Universal Test Bench Fixture – Multi‑Platform Injector & Pump Adapter System For High‑Flow And Leakage Testing

A diesel test bench is only as reliable as the connection between the bench's hydraulic supply and the component being tested. Injectors from Bosch, Denso, Delphi, and Siemens have different high‑pressure inlet threads, different return port configurations, and different clamping geometries. Workshops often accumulate a drawer full of adapters-most of which are mismatched or damaged. This universal fixture eliminates that chaos with a modular adapter system that includes 12 interchangeable sealing heads, each designed for a specific injector or pump family. The fixture's base plate mounts directly onto any standard test bench (Hartridge, Bosch EPS, Denso, or Delphi) via a universal 4‑bolt pattern (80 mm × 80 mm PCD), while the adapter heads are swapped in under 10 seconds using a quick‑release bayonet lock. The result is a single fixture that covers 95% of common‑rail and unit injector service work, reducing setup time from 15 minutes to under 2 minutes per test.

---

Each adapter head is colour‑anodized for instant identification:

Red heads (10 pieces): For Bosch CRIN 1/2/3 and CRSN piezo injectors – M12×1.5 and M14×1.5 inlet threads.

Blue heads (6 pieces): For Denso G2 and G3 injectors – proprietary thread with a 45° sealing cone.

Green heads (4 pieces): For Delphi DFI 1.2 and 1.5 – M10×1.0 with a flat seal.

Yellow heads (2 pieces): For Siemens / Continental piezo injectors – M10×1.5 with O‑ring seal.

Each head includes a built‑in pressure sensor port (1/8" BSP), allowing you to monitor the injection pressure directly at the injector inlet-bypassing the test bench's internal pressure sensor, which may have a slower response time. The sensor port is sealed with a metal cap when not in use.

---

The fixture uses a dual‑sealing concept to handle the extreme pressures (up to 2,500 bar) generated during testing:

Primary seal: A hardened steel cone (60° included angle) that mates with the injector's inlet port, providing a metal‑to‑metal seal that does not degrade with temperature.

Secondary seal: An O‑ring (FKM or HNBR, depending on the fuel type) that backs up the primary seal and provides a barrier against leakage in case the cone is worn.

The cone is replaceable; each adapter head has a threaded cone that can be swapped out when worn (after approximately 1,000 tests). A torque‑limiting collar on the fixture's clamping screw ensures the cone is tightened to 25 Nm-enough to create a seal, but not so tight that it deforms the injector's inlet.

The fixture holds the injector (or pump) using a top‑clamping plate that presses down on the component's body, not on its delicate connector pins or actuator housing. The clamping plate has a 20 mm travel range, accommodating components from 30 mm to 60 mm in body height. The plate is guided by two hardened steel pillars and locked with a single‑handed cam lever that applies a clamping force of 500 N-sufficient to hold components even at maximum test pressure.

Alignment pins: Two dowel pins on the base plate engage with the adapter head, ensuring the injector is perfectly vertical within ±0.1°-critical for accurate spray pattern analysis.

Quick‑release: The bayonet lock releases the adapter head with a 30° twist-no tools required.

An optional accessory (sold separately) is a leakage sensor tray that clips onto the fixture's base. The tray has a pair of conductive probes; if even a single drop of fuel bridges the probes, an LED on the fixture lights up and an audible alarm sounds-alerting the operator to a seal failure before the fuel spills across the test bench. This feature is particularly valuable when testing high‑pressure pumps, where a sudden leak can be hazardous.

Q1: I have a test bench with a non‑standard mounting bolt pattern (e.g., 100 mm × 100 mm PCD). Does the fixture include an adapter for that?
A: The base plate has the universal 80 mm × 80 mm pattern. For other patterns, we offer a conversion plate (sold separately) that mounts between the bench and the fixture. It is available in 85 mm, 90 mm, and 100 mm PCD variants, and also for Bosch EPS 815 and Hartridge AVM2 benches (which have a different hole spacing). Please specify your bench model when ordering.

Q2: The metal cone seals are great, but they seem to wear out quickly when testing at 2,000 bar-how often should they be replaced?
A: With proper lubrication (a thin film of the included anti‑seize compound on the cone threads), the cone should last for 800–1,000 high‑pressure tests. After that, you may notice a slight increase in the leak‑off rate. The kit includes two spare cones for each adapter head; replacements are also available separately. A visual inspection: if the cone's sealing surface shows any pits or scratches, replace it immediately.

Q3: Can I use this fixture to test both injectors and pumps (e.g., CP3 high‑pressure pumps) on the same bench?
A: Yes, the fixture's base plate and clamping mechanism support both. For pumps, you need a different set of adapter heads-the pump adapters have a larger inlet thread (M16×1.5 or M18×1.5) and a wider clamping plate. We offer a "pump adapter kit" that includes 4 pump‑specific heads; the fixture body itself is the same. Just swap the heads.

Q4: I often test injectors that have a 45° sealing cone, not a 60° cone. Are there adapters for that?
A: Yes, the Denso G2/G3 adapters (blue heads) use a 45° cone-they are included in the set. For other 45° variants (e.g., certain Delphi prototypes), we offer a custom machining service-send us a dimensioned drawing, and we can produce a head for you. The standard set covers 95% of production injectors.

Q5: The cam lever clamping force feels lower than 500 N-how do I adjust it?
A: Over time, the cam lever's wear pads can compress. There is an adjustment screw on the lever pivot; turning it clockwise increases the clamping force. Use a torque wrench on the adjustment screw to 10 Nm, then test the clamp with a force gauge (not included). If the force is still low, the lever may need replacement-contact us for a spare.

Q6: My test bench uses a different test fluid (not diesel) that may attack the O‑rings. Are other seal materials available?
A: We offer O‑ring sets in FFKM (perfluoroelastomer) for aggressive fluids, including synthetic test oils and biodiesel blends above B50. The FFKM set is an optional upgrade-it has a higher temperature rating (up to 200 °C) and better chemical resistance, but it is more expensive. The standard set uses FKM and HNBR, which are suitable for most diesel and biodiesel blends (up to B20). Please inform us of your test fluid when ordering.

 

To make your purchasing experience smooth and easy, we offer a variety of secure payment options:

We're here to make your order process worry-free - choose the payment method that works best for you!

 

 

Hot Tags: universal test bench fixture – multi‑platform injector & pump adapter system for high‑flow and leakage testing, China universal test bench fixture – multi‑platform injector & pump adapter system for high‑flow and leakage testing manufacturers, suppliers, factory