Injecter Pop Tester

[icanfixall]

Today I was trying to make an injecter tester out of a psd injecter pump that came in the complete psd tester kit.... I removed a hard line fitting off my spare DB2 pump but... They are compression fitting and probably a metric fine thread. I have an injection repair shop near me but the closest he could get me to a pipe thread fitting and the hard line connecter was a 1/8 inch national pipe straight thread. Close but not close enough. I have a new hydraulic pump but no fitting. So its time to start watching Evil bay again... There is a Kent Moore tester that looks filthy and some parts are missing for around $275.00.... Way too much for the asking price.....

 

[6 Nebraska IDIs]

Yea, I've been looking for one of these testers too. With now 7 trucks and all but one needing new injectors, it would be nice to have one, as having a set tested costs just over $100 here.

 

[tradergem]

Pop Tester

Why don't you just go the poorman's route?
How to build a pop tester

Jim

 

[icanfixall]

Very interesting reading. That Northern Tools pump is what I used in the machine shop all the time. We had some that were compound and about 4 inch diameter....

 

[Diesel JD]

I want to do this too! I wonder what the total cost for all this would be and if its dangerous.

 

[discbrks]

I just built one. Used a 10 ton porta-power pump from Northern (about 40 bucks, I think) and a 3000 psi gauge (also from Northern, about 30 bucks). I have a whole set of hard lines laying around, so I used one of them. I tried for WEEKS to find an adapter to go from the 1/4 npt on the pump to whatever the inj. line thread is. No luck at all. I tried everywhere, including my local Parker Store (hose & fitting supplier). So I had one of the guys at the shop weld the inj. line to the original fitting that came with the pump. Works great. I can give you guys a pic if ya want, but it might be later tonight.

 

[DeepRoots]

dangerous? not if you don't break any lines or stick your hand under the injector.
wouldn't be a bad idea to have a way to vent the pressure.

if you've ever seen an injection wound with something like paint or diesel, it'd turn your stomach.

 

[RLDSL]

I want to do this too! I wonder what the total cost for all this would be and if its dangerous.

Trying to make one is very dangerous. Use only fittings from a hydraulic supply that are rated for the pressure that you will be working with, do not, under any circumstances use pipe fittings from Home Depot etc. Plumbing parts are only rated for a couple of hundred PSI at best. If you are trying to rig one where it requires welding, if you aren't 100% confident in your welding skills to make joints that have no air bubbles, think hard about buying a tester.Don't try out for the Darwin awards

 

[tradergem]

If you need welding done take it to a reputable certified welder. I believe the built in pressure relief valve on the bottle jack or northern pump will still work.
When you finish building your tester, you should place it behind a metal shield of some sort to do the first few pressure tests of the pop tester, fittings and lines. You should test to 1.5 times the expected operating pressure to make sure everything will not break or leak during normal use.
Jim

 

[69dieselfreak]

Why don't you just go the poorman's route?
How to build a pop tester

Jim

good find i think that i just might half to give building it a shot later

 

[icanfixall]

I was certified to weld anything. Stick, tig or mig... Inconel was the most weld work I did ob turbine diaphrams blade repair. We actually cut away the blades and made a copper backing plate. Then we welded the blade using the copper piece as a form. Then plenty of grinding, sanding, power filing... The Scotchbrite pads to finish things off. Stainless was another frequently welded material. I would never use the crap from HD or any other place like that. Usually they are only 150 lb fittings. I can get the 10,000 and 20,000 lbs fittings. I really don't need them but I can get them. Around 2200 lbs is as high as a pressure I will ever see but testing to 1 1/2 times rated pressure is standard test pressures on everything. Same with lifting equiptment.

 

[Diesel JD]

Thanks for the warning, someone like myself who doesn't know much about hydraulics might have assumed a fitting was a fitting. Where can you get the quality stuff rated for high pressure. Obviously it ain't going to be cheap but nobody wants a diesel injection injury. I can see how serious this would be. I had a very mild injury from a pressure washer all along I was thinking if that relatively low pressure with non toxic pure water could hurt me like that then diesel or paint at much higher pressures...I see why it is a serious or potentially fatal condition.

 

[DeepRoots]

our small town hardware store makes hydraulic hoses and carries fittings.
for you how bout:
Hollander's Hydraulics, Inc
5516 N W 13th Street
Phone 352-376-5319

if I'm holding pressure at 2000psi, everything I use will be 5000psi, 4000 minimum.

 

[RLDSL]

You can get the high pressure fittings at any industrial hose shop or hydraulic supply. They generally aren't that much more expensive than the low pressure stuff. Cheap insurance.

 

[lotzagoodstuff]

Quality hydraulic components are rated at 4 to 1. You should have little problems getting 2200 psi with the small sizes that you are working with (1/4 and 3/8 connections are typically rated to 5000 psi), the only really questionable part would be the welding.

I am contemplating a mild engine makeover (turbo, injectors, better fuel filtration, etc), which would involve replacement injectors which would need to be pop tested. At that point I am going to build a pop tester, complete with digital pressure tranducer with recording capability so I can provide a printout of injector testing.

I will put together a build sheet if somebody wants to duplicate it, however, I am guessing this will be an "after it starts raining" project as it's still too nice to work inside here in the Northwest.