2

1. NT-919 Operating Instructions ................................................... 4

2. EUI EUP operation instruction .................................................... 61
3. CAT HEUI injector, HEUI pump operating instructions ............... 84
4. CAT320D oil pump installation, test .......................................... 113
5. Bosch CP3 Oil Pump Installation & Testing ................................ 127
6. DENSO HP0 Pump Installation & Testing ................................ 138
7. VP37 VP30 VE37 oil pump test & installation ......................................... 149
8. VP44 oil pump installation test ............................. 162
9. RED4 oil pump installation test ................................................... 175
10. SIEMENS VDO oil pump ................................................... 188
11. Maintenance ............................................................................. 197

3
 NT-919 Operating Instructions

1：Preparation before test bench operation.

2：Boot Up
3：High pressure common rail injector test operation process.
3.1：Operation system
3.2：Fuel injector mounting
3.3：Injector test
3.4：Test result printing
3.5 : Data rewriting and model addition
4：Remote assistance
5：Online upgrade
6：QR code generation strategy
7：Turn off the machine

4
Standard accessories

5
1：Preparation before test bench operation

1.1：Fill with test oil. Fill up to ruler F200. Diesel tanks must be filled with clean
diesel or standard ISO4113 calibration pump oil. Fill the oil tank with # 46 hydraulic
[Link] lubricant tank needs to be filled with 1 liter of CD-grade lube oil.

6
1.2：Connect the power supply [Link] wire is standard 6 ㎡ copper
wire.“R/S/T” at the junction is three live wire,“N” is neutral wire.
Five wire connection, remove the connecting piece, and connect the
earth wire with the lowest interface.

Connecting piece
7
2：Boot Up
Turn right, turn on the power supply switch from 0 to 1

8
2.4：Determine whether the Diesel fuel supply switch
supply phase is correct.
1):Press the diesel fuel supply switch.
2):Observe the "Diesel pressure gauge"
in the operation room .The pointer rises,
indicating that the power supply line is
connected .Mean correct. Otherwise,
RST three power supplies wires
Interchange position of any two wires.

Diesel pressure gauge

9
3：Operation guide of high pressure common rail
Common rail injector operation. The system starts and automatically enters
the function selection interface.

10
3.1：Install high pressure oil pipe
High pressure oil outlet interface
Connect the high-pressure pipe to
the high-pressure oil outlet,
Tightening torque 35NM

High pressure pipe

11
3.2：Installing the fuel injector
1):Insert the injector rotation into the oil collector, be careful ，not to
damage the sealing ring. Tighten the handle of oil collector and lock the
Injector.
2):The injection connector is inserted into the "injection" jack on the
panel, and the return connector is inserted into the "return" jack on the
panel.

Solenoid valve harness

Injector return pipe

Fuel injection pipe

Handle

12
3.3：Injector test
1):Click the "CR injector" icon in the system interface to enter into the common
rail injector database.

13
2):Enter the injector model to be tested in the “query box” in the upper right
14
corner.
3):Click on the selected model. 15
4):Click “Continue”. Enter the injector automatic test interface. 16
 1 2 3 4 5

6 7 8 9 10

1：Motor set rotation speed 6：Injector solenoid resistance

2：Actual speed of motor 7：Injector solenoid inductance
3：Temperature of diesel 8：Injection response time（BIP）
4：Temperature of lubricating oil 9：ZME drive current value 17
5：Test time 10：DRV drive current value
5):Click the "start" button. The system will automatically test the working
conditions of the fuel injector in turn.
6):After the test, the test results report is generated automatically. Click the
"report" button to view the test results.

18
7):Click "edit" to edit the company information and customer information.
The test report displays this information when printed .

19
8):QR code is automatically generated under the BOSCH 110 series fuel injector
report.

3.4：Print test results

20
1）：Click the "Print" button, the interface changes as shown below.
2):Click "print", the printer can print out the test results automatically. 21
3.5: Data rewriting and model addition
(1):Data rewriting
1)Return to the database interface and click "Edit".

22
2):Password:123456

123456

23
3):Enter the database editing interface, the calibration data of each test condition
can be rewritten independently. Then click "Save". Data rewriting is completed.

24
(2):Model addition
1):Return to the database interface and click "Add".

25
2):Enter the model to be added in the model column and click "Save". The
database generates new model data.

26
27
3):Delete the model. Select the model to be deleted and click "Delete" in
the function bar.

28
Click "OK" database to delete the model data.

29
4：Remote Assistance TeamViewer
u Connection method for WIFI
4.1：Exit NT-919 test system

30
4.2：Click the WIFI connection icon in the upper right corner of the
[Link] to open it.“Turn off WiFi”Means closed .“Turn ON WiFi”Means
[Link] your own WIFI name to connect to the network.

31
4.3:After successful networking, open the remote assistance software to
generate the unique ID code of the machine. Send the picture to the
company service specialist. He will troubleshoot and maintain your
equipment remotely.

32
5:System online upgrade
5.1:The device is connected to the Internet. Click " Online Upgrade".

33
5.2:The system enters the upgrade interface. The green box is the program that needs
to be upgraded. Click on the green square and the program will automatically upgrade.

34
5.3:After the upgrade is successful, click the "Quit" button to exit the
NT-919 test system. Restart the NT-919 test system to complete the
upgrade.

35
 Introduction of QR code generation for injector
QR code of injector
Injector's QR code （IMA /ISA）
Use the software method to correct the error of fuel injection during maintenance.
The common rail fuel injector assembly has a certain deviation due to the error of
the mechanical components. Use QR coding technology to calibrate the injection
quantity. Ensure the consistency of the engine cylinders. Make the engine more
economical and more reasonable emissions.

Bosch 6、7、8、9 digits QR Code

Bosch Piezo IMA ISA Code

Denso QR Code（30 digits）

Delphi C2i C3i Injector Code（20 digits）

Siemens（VDO) IIC Code

36
Two methods of QR code generation
1:In the database , directly select the injector model for testing. The test
results are qualified for all working conditions, and the system
automatically generates a QR code in the report.

37
1.1：Bosch injector QR code generation. Enter the database to select the
model.

38
Click "Start" to test the injector.

39
The test result is qualified, click "Report" to view.

40
QR code is automatically generated under the BOSCH 110 series fuel injector
report.

3.4：Print test results

41
1):Click the "Print" button, the interface changes as shown below.
2):Click "print", the printer can print out the test results automatically. 42
2：QR code professional generation
Interface of function selection, click the "IQA Coding" icon.

43
1：QR Code Generation Strategy of BOSCH Injector
1):Click to select the "Bosch" icon.

44
2):Enter the Bosch injector database interface. Select the model of the
injector to be tested and click "Continue" .

45
3):After the automatic test is completed and all test results are qualified,
the system can automatically generate a QR code. Click "Report".

46
4):Below the content of the test report, the 7-digit QR code is automatically
generated. (Numbers, letter codes and QR codes). If need other types of QR
codes, click on the function bar "QR code".

47
5):In the QR code type selection interface, click the triangle mark in the type
column. You can choose any type of 6 7 8 9 digits.

48
6) :Click "Save" to regenerate a new QR code.

49
2：QR Code Generation Strategy of Delphi Injector
1):Click to select the "Delphi" icon.

50
2):Click to select the model and click "Continue".

51
3):In the test interface, enter the old QR code of the injector . Click "Start" to
automatically complete the calibration of each operating point of the injector.

52
4):After the test, a new QR code will be automatically generated in the "New
QR Code" column.

53
3：QR Code Generation Strategy of Denso injector
1):Click to select the "Denso" icon.

54
2):Select the test model.

55
3):Enter the old QR code of the injector in the old QR code field. Click "Start"
to test the injector.

56
4):After the test, a new QR code will be automatically generated in the "New QR
Code" column.

57
7：Introduction of additional functions
Common rail pump components. On the function selection interface, click the
"CR Pump part" icon

58
Manual function introduction
Self-calibrate and test each working condition of common rail pump
"ZME or DRV".

59
Shutdown
Click the "Quit" button and click "Shutdown". After exiting the
system, turn the main power switch to the left from 1 to 0.

60
 EUI/EUP Technical Information

EUI EUP operation instruction.

1. EUI EUP outline.
2. Cam box assembly installation standards.
3. EUI detailed installation standards
3.1. Cam choice and installation method.
3.2. Input lub oil.
3.3. EUI adapter installation standards.
3.4. Adjusting method of top rod height.
3.5. Fuel channel connection , fuel feeding pressure
adjustment.
3.6. Connection method of wire harness.
4. EUP installation standards
5. Test.
[Link]/EUP model .
[Link] interface introduction.
[Link] and display of testing result.
[Link] testing result.
61
 EUI/EUP
1：EUI EUP outline

62
EUI/EUP

70
 EUI/EUP
2、Cam box installation standard.
2.1. Cam box assembly is installed on operation platform . Wire harness
is connected into socket of EUI cam shaft sensor on Operation room
panel.

64
2.2. Strength moment of screw on universal coupling is 120Nm, and
55Nm is for screw on cambox base.

120Nm

55Nm

65
 [Link] detailed installation standards
3.1. Choose proper cam.
Choose the right cam for EUI . Open the transparent cover back cam
box , loosen screws of cam and disassemble cam by rama. Install cam
onto cam shaft. (Please note semi-round position) tighten screw of
cam with 125Nm .

66
3.2. Input lube oil.
Install cover on back and tighten handle screw with 12 Nm. Insert the
lube oil pipe which indicates height of lube oil ,on side of cam box,
into "Lube oil in/out" socket on test bench fuel supply module. Rotate
clockwise "oil in oil out" switch . Input lube oil into cam box until lube
oil cover cam shaft.

67
3.3. EUI/EUP adapter installation standard.
Find according adapter ,top rod and fuel collector of EUI or EUP in
attached table. Apply lube grease on surface of EUI/EUP seal ring
and install it on EUI/EUP. Screw top rod onto tappet, Install EUI and
let EUI spring on below direction on middle of cam box's supporting
plate. Fuel collector is above of adapter. Tighten the pressing screw
with 65Nm.

Fuel collector

Adatper

EUI

Tappet

68
3.4. Adjustment method of top rod height.
① 270゜(Bottom dead center,BDC).Rotate cam to BDC position, EUI
plunger spring touches top surface of top rod, then rotate clockwise
the top rod with 270゜ , screw the nuts on the blow tightly.
② 180゜(Top dead center,TDC). Rotate cam to TDC position until there
is no gap of EUI plunger, then rotate counterclockwise with 180゜,
tighten the lock nut on the blow.

69
③ Please make sure that cam shaft can rotate 360゜ smoothly and
cam box can work without fault.

70
3.5. Fuel channel connection and fuel feeding pressure adjustment.
① Apply EUI-special fuel supplying pipe YG06. The word "IN" on adapter
is corresponding to "Diesel pump" quick-socket on left panel of operation
room. "OUT" is for "Diesel Return". Try to pull fuel pipe after inter , to
confirm the Quick Connector is on right positon. Manufacture fuel
injecting pipe : cut transparent fuel pipe to proper length, install small
copper Quick Connector on it. Insert one end of the pipe into fuel collector ,
and insert the other end into "Injection" socket on operation room panel.

71
② Adjustment of fuel supply pressure.
Adjust "Diesel Regulator" pressure adjust valve to proper pressure. Fuel
supply pressure of Cummins M11 N14 EUI is 1Mpa, fuel supply pressure
of the other EUI is 0.6Mpa.

72
3.6. Driving wire harness connection.
① Single solenoid EUI. Choose proper EUI short wire harness, intert
it to EUI solenoid socket, the other end is inserted to "Inject 1" socket.

73
②Double solenoid EUI (E3) connection.
1# solenoid plug is for "Injector 1" on operation panel, 2# solenoid
plug is for "Injector 2",......., 6# solenoid plug is for "Injector 6".

74
4. EUP installation standard.

75
 Techique
information HPI-TP

5. Cummins HPI installation standard.

Adapter
NT1612022
Cam shaft
NT-X15

HPI
injector

Top rod
NTP01

76
HPI assembly, fuel circuit and wiring harness connection diagram

YG-06
YG-14

06
YG-

Electronically controlled
fuel supply module
77
 5. Test
5.1. Choose model number.
①Click EUI/EUP image and enter model query interface.

78
② Input EUI model number in query box,then click the choosed EUI
model to let the color of background become deep, then click
"Continue" to enter Test.

79
[Link] interface introduction.
1. Set up motor rotate speed, 2. Cam rotate speed,
3. cam angle of solenoid electrify. 4. Tested fuel temperature .
5. Hydraulic oil temperature. 6. Set up test time.
7. EUI Injection response time. [Link] pulse electrify cam angle.
9. Solenoid resistance value. 10. Solenoid inductance value.

80
5.3. Assessment and display of test results.
①: Click "Start" button, this system will complete all EUI EUP test in
different working situations automaotically.
②: Test result is displayed directly on test interface. Green color √
means "Pass", and red color X means "Failed".

81
5.4. Print test result.
①: Click "Report" button, system will create test report automatically.
Click "Print" .

82
②: Click "Print" , then printer start to print test result automatically.

83
CAT HEUI injector, HEUI pump operating instructions

Catalogue
1. HEUI Injector test operation specifications
1.1 Overview
1.2 HEUI injector mounting
1.3 HEUI injector testing
1.4 Check test result, save, and print it.
1.5 Test data editing and adding

2. HEUI pump test operation

2.1 HEUI pump mounting
2.2 HEUI pump testing

84
 1. HEUI Injector test operation specifications
1.1 Overview

injection pipe
Diesel fuel
Drive harness

YG-08 High lube

oil pipe
YG-11 Diesel tube

YG-13

85
YG-07 Diesel tube
1.2 HEUI injector mounting
1.2.1 Grease the injector seal and press it into the clamp. Gently bring the
two injector fixing screws. Tighten the fuel collector handle to the right.
Insert the injector harness. Put the oil hood cover well and install the
adapter, tighten the handle and compact the cover. Close the ventilation
switch handle.

86
1.2.2 Diesel fuel supply pressure adjustment: Press the diesel fuel
supply switch, Adjust pressure adjusting valve "diesel regulator" on
the side panel to supply pressure 0.4Mpa.

87
1.3 HEUI injector testing
1.3.1 Click on the "HEUI injector" icon on software screen

88
1.3.2 Click "Continue"

89
1.3.3 Click "Start" to automatically complete testing of each condit-ion of the injector
1：Fuel pump setting speed and actual speed 6：Injector resistance
2：System set test pressure 7：Injector inductance
3：Diesel tank temperature 8 : injection response time (BIP)
4：Lube oil tank temperature 9：ZME
5：Testing time 10：DRV

90
1.4 Check test result, save, and print it.
1.4.1 The test results are automatically judged, and green is
displayed for passing and red is displayed for failing. Click "Report".

91
1.4.2 Click“print”

92
1.4.3 Click“Print”, testing report will be printed automatically.

93
1.5 Testing data editing and adding
1.5.1 Enter the database interface and click "Edit".

94
1.5.2 The password is 123456 for editing test database

123456

95
1.5.3 Enter the database calibration interface. Each test condition of
the injector can be edited independently. Click "Save" when you finish.

96
1.5.4 Adding Test data
Return to the database model selection interface and click "Add".

97
1.5.5 Enter the desired model in the model box and click "Save".

98
1.5.6 The database will automatically generates new test data.

99
1.5.7 Test data deletion. Click "Delete" in the function bar, and click
"OK". The test data disappears automatically, finally quit software
system, restart the NT-919 system, and complete test data editing.

100
2. CAT HEUI pump test operation
2.1 CAT HEUI pump mounting

Proportional valve electrical interface

Low pressure lube oil inlet

High pressure lube oil outlet

Diesel outlet
Diesel inlet
101
2.1.1 Pls use special adapter to mount CAT HEUI pump
Install the adapter and pump on the test bench. Tightening torque
of adapter base fixing screw: 55Nm, tightening torque of main
connection tightening screw: 120Nm

120Nm

55Nm

102
2.1.2 Diesel fuel pipe connecting
Choose 2pcs YG-03 diesel fuel supply pipes. 1/4 to 18 transfer
connector and 1/4 self-locking quick plug, 14x1.5 hollow screws.
Connect "pump self feeding" of the side panel to the diesel inlet of
CAT HEUI pump. Connect “DRV diesel return” on the panel to the
gear pump diesel outlet.

YG-03 diesel fuel pipe YG-03 diesel fuel pipe

103
2.1.3 lube oil (engine oil) connecting
Connect “Lube oil pump” on the panel to low-pressure lube oil inlet
of HEUI pump. Choose YG-10 fuel pipe (pressure bearing> 30Mpa), 14
to 18 transfer connector, 1/4 to 18 transfer connector and 1/4 quick
plug (Reminding: the quick plug is hollow).
Connect the high-pressure pipe from “Lube Oil Regulator” on the
panel to high-pressure lube oil outlet of HEUI pump.

Lube oil inlet YG-09

High pressure lube oil

outlet YG-10

104
2.1.4 Harness connecting
Proportional valve harness connecting. Insert the "ZME2" drive harness
connector on the panel into the electrical interface of the proportional
valve.

105
2.1.5
Press down "Lube oil" supply switch. Rotate "Lube Oil Regulator" knob
to adjust the lube oil supply pressure to 0.5Mpa

106
2.2 HEUI pump testing
2.2.1 Click the "HEUI pump" icon on the software system function
interface

107
2.2.2 Click the model No. of HEUI pump which will be tested and then
lick "Continue" to enter the injector test interface.

108
1：Motor speed 6：
2：Set pressure 7：
3： 8：Diesel tank temperature
4： 9：Lube oil tank temperature
5：Testing time 10：

1 2 3 4 5

6 7 8 9 10

109
2.2.3 Click "Start" and then he HEUI pump testing will be completed
automatically. Passed testing is displayed in green, failing testing is
displayed in red. Click "Report" to check complete testing result.

110
2.2.4 Click “print”

111
2.2.5 The testing report will be printed automatically after click
“print”

112
 CAT320D oil pump installation, test

catalogue
1： Oil pump mounting
2： Oil circuit connection method
3： Line connection method
4： Test
5： View and judge the test results
6： Repair instruction

113
 1： Oil pump mounting
• The special coupling flange for CAT320D oil pump can be found in the
attachment. Fixed on equipment curved plate, fixed oil pump on flange.
Select coupling II. Pay attention to tighten the coupling compression
nut. Tightening torque 95 Nm. The tightening torque of the spindle
connection fastening screw is 120 Nm.

114
 2： Oil connection
2.1： Low-pressure oil circuit connection
YG-02 3 tubing,# 12mm inlet pipe screws 3,# 10 oil ball 1, #6 tubing
1 meter.
# 10mm Tubing Screw One,Three quarter-to-18 connectors,4
quarter self-locking quick inserts,One quarter to six quick connector.

115
2.2: High-pressure oil circuit connection

116
 3：line connection method
3.1 The oil pump camshaft sensor is connected. Top left wiring line
module in the operating room, The "CAT" port harness is inserted directly
into the oil pump camshaft sensor harness port.
3.2 The oil pump solenoid valve is connected.

117
 4: test Note
(before the test ,the inner of the oil pump must be filled with 250ml lubricating oil)
4.1 Select “Caterpillar pump “in the test interface.

118
4.2:Click the model of the oil pump to be tested and it will turn into a
dark [Link] click the “continue”button.

119
①：System setting motor speed ⑥： Testing time
②：Actual motor speed ⑦： Oil pump solenoid valve resistance
③：Oil pump solenoid valve working angle ⑧： Fuel pump solenoid valve inductance
④：System set rail pressure ⑨： Injector response time
⑤：Fuel tank temperature ⑩： Rail DRV control current value

① ② ③ ④ ⑤

⑥ ⑦ ⑧ ⑨ ⑩

120
4.3：Click the “start”button,the equipment will automatically complete
the test of each condition of oil pump (or click the keyboard F1)

121
 5. View and judge test results
5.1：After the test is over, the actual test results are displayed on the right
of the test step, and the system automatically determines，
green √ qualified ， red ×Disqualified。

122
[Link] the "Report" button in the test interface. Display test report
automatically.

123
[Link] the”print”Button

124
5.4：Click print to automatically print the test results.

125
 6： Repair instruction

6.1："Zero oil supply" is unqualified. Clean and check whether

the oil pump solenoid valve is stuck.
6.2："Startup" failed, check plunger pump head.
6.3："Best efficiency" failed . Check plunger pump head.
6.4："Maximum oil volume" check plunger pump head.

126
Bosch CP3 Oil Pump Installation & Testing

Catalogue
1：Installing pump
2：Diesel circuit and lines connection
3：Pump testing
4：Testing report printing and
maintain guidance

127
 1: Pump installing
Find the special flange for the CP3 pump from machine
accessories. Fix flange on plate of machine, fix Pump on flange.
Select coupling III. Tighten the coupling and press the nut with torque
95 Nm. The main shaft is connected with the screw with a torque of
120 Nm.

120Nm

55Nm
128
 2：Diesel circuit and lines connection
2.1：Low-pressure diesel circuit [Link]-03 pipe 4pcs,#14mm
Inlet pipe screws 4pcs.4pcs 4/1 to 18 connector,4 pcs 1/4 Self-
locking quick plug.

YG-03

YG-03

YG-03

YG-03

129
2.2: High-pressure oil circuit [Link] high-pressure oil
outlet connect to rail of high-pressure oil inlet

2.3: Lines connection. Control panel “ZME1” wiring harness

connect to pump ZME jack

130
 [Link] testing
3.1：Start machine and enter the function selection interface. Click the
"CR Pump" icon.

131
3.2: Click CP3 in the "Features" column. Click “Model” to select
the model of the pump to be tested. Then click "Continue".

132
 1 2 3 4 5

6 7 8 9 10

1: Spindle motor speed 6: Test time

2: Orbit set pressure 7:
3: 8: ZME control current
4: 9: DRV control current
133
5: Test oil temperature 10:
3.3: Click the "Start" button on the test interface, and the system
will automatically complete each test condition. The test results are
displayed on the right side of each test step, and automatically
determine whether it is qualified.

134
 4：Test result printing and repair instructions
4.1：Clicking “report”,Click“print”.

135
4.2: Click Print, the system print the test report automatically.

136
4.3: maintenance diesel pump instructions

4.3.1: "Zero diesel supply" ×. Clean or replace ZME.

4.3.2: "Start" ×, check the inlet and outlet valves and plunger.
Observe the pump cavity pressure.
4.3.3: "Maximum diesel volume" ×, check the inlet and outlet
valves and plunger. Observe the pump cavity pressure.
4.3.4: "Best efficiency" ×, check the inlet and outlet valves and
plunger. Observe the pump cavity pressure.

137
DENSO HP0 Pump Installation & Testing

catalogue
1：Installing pump
2：Diesel circuit and line connection
3：Pump testing
4：Testing report printing and maintain guidance

138
 1:Pump installing
Find the special flange for the Denso pump from machine accessories. Fix
flange on plate of machine, fix Pump on flange. Select coupling III. Tighten
the coupling and press the nut with torque 95 Nm. The main shaft is
connected with the screw with a torque of 120 Nm.

139
 2: Diesel circuit and lines connection

2.1：Diesel circuit connection

2.1.1. Low pressure diesel circuit [Link]-04 pipe 4pcs，
#16 pipe screws 4 pcs.4 pcs 4/1 to 18 connector，4 pcs 1/4
Self-locking quick plug.

140
2.2.2 High pressure diesel circuit connection
High pressure pipe 2pcs,2pcs14 to 14 high pressure bent connector.

141
2.2.3: PCV valve harness and pump camshaft sensor connection

A B

142
3: Testing
3.1：Function selection interface. Click the "HP0 Pump" icon.

143
3.2: Into HP0 pump model selection interface,select the model of
the pump to be tested. Then click "Continue" into pump testing
interface.

144
 1 2 3 4 5

6 7 8 9 10

1：System setting motor speed 6：Testing time

2：Actual motor speed 7：SCV valve control current
3：System set rail pressure 8：System control DRV current
4： 9：Test oil temperature
5： 10： 145
3.3: Click the "Start" button on the test interface, and the system will
automatically complete each test condition. The test results are
displayed on the right side of each test step, and automatically
determine whether it is qualified.

146
4: Test result printing and repair instructions
4.1：Clicking “report”,Click“print”.

147
4.2: Click Print, the system print the test report automatically.

148
VP37 VP30 VE37 oil pump test & installation

Catalogue
1: oil pump installation
2: oil road installation
3: drive harness
4: oil pump test

149
1: Oil pump assembly
The special connection flange for VP37 oil pump is found in the
attachment. It is fixed on the bending plate, and the oil pump is fixed
on the flange. Select coupling number II. Pay attention to tighten the
coupling compression nut. Tightening torque 95 Nm. The tightening
torque of the spindle connection tightening screw is 120 Nm.

150
2: Oil circuit assembly
4 YG-02 oil pipes, 1 # 12 oil pipe screw. There are 4 high-pressure oil
pipes, 2 1/4 to 18 connectors, 2 1/4 self-locking quick plugs, 1/8 to 6
copper quick plugs, 5 # 6PVC hard oil pipes 1 meter. There are 4
standard fuel injectors and 1 bracket.

151
2.1: Low pressure oil circuit
Oil supply module "Oil pump self-priming" --- low pressure oil inlet
of the oil pump Oil supply module "diesel oil return" --- oil pump oil
return panel Pump chamber pressure --- oil pump oil return

YG-07

YG-06

152
2.2: High-pressure oil circuit.

2.3: Oil quantity measurement. The standard injection port is

connected to the panel return port.
A B C D

153
3. drive harness
Use the special VP37 drive harness to connect the oil pump to the
dedicated interface on the panel. Single crocodile clip harness is
ground.

154
 Pin definition of oil pump wiring harness port

VP37 electric control distribution pump repair-electrical test

Use a multimeter to test the following steps before debugging the fuel injection pump,
otherwise the next step is not allowed
Between terminal 1 and 3 ohm 9.8~13.0 Between terminal 1 and 2 ohm 4.9~6.5
Between terminal 2 and 3 ohm 4.9~6.5 Between terminal 2 and 7 ohm 1.0
Between terminal 4 and 6 ohm 1.0 Between terminal 5 and 6 ohm 0.5~2.5
Between terminal 4 and 7 kohm 0.45~1.1 Between terminal 9 and 10 ohm 12~20

Terminal names of fuel injection pump monitoring plug

1. Adjust the sliding sleeve position sensor (+) 2. Adjust the sliding sleeve position sensor (-)
3. Adjust the sliding sleeve position sensor (+) 4. Fuel temperature sensor (-)
5. Fuel regulator (-) 6. Fuel regulator (+)
7. Fuel temperature sensor (=) 8. Fuel shut-off valve
9. Timing control valve (+) 10. Timing control valve (-)

155
4: Test
4.1: System function selection interface, click to select "VP37 pump"

156
4.2: Enter the VP37 oil pump model selection interface, select the tested
oil pump model. Click "Continue" to enter the oil pump automatic test
interface.

157
1: Oil pump speed 4: Control module drive voltage
2: Test oil temperature 5: Test time
3:

1 2 3 4 5

158
4.3: Click the "Start" button on the test interface, the system automatically
completes all test conditions. The test result is displayed on the right side
of each test step, and it automatically judges whether it is qualified.
During the test, pay attention to observe whether the pressure of the
pump chamber is appropriate.

159
4.4: Click "Report", click "Print"

160
4.5: Click Print, the system automatically prints out the test report

161
VP44 oil pump installation test

Catalogue
1: oil pump installation
2: oil circuit assembly
3: drive harness
4: oil pump test

162
1: oil pump installation
The special connection flange for VP44 oil pump is found in the
attachment. It is fixed on the bending plate, and the oil pump is
fixed on the flange. Select coupling number II. Pay attention to
tighten the coupling compression nut. Tightening torque 95 Nm.
The tightening torque of the spindle connection tightening screw is
120 Nm.

163
2：oil circuit assembly
2.1: 2pcs YG-03 oil pipes and 1 # 14 oil pipe screw. Four high-pressure oil
pipes, two 2 quarter to 18 connectors, two quarter self-locking quick plugs, one
eighth to 6 copper quick plugs, 5 # 6PVC hard oil pipes 1 meter .There are
4pcs standard fuel injectors and 1 bracket. One pump cavity pressure test
adapter.

164
2.2: Low-pressure oil circuit
Oil supply module "Diesel Pump" --- low-pressure oil inlet of oil
pump Oil supply module "Diesel return" --- Oil pump oil return
Remove # 10 internal hexagon plug and install pump cavity
pressure test connector.

Pump cavity pressure test interface

165
2.3: High-pressure oil circuit

166
3: drive harness connection
3.1: Connect the VP44 drive harness
3.2: Remove the upper cover of the electronic module. Install the cam
signal electronic module.
3.3: Use a special probe to pierce the outermost wiring harness of the
electronic module.

Cam signal electronic module

167
168
4: Test
4.1: System function selection interface, click to select "VP44 pump"

169
4.2: Enter the VP44 oil pump model selection interface, select the tested oil
pump model. Click "Continue". Enter the oil pump automatic test interface.

170
1: oil pump speed 4: oil supply duration
2: 5: Test time
3: Test oil temperature

1 2 3 4 5

171
4.3: Click the "Start" button on the test interface, the system automatically
completes all test conditions. The test result is displayed on the right side
of each test step, and it automatically judges whether it is qualified.
Observe whether the pressure in the pump chamber is appropriate during
the test.

172
4.4: Click "Report", click "Print"

173
5: Click Print, the system automatically prints out the test report.

174
RED4 oil pump installation test

Catalogue
1: oil pump installation
2: oil circuit assembly
3: drive harness
4: oil pump test

175
1: oil pump installation
The special connection flange for RED4 oil pump is found in the
attachment. It is fixed on the bending plate, and the oil pump is
fixed on the flange. Select coupling number III. Pay attention to
tighten the coupling compression nut. Tightening torque 95 Nm.
The tightening torque of the spindle connection tightening screw is
120 Nm.

176
2：oil circuit assembly
2.1: 6pcs standard fuel injectors.6pcs high-pressure oil pipes.2pcs YG-03 oil
pipes

177
2.2: Low-pressure oil circuit
Oil supply module "Diesel Pump" --- low-pressure oil inlet of oil
pump Oil supply module "Diesel return".

178
2.3: High-pressure oil circuit

179
For example:

180
3: drive harness connection
3.1: Connect the RED4 drive harness

181
4: Test
4.1: System function selection interface, click to select "RED4 pump"

182
4.2: Enter the VP44 oil pump model selection interface, select the tested oil
pump model. Click "Continue". Enter the oil pump automatic test interface.

183
1: oil pump speed 4:
2: Test time 5:
3: Test oil temperature

1 2 3 4 5

184
4.3: Click the "Start" button on the test interface, the system automatically
completes all test conditions. The test result is displayed on the right side
of each test step, and it automatically judges whether it is qualified.
Observe whether the pressure in the pump chamber is appropriate during
the test.

185
4.4: Click "Report", click "Print"

186
5: Click "Print", the system automatically prints out the test report.

187
 SIEMENS VDO oil pump

Catalogue
1: Test bench oil pump assembly
2: oil circuit and wiring harness connection
3: test
4: Test result printing

188
1: Test bench oil pump assembly
The attachment flange for Siemens oil pump is found in the attachment.
Fix on the equipment bending plate, fix the oil pump on the flange.
Select the I coupling. Pay attention to tighten the coupling compression
nut. Tightening torque 75 Nm. The tightening torque of the spindle
connection tightening screw is 120 Nm.

189
2: Oil circuit and wiring harness connection
2.1: Oil circuit connection.
2 YG-05 oil pipes, 2 # 12mm inlet pipe screws. 2 quarter-to-18
connectors, Two one-fourth self-locking quick plugs. One high-
pressure fuel pipe and one 14-turn 12 oil pipe elbow.

190
2.2: wiring harness connection

ZME1

ZME2

191
3. Oil pump test
3.1: Turn on to enter the function selection interface. Click the "CR
Pump" icon.

192
3.2: Click "SIEMENS" in the "Features" column. Select the model of the
tested oil pump in "Model". Then click "Continue". Enter test interface

193
3 . 3 : C l i c k t h e " St a r t " b u t to n o n t h e te s t i n te r f a c e , t h e s y s t e m
automatically completes all test conditions. The test result is displayed on
the right side of each test step, and it automatically judges whether it is
qualified.

194
4: Test result printing
4.1: Click "Report", click "Print"

195
4.2: Click "Print" to automatically print the test results.

196
 Maintenance
1: each oil duct hose of test bench
1.1: Oil duct hose needs to be replaced after 60 months inspection
1.2: Check for loose or leaking oil duct hose connections every 2 months.

2: test oil
2.1: ISO4113 standard test oil, replaced in 36 months. Or inspect
300 fuel pumps and 3000 injectors.
2.2: Ordinary diesel, replaced within 12 months. Or test 1000 fuel
injectors for 100 oil pumps.
2.3: # 46 hydraulic oil, replaced within 24 months. Or test 800 HEUI
assemblies with 50 actuated pumps.
2.4: Lubricate the engine oil and replace it in 12 months.

197
3: Filter maintenance
3.1: Fuel injection filter.
2 months or testing 50 fuel injectors
Clean the filter with clean gasoline and
blow dry with high pressure air.
DisassemblyMethod: loosen the transparent
cover to the left to loosen the filter
fastening screw, Remove the filter.
It needs to be replaced within 12 months.

3.2: Oil pump test metering oil passage filter

Replace the new filter element in 24 months
or test 100 oil pumps.
Remove the filter element with a special
wrench, and fill the new filter element with
test oil.
Tighten

198
3.3: Diesel fuel line filter.
Replacement of new filter
element in 12 months

3.4: oil filter

Replacement of new filter
in 12 months

199
4: regulating the internal cavity high-pressure filter
System prompts unbalanced rail pressure, Clean the filter.

90Nm
30Nm
90Nm

High pressure filter

200
5: Inspection and cleaning of waste oil tank
Check the position of the oil level in the waste oil tank every 200
hours to prevent spillage. And clean up in time.

6: Precautions for the use of high-pressure oil pipes

Check the indentation of the cone surface of the
high-pressure oil pipe from time to time. When
the indentation depth exceeds 100um, please
replace it in time

201
7: tightening torque
7.1: Fastener

7.2: Transmission coupling

202
7.3: Coupling

7.4: Tightening torque of fastening bolts

203