Bosch EPS 610 Original Instructions Manual Download Page 1 | Manualshive

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EPS 610

en

Original instructions
Injection pump test bench

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Summary of Contents for EPS 610

Page 1: ...EPS 610 en Original instructions Injection pump test bench ...

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Page 3: ...anging the set values 18 5 3 1 Setting the motor speed 18 5 3 2 Change direction of rotation 19 5 3 3 Set number of strokes 19 5 3 4 Oil temperature control 19 5 4 Automatic selection of stroke count and motor speed 19 5 4 1 Selecting a preset stroke count 19 5 4 2 Selecting a preset motor speed 19 5 5 Saving customer specific speed rates 20 5 6 Activate stroke counting 20 6 Operation 20 6 1 Switc...

Page 4: ...on Practical hints and other useful information 1 2 Multi step operation Instruction consisting of several steps e One step operation Instruction consisting of one step Intermediate result An instruction produces a visible inter mediate result Final result There is a visible final result on com pletion of the instruction WARNING Danger of hands getting trapped between rotating parts Never hold you...

Page 5: ...mation on copyright liability and warran ty provisions as well as on equipment users and com pany obligations can be found in the separate manual Important notes on and safety instructions for Bosch Diesel Test Equipment These instructions must be care fully studied prior to start up connection and operation of the EPS 610 and must always be heeded 2 2 Safety instructions All the pertinent safety ...

Page 6: ... in order to provide suf ficient cooling R R The cooling water temperature must not exceed 17 C If the coolant feed temperature exceeds 17 degrees Celsius a cooling device must be fitted by the customer R R Provision of a grounded symmetrical 3 phase AC network with 50 Hz mains frequency R R Back up fuse protection required 400 V 500 V 35 amps R R Safety equipment such as safety goggles ear protec...

Page 7: ... 1 EPS 610 1 Measuring glass carrier MGT assembly 2 Mains on indicator 3 Emergency stop 4 Human Machine Interface HMI 5 MGT illumination switch 6 Motor Right Hand RH side panel 7 Control cabinet door 8 Graduated flywheel 9 Coupling guard 10 Fuel injection pump mounting bed 11 Bottom right panel 12 Pressure control valve regulator 13 Swivel arm 14 Swivel plate ...

Page 8: ...movement of the swivel plate 3 5 2 Drive 1 2 3 4 458877_8 1Nkv Fig 2 Drive 1 11 kW motor 2 Flywheel 3 Coupling guard 4 T slot Ensure that the coupling guard is in place before starting the drive The ISO drive coupling is a safety compo nent of the EPS 610 The ISO drive coupling may only be repaired only by Bosch service technicians The drive system consists of a motor Fig 2 Pos 1 flywheel Fig 2 Po...

Page 9: ...est oil fed into the measuring glasses is controlled by the movement of a stroke valve The di rection and movement of the stroke is governed by the electronic control unit of the bench The test oil is routed back from the MGT to the tank via the hose Fig 4 Pos 3 1 2 3 459877_83Nkv Fig 5 MGT height adjustment mechanism 1 Bush 2 Locking screw for MGT vertical movement 3 Screws for fixing the vertica...

Page 10: ...e HMI can be turned and positioned conveniently for viewing the display from either side of the EPS 610 re fer Fig 21 3 5 6 Control cabinet DANGER Risk of electric shock from live parts Touching live parts in the control cabinet might result in shock and fatal injury or death Work in the control cabinet is only to be performed by qualified electricians or au thorized personnel under the supervisio...

Page 11: ...at the pressure line connection The pressure can be adjusted between rotating the hand knob The pressure ranges are as follows R R For phasing 0 4 Mpa R R For calibration 0 400 Kpa 3 6 Test oil tank The test oil tank mounted on the frame of the EPS 610 has a capacity of 50 lts To access the test oil tank open the rear bottom panel i i Ensure that the test oil tank is always filled to its capacity ...

Page 12: ...trips 3 6 2 Heating the test oil The test oil is heated by an electrical resistance heater installed in the test oil tank i i To prevent the risk of fire due to overheating of test oil adequate safety measures have been provided The time required for heating the test oil from room temperature to 40 C depends on the amount of test oil in the tank When the Test oil pump on off key is switched on the...

Page 13: ... and adjust the hoisting cables 4 2 Unpacking the EPS 610 Do not use excessive force to open the packing 1 Visually check if there is any damage to the packing case i i In case of damage do not dispose of the damaged items They have to be preserved for inspection by Bosch and the insurance company i i Observe the method of packaging on one side 2 Dismantle the packaging case on any of the sides 4 ...

Page 14: ...The bench does not need anchoring grouting The bench must be installed on a firm and level floor Although the design and construction of the EPS 610 are rugged enough sudden shocks and jerks may disturb the accuracy of the bench If the EPS 610 has to be levered into position with a crowbar ensure that it is done with short smooth strokes with wooden skids placed underneath Thereby the bench always...

Page 15: ...e system ground is connected to the power earth terminal of the incoming 3 phase supply via a 10 mm2 green yellow earth cable Ensure that the conduit which connects to the main supply bus bars is properly grounded 4 Conduct a Megger test to check if the earthing is OK 5 Check the primary voltage of the control trans former The primary terminal connections should be modified as per the measured pri...

Page 16: ... the other dome nut 1 2 3 4 5 6 7 Fig 14 Tightening the dome nut 1 Plug 2 Stud 3 Spring washer 4 Dome nut 5 Slot for tightening the dome nuts 6 Lever 7 Ratchet 12 Rotate the HMI to a convenient position Overtightening the screw might damage the spring 13 Insert the locking screw Fig 13 Pos 4 into the spring Fig 13 Pos 3 Insert a plain washer Fig 13 Pos 2 and nylon washer Fig 13 Pos 1 at the other ...

Page 17: ...n Explanation Test oil pump on off Switch on off the test oil pump Fixed RPM setting Set constant setting of 200 RPM Direction of motor rotation 2 Change the direction of the motor rotation Drive motor on 2 Start drive motor Heater on off 2 Switch on off the heater Temperature selec tion Change the set temper ature of the test oil tank and the inlet outlet of the fuel injection pump RPM selection ...

Page 18: ...reen symbols 1 In view to the shaft of the injection pump i i Refer to the test specification of the pump and change the parameters accordingly 5 3 Changing the set values i i The changes are saved and are available after switch ing the EPS 610 off and back on again i i Changes to the set value are only possible with a switched on test oil pump 5 3 1 Setting the motor speed 4 Press RPM selection T...

Page 19: ...s set and displayed i i In case an additional temperature is required set value with o or u and repeat the procedure i i The temperature for supply or return can be changed while the drive motor is running 5 4 Automatic selection of stroke count and motor speed The automode feature provides easy selection of preset speeds and stroke counts This feature is useful when different pumps are repeatedly...

Page 20: ...ter switch The EPS 610 is ready for operation 3 Press the Heater on off key to start heating the test oil 4 From the HMI switch on the test oil pump 5 5 Saving customer specific speed rates i i The RPM can be programmed from 100 to 4000 with resolution of 1 RPM 1 Press RPM selection for three seconds till the cur sor blinks on the HMI display The program number and the corresponding RPM value are ...

Page 21: ... the EPS 610 before mounting or dismounting the fuel injection pump 1 Using the required mounting accessories mount the injection pump to be tested on the pump mounting bed i i Contact your Bosch dealer for ordering mounting accessories Tighten the tensioning bolts with a torque wrench Refer to chapter 10 3 for the torque values Tension ing bolts which are not properly fastened could work loose du...

Page 22: ...test oil return line i i The temperature sensor on the flushing valve must always be fitted in such a way that the connecting cable is in a vertical position Warning Risk of trapping in rotating parts Clothing jewelry or hair can get caught in rotating parts and result in serious injury Keep well away from rotating and moving parts Cover rotating parts Keep hands away from rotating parts 6 Refer t...

Page 23: ...Set the dial gauge to zero 6 Set the oil supply to the appropriate low pressure by rotating the hand wheel on the control valve in a clockwise direction The pressure in the supply line can be read on the low pressure gauge Test oil flows out of the over flow pipe on the measuring device 7 Slowly rotate the drive shaft in the direction of rota tion until start of delivery i i Start of delivery is c...

Page 24: ...tact customer service 09 R R Test oil motor thermal overload relay tripped R R Test oil motor is jammed Contact customer service 10 Inlet temperature sensor S6 is shorted Contact customer service 11 Inlet temperature sensor S6 is disconnected Contact customer service 12 Test Oil Motor Contactor Faulty Contact customer service 13 Outlet temperature sensor S7 is disconnected Contact customer service...

Page 25: ... the frequency converter trips and issues an alarm 1007 The intermediate circuit voltage is higher than the over voltage limit of the control system The frequency con verter is still live R R Check the incoming connection braking resistor and the fuel injection pump under test R R Contact customer service 1008 Torque Limit R R Check the condition of the fuel injection pump under test 1009 Brake Re...

Page 26: ...e task Daily Weekly After testing 200 pumps During inspec tion Yearly 8 1 Cleaning of EPS 610 x x Check the measuring glasses visually for any defects In case of defects con tact customer service to order spare measuring glasses x x 8 3 2 Drain the used test oil from the top tray x x 8 3 3 Cleaning of strainer in MGT x x Check the nozzle opening pressure pursuant to the regulations If required adj...

Page 27: ... the filter insert Risk of burning The test oil might be hot and can cause burning Allow the test oil to cool before pro ceeding with the maintenance task Wear safety gloves Warning Risk of slipping Stepping on test oil might could lead to slip page and injury Ensure that test oil does not spill on the floor Wear slip resistant safety shoes 8 3 2 Removing contaminated test oil i i The contaminated...

Page 28: ... The test oil from the tank starts collecting in the vessel When the oil level dips below the minimum quantity the test oil motor stops 7 Switch off the EPS 610 8 Disconnect the mains supply 9 Place a tray capable of collecting about 16 lts of test oil on the floor just below the test oil tank 10 Reach beneath the base of the EPS 610 and open the drain The remaining test oil starts collecting in t...

Page 29: ...e hose connection is OK If there is any leakage switch off and check the hose connections again 22 Switch off the EPS 610 23 Close the rear bottom panel The suction strainer is cleaned 8 3 7 Flexible coupling It is recommended to remove the flexible coupling for inspection and reconditioning However this has to be done only by technicians from Bosch Contact customer service to replace the flexible...

Page 30: ... the EPS 610 9 3 2 EPS 610 and accessories 1 Disconnect the EPS 610 from the mains and detach the power cord 2 Dismantle the EPS 610 and sort out and dispose of the different materials in accordance with the ap plicable regulations 9 3 Disposal and scrapping 9 3 1 Substances hazardous to water Oils and greases as well as refuse containing oil and grease e g filters represent a hazard to water 1 Su...

Page 31: ...ml 30 and 180 calibrated at 27 o C to achieve accuracy Quantity of measuring glasses 8 each Bench Moment of inertia of graduated flywheel Kgm 0 75 Shaft height mounting rail height to axis of drive coupling mm 125 0 1 Logic board Stroke counting Stroke 1 9999 Delivery pump capacity Test oil low pressure l min 16 5 Test oil high pressure l min 1 8 Test oil heater rating KW 2 5 Test oil cooling Conn...

Page 32: ... dB A 83 18 Auxiliary power supply Adjustable DC power supply for start stop magnet V 12 24 A 7 Permissible ambient temperature ranges Maximum ambient temperature C 40 Operating range C 5 to 40 Storage temperature C 25 to 60 Miscellaneous Average time taken to heat test oil from 25 C to 45 C minutes approximately 20 minutes 10 2 Bench layout 1490 for grouting 1762 1420 412 For grouting 0 POSITION ...

Page 33: ... pump camshaft Size Bevel gear diameter mm Tightening torque Nm M 12 17 60 10 M 14 x 1 5 20 80 10 M 18 x 1 5 25 130 10 M 20 x 1 5 30 200 20 M 24 x 1 5 35 250 50 M 30 x 1 5 40 300 50 10 4 Machinery noise information pursuant to the bench safety code R R Noise measurement performed in accordance with DIN EN ISO 3744 and DIN EN ISO 11201 standards R R Sound power measurement performed in accor dance ...

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Page 36: ...Bosch Limited P B No 3000 Hosur Road Bangalore 560 030 INDIA www boschindia com Mailbox service2 in bosch com F 002 DG9 918 2017 10 16 ...

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