NCT-1500 Common Rail Tester Quick Manual
Contents
1. Fuel Filter Plug 19 Dummy Resister 20 Dummy Injector 21 Compression Gauge 22 Block Tube 23 User s Manual OOANOOaBRWND 1 LOW PRESSURE TEST Nextech 3 DIAGNOSTIC 4 1 DIAGNOSIS PROCEDURE ACCORDING TO SYMPTOM 1 When the engine is not able to start 1 Low Pressure Line Test gt Injector Back Leak Test Static Test gt 3 High Pressure Line Test 2 When the engine is able to start Low Pressure Line Test Injector Back Leak Test Dynamic Test 3 High Pressure Line Test 4 2 LOW PRESSURE FUEL LINE TEST al 1 Remove fuel hose from fuel filter and connect low pressure gauge NCT 1051 or vacuum gauge NCT 1050 according to engine system as shown Additional parts needed tube for gauge connection NCT 1052 Connection adapter with hose NCT 1054 connection adapter NCT 1053 Fuel Filter Plug NCT 1055 2 Start the engine and keep idle approximately 5seconds then turn of the engine Internal suction pump type Bosch Type A engine U engine Vacuum Gauge Vacuum Gauge Test Tube Assay Connection Adapter d Internal suction pump type Bosch Type CASE VACUUM JUDGMENT 10 20 cmHg System normal good condition D 20 60 cmHg Filter or fuel line clogging pump in good condition 0 10 cmHg E leak in to the system or Suction pump amage 1 LOW PRESSURE TEST Nextech Electric pump type Bosch Type Il Pressure Gauge Low Pressure Gau2. above 200 excessive back leak agn E i rail pressure sensor ES O 1000 O 200 HP Pump below 1000 below 200 Insufficient pressure 500 1000 500 1000 1500 1500 1800 DELPHI HI z HI BOSOH bar BOSOH BOSOH Dal 1 ALE r t l r kg CHP 1 SOALE 100 bar gt S D Sensor abnormal Low Normal pressure High pressure Pump 2 INJECTOR BACK LEAK TEST DYNAMIC 4 4 INJECTOR BACK LEAK TEST DYNAMIC 1 Remove the return hose from each injector and Install injector return hose adapter NCT 1032 visible tubes NCT 1032 flasks NCT 1030 and injector return hose plug NCT 1033 referring to Injector back leak test STATIC in previous page 2 Conduct the high pressure leak test referring to following explanation BOSCH Type II Ill D3EA 1 5D ENG D4EA 2 0D ENG D4FA U ENG D4CB 2 5A ENG 3 Start engine 3 minutes at idle accelerate engine up to 2500 rpm and keep the 2500rpm for 30sec 3000rpm 2 minutes Stop Engine after 2 minutes 4 When the test is completed measure the amount of fuel in each flask NCT 1030 Start 1min stop 5 Judgments BOSCH Type Il Ill Replace the injector which is shown more 3 times than the minimum value Normal condition 2 Injector abnormal sae emin TL LIL Stop Idle acceleration 1 2 3 4 1 2 3 4 DELPHI J3 2 9L 3 Connect the Hi Scan and select the High Pressure Leak Test mode 4 Conduct the High Pressure L
3. connector and connect the PRV connector and battery lead wire to the battery for the test And then turn on the power switch so that High pressure Pump pressure control valve will block fuel return from rail 5 Crank the engine for 5 6 seconds For the accuracy of the test perform the test twice and select the higher pressure one as a measured value 6 Judgment If the fuel pressure indicated on the gauge is within the range of specification the high pressure pump is normal But if not DELPHI check the below items before the High pressure pump replaced System High pressure sensor NOTE The buzzer will be ringing and changed the color of bulb after Sminuts of each test for the safety reasons to prevent over heating and battery discharged 0 5 minutes Maximum currant supply to the PRV 5o0rover Low regulated currant are supply to the PRV buzzer ringing Pressure Valve Connector High pressure Pump Current 0 5 10 Minute 3 HIGH PRESSURE TEST Nextech 4 5 HIGH PRESSURE PUMP TEST b If fuel pressure is lower than specification test it again when coolant temperature is below 30 C The pump is in normal condition if the pressure restores to normal range c In case of the system in which pressure control valve implemented check the valve condition amp internal leak and replace them if necessary Refer to 4 6 pressure control valve test procedure If fuel pressure indicated on the gauge is lower tha
4. NCT 1500 Common Rail Tester Quick Manual Nextech 1 GENERAL This Tester has been developed to diagnose efficiently and accurately for diesel vehicles with common rail system 1 1 Criteria of diagnosis using Common Rail Tester Impossible to start engine or engine stall while driving x It would be recommended performing Power Balance Test by Scanners for Bosch system or by disconnecting injector s connecter one by one for Delphi system if vehicle has problem beside the above symptoms such as engine vibration or emission of black white smoke while engine idle The problem may be due to differences of the injected amount in each injector 1 2 Notice A CRDi system has been constructed using precision made components If an extremely small foreign particle enters the system during service it may cause sticking or clogging of injectors Therefore be sure to eliminate any dust or contaminated deposits on or around the engine and fuel lines during service 2 COMPONENTS ew a Ope a a a M12mm M14mm Tool Case Plug for Delphi Plug for Bosch Flask amp Holder Injector return hose adapter Injector return hose plug Flushing Tube Dust Cap High pressure gauge set 10 Adapter connector for Delphi old 11 Adapter connector for Delphi new 12 Adapter connector for Bosch 13 Vacuum Gauge 14 Low pressure gauge 15 Gauge connection tube 16 Connection Adapter 17 Connection adapter with hose 18
5. eak Test untill the Hi Scan finish the test automatically or manualy Start engine 2minutes at idle 3 times acceleration Stop Engine 5 For the accuracy of the test perform the test more than twice and select the largest amount as a measured value x The flasks NCT 1030 should be empty before the 2nd test started 6 Judgments DELPHI Replace the injector which indicates exceeds 25cc Service Limit 25cc Abnormal D 3 4 injector 3 HIGH PRESSURE TEST Nextech 4 5 HIGH PRESSURE PUMP TEST Purpose of the test Inspection for mechanical capability of the High pressure pump Maximum pressure check BOSCH l l System Method Check the pumping capability of the high pressure pump by actuating pump after blocking rail s outlets using the plug and regulator Plug Blocking the rail circuit Regulator Valve Preventing over pressure of high pressure line 1 Clean the regulator valve regulator valve adaptor and plugs with diesel fuel 2 Remove all 4 fuel injector pipes from the common rail and disconnect the rail pressure sensor s connector Dummy Resister 3 Install the regulator valve plugs dust caps adapter connector and High pressure gauge to the common rail securely as shown x Be sure that the regulator valve and the plugs NCT 1020 or NCT 1021 have installed securely so that there will not be any fuel leakage Delphi Bosch Type A engine U engine 4 Disconnect Pressure Control Valve
6. ge Test Tube Assay Connection Adapter Connection Adapter with Hose Hose Clamp Fuel pump Electric Internal suction pump type Delphi CO E Vacuum Gauge ES Test Tube Assay Connection Adapter E Fuel Fitter Plug Electric pump type BOSCH Type EURO model si PRESSURE bar JUDGMENT a 1 5 3 5 kg cm System normal normal ga 0 1 5 kg cm Fuel Filter or fuel line strainer clogging Abnormal function of fuel pump EURO IV model rA PRESSURE bar JUDGMENT EE 2 5 5 kg cm System normal normal B 0 5 2 0 kg m Filter or fuel line clogging pump in good condition 3 nopressure Abnormal function of fuel pump Internal suction pump type Delphi CASE VACUUM JUDGMENT 10 20 cmHg System normal good condition D 20 60 cmHg Filter or fuel line clogging pump in good condition Air leak in to the system or Suction pum 0 10cmHg damage y paa 1 LOW PRESSURE TEST Nextech 4 3 INJECTOR BACK LEAK TEST STATIC SERVICE SPEC 1 Remove the return hose from each injector and Install injector return hose adapter aa j High pressure Above 700 bar with normal Back Leak condition visible tubes and connect the visible tube s end to the flasks i _ 2 Disconnect A point on the fuel return hose in below photograph and block the fuel return hose x Exceeding back leak can cause insufficient high pressure in the direction of the high pressure p
7. n specification there may be a problem in the rail pressure sensor or its circuit even fuel flows out from the regulator valve NCT 1020 Specification of high pressure of common rail BOSCH System 1000 1500 bars DELPHI System 1050 1600 bars 4 PRESSURE CONTROL VALVE TEST Nextech 4 6 PRESSURE CONTROL VALVE TEST 1 Remove fuel return connector from PCV upper BOSCH 2 Remove fuel return hose from PCV lower Se Rail Plug 3 Disconnect Pressure Control Valve connector and connect S N the High Pressure Gauge NCT 1040 to the Pressure Control Valve and then connect the High Pressure Gauge NCT 1040 s lead to battery so that pressure control valve will block fuel return from rail 4 Put fuel return pipes to flasks NCT 1030 5 Crank the engine for 5 seconds ea 6 Check fuel return amount x Service Limit Less than 10cc 5second Fuel pressure must over 1000 bars Dummy Resister High pressure Pump Fuel pipe end Air gun nozzle 1 Before connecting the fuel pipes to the engine be sure that all the pipe outlet surfaces inner passages and especially fuel pipe fitting nuts are clean Clean using air gun if necessary 2 Assemble all fuel pipes except the fuel pipe fitting nuts of injector side 3 Temporarily tighten the fuel pipe fitting nuts to injectors by hand after aligning the nuts to the injectors 4 To prevent contamination on engine room wrap up around the injector pipe using pape
8. r towel or shop rag as shown 5 Crank the engine 2 to 3 times for 5 to 6 seconds to flow out the fuel contamination from injector connection area 6 Tighten the nuts with specified torque using special tool 7 Erase the DTC code by Scanner Loosen the nuts Tighten the nut 5 CYLINDER COMPRESSION TEST Nextech Cylinder compression comparison Test Purpose of this test is to perform the compression comparison test for each cylinder to determine the abnormal cylinders You can perform the test quickly and easily 1 Remove the injectors from the engine and install the dummy injectors to prevent oil spill in to the cylinders during test 2 Select the correct groove for engine type to install the dummy injectors 3 Using the quick coupling on the dummy injectors you can do the compression test easily and fast X Select the correct groove for engine type to install the dummy x Using the quick coupling on the dummy injectors Injectors _ E me you can do the compression test easily and fast Groove
9. ump with injector return hose plug Back Leak Less than 3 5 times than minimum amount injector 3 Connect the adapter connector to rail pressure sensor and connect high pressure gauge as shown 4 Disconnect the injector connectors to prevent its operating eer iil a ie is failed ti Delphi Bosch Type Fuel Leak rail plug or pipes connection 5 for A engine Remove the Inlet Metering Valve connector to allow fuel feeding to high pressure line PRV leakage or damaged Bosch Type l Fuel line clogging filter 6 Disconnect the Pressure Control Valve connector and connect the power line on High Pressure HP pump leakage or damaged Gauge to the Pressure Regulator Valve and then connect High Pressure Gauge s lead to battery so that pressure control valve will block fuel return from rail 7 Crank the engine once for 5 6 seconds x Cranking engine about 10second build pressure test again if pressure are not reach to maximum pressure x Cranking RPM must exceed 200 RPM x Perform the test under 30 C with coolant temperature If the fuel pressure test performed over30 the fuel pressure indicated may be different according to fuel viscosity change 8 Read the pressure from high pressure gauge and measure the amount of fuel contained at each visible tube 9 Judgment CASE PRESSRUE BACK LEAK JUDGEMENT es 1000 1800 0 200mm sore above 1000 below 200 D O 1000 200 400 Faulty injector f Adapters for below 1000
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