral absorbent material. Mop up and clean floor to
remove oil residue.
FLASH POINT: Above 55°C
FIRE: (Extinguisher media)
Use carbon dioxide, dry chemical powder or foam extinguishers. Do NOT use water jets.
ENVIRONMENTAL PROTECTION (Spillage land / water, disposal)

SPILLAGE: Advise authorities if product has entered or may enter sewers, water courses or
extensive land areas.
DISPOSAL: All waste should be put into identified containers and stored at a specific disposal point.
Arrange for off site disposal in accordance with local regulations for notified waste.
THE INFORMATION AND RECOMMENDATIONS IN THIS PUBLICATION ARE TO THE BEST OF OUR KNOWLEDGE INFORMATION
AND BELIEF ACCURATE AT THE TIME OF PUBLICATION NOTHING HEREIN TO BE CONSTRUED AS A
WARRANTY, EXPRESS OR IMPLIED IN ALL CASES. IT IS THE RESPONSIBILITY OF THE USERS TO
DETERMINE THE SUITABILITY OF ANY PRODUCTS FOR THEIR OWN PARTICULAR PURPOSE.
RECOMMENDATIONS FOR HANDLING, PROTECTION ETC. ARE ADVISORY ONLY.
3
P2. Installation
2.1 Positioning the Test stand
Refer to Figure 2.1. Observe the following when transporting and positioning the test stand:
Use the forklift for transporting the test stand. The test stand should be lifted according to it’s
center of the gravity.
Figure 2.1 Transporting the Test Stand
Ref. No. PT01E 5

1008
2.2 Connecting the Air Supply

Refer to section 1.2 for specification. Connect the air supply to the 8mm diameter barb connector
(Fig 3.6 item 19) located at the rear of the test stand.
NOTE:
The display on the Central Control Unit will not illuminate if the air supply is not connected.
2.3 Connecting the Cooling Water

Refer to section 1.2 for specification. Connect the cooling water supply (Fig.3.8 item 5) and return
(Fig.3.8 item 6) pipes to the two 10mm diameter barb connectors located at the rear of the test stand.
2.4 Filling the Test Fluid Tank

The test stand uses ISO4113 test fluid (see Calibrating Fluid Data Sheet in section 1). Remove the
right hand side panel which provides access to the test fluid tank. Lift off the tank lid and fill the tank to
the maximum level shown by the sight level gauge. The tank capacity is approximately 48 litres.
Check that the tank thermostat is set to 60°C. Replace the tank lid and access panel.
NOTE:
The display on the Central Control Unit will not illuminate if the tank level is below the minimum level.
Keep the tank well above the minimum level as indicated on the level gauge.
NOTE:
Before starting test bench remove transit bandson float switchesi
2.5 Electrical Installation

The connection of electrical supplies must comply with the local and national electrical regulations.
Make sure the connection of 3 phase electrical power is carried out by a suitably qualified electrician.
WARNING!
THE EQUIPMENT MUST BE HARDWIRED AND BONDED TO A
PROTECTIVE EARTHING SYSTEM BEFORE THE MAINS SUPPLY WIRES
ARE CONNECTED. THE EARTH WIRE MUST BE TAKEN DIRECTLY TO
EARTH INSTEAD OF OR AS WELL AS THROUGH A PLUG AND SOCKET.
2.5.1 Connect the Test Stand

WARNING!
THE INCOMING MAINS CABLE MUST BE CAPABLE OF CARRYING THE
TOTAL LOAD CURRENT OF THE TEST STAND.
The following minimum cable sizes should be used . PT2012: 10 mm² section.
CAUTION
Do not use cables longer than 20 m to connect the test stand to the mains power.
Refer to Fig 2.2.
1. Feed the cables through the holes provided in the base of the test stand.
2. Connect the cables and ground wire to the main switch.
6 Ref. No. PT01E

3. Check the rotation of the test fluid pump motor. Start the test fluid pump using the Test Fluid
Supply Pump ON/OFF button (Fig. 4.1 item 14). Adjust the test fluid pressure control valve (Fig.
3.2 item 29) to give a positive pressure on the gauge (Fig. 3.5 item 1). If a positive pressure
cannot be achieved, the pump rotation is incorrect. In this case, switch off and isolate the test
stand. Change over the connections of any two of the three incoming phase wires.
NOTES:
a. If the power supply exhibits voltage fluctuations, contact your nearest dealer for assistance.
b. Refer to the Troubleshooting section of this manual to solve simple problems experienced during
operation. Contact your nearest dealer if you cannot identify and solve the problem using this
manual.
2012
Figure 2.2 Electrical Connections
NOTE:
The glycerin filled pressure gauges have a cap in the body top to allow the glycerin to ‘breathe’ and
avoid condensation. As soon as the test stand is installed, loosen the caps slightly to prevent
condensation. Do not remove the caps.
Ref. No. PT01E 7

1008
2.6 Installation Checklist
Before starting the test stand, check:
• Test stand correctly positioned and level

• Air supply connected
• Cooling water connected
• Test fluid tank filled to correct level (and lube oil tank if system fitted)
• Internal transformer voltage correctly set
• Cables connected to main switch
• Glycerin filled pressure gauge caps loosened slightly
• Test fluid pump motor rotation checked
• Tank thermostat set to 60°C
• All access panels and fixed covers fitted and all doors closed
8 Ref. No. PT01E

3. Systems
3.1 Pressure Gauges, Pressure Controllers and Bulkhead Connections
Refer to Figure 3.1.
PT 1012 - PT 1008 PT 1012 - PT1008 LUBE
6 8 6 8 1 6 8 6 8 1
2 2
100 100 20 100 100 20

4 10 4 10 30 4 10 4 10 30
10 10
150 50 150 40 150 50 150 40
50 0 3 50 0 3
0 0
2 12 2 12 200 10 2 12 2 12 200 10
50 50
200 400 20 200 400 20
0 200 0 0 200 0
30 60 30 60
600 600
0 14 0 14 4 0 14 0 14 4
30
1 1,5 30 1 1,5 20 40
400
20 40 20 600
20
400
200
10 600 10 50
0,5 2 0,5 2 10
30 200 30 800
50
10 0 0
800
0 0 0
0 60 0
0 2,5 0 2,5
0 60
60bar 4bar
60bar 4bar
2.5bar 2.5bar
60bar 1 4bar 60bar 1 4bar
10bar
l / min. l / min.
Figure 3.1 Pressure Gauges, Pressure Controllers and Bulkhead Connections

KEY TO FIGURE 3.1
1 Transfer Pressure Reading Group 8 Vacuum Valve
2 Test Fluid Supply Connection 9 Lube Supply Connection
3 Direct Tank Connection 10 Lube Return Connection
4 Flowmeter Return Connection 11 Test Fluid Box Return Connection
5 Air Supply Connection 12 Lube System Control Group
6 Auxiliary Pressure Reading Group 13 High Pressure Control Group
7 Air Pressure Control Group 14 Auxiliary Pressure Control Group
(Only for PT2012)
Ref. No. PT01E 9

1008
3.2 Electrical Equipment

Refer to Figures 3.2, 3.3 and 3.4.
Control Button Group (1)
Buttons in group (1) operate temperature control, temperature set point and test fluid pump, metering
system shot count, main drive direction of rotation and main drive motor.
Control Display (2)
Gives readout of speed, temperature, drive direction, shot count and temperature control status.
Speed Control Potentiometer (3)
This manually operated potentiometer is used to set the speed of the main drive motor. The Speed
range is from approximately 50 rpm to 4000 rpm (PT2012), 75 rpm to 3500 rpm (PT1012, PT1008)
Selector Switch 12/24 Volt d.c. (4)
Used to select either 12 or 24 V d.c.
12/24 Volt d.c. Reset Push-button (5)
Resets the supply should the voltage trip out.
Socket 12/24 Volt d.c. Supply (6)
Connection socket for the 12/24 V d.c. supply.
Temperature Sensor - Test Fluid Supply (7)
This temperature sensor senses the temperature of the test fluid supply and sends the signal to the
Central Control Unit. The test fluid supply temperature is controlled to the set temperature.
Calibrator Lamp (8)
A 14 W Ecotone lamp is provided to assist the operator in viewing the graduates.
Mains Isolater Switch (9)
Used to switch the test stand on and off. The switch isolates the test stand from the incoming mains
electrical supply.
Main Motor (10)
Refer to 3.2.1 for specification. The flywheel is directly coupled to the main motor.
Encoder (11)
An encoder is mounted on the back of the main motor and picks up a signal as the motor is running.
The signal is used to control the speed of the main motor.
Transformer (12)
Regulates the internal test stand voltage.
Main Control Unite (13)
Houses the test stand electronic control circuits.
Cooling System Solenoid (14)
The test stand uses water to control the test fluid temperature. Water is circulated through the cooling
coil inside the tank. The central control unit operates the solenoid valve to allow cooling water to pass
through the cooling coil when required.
Test Fluid Tank Low Level Switch (15)
When the switch is actuated the main drive and test fluid supply pump are switched off and the test
stand electrical equipment is disabled. The display is also switched off.
Heater (16)
Ref. No. PT01E 10

The 2100 W heater is located in the test fluid tank.

Test Fluid Tank Over- temperature Thermostat (17)
If the test fluid system temperature rises above 60ºC the thermostat will switch off the power to the
test fluid tank heater.
Test Fluid Tank Low Level Switch (18)
When the switch is actuated the main drive and test fluid supply pump are switched off and the test
stand electrical equipment is disabled. The display is also switched off.
Temperature Sensor - Test Fluid Return (19)
This temperature sensor senses the temperature of the test fluid return and sends the signal to the
Central Control Unit.
Emergency Stop Buttons (20)
These are situated on each side of the control console. Pressing either will stop the main drive, test
fluid supply pump and disable the test stand electrical equipment. The display is switched off.
NOTE:
The Air Low Pressure switch (18) and the Test Fluid Tank Low Level switch (15) act in the same way
as the Emergency Stop buttons. The main motor fan is not disabled when an Emergency Stop button
is operated.
Turn the Emergency Stop button clockwise to unlatch the button and restore the electrical supply to
the control console.
Metering Shutter Actuator (21)
This operates the metering shutter.
Main Motor Cooling Fan (22)
The cooling fan provides cooling air for the motor.
Test Fluid Supply Pump/Motor (23)
The transfer pump is run by a 1.5 hp/1.1 kW a.c. motor.(for the Lube system 1.5 kw)
Electrical Panel Enclosure (24)
Accommodates the switch gear and speed control system as well as the control transformer.
Air Low Pressure Switch (25)

If the inlet air falls below 4.5 bar the switch will stop the main drive, test fluid supply pump and will
disable the test stand electrical equipment except for the main motor cooling fan.
Brake Actuator Solenoid (26)
This controls the air brake that stops the main drive when an Emergency Stop button is pressed.
RFI Filitre (27)
Suppresses the magnetic and electronic noises which may be harmfull to any other devices in the
same working environment.
Brake Resistor(28)
Provides energy storage to obtain dynamic braking despite the big flywheel.
Ref. No. PT01E 11

1008
6 8 1 2
100 20
4 10 10
30
50 150 0 40
0 3
2 12 200 10
50
400 20
0 200
30 60
600
0 14 4
30
1 1,5
20 40
20 400
600
10
0,5 2 200
30 50
10
800
0 0
0 2,5 0 60
4bar 60bar
2.5bar
1 4bar
l / min.
Figure 3.2 Electrical Equipment (front view)
KEY TO FIGURES 3.2, 3.3 & 3.4

1 Control Button Group 14 Cooling System Solenoid
2 Control Display 15 Test Fluid Tank Low Level Switch
3 Speed Control Potentiometer 16 Heater
4 Selector Switch 12/24 V d.c. 17 Test Fluid Tank Over-temperature Thermostat
5 12/24 V d.c. Reset Push-button 18 Air Low Pressure Switch
6 Socket 12/24 V d.c. Supply 19 Temperature Sensor – Test Fluid
Return
7 Temperature Sensor – Test Fluid 20 Emergency Stop Buttons
Supply
8 Calibrator Lamp 21 Metering Shutter Actuator
9 Mains Isolater Switch 22 Main Motor Cooling Fan
10 Main Motor 23 Brake Actuator
11 Encoder 24 Electrical Panel Enclosure
12 Transformer 25 Test Fluid Supply Motor
13 Main Control Unit 26 Brake Actuator Solenoid
27 RFI Filter
28 Brake Resistor
Ref. No. PT01E 12

1012
Figure 3.3.a Electrical Equipment (side view)
Figure 3.3.b Electrical Equipment (side view)
Ref. No. PT01E 13

1008
Figure 3.4 Electrical Equipment (rear view)

3.2.1 Electrical Circuit Description
Refer to the electrical panel layout (Fig 3.13), electrical circuits (Figs 3.14, 3.15, 3.16) and the
electrical component layout drawings (Figs 3.2, 3.3, 3.4). Numbers in brackets refer to Figs 3.2, 3.3,
and 3.4 unless otherwise stated.
Power circuits
Incoming power is 3 phases (50 Hz, 380 A.C.) and earth via main isolator switch (9) - no neutral is
used. Any supplies outside the range 380 to 480 V require an external transformer.
The isolator switch (9) on the side of the machine disconnects the 3 phase input supply. The 3
phases pass through the machine main trips F1 which sense overload in any phase and then trip all
three phases. They are manually reset.
All low voltage supplies are derived from a control transformer (12) mounted inside the machine,
powered from 2 phases via trip F2. This trip is manually reset. The input wire 56 should be
connected to the tapping which is nearest in value to the supply voltage into the machine.
The fuel pump motor runs when contactor LC1 is energised. An overload trip (with reset by pressing a
button) is attached to the contactor for protection.
The heater is powered when RL2 is energised. Overload trip F3 protects the circuit. A thermostat, set
to 60°C, breaks the heater power circuit if the tank oil is too hot.
The heater consists of 2 elements connected in series. Each element has a resistance between 50
and 60 ohms. Current is 3 to 4 amps. An indicator lamp located next to the thermostat turns on when
there is voltage across one of the elements.
For cooling, a 220 V a.c. solenoid (14) is energised to allow water to flow through cooling coils in the
test oil tank. There is no internal pump; supply pressure defines the water flow. If a chiller unit is
used, this has its own pump to circulate the water.
Ref. No. PT01E 14

Interlocks
The 2 emergency stop buttons (20), tank level switch (15), air pressure switch (18), and fuel pump
motor overload trip T1 are wired in series to connect 24 V a.c. to the emergency stop relay RL1. If
any of these switches operate, then power is removed from the Control Panel, and the drive and fuel
pump will stop.
The drive and temperature control cannot be started unless the fuel system has been switched on.
Both are switched off if the fuel system is switched off. This logic is performed in the microcontroller
circuit board.
Temperature Control and Measurement
A temperature sensor is located in the fuel return port of the pressure control valve. The sensor
outputs its signal as digital pulses to the microcontroller board in the control panel. An LED
illuminates on this board to indicate that the sensor is generally working.
The supply temperature is normally shown on the display (Fig 4.1 item 19).
If the temperature control system is switched on, this temperature is compared to the set demand. If
the temperature is rising, the heater switches off when the temperature equals the set demand. If the
temperature is falling, the heater switches on when the temperature is one degree less than the set
demand.
The cooler solenoid energises when the temperature is one degree above the set demand. It
switches off when the temperature equals the set demand.
LEDs on the display (Fig 4.1 items 6, 7, 8) indicate the temperature control status.
To turn the heater on, the microcontroller board energises a relay on the Relay board. This relay in
turn energises the heater relay RL2 to power the heater.
To turn the cooler on, the microcontroller board energises a relay on the Relay board. This relay in
turn energises the cooler solenoid.
A second identical temperature sensor, located in the bulkhead connection to the flowmeter, is used to
measure the temperature of the back leakage return oil. An LED illuminates on the microcontroller
board to indicate that the sensor is generally working.
The back leakage temperature is displayed in place of the supply temperature if the set temperature
button (Fig 4.1 item 18) is pressed while the drive is running. Back leakage temperature cannot be
viewed when the drive is off.
Drive system
The drive system consists of:
AC motor: PT2012: 20 hp at 1500 rpm (380 V ). Maximum speed 4000 rpm
Max. Current 41 A.
PT1012: 10 hp at 1500 rpm (380 V-50 Hz). Maximum speed
3500 rpm . Max. Current 16A.
PT1008:
Encoder: 2 channels of 60 pulse per rev. Mounted directly on the back of the motor.
Speed demand: Single turn 10 K potentiometer with a large diameter marked speed dial.
Contactor: The Contactor energised by drive supplies.
Interlocks: Drive on/off and direction controls on the front panel input to the
microcontroller board, which then operates the drive contactors and brake
as required.
Dynamic operated Operates to brake the flywheel when the emergency stop relay is de-
brake: energised. When the drive button is pressed, the drive is stopped by the
dynamic brake system.
The operation of the drive contactors is controlled by the microcontroller board independently of the
status of the drive unit or speed board.
Ref. No. PT01E 15

1008
The output is raised if the speed demand is greater than the speed measured from the encoder pulse
rate. The output is clamped low when the contactor is not energised.
Voltage from the drive is compared to the speed measured by the board to check for loss of feedback
pulses. A red indicator on the speed board latches on for a speed feedback loss condition, reset
when the drive run indicator is off.
Speed measurement
One channel of the 60 pulse per rev encoder output is connected to the microcontroller board. An
indicator on the microcontroller board flashes for each pulse input. Pulses are counted over 1 second
to give the speed in rpm. This pulse input is also used for the stroke countdown control.
Stroke system
The microcontroller board energises the stroke relay and LED on the relay board to operate the
mechanism which deflects the injected oil into the graduates. The stroke board requires a 24 V a.c.
supply. The board outputs a positive pulse to drive the stroke 12 V d.c. motor to the metering position,
and a negative pulse for back. The red indicator on the board shows that 24 V a.c. supply power is
present. The green indicator turns on to show metering. Note that the output is a pulse through a
capacitor, and is therefore difficult to check with a voltmeter.
Fuse and overload settings
Refer to Fig 3.13.
Description Reference PT2012 PT1012

PT1008
Main Trip F1 63 A 32A
Control Transformer Trip F2 6A 6A
Heater Trip F3 6A 6A
Fuel Pump Motor Overload Trip T1 3.1 A 3.1A
Relay board 24 V a.c. fuse (20 mm x 5 mm) S1 (on board) 2.5 A 2.5A
Relay board 220 V a.c. fuse – cooling solenoid (20 mm x 5 mm) S2 (on board) 0.2 A 0.2A
Relay board 220 V a.c. fuse – DC motor fan (20 mm x 5 mm) S3 (on board) 2.5 A 2.5A
Relay board S4 (on board) not used Not used
Relay board 220 V a.c. fuse – transformer (20 mm x 5 mm) S5 (on board) 1A 1A
DC Supply (Adapter) Board fuse (20 mm x 5 mm) - 5A 5A
Micro Control Card Supply Fuse (18V) F4 1A 1A
Micro Control Card Supply Fuse (15V) F5 1A 1A
Relay board yellow indicators

The nine relays on the relay board are driven by the microcontroller board. A yellow indicator LED
(located to the left and slightly above each relay) shows when the relay is energised. From top to
bottom the functions are:
Brake Energised while the motor is stopping.
Motor direction Energised for anti-clockwise direction.
Drive Energised for drive on.
Fuel pump Energised for fuel pump on.
Lube oil PT2012: energised for lube oil pump on (if fitted).
Stroke Energised for metering of injected fuel.
Cooler Energised for cooling water solenoid energised.
Heater Energised for heater turned on.
Ref. No. PT01E 16

Ref. No. PT01E 17

1008
3.3 Test Fluid and Pneumatic Equipment

Refer to Figures 3.5 and 3.6.
Supply Pressure Gauge (1)
Measures the supply pressure of the test fluid from –1 to 4 bar.
Auxiliary Pressure Gauge (2)
Measures up to 6 bar.
Transfer Pressure Gauge (3)
Measures up to 14 bar.
Air Pressure Gauge (4)
Measures from 0 to 2.5 bar.
High Pressure Phasing Gauge (5)
Measures up to a maximum pressure of 60 bar.
Flowmeter (6)
The flowmeter measures test fluid return flow. For accurate measurement the test fluid should be
certified ISO4113. Refer to the Data Sheet for Calibration Fluid ISO4113 in section 1.
Test Fluid Pressure Control Valve (7)
Test fluid pressure can be adjusted up to a maximum of 3 bar for pump feed pressure, as indicated on
pressure gauge (1).
NOTE:
IT IS RECOMMENDED THAT THE PRESSURE BE REDUCED TO A MINIMUM AFTER A PUMP
HAS BEEN TESTED.
Test Fluid High Pressure Control Valve (8)
Test fluid pressure can be adjusted up to a maximum of 50 bar for pump feed pressure, as indicated
on pressure gauge (5).
Waste Fluid Tank and Drain Valve (9)
The waste fluid tank collects any spilt test fluid and lubrication oil mixture from the drip tray. A drain tap
mounted below the tank inside the test stand is used to drain the waste tank.
Test Fluid Filter (10)
The filter is placed in its own section of the tank to prevent aeration.
Waste Fluid Tank Filter (11)
A drain tap mounted below the tank inside the test stand is used to drain the waste tank.
Test Fluid Supply Pump (12)
The gear type pump supplies test fluid up to a maximum of 9 lt./min.
Air Pressure Control Valve (13)
Used to adjust the air supply pressure.
Lube Pressure Control Valve (14)
Pressure can be adjusted up to 10 bar.
Pressure Gauge (15)

Lube Oil Pressure is displayed at the Gauge 15. It can measure up to 10 bar.
Lube Pressure Supply Connection (16)

Lube oil is supplied at this connection port. Use the hose provided together with the test bench to
Ref. No. PT01E 18

connect the lube oil supply to the pump.
Lube Return Connection (17-18)

Return oil connection.
Air Inlet (19)

Test stand air supply connector.
Air Pressure Gauge (20)
1012
Figure 3.5 Test Fluid and Pneumatic Equipment (rear view)
KEY TO FIGURES 3.5 & 3.6

1 Supply Pressure Gauge 7 Test Fluid Pressure Control Valve
2 Auxiliary Pressure Gauge 8 Test Fluid High Pressure Control Valve
3 Transfer Pressure Gauge 9 Waste Fluid Tank and Drain Valve
4 Air Pressure Gauge 10 Test Fluid Filter
5 High Pressure Phasing Gauge 11 Waste Fluid Tank Filter
6 Flowmeter 12 Test Fluid Supply Pump
13 Air Pressure Control Valve
14 Lube Pressure Control Valve
15 Lube Supply Pressure Gauge
16 Lube Pressure Supply Connection
17 Lube Return Connection
18 Lube Box Return Connection
19 Air Inlet
20 Air Pressure Control Regulator
Ref. No. PT01E 19

1008
1012
Figure 3.6 Test Fluid and Pneumatic Equipment (side view)
Ref. No. PT01E 20

3.4 Metering System

The metering unit assembly is mounted on a rotating arm and can be moved around to the front or
either side of the test stand.
Graduates (1 & 2)
The capacities of the graduates are as follows:
PT1008 PT2012-PT1012
3
Small Graduates 26 cm 38 cm3
Large Graduates 120 cm3 170 cm3
Test Injectors (5)

The injector mount assembly can accommodate most common types of test injectors by fitting suitable
adapters.
Figure 3.7 Metering System Equipment
KEY TO FIGURE 3.7

1 Small Graduate 6 Small Graduate Holder
2 Large Graduate 7 Large Graduate Holder
3 Spray Chamber 8 Shutter Actuator
4 Drop Pin 9 Position Lock
5 Injector 10 Metering System
Ref. No. PT01E 21

1008
3.5 Cooling System

The cooling system operates in conjunction with the heater as part of the integrated temperature
control system. The test stand Central Control Unit monitors the temperature of the test fluid via a
temperature sensor and operates the solenoid valve to allow a flow of the cooling water to the cooling
coils when required. The cooling system consists of a cooling serpentine (1) mounted in the test fluid
tank and a water inlet solenoid valve (2).
1012
Figure 3.8.a Cooling System Layout

KEY TO FIGURE 3.8. a
1 Cooling Serpentine 4 Water Supply Line
2 Supply Inlet Solenoid Valve 5 Supply Connector
3 Water Return Line 6 Return Connector
Ref. No. PT01E 22

1012
KEY TO FIGURE 3.8.b

1 Cooling Serpentine 6 Drayer
2 Copper Pipe – 3/8” 7 Cooling Fan
3 Copper Tube – Hair Thin 8 Chiller Unit
4 Gas Insert Tap 9 Copper Pipe – 5/16”
5 Radiator
Ref. No. PT01E 23

1008
3.6 Emergency Stop Braking System

The brake system uses a friction type mechanical brake to stop the drive. The brake is active when
the power to the test stand is off. Operating an Emergency Stop button applies the brake to stop the
drive in an emergency.
3
1 2
2 4
40 20
30
10
60
0 40
20 0 3
1 5 200 10
50
80 20
400
0 30 60
600
0 6 4
30
1 1,5
20 40
20 400
600
10
0,5 2 200
30 50
10
800
0 0
0 2,5 0 60
4bar 60bar
2.5bar
1 4bar 60bar
l / min.
Figure 3.9 Braking System Layout
KEY TO FIGURE 3.9

1 Brake Pads 4 Air Pressure Regulator
2 Connector Rod 5 Air Pressure Gauge
3 Air Piston 6 Pneumatic Valve
Ref. No. PT01E 24

Ref. No. PT01E 25

1008
3.7 Central Control Unit
MIN-1
0 40
00
0
50
350
0
SEC
1000
3000
00
15
25
00
2000
I I
Figure 3.10 Central Control Unit

KEY TO FIGURE 3.10
1 LED Display 5 Emergency Stop Button
2 Touch Button Group 6 Display Board
3 Speed Control Potentiometer 7 Micro Control Board
4 Common keyboard
Ref. No. PT01E 26

7.Circuit Diagrams
7.1 Pneumatic Circuit Diagram
AP 1227 REGULATED AIR PRESSURE SWITCH
7.2 Hydraulic Circuit

Ref. No. PT01E 45
7.3Hydraulic Circuit (Lube)
Ref. No. PT01E 46

Ref. No. PT01E 47

7.4 Electrical Equipment Enclosure Layout
Ref. No. PT01E 48

7.5 Electrical Circuit Diagram (1/2)
M
3
Ref. No. PT01E 49

USER MANUAL
7.5 Electrical Circuit Diagram (2/2)
Ref. No. PT01E 50

7.6 Electrical Relay Control
R2 R1 R4 R3 R5 R6
START DRIVE STROKE FUEL COOLING HEATING
DIRECTION PUMP
2.5A
K6 K4
K5 STROKE K1
COOLING HEATING K3
K2
DRIVE
START
FUEL DIRECTION
2.5A 0.2A
PUMP
LC1
BRAKE
SEL.
RL1 RL1
SW
AIR
PRESSURE
COOLING
M~
220V
FAN
Ref. No. PT01E 51

4. Operating the Test Stand

IMPORTANT NOTE
Read and understand all warning, caution, prohibition and mandatory notices and labels on the
equipment before operating the test stand.
WARNING!
MAKE SURE THE COUPLING GUARD IS FITTED OVER THE COUPLING
DURING OPERATION. A DAMAGED COUPLING MAY CAUSE SERIOUS
PERSONAL INJURY AND DAMAGE TO THE TEST STAND.
4.1 Before Testing

Refer to Fig 4.1. The numbers in brackets ( ) refer to items in Fig 4.1, unless otherwise stated.
1. Switch on the test stand power using the mains isolator switch at the back of the test stand.
(Fig 3.3 item 9).
2. Mount and connect the pump to be tested. Refer to Section 4.5 for mounting arrangements, and
to Fig 3.1 for the pump connections, i.e. supply, return etc. The various adapters and brackets
used to mount different pumps are given in Section 4.4.
3. Check the drive direction of rotation by looking at which indicator (3 or 1) is illuminated. Set the
direction of rotation for the pump being tested by pressing button (13).
4. Press button (15) to start the test fluid supply pump, the indicator (4) will illuminate. Pressing
button (15) again will stop the supply pump,
5. Adjust the test fluid supply pressure using control valve (Fig 3.5 item 1) monitoring the pressure
displayed by gauge (Fig 3.1 item 1 ). The maximum supply pressure is approximately 3 bar
(45 lbf/in²).
6. Screwing the test fluid supply regulator (Fig 3.5 item 5) in further will supply a high pressure of up
to 50 bar for pressure phasing to the connection on the front bulkhead. The pressure set can be
seen on the 0 - 60 bar gauge (Fig. 3.5 item 5).
8. View the fuel temperature demand by pressing button (6). Adjust if necessary using the up and
down arrow buttons (17 and 16). Press button (6) again to accept the set demand and return to
the supply temperature display.
NOTES:
a. The temperature demand can be set between 26°C and 50°C.
b. Pressing button (6) while the drive is running displays the backleak temperature. This is shown
in the display (21), prefixed by ‘b’. Pressing button (6) again returns the display to the supply
temperature.
9. Turn on the temperature control system by pressing button (19), indicator (7) will illuminate. If the
heater is on, indicator (6) will illuminate. If the cooling system is on, indicator (8) will illuminate.
NOTE:
The heater will not operate unless the test fluid pump is on.
10. Set the speed to minimum by turning the speed control knob (20) fully anti-clockwise.
11. Start the main motor by pressing button (14), the indicator (2) will illuminate.
Ref. No. PT01E 25

1008
4.2 Pump Delivery

1. To select a pump delivery, measured as a number of strokes, press button (10). The number of
strokes selected is displayed on the ‘Stroke’ display (22).
2. Each press of button (10) increases the measured stroke count by 100 strokes up to 1000
strokes maximum. After 1000 strokes, the setting returns to 100.
3. Start the delivery measurement by pressing button the Start Count button (11).
4. Abort the measurement if required by pressing the ‘ESC’ button (12).
5. To select a pump delivery measured as a unit of time press button (9). The time selected is
displayed on the ‘SEC’ display (24). Each press of button (9) increases the measured time by 10
seconds up to 100 seconds maximum.
6. Start the delivery measurement by pressing button Start Count button (11).
4.3 Auxiliary Voltage Supply

A 12V d.c. or 24V d.c. supply is available to energise pump solenoids. Push-button (Fig 3.2 item 4)
selects the voltage. Push-button ‘ESC’ (Fig 3.2 item 5) resets the voltage to the supply socket (Fig 3.2
item 6).
1. Unscrew the protective cap from the supply socket.
2. Screw in the Connection Cable (Part No. AP1245) supplied with the test stand.
3. Connect the + and – leads to the pump to be tested.
26 Ref. No. PT01E

MIN-1
0 40
00
0
50
3500
SEC
1000
3000
00
15
25
00
2000
I I
Figure 4.1 Control Panel
TABLE 4.1 KEY TO FIGURE 4.1
1 Main Motor CCW Rotation Indicator 14 Main Motor ON/OFF

2 Main Motor On Indicator 15 Test Fluid Supply Pump ON/OFF
3 Main Motor CW Rotation Indicator 16 Temperature Set Point - down
4 Test Fluid Supply Pump On Indicator 17 Temperature Set Point - up
5 Lube Oil Pump On Indicator 18 Temperature Set Mode/Store
6 Heater ON Indicator 19 Temperature Control ON/OFF
7 Temperature Control System On Indicator 20 Speed Control
8 Cooling System On Indicator 21 Test Fluid Temperature Display
9 Time Select 22 Stroke Display
10 Stroke Select 23 Speed Display in RPM
11 Start Count 24 Second Display
12 Cancel Count 25 Emergency stop button
13 Main Motor Direction
Ref. No. PT01E 27

1008
4.4 Pump Mounting Table

The following table lists the Part Numbers of the mounting components that can be used to mount
rotary and in-line pumps to enable them to be tested on the Pumpmaster. The mounting components
are described in 4.5 Mounting Pumps to the Test Stand.
Pump Main Bracket(s) / Mounting Plate / Adapter (if Coupling
Clamps Drive Hub required)
Rotary Pumps
Lucas DPA AA2010 or
AA1996 Plate AA2012 AA1195 or 3-hole
(supported) AA2011
Lucas DPA
AA1996 KO1127 AA1185 -
(unsupported)
Plate AA1186 or
Lucas DPC AA1996 AA2010 AA1193, AA1194, or AA1195
AA2012
Lucas DPS AA1996 Plate AA2012 AA2010 AA1193 or AA1195
Plate AA1186 or
Lucas DP200 AA1996 AA2010 AA1195
AA2012
Plate AA1186 or
Bosch EPVE AA1996 AA2010 AA1193, AA1194, or AA1195
AA2012
In-Line Pumps
Bosch P type AA1996 and AA1998 AA1592 n/a AA1376 or AA1377
AA1991 and AA1999
Other Bosch n/a n/a AA1376
(2 of each)
AA1992 and AA1999
Simms n/a n/a AA1375 or AA1376
(2 of each)
28 Ref. No. PT01E

4.5 Mounting Pumps to the Test Stand

4.5.1 In-Line Pump Mounting Brackets (Part Numbers AA1991 and AA1992)
Two sets of pump mounting brackets with different height dimensions enable most common in-line
pumps to be fitted to the Pumpmaster test stand. These brackets are bolted to the T slot in the test
stand mounting bed.
Figure 4.2 In-Line Pump Mounting Brackets

4.5.2 Quick-Action Clamps for In-line Pumps (Part No. AA1999)
Two quick-action clamps are used to secure in-line pumps to the mounting brackets.
1. Fit the pump to be tested to the correct mounting bracket.
2. Align the pump with the anti-backlash coupling before bolting the pump down to the T slot.
3. Place the quick action clamps in the T slot of the mounting bed, at each end of the pump.
4. Bolt the clamps to the T slot.
5. Place the clamp jaws on top of the pump body.
6. Tighten the knurled rings by hand.
7. Turn the clamping levers, at the base of the clamp, clockwise to lock the pump to the mounting
brackets.
Ref. No. PT01E 29

1008
Figure 4.3 Quick-Action In-line Pump Clamp

4.5.3 Bosch P Flange Adapter Plate (Part No. AA1592)
This flange adapter plate, which is bolted to the horseshoe shaped Rotary Pump Mounting Bracket
(see 4.4.4), accepts Bosch P pumps with a flange diameter of 107 mm. A tail support (Part No.
AA1998) supports the governor end of the pump.
4.5.4 Rotary Pump Mounting Bracket (Part No. AA1996)

This horseshoe shaped bracket accommodates the two drive hubs (Part Numbers KO1127).
The bracket is normally bolted to the T slot of the test stand bed to ensure alignment with the anti-
backlash drive coupling.
30 Ref. No. PT01E

4.5.5 Pump Mounting Adapter Plate with 4 Pump Fixing Holes (Part No. AA1188)
This mounting plate is used to mount rotary and small In-line pumps with internal bearings requiring a
4-hole adapter plate. The plate (2) is bolted to the Rotary Pump Mounting Bracket (1) (Part No.
AA1996).
Rotary and small in-line pumps with a spigot diameter of 68 mm, 85 mm and 92 mm can be fitted to
this type of bracket and mounting plate. Two types of adapter ring insert reduce the spigot diameter
from 92 mm to 85 mm (Adapter Ring Part No. AA1190) and 92 to 68 mm (Adapter Ring Part No.
AA1189).
Figure 4.4 Adapter Plate (Part No. AA1188)

4.5.6 Rotary Pump Adapter Plate with 9 Pump Fixing Holes (Part No. AA2012)
This adapter plate enables a wide variety of rotary pumps having either a 2, 3 or 4 hole fixing to be
mounted. The plate is bolted to the Rotary Pump Mounting Bracket (Part No. AA1996).
Two ring inserts are supplied to reduce the spigot diameter to 50 mm (Part No. AA2010) and 46 mm
(Part No. AA2011). This allows rotary pumps manufactured by Lucas, Bosch, Denso, Zexel and
Stanadyne to be mounted.
Figure 4.5 Adapter Plate (Part No. AA2012)
4.5.7 Rotary Pump Adapter Plate with 3 Pump Fixing Holes (Part No. AA1186)
This mounting plate has a 68 mm spigot diameter for mounting DPS type pumps. The mounting plate
is bolted to bracket (Part No. AA1220).
Ref. No. PT01E 31

1008
4.5.8 Antibacklash Coupling And Coupling Cover

Pump coupling is fixed to the appropriate slot on the front
plate, leaving at least 1,5 mm clearance between the
front plate and the pump coupling, figure 4.6. Otherwise
there is a high risk of having the coupling flex plates
bended due to possible misalignment of pump mounting.
After leaving the necessary clearance Figure 4.7 in
between, the main cradle or the base brackets are
secured on the
pump mounting bed. Setscrews in the holes at the rim of
the front plates are used to secure the pump coupling
Figure 4.5 Coupling cover jaws in the coupling slots. The setscrews of the free slots
are also secured to prevent them from coming off when
rotating, figure 4.8. Make sure to place the coupling cover
during the entire operation.
Figure 4.6 Coupling cover
Figure 4.7 Coupling cover Figure 4.8 Clearance between two coupling
32 Ref. No. PT01E

5. Maintenance
WARNING!
BEFORE CARRYING OUT ANY MAINTENANCE, ISOLATE THE TEST
STAND AT THE SWITCH ON THE WALL. MAKE SURE ALL PANELS
ARE FITTED AND DOORS ARE CLOSED BEFORE SWITCHING THE
TEST STAND ON AFTER CARRYING OUT ANY MAINTENANCE.
5.1 Daily Checks

5.1.1 Check the Tank Test Fluid Level
1. Remove the small left hand side panel.
2. Check the test fluid level using the sight level gauge.
3. If required, top up to the maximum level mark.
4. Refit the side panel.
5.1.2 Check the Air Supply

1. Open the rear cabinet door.
2. Check the supply pressure is correct (6 bar).
3. Check the air separator bowl for water.
4. If required, drain the water separator bowl into a container by pushing in the button on the bottom
of the bowl.
5. Close the rear cabinet door.
5.2 Every 300 Running Hours

5.2.1 Drain the Test Fluid Tank
1. Remove the small panels on each side of the test stand.
2. Drain the test fluid into a suitable container by removing the drain plugs on the rear facing side of
the tank.
3. After the tank is completely empty, wipe out the inside of each section of the tank with a clean dry
absorbent cloth.
4. Change the test fluid tank suction filter at the same time (Figure 3,5-10).
5. Refit the drain plugs.
6. Re-fill the tank to the full level with the correct specification test fluid.
5.2.2 Change the Test Fluid Tank Filter

1. When the test fluid tank is drained, remove the suction filter by unscrewing the knurled nut and
pulling the filter from the stud.
2. Discard the old filter.
3. Fit a new filter.
Ref. No. PT01E 33

1008
5.2.3 Empty the Waste Oil Tank

1. Remove the small panel on left hand side of the test stand. The waste oil tank is situated above
the test fluid tank.
2. Open the waste oil tank drain valve and drain the waste oil into a suitable container.
3. Change the waste tank filter at the same time (Figure3,5-9).
4. When the tank is empty, close the drain valve. (Figure3,5-11)
5.2.4 Change the Waste Oil Tank Filter

1. Lift the test area drip tray out.
2. Clean out the drip tray sump.
3. Unscrew the waste oil tank filter from the drip tray sump.
4. Discard the old filter.
5. Fit a new filter in the drip tray sump.
5.2.5 Check the Test Injectors

1. Remove the test injectors from the metering console.
2. Carry out dry seat, back leakage and pressure setting tests on each injector. These should
normally be set to either 125 +3/-0 or 172 +3/-0 dependent on the pump to be tested. Refer to the
testplan provided by the pump manufacturer.
3. Re-set the injectors as necessary.
4. Refit to the metering console.
5.3 Every 500 Running Hours

5.3.1 Check the Motor Brushes
1. Check the brushes of the main motor by removing the side cover opposite the main motor cooling
fan (Fig 3.4 item 22).
2. If there are black traces of brush material and sparks are observed while the motor is running, the
brushes must be changed.
3. Your nearest dealer can provide assistance in changing the brushes.
34 Ref. No. PT01E

5.4 Fault finding

Fault: AC motor fan does not run when the isolator is switched on.
Check:
• 380 to 480 V a.c. between each pair of phases at the connection box.
• Trips F1 to F4 are set on.
• Fuse S3 on the relay board is OK.
• 220 V a.c. across terminals TB114/115 (wires 24/8) on the electrical chassis.
Fault: No displays illuminated on the control panel
Is the red indicator in RL1 off?
Yes: Check:
• The two emergency stop buttons are released.
• Oil level in the tank is above the level switch.
• Air is connected and is greater than 6 bar.
• Fuel pump overload is reset.
• Trips F1 to F4 are set on.
No: Check:
• 220 V a.c. on the Control Unit transformer input.
• 15 V and 18 V a.c. on the Control Unit transformer outputs.
• Change the microcontroller board and display.
Fault: No supply fuel pressure
Does the fuel pump motor run?
Yes Check the direction of rotation is correct (correct direction is clockwise as viewed
from the front of the machine). If incorrect, swap over any two of the three
incoming phase connections.
No: Does the 4th yellow indicator down on the relay board turn on/off as the fuel button
is pressed?
No: Check
• cable 46 between the microcontroller and relay boards.
• 15 V and 18 V a.c. on the Control Unit transformer outputs.
• Change the microcontroller board.
• Change the relay board.
• Change the left control button group panel.
Yes: Check
• If contactor K1 does not operate with the above relay, check the
wiring to the contactor and check for 24 V a.c. across the contactor
coil.
• If the contactor operates but the fuel pump does not run, check a.c.
voltage at the fuel pump motor is within 10% of the nominal supply.
Ref. No. PT01E 35

1008
Fault: Drive does not run.

Note that the drive will only operate when the fuel system is running.
Does drive contactor LC pull in/drop out each time the drive start button is pressed?
No: Does the 3rd yellow indicator down on the relay board turn on/off?
No: check:
• Cable 46 between the microcontroller and relay boards.
• Change right control button group panel.
Yes: check:
• Wiring from relay board to contactors.
Yes The relay & microcontroller boards are OK.
• Check for 10V across drive terminals 10 (brown wire) and 7 (green
wire).
• Check the drive displays:
• If this voltage is near zero, the problem is with the speed board.
• DRIVE READY flashing indicates a drive fault. Press RESET to try
to clear. If the fault repeats, report the fault, noting the error
indicated on the flashing upper display.
Fault: Drive runs away to between 500 & 1000 rpm and cuts out.
Pressing the drive button to stop, then again to start repeats the runaway. This indicates
loss of speed feedback pulses from the encoder.
If there is a display of speed during runaway, this indicates loss of the second channel of
pulses only from the encoder to the speed board.
Check for the speed board pulse indicator showing 2 flashes for every one flash on the
microcontroller board.
Check wiring from encoder to speed board.
Change encoder.
Change speed board.
Fault: Stroke shutter does not operate.
Note that the shutter will only operate when the drive is running.
Does the 6th yellow indicator down on the relay board turn on for the count period?
No:
• Check cable 46 between the microcontroller and relay boards.
• Change the right control button group panel.
Yes:
• Check that the stroke board red indicator is always on (24 V a.c.) and the green
indicator is on for the count time.
36 Ref. No. PT01E

• Check that the mechanism is free to move in and out of the stroke motor.
• Check the motor by very briefly applying 12 V d.c. from a battery. Swap wires to drive
back by again very briefly applying 12 V d.c.
• Change the stroke board.
Fault: Temperatures not correct.

Check the temperatures when the machine is cold. The temperatures displayed should be
the same as ambient temperature.
If one sensor operates, but not the other, swap over the green wires in terminals 13 and 14
of the microcontroller PCB. If the fault stays with the display, change the microcontroller
PCB. Otherwise change the sensor.
If the temperature is too low:
Check that the set demand is at the level required.
Check that the temperature control is turned on and demanding heat.
Check if the indicator next to the thermostat is on (indicating heating).
Check if RL1 operates, F5 trip is set, and heater current is 3 to 4 A.
Check that, if cooling water is connected, it is not flowing through the cooler solenoid
(solenoid stuck open).
Check each heater element has a resistance about 60 ohm.
Check that oil is passing through the return from the pressure controller direct to tank (over
the temperature sensor).
Ref. No. PT01E 37

1008
6. Spares List
The following list of parts are those which are likely to have a limited life and require replacement.
When ordering spares, always quote the product type and serial number. This information is provided
on the identification plate fixed to the back of the test stand.
6.1 Electrical Spares

Description Fig. Item Ref. Part No.
Touch Button Group 3.10 2 BJ1036
Control Display (Lexan Sticker) 3.10 1 BJ1035
Control Units Spares 3.10 3 KO1254
4 AP1548
12/24 V d.c. Reset Button/Selector Switch 3.2 5 AP1549
Socket 12/24 V d.c. 3.2 6 AR1172-B

Temperature Sensor - Supply/Return 3.4 7/19 KO1292
Lamp 3.3 8 YP1012
Main Isolator Switch 3.3 9 AP1235
Main Motor 3.3 10 AL1072
Encoder 3.3 11 AR1773
Control Transformer 3.2 12 AP1573
Cooling Solenoid 3.3 14 AP1019
Tank Low Level Switch 3.3 15 AR1807
Heating 3.3 16 AP1461
Tank Thermostat 3.3 17 AP1192
Air Pressure Switch 3.3 25 AP1227
Emergency Stop Buttons 3.2 20 AP1032
Metering Shutter Actuator 3.3 21 AP1003
Main Motor Cooling Fan 3.3 22 AL1003
Brake Actuator Solenoid 3.3 26 BA1201
Test Fluid Supply Motor 3.4 23 AL1027
Main Trip (3 x 63 A) 7.4 F1 AP1151
Control Transformer Trip (6 A) 7.4 F2 AP1007
Heating Trip (6 A) 7.4 F3 AP1007
Drive Direction Contactor 7.4 LC AP1133
Pump Motor Contactor 7.4 LC1 AP1116
Speed Control Unit (PT2012) 7.4 - AR2118
Speed Control Unit (PT1012) 7.4 - AP2082
Breake Resistor (PT2012) 7.4 - AR2126
Breake Resistor (PT1012) 7.4 - AP2084
RFI Filter (PT2012) 7.4 - AR2127
RFI Filter (PT1012) 7.4 - AP2083
Stroke Control Board 7.4 - AR1016
Relay – Fuse Board 7.4 - AR1857
Adapter Board 7.4 - AR1180
38 Ref. No. PT01E


Emergency Stop Relay 7.4 RL1 AP1139
Heating Relay 7.4 RL2 AP1231
Pump Motor Overload Trip 7.4 T1 AP1117
6.2 Test Fluid & Pneumatic System Spares

Air Pressure Control Valve 3.5 13 BA1151
0 - 60 bar Pressure Gauge 3.5 5 BB1001
-1/+4 Supply Pressure Gauge 3.5 1 BB1003
0-14 bar Transfer Pressure Gauge 3.5 3 BB1005
0 - 6 bar Auxiliary Pressure Gauge 3.5 5 BB1006
0 - 2.5 bar Air Pressure Gauge 3.5 6 BB1004
Flowmeter 3.5 7 KO1037
Supply Pressure Control Valve 3.6 8 KO1164
Test Fluid Filter 3.5 10 BA1003
Test Fluid Supply Pump 3.5 11 BA1006
6.3 Metering System Spares

Shutter Actuator 3.7 8 AP1003
Graduate – 170 cc 3.7 2 BC1002
Graduate - 26 cc 3.7 1 BC1006
Injector 3.7 5 KO1252
Graduate Holder – large 3.7 7 BE1009
Graduate Holder – small 3.7 6 BE1008
Position Lock 3.7 9 KO1256
Injector Adapter 3.7 11 AA2535
6.4 Cooling System Spares

Cooling Serpentine 3.8 1 BL1013
Supply Inlet Solenoid Valve 3.8 2 AP1019
Supply/Return Line 3.8 4, 3 BM1008
Supply/Return Connection 3.8 5, 6 AA1528
Ref. No. PT01E 39

1008
6.5 Braking System Spares

Brake Pads 3.9 1 AN2373
Connector Rod 3.9 2 AA2721
Air Piston 3.9 3 BA1201
Air Pressure Regulator 3.9 4 BA1151
Air Pressure Gauge 3.9 5 BA1058
Pneumatic Valve 3.9 6 BA1099
6.6 Central Control Unit Spares

Display (Lexan Sticker) 3.10 1 BJ1035
Touch Button Group 3.10 2 BJ1036
Speed Control Potentiometer 3.10 3 KO1254
Speed Control Dial (PT2012) KO1293
3.10 3
(PT1012) KO1294
Emergency Stop Button 3.10 5 AP1032
Display Board 3.10 6 AR1830
Micro Control Unit Board 3.10 7 AR1274
6.7
Standard Accessory
NO DESCRIPTION QTY
AA1276 FLYWHEEL TURNING BAR 1
BA1007 BANJO CONNECTOR 14 MM 2
BA1236 BANJO CONNECTOR 12 MM 2
AA1205 DRIVE HUB 18mm SPLINE, 46mm SPIGOT 1
AA1194 COUPLING 17mm DIA 1
AA1195 COUPLING 19mm DIA 1
AA1271 TEST OIL RETURN CONNECTION 2
AA1272 CAM BOX PRESSURE CONNECTION 1
AA1277 INLET SCREW M14 1
AA1278 INLET SCREW M12 1
AA1330 PRESSURE ADJUSTING SCREW 1
AA1193 COUPLING DPS (DOG DRIVE) 1
AA1257 COUPLING PULLER FOR DIA 96 1
AA1379 COUPLING PULLER FOR DIA 110 1
40 Ref. No. PT01E

NO DESCRIPTION QTY
AA1996 HORSESHOE BRACKET 1
AA1991 SUPPORT BRACKET (HEIGHT 97mm) 2
AA1992 SUPPORT BRACKET (HEIGHT 104mm) 2
AA1995 SUPPORT BRACKET ( HEIGHT : 106MM ) 2
AA3159 OUICK ACTION CLAMP 2
BN1004 TEST LINE OD:6 ; ID:2 ; L:600 ; P:12x1,5 ; I:14x1,5mm 8
AA1213 DRIVE HUB 36mm SPLINE, 50mm SPIGOT 1
NO DESCRIPTION QTY
AA1592 P TYPE MOUNTING PLATE 107mm DIA 1
AA1882 P TYPE MOUNTING PLATE 95mm DIA 1
AA1998 TAIL SUPPORT 1
AA1698 COUPLING Ø22-LONG 1
AA3070 LONG COUPLING 25mm DIA 1
AA3071 LONG COUPLING 30mm DIA 1
AR1145 FUSE -5A- 3
AR1192 FUSE -1A- 3
AR1193 FUSE -2,5A- 3
AR1190 FUSE -200mA- 3
AA1976 COUPLING 35 MM DIA 1
AA1473 COUPLING SPANNER 1
AP1245 PUMP SELENOID CABLE 1
Ref. No. PT01E 41

1008
NO DESCRIPTION QTY
AA1185 ADAPTER PLATE 50mm 1
AA1186 MOUNTING PLATE 3-HOLE, 68mm DIA 1
AA1188 MOUNTING PLATE 4-HOLE, 92mm DIA 1
AA1189 RING INSERT 68mm 1
AA2012 MOUNTING PLATE 9-HOLE 1
AA1348 DPS Ø75 FLANGE ADAPTOR 1
AA3043 FLANGE ADAPTOR WITH SLOT MOUNTING HOLES 1
BA1161 RUBBER FEET 4
BR1001 HOSE PNEUMATIC 4x1 1
KO1039 HOSE TRANSPARENT TRANSFER AND RETURN 2
KO1040 HOSE 3/8 SAE 100 R1 HIGH PRESSURE 1
KO1041 HOSE FOR AIR CONNECTION WITH BANJO END 1
NO DESCRIPTION QTY
KO1031 TEST INJECTOR 12SD12 ISO4010 12
42 Ref. No. PT01E

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FUEL INJECTION PUMP

Ref. No. PT01E i

Warnings, Cautions and Notes

ii Ref. No. PT01E

Isolate the electrical supply before performing any maintenance operations. Do

Ref. No. PT01E iii

There must be no naked flames. Potentially flammable vapours are present in

Accidents can occur to unauthorised personnel during testing. Untrained

iv Ref. No. PT01E

Ensure good levels of lighting for safe, efficient equipment operation.

Take care to ensure only recommended equipment is connected to the test

This equipment contains electrostatic sensitive devices. Observe the necessary

Ref. No. PT01E v

1.1 Test Stand General Arrangement

1843 (PT2012) 1703 (PT1012-PT1008)

1912 (PT2012) 1772 (PT1012-PT1008)

Figure 1.1 Test Stand General Arrangement

ÖZELLİKLER PT2012 PT1012-PT1008

380 V A.C. 380 V A.C.

PRODUCT DESCRIPTION - COMPOSITION

SAFE HANDLING ADVICE (Protection - Usage, Storage & Transport)

EMERGENCY & FIRST AID PROCEDURE (Eyes, skin, ingestion, inhalation)

FIRE HAZARDS & PROTECTION (Flash point, spillage)

ENVIRONMENTAL PROTECTION (Spillage land / water, disposal)

Figure 2.1 Transporting the Test Stand

Ref. No. PT01E 5

2.2 Connecting the Air Supply

2.3 Connecting the Cooling Water

2.4 Filling the Test Fluid Tank

2.5 Electrical Installation

2.5.1 Connect the Test Stand

6 Ref. No. PT01E

Figure 2.2 Electrical Connections

Ref. No. PT01E 7

2.6 Installation Checklist

Before starting the test stand, check:

• Test stand correctly positioned and level

8 Ref. No. PT01E

PT 1012 - PT 1008 PT 1012 - PT1008 LUBE

100 100 20 100 100 20

60bar 1 4bar 60bar 1 4bar

Figure 3.1 Pressure Gauges, Pressure Controllers and Bulkhead Connections

Ref. No. PT01E 9

3.2 Electrical Equipment

Ref. No. PT01E 10

The 2100 W heater is located in the test fluid tank.

Air Low Pressure Switch (25)

Ref. No. PT01E 11

Figure 3.2 Electrical Equipment (front view)

KEY TO FIGURES 3.2, 3.3 & 3.4

Ref. No. PT01E 12

Figure 3.3.a Electrical Equipment (side view)

Figure 3.3.b Electrical Equipment (side view)

Ref. No. PT01E 13

Figure 3.4 Electrical Equipment (rear view)

Ref. No. PT01E 14

Ref. No. PT01E 15

Description Reference PT2012 PT1012

Relay board yellow indicators

Ref. No. PT01E 16

Ref. No. PT01E 17

3.3 Test Fluid and Pneumatic Equipment

Pressure Gauge (15)