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2.1 Introducing IOP SafeTest Technology and the Program Switch The VPUD 1000-4 was introduced in 2009 and features a new generation of the electronic control
system. The new system features an enhanced version of the IOP SafeTest Technology (Patented)
and data collection system introduced in 2004, with 10+ updates to the digital display per second as
well as a new program selector.
The program selector controls the operation of the unit, and with a specific program selected, the
unit will behave in a specific way, in order to make it even easier
In Prefill mode, it is ensured that pressure cannot exceed 200 bar. No value will be logged.
In the Opening Pressure mode, it is ensured that the unit will stop when an opening of the fuel
injector nozzle takes place and the measured pressure is logged on the lower display.
In the Nozzle Leakage Test mode, it is ensured that the unit will stop if an opening of the fuel
injector takes place. In addition data from the Opening Pressure Test are available during
Nozzle Leakage test, so it is easy to see which value one should stay below.
In Venting / Non-return Valve Test mode, pressure build-up will be terminated before 200
bar and then the sudden pressure drop happening when the non-return valve inside the injector
opens, will be detected.
In O-Ring Sealing Test mode, pressure build-up will be terminated automatically around 100
bar. No data will be logged.
2.2 Start-up preparations (new units / units where oil tank has run empty): Fill tank with hydraulic oil (viscosity 7-10 cSt at 50ºC) through the filler cap (11) in the right side
of the top panel. The tank will hold 6 litres.
Connect compressed air is to the stud marked “AIR INLET” (9) on the right side of the
cabinet.
To avoid contamination of the pump, it is essential that an effective air filter and water separator
are inserted in the air line. A lubro unit should however be avoided - see lubrication instruction in
section 6
Open the Pressure Relief Valve (2) by turning anti-clockwise
The Pressure Control Valve (3) is opened by turning the handle clockwise until the gauge
indicates approx. 2 bar
Pumping of fuel oil through the whole system is now done for about one minute to make sure that
no entrapped air is found in the unit. This pumping is only necessary to repeat, if the oil tank runs
empty.
Turn Pressure Control Valve (3) counter-clockwise to switch off air supply
Open Pressure Relief Valve (2) by turning counter-clockwise
3. Operation instructions The VPUD 1000 (patented worldwide) ensures correct testing of MAN Diesel slide fuel valves.
The below procedure for fuel-valve testing is in compliance with the MAN Diesel A/S’ guidelines
for testing of fuel-injection valves. Please refer to the engine manufacturers manual for general fuel
valve maintenance as well as possible derivations from the below procedure. All numbers in the
text refers to numbers found on the VPUD 1000 front panel. If the test unit runs out of hydraulic oil
during testing, please consult section 2 of this manual.
Connection of the fuel injector to the VPUD test unit: Make sure that section 2.2 has been completed before testing first injector. Then fit the MAN Diesel
2-stroke engine fuel injector into the valve holder. Note that MAN Diesel injectors must have leak
hole facing forward and many are to be tightened with MAN Diesel spring-houses fitted. The fuel
injector is connected to the pump unit through the stud marked “FUEL OUTLET” (10) found on the
left side of the cabinet. The fuel injector is connected to the test unit by means of a flexible high-
pressure-hose. The test unit is now ready for use.
Program A: Prefill injector Before testing, the slide-valve fuel injector must be completely filled with test-oil:
Switch knob (5) to position PREFILL
Close pressure relief valve (2) by turning clockwise
Turn pressure control valve (3) clockwise, until the CURRENT OUTPUT PRESSURE
display (7) shows a pressure above zero*
The valve is now filled with oil. When clear oil without air-bubbles tickles from the venting
hole through the breathing-pipe, the valve is full
Turn pressure control valve (3) counter-clockwise to switch off air supply
Open pressure relief valve (2) by turning counter-clockwise * Note: The unit will not be able to pass 200 bar in position PREFILL. The IOP SafeTest Technology may be activated
during this process if pressure increases too much. If activated, the pump will stop operating. Complete the described
procedure and press RESET to restart the PREFILL program.
Program B: Opening Pressure Test
Switch knob (5) to OPENING PRESSURE position.
Close pressure relief valve (2)
Adjust pressure control valve (3) until until opening pressure is reached and the injector sprays
once in the test chamber. The measured opening pressure is shown on the lower part of the
digital display (7). The pump stops automatically
Close pressure control valve (3) – turn it counter-clockwise
Open pressure relief valve (2) – turn it counter-clockwise
Evaluate measured pressure – it should be lie within the range 320 and 380 bar (350 bar +/-