nows the time to make one! i dont think it has to be fancy, just being able to check that each cylinder brings the same amount of fuel is what i think the most important part and something you cant figure out when the pump is on the engine. I am going to make a rig to test the phasing of the injection-timing to
Hello Glenn, yeah it worked quite well, and theres lots more adjustments i might need to add to the testbench like some way to check timing on each injector, but i got plans on how to build some extra stuff on the exsisting bench there
You are a young man and use your knowledge to help others persons, that God Jehovah bless your life, I will try to do the same work you did, one test bench not only for injector pump, but for governor of the engine Caterpillar 3116. My congratulations to you and thabks for the oportunity.
Good to see you still working on projects. Looks like you brought your home project to work. I guess you could add some kind of magnetic pick up sensor to the coupler and add a tach to your control panel to see if the speed changes. Great project and very well thought out. Being able to check and set flow rates on your own bench will be a huge time and money saver.
Hello Cullen, Yeah "home made" is a stretch, but what i ment is that it isnt "store bought" rather made myself. Its nice to be inside in winter-time. I got an old RPM counter from IFM and a magnetic pickup sensor now so i am going to mount it (permanen or just a mockup i havent decided on yet).
@@ladytigra6167 no i made this one without blueprints. I did have a DWG file for the flange in the front but i cant find that one anymore (if you look down in the comments some others have requested those to)
@@Foffe2000 ok. It's the question from my mate who got ban on YT so he couldn't ask You by himself. I'll tell him what You'd written. Thanks for the answer and best regards for You :).
Häftigt bygge ! Jag har också fantiserat om att bygga en testbänk, men jag kom över kvarlevorna av en gammal dieselverkstad. Jag har 2 Bosch testbänkar. Den ena är till salu.
You are my hero! I just subscribed..your inspiration is awesome! I have om606 engine and bought om603 mechanical fuel pump also DPUK 7,7mm plunjers…so i have same idea to build bench like this and calibrate and phasing myself..congrats bro!i really appreciate it👍👍👍👌
Thanks! about phasing i havent found if that is needed or possible on these pumps? but i guess there could and should be adjusted. I havent built anything to do this yet but adding a little 12V carburetor fuel pump and a degree-wheel on this testrig should do the trick.
@@Foffe2000 That's exciting ! What size elements do you have? I bought Diesel meken's 7.5 pump building kit from his distributor in Texas a couple years ago and haven't built My 603 pump yet. I've been researching online for a couple years and you are in my opinion the world leader right now in building your own test stand and explaining to us the test information and how to build a stand. Once you get this fully working with a built pump running on your engine smoothly, you are going to be swamped by people who want to have you build their pump. Keep up the good work can't wait to see more videos. PS I was planning on building something similar when I bought my elements and for a constant RPM drive motor I was going to use my VW TDI engine with a PTO on it to drive the pump. Sounds crazy but I'm pretty sure it would work and it would be really cheap since I already have it. Ross
@@rossconverse7038 i got the 7,7mm DPUK elements, they where the only one´s i know of who sells rebuild kits right now. I am hoping to make a video soon on swaping in those elements and hopefully being able to get it running as it should. Got a summer project where i need a pump that can bring a little bit more fuel than the original. But first i am going to take a break for a couple of weeks
@@Foffe2000 okay thanks for getting back to me, looking forward to future videos on the subject. Do you have a Patreon or PayPal account? I want to make a contribution to your channel. Ross
Great video please keep us updated with any updates or improvements to your test bench, I plan to build my own as well having trouble finding info on here this was great👍 one question do you plan on swapping elements in the future or no
It should be a little bit over 2000rpm at 50hz, they got a standard speed. But its all running with a frequency modifyer so i can run it 10% (200rpm) or 200% 4000rpm ..
Hello, I greet you from Argentina, my name is Sergio, I am a subscriber to your channel, your videos are very good, I need you to help me in the construction of the bench to test pumps, such as the size of the motor and the electronic part, so I will see if I can do it. for my workshop... best regards
I was wondering if people could help me, I have a 1998 G wagon with an om606 engine but I wanted to get more power somewhere 220-250 PH how is this work possible, Should I change the electronic IP with a mechanical IP, what changes should I make in the engine since I am a beginner. Thanks for understanding guys
Hello greg, i dont understand the question. The 7.7mm elements got the same outer diameter so no adjustments there. When it comes to adjust the amount of fuelt of each element its from pump to pump, if you do any job on the pump where you loosen the adjustment screws you got to adjust them again afterwards and thats what i am doing in this video
Hello, thank you for the answer, in fact I installed the elements as in your video, I still have to adjust the flow, my diesel specialist asks me how much flow to adjust, I thought -off boost 55cm3 -on boost 120cm3 -Max 160cm3 What do you think? at what rpm should we make the flow adjustments.. sorry for my spelling, I am French and I use a translator.. Thanks in advance
What would happen, if I messure the pressure between a injector and the pump? Isn,t there a context between the pressure and the amount of diesel is injected in the engine? I had the idea to make messurement mounts in the injection line with manometer/pressure Gauge. Less diesel should be messuered in low pressure....so my thoughts... Thank you for your videos.
I dont think that it would work, when the line/injector got the "pop" pressure (130-145 bars) the fuel sprays in to the combustion chamber and this happens both on idle and full load, what differs between full load and idle speed is the amount of fuel delivered but the pop-pressure should be the same and the injector just makes a shattering noise for a longer term of time (opens and closes superfast). i got other videos where i pop-test injectors with a bench device, there you can see how the pressure on the line acts, and just imagine me pulling on the pumphandle faster or slower ..
Yes you are totaly right. I didnt think on that fact, the pressure and time of pressure is important. But if you could messure the pressure and the time the pressure is lasting would that be enough? I am thinking of an eletric pressure unit which you are screwing in the injection line before the injector. It messures the time of pressure and pressure in miliseconds like a Oszilloskop or something.
@@kuchenimbart4576 yes that would be possible, there are advices that listens to the piping of a diesel engine by a sensor thats mounted against them, either when is expands due to high pressure of vibration? its used to set the right timing of the pump. i got an old mercedes one bought second hand from some service-shop. Maybe if you make something simular thats hooked up to a oscilloscope? not measuring pressure but rather frequency when the shattering of the injector accure? Or maybe build a pump like in this video .. if you are going to do adjustments its kinda hard with the pump on the engine anyhow
At the moment I am trying to find every information, how to adjust the amount of diesel on the pump....which part do I have to move to adjust the diesel amount? Could you explane the adjustment work? I will ask a good friend of mine, he knows much about programming...I thought on a mount which you can screw on top on the injectors and on the messuring device the fuel line. There are pressure sensors which messure the time and pressure. At the moment I am repairing a Mercedes T1 with om601. At first I have to bring the car to the technical inspection here in Germany, so that I am allowed to drive for the next 2 years legally. After this I wanna start a Turbo conversion. There is a om601 turbo in the vito 638. But in the T1 there is no room for the original manifault of the om601 fro m the vito. So I will make a costoum excaust and set the turbo a little bit behind the motor. The oil I will take it from the oil cooler in line to the turbo. For the turbo I will take take the original 638 turbo with own wastegate Regulation. And then a intercooler in front. And also I thought of using then the diesel pump from the vito 638. In Internet I found out that is has bigger 6mm elements inside. I think I need a few weeks to make this project happen. If you want I can tell you my experiences with this project.
Excellent project, I am also building a pump test bench diy, to test the VE bosch pump. The test injectors at what pressure you set them? Thanks for sharing your videos
I mention it in the intro, i think they are popping at 125bars, and i am guessing that the real testbenches got adjustable injectors, my guess. They do run on specially calibration oil and monitered temperature (20C) to give them same results.
@@Foffe2000 sorry but I had escaped, my English is bad, I had subtitles in Italian. In the video you are using diesel or calibration oil 4113 for testing? I'm looking for the calibration sheet of my VE 1460406013 bosch pump, you know where I can find it? Thanks
@@Fredhandyman no straight diesel and even blended with some motor-oil (the jug wasnt clean). The calibration oil is prefered . . from what i heard it doesent smell at all and its safer on you skin and if you woild accidently blast that oil trough your skin and in to your bloodstream it wouldnt cause as much damage as with diesel. I got no sheets on the bosch-pumps whats so ever. Just some exploded views of the actuall pump from some handbooks..
Pressure should be around 175 bar. The nozzles in the test injectors are the most important thing. 12SD12T is a common test nozzle. Also heating the test fluid to around 30-40deg celsius. Feed pressure of around 1 bar Injector test pipes should teally be made from 6mm od x 2mm id steel pipe but if yours is working then sweet. And compression olives are fine for the ends of the pipes if olives are steel. If you dona lot of pump testing and the pipes are getting removed a lot then replacing olives is way quicker than re swaging an end on a pipe, well for me it is. And reswaging/forming and end loses you roughly 13mm of pipe a time.
Sent you an email to see if you built a test bench. Im currently building one in Australia struggling to get all the parts to connect the pump etc and any help would be appreciated have chat about. I wander if this adaptor in this video will fit the VE Type pump. I don't know where to buy any test bench injectors either, think they called 12s? They seem hugely expensive. Anyone got any links to adaptor coupling parts. The bits that connect the ve pump to the electric motor and the mount etc. My pump is DENSO PUMP NO. 21200-1C310. 196000-5290. The spline and keyway on the pump itself is tapered 20mm down to about 16-17mm and the keyway is 4mm. Not as easy as it looks to set one these things up.
And the flange i made in CAD and got a company to cut out for me. But its not more komplex that you cant drill and cut it out of a steel plate yourself.
@@Foffe2000 ok! thanks, have asked some people on what type of cone that you use to make new hard lines. how did you make those? is it a bubble flare or something you can buy to make your own hard lines?
@@alexandernesse4013 i got a flare kit for brake-line and also used brake line for piping (kopper-nickel alloy) you might argue that they might flex a bit but still built to widthstand 200-300bar and if they do flex they flex the same all over (same lenght of the piping) if i remember correctly i used single flare 45degree on a test-piece and it worked, but i still double flared the lines to give more room between the nut and the injectors so those wouldnt risk to bottom out on eachother if the flare would collapse over time.
Its a Siemens Sinamics V20 , and as i commented on your other post. You can use these to transform 230VAC to 400VAC. Just mind the power-rating so you dont overload the frequency inverter.
I am using a 3 phase motor, but they are actually the same as a 1phase. On a one phase you just mount a capacitor in parallell. In this 3kW case a 90uF between W2 and V2 , and then 230VAC on U1 and N on U2. But as i said i used 3phase .. and on top of that the frequency inverter is capable of taking 230VAC on the input and you get 400VAC on the output.
hello Shane, thanks for asking, i am not selling pumps or the pump equipment. If you need a tuned up pump i recomend Dieselmeken in sweden or DPUK in England.
I've always wanted to try building a testing rig myself. Good job man!
nows the time to make one! i dont think it has to be fancy, just being able to check that each cylinder brings the same amount of fuel is what i think the most important part and something you cant figure out when the pump is on the engine. I am going to make a rig to test the phasing of the injection-timing to
Very Very impressive basic pump test bench build, well done on going into the "Mystical dark art's" of Bosch injection pumps.
Cheers from DownUnder.
Hello Glenn, yeah it worked quite well, and theres lots more adjustments i might need to add to the testbench like some way to check timing on each injector, but i got plans on how to build some extra stuff on the exsisting bench there
You are a young man and use your knowledge to help others persons, that God Jehovah bless your life, I will try to do the same work you did, one test bench not only for injector pump, but for governor of the engine Caterpillar 3116. My congratulations to you and thabks for the oportunity.
Good to see you still working on projects. Looks like you brought your home project to work. I guess you could add some kind of magnetic pick up sensor to the coupler and add a tach to your control panel to see if the speed changes. Great project and very well thought out. Being able to check and set flow rates on your own bench will be a huge time and money saver.
Hello Cullen, Yeah "home made" is a stretch, but what i ment is that it isnt "store bought" rather made myself. Its nice to be inside in winter-time. I got an old RPM counter from IFM and a magnetic pickup sensor now so i am going to mount it (permanen or just a mockup i havent decided on yet).
@@Foffe2000 Hey, can I have a blueprint for building this machine? dimension files? Regards
@@ladytigra6167 no i made this one without blueprints. I did have a DWG file for the flange in the front but i cant find that one anymore (if you look down in the comments some others have requested those to)
@@Foffe2000 ok. It's the question from my mate who got ban on YT so he couldn't ask You by himself. I'll tell him what You'd written. Thanks for the answer and best regards for You :).
@@Foffe2000Hello dear, can I contact you? I have a graduate project on this same device. I need some information
Glad to see a new video. Thanks mate
Fitting lights over the measuring tubes could make the readings more visible.
Häftigt bygge !
Jag har också fantiserat om att bygga en testbänk, men jag kom över kvarlevorna av en gammal dieselverkstad. Jag har 2 Bosch testbänkar. Den ena är till salu.
Hi there, I do like this tester design. Really nice done. Do you have the plans for the plasma cut parts?
You are my hero! I just subscribed..your inspiration is awesome! I have om606 engine and bought om603 mechanical fuel pump also DPUK 7,7mm plunjers…so i have same idea to build bench like this and calibrate and phasing myself..congrats bro!i really appreciate it👍👍👍👌
Thanks! about phasing i havent found if that is needed or possible on these pumps? but i guess there could and should be adjusted. I havent built anything to do this yet but adding a little 12V carburetor fuel pump and a degree-wheel on this testrig should do the trick.
?
I am on my way to this 🎉
@@Foffe2000 phasing is done with different size rollers.
Hi, this is terrific what you've accomplished.
Looking forward to more videos on this.
Ross in Maine.
Yeah it turned out good! I am planing on mounting some bigger pump elements on a pump later on
@@Foffe2000 That's exciting ! What size elements do you have? I bought Diesel meken's 7.5 pump building kit from his distributor in Texas a couple years ago and haven't built My 603 pump yet. I've been researching online for a couple years and you are in my opinion the world leader right now in building your own test stand and explaining to us the test information and how to build a stand. Once you get this fully working with a built pump running on your engine smoothly, you are going to be swamped by people who want to have you build their pump. Keep up the good work can't wait to see more videos. PS I was planning on building something similar when I bought my elements and for a constant RPM drive motor I was going to use my VW TDI engine with a PTO on it to drive the pump. Sounds crazy but I'm pretty sure it would work and it would be really cheap since I already have it.
Ross
@@rossconverse7038 i got the 7,7mm DPUK elements, they where the only one´s i know of who sells rebuild kits right now. I am hoping to make a video soon on swaping in those elements and hopefully being able to get it running as it should. Got a summer project where i need a pump that can bring a little bit more fuel than the original. But first i am going to take a break for a couple of weeks
@@Foffe2000 okay thanks for getting back to me, looking forward to future videos on the subject. Do you have a Patreon or PayPal account? I want to make a contribution to your channel.
Ross
@@rossconverse7038 Thanks how kind of you, but i dont take contribution for now, but thanks anyhow Ross
Great job. Great video.
Great video please keep us updated with any updates or improvements to your test bench, I plan to build my own as well having trouble finding info on here this was great👍 one question do you plan on swapping elements in the future or no
Nevermind haha I just past the part that showed you have bought new elements good to hear and good luck with that
I am indonesia and tutorial you best
Freakin' brilliant!
Bravo
Good work my friend.simple and efficient. How many rpm is that electric motor.thanks
It should be a little bit over 2000rpm at 50hz, they got a standard speed. But its all running with a frequency modifyer so i can run it 10% (200rpm) or 200% 4000rpm ..
@@Foffe2000 thanks a lot my friend. I have a washing machine motor but it cannot run at 2000rpm.it need to multiplie the rpm ×3 at least.bye.
Hello, I greet you from Argentina, my name is Sergio, I am a subscriber to your channel, your videos are very good, I need you to help me in the construction of the bench to test pumps, such as the size of the motor and the electronic part, so I will see if I can do it. for my workshop... best regards
I was wondering if people could help me,
I have a 1998 G wagon with an om606 engine but I wanted to get more power somewhere 220-250 PH how is this work possible,
Should I change the electronic IP with a mechanical IP, what changes should I make in the engine since I am a beginner.
Thanks for understanding guys
Hello, do you have the adjustment values for the pump in 7.7.7mm? thanks in advance
Hello greg, i dont understand the question. The 7.7mm elements got the same outer diameter so no adjustments there. When it comes to adjust the amount of fuelt of each element its from pump to pump, if you do any job on the pump where you loosen the adjustment screws you got to adjust them again afterwards and thats what i am doing in this video
Hello, thank you for the answer, in fact I installed the elements as in your video, I still have to adjust the flow, my diesel specialist asks me how much flow to adjust, I thought -off boost 55cm3 -on boost 120cm3 -Max 160cm3 What do you think? at what rpm should we make the flow adjustments.. sorry for my spelling, I am French and I use a translator.. Thanks in advance
Very good
What would happen, if I messure the pressure between a injector and the pump?
Isn,t there a context between the pressure and the amount of diesel is injected in the engine?
I had the idea to make messurement mounts in the injection line with manometer/pressure Gauge. Less diesel should be messuered in low pressure....so my thoughts...
Thank you for your videos.
I dont think that it would work, when the line/injector got the "pop" pressure (130-145 bars) the fuel sprays in to the combustion chamber and this happens both on idle and full load, what differs between full load and idle speed is the amount of fuel delivered but the pop-pressure should be the same and the injector just makes a shattering noise for a longer term of time (opens and closes superfast). i got other videos where i pop-test injectors with a bench device, there you can see how the pressure on the line acts, and just imagine me pulling on the pumphandle faster or slower ..
Yes you are totaly right. I didnt think on that fact, the pressure and time of pressure is important.
But if you could messure the pressure and the time the pressure is lasting would that be enough?
I am thinking of an eletric pressure unit which you are screwing in the injection line before the injector. It messures the time of pressure and pressure in miliseconds like a Oszilloskop or something.
@@kuchenimbart4576 yes that would be possible, there are advices that listens to the piping of a diesel engine by a sensor thats mounted against them, either when is expands due to high pressure of vibration? its used to set the right timing of the pump. i got an old mercedes one bought second hand from some service-shop. Maybe if you make something simular thats hooked up to a oscilloscope? not measuring pressure but rather frequency when the shattering of the injector accure?
Or maybe build a pump like in this video .. if you are going to do adjustments its kinda hard with the pump on the engine anyhow
At the moment I am trying to find every information, how to adjust the amount of diesel on the pump....which part do I have to move to adjust the diesel amount? Could you explane the adjustment work?
I will ask a good friend of mine, he knows much about programming...I thought on a mount which you can screw on top on the injectors and on the messuring device the fuel line. There are pressure sensors which messure the time and pressure.
At the moment I am repairing a Mercedes T1 with om601.
At first I have to bring the car to the technical inspection here in Germany, so that I am allowed to drive for the next 2 years legally.
After this I wanna start a Turbo conversion. There is a om601 turbo in the vito 638. But in the T1 there is no room for the original manifault of the om601 fro m the vito.
So I will make a costoum excaust and set the turbo a little bit behind the motor. The oil I will take it from the oil cooler in line to the turbo. For the turbo I will take take the original 638 turbo with own wastegate Regulation. And then a intercooler in front.
And also I thought of using then the diesel pump from the vito 638. In Internet I found out that is has bigger 6mm elements inside.
I think I need a few weeks to make this project happen. If you want I can tell you my experiences with this project.
Sir how many horsepower of your ac motor?
2,2kw or 3hp depending on wich measurement you use.
It is amazing, can you Tell me te specs of the elétric motor you use?? Hugs from Brazil.
Yes its a 2,2kW or 3hp engine, they commonly have a 24mm shaft. Hugs from Sweden
@@Foffe2000 thanks Very much!!!
Excellent project,
I am also building a pump test bench diy, to test the VE bosch pump.
The test injectors at what pressure you set them? Thanks for sharing your videos
I mention it in the intro, i think they are popping at 125bars, and i am guessing that the real testbenches got adjustable injectors, my guess. They do run on specially calibration oil and monitered temperature (20C) to give them same results.
@@Foffe2000
sorry but I had escaped, my English is bad, I had subtitles in Italian. In the video you are using diesel or calibration oil 4113 for testing? I'm looking for the calibration sheet of my VE 1460406013 bosch pump, you know where I can find it? Thanks
@@Fredhandyman no straight diesel and even blended with some motor-oil (the jug wasnt clean). The calibration oil is prefered . . from what i heard it doesent smell at all and its safer on you skin and if you woild accidently blast that oil trough your skin and in to your bloodstream it wouldnt cause as much damage as with diesel. I got no sheets on the bosch-pumps whats so ever. Just some exploded views of the actuall pump from some handbooks..
Pressure should be around 175 bar.
The nozzles in the test injectors are the most important thing.
12SD12T is a common test nozzle.
Also heating the test fluid to around 30-40deg celsius.
Feed pressure of around 1 bar
Injector test pipes should teally be made from 6mm od x 2mm id steel pipe but if yours is working then sweet. And compression olives are fine for the ends of the pipes if olives are steel. If you dona lot of pump testing and the pipes are getting removed a lot then replacing olives is way quicker than re swaging an end on a pipe, well for me it is. And reswaging/forming and end loses you roughly 13mm of pipe a time.
Sent you an email to see if you built a test bench. Im currently building one in Australia struggling to get all the parts to connect the pump etc and any help would be appreciated have chat about. I wander if this adaptor in this video will fit the VE Type pump. I don't know where to buy any test bench injectors either, think they called 12s? They seem hugely expensive. Anyone got any links to adaptor coupling parts. The bits that connect the ve pump to the electric motor and the mount etc. My pump is DENSO PUMP NO. 21200-1C310. 196000-5290. The spline and keyway on the pump itself is tapered 20mm down to about 16-17mm and the keyway is 4mm. Not as easy as it looks to set one these things up.
love your videos! great to see some diy on these pumps. But what type of flange did you use, and where did you buy the nuts?
The nuts are M12X1.5 , i bought mine from Sagro.se. But i would guess you can buy them from any hydraulic firm
And the flange i made in CAD and got a company to cut out for me. But its not more komplex that you cant drill and cut it out of a steel plate yourself.
Skulle du kunna tänka dig att dela med dig av cad filen på plattan som du bultar pumpen i? Skulle underlätta att slippa rita upp det själv. Mvh
@@Foffe2000 ok! thanks, have asked some people on what type of cone that you use to make new hard lines. how did you make those? is it a bubble flare or something you can buy to make your own hard lines?
@@alexandernesse4013 i got a flare kit for brake-line and also used brake line for piping (kopper-nickel alloy) you might argue that they might flex a bit but still built to widthstand 200-300bar and if they do flex they flex the same all over (same lenght of the piping) if i remember correctly i used single flare 45degree on a test-piece and it worked, but i still double flared the lines to give more room between the nut and the injectors so those wouldnt risk to bottom out on eachother if the flare would collapse over time.
What your brand tipe speed control motor
Its a Siemens Sinamics V20 , and as i commented on your other post. You can use these to transform 230VAC to 400VAC. Just mind the power-rating so you dont overload the frequency inverter.
Alat yg digunakan untuk mempercepat putaran motor sama untuk mrmbalik putaran motor nanya ap??
you will have to write in english or swedish for me to understand
Great video. Inspired to build one! What is used to adjust the speed rotation of the motor called?
Maybe some stainless steal wool inside the top of the tubes will stop the injector turbulance and still let the oil strain to the bottom.
frequency driver ? or just "converter" maybe .. i ended up using a Siemens
@@ForPropertyInvestors yeah good idea
@@Foffe2000 Isa three phase able to be used on 240v 10amp via a converter? I heard single phase would not work on this application!
I just want to do a regular VE diesel pump off 1HZ Toyota Motor!
а почему вращение левое?
Using motor 3phase or 1phase
I am using a 3 phase motor, but they are actually the same as a 1phase. On a one phase you just mount a capacitor in parallell. In this 3kW case a 90uF between W2 and V2 , and then 230VAC on U1 and N on U2. But as i said i used 3phase .. and on top of that the frequency inverter is capable of taking 230VAC on the input and you get 400VAC on the output.
Okay sir your using motor 3phase how many hp for the motor
@@frenzyheavyequipment7396 3hp motor , wouldnt go any smaller, rather bigger like 5hp
coast of this project sir ?
i would recon about 1000 euros .. the frequency-driver being the major investment .. about 600euors for one of those with external-controller added on
Could I buy this from you?
hello Shane, thanks for asking, i am not selling pumps or the pump equipment. If you need a tuned up pump i recomend Dieselmeken in sweden or DPUK in England.
@@Foffe2000 i was referring to the injection pump test stand
@@shanecall Oh, no i need it myself
fränt :)
Ja denna uppfinning vart bra
форсунки тут не нужны....нужно только объем и одинаковый налив...наполнение...