EUS-NT800

EUI/EUP TESTER
USER’S MANUAL
(EUS-NT800）
V2.3

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Table of Contents

1 Preface...................................................................................................................................1
1.1 Symbols...........................................................................................................................1
2 General Introduction..........................................................................................................1
2.1 Function...........................................................................................................................1
3 Introduction for Assembly............................................................................................... 3
3.1 Mechanical Assembly....................................................................................................3
3.1.1 EUP Setup................................................................................................................3
3.1.2 EUI Setup................................................................................................................. 4
3.1.3 CamBox Assembly..................................................................................................4
3.1.4 EUP Adapters.......................................................................................................... 6
3.1.5 EUI Adapters............................................................................................................7
3.2 EU-800 Controller.......................................................................................................... 9
3.3 System Components List............................................................................................11
4 Installation..........................................................................................................................12
4.1 Installation of Cambox.............................................................................................12
4.2 Setup EUP.................................................................................................................13
4.3 Setup EUI.................................................................................................................. 16
5. EU-800 Controller Operation........................................................................................19
5.1 Preparation................................................................................................................... 19
5.2 Edit Injection Parameters without Fuel Injection.....................................................19
5.3 Edit Injection Parameters with Fuel Injection...............................................................
6. Handling.............................................................................................................................19
7. Safety..................................................................................................................................20
8 Additional Information.................................................................................................... 20
8.1 Specifications of controller EU-1001........................................................................ 20
8.2 Warranty........................................................................................................................21

EUS-800EUI/EUP Tester i
This USER’S MANUAL allows you to exploit all the functions of the tester. We strongly
suggest you to read this manual with attention before using the tester, and retain it for
future reference.

1 Preface

1.1 Symbols
The following symbols are used throughout this manual. Safety warnings must be
strictly observed during operation.

Caution: Cautions describe conditions, activities,

operations which could result in danger.

Note: Notes provide important supplementary information.

2 General Introduction

2.1 Function
The EUS-800 repair tester is designed to perform repair tests for different type of
Electronic Unit Injectors (EUI) and Electronic Unit Pumps (EUP). The tester consists
of a mechanical cambox with specified EUP adapter kits, EUI adapter kits and an
electronic controller. The cambox will be driven by a conventional test bench for high
pressure fuel injection pumps.
An EUP or EUI is installed in the cambox, CB-1000, with respective adapt kits. A
speed sensor on the cambox feeds the synchronization signal to the electronic
controller EU-800, which provides signal to drive the EUI/EUP solenoid synchronous
with camshaft rotation. The EUP high-pressure fuel outlet is connected through high
pressure fuel line to an injector. The fuel injection quantities of an EUP/EUI can be
checked at given speeds and loads to judge its quality. And the atomization of injector
can also be checked through this tester.
The design features are as following:
 Build-in speed sensor in the cambox to synchronize fuel injection control
 Provide three types of solenoid driving signals, 24V for EUI/EUPs, which need low
voltage drive; 80V for Caterpillar EUIs, which need high voltage drive; and
Cummins Celect EUIs, which need special timing control.
 Angle of beginning of injection (BOI) and pulse width (PW), both in terms of crank
angles, of solenoid driving signal are user adjustable.
 Maximum limit of injection pulse width in terms of time is used to prevent
excessive long pulse width to damage EUP/EUI solenoid.

EUS-NT800 EUI/EUP Tester 1

 Modulated driving signal to ensure the safety of EUP/EUI solenoid.

EUS-800 with an EUI EUS-800 with an EUP

(a) (b)

EU-NT800 Controller
(c)
Figure 1

2 EUS-NT800 EUI/EUP Tester

3 Introduction for Assembly

3.1 Mechanical Assembly

3.1.1 EUP Setup

Figure Mercedes Benz OM-460/457 EUP installed

EUS-NT800 EUI/EUP Tester 3

3.1.2 EUI Setup

Figure 3 Detroit Diesel Series 60 N3 EUI installed

3.1.3 CamBox Assembly

The main design parameters of cambox CB-1000 are listed in the table below.
Maximum
Cam Lift Timing
Item Cam Speed Cam Lobe Lubrication
mm Sensor
rpm
Dat Constant Magnet-
18.5, 16, 13, 10 1500 Oil in Cambox
a Velocity Electric

Figure 4 is the project view of the cambox, and the Figure 5 is the drawing of the
cambox with profile dimensions.
Item Dimension
Thread on the end of the Camshaft M24×1.5
Camshaft end taper 1:5
Installation height, (from the centre of the 125mm
camshaft to the bottom surface)
Width of center notch 20mm

4 EUS-NT800 EUI/EUP Tester

 Dowel Pin

O-Ring

Oil Filling Screw

Oil Drain Screw

Timing Sensor

Figure 4 The project view of the cambox, CB-1000

Figure 5 Profile drawing of the cambox, CB-1000.

EUS-NT800 EUI/EUP Tester 5

 Figure 6 Explosive drawing of the cambox, CB-1000.

3.1.4 EUP Adapters

The table below lists the EUP adapter kits available now
Part
EUP Model
Number
900900 Deutz 1013
900940 Mack, Renault, DAF, KHD, Deutz 2015
DDC/MTU S2000
900920
Mercedes Benz OM460/OM457/MBE4000, Mercedes Actros
900930 Mercedes Benz OM900/MBE900, Mercedes Stego

Figure 7 EUP adapter kits/cap

6 EUS-NT800 EUI/EUP Tester

3.1.5 EUI Adapters
The EUI general adapter kits on Figure7:

Figure 8 EUI adapter kits

The available model specific adapter kits of the EUS-800 test fixture cover most
commercial EUI models made by all manufacturers and all vehicle/engine
applications, such as Bosch, CAT, Cummins, DDC, Delphi, Mercedes Benz, Volvo,
Scania, Iveco, etal. Customer may refer the product matrix table to choose the
required adapters and the matching camshafts.

EUS-NT800 EUI/EUP Tester 7

 Product Matrix Table
The chart below defines the necessary components to test target EUI/EUPs
EUI
Mounting
EU-1001 Cambox
EUI/ Vehicle/Engine Controller assembly Base and Camshaft Camshaft Camshaft Camshaft Adapting
Pillar P/N: P/N: P/N: P/N:
EUP Manufacturers P/N: P/N: Assembly 900628 900631 900633 900635 Kits P/N
721001 900695
P/N:
900696
EUI Detroit Diesel     900750
Series 50/60 N2
Detroit Diesel    
EUI 900757
Series 60 N3
Cummins
EUI L10, M11     900765
Celect, LSM
EUI Cummins N14     900785
Celect
Caterpillar
EUI 3196/3176A/     901700
3176B
Caterpillar
EUI 3176C/,     901710
C10/C12
EUI DDC92     901800
EUI Caterpillar     901720
3406E, C15
EUI Delphi A3, E1     901730
Volvo 420-460
EUI Iveco Cursor 8     901740
Iveco Cursor 10/13
Iveco Stralis
Volvo D12A,
EUI D12C,
    901750
Bosch EUI for
Volvo 420-460
Scania    
EUI 901760
DC/DSC
EUI Audi/VW Seat,     901770
Skoda
EUI Land Rover     901780
EUI John Deer     901790
EUI CAT3500     902350
MUI CAT3500     902360
DDC/MTU S2000,
EUP Mercedes Benz     900920
Actros, MBE4000
Mercedes Benz
OM900/MBE900,
EUP
Mercedes Axor,
   900930
Atego, Econic
Mack, Renault DAF,
EUP Deutz 2015
   900940

EUP Deutz 1013    900900

8 EUS-NT800 EUI/EUP Tester

3.2 EU-NT800 Controller
Front Panel

Figure 9 EU-NT800 Controller front panel

The following items are on the front panel.
 LCD display unit
 Six-button mini key pad
LCD screens
 Welcome screen

The welcome screen show on the LCD once turned on the AC power of the EU-1001
controller.
The LCD screen displays the operational mode, status and driving signal settings for
the injectors being tested.
 Initial screen after AC power turned on.

 Fuel injection Active

 Parameters
 “OFF” or “ON”：injection status
 “COM HV” , “COM LV” or "CUMMINS"：injector type,
 “PW=”：Pulse Width, in terms of crankshaft degree, range 000~100, default value is 010.
 “BOI=”：Begin of Injection, in terms of crankshaft degree, ranges 000~100, default value
is 000.

EUS-NT800 EUI/EUP Tester 9

Mini key pad

Figure 10 6-key mini key pad

 < INJ>
Start or stop injection.
 < TYP >
 Select injector type. Push < TYP > to choose three injector types, “COM HV” for
80V drive, “COM LV” for 24V drive, or "CUMMINS" for Cummins Celect EUIs
 < PW >
Move cursor on LCD screen to “PW=”, to set the value of pulse width
 < BOI >
Move cursor on LCD screen to “BOI=”, to set the value of Begin of injection
 <+>
Increase the value of the parameter with cursor, step is 1 degree.
 <->
Decrease the value of the parameter with cursor, step is 1 degree.

10 EUS-NT800 EUI/EUP Tester

Back Panel

Figure 11 Back panel of EU-800 Controller

The following items are on the back panel.
 AC Power supply switch/socket/fuse pack
 Safety ground terminal. A grounding wire must be used to connect the EU-1001
case to test bench.
 Harnesses socket

3.3 System Components List

Check immediately after the shipping package being opened to ensure the contents
agree with the packing list. If any items are missing, contact after-sale service for
assistance. The follows are the typical items in a EUS-1001 package.
Components for EUP/EUI Tester
 EUS-800 Components Including :
Part Products
Description Qty
Number Model
EU-1001 EUI/EUP Controller 1
900695 CB–1000 Cambox Assembly 1
900696 EUI Adapter Kits 1
Model Specific EUI Adapter kits
Model Specific EUP Adapter Kits
721050 User’s operational Manual 1

EUS-NT800 EUI/EUP Tester 11

4 Installation

4.1 Change Camshaft

1. Remove EUI\EUP Adapter installed on Cambox, discharge oil by loose the oil
plug.(12-1)
2. Uninstall the Front Cover Plate and the Back Cover Plate.(12-2)
3. Knock the tail of Camshaft by wooden hammer，remove the Camshaft from the
Cambox.(12-3)
4. Mount the desired Camshaft into the Cambox, (12-4) knock the thread end of the
Camshaft by wooden hammer, till the Camshaft fit the holes tightly.(12-5)
5. Install the Back Cover Plate on the cambox, the tighten torque of the M8 nut is
38±2N·m.(12-5)
6. Install the Front Cover Plate on the cambox, the tighten torque of the M8 nut is
38±2N·m.(12-6)
7. Tighten the oil plug.(12-7). Fill up lubrication oil from the top opening into the
camshaft chamber.

12-1 12-2

12-3
Disassemble

12 EUS-NT800 EUI/EUP Tester

 12-4 12-5

12-6 12-7
Assemble
Figure 12 Change Camshaft

4.2 Installation of Cambox

1. The cambox should be installed on a diesel fuel injection test bench with
installation height 125mm and the width of the platform center slot 20mm.
2. Put a matching coupling flange with 5:1 conical bore to the camshaft end and then
the M24X1.5 nut with a washer. The tighten torque of the M24 nut is 195±5N·m.
3. After the shaft coupling flange is mounted, adjust the cambox’s location to engage
the main driving shaft coupling flange of the test bench.
4. Tighten two M12 anchor bolts of the cambox to the bench platform with torque
80±5Nm.

4.3 Setup EUP

Procedure of EUP Installation

1. Install the cambox on the test bench platform.
2. Fill up lubrication oil into the camshaft camber.

EUS-NT800 EUI/EUP Tester 13

 Figure 13 Installation of EUP adapter

3. Install the EUP adapter, item 3 on Figure 12, on the cambox.

a) Rotate camshaft to set the lowest point of the cam lobe on the up position.
b) Put the O-ring (P/N 900709) on the cambox top circular slot.
c) Insert the EUP adapter into the bore of the cambox, aligned it with the dowel
pin position on the cambox top surface.
d) Tighten four M10 bolts, item 2 on Figure 12, with torque 65±5N·m.

Figure 14 Installation of EUP

4. Install EUP into the fixture
a) Apply Vaseline on the O-Rings on the EUP body

14 EUS-NT800 EUI/EUP Tester

 b) Insert the EUP into the adapter bore
c) Tighten the EUP with the two M10 bolts, items 1 on Figure 13, to the cambox.
The tighten torque is 65±5N·m.

Figure 15 Installation of low pressure fuel supply and return hoses

5. Installation of low pressure fuel supply and return hoses

a) Using the M14 × 1.5 hollow bolt, and hose with matching banjo fitting and
copper washers on both sides of the banjo fitting to connect fuel inlet port on
the test bench. The tighten torque of the hollow bolt is 35±3N·m. The supply
pressure of the test fuel should be less than 0.2MPa. There must be a fuel
filter before the fuel inlet port. The filter specification is 5μm.
b) Using the M14×1.5 hollow bolt pressure relief valve, and hose with matching
banjo fitting and copper washers on both sides of the banjo fitting to connect
fuel return port on the test bench. The tighten torque of the hollow bolt is
35±3N·m.
6. Install fuel injector line.
a) Finger tight the end nut of fuel line to the M14 port on the top of the EUP
b) Using torque wrench to tighten the end nuts to 30N·m for both injector and the
EUP
7. Using the harnesses to connect EUP solenoid terminals and the speed sensor
socket to the EU-800controller.
8. Turn on the power of the EU-1001 controller
9. Run the test bench and check fuel leakage of the EUP test fixture.
10. May need to bleed the trapped air in the fuel circuit.
Disassemble EUP Setup
1. Turn off the power of the test bench.
2. Turn off the power of the EU-800 controller, disconnect the harnesses
3. Loose the hollow bolts and remove the low pressure fuel hoses from the EUP
adapter.
4. Loose the end nut of high-pressure fuel line at the injector and remove the other
end nut on EUP.
5. Loose the two M10 bolts to hold the EUP, pull out the EUP.

EUS-NT800 EUI/EUP Tester 15

6. Loose the four M10 bolt to hold the EUP adapter, pull out the EUP adapter from
the cambox.
7. Loose the two anchor bolts, disengage the cambox from the test bench coupling.
8. Upon the oil quality, may need to drain the oil in the cambox through the oil drain
port.
9. Clean all the parts, put them in a dry clean place.

4.4 Setup EUI

Procedure of EUI Installation

1. Install the cambox on the test bench.
2. Loose the oil filling plug on the side of the cambox to fill up lubrication oil into the
camshaft camber. After oil fill-up, tighten the plug.

Figure 16 Install the EUI general adapter on the cambox

3. Install the EUI general adapter kits, item 2 on Figure 16, on the cambox.
a) Rotate camshaft to set the lowest point of the cam lobe on the up position.
b) Put an O-ring P/N 900709)on the cambox top circular slot.
c) Insert the EUI general adapter kits into the bore of the cambox, aligned it with
the dowel pin position on the cambox top surface.
d) Tighten four M10 bolts, item 1 on Figure 16, with torque 65±5N·m.

16 EUS-NT800 EUI/EUP Tester

 Figure 17 Assemble EUI to its adapter cup

4. Apply Vaseline on the O-Rings on the EUI body. Insert the EUI into the EUI
adapter cup, item 1 on Figure 17.

Figure 18 Assembly EUI to the cambox

5. Assembly EUI to the cambox.
a) Put the assembly of EUI adapter cup with the EUI into the center hole of the
EUI general adapter.
b) Install the EUI mounting plate, item 3 on Figure 18, to let the EUI adapter cup
insert its center hole and the two pillars through the two side holes.
c) Secure the EUI mounting plate position by tightening the two M16 nuts with
space washers, item 1 and 2 on Figure 18. The tighten torque of the M16 nuts
is 80±2N·m.

EUS-NT800 EUI/EUP Tester 17

 Figure 19 Assemble fuel hoses and fuel lines

6. Installation of low pressure fuel supply and return hoses

a) Using the M14×1.5 hollow bolt, item 1 on Figure 19, and hose with matching
banjo fitting and copper washers on both sides of the banjo fitting to connect
fuel inlet port on the test bench. The tighten torque of the hollow bolt is
35±3N·m. The supply pressure of the test fuel should be less than 0.2MPa.
There must be a fuel filter before the fuel inlet port. The filter specification is
5μm.
b) Using the M14×1.5 hollow bolt pressure relief valve, item 2 on Figure 19, and
hose with matching banjo fitting and copper washers on both sides of the
banjo fitting to connect fuel return port on the test bench. The tighten torque of
the hollow bolt is 35±3N·m.
c) Fit the fuel pipe casing and stealing washers over the two swivel pipe joints,
fix it on the EUI shell, the tighten moment is 50±2N·m. Let test fuel into the
fuel pipe, the max pressure is 0.2MPa.
7. Insert plastic fuel line to the quick fitting on the top of the EUI adapter cup to
collect fuel injected to the fuel injection measuring device on the test bench.
8. Connect EUI solenoid and the speed sensor to the EU-800 controller with the
harness.
9. Turn on the EU-800 controller and run the test bench motor to test fuel leakage of
the EUI setup.
10. May need to bleed the trapped air in the fuel circuit.

Disassemble EUI
1. Turn off the power of the test bench
2. Turn off the power of EU-800 controller, disconnect the harnesses.
3. Loose the hollow bolts and remove the low pressure fuel hoses from the EUI
adapter cup.
4. Remove the plastic fuel line from the quick fitting on the top of the EUI adapter
cup.
5. Loose and remove the two M16 nuts and space washers on the pillars.
6. Remove the EUI mounting plate.
7. Remove the assembly of EUI and EUI adapter cup.

18 EUS-NT800 EUI/EUP Tester

8. Remove the EUI being tested by loosing the two M6 bolts to hold the horse-shoe
plate.
9. Loose the four M10 bolt, and remove the EUI general adapt kits from the cambox.
10. Loose the two anchor bolts to free the cambox from the test bench.
11. Disengage the coupling from test bench motor shaft.
12. Upon the oil quality, may need to drain the oil in the cambox through the oil drain
port.
13. Clean all the parts, put them in a dry clean place.

5. EUs-800 Controller Operation

5.1 Preparation
1. Install the EUI or EUP being tested, check the oil quality and oil level of the
cambox, connect all hoses and fuel lines.
2. Connect the speed sensor on the cambox, the solenoid on EUI or EUP being
tested to the controller with the harnesses, connect the power line.
3. Switch on the AC power of the controller. The LCD screen displays the welcome
screen as below

4. Switch on the power of the test bench, run the test bench at a certain speed
5. The EUI or EUP test fixture may need to bleed the trapped air in the fuel circuit’

5.2 Operation
 Initial screen
The initial screen with default parameter values after AC power is turned on

 Start fuel injection

You may press < INJ > key to start fuel injection. The screen shows as below.

 Chang parameter value

The user may change the values of any injection parameters, regardless fuel injection is active or
not, by pressing the key <PW> , <BOI> or <TYP>, to move the cursor to the parameter being
edited. And then to press <+> or <-> key to change the value of the parameter with the cursor.

6. Handling
(1) Do not throw, drop or step on the device or accessories, and do not allow the
device subject any strong impact.
(2) Do not insert foreign objects into the connection sockets of the device.
(3) Do not allow water or other liquid to flow into the device or accessories.

EUS-NT800 EUI/EUP Tester 19

(4) Do not touch the main power plug of the AC power cord with wet hands.
(5) Do not allow dust or foreign matter to build up around the connection sockets of
the device or accessory connectors. If there is dust or foreign matter on the
device's connection sockets or the AC power socket, wipe it off with a dry cloth
before connecting the harnesses and power cord. Dust or other matter on the
connection sockets can cause fire or electrical shock. Unplug the AC power cord
from electrical outlet for the device before cleaning.
(6) Protect the AC power cord from being stepped on or pinched, particularly at plug
and extension receptacle.
(7) Carefully assemble and disassemble the EUI/EUP setup by exactly following the
user’s manual.
(8) Replace the lubrication oil in the cambox with fresh oil every 3 months or 200
hours whichever comes first. The same lubrication oil should be applied as that
for diesel engines.

7. Safety
To ensure accident-free operation, follow these guidelines:
(1) Safety goggles should be worn by the operator, during operating the tester.
(2) All the bolt should be tighten to the torques indicated in the user’s manual to insure
the safety.
(3) Do not touch the rotating parts in operation.
(4) The AC power outlet should be three-pole with safety ground connection.
(5) The case of EUS-1001 must be connected to test bench via the terminal on the
back panel.
(6) An AC power regulator is necessary for the tester, if the AC power supply is not
stable.
(7) Regularly check the AC power cord for damage and the mains power plug and
electrical outlet for dust build-up around.
(8) In case the device shows abnormal behavior, produces unusual sounds or smells
or becomes too hot to touch, stop operation immediately by unplugging the AC
power cord form the electrical outlet and disconnecting all other cables.
(9) Call the service phone number listed on your warranty card if the device does not
operate properly.

Caution: This product has been designed with the highest

concern for safety. However, like any electrical device, if
used improperly, it has the potential for causing fire,
electrical shock or personal injury.

8 Additional Information

8.1 Specifications of CB-1000 Cambox

Name Description
Center Height, cam shaft center to bench platform 125mm

20 EUS-NT800 EUI/EUP Tester

Center Notch Width 20mm
Cam Lift 10, 13, 16, 18.5mm
Cam Shaft End Taper 5:1
Cam Shaft End Thread M24×1.5
Rotation Direction Clockwise or counter-clockwise
Speed Sensor Build-in, magnetic sensor
External Dimensions, length×width×height (mm) 224×140×215mm
Net Weight 21 kg

8.2 Specifications of EU-1001 Controller

Name Description
LCD screen 99×24mm, display 2 lines of 16 characters of
5×8 dots
Keyboard 6 buttons
AC Power 100 ～ 240V AC, 50/60Hz
AC Fuse 2A
External dimensions 500×350×270mm
Net Weight 7.0kg
Operating ambient temperature 0℃ ～ +50℃
Design and specifications are subject to change without notice.

8.3 Warranty
(1) Injectronix will replace free of charge any EUS-1001 Tester, which fails in use
within a time period of one (1) year from the date of delivery due to faulty material
or workmanship, as determined by Injectronix, provided that the EUS-1001 Tester
is returned prepaid to Injectronix within one month from the date of failure with an
APPLICATION FOR REPLACEMENT UNDER WARRANTY signed by a
responsible engineering representative of the customer.
(2) This warranty does not cover any coincidental or consequential damages of the
EUS-1001 Tester.
(3) During the warranty period, Injectronix is not liable for any losses or damages of
any kind resulting from the improper use of this product, and user charges for the
repair cost.
(4) After the warranty period, user charges for the repair cost.

EUS-NT800 EUI/EUP Tester 21