16-Cylinder Fuel Injection Pump Test Bench with Graduated Measuring Cylinders

Fuel Delivery Measurement, Calibration and Synchronisation of Large Inline Injection Pumps and V16 Tandem Pump Assemblies

The professional overhaul of a mechanical large-diesel fuel injection pump does not end with reassembly.

Only controlled test-bench operation can verify whether all pumping elements deliver the specified fuel quantity, whether cylinder-to-cylinder delivery is balanced and whether the complete injection-pump system operates reliably and reproducibly.

Einspritzpumpen Manufaktur NRW operates a specially configured 16-cylinder fuel injection pump test bench with volumetric fuel-delivery measurement using graduated glass measuring cylinders.

The system is designed for the testing, calibration and mechanical synchronisation of large inline fuel injection pumps and complete tandem pump assemblies used on V16 diesel engines.

Its principal capabilities include:

simultaneous measurement of up to 16 individual fuel-delivery quantities
direct volumetric measurement using graduated glass cylinders
testing of large individual inline injection pumps
testing of complete mechanically coupled tandem pump assemblies
comparison of every individual pumping element
calibration of cylinder-to-cylinder fuel-delivery uniformity
comparison of both halves of a tandem pump system
mechanical synchronisation of coupled injection pumps
repeated testing at defined pump speeds and control positions
and final verification following complete overhaul

A particular area of expertise is the testing and calibration of mechanical Bosch P9 and Bosch P10 inline fuel injection pumps used in MWM, Deutz, MTU and other medium- and large-diesel engines.

Based in North Rhine-Westphalia, Germany – supporting marine operators, power-generation companies, industrial engine operators and specialist workshops worldwide.

Request a 16-Cylinder Test-Bench Assessment

Please send us photographs of the complete injection-pump assembly, all nameplates, engine data and any available calibration specifications before shipping the unit.

Contact Our Large Injection Pump Specialists

Volumetric Fuel-Delivery Measurement

Direct Measurement of Every Pumping Element

Each pumping element is connected to its own measuring position.

During a defined measuring cycle, the test fluid delivered by each pump section is collected in a separate graduated glass measuring cylinder. The resulting volumes can then be read and compared directly.

For a 16-cylinder injection system, the delivery quantities of all 16 pumping elements are visible side by side.

This allows us to identify:

individual pumping elements with excessive or insufficient delivery
differences within the first injection pump
differences within the second injection pump
variation between both halves of a tandem system
unstable or non-repeatable delivery behaviour
and changes resulting from individual adjustment corrections

The measurement is carried out under controlled test conditions.

Depending on the pump design and available technical specification, these conditions may include:

defined pump speed
defined control-rack or actuator position
defined measuring period
defined number of pumping strokes
controlled test-fluid temperature
defined test-fluid supply pressure
specified outlet test conditions
complete bleeding of the test system
and repeated measuring cycles

Reliable comparison is only possible when all pump sections are tested under identical conditions.

Why Graduated Measuring Cylinders Are Used

Volumetric measurement with graduated cylinders provides a transparent and directly observable comparison of the individual fuel-delivery quantities.

The method offers several important advantages:

direct visual representation of every measured volume
simultaneous comparison of all cylinders
rapid identification of delivery deviations
verification of adjustment changes
comparison of two coupled injection pumps
assessment of measurement repeatability
and clear final inspection following overhaul

The measurement result is represented by the actual volume collected from each pumping element.

This is particularly valuable for historical mechanical large-diesel injection pumps, where direct comparison of all pump sections remains a reliable and technically transparent method of evaluating delivery uniformity.

Why Uniform Fuel Delivery Is Essential

Every pumping element of an inline injection pump supplies one engine cylinder.

If one element delivers a different quantity from the others, the individual cylinders operate under different combustion conditions.

Possible consequences include:

unequal cylinder output
irregular engine operation
uneven load distribution
different exhaust-gas temperatures
increased thermal loading of individual cylinders
excessive smoke
increased fuel consumption
poor load acceptance
reduced overall engine output
increased mechanical stress
and reduced engine service life

On a V12 or V16 large diesel engine, even comparatively small delivery differences can affect the operation of the complete engine.

The objective of test-bench calibration is therefore not simply to achieve a high total fuel-delivery quantity.

The decisive requirement is:

Uniform, repeatable and specification-compliant fuel delivery across every cylinder of the engine.

Testing Large Bosch P9 and P10 Injection Pumps

Bosch P9 and Bosch P10 inline fuel injection pumps are among our principal specialist fields.

These mechanical high-capacity pumps are used in applications including:

marine main propulsion engines
marine auxiliary engines
stationary large diesel engines
generator sets
power-generation installations
emergency power systems
industrial drives
pump and compressor drives
railway applications
and other continuously operated heavy-duty diesel engines

Depending on their individual configuration, Bosch P9 and P10 pumps may differ in:

number of pumping elements
plunger-and-barrel diameter
fuel-delivery range
camshaft design
cam profile
direction of rotation
drive arrangement
rated pump speed
control mechanism
associated engine output
and technical production status

A professional test-bench calibration must therefore be based on the exact pump and engine configuration.

The general designation “Bosch P9” or “Bosch P10” alone is not sufficient to define the required test values.

For reliable preparation, we require as much of the following information as possible:

complete Bosch pump designation
Bosch part number
MWM, Deutz, MTU or other OEM reference
exact engine designation
number of cylinders
rated engine output
rated engine speed
direction of rotation
application
and available testing or calibration data

Complete V16 Tandem Injection Pump Testing

Testing Both Injection Pumps as One System

Several V16 large diesel engines use two mechanically coupled injection pumps operating together as one complete tandem assembly.

Each injection pump supplies a separate group of engine cylinders.

The two pumps can initially be:

overhauled individually
mechanically adjusted individually
operated separately on the test bench
and calibrated according to their respective specifications

However, individual testing alone does not always verify how both pumps will operate after being mechanically coupled.

Following successful individual calibration, both pumps can therefore be assembled as a complete tandem system and operated together on the 16-cylinder test bench.

This allows us to assess whether:

both pumps are positioned correctly in relation to one another
the mechanical coupling is correctly adjusted
the complete drive system operates smoothly
all 16 pumping elements deliver consistently
the first and second pump halves are correctly matched
no unacceptable delivery deviation exists between the two pumps
the full tandem system produces repeatable results
and the complete assembly is correctly synchronised

Testing the complete tandem assembly provides an additional level of quality assurance beyond the individual testing of each injection pump.

Typical V16 Applications

Depending on the exact pump design, mounting arrangement and available test data, relevant applications may include injection-pump systems for:

MTU 396 V16 engines
MWM/Deutz TBD620 V16 engines
MWM/Deutz TCD2020 V16 engines
and other mechanically controlled V16 diesel engines

Every pump assembly is assessed individually before acceptance.

The ability to mount and test a particular system depends on:

overall dimensions
mounting points
drive-shaft position
coupling design
direction of rotation
required test speed
required drive torque
and availability of suitable technical data

Why Tandem Pump Synchronisation Is Necessary

Two injection pumps that have been calibrated correctly as individual units do not automatically form a correctly synchronised tandem assembly.

Additional deviation can result from:

coupling tolerances
different mechanical basic positions
installation alignment
drive-system play
connection-element clearances
different actuator responses
incorrect relative pump position
and previous undocumented adjustments

Only joint test-bench operation can verify how both pumps interact when mechanically connected.

Correct synchronisation is important for:

uniform fuel delivery across all 16 cylinders
minimum variation between both cylinder banks
balanced engine output
comparable exhaust-gas temperatures
smooth engine operation
reliable load acceptance
stable operation at the defined test points
and long-term operational reliability

Our 16-Cylinder Test-Bench Technology

Designed for Large Mechanical Injection Pumps

Large inline injection pumps impose substantially higher mechanical demands on a test bench than conventional automotive or commercial-vehicle pumps.

The required test equipment must provide:

sufficient drive power
stable speed control
high mechanical rigidity
secure pump mounting
accurate drive alignment
controlled test-fluid supply
smooth rotational operation
and sufficient measuring capacity for every pump section

Our dedicated test-bench configuration therefore includes the following features.

High-Capacity Drive System

The test-bench drive is designed for the mechanical requirements of large injection pumps and complete tandem assemblies.

Adequate drive capacity is essential to operate the pump reliably throughout the required test range.

Increased Rotating Mass

The increased flywheel mass supports smooth rotational operation and helps reduce short-term speed fluctuations during the testing of large multi-element injection pumps.

Stable pump speed is an important condition for comparable volumetric measurements.

Extended Pump Bed

The extended pump bed provides the installation space required for large individual pumps and complete tandem pump assemblies.

It also allows the drive, mounting brackets and pump units to be aligned correctly.

Sixteen Individual Measuring Positions

Up to 16 pumping elements can be connected to separate graduated measuring cylinders.

This makes it possible to evaluate every pump section individually while simultaneously comparing the complete injection system.

Application-Specific Pump Mounting

Large injection pumps do not share standardised mounting dimensions.

Depending on the pump system, differences may exist in:

mounting points
shaft height
drive coupling
direction of rotation
pump length
drive arrangement
and mechanical support requirements

The mounting configuration is therefore prepared for the individual pump assembly.

Before accepting a test order, we assess the available photographs, dimensions, drawings and technical data.

Our Test-Bench Calibration Process

1. Technical Identification

Before testing begins, we record:

pump manufacturer
complete type designation
all part numbers
number of pumping elements
direction of rotation
drive configuration
associated engine type
rated engine output
rated engine speed
application
and available calibration values

For tandem assemblies, both injection pumps are documented separately.

2. Incoming Inspection

The injection pump is inspected for:

visible mechanical damage
missing components
corrosion
fuel leakage
oil leakage
free movement of mechanical components
condition of the drive
and evidence of previous repairs

Test-bench calibration requires a technically testable injection pump.

A worn or mechanically damaged pump cannot be restored permanently by adjustment alone.

3. Individual Testing Following Overhaul

For tandem systems, both pumps are initially tested individually.

The assessment may include:

mechanical function
movement of the control mechanism
leakage
delivery behaviour
differences between pumping elements
and repeatability of the measured quantities

Required corrections are first carried out on each individual pump.

4. Assembly of the Tandem System

After successful individual testing, both pumps are mechanically connected according to their later operating configuration.

The following points are verified:

correct assignment of both pumps
mechanical basic position
coupling configuration
drive alignment
direction of rotation
actuator connection
and synchronisation position

5. Filling and Bleeding

The complete test system is supplied with suitable test fluid and carefully bled.

Air within the system can distort volumetric measurements and must be removed before delivery quantities are evaluated.

6. Conditioning Run

Before final measurement, the injection pump is operated under controlled conditions.

This conditioning phase establishes stable conditions regarding:

test-fluid temperature
lubrication
filling of the pumping elements
rotational behaviour
and movement of the mechanical control components

7. Measurement in the Graduated Cylinders

At the defined test points, the volume delivered by every pumping element is collected separately.

After the defined measurement cycle, all cylinders are evaluated together.

The assessment includes:

absolute delivery quantity
variation between individual pumping elements
variation within each pump
variation between both injection pumps
and repeatability over several measurement cycles

8. Fuel-Delivery Adjustment

Detected deviations are corrected within the adjustment range permitted by the pump design.

After each relevant correction, the measurement cycle is repeated.

Adjustment continues until the delivery quantities correspond to the confirmed manufacturer data or the agreed technical specification.

9. Tandem Synchronisation

The two coupled injection pumps are mechanically matched to one another.

The complete 16-cylinder system is assessed rather than treating both pumps as unrelated individual units.

10. Repeatability and Final Inspection

Following completion of all adjustment work, repeated measurement cycles are carried out.

These verify whether:

the fuel-delivery quantities remain repeatable
no unacceptable deviation exists
the mechanical settings remain stable
the pump assembly operates without unacceptable leakage
and the tandem system remains correctly synchronised

Calibration According to Confirmed Technical Data

Calibration is carried out wherever possible using confirmed:

Bosch test specifications
engine-manufacturer data
original calibration documentation
documented technical specifications
or clearly agreed customer-specific target values

Historical large-diesel injection pumps often exist in numerous variants.

Externally similar pumps may contain different:

pump elements
camshafts
cam profiles
delivery specifications
speed ranges
control components
and drive configurations

Test values must therefore not be transferred from a visually similar pump without technical verification.

Where complete original data are no longer available, the usable documentation, pump identification, engine specification and previously recorded operating data must be evaluated before calibration begins.

Test-Bench Adjustment Cannot Replace Mechanical Overhaul

A test bench can identify fuel-delivery deviations, but it cannot compensate permanently for worn or damaged pump components.

Possible causes of unstable or unequal delivery include:

worn plunger-and-barrel assemblies
damaged delivery valves
corrosion
restricted control components
worn camshafts
damaged tappet rollers
worn roller tappets
excessive bearing clearance
incorrect pump-element allocation
internal leakage
unsuitable component combinations
and previous improper repair work

Where these conditions are present, the pump must first undergo complete technical inspection and overhaul.

Adjustment without correcting the underlying mechanical wear cannot produce stable and repeatable long-term results.

Advantages of Complete 16-Cylinder Testing

Testing the complete injection-pump system provides important technical advantages:

direct comparison of all 16 fuel-delivery quantities
identification of individual abnormal pumping elements
comparison of both injection-pump halves
verification of the complete mechanical coupling
calibration of the entire V16 fuel injection system
assessment of measurement repeatability
mechanical synchronisation of both pumps
evaluation of the complete assembly rather than isolated components
and improved confidence before reinstallation on the engine

For marine, industrial and power-generation engines, removing and reinstalling a large tandem pump assembly involves substantial cost, downtime and technical risk.

Complete test-bench verification helps reduce the risk of delivery differences becoming apparent only after the pumps have been reinstalled and the engine returned to operation.

Typical Customers and Applications

Our 16-cylinder test-bench services are intended for:

shipping companies
vessel operators
shipyards
marine-engine service companies
power-generation businesses
stationary generator operators
emergency power operators
industrial companies
engine rebuilders
large-diesel service companies
fuel injection specialists
spare-parts suppliers
and operators of historical large diesel engines

International testing and overhaul enquiries are accepted by prior technical arrangement.

Information Required for an Initial Assessment

Please provide as much of the following information as possible:

injection-pump manufacturer
complete pump type designation
all Bosch, MWM, Deutz, MTU or other OEM references
exact engine designation
number of cylinders
rated engine output
rated engine speed
direction of rotation
application
individual pump or complete tandem assembly
photographs of the complete pump system
photographs of every nameplate
photographs of the coupling and drive side
overall dimensions of the pump assembly
available test or calibration documentation
description of the fault
information about previous repairs
and the required testing or overhaul scope

For a tandem pump system, we require photographs of the complete coupled assembly as well as the individual nameplates of both pumps.

Please do not dismantle, separate or readjust the pumps unnecessarily before technical consultation.

The existing installation position and mechanical relationship may be important for later synchronisation.

Frequently Asked Questions

Can You Test Complete V16 Tandem Injection Pump Assemblies?

Yes. Our 16-cylinder test bench is specifically configured for the testing of large individual injection pumps and complete mechanically coupled tandem assemblies.

The mounting feasibility of each system is assessed in advance using dimensions, photographs and technical data.

Why Do You Use Graduated Measuring Cylinders?

Graduated cylinders provide direct volumetric measurement of the test-fluid quantity delivered by every pumping element.

This allows all cylinders to be compared simultaneously and makes delivery deviations immediately visible.

Are Both Pumps Tested Individually First?

Yes. In a tandem system, both injection pumps are initially assessed and calibrated individually.

They are then assembled as a complete tandem system, operated together and mechanically synchronised.

Can Bosch P9 and P10 Injection Pumps Be Tested?

Yes. Bosch P9 and Bosch P10 large-diesel injection pumps are among our principal specialist fields.

The exact testing capability depends on the pump version, drive configuration, mounting arrangement and available technical data.

Can Other Large-Diesel Injection Pumps Be Tested?

Other mechanical inline injection pumps and multi-pump systems can be submitted for technical assessment.

We require clear photographs, overall dimensions and complete identification details before acceptance.

Is Test-Bench Adjustment Possible Without Overhaul?

That depends on the technical condition of the pump.

If the injection pump is mechanically sound and only requires adjustment, testing and calibration may be sufficient.

If wear, corrosion, internal leakage or mechanical damage is present, overhaul must be completed first.

Do You Use Original Manufacturer Specifications?

Calibration is carried out using available and confirmed manufacturer data or a clearly agreed technical specification.

Unverified values from similar pump versions are not transferred without technical assessment.

Can International Customers Send Injection Pumps to Germany?

Yes, by prior arrangement.

Before shipping, all pumps must be drained, open connections securely sealed and heavy assemblies mounted safely on a suitable transport pallet.

Request a 16-Cylinder Test-Bench Assessment

Do you need a large mechanical injection pump or complete V16 tandem pump assembly tested, calibrated or synchronised?

Please send us:

clear nameplate photographs
complete pump designations
engine data
photographs of the complete assembly
available calibration values
and a description of the required work

After reviewing the information, we will assess:

whether the pump can be mounted on our test bench
which adapters or drive components are required
which technical specifications are needed
whether the pump is in a testable condition
whether overhaul is required before calibration
the appropriate test procedure
and the expected scope of work

A binding evaluation may require receipt, dismantling and technical inspection of the pump assembly.

Contact Our 16-Cylinder Injection Pump Test-Bench Department

Name *

Company

Country

Email Address *

Telephone Number

Engine Manufacturer and Model

Injection Pump Manufacturer

Pump Type and Part Number

Individual Pump or Tandem Assembly

Description of the Required Work *

Upload Nameplate and Pump Photographs

Submit Technical Enquiry

Einspritzpumpen Manufaktur NRW

Specialist for Large Mechanical Injection Pumps and V16 Tandem Systems

Our services include:

testing of large mechanical inline injection pumps
Bosch P9 test-bench calibration
Bosch P10 test-bench calibration
volumetric fuel-delivery measurement using graduated glass cylinders
simultaneous measurement of up to 16 pumping elements
cylinder-to-cylinder fuel-delivery balancing
testing of complete tandem pump assemblies
mechanical synchronisation of coupled injection pumps
final test-bench operation following overhaul
technical documentation of pump configurations
reverse engineering of obsolete pump components
and complete overhaul of mechanical large-diesel injection pumps

Precise measurement of all 16 fuel-delivery quantities—not merely separate testing of two individual pump halves.