TECNOMOTOR TM 514 - User Manual

The provided manual describes the Tecnomotor TM 514 - Common Rail Test equipment, a device designed for testing components of diesel injection systems, specifically Common Rail systems.

Function Description

The TM 514 is a microprocessor-controlled electronic test system that allows for precise control of fluid temperature and pressure throughout the testing process. It stores test data for later viewing and transfer to a computer. The equipment is capable of performing various tests on injectors, pressure regulating valves (DRV, PCV, MPROP), and pressure sensors.

Injector Testing: The TM 514 tests one injector at a time, whether it's an inductive or piezoelectric type, to verify its electrical and mechanical conditions.

• Electrical Test: Checks the electrical condition of the solenoid or piezoelectric element. For piezoelectric injectors, resistance is not displayed due to their electrical characteristics. Possible conditions include:
  • OK: Injector is ready for the electrical test. For inductive injectors, resistance is shown.
  • OPEN: Indicates an open circuit or no injector connected.
  • SHRT (Short): Indicates a short circuit in the injector or connection/cable.
  • ERRO (Error): Indicates an injector with resistance outside the known range.
• Leak Test (Estanqueidade): Pressurizes the injector without activation to visually check for leaks in nozzles and connections. This test is performed at 1300 bar pressure. A failure message is displayed if leakage or excess oil is detected.
• Starting Test (Partida): Verifies the spray jet condition of the injector visually under critical vehicle conditions. The jet breaker must be removed for this test, and the injector is placed inside the vat. This test requires caution due to the fine oil jet under pressure, which could ignite if sparks are present. The test lasts ten seconds and should be performed with the safety cover closed.
• Flow Tests (Vazão): Measures injection and return flow under various load conditions:
  • Full Load Condition: Tests the injector under full vehicle load conditions.
  • Partial Load Condition: Tests the injector under partial vehicle load conditions.
  • Idle Condition (Marcha-lenta): Tests the injector under vehicle idle conditions.
  • Pre-injection Condition: Tests the injector under vehicle pre-injection conditions. Each flow test provides values in "ml" per thousand injections at system-specified rates. The injector actuation test always starts with heating the injector, as its operating temperature affects flow. Users can choose to skip warming, but this may lead to inaccurate results.
• User Test Plan: Allows users to configure specific parameters (pressure, injection time, frequency) for customized injector testing via the Common Rail PC Fast software.

Pressure Regulating Valve Testing (DRV, PCV, MPROP): The TM 514 tests various types of pressure regulating valves, including those operating directly in the high-pressure region and those controlling the inlet flow of pressure pumps.

• Electrical Test: Measures the valve's resistance. Conditions are similar to injector electrical tests (OK, OPEN, SHRT, ERRO).
• Pressure Regulation Curve Measurement: The system performs tests at five specific points, allowing observation of the generated pressure variation. This information helps detect problems in valve operation and isolate defects.

Pressure Sensor Testing: The TM 514 tests pressure sensors with ease and precision.

• Pressure Curve vs. Voltage Measurement: The system generates pressure and verifies the sensor's output voltage, providing data on the pressure curve versus sensor voltage. There is no electrical test for sensors.
• Operation Cycles: Can be manual or automatic, allowing users to choose specific, custom tests or let the equipment perform all necessary tests.

Important Technical Specifications

• Motor: 5 CV Three-phase
• High-pressure pump: Bosch CP3 Mechanical
• Tank resistance: 220V, 800W
• Maximum torque on hydraulic adapters: 30 Nm (3 kgf)
• Fluid reservoir capacity (ISO4113): 5.5 liters
• Fluid filter: Delphi HDF670
• Electric power: 5000 VA
• Power supply: Three-phase 220V or 380V (50/60Hz), configurable.
• Dimensions (without packaging): 800 (W) x 730 (H) x 730 (L) mm
• Dimensions (with packaging): 1150 (W) x 1540 (H) x 830 (L) mm
• Weight (without packaging): 119 kg
• Weight (with packaging): 180 kg
• Maximum working pressure: 2000 bars
• Units of measurement:
  • Temperature: -10 °C to 130 °C (Resolution: 1 °C)
  • Pressure: 180 to 2000 bars (Resolution: 1 bar)
  • Flow rate: 0 to 400 ml/1000 injections (Resolution: 0.1 ml/1000 injections)
  • Voltage: 0 to 5V (Resolution: 0.01V)
  • Volume: 0 to 100 ml (Resolution: 0.1 ml)

Usage Features

• Software Integration: The TM 514 operates with the CommonRailPC Fast software, which is essential for selecting injectors/valves/sensors, configuring tests, monitoring parameters, and generating reports.
• Safety Cover: The equipment features a safety cover made of durable, temperature-tolerant plastic. It has a safety sensor that stops the machine if the cover is opened during a test. The cover should always be closed during operation to prevent hot oil splashes and contamination.
• Emergency Stop: An emergency key is available for immediate shutdown.
• Hydraulic Connections: Adapters are designed for easy installation, with conical high-pressure connectors for secure sealing with low torque. Maximum torque for tightening is 30 Nm.
• Electrical Connections: Electrical connectors are identified by plastic labels and codes, which are cross-referenced with a table in the software.
• Fluid Management: The system monitors fluid level and indicates when fluid needs to be added (Low Fluid Level message). It also has automatic features to inform when fluid and filter changes are necessary.
• Test Pausing: Tests can be paused by pressing F10 or opening the safety cover. If paused due to low fluid, fluid must be added to resume. Data from the paused test point is discarded and retested upon resumption.
• Reports: Detailed test reports can be generated and saved, including data for injectors, valves, and sensors.
• USB Connectivity: The TM 514 connects to a PC via a USB cable for software operation and data transfer.

Maintenance Features

• Preventive Maintenance: Regular cleaning is crucial for equipment longevity and accuracy.
  • Vat Cleaning: The vat should be cleaned after each use with a soft, water-free absorbent paper to prevent drain clogging. Keys, connectors, or adapters should not be left inside. The safety cover should remain closed when not in use to prevent dust and residue accumulation. Contaminated fluid from the vat does not return to the tank and should not be reused, as this voids the warranty.
  • Device Cleaning: Injectors, sensors, and valves must be cleaned of dirt, carbon, grease, and other residues before testing to prevent contamination of the hydraulic system. Pre-cleaning can be done with degreasing substances, specific equipment, or simple methods like cleaning paper and kerosene. Fabrics that shed particles should not be used.
  • Panel and Cover Cleaning: Use a soft cloth with alcohol; avoid solvents or abrasives.
  • Tank Cleaning: When changing the test fluid, the equipment should be tilted to allow impurities at the bottom of the tank to drain.
• Filter and Fluid Replacement:
  • The test fluid and filter have a lifespan of approximately 100 hours of use. The system will alert the user when replacement is needed.
  • Recommended Fluids: Ipiranga ULTRASENE 4113, CASTROL 4113, Shell S.9365 ISO 4113, Tirreno TIRROIL-519A ISO4113, Kelpen Oil - Keen Fluid FC4113 - ISO4113, Bardhal - Maxlub Injector Oil, Luchetti - DEITON BEAK 4113.
  • Changing Fluid: Drain old fluid from the tank's drain valve (item 5 in Side View 1 image). Clean any visible particles from the tank with kerosene or ISO4113 fluid; do not use water or ethanol.
  • Changing Filter: Remove the old filter (item 7 in Side View 1 image) by unscrewing it and replace it with a new one. Apply fluid or mineral oil to the rubber ring of the new filter for easier tightening.
  • Sintered Filter Inspection and Replacement: Filters should be checked and cleaned every 20 hours of operation (software alert). They must be replaced after 200 hours of use or if they show signs of efficiency loss or clogging. The closed face of the sintered filter must be in contact with the spring during reassembly.
• Hour Meter Reset: After changing the fluid and/or filter, the corresponding hour meters in the CommonRailPC Fast software ("Remote Configuration" menu) must be reset to zero.
• Periodic Maintenance: A complete periodic maintenance is recommended every 6 months by Tecnomotor's authorized technical assistance. This includes:
  • Cleaning of the entire hydraulic system (pipes, rail, tank, radiator, measuring vessels).
  • Changing calibration fluid.
  • Changing main and sintered filters.
  • Cleaning the pressure control valve.
  • Retightening all electrical connections.
  • Recalibration of the measuring system.
  • Retightening hose clamps or exchanges.
  • Software and firmware updates.
  • Complete system testing.
• Warranty: Failure to follow proper usage and maintenance practices, including removing or damaging the CQ-OK seal without authorization, results in loss of warranty.

Safety Guidance

• Read Manual: Users must carefully read the operation manual, especially safety instructions, before use.
• Trained Personnel: The equipment must be operated only by properly trained and qualified personnel.
• Fluid Type: Only manufacturer-recommended fluid (ISO 4113 standard) should be used.
• High Temperatures: Components and test fluid can reach high temperatures (up to 100°C). Thermal protective gloves (up to 250°C) are mandatory for handling parts after testing, or wait approximately 10 minutes for cooling.
• Fire and Explosion Risk: Calibration fluid is flammable (similar to diesel). No smoking, open flames, or spark sources near the equipment. Ensure good exhaust and ventilation.
• Injuries: Be careful when tightening hydraulic connections (use a torque wrench, max 30 Nm). Avoid touching rotating or moving parts. The heat radiator fan can operate unexpectedly. Keep electrical cables clear to prevent tripping.
• Noise: The equipment can generate noise up to 90 dB(A) for up to 1 hour under high pressure. Ear protection (shell-type) is mandatory during operation.
• Corrosion: Calibration fluid can corrode some rubbers and plastics. Avoid contact with non-equipment parts and clean devices after testing.
• Eye Protection: Always operate with the safety cover closed. Tighten connections sufficiently to prevent leaks. In case of eye contact, rinse and seek medical attention.
• Copyright: Software and data are Tecnomotor's property. Duplication or reproduction is prohibited.
• Electrical Connection: Connect only to grounded and protected outlets. Use specified plugs and sockets. Replace damaged cables.
• Ventilation: Install the machine in a well-ventilated area.
• MSDS: Keep the Material Safety Data Sheet (FISPQ) for the test fluid near the machine and follow all instructions.
• No Modifications: Do not improvise protections or attempt unauthorized repairs.
• Movement: Do not move the unit or leave it on an inclined plane during operation.
• Contamination: Do not connect dirty pressure tubes or injectors. Accumulation of particles can damage the hydraulic system and void the warranty.

Minimum PC Specifications for CommonRailPC Fast Software

• Processor: Multicore 2 GHz (x86 or x64) or higher.
• RAM: 2 GB (32-bit) or 4 GB (64-bit).
• Hard Disk Space: 1 GB available.
• Graphics: DirectX 9 with WDDM 1.0 driver or higher.
• Display: LCD monitor with minimum 1024 x 768 resolution.
• Peripherals: Mouse, keyboard.
• Connectivity: USB 2.0 port.
• Operating System: Windows 7 or higher.
• Internet: Access for software and hardware updates.