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Carbon Zapp CRU.2R Operation Manual Download Page 1

Operation Manual 

For CRU, GDU, DS, GD, UIP, HUI, TBCR, DCD, ECMR Units “R” version 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

v201902

 

 

Summary of Contents for CRU.2R

Page 1: ...Operation Manual For CRU GDU DS GD UIP HUI TBCR DCD ECMR Units R version v201902 ...

Page 2: ...nformation Carbon Zapp 364 Varis Koropiou Ave Athens Koropi 19400 GREECE Support Sales Telephone 302109856110 Support email support carbonzapp com TeamViewer email tv carbonzapp com Sales email office carbonzapp com URL www CarbonZapp com ...

Page 3: ...age of cleaning solvents and chemicals not provided or indicated approved by Carbon Zapp use of parts and components not supplied or approved by Carbon Zapp Note Failure to clean injectors with Carbon Zapp s ultrasonic device before any test is performed on the test bench will void the warranty of the machine if dirt particles from the injectors or components tested enter the machine and valves As...

Page 4: ...ety symbols 7 Definition of Terms and Abbreviations 7 Product Description 12 CRU 4R 12 CRU 2R 13 GDU 4R 14 GDU 2R 15 DS R 16 DSF R 17 GD R 18 UIP R 19 HUI R 20 TBCR 21 DCD 23 ECMR 24 Adapters 25 Flush Adapter 25 SPR 25 RSP 25 CRIN 26 EUI 26 HEUI 26 Commissioning 27 Installation 27 Electrical Connections 27 ...

Page 5: ...p 31 Language Selection 31 Wi Fi Setup 31 Printer setup 32 Personal Data Accounts 32 Connection to the PCB DEMO Mode 33 Software Orientation 34 HOME 34 User Logins 35 SETTINGS 36 INJECTOR COMPONENT SELECTION 36 CUSTOMER DATA 37 COMPONENT DATA 37 CFL 1 2 3 38 ADJUST HP 39 EUI 40 CRP 40 SELECT TESTS 41 MACC 42 TEST 44 REPORTS 46 REPORT VERSIONS 47 SHARE 48 Save to USB 49 Operation 50 Before Testing ...

Page 6: ...Operation Manual R Units 6 Cleaning and Testing the Injector s 50 Results and Reports 52 Maintenance 53 Regular Maintenance 53 Troubleshooting 55 Technical Specifications 56 ...

Page 7: ...y used Symbol used for Testing Tank Fluid Fill Port Drain Valve Use only specified fluid in Specifications area of this manual Symbol used for MACC Cleaning Tank Fluid Fill Port Drain Valve Use only specified fluid in Specifications area of this manual Symbol used for Hydraulic Oil Tank Fluid Fill Port Drain Valve Use only specified fluid in Specifications area of this manual This tank is availabl...

Page 8: ...the slot Port for measuring the Return Volume of the Injector Component For multi slot units the making 1 2 3 4 is used to denote the slot For multi slot units the making 1 2 3 4 is used to denote the slot The Common Rail output port s Connect appropriate HP Hoses approved by your Service Provider Since it is a common rail use HP Plugs to plug the unused ports in a multi slot machine The main are ...

Page 9: ...E Connect to the Feed port on the adapter of the UI injector When 2 Ports on the adapter are horizontally aligned the order is arbitrary when the ports are vertical the Port marked with a DOT is the Feed Port Use this indicator to adjust the CAM lift of the EUI Injector Plunger USB Port for connecting USB Stick Drive USB Printer USB Mouse Keyboard Package version Software version APK version Appli...

Page 10: ...arge BIP adapter needed iVM DFi Dynamic Volume Metering test Measure Discharge and or Return Injection Volume LKT Static Volume Measuring of Return Volume mm3 VS mg mm3 is Volume V and mg is Mass m Some machines have an advanced measuring unit that measure mass An approximation volume to mass as a dynamic under HP pressure flow would be V m 0 775 TP Test Plan a set of parameters for a specific tes...

Page 11: ...he Piezo stack for Conti Bosch and Denso Piezo injectors respectively This feature will repair injector to increase their injection volume CGL is Conti Gap Lift Feature that will diagnose the condition of the stack for Conti injectors and provide information for its repair ...

Page 12: ...testing of these Pump Injectors 1 by 1 and also use RSP and BIP adapters This unit uses a Dynamic Mass Metering system and can do Coding on select injectors Front View Figure CRU 4R 1 Diesel Injector Not included 2 Injector Harness Cables 3 Injector Clamp Discharge Height Adjuster iPSC mounted with LED 4 Protective Hood 5 Control Panel PC 6 USB Port 7 On Off Switch for PC 8 Cushioned Adjustable su...

Page 13: ...ctors 1 by 1 and also use RSP and BIP adapters This unit uses a Dynamic Mass Metering system and can do Coding on select injectors Front View Figure CRU 2R 1 Diesel Injector Not included 2 Injector Harness Cables 3 Injector Clamp Discharge Height Adjuster iPSC mounted with LED 4 Protective Hood 5 Control Panel PC 6 USB Port 7 On Off Switch for PC 8 Cushioned Adjustable support pads 9 Air Vents 10 ...

Page 14: ...ctors This unit uses a Dynamic Mass Metering system Front View Figure GDU 4R 1 Gasoline Injector Not included 2 Injector Harness Cables 3 Injector Clamp Discharge Height Adjuster iPSC mounted with LED 4 Protective Hood 5 Control Panel PC 6 USB Port 7 On Off Switch for PC 8 Cushioned Adjustable support pads 9 Air Vents 10 Carrying Handles 11 Test Oil level Indicator 12 Emergency Stop Switch 13 Test...

Page 15: ...ynamic Mass Metering system Front View Figure GDU 2R 1 Gasoline Injector Not included 2 Injector Harness Cables 3 Injector Clamp Discharge Height Adjuster iPSC mounted with LED 4 Protective Hood 5 Control Panel PC 6 USB Port 7 On Off Switch for PC 8 Cushioned Adjustable support pads 9 Air Vents 10 Carrying Handles 11 MACC level Indicator 12 Test Oil level Indicator 13 Emergency Stop Switch 14 MACC...

Page 16: ... Volumetric Tubes for measuring the injected volume User intervention is needed in the A units to complete the test for adjusting the Test Pressure and Entering the Volumetric Data Front View Figure DS R 1 Injector Harness Cables 2 Diesel Injector Not included 3 Injector Clamp Discharge Height Adjuster iPSC mounted with LED 4 Protective Hood 5 HP Knob for controlling the Pressure Manual HP Machine...

Page 17: ...y 1 The Unit comes with 2 tanks for cleaning and flushing Front View Figure DSF R 1 Injector Harness Cables 2 Diesel Injector Not included 3 Injector Clamp D Adapt mounted 4 Protective Hood 5 HP Knob for controlling the Pressure Manual HP Machines only 6 Control Panel PC 7 On Off Switch for PC 8 USB Port 9 Adjustable support pads 10 Air Vents 11 MACC level Indicator 12 Test Oil level Indicator 13 ...

Page 18: ...t for adjusting the Test Pressure and Entering the Volumetric Data Front View Figure GD R 1 Injector Harness Cables 2 Gasoline Injector Not included 3 Injector Clamp Discharge Height Adjuster iPSC mounted with LED 4 Protective Hood 5 HP Knob for controlling the Pressure Manual HP Machines only 6 Control Panel PC 7 On Off Switch for PC 8 USB Port 9 Adjustable support pads 10 Air Vents 11 MACC level...

Page 19: ...and Pumps Front View Figure UIP R 1 CAM securing lock 2 Protective Hood 3 Adapter Connections 4 Adjustable support pads 5 LP Low Pressure gauge 6 Test Oil level Indicator 7 MACC level Indicator 8 Injection Connections 9 Injector Clamp Discharge Height Adjuster iPSC mounted with LED 10 EUI Injector Not included 11 Plunge ROD 12 CAM Adjuster always use the headless screw to secure ...

Page 20: ...nt View Figure HUI R 1 Protective Hood 2 Adapter Connections 3 Hydraulic Oil Gauge 4 Hydraulic Oil Adjusting Knob Adjust on each TP 5 Hydraulic Oil level Indicator 6 LP Low Pressure gauge 7 Test Oil level Indicator 8 MACC level Indicator 9 Adjustable support pads 10 Injection Connections 11 Injector Clamp Discharge Height Adjuster iPSC mounted with LED 12 HEUI Injector Not included ...

Page 21: ...arrying Handles 4 Emergency Stop Switch RDS Calibrate Maintenance Section More Information Instructions 5 Injector Harness Cables 6 Sensor Cables 7 Extension Harness for HK1400A 8 HP Pressure Control Control Pump LED BCR Kit 9 Return Tank Hoses 10 Pump Hoses Connections 11 Injector Hoses Connections All requirements must be met by the operator prior to initial setup of TBCr unit NOT included Commo...

Page 22: ... R Units 22 Electrical and Hydraulic Connections Notes if you don t have BCR Kit you have to calibrate RDS before use for further clarifications please contact with our Support Department e mail support carbonzapp com ...

Page 23: ...Switch only for DCDS models RDS Calibrate Maintenance Section More Information Instructions 7 HP Pressure Control only for DCD models 8 Injector Hoses Connection 9 Injector Harness All requirements must be met by the operator prior to initial setup of DCDr unit NOT included Common Rail Pump we suggest 0445010081 0445010090 0445010107 0445010125 0445010213 0445010343 0445020037 0445020039 044502010...

Page 24: ...s Control Data Test Bench Pressure Control Simulator It comes in many versions and the connections and component capability change and are dependent on the specific version Front View Figure ECMR 1 Control Panel PC 2 Adjustable support pads 3 On Off Switch for PC 4 USB Port 5 Air Vents Side Panel 6 Sensor Harness Cables 7 Injector Harness Cables Electrical and Hydraulic Connections ...

Page 25: ... for visually checking the Spray of the injector different for Gasoline and Diesel Injectors on every TP at pressures up to 2500bar This adapter is optional MACC feature should not be used with this adapter RSP This adapter is for performing the RSP and aNOP Tests This adapter is optional for All codings BC 01 DLC 03 DNC 04 VC 05 ...

Page 26: ...tors for adapting on to the machine These adapters are optional EUI Various adapters are available for EUI EUP Injectors and Pumps for adapting on to the machine These adapters are optional HEUI Various adapters are available for HEUI Injectors for adapting on to the machine These adapters are optional ...

Page 27: ...length and diameter and compressor capacity according to the specifications ALWAYS Purify the air coming to the unit so it is free of water oil and particles 1 Close the air supply from the compressor 2 Connect the necessary hose connector not in scope of delivery on the rear of the machine if required 3 Connect and secure the Air Supply hose on the machine connector 4 Open the air supply from the...

Page 28: ...Operation Manual R Units 28 ...

Page 29: ...essure Oil HEUI System use ISO 4113 The procedure is the same for all types of Fluids 1 Assure the correct filter is placed for this tank 2 Open the Cap for the Tank Port 3 Using the provided funnel fill with the specific Oil on to the point Marked at the same tank level indicator 4 Close the tank port cap After the first use the level may drop since the hydraulic system and filter will fill as we...

Page 30: ...r drain valve or Add more Test Oil You can monitor the level sensors in the Service Screen Settings Degassing the system When Changing a Filter or Fluid it is necessary to perform a Hydraulic System Degas Control Panel HOME Options Settings Machine HP Degas This function will ensure that the hydraulic system is free of air This function should be repeated as many times necessary if the user feels ...

Page 31: ...e PC Vendor Logo is displayed Wait for a few seconds for the PC to boot Switch Off the PC Press the On Off Switch for a few seconds until the POWER OFF message is displayed Select to Power Off or Reboot INFO Although the PC can stay in Stand By Mode a few days Short Press the On Off Switch it is recommended to Power Off the PC to conserve battery and battery Life Software Setup Language Selection ...

Page 32: ...chine on the same WiFi network or via USB Bluetooth 3 Open the Printer Application from the Applications list and make the connection 4 Print a test page to verify correct operation Personal Data Accounts OWNER INFO Go to HOME Options Settings Owner Info and enter the data for the owner of the machine This data will be shown on the saved and printed report GMAIL The saved reports can be shared als...

Page 33: ...re AZO is designed to run in DEMO Mode whenever there is no connection to the PCB Board or there is loss of power Once power and connection is restored the software will restart automatically The iPSC Led will be lit when the connection is established and NOT in DEMO mode ...

Page 34: ...Operation Manual R Units 34 Software Orientation HOME ...

Page 35: ...Multi Page Report DS GD DCDR ECMR duplicate edit oscilloscope Username suser Password su Single Page Report Username sdeveloper Password su Multi Page Report This is the startup screen of the Application the HOME Screen From here the user can access Start a new test go into the system settings logout update the system ask for remote support and access previously created report ...

Page 36: ...rns results that contain the letter d and also the number 3 in the fields of brand type and part Once a component has been selected the Connection Information and a basic diagram of the type of the injector is shown on the right part of the screen along with information like the Brand Types and Maximum Pressure In addition the user can select here if MACC Cleaning will be performed before testing ...

Page 37: ...the client COMPONENT DATA Once the required slots have been selected multi Slot machines it is mandatory to enter the Serial Number of the component since this is the unique identification Further the user can also enter other info like Fabrication Data and or existing Coding of the component ...

Page 38: ...ly Step 1 3 applies a low pressure in order to diagnose basic immediate leaks Step 2 3 applies maximum component pressure to assure no leak is present Step 3 3 applies the maximum pressure again but with the component operating in order to check for machine capability component operation and adapter leak The last step can also be used to clear lines and adapters from air Advanced users can Skip th...

Page 39: ...Operation Manual R Units 39 ADJUST HP In some machines some options are not automatic and therefore the user is responsible to adjusting the required pressure and or feature to the TP ...

Page 40: ...nual R Units 40 EUI Some machines also have an RPM Meter by proximity sensor or Low Pressure hydraulic system For the LP no sensor is available rather a Percentile of the maximum capacity which is 10bar usually CRP ...

Page 41: ... to enter Manual Mode Test plan meanings R2LC resistance inductance capacitance test ANOP automatic nozzle opening pressure test only with RSP sensor RSP injector nozzle response test only with RSP sensor IVM VL full load injection measurement test IVM EM TL part load emissions injection measurement test IVM LL low load idle speed injection measurement test IVM VE pre post injection measurement te...

Page 42: ...ically Flush with Test Oil while wasting this Oil in the MACC Tank During MACC test you need Flush adapter and when the test is finished you need to remove the Flush adapter and you have to use RSP Sensor or iPSC Chamber Once the MACC Step is over the unit will automatically begin Testing the component s USON Backflush only for GD and GDU series ...

Page 43: ...Operation Manual R Units 43 REVERSE Backflush only for GD and GDU series ...

Page 44: ...easurements and depends on each test There are various result sates depending on the result Blue Color Very Good Result Green Color Good Result Yellow Color Almost Fail Result Red Color Fail Result Orange Error High Pressure After Conditioning period if the Pressure is outside the limits there will be an error displayed Advanced users can edit the test and save the changes by pressing on the Optio...

Page 45: ... Test List button a List of the tests will be shown By Long Pressing a Test with results a Quick Report will be displayed When stopped by pressing a test from the list it will repeat it and or jump directly to it by skipping the in between tests ...

Page 46: ...Operation Manual R Units 46 Once all the tests are finished the software will ask to create a report or not If in Manual mode this will never be displayed REPORTS ...

Page 47: ...ve to USB A USB Drive need to be connected to the system A PDF is saved on that medium with the name of the machine component and date Delete This options completely deletes the report Share Share provides a variety of options to share the report including but not limited to Printing Emailing and saving to a Dropbox Folder REPORT VERSIONS For Basic Users logged in as Guests ...

Page 48: ...Operation Manual R Units 48 SHARE ...

Page 49: ...Operation Manual R Units 49 Save to USB ...

Page 50: ... Information on adaptability is provide in the Injector component selection screen INFO Always use the Connections Leaks screen to assure the injector is connected without leaks IMPORTANT Always take care when connecting HP Hoses The minimum pending radius is 90mm Over bending the hose my result in destroying the hose INFO When using a multi slot machine it is possible to connect only specific slo...

Page 51: ...al Mode from the Top Right 3 dots option button When performing ONLY MACC please select only the R2LC as a test since at least 1 test should be performed 7 Once the Testing procedure is initiated the software will follow the list of tests beginning from the MACC At any point during testing the user can select a test be long pressing on it to get a Quick Report If the test is stopped the user can s...

Page 52: ...a user profile Coding is only available for units using a Mass Measuring unit There are a few types of results and report styles for easier diagnosis and client handling Result Colors Blue The value of the test is PASS and very good Green The value of the test is PASS and within the operating limits Yellow The value of the test is Almost Passing the component will soon fail Red The values of the t...

Page 53: ...lters and fluids when the Control Panel reminds or when the Fluid becomes Darker Note the Discharge and Return Hoses also have small filters these filters are also to be replaced and In Line Filters need to be replaced message CHECK INLINE FILTERS Log in as service username service password 12345 Regularly change the screen filter in the Discharge and Return Hoses after a 10 injector tests Use Con...

Page 54: ...ort RDS Calibration Log in as service username service password 12345 Go to 3Dots Settings Machine Service Machine Select Calibrate RDS Connect ONLY HP Gauge 2000bar Note DCDS TBCR units on the first startup of the unit before any test ...

Page 55: ...ure the hydraulic system is free of air Degassed Use the Provided Plug to eliminate a failing injector factor If the pressure cannot be reached again contact your service provider Pressure on the screen gauge is erratic and no actual pressure is present The Software is in DEMO Mode Reconnect Power to the machine Check USB Connection Injection Injector not injecting EUI Proximity sensor is not conn...

Page 56: ... Test Oil Filter 2 microns Noise Emissions 71 5dB A Dimensions W x D x H Weight 66 x 77 x 79 cm 90kg CRU 2R Mains Supply 100 240 VAC 1P 50 60Hz 10 Compressed Air 6 5 10 0 bar 400lt min Compressed Air Hose 10m long Internal Diameter 10mm Rated Current Fuse 5 A Rated Power 300 Watt Storage Temperature 25 o C 60o C Operating Temperature 5 o C 45o C Normal Operating Temperature 10 o C 40o C Max Pressu...

Page 57: ...acity 3 5lt MACC Fluid Filter 8 microns Noise Emissions 71 5dB A Dimensions W x D x H Weight 66 x 77 x 79 cm x0 50kg x1 60kg DSF R Mains Supply 100 240 VAC 1P 50 60Hz 10 Compressed Air 3 10 0 bar 300lt min Compressed Air Hose 10m long Internal Diameter 10mm Rated Current Fuse 5 A Rated Power 300 Watt Storage Temperature 25 o C 60o C Operating Temperature 5 o C 45o C Normal Operating Temperature 10...

Page 58: ...ter 2 microns Noise Emissions 71 5dB A Dimensions W x D x H Weight 66 x 77 x 79 cm 90kg GDU 2R Mains Supply 100 240 VAC 1P 50 60Hz 10 Compressed Air 6 5 10 0 bar 400lt min Compressed Air Hose 10m long Internal Diameter 10mm Rated Current Fuse 5 A Rated Power 300 Watt Storage Temperature 25 o C 60o C Operating Temperature 5 o C 45o C Normal Operating Temperature 10 o C 40o C Max Pressure bar 30 300...

Page 59: ...mperature 25 o C 60o C Operating Temperature 5 o C 45o C Normal Operating Temperature 10 o C 40o C Max Pressure bar 300 Tightening Torque for High Pressure Connections 25 30 Nm Clamping Diameter 17 32 mm Test Oil Type Capacity Calibration Oil RDXL 3 5lt Test Oil Filter 2 microns MACC Fluid Capacity 3 5lt MACC Fluid Filter 8 microns Noise Emissions 71 5dB A Dimensions W x D x H Weight 66 x 77 x 79 ...

Page 60: ...mpressed Air Hose 10m long Internal Diameter 10mm Storage Temperature 25 o C 60o C Operating Temperature 5 o C 45o C Normal Operating Temperature 10 o C 40o C Max Pressure bar 300 Tightening Torque for High Pressure Connections 25 30 Nm Test Oil Type Capacity ISO4113 3 5lt Test Oil Filter 2 microns MACC Fluid Capacity 3 5lt MACC Fluid Filter 8 microns Hydraulic Oil Type Capacity ISO4113 3 5lt Hydr...

Page 61: ...Temperature 5 o C 45o C Normal Operating Temperature 10 o C 40o C Dimensions W x D x H Weight 35 x 48 x 34 cm 14kg ECMR Mains Supply 100 240 VAC 1P 50 60Hz 10 Rated Current Fuse 5 A Rated Power 300 Watt Storage Temperature 25 o C 60o C Operating Temperature 5 o C 45o C Normal Operating Temperature 10 o C 40o C Dimensions W x D x H Weight 35 x 48 x 34 cm 14kg ...

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