operating and servicing manual - diesel.autokelly.cz · hartridge limited hk870 operating &...

World Leaders in Diesel Fuel Injection Test Equipment

HK870

EUI & EUP Test Kit for AVM2-PC

with

Injector/pump specific kits

Operating and Servicing Manual

HL026(EN) Issue 5, H1918, 11/2011

THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.

HARTRIDGE LIMITED HK870 OPERATING &SERVICING MANUAL

HL026(EN), Issue 5, H1918, 11/2011 1

CONTENTS

1 FOREWORD ............................................................................................................................................................ 3

2 INTRODUCTION .................................................................................................................................................... 6

2.1 GENERAL ............................................................................................................................................................. 6 2.2 HK870 SPECIFICATION ........................................................................................................................................ 6

2.2.1 Hardware .................................................................................................................................................... 6 2.2.2 Programmable parameters: ........................................................................................................................ 6 2.2.3 Measured parameters ................................................................................................................................. 6

3 INSTALLING THE KIT ......................................................................................................................................... 8

3.1 REQUIREMENTS ................................................................................................................................................... 8 3.2 INSTALLING THE INTERFACE BOARD ................................................................................................................... 8 3.3 SOFTWARE REQUIREMENTS ................................................................................................................................. 8 3.4 CAMBOX INSTALLATION ...................................................................................................................................... 8 3.5 CONNECTING THE PIPES AND CABLES .................................................................................................................. 9

4 SYSTEMS AND PRINCIPLE OF OPERATION ................................................................................................. 9

4.1 GENERAL PRINCIPLES .......................................................................................................................................... 9 4.2 SAFETY INTERLOCKS ......................................................................................................................................... 10 4.3 SUPPLEMENTARY KITS ............................................................................................................................... 10 4.4 PRINCIPLES FOR TESTING .......................................................................................................................... 10

OPERATION .................................................................................................................................................................. 11

GUIDELINES FOR SAFE WORKING PRACTICE ................................................................................................................. 11 4.5 GENERAL OPERATION ........................................................................................................................................ 11

4.5.1 Initial preparations ................................................................................................................................... 11 4.5.2 Setting up and Start up procedure ............................................................................................................ 12

4.6 SETTING UP A TEST PLAN USING THE AVM2-PC SOFTWARE .............................................................................. 13 4.6.1 Main Screen .............................................................................................................................................. 13 4.6.2 find an existing test plan ........................................................................................................................... 13 4.6.3 to create a new application – .................................................................................................................... 14 4.6.4 to save results ............................................................................................................................................ 14 4.6.5 print results ............................................................................................................................................... 15

4.7 RUN TEST PLAN DISPLAYED ON MAIN SCREEN .................................................................................................. 15 4.8 RUNNING THE TEST ............................................................................................................................................ 15

4.8.1 Measuring the Coil Resistance .................................................................................................................. 16 4.8.2 Measuring coil response ........................................................................................................................... 16 4.8.3 Measuring fuel delivery ............................................................................................................................ 16 4.8.4 Injector timing measurement..................................................................................................................... 16 4.8.5 Injection pressure ...................................................................................................................................... 16

4.9 ASSESSING THE INJECTOR UNDER TEST .............................................................................................................. 16

5 MAINTENANCE ................................................................................................................................................... 16

5.1 REGULAR MAINTENANCE .................................................................................................................................. 16 5.2 TROUBLESHOOTING ........................................................................................................................................... 17

6 SPARES .................................................................................................................................................................. 18

6.1 ................................................................................................................................................................................. 18

7 APPENDIX 1 .......................................................................................................................................................... 19

INSTALLING THE INTERFACE BOARD ............................................................................................................................. 19

8 APPENDIX 2 - CIRCUIT DIAGRAMS ............................................................................................................... 21


HARTRIDGE LIMITED HK870 OPERATING & SERVICING MANUAL

2 Issue 5, H1918, 11/2011 HL026(EN)

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HL026(EN), Issue 5, H1918, 11/2011 3

1 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.

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 test equipment 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.

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 injection pump cannot chafe or become entangled in the drive, thus causing a hazard.



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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.

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 test stand 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 test stand 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.

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.



HL026(EN), Issue 5, H1918, 11/2011 5

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.

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.

Take care to ensure only recommended equipment is connected to the test stand auxiliary power socket and that it is correctly earthed.

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 test stand. The electrical supply to welding equipment must be provided from a remote isolating transformer. Arc welding can disturb the measuring circuit.



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2 Introduction

2.1 General

The HK870 EUI base kit with associated application specific kits is designed to be fitted to the AVM2-PC Test Stand to enable testing of EUI and EUP fuel injection equipment. A list of the application specific kits is in the Sales leaflets.

NOTE: The AVM2-PC must be fitted with the following items in order to use HK870:

- Version 33 (or later) Magmah PC software and suitable dongle.

The following items may be required:

HB374 SOFTWARE UPDATE

HB374P SOFTWARE UPDATE WITH PHASING

HB374T SOFTWARE UPDATE WITH TIMING

HB374PT SOFTWARE UPDATE WITH PHASING & TIMING

If not already fitted: -

A069B006 INTERFACE PCB ASSEMBLY

2.2 HK870 specification

2.2.1 Hardware

Max speed (standard tappet assembly) 1200rpm, high speed tappet - 2400rpm. Direction of rotation set by software

Max cam lift 17mm from base circle diameter of 60mm.

Max delivery (limited by AVM metering) 550 mm3/st

Injector clamp load up to 1.5 tonnes applied using load screw

Weight of dry cambox assembly with typical kit fitted - 64kg (140lb)

Weight of control assembly 5.5kg (12lb)

Weight of injector power supply assembly 6.5kg (14lb)

Electrical power supply - 1 phase 85/265 volt 47/100 Hz fused 5A with IEC connector

2.2.2 Programmable parameters:

Bench speed (max speed programmed for each injector application)

Injector drive peak current, peak timing and hold current

Injector pulse duration set in camshaft degrees or time in milliseconds

Injector pulse delay from 1 pulse per rev signal

Limits max and min for metering, timing and coil resistance measurements

2.2.3 Measured parameters

Speed rpm

Delivery from injector mm3/st

Supply pressure bar / psi

Injector coil resistance ohms

Injector coil timing delay from electrical supply pulse deg cam or milliseconds

Injector overall timing delay from electrical supply pulse deg cam or milliseconds



HL026(EN), Issue 5, H1918, 11/2011 7

When load cell option is fitted

NOP (not at all injection speeds) bar

Peak pressure bar

Injector overall timing delay from electrical supply pulse deg cam or milliseconds

Definition of Terms and Abbreviations

EUI Electronic (controlled) Unit Injector EUP Electronic (controlled) Unit Pump ECU Electronic Control Unit FIE Fuel Injection Equipment PPR Pulses per Rev NOP nozzle opening pressure (bar) ADS Application Data Sheet



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3 Installing the Kit

SWITCH OFF POWER SUPPLIES BEFORE STARTING THE INSTALLATION PROCEDURE.

3.1 Requirements

High quality gearbox lubricating oil (SAE 30) for cambox – 550ml quantity is required.

1 phase 85/265 volt 47/100 Hz electrical supply with IEC connector

3.2 Installing the Interface Board

If the interface with the AVM2-PC computer for testing Common Rail injection equipment has not been fitted kit A069B006 must be ordered; refer to Appendix 1 for fitting instructions.

3.3 Software Requirements

Control of the kit is done from the machine PC. This kit requires software version 33.0 or later. If this version is not fitted to the machine a self-loading CD plus the relevant dongle, see section 2.1 for details, must be separately ordered. Please contact the factory with the machine details for advice on which part is needed. The software is auto loading and the kit comes with instructions.

3.4 Cambox Installation

The kit is in two parts. The cambox assembly is mounted on the machine bedplate and secured using standard clamp APB220. The electrical control and power supply assemblies can be fitted to either side of the machine bed.

a. Ensure that the bed and table area is clear and the metering arm is positioned out of the way.

b. Hartridge recommend the use of trolley HM1050 for safe easy mounting of the cambox assembly. 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 a trolley is not available lift the cambox assembly onto the bracket with a lifting crane using lifting eyes provided or a sling under the cambox. The angle between ropes fitted to the eyebolts should not exceed 45

O. If a rope sling under the cambox is used, care must be taken to prevent damage to the rotation

sensor.

CAUTION! The assembly is heavy and must not be manually lifted on/off the machine

c. Slide the assembly along the bed and, with the drive dogs horizontal, rotate the machine drive coupling to align with cambox coupling, and then engage them together. Withdraw the cambox assembly until there is about 1mm gap between machine coupling and cambox coupling. Tighten the coupling clamp screws inside the machine coupling using 4mm hexagon tool. Rotate the machine drive to ensure the cambox coupling is symmetrically engaged in the machine coupling. Tighten the cambox mounting bracket clamp.



HL026(EN), Issue 5, H1918, 11/2011 9

3.5 Connecting the pipes and cables

Electrical connections

The electrical cables are fitted as shown above. See the application data sheet for details of the cable from the power supply box to the injector/pump. Electromagnetic injector coils are not polarity sensitive so the electrical connectors can be fitted to either terminal.

Hydraulic connections

The standard oil supply and return pipes on the machine are used to supply and return oil to and from the injector/pump. The kit contains a length of spiral wrap used to wrap the supply and return pipes together to prevent rubbing against the cambox and excessive vibration. In general the supply pipe is the upper pipe and the return is the lower pipe. Hartridge recommend identifying the supply pipe with a cable tie or similar device so that the pipes can be easily and correctly connected.

Insulated braided pipe (A069B013) is fitted between the injector nosepiece and one of the lines on the metering unit.

4 Systems and Principle of Operation

4.1 General Principles

Injector electrical control

EUI and 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) valve as quickly as possible. The current is then reduced and this is held until the required duration of injection event is complete. 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 the special EUI software installed in the AVM2-PC machine. 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 rate and timing.



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

4.2 Safety Interlocks

The HK870 is safety-interlocked so that:

the drive cannot be started if the guard is open,

the drive will stop if the guard is opened whilst it is running.

the drive rotation is set to suit the cam designs

the drive will not start unless the feed pump is switch on.

4.3 SUPPLEMENTARY KITS

In general each EUI/EUP type requires:

Interchangeable cam – each EUI/EUP type needs a specific cam and this can be easily changed.

A nosepiece that collects the injected oil that is piped to the metering unit. The nosepiece incorporates a piezo transducer used to measure the response of the injector,

a fuelling sleeve to provide supply and return oil flow and form part of the clamping system,

a mounting bracket for the injector,

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

second piezo transducer held against the electrical coil housing of the injector to provide a coil response measurement.

An extensive range of application kits is available. Contact your local distributor for details. Fitting and running information is provided with each kit.

4.4 PRINCIPLES FOR TESTING

The EUI 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 the EUI or EUP to be tested to the cambox. Connect oil supply and return and electrical connections.

2. Rotate the drive by hand to ensure free rotation.

3. Run the unit at ‘purge’ condition until repeatable delivery readings are obtained

4. Run the unit at maximum speed and delivery condition FOR 2 MINUTES and then record results.

5. Select the next lower operating condition and run for 1 minute. Record results.

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

7. Stop the machine and save the results if required.

8. Remove the unit under test.

9. Test all subsequent EUI or EUP in exactly the same way.

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.



HL026(EN), Issue 5, H1918, 11/2011 11

Operation

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

DO NOT ATTEMPT TO BY-PASS THE SAFETY INTERLOCK

Guidelines for Safe Working Practice

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

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

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.

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.

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.

4.5 General Operation

CAUTION Always switch off the test stand 3-phase supply before connecting or disconnecting any cables from the EXT1 and EXT2 sockets.

4.5.1 Initial preparations

Hardware

The cambox hardware must be placed onto the machine bedplate as described in Section 2.4. The cambox must be filled with about 550ml high quality clean gearbox oil (SAE 30) to just above the lower mark on the bracket that supports the oil filler pipe.



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The control assembly and the power supply assembly for the injector/pump to be tested are mounted on the side of the machine and the connections made (see section 3.5). The control and supply assemblies can be mounted on either side of the machine.

The piezo P1 measures the response of the electrical coil on the injector. It must be fitted with the transducer against a flat face on the coil housing. See the application data sheet for details.

If it is necessary to change the P1 clamping ring remove the 2 screws in the aluminium clamp plate and remove the red ring in use. Position the new ring so that the join is in the middle of the groove in the sensor assembly and replace the clamp plate.

4.5.2 Setting up and Start up procedure

Electrical set-up

Fit EUI/EUP control assembly and the required power supply assembly to the machine and connect cables. See section 2.5.

Mechanical set-up

Information on what parts are needed and how the injector/pump is mounted is provided on the application data sheets sent with each application kit.

If a different cam is needed,

Drain oil from cambox by unclipping filler pipe and run oil into a tray

Remove cam cover

Lock main drive and loosen cam nut. Remove cam using a puller.

Fit required cam. Tighten cam nut to 120Nm. Unlock the main drive

Replace cam cover and refill with oil.

Select and fit the fuel sleeve over the injector/pump. Position the fuel connections on the sleeve exactly opposite the electrical coil on the injector. This will ensure ease of fitting the injector.

Fit the metering line to one of the lines of the AVM metering system. Select on the PC screen the line to which the pipe is fitted

Add a small volume of oil to the pushrod (under the injector or pump) to ensure its lubrication during the test.

Fit the injector coil piezo transducer according to the application data sheet.

Fit the injector/pump and sleeve into the fixture. Check the alignment of the injector with the cradle.

Tighten the clamp screw to the correct torque :- 25Nm is correct for most injectors

Connect oil supply and return pipes. Supply is the upper connector and return the lower connector.

If this is the first injector of a series, 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.

Switch on main machine isolator and start AVM2 PC feed pump to heat the oil.

Set the supply pressure. Check there are no leaks and fuel is flowing down the return (lower) pipe.

Oil to be level or just above bottom of bracket



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4.6 Setting up a test plan using the AVM2-PC software

Check that the control box, power supply, cambox cable are connected and the EUI control box is switched on.

4.6.1 Main Screen

Press f2 “Metering”; the EUI main screen will be displayed.

The test machine is controlled using the main EUI screen. The initial main screen displays the last test plan used on the machine as shown above.

If this matches the EUI/EUP to be tested, Read Section 4.3 and proceed.

NOTE:

If f9 box (I/O) is ‘red’ then one of the safety requirements is not correct. Press button f9 and a pop-up screen will indicate the necessary action to eliminate the problem.

4.6.2 find an existing test plan

Press f2,

press engine manufacturer & select

select injector type

select test plan required



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4.6.3 to create a new application –

f3 from main screen

select ‘create’ for new Engine Manufacturer

enter Manufacturer’s name & OK

(This will create a new directory file for the new Manufacturer)

Select Injector Type box

Enter name for injector/pump

Enter injector/pump parameters

When all fields are complete press OK.

Fill in the test steps required on the main screen

The new test plan can be run. When the new test is complete press f3 and confirm test plan and it will be saved under the new Engine Manufacturer

4.6.4 to save results

press f4

Enter EUI/EUP serial number

Enter operator name

Enter customer reference & comments if

required

Press save

The new pop-up screen will allow selection of the directory to which the results will be saved.



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4.6.5 print results

4.7 Run test plan displayed on Main Screen

The 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 the flow chart below.

The injector/pump must be correctly installed: -

Check the injector is clamped and the injector delivery, supply and return pipes are connected. Supply is the top pipe.

Fit the electrical cable to the electrical solenoid

Fit the solenoid piezo P1 to the coil. See application data sheet.

Select the metering line to which the injector delivery pipe is connected.

Start the feed pump and set the pressure. Start the main drive.

The software will automatically run a resistance check on the solenoid coil. If the resistance is within tolerances set, the drive will start and the bench will run at 30 rpm. If the resistance is not in tolerance the drive will not run and the injector must be corrected.

Injector response.

The static response time of the injector can be measured if the piezo transducer is fitted and the drive is not running. If the Coil Response line is selected the system will apply an electrical current to the solenoid and measure the response time.

It is recommended that the injector is run at a medium speed and pulse width to purge the oil system and enable the metering unit to learn the phasing of the injection.

Speed and pulse width test parameters can be altered while a test is running.

4.8 Running the test

In the Main Screen, a programmed step is selected by using the PC mouse to ‘click’ on the box at the left of the required line in the test plan.

The programmed parameters will be applied and the machine run at the speed and the injector supplied with the required voltage and current. Limits are set in the software to prevent the machine running with conditions that would damage machine or injector.

The programmed test parameters of speed and injector pulse duration can be changed at any time.

Select any saved test

results



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4.8.1 Measuring the Coil Resistance

The machine measures the coil resistance automatically before each test. The test cannot proceed if the result is outside the tolerances set.

4.8.2 Measuring coil response

Piezo transducer P1 is used to measure the coil response. This test can be started by pressing the ‘Coil Response’ button on the PC screen with the drive stopped. The system will apply an electrical pulse to the coil and measure the time delay between the beginning of the electrical signal to the end of the solenoid valve movement (the ‘click’). The software captures 5 results and displays the average.

4.8.3 Measuring fuel delivery

The system automatically measures and displays the delivery using the AVM2 metering unit. Readings are compared with the tolerances set in the test plan. In limit readings are displayed green, readings outside limits are red. Limits can be set while a test is being carried out.

4.8.4 Injector timing measurement

Hartridge supply two alternative systems for measuring overall injector response time; a piezo P2 measurement system or a load cell system. Both systems measure the time from the beginning of the electrical signal to the measurable injector response.

Piezo measurement

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

Load cell measurement.

The load cell measures the force applied to the injector by the cambox tappet. The response time is the time from the electrical signal to a pre-set load threshold that corresponds to an internal pressure in the injector/pump. The load cell figure is not affected in the same way as the piezo by speed and delivery values and generally gives a more reliable result.

4.8.5 Injection pressure

When a load cell system is fitted the software will measure the load applied to the injector/pump and calculate the pressure inside the injector. Analysing the signal allows the nozzle opening pressure (NOP) to be deduced and the peak pressure to be measured. Both are vital pieces of information in assessing the health of an injector/pump.

4.9 Assessing the injector under test

There are no parts programmes or test plan information published by the injection equipment manufacturer. Hence the recommended procedure for setting the acceptance criteria for a particular injector type is to use a known good 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.

5 Maintenance

5.1 Regular Maintenance

1. Change the cambox oil every 4 months or 250 running hours



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2. Clean the inside of the cambox and magnet every time the cam is changed. Examine for the magnet for debris and investigate if material found there.

3. Inspect the O ring in the nosepiece every 20 injectors to ensure it remains in good condition.

5.2 Troubleshooting

Abbreviations: ADS = Application Data Sheet

Problem Possible Cause Action needed

Installation issues

5.2.1.1 Drive will not rotate Incorrect cam or pushrod fitted

Check correct fixture parts used – see ADS

5.2.1.2 Injector/pump moves in fixture when drive run

Incorrectly fitted Check top clamp bolt tight

Check correct fixture parts used – see ADS

Operational Problems

5.2.2.1 Drive will not run Machine not set correctly

Select f9 and determine cause

Check feed pump on

Close the cambox door if it is open

Incorrect power supply selected – fit correct one

5.2.2.2 Injector/pump does not fire

Fuel not supplied

Injector coil not energised

Check supply and return pipes fitted .

Check correct supply pressure set.

Check injector spill ports not blocked.

Power leads not fitted correctly

Incorrect pull-in current set – see section 5.4.3 for set-up procedure.

5.2.2.3 No delivery displayed Injector/pump not firing

Metering not operating

Injector/pump firing but no delivery

See 5.2.2.2

Check pipe to metering unit connected

Check correct line is selected

Check set-up parameters match ADS information – see 5.4.3 for details

5.2.2.4 Coil response not displayed

Coil not working

Transducer not detecting input

See 5.2.2.2

Check transducer connected to P1 lead

Check transducer fitted correctly – see ADS

Check specified mounting cord is used. If loose shorten or renew.

5.2.2.5 Injector response not displayed

Coil not working

Transducer not detecting input

See 5.2.2.2

Check transducer connected to P2 lead

Change operating condition – speed or pulse width and retry.

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



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6 Spares

6.1

Figure 6.1: Spares

Item Description Part Number

1 Tappet assembly (standard) A085A001

2



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7 Appendix 1

SWITCH OFF THE 3-PHASE ISOLATOR BEFORE STARTING THE INSTALLATION PROCEDURE.

Installing the Interface Board

If the interface with the AVM2-PC computer has already been fitted for testing Common Rail injection equipment, ignore this section of instructions.

1. Remove the gland plates from the rear panel of the console (Item 1, Figure 2.1).

2. Fit the Guard Interface Board Assembly A069B006 in place of the gland plates, so that the EXT1 (9-way) and EXT2 (14-way) sockets protrude through the panel cut-outs. If other cables pass through the gland plates (e.g. to a printer), they can be routed through the slots in the new PCB bracket.

7.1.1.1 Figure 2.1: Console Rear Panel

3. Connect the comms cable from the new PCB assembly to PC COM 1.

4. Remove the machine right hand top panel to access the electric cabinet / System Control Board.

5. Feed the remaining 2 cables from the new PCB assembly down through the base of the console and into the electric box. Connect as shown in the tables below.

A: 2-Core Cable:

Wire Colour Function Connect To

White 0 Vac AVM2 0V BUS

Brown 110/132 Vac SCB2 PIN 115

B: Multi-core Cable:

Wire Colour Function Connect To

Violet Screen SCB2 PIN 197

Blue 0 V SCB2 PIN 172

Red 18 V SCB2 PIN 198

Green (See note 1) 128 ppr -

Yellow (see note 1) 128 ppr SCB2 PIN 167

White (see note 2) DRIVE OK -

Brown (see note 2) STOP SCB2 PIN 27



20 Issue 5, H1918, 11/2011 HL026(EN)

NOTE 1: Remove the existing green wire from pin 167 on the SCB2 and connect it to the green wire on the multi-core cable. Connect the yellow wire from the cable to SCB2 pin 167.

NOTE 2: Remove the existing white wire from pin 27 on the SCB2 and connect it to the white wire on the multi-core cable. Connect the brown wire from the cable to SCB2 pin 27.

The electrical circuit diagram is shown below.



HL026(EN), Issue 5, H1918, 11/2011 21

8 Appendix 2 - Circuit diagrams

Circuits are for 90 volt supply. 12/24v circuit is identical except for power supplies



22 Issue 5, H1918, 11/2011 HL026(EN)

Circuit Controller to Amplifier



HL026(EN), Issue 5, H1918, 11/2011 23

90V Amplifier Circuit



24 Issue 5, H1918, 11/2011 HL026(EN)

Controller to AVM and Cam Box



HL026(EN), Issue 5, H1918, 11/2011 25

Base Kit Interface Circuit



26 Issue 5, H1918, 11/2011 HL026(EN)

12/24 v Amplifier Circuit


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