A vital part of the engine is the fuel line, which includes components like the fuel pump and the fuel injector. As owners of medium- and high-speed engines becomes more alert to emission control, fuel consumption and engine performance, fuel injector testing becomes an increasingly important part of their solution. IOP Marine is continuously working to develop the best equipment for testing and calibrating these components.

New fuel injector test equipment for mid- and high-speed engines

Medium-Speed Test Solutions

High-Speed Test Solutions

Solutions for Wärtsilä, MaK, MAN Diesel etc.

Solutions for Caterpillar, MTU, Deutz, Yanmar etc.

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Summer 2009

IOP Marine has been the world leader in fuel injector test equip-ment and hydraulic powerpacks for onboard, power-plant and workshop use since 1969.

NEWS

Complete replacement of 12 injectors *1500 €/injector = 18.000 € spent every 12.000 hours

Extended to 18.000 hours will save 1 out of 3 overhauls = 18.000 € saved every 36.000 hours (4 years)

“We are testing all of our high speed fuel injectors ourselves. Of course we save time and

money from this, but more important; we are not depending on anyone outside our facility”.

Carsten Hansen Royal Danish Navy Workshop

Reduce maintenance cost – example: Caterpillar 3612

Replacements of fuel injectors are recommended every 12.000 running hours, but why replace perfectly working injectors? Experience shows, that injectors tested after 12.000 hours, can be reinserted, if performing good.

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Upon request from several customers of IOP Marine we have developed a new fuel injector test rig for Caterpillar engines, which can save time, money and grant the owners the freedom of being more independent.

Caterpillar 3600 fuel injectors are recommended to be checked after 6000 running hours and replaced with overhauled/new injectors after 12000 running hours. The manual states “factory calibration only”, but to verify if the injector needs calibration, owners have hardly any option than contacting a Caterpillar workshop.

The new VPU 1500 C will enable our customers to verify the performance of the injectors and thereby save the trouble of sending well-working fuel injectors for service. Now an engineer can easily take all the injectors from a Caterpillar engine, put them in VPU 1500 C test rig, and within minutes determine if all are working to perfection, or if one / several are failing to perform at its optimum.

It’s more than just a fuel injector tester!Since the unit uses hydraulic oil under high pressure as test medium, the actual test also works as a cleaning process. Impurities in fuel spray holes are often removed simply by performing a couple of spray test. Under all circumstances the injector will be in a better shape when reinserted in the engine after tested with the VPU 1500 C.

Doubles as a high-performance powerpackDue to its pneumatically powered high pressure pump, it can also be used as a fast automatic hydraulic power unit. With this unit there will be no more hydraulic jacks to be pumped up by hand. The process of operating hydraulic tools will be faster, easier and more accurate.

Contact IOP Marine for a custom solution matching your main and auxiliary engines.

On-board solution for test of Caterpillar fuel injectorsSolutions also available for engines from Deutz, MTU, Daihatsu, Yanmar and others.

All test rigs are supplied with a closed spray chamber, which, with an integrated air purifier (optional), prevent emission of aerosols to the

working area. Healthier for the operator & the environment – and no more oil-slippery floors!

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Optimal power output requires optimal fuel injector performance. New technology verifies that your fuel injectors perform as expected and makes it possible to calibrate them far more accurately, resulting in improved engine performance, less cleaning during maintenance and reduced emissions.

A well-performing injector equals correct fuel atomization, non-leaking nozzles, less engine fouling, best possible fuel economy and increased injector lifetime.

Engine designers now recommends air-powered test rigsTraditionally, test equipment for medium speed engine fuel injectors has been powered by hand. This is not only a tedious process, it also makes it difficult to verify the actual properties of the injector, as the supplied pressure is vary-ing at all times and it’s virtually impossible to test injectors and inspect their spray pattern, when the opening pressure exceeds 400 bar.

As early as 2003 MAN Diesel started to recommend IOP Marine pneumatic fuel injector tester for their range of 4-stroke engines in addition to their recommendation since many years for their 2-stroke engines. Around 2005 Wärtsilä asked for development of a similar solution for their fuel injectors. The resulting VPU 900 solution will with time com-pletely replace hand pump technology. A similar scenario took place at Rolls Royce in 2007, and also here the IOP solution is today recommended instead of the traditional hand-pump.

Accurate and fast An air-powered VPU unit from IOP secures fast and very pre-cise adjustment opening pressure adjustment, best possible seal and nozzle-leak testing and a chance to perform con-tinuous openings for spray pattern inspection. The optional multi-valve holder makes sure that one test unit can be used for multiple types of injectors and safety valves.

Opening Pressure test

Perform basic opening pressure test ✓ ✓Precise control of pressure build-up ✗ ✓Adjust opening pressure during active testing ✗ ✓

Secure identical opening pressure for all injectors ✗ ✓

Nozzle Leakage test:

Perform basic nozzle leakage test (✓) ✓Maintain set pressure during visual inspection ✗ ✓

Spray Pattern / Atomising test

Perform basic spray pattern test (✓) ✓Continous openings ✗ ✓High-pressure spray test ✗ ✓Environmental features

Closed test Chamber for better working environment ✗ ✓

Ready for integrated air purifier ✗ ✓Extended usage

Double as air-powered hydraulic powerpack ✗ ✓

Test of multiple injectors ✗ ✓Test of safety valves ✗ ✓

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Comparison – hand- vs. air-powered test solutions

Better 4-stroke engine injector testing with air-powered test rigsSolutions available for mechanical & electronic injectors from most 4-stroke engines.

Contact us for a test rig quote matching your installation – contact@iopmarine.dk

VPU 1500-2 – Test Rig and PowerPackOutput pressure 0-1500 bar

Hydraulic flow Up to 0,55 l/min

Tank capacity 4 l

Hydraulic gauge 1600 bar scale, class 1.0, analogue Ø160

Air inlet ¼” x Ø8

Liquid outlet ¼“ BSP Female (ISO-228-1-G ¼”)

Weight (excl. holder & oil) 16 kg

Dimensions ( L x W x H ) 432 x 250 x 425 mm (excl. injector holder)

VPU 900-2 – Test Rig onlyOutput pressure 0-900 bar

Hydraulic Flow 0,45 l/min

Tank capacity 4 l

Hydraulic gauge 1000 bar scale, class 1.0, analogue Ø100

Air inlet ¼” x Ø8

Liquid outlet ¼“ BSP Female (ISO-228-1-G ¼”)

Weight (excl. holder & oil) 8 kg

Dimensions (L x W x H) 432 x 213 x 398 mm (excl. injector holder)

IOP MARINE A/SEngager 7 DK-2605 Brøndby Denmark Tel +45 44 98 38 33 Fax +45 44 98 11 25 contact@iopmarine.dk www.iopmarine.dk

4 l tank

The IOP Marine 4-stroke engine test solution Connect VPU to injector or

hydraulic tools

High-pressure valve for better

execution of spray tests

(optional)

Locking injector in place for quick

adjustment

Attach air purification system (optional)

Closed test chamber for a better working

environment

Flexible hose for flexible positioning

High-precision Class 1 gauge

Pump supplying continous high pressure

Precise pressure adjustment with option to pre-set opening pressure

Multi-valve holder for injectors and safety valves

Powered by air

Optional AccessoriesSingle- & multi-valve holders, integrated air purifier, CEJN hoses & couplings, injector dis-/re-assembly tools and more.