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HL067(EN) Issue 2, 12/2015 (AT2903)

All Makes Bench EUI/EUP Kit (HK1400)

Patents Pending: PCT/EP2015/068583 & EP15180772.4

Installation and Operating Manual

HARTRIDGE LIMITED HK1400 All Makes Bench EUI/EUP

HL067(EN) Issue 2, 12/2015 (AT2903) 3

CONTENTS

FOREWORD ..................................................................................................................................................................... 7

1 INTRODUCTION & SPECIFICATION ............................................................................................................. 11

1.1 GENERAL ........................................................................................................................................................... 11 1.1.1 Features .................................................................................................................................................... 11

1.2 HOST BENCH REQUIREMENTS ............................................................................................................................ 11 1.2.1 Host Bench Recommended / Minimum Specifications .............................................................................. 12

1.3 SPECIFICATION ................................................................................................................................................... 12 1.3.1 Cambox Hardware .................................................................................................................................... 12 1.3.2 Electrical supply ........................................................................................................................................ 12 1.3.3 Fluids ........................................................................................................................................................ 12 1.3.4 Programmable parameters: ...................................................................................................................... 12 1.3.5 Measured parameters ................................................................................................................................ 12 1.3.6 Definition of Terms and Abbreviations ..................................................................................................... 12

2 INSTALLING THE KIT ....................................................................................................................................... 13

2.1 CAMBOX INSTALLATION .................................................................................................................................... 13 2.1.1 Injector access position ............................................................................................................................. 14 2.1.2 Injector access guard ................................................................................................................................ 14 2.1.3 Coupling guard ......................................................................................................................................... 15 2.1.4 Cambox Mounting ..................................................................................................................................... 16 2.1.5 Safety interlock connection ....................................................................................................................... 18

2.2 COMPUTER / USER INTERFACE ................................................................................................................. 21 2.2.1 Computer hardware .................................................................................................................................. 21 2.2.2 Computer software .................................................................................................................................... 21 2.2.3 Software Data Installation ........................................................................................................................ 23 2.2.4 Computer IP Address ................................................................................................................................ 24

3 SYSTEMS AND PRINCIPLE OF OPERATION ............................................................................................... 31

3.1 GENERAL PRINCIPLES ........................................................................................................................................ 31 3.2 SAFETY INTERLOCK AND OVERLOAD PROTECTION ............................................................................................. 31

3.2.1 Safety interlock .......................................................................................................................................... 31 3.2.2 Thermal overload protection ..................................................................................................................... 31 3.2.3 Cambox overload protection ..................................................................................................................... 32

3.3 SUPPLEMENTARY KITS ...................................................................................................................................... 32 3.4 PRINCIPLES FOR TESTING ................................................................................................................................... 32

4 OPERATION .......................................................................................................................................................... 35

4.1 GUIDELINES FOR SAFE WORKING PRACTICE ...................................................................................................... 35 4.2 GENERAL OPERATION ........................................................................................................................................ 36

4.2.1 Cam Removal (if already fitted) ................................................................................................................ 36 4.2.2 Cam Fitment .............................................................................................................................................. 38

4.3 EUI FITMENT AND HYDRAULIC CONNECTIONS ................................................................................................. 42 4.4 EUP FITMENT AND HYDRAULIC CONNECTIONS ................................................................................................. 44 4.5 PRELOAD ADJUSTMENT ...................................................................................................................................... 45

4.5.1 Electrical connections ............................................................................................................................... 47 4.6 SOFTWARE ......................................................................................................................................................... 49

4.6.1 Menu tree .................................................................................................................................................. 49 4.6.2 Message box .............................................................................................................................................. 50 4.6.3 Main Test Screen ....................................................................................................................................... 50 4.6.4 Testplan Screen ......................................................................................................................................... 52 4.6.5 Results (Saving) Screen ............................................................................................................................. 53 4.6.6 Results (Loading) Screen .......................................................................................................................... 54 4.6.7 Diagnostic Screen ..................................................................................................................................... 54 4.6.8 Owner Detail Screen ................................................................................................................................. 56 4.6.9 Logon Dialogue ......................................................................................................................................... 57 4.6.10 Injector Details Screen .............................................................................................................................. 58

4.7 LOADING A TESTPLAN ....................................................................................................................................... 58 4.7.1 Edit an existing testplan ............................................................................................................................ 59

HK1400 All Makes Bench EUI/EUP HARTRIDGE LIMITED

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4.8 STARTING THE TESTPLAN DISPLAYED ON THE MAIN SCREEN ........................................................................... 60 4.8.1 Injector response ...................................................................................................................................... 61 4.8.2 In edit mode .............................................................................................................................................. 61 4.8.3 Test step results ........................................................................................................................................ 61 4.8.4 Measuring the Coil Resistance (coil injectors only) ................................................................................. 61 4.8.5 Measuring fuel delivery ............................................................................................................................ 61

4.9 SAVING RESULTS .............................................................................................................................................. 62 4.10 VIEWING RESULTS ............................................................................................................................................ 62 4.11 EXAMPLE RESULTS SHEET ................................................................................................................................. 63 4.12 ASSESSING THE INJECTOR UNDER TEST ............................................................................................................. 63

5 MAINTENANCE .................................................................................................................................................... 65

5.1 REGULAR MAINTENANCE ................................................................................................................................. 65 5.1.1 Inspect nosepiece O-Ring ......................................................................................................................... 66

5.2 TROUBLESHOOTING .......................................................................................................................................... 67

6 SPARES ................................................................................................................................................................... 69

6.1 CONSUMABLES .................................................................................................................................................. 69 6.2 GENERAL SPARES ............................................................................................................................................. 70

APPENDIX A - CIRCUIT DIAGRAMS ....................................................................................................................... 71

APPENDIX B: HEALTH AND SAFETY DATA SHEET .......................................................................................... 79


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LIST OF FIGURES

Figure 2.1 125mm centre height (e.g. Bosch) ................................................................................................ 13

Figure 2.2 246mm centre height (e.g. Hartridge) ........................................................................................... 13

Figure 2.3 Injector access position .................................................................................................................. 14

Figure 2.4 Injector access guard ..................................................................................................................... 15

Figure 2.5 Coupling guard ............................................................................................................................... 15

Figure 2.6 Coupling Drive Engagement .......................................................................................................... 16

Figure 2.7 Coupling Drive Clearance .............................................................................................................. 17

Figure 2.8 Coupling Clamp Screws ................................................................................................................. 17

Figure 2.9 Securing Cambox to Bedplate ....................................................................................................... 18

Figure 2.10 Drive Coupling Rotational Check ................................................................................................. 18

Figure 2.11 Interlock Connector ...................................................................................................................... 19

Figure 2.12 Safety interlock connector ............................................................................................................ 20

Figure 2.13 User Account Control Dialog ........................................................................................................ 21

Figure 2.14 Magmah Installer Language Selection ......................................................................................... 22

Figure 2.15 Magmah Software Installer Welcome Screen .............................................................................. 22

Figure 2.16 Magmah Software Installer Components Screen ........................................................................ 22

Figure 2.17 Magmah Software Installer Progress Screen .............................................................................. 23

Figure 2.18 Application Data Installer Warning Screen .................................................................................. 23

Figure 2.19 Windows XP Start Menu .............................................................................................................. 24

Figure 2.20 Windows XP Control Panel .......................................................................................................... 24

Figure 2.21 Windows XP Network Connection Screen ................................................................................... 25

Figure 2.22 Windows XP LAN Properties Screen ........................................................................................... 25

Figure 2.23 Windows XP IP Address Configuration Screen ........................................................................... 26

Figure 2.24 Windows 7 Start Menu ................................................................................................................. 26

Figure 2.25 Windows 7 Control Panel ............................................................................................................. 27

Figure 2.26 Windows 7 Network and Internet Screen ..................................................................................... 27

Figure 2.27 Windows 7 Network and Sharing Screen .................................................................................... 28

Figure 2.28 Windows 7 Network Connections Screen .................................................................................... 28

Figure 2.29 Windows 7 LAN Properties Screen .............................................................................................. 29

Figure 2.30 Windows 7 IP Address Configuration Screen .............................................................................. 29

Figure 4.1 Draining Oil from Cambox ............................................................................................................... 36

Figure 4.2 Cam Cover and Cam Removal ....................................................................................................... 37

Figure 4.3 Cam Removal from Camshaft Spline .............................................................................................. 37

Figure 4.4 Cam Fitment .................................................................................................................................... 38

Figure 4.5 Cam Nut, Spring Washer and Load Washer Fitment ...................................................................... 38

Figure 4.6 Cam Nut Torque Procedure ............................................................................................................ 39

Figure 4.7 Cambox Cover Fitment ................................................................................................................... 40

Figure 4.8 Tappet Breather Oil Fill Location..................................................................................................... 41

Figure 4.9 Drain/Level Pipe Oil Fill Location .................................................................................................... 41

Figure 4.10 EUI Fixturing .................................................................................................................................. 42


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Figure 4.11 EUI Hydraulic connections .......................................................................................................... 43

Figure 4.12 EUP Fixturing .............................................................................................................................. 44

Figure 4.13 EUP Hydraulic connections ......................................................................................................... 45

Figure 4.14 Preload ......................................................................................................................................... 46

Figure 4.15 Cable Connections ...................................................................................................................... 47

Figure 4.16 Launch Screen ............................................................................................................................ 49

Figure 4.17 Clickable Tabs ............................................................................................................................. 49

Figure 4.18 Menu Tree ................................................................................................................................... 49

Figure 4.19 Message Box ............................................................................................................................... 50

Figure 4.20 Main Test Screen ........................................................................................................................ 50

Figure 4.21 Testplan Screen .......................................................................................................................... 52

Figure 4.22 Results (Saving) Screen .............................................................................................................. 53

Figure 4.23 Results (Loading) Screen ............................................................................................................ 54

Figure 4.24 Diagnostic Screen ....................................................................................................................... 55

Figure 4.25 Owner Details Screen.................................................................................................................. 56

Figure 4.26 Logon Dialogue ........................................................................................................................... 57

Figure 4.27 Injector Type Screen ................................................................................................................... 58

Figure 4.28 Testplan Selection drop down boxes .......................................................................................... 58

Figure 4.29 Drive direction .............................................................................................................................. 60

Figure 4.30 View Results ................................................................................................................................ 62

Figure 4.31 Results File .................................................................................................................................. 63

Figure 5.1 Inspect Nosepiece O-Ring ............................................................................................................ 66

Figure 6.1 Consumables ................................................................................................................................. 69

Figure 6.2 General spares .............................................................................................................................. 70


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Foreword

Copyright

Hartridge™ Ltd. reserves the copyright of all information and illustrations in this publication which is supplied in confidence and which may not be used for any other purpose other than that for which it was originally supplied. The publication may not be reproduced in part or in whole without the consent in writing of this company.

© Hartridge™ Ltd.

Warranty Statement

The equipment is covered by the Hartridge™ Ltd standard Terms and Conditions of Sale or Supply. Section 7, 8 and 9 of these Terms and Conditions of Sale or Supply relate to guarantee. ‘The Company’ refers to Hartridge Limited. A complete copy of the Terms and Conditions of Sale or Supply is available on request.

Please note that all guarantees and warranties are limited to use of the equipment with software installed as supplied and expressly exclude the correct operation of, or any interaction between the kit software and, any software and/or hardware supplied by a third party and installed on the Machine. Such software and/or hardware shall be considered as an accessory as defined in Section 7c of the Terms and Conditions of Sale or Supply and installation of third party software may be considered as misuse of the equipment as defined in Section 9(a).

Similarly it is vital that the equipment is operated correctly and in accordance with the instructions and messages displayed on the Host Machine and EUI/EUP control software. Failure to do so may be treated as misuse under section 9b (iii) of the Terms and Conditions of Sale and Supply and particular attention must be paid to closing the Machine down where it is vital the specified procedure is followed.

More specifically, the following are excluded from any express or implied warranties relating to the equipment:

Damage caused by poor mains supply quality.

Damage caused by improper electrical connection of injectors.

Damage caused by improper hydraulic connection of the cambox to the test bench.

Damage caused by incorrect connection of the safety interlock into test benches.

It is the Client’s responsibility to ensure that any third party accessories (e.g. modem or network card) installed on the Host Machine by the Client or at the Client’s request are compatible with the equipment and will not detract from its correct operation.


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Safety Information

Warnings, Cautions and Notes

The precautionary notes in this publication, indicated by the words WARNING, CAUTION, or NOTE provide information about potential hazards to personnel or equipment. Ignoring these notes may lead to serious injury to personnel and/or damage to equipment. These notes appear as follows:

WARNING!

INDICATES THAT A SITUATION MAY BE HAZARDOUS TO PERSONNEL.

INSTRUCTIONS ARE PROVIDED FOR AVOIDING PERSONAL INJURY.

CAUTION! Indicates that conditions exist that could result in damage to equipment. Instructions are provided to prevent equipment damage.

NOTE Indicates additional information for clarification where there may be confusion.

General Warnings

Isolate the electrical supply before performing any maintenance operations. Do not work on electrical equipment while voltage is supplied. If such cannot be avoided, e.g. for measurements, tests or adjustments, have the action carried out by qualified personnel only.

Safety glasses must be worn when working on this equipment for the following reasons:

1.The EUI/EUP base cambox kit is capable of producing high pressure fluid jets or sprays which can cause severe eye injury in the event of a malfunction.

2.The test stand uses calibration fluid which is harmful to the eyes.

Make sure any rotary machinery is stationary before opening any access panels or removing fixed panels.

Ensure the cambox drive coupling guard is in place before starting the test bench drive.

Use extreme care to avoid being drawn in to the test stand. Check that all clothing, especially sleeves and ties, and hair is safe and cannot be caught in revolving parts. Check that hoses connected to the injector cannot chafe or become entangled in the drive, thus causing a hazard.

Ensure the cambox drive coupling guard is in place before starting the test bench drive

Make sure there is adequate ventilation. Oil vapour may be released from hot fixtures or high pressure leaks. The specific directions in Health & Safety Data Sheets must be adhered to.

Keep hands and the body away from fluid sprays, especially injectors, leaking high pressure pipes and seals. High pressure injection through the skin can result in fatal injury. In the event of injection into the skin, seek urgent medical attention. Refer to the Health & Safety Data Sheets.


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Impervious gloves and overalls should be worn if regular contact with ISO4113 test fluid is likely. Gloves should also be worn when handling fixture parts or injectors after testing which may be hot. Refer to the Health & Safety Data Sheets.

Burns will occur to the hands if certain parts of the kit or equipment under test are touched. Keep hands away from the injector or high pressure pipes after periods of extended running.

Safety footwear must be worn in the test area at all times. Injury to the feet may be sustained in the event that equipment under test (during loading or unloading) or covers are dropped.

Severe injury can be caused by slipping on spilt oils or fluids. All spillages of fluids in the test area must be dealt with immediately. These can be mopped up and mineral absorbent material spread over the affected area.

Ensure that any cables between the cambox and the EUI/EUP control box are safely routed and do not present a trip hazard.

Use calibration fluid and lube oil of the correct specification only. Obtain the manufacturers Health & Safety Data Sheets and follow the advice given therein. Prolonged and repeated contact with oil products, ingestion or excessive and prolonged inhalation of oil mists can be detrimental to health. Use an appropriate barrier cream.

Ensure that the servicing requirements and intervals as set out in the Maintenance section are adhered to. Operate and service this equipment only if competent to do so. Carry out regular inspections to make sure all high pressure connections are tight and safe.

Remove any tools, cleaning rags or other debris from the test stand before starting up. Make sure the inching bar is not fitted to the test stand before starting up.

There must be no naked flames. Potentially flammable vapours are present in the test stand and ignition is possible although unlikely. Smoking whilst operating the equipment is strictly forbidden.

Accidents can occur to unauthorised personnel during testing. Untrained person(s) must not be present in the test area when the equipment is operating. Only qualified personnel are to operate this equipment.

Ensure good levels of lighting for safe, efficient equipment operation.


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This equipment uses Viton (fluoroelastomer) seals. If these seals are exposed to high temperatures, they decompose into a corrosive substance which is extremely harmful and will contaminate skin. Do not touch Viton seals or the sealing surfaces if they have been burnt or exposed to temperatures in excess of 400ºC.

Ensure that the mains electrical supply to the EUI/EUP control box is correctly earthed (grounded).

Ear defenders or ear plugs must be worn by all personnel in the test area. High noise levels will damage the inner ear and cause deafness.

CAUTION

This equipment contains electrostatic sensitive devices. Observe the necessary precautions for handling electrostatic discharge sensitive devices. Do not touch printed circuit boards and associated electronic connections and components.

Arc welding equipment must not be operated within 5 metres of the kit. The electrical supply to welding equipment must be provided from a remote isolating transformer. Arc welding can disturb the measuring circuit.

Always start the system running at a low speed, check for correct injector function and visually check for any leaks before setting higher speeds/pressures.

This particularly applies having just mounted a system, or having just replaced a component.

Do not open the cambox injector guard while the system is running. Wait for the test bench drive to stop and for the pressure to decay to a low level before opening the guard.

At the end of its useful life, please ensure your Hartridge product(s) is disposed of in

accordance with national regulations.


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1 Introduction & Specification

1.1 General

The kit is designed to be connected to traditional diesel test benches to enable testing of EUI/EUP fuel injection equipment. A typical system for a specific application would consist of:-

Cambox and controller

Application kit for injector type (fuel sleeve, nose piece, cable, cam and pushrod)

Computer/software

The kit consists of a single cam cambox and basic tooling. Injectors are mounted to the cambox using existing components from the Hartridge catalogue, and the cambox is mechanically driven by the host test bench. Fuel supply and delivery measurement will be via the host test bench. A control box drives the injectors electrically, results are read from the host test bench and manually entered into the computer software for results display and analysis.

The control box may be installed in a generic 19” rack or used free standing on a desk top.

1.1.1 Features

Single cam for all low speed applications

Single cam for all high speed applications

Compatible with 125mm and 246mm* drive line centre heights to suit a range of machines

Adjustable injector plunger lift

Adjustable injector plunger pre-load

Guard for protection from moving parts and high temperatures

Volt free interlock contact for connection into host bench drive control circuit

12V, 24V, 50V and 90V coil injector actuator capability

185V piezo injector actuator capability

Dual injector actuator capability (angle/time overlapping) for E3 injectors

Nozzle response time measurement

Automatic Injector voltage selection via injector cable

Thermal overload protection (refer to section 3.2.2)

Cambox overload protection (refer to section 3.2.3)

*Requires additional components to adapt cambox centre height (refer to section 2.1)

1.2 Host Bench requirements

The host test bench is to provide:-

Drive speed and direction control

Fuel supply & return

Injected quantity measurement

All fittings to the test bench are to be provided by the customer as these are specific to the host test bench, which are beyond Hartridge control.


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1.2.1 Host Bench Recommended / Minimum Specifications

Min Max Engineering Units

Drive Power 10 Hp

Drive inertia 0.5*1

Kgm2

Drive coupling stiffness ISO4008*1

Fuel supply pressure 3*2

7*2

Bar

Fuel supply temperature 35*3

45*3

°C

Fuel supply flow rate 2 10 Litres/min

*1 Recommend specification for RPM stability and test repeatability. It is possible to use the HK1400 EUI/EUP

cambox with a host bench which has a drive inertia lower than stated, however depending on application being tested low speed stability and test repeatability could be affected.

*2 Dependent upon application being tested, refer to application sheets within HK1400 software.

*3 Recommended specification for test repeatability.

NOTE : The HK1400 cambox is not compatible with Hartridge VDM electronic metering systems.

1.3 Specification

1.3.1 Cambox Hardware

Max speed 2400rpm.

Max cam lift 18 mm.

Injector clamp load up to 1.5 tonnes applied using load screw

Weight of dry cambox assembly without application kit fitted - 26kg.

1.3.2 Electrical supply

Single phase 85 - 264 volt, 50/60 Hz, fused at 2A with IEC connector inlet

1.3.3 Fluids

Test oil – ISO 4113 Calibration Fluid

Lubrication oil – 10W – 40W or Similar

1.3.4 Programmable parameters:

Injector coil drive peak current, peak current duration and hold current

Injector piezo charge & discharge current.

Injector pulse duration.

Injector cam timing.

Maximum & minimum limits for injected quantity, response time and coil resistance measurements

1.3.5 Measured parameters

Drive shaft speed.

Injector response time.

Solenoid resistance.

1.3.6 Definition of Terms and Abbreviations

ECU Electronic (engine) Control Unit EUI Electronic (controlled) Unit Injector EUP Electronic (controlled) Unit Pump NOP Nozzle Opening Pressure (bar) NCV Nozzle Control Valve SCV Spill Control Valve


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2 Installing the Kit

SWITCH OFF POWER SUPPLIES BEFORE STARTING THE INSTALLATION PROCEDURE.

2.1 Cambox Installation (Refer to TB450_39)

To install the cambox on a host test bench which has a 125mm drive centre height, perform the following:

1) Install the keyway into the base of the cambox with the 3 retaining bolts, torque to 10Nm.

2) Lift the cambox onto the host test bench and secure to the bedplate using suitable clamps.

Figure 2.1 125mm centre height (e.g. Bosch)

To install the cambox on a host test bench which has a 246mm drive centre height, perform the following:

1) Install the keyway into the base of the cambox as instructed above.

2) Locate APB224 onto the host test bench bedplate and secure using clamps APB220.

3) Install adapter plate A242A127 onto APB244 upper face using the 2 retaining bolts, torque to 100Nm.

4) Lift the cambox onto adapter plate A242A127 and ensure the cambox key is located within the adapter plate keyway.

5) Install 2 retaining bolts through the cambox mounting holes into adapter plate A242A127 and torque tighten to 100Nm.

Figure 2.2 246mm centre height (e.g. Hartridge)

125mm

246mm


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2.1.1 Injector access position

Access to the injector (left or right) can be changed by removal of the pressure plate (Figure 2.3A), changing the orientation of the Injector support plate (Figure 2.3B) and refitting of the pressure plate (Figure 2.3A), ensuring that the 2 retaining bolts (Figure 2.3D) are torqued to 25Nm. The Junction box cables (Figure 2.3C) must be disconnected during the procedure and reconnected afterwards.

Figure 2.3 Injector access position

2.1.2 Injector access guard

A clear polycarbonate guard is provided, to enclose the Injector under test. The guard is intended to prevent operator contact with:-

Parts which develop high temperatures under test conditions NOTE : High temperatures will also be present on components, pipes and fittings outside of the guard.

Electrical contacts of Injectors under test

Potential pinch points during tests

If the Safety Interlock Connection has been wired into the host test bench as instructed, the test bench drive will also be prevented from starting, or will be stopped if the cover is removed during tests.

Referring to figure 2.4, fit the injector access guard by resting it on the base of the fixed interlock cover (Figure 2.4A). Rotate and push the guard forward, ensuring the interlock key (Figure 2.4B) is aligned with the interlock body (Figure 2.4C) and the guard clips (Figure 2.4D) click into position on the support pillars (Figure 2.4E).

A

B

C

25Nm

2 D


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Figure 2.4 Injector access guard

DANGER!

Do not attempt to bypass the interlock switch, remove the interlock or attempt to fit the cover in alternate positions.

2.1.3 Coupling guard

A coupling guard is provided to prevent entanglement with a rotating drive. The outer sleeve of the guard can be retracted to allow access to a drive coupling for purposes of barring over the cam.

The guard MUST be returned to the fully extended (Test bench operating) position when running the test bench, for operator safety.

Figure 2.5 Coupling guard

Test bench operating position

Barring over position

A

B

C

D

E

Click


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2.1.4 Cambox Mounting

Hartridge recommend the use of trolley HM1053 for safe easy mounting of the cambox assembly to Hartridge test benches. If the trolley is used, align the trolley with the bedplate, secure it to the machine using the clamp, release the cambox clamp and carefully slide the cambox onto the bedplate.

If the Hartridge APB244, APB220 and A242A127 are utilised the cambox can be mounted on the Hartridge trolley, otherwise the cambox must be lifted by a crane and strap around the top pressure plate of the cambox.

The assembly is heavy and should not be manually lifted on/off the machine by one person.

1. Slide the cambox assembly along the machine’s test bed and, with the drive dogs horizontal, rotate the machine drive coupling to align with the cambox coupling, and then engage them together. Refer to Figure 2.6.

Figure 2.6 Coupling Drive Engagement


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2. Withdraw the cambox assembly until there is about 1mm gap between machine coupling and cambox coupling. Refer to Figure 2.7.

Figure 2.7 Coupling Drive Clearance

3. Tighten the test bench coupling clamp screws to secure the cambox coupling. Refer to Figure 2.8.

Figure 2.8 Coupling Clamp Screws

4. Secure the cambox to the test bed using APB220 clamps (for Hartridge standard 246mm centre height test benches) or the generic test bed securing bolts used on other manufacturer test benches. Refer to Figure 2.9.


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Figure 2.9 Securing Cambox to Bedplate

The cambox MUST be adequately secured to the test bed.

5. Rotate the machine drive manually to ensure the cambox coupling is symmetrically engaged with the machine coupling. Refer to Figure 2.10.

Figure 2.10 Drive Coupling Rotational Check

2.1.5 Safety interlock connection

The cambox has a safety interlock contact available for connection into the test bench drive control circuits. The contact is open when the cambox guard is removed and closed when the guard is in place. This provides a means of preventing the test bench drive from rotating until hands are clear of the area and the guard is in position


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It is strongly recommended that the cambox safety interlock is utilised to ensure maximum operator safety

The interlock is available via the 3 pin DIN connector on the cambox junction box. To wire the connector:-

1. Remove the central retaining screw

2. Use a 3mm flat blade screwdriver to unclip the connector cover

3. Thread the cable/wire from the test bench through the connector entry gland/grommet. The maximum cable diameter allowed is 6mm.

4. Connect wires to the screw terminals. The terminal capacity is 0.75mm2 maximum wire

cross sectional area.

The connector pinout is –

Pin 1 Contact IN

Pin 2 Contact OUT

Pin E Not connected

The switching capacity of the interlock contact is 5 Amps maximum, 60V maximum (as designated on the junction box label).

Correct connection into test benches other than the Hartridge AVM2-PC is the responsibility of the end user. It is the responsibility of the end user to determine whether the host test bench systems are suitable for integration of the safety interlock. Consult your test bench product manual or manufacturer before wiring in the safety interlock.

Hartridge Ltd. Accept no responsibility for improper connection into third party test benches.

A typical installation would involve wiring the interlock into the host test bench drive STOP control.

Figure 2.11 Interlock Connector

1 2

4

3

Click

Max

6mmØ

cable

Max

0.75mm2

wire


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Note: When the interlock is wired into the host bench and the Cambox is not being used then

Cambox Interlock Link Assembly A242P010 can be used to enable normal operation of the

host bench.

Figure 2.12 Safety interlock connector

For connection into a Hartridge AVM2-PC machine, contact Hartridge Customer Support –

Email: [email protected]

Tel: +44 (0)1280 825650

1 2 Typical installation example

mailto:[email protected]


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2.2 COMPUTER / USER INTERFACE

2.2.1 Computer hardware

The HK1400 All-Makes cambox utilizes Hartridge’s feature rich Magmah software to drive the EUI/EUP application. Magmah requires a dedicated computer and this is not supplied as part of the HK1400 cambox, the end user is responsible for supplying the computer. The following hardware specification is required to utilize Magmah software and interface with the HK1400 cambox electronics.

Item Description

Operating System Windows XP or 7 Standard / Pro (x86 or x64)

Locale Restriction Western, non-ideographic language (i.e. not Chinese, Arabic, Japanese etc.).

Processor Intel dual-core 1.8GHz

RAM 4 GB RAM

Video Display Output VGA or DVI, resolution of 1280 x 768 @ 60fps minimum specification

Mass Storage Disc storage 120 GByte; (500 Mbyte for application and libraries)

USB interface 1x USB2 port

Network Port 1x 10/100 Mbps Ethernet

2.2.2 Computer software

The Magmah software is included on the USB memory device included within the HK1400 kit, part number: A242A603.

It is recommended to copy the setup files from the USB memory device to the computer and run the following installation program:

HK1400-EUI-EUP-Setup.exe

Please note that the installer makes changes to the computers registry. If more than one user account is to use the software then the software must be installed by each user under their account log in.

1. If the following message appears when installing, just accept by pressing “yes”.

Figure 2.13 User Account Control Dialog


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2. From the drop down list box select the language the installer will use.

Figure 2.14 Magmah Installer Language Selection

3. Select next to continue the installation.

Figure 2.15 Magmah Software Installer Welcome Screen

4. Select the components to install. The “Core HK1400-EUI-EUP” software install is checked by

default and should usually be left checked. The Application is in English by default but it is possible to install 1 alternative language which can be selected from the drop down list box. If at a later date a different alternative language is required this can be achieved by running the installer again and selecting from the drop down list box the required alternative language (the “Core HK1400-EUI-EUP” software Install can be unchecked as this is already present).

5. Press the “Install” button.

Figure 2.16 Magmah Software Installer Components Screen


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6. A dialogue displays the progress of the installation

Figure 2.17 Magmah Software Installer Progress Screen

7. Press close. The application is installed

2.2.3 Software Data Installation

Before launching the HK1400 cambox software it is necessary to install the test data, this consists of example test plans, Injector type information (used to configure the injector drive circuit with the correct values of current and voltage for a particular injector) and the style sheets (which are used to render the result files in to a suitable form for displaying and printing via Internet explorer. This is data is also included on the USB memory stick provided.

It is recommended to copy the data installer from the USB memory stick to the COMPUTER and run the following installation program:

HK1400-EUIEUP-Data-Setup.exe

Installation is the same as for the application. During installation the following dialogue may appear.

Figure 2.18 Application Data Installer Warning Screen

This is just to inform that the data or previous version of the data has already been installed. Selecting “yes” will over write the Hartridge supplied test plans. These test plans are usually read


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only so that the user cannot over write modified versions of them but can save modified copies under a different name.

Selecting “yes” will over write the existing test plans with those from the data. Only the read only test plans will be over written, any customer generated test plans with a different name will not be over written.

2.2.4 Computer IP Address

The HK1400 EUI/EUP software communicates with the AE65/1 Control Box via an Ethernet connection.

For Windows XP

The IP address of the host COMPUTER must be set manually as defined below:

1. Click the ‘Windows Start Icon’ and select ‘Control Panel’.

Figure 2.19 Windows XP Start Menu

2. Select ‘Network Connections’ within the Control Panel screen.

Figure 2.20 Windows XP Control Panel


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3. Right click on ‘Local Area Connection’ and select ‘Properties’.

Figure 2.21 Windows XP Network Connection Screen

4. Highlight ‘Internet Protocol (TCP/IPv4)’ and select ‘Properties’.

Figure 2.22 Windows XP LAN Properties Screen


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5. Select ‘Use the following IP address’ and define the parameters as stated below:

IP Address = 192.168.42.1

Subnet mask = 255.255.255.0

Figure 2.23 Windows XP IP Address Configuration Screen

6. Click OK The IP address is now configured for the host computer.

For Windows 7 The IP address of the host computer must be set manually as defined below:

1. Click the ‘Windows Start Icon’ and select ‘Control Panel’.

Figure 2.24 Windows 7 Start Menu


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2. Select ‘Network and Internet’ within the Control Panel screen.

Figure 2.25 Windows 7 Control Panel

3. Select ‘Network Sharing Centre’ within the Network and Internet screen.

Figure 2.26 Windows 7 Network and Internet Screen


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4. Select ‘Change adaptor settings’ from the left panel of the Network and Sharing Centre screen.

Figure 2.27 Windows 7 Network and Sharing Screen

5. Right click on ‘Local Area Connection’ and select ‘Properties’

Figure 2.28 Windows 7 Network Connections Screen


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6. Highlight ‘Internet Protocol Version 4 (TCP/IPv4)’ and Click on ‘Properties’

Figure 2.29 Windows 7 LAN Properties Screen

7. Select ‘Use the following IP address’ and define the parameters as stated below:

IP Address = 192.168.42.1

Subnet mask = 255.255.255.0

Figure 2.30 Windows 7 IP Address Configuration Screen

8. Click OK The IP address is now configured for the host computer.


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3 Systems and Principle of Operation

3.1 General Principles

EUI/EUP equipment used on current applications are controlled using variable voltages and currents from the engine ECU. In general, the injector is initially supplied with a short duration high current that closes the high pressure spill control valve (SCV) as quickly as possible. The current is then reduced and this is held until the required duration of injection event is complete. Closing the SCV allows the fuel to be compressed by the plunger until the pressure is sufficient to lift the needle off its seat and the fuel is injected. Opening the SCV allows the needle to re-seat and the injection ends.

For unit injectors that have dual actuator control, i.e. E3 injectors, there is a Nozzle Control Valve (NCV) in addition to the SCV. Closing the SCV allows the fuel to be compressed as for a single valve injector, but injection cannot occur until the NCV is activated and the pressurised fuel is applied to the nozzle needle. This means that fuel pressure can be pumped up to a much higher level before the NCV is activated to allow the nozzle needle to open, providing a means of substantially increasing the NOP and level of injection pressure during injection

The correct definition of the injector currents and voltages are essential for an injector to be tested correctly.

The injector test plan is controlled using special EUI/EUP software. This enables the correct parameters to be precisely entered, the machine controlled within safe limits and the test data saved and used as required.

Mounting requirements

The injector must be rigidly mounted with a fixture strong enough to withstand the injection forces.

It must be operated using a cam with the correct profile, i.e. the correct lift and timing.

The electrical signal to the injector must be accurately timed relative to the cam profile. The combination of the speed, cam profile, tappet and pushrod are critical to give a correct installation and performance.

3.2 Safety Interlock and overload protection

3.2.1 Safety interlock

When fully and correctly installed the Cambox kit is safety-interlocked so that:

The drive cannot be started if the guard is open (subject to the safety interlock being wired into the host test bench).

The drive will stop if the guard is opened whilst it is running (subject to the safety interlock being wired into the host test bench).

3.2.2 Thermal overload protection

The software will calculate the thermal load and turn off the injector when this value reaches a maximum.

The main screen displays a live thermal load value as a percentage of the maximum allowable.

The setting screen displays the following values:

Heating factor

Cooling factor

Sample time interval.

An error message will be displayed on screen to inform the operator that the thermal load has exceeded the maximum.


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3.2.3 Cambox overload protection The overload protection is based on the maximum injector firing angle. Each injector type has a separate maximum injector firing angle, derived from tests and stored in software.

This value is used to check that the angle is not exceeded during test plan editing and also prior to setting the pulse width when running a test.

The injector type screen will allow the entry of the following parameters which will be stored and read from the existing injector type files:

Maximum pulse angle (actuator 1) (SCV) 0 – 360°

Minimum overlap angle (actuator 1 - 2) 0 – 360°

An error message will be displayed on screen to inform the operator that the maximum angle has been exceeded or the overlap angle is too small.

3.3 Supplementary Kits

In general each EUI/EUP type requires:

The correct cam set to the correct position in the cambox to suit the injector type.

A nosepiece that collects the injected oil that is piped to the host machine’s injected quantity measuring system. The nosepiece incorporates a piezo transducer used to measure the response of the injector,

A fuelling sleeve to provide supply and return test oil flow and form part of the EUI/EUP clamping system,

A push rod/spacer that axially positions the EUI/EUP plunger in the correct position relative to the cam

An extensive range of application kits is available. Contact your local distributor for further details.

3.4 Principles for Testing

The kit is capable of operating over a wide range of conditions but to obtain maximum use and efficiency it is important that the testing is carried out in a controlled and consistent way.

As a result of extensive testing and development at Hartridge Ltd. it is recommended that the following procedure is followed;

1. Fit a ‘master’ EUI/EUP to the cambox following the instructions within the application data sheet, which can be accessed when starting the test plan within the HK1400 software.

2. Connect test oil supply and test oil return and electrical connections.

3. Rotate the drive by hand to ensure full 360 degree rotation.

CAUTION:

Care should be taken when manually rotating the drive by hand as the EUI/EUP plunger spring can cause the drive to rotate suddenly due to being compressed by the cam.

4. Run the unit at the “Purge” test step until repeatable delivery readings are obtained. If delivery is not obtained then refer to section 5.2 to determine possible faults.

5. Select a performance test step, i.e. idle, max power, max torque, and run the test for at least 30 seconds for the delivery and response time to stabilise before recording the values.

6. Repeat the process until all test points have been performed.

7. Stop the machine.

8. Save the results.

9. Generate ‘master’ pass / fail limits.

10. Remove the EUI/EUP.


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11. Test all subsequent EUI/EUP’s against the ‘master’ limits.

This process will ensure the fastest warm-up and will give the most consistent results. Longer time at the maximum speed/delivery condition will give more stability but at the expense of test time. Ensure that all EUI/EUP units are tested in exactly the same way so that meaningful comparisons can be made.

Note: The EUI/EUP resistance is only measured when executing the first test step, therefore once measured the value will be locked until the test is restarted.


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4 Operation

WARNING! HIGH PRESSURE FLUID SPRAYS CAN CAUSE SERIOUS INJURY OR DEATH.

DO NOT ATTEMPT TO BY-PASS THE GUARD SAFETY INTERLOCK

4.1 Guidelines for Safe Working Practice

CAUTION:

Do not open the guard while the system is running. Wait for the test bench drive to stop before opening the guard.

CAUTION:

Check that the fixture is correctly aligned and that the injector is clamped to the correct load before running the machine.

CAUTION:

The injectors produce high internal pressures that give high temperatures of injector, fixture and pipes.

Use protective gloves when loading and unloading or adjusting the fixture.

CAUTION:

Do not unclamp the injector while oil is still being supplied to the injector.

The injector may be forced out of the sleeve by the pressure and a major spillage will occur.

CAUTION:

Support the injector when it is unclamped.

When the injector is unclamped and the supply and return pipes removed the injector may fall out of the fixture and cause injury or damage.


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4.2 General Operation

Information on which parts are needed and how the injector is mounted is provided on the application data sheets, which are included on the USB memory device, A242A603, provided with HK1400.

4.2.1 Cam Removal (if already fitted)

1. Drain all oil from the cambox by unclipping the filler/drain pipe (Figure 4.1A) and drain the oil into a suitable container (Figure 4.1B).

Figure 4.1 Draining Oil from Cambox

CAUTION:

High Temperature Oil

After running the cambox the oil temperature could reach high temperatures.

A

D Click

B


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Figure 4.2 Cam Cover and Cam Removal

2. Remove the 4 cam cover retaining bolts (Figure 4.2A) and pull off the cam cover (Figure 4.2B).

NOTE If extraction assistance is required, remove the centre bolt (Figure 4.2C), and use the supplied M8 x 70 jacking bolt.

3. Lock the drive shaft to prevent it from turning using the holes provided in the drive coupling (D).

4. Remove the cam nut (Figure 4.2E), using a suitable 1/2inch square drive, spring washer (Figure 4.2F), load washer (Figure 4.2G).

5. Remove the cam (Figure 4.3H) from the splined camshaft.

NOTE On initial use the cam may be tight on the camshaft splines, this tightness will reduce with continued use.

Figure 4.3 Cam Removal from Camshaft Spline

A

B

C

D

E

F G

H


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4.2.2 Cam Fitment

1. Line up the required cam position number with the indented hole in the camshaft (Figure 4.4), refer to the application datasheet for the correct cam position number for the EUI/EUP being tested.

2. Push cam onto camshaft splines, ensuring it is fully located.

NOTE On initial use the cam may be tight on the camshaft splines, this tightness will reduce with continued use.

Figure 4.4 Cam Fitment

3. Fit load washer (Figure 4.5A), spring washer (Figure 4.5Figure 4.5B) and cam nut (Figure 4.5C) onto the camshaft. Ensuring the load washer is fitted with the tapered edge against the camshaft splines.

Figure 4.5 Cam Nut, Spring Washer and Load Washer Fitment

CAUTION:

Cam Position

Incorrectly setting the cam positon could cause damage to the cambox or EUI/EUP. Refer to the application data sheet to select the correct cam position number for the application being tested.

CAUTION:

Load Washer

Ensure load washer is fitted with the tapered edge towards the camshaft splines to prevent damaging the camshaft splines.

C

B

A


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4. Lock the drive shaft to prevent it from turning using the holes provided in the drive coupling.

5. Using a 1/4in square drive torque wrench, torque the cam nut to 125Nm (Figure 4.6).

Figure 4.6 Cam Nut Torque Procedure

CAUTION:

Cam Nut Torque

Ensure the cam nut is torqued to the correct value as specified to prevent the cam nut becoming loose at high drive speeds. If the cam nut is not correctly tightened then possible damage could be caused to the cambox bearings.

125Nm


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6. Remove the extraction bolt (Figure 4.7A) from the cambox cover (if previously fitted).

7. Replace the cambox cover and torque tighten the 4 x cover retaining bolts to 20Nm.

8. Fit the cambox cover removal blanking plug (Figure 4.7B).

Figure 4.7 Cambox Cover Fitment

9. Fill the cambox with 1 litre of lubrication oil 10W – 40W or Similar. The cambox can be filled with oil in the following locations:

o Tappet housing breather hole (Figure 4.8) – requires removal of the EUI/EUP and pushrod.

o Drain/Level pipe (Figure 4.9) - using a suitable funnel.

CAUTION:

Oil Level

Ensure the oil level is above the minimum mark as indicated on the cambox, if not add more oil. Inadequate oil level will cause premature wear to the cambox bearings and possible damage to the cam and tappet assembly.

Oil level should only be checked when the cambox is static and in an upright position

The oil level should be checked before starting a new EUI/EUP test.

A

B

20Nm

4


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Figure 4.8 Tappet Breather Oil Fill Location

Figure 4.9 Drain/Level Pipe Oil Fill Location


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4.3 EUI Fitment and Hydraulic Connections

Note: EUI accessories are not included with the HK1400 base cambox; these are available separately for each application, refer to application datasheet for more information. For reference a typical example is shown below.

1. Select the correct fuel sleeve (Figure 4.10A) according to the application datasheet. Push the EUI fully into the fuel sleeve.

2. Select the correct nose piece (Figure 4.10B) according to the application datasheet. Locate the nose piece over EUI and fuel sleeve.

3. Locate the fuel sleeve and nose piece assembly into the base fixture (Figure 4.10C). Check the alignment of the EUI within the cambox fixturing, the EUI electrical connector should not be touching any part of the HK1400 fixturing.

4. Tighten the clamp screw (Figure 4.10D) to the correct torque, as indicated on the application data sheet.

Figure 4.10 EUI Fixturing

5. Connect the check valve assembly (Figure 4.11C), A242C003, to the nose piece quick release port*

6. Connect the supplied ALP339 delivery pipe to the outlet of the check valve assembly, the other end of the ALP339 delivery pipe should be connected to the host test bench metering system**.

A

B

C

D


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7. The fuel sleeve (Figure 4.11A) contains 2 x quick release connectors which provide the fuel supply (Figure 4.11E) and fuel return (Figure 4.11F) to the EUI being tested, using the supplied connectors, 8924266, and configure the hydraulic pipe for connection to the host test bench**.

Note: Fuel supply is the upper connector, return is the lower for all EUI fuel sleeves.

Figure 4.11 EUI Hydraulic connections

*It is important to ensure that check valve assembly, A242C003, is connected to the nose piece, failure to do this will result in unstable response times.

** It may be necessary to modify the hydraulic components provided to suit the host test bench. Connection to the host test bench is the responsibility of the end user; no parts are supplied for this.

F

E

B

A

C

ALP339


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4.4 EUP Fitment and Hydraulic Connections

Note: EUP accessories are not included with the HK1400 base cambox; these are available separately for each application, refer to application datasheet for more information. For reference a typical example is shown below.

1. Select the correct fuel sleeve (Figure 4.12A) according to the application datasheet. Push the EUP fully into the fuel sleeve.

2. Locate the fuel sleeve and EUP assembly into the base fixture (Figure 4.12C). Check the alignment of the EUP within the cambox fixturing, the EUP retaining points should be in line with the HK1400 cambox uprights.

3. Select the correct EUP clamp plate and clamping pins (Figure 4.12B) according to the application datasheet. Screw the clamp pins within the EUP clamp plate and then locate the clamp pins within the EUP retaining holes.

4. Tighten the clamp screw (Figure 4.12D) to the correct torque, as indicated on the application data sheet.

5. Fit the EUP injector mounting assembly to the cambox base fixture using the 2 retaining bolts, torque to 5Nm.

Figure 4.12 EUP Fixturing

A

B E

C

D

5Nm

2


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6. Fit the flexible HP pipe (Figure 4.13F) between the EUP and test injector and torque as indicated on the application data sheet

7. Connect the supplied ALP339 delivery pipe to the outlet of the injector assembly, the other end of the ALP339 delivery pipe should be connected to the host test bench metering system**.

8. The fuel sleeve (Figure 4.13A) contains 2 x quick release connectors which provide the fuel supply and fuel return to the EUP being tested, using the supplied connectors, 8924266, and configure the hydraulic pipe for connection to the host test bench**.

Note: EUP fuel sleeves will be marked / etched to identify “IN” for supply fuel and “OUT” for return fuel.

Figure 4.13 EUP Hydraulic connections

4.5 Preload adjustment

1. Fit the correct pushrod (Figure 4.14A) for the application, as instructed by the application datasheet.

2. Adjust the gap (Figure 4.14C) according to the application datasheet and lock into position with the lock nut (Figure 4.14B).

ALP339

A

F


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Figure 4.14 Preload

NOTE It is important to check the hydraulic connections for leaks, ensure the fuel supply and return hydraulic pipes are connected to the fuel sleeve. Switch on the fuel supply via the host test bench, configure the supply pressure as instructed by the application datasheet and check for any leaks.

CAUTION:

EUI/EUP Preload

Failure to set the correct preload could cause damage to the EUI/EUP being tested, the HK1400 cambox and/or the host test bench.

Rotate the drive by hand to ensure the set-up is correct and does not lock up. Check the EUI/EUP does not move vertically; re-clamp if it does.

A

B

C


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4.5.1 Electrical connections

Figure 4.15 Cable Connections

85-264Va.c. Host Computer Ethernet Connection

Ref 2.1.5

AE66/…


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Do not try to force the connectors together, this may cause irreparable damage. Always ensure the lugs are lined up correctly before attempting to push the two parts together.

Route the cables tidily between the control box and the test bench, ensuring that they do not present a trip hazard, are clear of rotating parts and that there is adequate access to the machine.

See the EUI/EUP specific Technical Bulletin (TB450) for details of the cable from control box to the injector. EUI/EUP actuators / coils are not polarity sensitive so the crocodile clips of injector cables (if present) can be fitted to either terminal.

The connectors on the front of the control box have bayonet coupling rings incorporating a metal wave spring, which locks with an audible positive ‘click’. All connectors have locating lugs, line up the lugs with the corresponding socket lugs and then push the plug into the socket. Rotate the outer coupling ring clockwise until it reaches the end of its travel and a ‘click’ is felt, indicating the connector is locked into position.

Switch the control box on using the red ON/OFF rocker switch on the front panel. The power switch will illuminate to indicate power is connected.


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4.6 Software

When the Magmah software is launched on a host computer, the program performs an initialisation sequence. The EUI/EUP Control Box must already be powered up for the initialisation to complete successfully. If the initialisation is unsuccessful, a warning is displayed that the software will not function without the appropriate hardware.

On launching the software the main test screen is displayed.

Figure 4.16 Launch Screen

4.6.1 Menu tree

Access to other display screens is available via the clickable tabs which are to be found on the upper section of all screens (Figure 4.17). The functions available are detailed in the Menu Tree (Figure 4.18)

Figure 4.17 Clickable Tabs

Figure 4.18 Menu Tree

MAIN SCREEN (Tab Selection)

Main TestPlan Results Diagnostic Settings Injector type

Test & Measurement

- Edit/Save Test step - Start/Stop Test - User Measurement

entry - Live test data view Testplan

Load/Save

Results File

- Selection - Display/Print

Control Box

Diagnostics

Owner Details

Production Setup

- Admin logon

Edit/Save Injector File

(Password protected)


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4.6.2 Message box

The message box at the bottom of all of the screens provides messages to guide the user through running a test. This box is also used for warning messages and error alerts. Some message clear themselves, others require an acknowledgement from the user by pressing the “OK” button.

Figure 4.19 Message Box

4.6.3 Main Test Screen

The initial main screen displays the last test plan used on the machine.

If the testplan shown on screen matches the EUI/EUP to be tested, Read Section 4.8 and proceed.

Figure 4.20 Main Test Screen Main Test Screen Overview

a

Starts and stops a test.

Loads a test plan

Edit / Disable edit button: used to allow / prevent test parameters and limits from being changed.

Provides functionality to Save / Delete the test plan which is loaded (only activated when a test plan is loaded and in EDIT mode)

Used to display previously captured results.


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b

Fuel supply pressure and test bench controlled temperature these values set for the whole test. They are stored in the test plan and are the values to be manually set on the bench before starting a test (these values can be changed when editing a test plan).

The thermal load is calculated and is displayed as a percentage of the maximum thermal load allowable. When it reaches 100% the injector is disabled to prevent damage.

c

Displays the speed from the 1 pulse per revolution into the EUI/EUP control box. The minimum and maximum speed limits are also displayed.

Displays the limits and the measured coil resistance values.

d

Test step select buttons (maximum of ten). If the button contains text then it is possible to select it and run the test step.

The green tick indicates that all the test step parameters have passed (red cross indicates a failed test step).

When a test step is selected the parameters appear in the bottom grid section. In edit mode the set points and test parameter limits can be changed otherwise they can only be observed.

e

This grid shows the test step set point values for up to ten test steps.

The NCV values are only displayed for injectors which have two actuators, such as Delphi E3.

In test plan edit mode these values can be edited for the current selected test step in the lower grid area.

f

The results grid area displays the results of all completed test steps for the whole test plan.

Results are shown in green if the test is in limits (pass) or red if out of limits (fail).

The currently running test step is shown in the lower grid area.

When the test step has completed the delivery value can be entered in the lower grid either as: cm

3 (cc)

(graticule metering systems) where the software converts the value to mm

3/st using the shot count, or

directly as mm3/st (for automatic metering systems).


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4.6.4 Testplan Screen

Figure 4.21 Testplan Screen

Testplan Screen overview

a

Loads a test plan

Saves an edited test plan

Deletes the current loaded test plan

When confirmation of a test plan save or delete is required cancel continues without taking any action.

If the user has access rights then the test plan can be edited, otherwise the log on dialogue is displayed to allow the user to change access rights.

Used to confirm overwrite of an existing test plan.

b

This dialogue is displayed when edit is selected and the user does not have access rights.

It allows the user to log on / off.

c

Drop down list boxes are used to select the required test plan to load, run, delete.

d

In edit mode these list boxes allow the data units to be selected, otherwise they display the current units from the test plan.


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e

Displays the file name and the test plan description. When saving a test plan in edit mode the filename field is used to change the file name of the current loaded file (save as), creating a separate file.

The test plan description text can be changed in edit mode.

Displays the test plan time and date.

4.6.5 Results (Saving) Screen

When a test has completed and the stop test button has been pressed on the main screen, the results saving screen is displayed.

Figure 4.22 Results (Saving) Screen

Results (Saving) Screen overview

a

Saves a results file.

Discards the current results, clears the data and returns to the main screen to allow the test to continue.

b

Displays the test plan settings used for the results being saved.


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c

Displays the generated default file name for the results which consists of a concatenation of :

Test plan, serial number, customer ref, year, month, day, hours, minutes and seconds.

This can be modified as required.

Allows the operator to enter a comment which will be stored in the results file for displaying and printing.

The time and date of the results to be stored in the file is displayed.

d

Data entered into these fields is included in the results file.

The default results file name consists of a concatenation of :

Test plan , serial number, customer ref, year , month , day, hours, minutes, seconds.

4.6.6 Results (Loading) Screen

The results loading tab displays a standard windows dialogue to select the results file to display or print. When the result file is selected internet explorer is launched to render and display the selected results file. Printing is performed using the internet explorer print function.

Figure 4.23 Results (Loading) Screen

4.6.7 Diagnostic Screen

This screen is used to access data on the EUI/EUP control box. It also displays the software version number of the application and the software in the EUI/EUP control box. This information is useful when contacting Hartridge for support. The screen displays EUI/EUP control box feedback values, status information and can, provided the user has the correct access rights; allow injector values to be set.


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WARNING!

THE SETTING OF VALUES IS FOR HARTRIDGE PERSONNEL ONLY AS THIS CAN POTENTIALLY CAUSE INJURY, DAMAGE TO THE CONTROL BOX AND THE EUI/EUP.

Figure 4.24 Diagnostic Screen

Diagnostic Screen overview

a

Changes to fields are sent to the EUI/EUP control box when this button is pressed.

If there is a fault on the EUI/EUP control box which has set one of the status flags this button sends a command to clear the error flag.

Shuts down the Magmah software application.

b

The current EUI/EUP control box status is displayed.

This displays the state of the EUI/EUP control box status flags.


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Machine Settings

This page provides configuration values which set the operating environment.

Language:

This selects the language to be used for operating the software and for displaying the results data. Note that exit and restart of the software is required for this change to be effective.

Network:

This shows the network address and port number for connection to the AE65 hardware. This is a critical setting and must match the AE65 hardware values or communication will not be achieved. A login is required to change these values.

4.6.8 Owner Detail Screen

This screen displays details of the work shop testing the injector. This data is included in the results file and results print out. This information can be changed when the user logs on.

Figure 4.25 Owner Details Screen


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4.6.9 Logon Dialogue

This dialogue appears when the user requires access rights to perform certain tasks. The dialogue allows the user to log on. Logging off or cancel will remove the user access rights to protected areas of operation

Figure 4.26 Logon Dialogue

There are two user access modes:

<Workshop>

1) Provides the ability to modify test plan set conditions and limits on the “Main Test” screen:

a. Parameter Name

b. Drive Speed Demand

c. SCV Pulse Width Demand

d. NCV Pulse Width and NCV Delay Demand (only applicable for dual actuator products, i.e. E3 EUI)

e. Response Time Limits

f. Delivery Limits

g. Resistance Limits

2) Provides the ability to save and delete a test plan on the “TestPlan” screen

3) Provides the ability to modify the “Owner Details” screen information

4) Provides the ability to modify the network settings parameters within the “Machine Settings” screen.

<Admin>

1) Provides all the functionality of the <Workshop> user access mode.

2) Unlocks the “Injector Type” screen so the injector configuration can be changed.


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4.6.10 Injector Type Screen

The injector type screen displays data which is specific to the injector type being tested such as: the current and voltage drive values for the injector; the maximum speed the injector can be driven. It is possible to change these values and create new injector types only by logging on and gaining access rights.

WARNING!

MODIFYING THE DEFAULT VALUES OR CREATING NEW INJECTOR TYPES REQUIRES KNOWLEDGE OF THE EUI/EUP AND IN DEPTH KNOWLEDGE OF THE HARTRIDGE EQUIPMENT TO PREVENT INJURY; DAMAGE TO THE EUI/EUP CONTROL BOX AND DAMAGE TO THE INJECTOR.

Figure 4.27 Injector Type Screen

4.7 Loading a Testplan

Load an existing testplan

Display the Testplan screen by selecting the testplan tab from the top of the screen, refer to Figure 4.21

Figure 4.28 Testplan Selection drop down boxes


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Select the Manufacturer from the drop down list.

Select the Injector Type.

Select the testplan required and click the ‘Load’ button.

If required the application datasheet can be viewed which details the equipment required to fit the EUI/EUP being tested, select the “Show Instructions” button.

4.7.1 Edit an existing testplan

Load a testplan as described above.

Refer to Figure 4.21

Click on the edit button and log on if necessary.

Select the correct units for temperature and timing from the drop down list box.

Select the main screen using the tab at the top of the screen.


Select the test step to edit using the step select buttons at the side of the main grid.

The test step data will appear in the lower grid this can be edited by selecting the fields and typing in the correct values.

If the test step name is blank a name must be entered because a test a blank name indicates that there are no more test steps in the test plan. It is also important that test steps are filled from the top to the bottom and any unused test steps (those which do not have a name) are at the bottom of the table of test step buttons.

Test step limit values can be changed while the test step is running.

To change the test step setting values when the test step is running, it is necessary to abort the test step first.

The supply pressure and temperature fields at the top of the screen can be set at any time in editing mode.

When testplan editing is complete select the Testplan tab at the top of the screen. It is then possible to save the test plan by pressing the save button, a confirmation message appears. To overwrite the existing test plan press save again to create a new test plan. Type in a new name in the filename field.

CAUTION:

If the original test plan is overwritten there is no way of recovering the original.

Unwanted test plans can be deleted by pressing the delete key and when asked to confirm pressing the delete key again.

CAUTION:

There is no way to recover a deleted test plan.


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4.8 Starting the Testplan Displayed on the Main Screen

Ensure that the injector access cover is in place before starting the test bench drive.

Ensure the cambox drive coupling guard is in place before starting the test bench drive.

Ensure that the test bench drive rotation selection is correct before starting.

Correct rotation is indicated by the arrow on the cambox coupling guard.


The test bench can be run immediately if the test plan displayed on the Main Screen is suitable.

If the test plan is not suitable the parameters of an existing plan can be modified on the Main Screen, see section 4.7.1 for details.

The EUI/EUP must be correctly installed: -

Check the EUI/EUP is clamped and the delivery, supply and return pipes are connected. Fuel supply is the top connection and fuel return is the bottom connection.

Check the correct electrical cable is connected from the EUI/EUP control box to the EUI/EUP electrical actuator refer to section 4.5.1

On the test bench select the metering line to which the injector delivery pipe is connected (if applicable).

Start the test bench fuel supply pump and set the pressure.

Check the test bench drive is set to minimum speed (about 30 rpm) and start the main drive. Check the drive rotation is correct.

Figure 4.29 Drive direction

Select a test step from the buttons to the left of the test settings grid on the main screen.


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4.8.1 Injector response

Injector response time is measured continually and the value is updated in the current test step grid towards the bottom of the screen. The response time value is stored when the OK button is pressed at the end of the delivery measurement.

The timing sensor detects the pressure rise in the nozzle adaptor as fuel flows from the injector nozzle. The sensor signal is affected by the drive speed and the delivery value. Readings are quite different from slow speed to high speed and injectors should be compared at the same running condition to determine if injectors are satisfactory.

4.8.2 In edit mode

Test settings and limits can be altered while a test is running, the current test step must be aborted to change the current test step speed and pulse width settings.

4.8.3 Test step results

When running a test step any parameter value within limits is displayed in green any fail in red. If a test step has passed the current test step grid has a green tick next to it a fail is a red cross. This is reflected in the main test grid. If neither a red cross nor green tick is shown then the test step has not been performed.

4.8.4 Measuring the Coil Resistance (coil injectors only)

The system measures the coil resistance(s) while running the first step only. The test cannot proceed if the result from the coil is outside the tolerances set.

4.8.5 Measuring fuel delivery

The test bench measuring system measures the delivery. The test bench is configured by the operator to capture a set number of delivery shots (revolutions of the drive).

The delivery result from the host test bench can be entered into the HK1400 cambox software in units for mm

3/str or in cc. If a cc value is entered then the number of counts selected on the test

bench must also be entered into the HK1400 cambox software and in turn the software will automatically calculate the mm

3/str value.


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4.9 Saving Results


At the end of a test when the stop test is pressed the results save screen is displayed.

Enter EUI/EUP serial number and customer name.

Enter customer reference number and/or customer name.

Enter other relevant fields.

The results file name is generated from the test plan name, serial number, customer reference, the current date and time. The generated default file name can be modified to suit user’s preference by typing in the filename field.

4.10 Viewing Results


Click Results from the Tab at the top of the screen.

Choose the results file to open.

Click ‘Open’. Internet explorer will be launched and the test results file will be loaded to view. The file can be printed on a printer attached to the test bench computer if required, using the internet explorer ‘File/Print…’ function.

Figure 4.30 View Results


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4.11 Example results sheet

Figure 4.31 Results File

4.12 Assessing the injector under test

There are no parts programmes or test plan information published by the injection equipment manufacturers. Hence the recommended procedure for setting the acceptance criteria for a particular injector type is to use a known master injector as the benchmark and to characterise that injector to establish the performance.

In general, unless more detailed information is available, Hartridge recommend that the injector is tested at a cranking speed, idle speed, maximum torque and maximum power conditions. A typical test programme is programmed into the software and can be used as a template for new test plans.

Information about the speeds can be found from engine data and the pulse widths required to achieve the typical deliveries can be found by experiment on the ‘master’ injector. Resistance measurement and the timing performance of both the overall injector and the electrical coil can also be established from the ‘master’ injector.

Further test information will be distributed when it is available.


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5 Maintenance

WARNING!

DO NOT RUN THE CONTROL BOX WITHOUT ALL THE COVERS FITTED.

ALWAYS ISOLATE THE CONTROL BOX AT THE MAIN VOLTAGE SUPPLY SWITCH ON THE WALL, BEFORE REMOVING ANY COVERS.

HIGH VOLTAGE!

ACCESS TO THE ELECTRICAL ENCLOSURES SHOULD ONLY BE ALLOWED SUITABLY QUALIFIED PERSONNEL.

ISOLATE AND LOCK THE ELECTRICAL SUPPLY OFF BEFORE PERFORMING ANY MAINTENANCE OPERATIONS. DO NOT WORK ON ELECTRICAL EQUIPMENT WHILE VOLTAGE IS SUPPLIED.

WARNING!

ALWAYS ISOLATE AND LOCK OFF THE TEST BENCH ELECTRICAL SUPPLY WHEN PERFORMING MAINTENANCE TASKS ON THE CAMBOX.

Impervious gloves and overalls should be worn if contact with ISO4113 test fluid and lubrication oil is likely. Gloves should also be worn when handling fixture parts or injectors after testing which may be hot. Refer to the Health & Safety Data Sheets.

5.1 Regular Maintenance

.

Operation Frequency of Check

Change Cambox oil Every 4 months or 250 test hours

Inspect nosepiece O-Ring After every 20 units tested

Table 5.1 Maintenance Schedule


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5.1.1 Inspect nosepiece O-Ring

Inspect the O ring (Figure 5.1B) in the nosepiece (Figure 5.1A) after every 20 unit tests to ensure it remains in good condition. Replace if there are signs of damage.

Figure 5.1 Inspect Nosepiece O-Ring

A

B


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5.2 Troubleshooting

Installation issues

Problem Possible Cause Action

1.

Drive will not rotate

Incorrect EUI/EUP

Incorrect cam position

Incorrect pushrod

Incorrect preload

Check correct cam position and fixture parts used – see Application Data Sheet

2.

Injector moves in fixture when drive runs

Incorrect EUI/EUP

Incorrect cam position

Incorrect pushrod

Incorrect preload

Check top clamp bolt tight

Check correct fixture parts used – see Application data sheet

Operational Problems

Problem Possible Cause Action

3.

Drive will not run

Safety interlock not wired correctly/guard not fitted

Ensure the Injector Access Guard is in position. Check for correct wiring of the safety interlock contact into the host test bench (if used).

4.

Injector does not fire

Test oil not supplied

Injector actuator not energising

Check supply and return pipes fitted. Check correct supply pressure set. Check injector spill ports not blocked.

Injector driver leads not fitted correctly Incorrect Injector driver lead used. Injector access guard not fitted

5.

No delivery displayed

EUI/EUP fault

Metering not operating

Leaks

Check pipe to metering unit connected Check correct line is selected on host machine’s metering system.

6.

Injector response not displayed

EUI/EUP actuator fault

Transducer not detecting input

See sections and 4.6.1 and 4.9.1

Check transducer connected to P2 lead at junction box. Change operating condition – speed or pulse width and retry.

Refer to your national Hartridge Distributor for any problems not covered by this guide.


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6 Spares

6.1 Consumables

Item Description Part Number

A Fuse 2 Amp Anti-surge, 250V 9842588

B O-Ring (Fuel Sleeve, Nosepiece) Refer to Application datasheets

TB450_35, TB450_36

Figure 6.1 Consumables

A

B


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6.2 General Spares

Item Description Part Number

A Cam follower assembly A242A002

B Piezo sensor P2 AE38/1

C Cambox electrical connection assembly A242B110 (includes part E, A242P006)

D Cable assembly 1/Rev A242P005

E Guardswitch assembly A242P006

F Roller Bearing Plate Assembly HS398

G Cover Plate Assembly A242C002

H Spring Washer 9371130

I Friction Disc A242A139

J Cam Nut A242A137

K Cover Plate Assembly O-Ring BS 4518_0995_30

Figure 6.2 General spares

A

B

C

E

D

G

I

H

J

K

F


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Appendix A - Circuit diagrams


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Appendix B: Health and safety data sheet

HEALTH & SAFETY DATA SHEET DATE Pub. No.

Information regarding the safe handling & storage of the named product. MAR 97 Applicable to employees and customers.

PRODUCT WARNING

CALIBRATION FLUID (ISO 4113) SEEK IMMEDIATE MEDICAL ATTENTION IF INGESTED

USE CLASSIFICATION

TEST FLUID FOR DIESEL INJECTORS, FLAMMABLE INJECTION PUMPS & OTHER DIESEL EQUIPMENT

PRODUCT DESCRIPTION - COMPOSITION

THESE FLUIDS ARE PETROLEUM BASED PRODUCTS CONTAINING SIGNIFICANT PROPORTIONS OF THE MORE VOLATILE PETROLEUM FRACTIONS AND OTHER SOLVENTS USED FOR LUBRICATION, ANTI-CORROSION AND DERMATITIC INHIBITION.

SAFE HANDLING ADVICE (Protection - Usage, Storage & Transport) USAGE: 1) Avoid eye splashes and extended skin contact. 2) Do NOT take internally. 3) Keep mist generated by machinery to a minimum, also avoid where possible vapours caused by elevated

temperatures. 4) Protective clothing to be regularly laundered. STORAGE: These are flammable products which should be stored in closed containers away from heat in a well ventilated area.

EMERGENCY & FIRST AID PROCEDURE (Eyes, skin, ingestion, inhalation) INGESTION: Do NOT induce vomiting. Give a glass of water and get immediate medical attention at Hospital. EYES: Flush with large amounts of water for 15 minutes. Seek medical help if irritation persists. SKIN: Wash thoroughly with soap & water. Seek medical help if irritation or skin rashes occur. Remove any contaminated

clothing. INHALATION: Inhalation includes oil mists or vapours. Remove victim to fresh air. Seek medical help if affliction persists.

FIRE HAZARDS & PROTECTION (Flash point, spillage) SPILLAGE: Contain spillages with sand or mineral absorbent material. Mop up and clean floor to remove oil residue. FLASH POINT: Above 75°C. FIRE: (Extinguisher media) Use carbon dioxide, dry chemical powder or foam extinguishers. Do NOT use water jets.

ENVIRONMENTAL PROTECTION (Spillage land / water, disposal) SPILLAGE: Advise authorities if product has entered or may enter sewers, water courses or extensive land areas. DISPOSAL: All waste should be put into identified containers and stored at a specific disposal point. Arrange for off site disposal in accordance with local regulations for notified waste.

HARTRIDGE LTD Network 421, Radclive Rd, Buckingham, MK18 4FD, England.

THE INFORMATION AND RECOMMENDATIONS IN THIS PUBLICATION ARE TO THE BEST OF OUR KNOWLEDGE INFORMATION AND BELIEF ACCURATE AT THE TIME OF PUBLICATION NOTHING HEREIN TO BE CONSTRUED AS A WARRANTY, EXPRESS OR IMPLIED IN ALL CASES. IT IS THE RESPONSIBILITY OF THE USERS TO DETERMINE THE SUITABILITY OF ANY PRODUCTS FOR THEIR OWN PARTICULAR PURPOSE. RECOMMENDATIONS FOR HANDLING, PROTECTION ETC. ARE ADVISORY ONLY.


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The Hartridge Building, Network 421, Radclive Road Buckingham, MK18 4FD United Kingdom Tel: +44(0) 1280 825 600 Fax: +44(0) 1280 825 601 Email: [email protected] www.hartridge.com

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