How a Diesel Injector Test Bench Works

1. THE IMPORTANCE OF THE TEST BENCH IN A MODERN WORKSHOP

In the world of diesel engine maintenance, precision is everything. When working on injectors, even the smallest anomaly can compromise engine performance, increase fuel consumption, and cause serious long-term damage. For this reason, workshops operating in the diesel sector must rely on reliable and highly specialized tools. Among these, the injector test bench is one of the most important devices.

A test bench allows precise testing of injector operation by evaluating flow rate, pressure, sealing, and response of the component. It is an indispensable tool for identifying issues invisible to the naked eye and ensuring that every repair or remanufacturing intervention is truly effective.

2. WHAT IS A DIESEL INJECTOR TEST BENCH

The test bench is a mechanical and electronic device designed to simulate real operating conditions of a diesel injector. Its goal is to replicate the injection cycle in a controlled and measurable way, providing useful data to determine the component's efficiency.

A professional test bench, such as those used by REDAT (Hartridge Sabre CRi Expert, Hartridge Toledo, Bosch EPS 815, Bosch EPS 625 with Hartridge Cambox), enables you to:

●     Perform dynamic tests on new, used, or remanufactured injectors

●     Verify compliance with the technical tolerances imposed by the manufacturer

●     Analyze the injector’s behavior under critical conditions

●     Simulate engine pressure and speed to evaluate each phase of injection

These tools are used not only in workshops but also in laboratories and research centers where new Diesel models and technologies are tested.

 

3. HOW A TEST BENCH FOR INJECTORS WORKS

The operation of the test bench is based on an electronic simulation cycle that reproduces engine behavior under controlled conditions. Here are the main steps:

1.     Connecting the injector to the bench

The injector is mounted in a dedicated seat and connected via fittings and electrical connections. It is essential at this stage to use the correct adapters, as each brand or model may require specific equipment.

2.     Simulating operating conditions

Through a software interface, the technician sets the test parameters: pressure, injection cycles, quantity of diesel, frequency and duration of electric pulses. The bench uses this data to simulate the injector’s work on the engine.

3.     Data acquisition

During the test, the bench measures and records various parameters:

●        Amount of fuel injected per cycle

●        Response time of the solenoid or piezo element

●        Any internal or external leaks

●        Injector behavior at different pressures

4.     Analysis of results

The bench software generates a report that indicates whether the injector falls within factory specifications or presents anomalies. A color code is often used for ease of reading: green for pass, red for failure.

 

4. TYPES OF TEST BENCHES: ELECTRONIC VS. MECHANICAL

There are several types of test benches. The most advanced models, like those used by REDAT, are fully electronic and software-controlled. They offer highly detailed tests and are compatible with the latest generation of common rail injectors.

Mechanical or semi-electronic benches, still found in some workshops, allow for more limited testing and are often used for less complex injection systems (e.g. mechanical injectors or rotary pumps).

The advantage of electronic benches is their ability to quickly adapt to new standards and provide highly accurate diagnostics even on modern components like piezoelectric injectors.

 

5. WHY IS THE TEST BENCH ESSENTIAL IN THE WORKSHOP?

Having a test bench in the workshop is not a luxury but a necessity for any business that wants to offer a professional and comprehensive service in the Diesel sector. Here are the main advantages of this tool:

Accurate fault diagnosis

It allows the detection of defects invisible to the naked eye, avoiding unnecessary replacements.

Quality control on the spare parts used

Before being put back on the market, injectors must pass bench tests.

Reduction of complaints

By testing every component, errors and unresolved repairs are drastically reduced.

Saving time and resources

A correct diagnosis on the first try allows more targeted actions without wasting time.

At REDAT, for example, all remanufactured injectors are tested using Hartridge Sabre CRi Expert benches, ensuring the highest level of reliability.

 

6. THE ROLE OF REDAT TEST BENCHES IN DIESEL MAINTENANCE

REDAT uses top-of-the-line test benches to ensure that every intervention is based on reliable data. Hartridge benches, in particular, offer advanced features such as:

●        Automatic injector model selection via code

●        Real-time monitoring of injection parameters

●        Variable load simulation for more realistic testing

Thanks to these tools, REDAT's workshop can test the operating conditions of Bosch, Delphi, Siemens, Denso, and Caterpillar injectors, ensuring components tested according to the highest international standards.

With reliable tools like those used by REDAT, every phase of the injector repair and testing process can be carried out with maximum safety. A test bench is not just a technical investment, but a strategic choice to improve work quality and stand out in the market.

 

7. WHO SHOULD USE A TEST BENCH?

The use of a test bench is recommended for:

➔     Workshops specialized in Diesel

➔   Injector remanufacturing centers

➔   Spare parts distributors who want to ensure product quality

➔   Industrial or marine maintenance companies working on large diesel engines

The test bench is an investment that pays off over time, improving workshop reputation, increasing customer trust, and reducing repair time and costs. It is not just a machine, but an indispensable ally for all workshops focused on competence, precision, and professionalism.

Contact us with no obligation for more information about REDAT products and services at +39 011 979 1111 or via email at [email protected] or [email protected].