Details
The Computerized Diesel Fuel Injection Pump Test Rig is a high-precision, fully automated testing and calibration system designed for fuel injection pumps used in diesel engines across industries such as railways, automotive, power generation, and defense. Equipped with a computerized control system, real-time monitoring, and advanced safety interlocks, this test rig ensures accurate measurement of fuel delivery rates, injection pressure, and stroke performance. Featuring a robust industrial design, self-lubrication system, and multi-stage filtration, it offers reliable, repeatable, and standardized testing to enhance engine efficiency and longevity. The Computerized Diesel Fuel Injection Pump Test Rig is a automated test bench designed to evaluate and calibrate diesel fuel injection pumps used in locomotive engines, heavy-duty commercial vehicles, industrial diesel engines, and specialized fuel systems. With a fully integrated computerized control system, the rig accurately measures fuel flow rates, injection pressure, and stroke performance—ensuring that each fuel injection pump meets OEM specifications. This advanced test rig is an essential tool for railway workshops, automotive manufacturers, defense applications, power generation industries, and research laboratories that require repeatable and precise fuel pump performance testing. 2. Why Choose This Test Rig? ✔ Industry-Leading Accuracy • ±0.5% flow measurement accuracy for high-precision calibration. • Real-time monitoring of fuel delivery rate, stroke count, and system temperature. • Programmable test sequences ensure standardized and repeatable results. ✔ Computerized & Automated Operation • Fully digital control panel with touchscreen interface for simplified operation. • Integrated data logging system for real-time performance tracking & reporting. • Automated interlocks & safety shutdowns for equipment protection. ✔ High-Speed, Multi-Purpose Testing • Capable of testing fuel injection pumps at idle speed, full speed, and over-speed conditions. • Suitable for railway diesel locomotives, military vehicles, construction equipment, marine engines, and power generators. ✔ Rugged Industrial Design • Heavy-duty steel frame and vibration-resistant construction for long-term durability. • Anti-corrosion, oil-resistant coating on all exposed parts. • Advanced lubrication system to ensure smooth operation of all moving components. ✔ Meets International Standards • ISO 9001, ISO 14001, and ISO 45001 certified quality manufacturing. • Compliant with OEM calibration standards for diesel fuel systems. 3. Key Features & Capabilities Precision Calibration & Measurement • Uses a high-accuracy flowmeter to measure fuel discharge volume per stroke. • Multiple test speeds for different operating conditions. • Digital displays & automatic data recording. Smart Control & Automation • Microprocessor-controlled testing cycles for repeatable accuracy. • Variable Frequency Drive (VFD) for speed adjustment. • Automated test result logging via an integrated software system. Multi-Stage Safety Systems • Overload protection and power interlocks prevent accidental operation. • Emergency stop button for immediate shutdown. • Automatic low-oil shutdown feature to protect the lubrication system. Robust, Maintenance-Free Operation • Advanced self-lubrication system prevents wear and extends component life. • Industrial-grade filtration system ensures clean, debris-free fuel supply. • Quick-connect fuel lines & modular design allow for easy maintenance. 4. Technical Specifications • Working RPM: 500 RPM • Working Stroke: 300 • Operating Temperature: 43°C - 48°C • Operating Pressure: 40 PSI • Drive Motor Power: 10 HP • Transfer Pump Motor Power: 0.5 HP • Calibration Oil Type: Diesel or IOCL Make • Lubrication Oil Type: Servo Super Multigrade 20W40 • Meets API CF/FS and IS:13656-2002 specifications • Recommended for automotive diesel and petrol engines Fuel Discharge Rate: • Maximum: • 401+4/-11 CC per 300 strokes at a 28 mm rack position • 351+5/-10 CC per 300 strokes at a 30 mm rack position • Minimum: • 45+1/-5 CC per 300 strokes at a 9 mm rack position • 34+1/-5 CC per 300 strokes at a 9 mm rack position • Flow Measurement Accuracy: ±0.5% Filtration System: • Primary filter: 10μm • Secondary filter: 3μm Power & Control: • Power Supply: Standard three-phase industrial power supply • Control System: Computerized monitoring with real-time data logging Safety Features: • Automatic lubrication shutdown • Overload protection • Emergency stop function • Low-oil cut-off sensor 5. Major System Components 5.1 Power Pack & Calibrating Fluid Supply System • 45-liter stainless steel tank with low-level cut-off sensor. • 2 kW heater with digital temperature controller. • Dual-stage filtration system (3μm and 10μm filters). • Diaphragm Accumulator (2.5L capacity) to stabilize pressure fluctuations. 5.2 Drive Motor & Timing Gear Arrangement • 10 HP high-efficiency motor with Variable Frequency Drive (VFD) for speed control. • Multi-pulley V-belt transmission system for efficient power transfer. • 750 mm flywheel for stable rotational energy. • Timing Gear Chain Drive for precise synchronization. 5.3 CamBox Assembly • Main drive shaft (70 mm diameter) for high load capacity. • Fuel injection pump mounting plate with quick-release mechanism. • Automated lubrication system for camshaft and follower mechanism. 6. Applications Railway & Locomotive Maintenance • Used by railway operators worldwide for diesel locomotive fuel pump calibration. • Ensures optimal fuel efficiency and engine longevity. Heavy Vehicle & Industrial Diesel Engine Testing • Ideal for trucks, buses, construction equipment, and agricultural machinery. • Meets OEM calibration standards for precision fuel injection. Marine, Power Generation, & Defense Applications • Essential for marine engines, power plants, and military vehicles. • Ensures consistent fuel delivery under extreme conditions. Research & Development • Used in automotive research labs for fuel system efficiency studies. • Supports alternative fuel research and engine performance optimization.
