Before discussing Common rail injector testing, we will give you some insights about common rail fuel injection.
In the common rail system, fuel is distributed to the injectors via a rail which is a high-pressure accumulator.
Electronics control the pressure in the rail and the start and end of the signal that turns on the injector for each cylinder.
So the benefits of a common rail system are that it can perform multiple fuel injections in a single combustion cycle and at a much higher pressure.
This leads to lower emissions and a better fuel economy, but this system comes with risks as it is susceptible to damage and being worn out.
Why Common Rail Testing is Needed?
Common rail injector systems need constant maintenance and testing because they can fail sometimes, especially with all the advanced technology they use.
Below are common rail failures that must be prevented by frequent common rail injector test benches:
Particle Contamination
If the filtration was inefficient, even a tiny strain of human hair can cause significant damage to the system. Such failures include alterations in the fuel spray pattern, which disrupts the timing and distribution of the fuel inside the engine.
Water Contamination
This is another cause of common rail injector failure, which occurs when there is excess water circulating in the fuel. If this happens, water will react with the chemicals within the fuel and thus corrode metal surfaces and reduce the lubrication between mobile parts. Water contamination leads to early wear and tear not only in the common rail injector but also in the high-pressure fuel pump.
Deposit Accumulation
If there is any fuel left in the injector after the engine is turned off, it will be “cooked” by the remaining heat, which creates carbon deposits; this is also called “coking.” If you don’t remove these deposits, they will build up around the tip of the nozzle and the parts inside the injector. This will make the needle stick, which can also change both how much and when the injection is given.
Faulty Installation
Another reason for premature common rail injector system failure is improper or incorrect installation. For example, if you forget to install the nozzle washer or set it up wrongly, the combustion residue will leak behind it. Several errors might seem simple and negligible, but in fact, they can cause serious damage like poor injector performance and less efficiency.
You can evade these errors by using one of the Maktest Common Rail Injector Testing machinery KO4000 (Computer-aided Assembly System) and/or A4000 (Computer-aided Repair System).
KO4000 & A4000 allow you to assemble the injector once and for all without having to go through a trial and error procedure. It has a precise measuring united and special tools that collaborate with software that instructs you what to do. Its interface is extremely user-friendly.
How To Know if A Common Rail Injector Tester is needed?
Below are some steps you can take or, in other words, signs you see for you to know that your Common Rail Injector and Pump need to go through testing.
Check Engine Light
Sometimes when there is something wrong with the engine, it gives you a sign by a lit button.
Check For Knocking Sound
Another signal that an engine might reveal to you that Common Rail injector test benches are needed is if it makes something like a knocking sound.
Watch Out For Engine Surge
In other words, engine revs will fluctuate if the injector is faulty because it might spray too much fuel into the cylinders.
Misfire
Faulty injectors cause disruption in the fuel supply inside the cylinders, which in turn may not be able to provide enough power for the vehicle to start.
Leakage of Fuel
If you observe any diesel on or near the injector, then a Diesel injector test bench is a must.
Poor Fuel Economy
Again, a faulty common rail injector will force the vehicle to compensate by over-fueling.
More Emissions
Bad injectors cause incomplete combustion of the fuel inside the vehicle, which leads to more emissions.
Equipment For Common Rail Injector Testing
After figuring out that the injector needs testing, you must utilize one of Maktest’s machinery in order to perform the Common Rail Testing process.
Below are 5 available machinery and their functions:
TK1029
HEAVY DUTY COMMON RAIL INJECTOR TEST BENCH
The TK1029 is suitable for both, regular and heavy-duty injectors. You can use the TK1029 for 24/7 Common rail testing. It was designed to endure continuous testing, and it provides better filtration, a larger and different design test oil tank, a cooling algorithm, a motor drive, and a master pump selection.
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TK1026
COMMON RAIL INJECTOR TEST BENCH
This common rail injector tester has a fast measurement system and many advanced and updated features. The TK1026 Injectester CRI can provide temperature control and updated info regarding repair instructions. It has the latest version of control software with a user manual and a guide for troubleshooting problems.
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TK1022
MANUAL ELECTRONIC INJECTOR TESTER
The TK1022 provides preliminary common rail injector test benches before running a full test on the TK1026 injectester CRb. This machine was designed to be simple and hand-operated for the purpose of doing quick, yet reliable common rail testing. An added feature is the new touch panel which displays instantaneous pressure on a graph screen.
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PT2012 CRe
MECHANICAL & COMMON RAIL PUMP TEST BENCH
This Mechanical Test Bench has been used and tested for a long time. The PT2012.CRe is able to test Common Rail Pumps; it sets itself apart from its competitors and shows that it is worth investing in. It also tests common rail pumps by controlling pressure, flow, and speed accurately.
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TK1035
COMMON RAIL PUMP TEST BENCH
The testing of common rail pumps gets more difficult with each subsequent generation of common rail systems.
This machine (TK1035) is capable of Testing newer generations of Common Rail pumps which now require more fine pressure controls, precision metering, in addition to highly exact speed control.
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Common Rail Injector Testing FAQ
How do you test common rail diesel injectors?
There are several ways to conduct a Diesel injector test bench, like checking the engine for light or noise or engine surge or misfire. however, for complete testing, you ought to opt for Maktest’s common rail injector testers.
How is Common rail injector repair done?
Common rail injector testing indicates the issue with the injector. However, common repair practices include replacing the nozzle, then disassembling the injector, and replacing the high-pressure sealing washer. Then you will need tools to repair valve sets and magnet assemblies.