World Leaders in Diesel Fuel Injection Test Equipment. CRi-PC. Common Rail Injector Test Stand. 1 line. Operating and Servicing Manual

Transcription

1 World Leaders in Diesel Fuel Injection Test Equipment. CRi-PC Common Rail Injector Test Stand line Operating and Servicing Manual

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3 Hartridge CRi-PC

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5 CONTENTS FOREWORD...5. INTRODUCTION SPECIFICATION...9 DEFINITION OF TERMS AND ABBREVIATIONS...9 INSTALLATION SITE REQUIREMENTS INSTALLING THE TEST STAND REFIT COMPUTER Computer installation WATER & AIR CONNECTION OIL & WATER DRAINAGE ELECTRICAL CONNECTION phase connection Single phase connection Setting for the correct supply voltage TEST OIL INITIAL POWER-UP SYSTEMS AND PRINCIPLE OF OPERATION CR INJECTOR OPERATION INJECTOR VALVE TYPES Solenoid Valves Piezo Valves PNEUMATIC SYSTEM FLUID SYSTEM TEMPERATURE CONTROL INJECTOR AND CR PUMP CONTROL Injector control CR pump control DELIVERY & FLOW MEASUREMENT Injector delivery Backleak flow CONTROLS CIRCUITS OPERATION RECOMMENDED TEST SEQUENCE SOFTWARE OVERVIEW Function keys (Main Menu) Function keys (Alternate Menu) Main Screen Areas Status/Diagnostic Screen Red Status Indicator TEST SETUP AND METHOD Load a Testplan Measure Injector Coil Resistance (if selected in the Start Test dialog) Install Injector in the Clamping Fixture & Clamp Start the CR pump Run the Test Steps Injector removal INTERPRETATION OF RESULTS Response Time Delivery

6 4.4.3 Backleakage Summary CREATING/EDITING/SAVING TESTPLANS General Parameters VIEWING AND PRINTING SAVED RESULTS CALIBRATION AND MAINTENANCE CALIBRATION & AUDIT REMOVING ACCESS PANELS REGULAR MAINTENANCE Check Emergency stop Check pressure dump valve Generally Clean Metering Audit Tests Backleak Audit With Magmah v9.0 onwards (If optional backleak measurement unit is fitted) Change test fluid & filter, clean magnet filter Change metering filter (Hartridge Number ) TROUBLESHOOTING General Computer / monitor Fault indicators Injector control CR pump control SPARES CONSUMABLES GENERAL SPARES... APPENDICES... 3

7 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. Operational Warnings WARNING! HIGH PRESSURE FLUID SPRAYS CAN CAUSE SERIOUS INJURY OR DEATH. COMMON RAIL SYSTEMS OPERATE AT EXTREMELY HIGH PRESSURES. IF USED AS INSTRUCTED THE TEST KIT WILL RELIEVE ANY HIGH PRESSURE WHENEVER THE GUARD DOOR IS OPENED. DO NOT ATTEMPT TO BYPASS THE PRESSURE DUMP VALVE OR THE SAFETY INTERLOCK. Always start the system running at a low pressure and visually check for any leaks before setting higher pressures. This particularly applies having just mounted a system, or having just replaced a component. Do not open the guard while the system is running. Wait for the test bench drive to stop and for the rail pressure to decay to a low level before opening the guard. Do not attempt to open the rear cover of the machine while the system is running. Wait for the test bench drive to stop and for the rail pressure to decay to a low level before opening. Safety glasses conforming to standard BS EN 66:996 must be worn when working on this equipment for the following reasons:. 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. 5

8 General Warnings Ensure good levels of lighting for safe, efficient equipment operation. 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. 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. Gloves conforming to standard BS EN 407:994 must be worn when handling parts after testing which may be hot. 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. Burns will occur to the hands if certain parts of the test stand or equipment under test are touched. Keep hands away from the calibration fluid heater element and injector or high pressure pipes after periods of extended running. Severe injury can be caused by slipping on spilt oils or fluids. All spillage of fluids in the test area must be dealt with immediately. There must be no naked flames. Smoking in the vicinity of the equipment is strictly forbidden. Potentially flammable vapours are present in the test stand and ignition is possible although unlikely. 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. 6

9 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. High fluid pressures exist within the test stand. Do not run the test stand without all cover panels fitted. Fluid sprays, especially from leaking high pressure pipes and seals, will cause high pressure injection through the skin which can result in fatal injury. 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. 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. High Voltage! Isolate and lock the electrical supply off before performing any maintenance operations. Do not work on electrical equipment while voltage is supplied. Be aware that the computer and monitor are supplied separately from the test stand 3 phase supply and may therefore still be powered when the test stand 3 phase supply is switched off. 7

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11 . Introduction The Common Rail Injector Test Stand (CRi-PC) is designed to enable testing of Common Rail injectors. The stand accommodates currently available injectors from Bosch, Delphi, Denso and Siemens. Fixture components are available for testing specific injector types. The test stand incorporates semi-automatic injector clamping. An interlocked safety door furnished with a 0mm clear PETg shield protects the operator from the high pressures generated in common rail systems. Injectors may be tested in manual or automatic mode by pre-configured testplans created in the Hartridge Magmah software. Injector control is via AE32 based hardware. Injector delivery measurement is based on the Hartridge AVM2 Positive Displacement Metering Unit & Metering Control Board. Injector backleak flow is measured by an HK90 or HK90-P based system.. Specification Injector Control Features Single channel injector drive circuit, suitable for current Bosch, Delphi & Denso solenoid injectors and Siemens piezo injectors. Injector Measurements Single channel solenoid resistance measurement. Single channel response time measurement. Backleak flow and temperature measurement. Injector delivery measurement within ±0.5% of reading. Test Fluid Supply System Tank capacity 43 litres nominal (40l. main tank, 3l. clean tank) Oil pump Filter Over-temperature thermostat Low fluid level protection (main and clean tanks). Level indicator and drain pipe. Sludge and magnetic particle traps. Temperature control ±2 C using electric heater and water / oil heat exchangers..2 Definition of Terms and Abbreviations CR CRIB FCV I/P IPM LED MAGMAH MCB4 O/P PC PCB PCV PLC VCV RS232 S/W UUT Common rail Common rail injector (control) board Flow control valve Input Injections per minute Light emitting diode Hartridge PC control software Metering control board 4 Output IBM compatible computer Printed circuit board Pressure control valve Programmable logic controller Volume control valve Serial communications Software Unit under test 9

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13 2. Installation Site requirements Allow metre around the front and sides of the test stand for access. The rear of the test stand should allow adequate space for the electrical, air and water connections. The site must have a clean level floor capable of supporting the test stand weight. Supply of clean water at 20 C maximum, with a nominal flow available of 5 litres/min. minimum pressure 2.5 bar (40 psi). The minimum water temperature should be 0 C, if the water temperature is too low condensation may occur on the water pipes inside the machine. The site should be well ventilated to dissipate heat and test oil vapour. Supply of clean, dry pressurised air - minimum pressure 6.5 bar (95 psi). Electrical Supply: 3 Phase and Earth V ± 6%, 50 Hz, fused at 25A 3 Phase and Earth V ± 6%, 60 Hz, fused at 35A. Lift the test stand from underneath using a fork lift placed under the test stand base. The dry weight of the test stand is approximately 400 kg. Installing the test stand The test stand must be levelled in both horizontal planes before use.. Position the test stand on the rubber feet supplied. 2. Place a spirit level on the top of the test stand. 3. If the test stand is not level place metal shims between the machine and the rubber feet as required to achieve support on all four feet, checking the level in both horizontal planes. 2.3 Refit computer 2.3. Computer installation Refer to Figure 2... Remove all packaging and strapping from the test bench. 2. Locate the PC mounting tray into the upper compartment () with foam feet down and the larger foam foot on the right and nearest the outside of the machine. Mount the computer onto the tray. The computer should be located to allow access to the CDROM and power switch through the hinged panel (2). 3. Feed the keyboard and mouse cables through the holes in the keyboard tray and facia panel (3), then up into the PC area. 4. Reconnect the cables at the rear of the computer, typically Power Monitor USB Mouse USB Keyboard Serial port (cable 77) Serial port 2 for optional printer (if fitted) Serial port 3 (cable 5) Serial port 4 (cable 50) 5. Connect the power cables of the computer and the printer (optional) to the power distribution block (4).

14 6. Ensure that the computer power supply voltage switch (5) is set in the correct position for the electrical supply of the end user (if applicable) Figure 2. Fitting the Computer 2

15 2.4 Water & air connection Refer to Figure 2.2. Connect the water IN (supply) pipe to the 0mm bulkhead fitting (). Connect the water OUT (return) pipe to the 0mm bulkhead fitting (2). Connect the air supply pipe to the supplied plug (¼ Gas female thread) (3). 2 3 Figure 2.2 Water & Air Connections 2.5 Oil & water drainage Refer to Figure 2.3 The yellow pipe () on the left of the machine, visible when the left side panel is removed, carries oil and water leakage from the high pressure pump/motor tray to prevent contamination of the oil in the main tank. This pipe must be routed to the back of the machine as shown and the fluid collected in a tray for safe disposal. Ensure the pipe is not trapped by the side cover when it is refitted. 3

16 Figure 2.3 Oil & Water Drainage 4

17 2.6 Electrical connection The connection of electrical supplies must comply with the local and national electrical regulations. Make sure the connection of 3 phase electrical power is carried out by a suitably qualified electrician. WARNING The equipment must be hardwired and bonded to a protective earth system before the mains supply wires are connected. The earth wire must be taken directly to earth instead of or as well as through a plug and socket. Failure to earth the test stand before applying mains power can cause a fatal electric shock. CAUTION The Common Rail Pump motor used on the test stand is phase rotation sensitive. Correct rotation of the motor is essential to prevent damage to the Common Rail pump. This can be checked by following the procedure given in Section phase connection Refer to Figure 2.4. Ensure the test stand isolator and incoming supply isolator switches are off. 2. Open the electrical cabinet door. 3. Feed the 3 phase and Earth wires from the main electrical supply through the hole () located at the rear of the cabinet. 4. Connect each phase to the isolator switch (2). 5. Connect the Earth wire to the earth terminal (3) Single phase connection. Using a suitable power cable terminated with a standard IEC socket. Connect the single phase supply to the test stand at the IEC plug located on the rear of the cabinet. 2. Ensure the connector retaining clip (4) is in place Figure 2.4 Electrical Connections 5

18 2.6.3 Setting for the correct supply voltage Refer to Figure 2.5 These settings should have been done before shipment, however it is possible that the customer s local supply is different to the standard national supply system.. Transformer supply setting. The primary tapping on the transformer needs to be set to match the voltage of the customer s incoming supply. This involves connecting the wires identified as 20 () & 30 (2) to the correct terminal studs on the transformer. Customer Voltage Supply Wire 20 transformer stud Wire 30 transformer stud 90V-209V 220V 20V ( = 200V) 20V-229V 220V 0V (220 0 = 220V) 230V-249V 220V -20V ( = 240V) 250V-270V 260V 0V (260 0 = 260V) 370V-389V 400V 20V ( = 380V) 390V-40V 400V 0V (400 0 = 400V) 4V-49V 45V 0V (45 0 = 45V) 420V-429V 400V -20V ( = 420V) 430V-449V 460V 20V ( = 440V) 450V-469V 460V 0V (460 0 = 460V) 470V-490V 460V -20V ( = 480V) 2. Frequency link. A red wire link (3) is located at positions 2/3 & 4 of the large terminal strip on the electrics chassis. If the voltage supply frequency is 50Hz, the link must be wired between terminals 2 and 3. If the voltage supply frequency is 60Hz, the link must be wired between terminals 3 and Figure 2.5 Supply Settings 6

19 2.7 Test oil Refer to Figure 2.6 WARNING! HIGH PRESSURE FLUID SPRAYS CAN CAUSE SERIOUS INJURY OR DEATH. COMMON RAIL SYSTEMS OPERATE AT EXTREMELY HIGH PRESSURES. DO NOT ATTEMPT TO OPEN THE TANK ACCESS PANEL WHILE THE SYSTEM IS RUNNING. The tank should be filled via the left side panel. Loosen the four panel retaining screws (A) and lift off the side panel. Remove the three panel retaining nuts (B) and lift off the tank access panel. Fill the tank with clean test fluid to Shell ISO 43 specification through the aperture in the side of the test stand. The fill level can be observed on the tank drain tube on the bracket below the tank access aperture. The window indicates the maximum & minimum levels and is also visible when all panels have been replaced. Replace the tank access panel and the left side panel. 7

20 A A B B B A A Max Min Figure 2.6 Tank Filling 8

21 2.8 Initial Power-up The CR pump motor must be checked for the correct rotation. WARNING! ISOLATE AND LOCK THE ELECTRICAL SUPPLY TO THE TEST STAND OFF BEFORE ATTEMPTING TO ALTER THE 3 PHASE SUPPLY WIRING AT THE MACHINE ISOLATOR. DO NOT ATTEMPT TO CHANGE THE PHASE WIRING OF THE MOTOR. HAZARDOUS VOLTAGES MAY STILL BE PRESENT ON THE MOTOR TERMINALS EVEN WHEN THE MOTOR IS AT REST DUE TO THE NATURE OF SOFT START DEVICES. HIGH VOLTAGE! THIS CHECK SHOULD ONLY BE PERFORMED BY SUITABLY QUALIFIED PERSONNEL. DO NOT TOUCH ANY COMPONENTS INSIDE THE ELECTRICAL CABINET WHEN WHILE THE TEST STAND IS SWITCHED ON.. Operate the air supply control valve (Figure 2.8 item ) and check that the pressure gauge nearest the valve is set to 4 bar (58 psi). 2. Open the electrical cabinet door at the right hand side of the test stand. Apply electrical power to the test stand and switch on the test stand by turning the isolator switch shaft 90 degrees clockwise. 3. Applying 3 phase power with the air supply switched on will start the Test Fluid circulation pump and enable the temperature control system. The ticking of the circulation pump should be audible. As the pipes and the clean tank fill with Test Fluid it is possible that the fluid level in the main tank falls sufficiently to operate the fluid level switch and stop the machine. In this case the sound of the circulation pump will cease and the low fluid level can be confirmed by observing the max/min level window on the left side of the test stand (Fig. 2.6). Top up the fluid level in the main tank as required. 4. Switch ON the red illuminated power switch at the rear of the machine to power-up the computer, check that the monitor screen comes on and the Hartridge Magmah software starts. 5. Follow the procedures in section to fit an injector into the clamping fixture and clamp up the injector. 6. To check the rotation of the CR Pump Motor, observe the motor fan rotation as seen from the electrical cabinet (Fig. 2.7). 7. Press the motor Start button (Figure 3.4 item 4) followed immediately by the motor Stop button (Figure 3.4 item 5). The fan blades inside the cowling at the rear of the motor should be seen to rotate. The correct direction of rotation is CLOCKWISE (Figure 2.6 arrowed). 8. If the direction of rotation is incorrect: 9. Switch off the main electrical isolator by rotating the switch shaft 90 degrees anticlockwise. 0. Switch off and disconnect the electrical supply at the wall.. Swap over any TWO of the motor supply wires inside the terminal box on the main motor (cable 55, cores /2/3). 2. If the motor does not start: 9

22 3. Switch off the main electrical isolator by rotating the switch shaft 90 degrees anticlockwise. 4. Switch off and disconnect the electrical supply at the wall. 5. Swap over any TWO of the of the mains supply wires going to the isolator switch. 6. Re-apply electrical power to the test stand and check the motor rotation as described in this procedure. 7. When the rotation is correct: Switch off the main electrical isolator. Close the electrical cabinet door, ensuring that the 0 symbol on the switch operating handle is visible as the door is closed. This is to ensure correct engagement between the isolator switch shaft and the handle. Figure 2.7 Motor Rotation Figure 2.8 Air preparation 20

23 3. Systems and Principle of Operation 3. CR Injector Operation One of the main differences between Common Rail injectors and traditional mechanical injectors is the introduction of electrical control; with Common Rail injectors the timing and duration of injection are controlled using an electrically-operated valve. There are currently two types of valve, described in section 3.2 below. In terms of the hydraulic operation, high pressure fuel is supplied to the nozzle body and to a chamber on top of the control needle. The electrical valve opens/closes a leak off path from this chamber into the return circuit. When the valve is closed, the high pressure acting on top of the control needle keeps the injector firmly closed. Opening the valve relieves the high pressure from the top of the needle, opening the nozzle and starting the injection. Closing the valve re-establishes the high pressure on top of the control needle, quickly shutting off the injection. mm3/stk The volume of fuel delivered is proportional to both the duration of the pulse (pulse width), and the applied pressure, as shown by the graph in Figure 3.. Typical pulse widths are in the range of 200 to 2000 s. There is a minimum pressure below which the injector will not open; this is typically around 200bar. bar s Figure 3. Effect of Pressure and Pulse Width on Delivery 3.2 Injector Valve Types 3.2. Solenoid Valves These are electromagnetic coil valves; Figure 3.2 gives a schematic of the drive signal (showing current against time). There is a higher pull-in current (Ip) to initially open the valve, followed by a lower hold current (Ih) to keep the valve open. The overall pulse width (T) is the combined width of the pull-in and hold phases. There is a maximum limit on the pull-in current to protect the solenoid. Injectors with solenoid valves are currently manufactured by Bosch, Delphi, and Denso. Each of these manufacturers uses a different specification for operating voltage and current levels. 2

24 Ip Ih T Figure 3.2 Solenoid Injector Drive Signal Piezo Valves These use the inherent properties of piezo crystals (that they deflect with applied voltage) to activate the valve. There is a positive current pulse (I) to switch the valve on, and a negative current pulse to switch the valve off. The overall pulse width (T) is the time between the positive and negative current pulses. I T Figure 3.3 Piezo Injector Drive Signal Siemens were the first manufacturer to introduce piezo injectors, the main advantage over solenoid valves being that piezo valves have a much faster response time. 22

25 3.3 Pneumatic System Refer to the Pneumatic Circuit diagram A29A702 at the end of this section. The pneumatic circuit performs 4 functions:. Clamping the injector to be tested into the fixture. This uses the same principle as the 4 line system in HB378 & HF900. A double solenoid valve controls the airflow to a double acting cylinder. The clamp load is controlled by spacers and conical springs. 2. Metering unit return pressure. Air is supplied to the metering unit to create a backpressure on the piston to drain oil from the unit and provide a backpressure for the oil. 3. High pressure safety dump valve. Air is supplied through a separate regulator that is set and locked at Hartridge. This controls the maximum pressure in the high pressure hydraulic circuit. The regulator setting must not be adjusted or the machine safety will be compromised. If the injector access door is opened the solenoid valve is de-energised and the high pressure is dumped. 3.4 Fluid System Refer to the Hydraulic Circuit diagram A29A70 at the end of this section. Test fluid is contained in a tank (nominal capacity 40 litres) in the base of the machine. The tank contains an electric heater element controlled by the test stand computer and a level switch to prevent a low fluid level exposing the heater element and causing a fire hazard. A pump moves oil through a filter to the clean tank (nominal capacity 3 litres). Test fluid is sucked from the clean tank to the high pressure pump and the surplus returns to the main tank. The clean tank contains a temperature sensor to measure and control the test fluid temperature and another level switch to ensure the high pressure pump is not starved of test fluid. The Siemens high pressure pump is directly driven by a fixed speed electric motor, the pressure to the rail and injector is set by a VCV (volume control valve) and a PCV (pressure control valve) integral to the pump and controlled by the test stand control system. By-pass flow from the high pressure pump passes through a water-to-oil plate heat exchanger and cooled test fluid returns to the main tank. (Water flow is controlled by solenoid valve when required). NOTE Test fluid is only cooled when the high pressure pump is running. The high pressure test fluid circuit is protected by a high pressure dump valve. A pressure transducer measures the system pressure. The air pressure to the dump valve is set such that if the pressure rises above 200bar the valve is opened and high pressure test fluid is dumped to the main tank. If the injector access door is opened a solenoid switches off the air supply to the valve and the high pressure system is made safe for an operator to enter the test area. Injected test fluid passes from the injector, past a piezo transducer used to measure response time to the delivery metering unit. The delivery metering unit is water cooled. 3.5 Temperature Control The main temperature control system comprises a heater element and a water-to-oil heat exchanger (on the pump spill flow) controlled by computer software via relays. The software monitors the temperature via a sensor in the clean tank connected to the CR pump control board. The software switches on or off the heater and cooler by controlling relays on a Programmable Logic Controller (PLC) to maintain the fluid temperature at the desired setpoint. NOTE: The normal operating temperature is set to 40 C and should not need to be altered. 23

26 3.6 Injector and CR Pump Control 3.6. Injector control The injector control electronics is based on the Hartridge AE32 All Makes CR Injector Test box. This incorporates A single channel injector drive circuit, suitable for current Bosch, Delphi and Denso solenoid injectors, and Siemens piezo injectors. A separate single channel solenoid resistance measurement circuit. A single channel response time measurement (via response time unit). An interface with (and control of) the Backleak Flow Measurement Unit (section 3.7). For further information on injector control see sections 3. & CR pump control The CR pump control electronics is based on the Hartridge AE3 All Makes CR Pump Test box. The CR pump generates the high pressure in the Common Rail. The solenoid valves on the pump are controlled to achieve and maintain the required rail pressure. A pressure transducer mounted on the Hartridge pressure dump valve provides feedback of the rail pressure. 3.7 Delivery & Flow Measurement 3.7. Injector delivery The injector delivery measurement system is based on the Hartridge Positive Displacement Metering Unit and a modified Metering Control Board Backleak flow The injector backleak flow measurement system is based on the Hartridge HK90 Backleak Measurement Unit. The unit is controlled by the Injector control board (section 3.6). A solenoid valve is energised to divert the backleak flow into a measuring tube. The volume of fluid in the tube is read by a sensor and converted into a flow reading. After measurement the solenoid valve is de-energised and the tube is drained, all fluid being returned to the main tank. 24

27 3.8 Controls Refer to Figure Emergency stop pressing the button stops the CR pump, dumps the CR pressure, disables the air supply and so stops the fluid system. This button should not be used as a general stop for the test bench; its use is intended for emergency situations. 2. Clamp pushbutton press to move the clamping mechanism upward, toward the injector. The button has to be held to maintain movement. When the clamping mechanism reaches its mechanical stop the button may be released. 3. Unclamp pushbutton press to move the clamping mechanism downward, to unclamp the injector. The button has to be held to maintain movement. CR pump motor start press I to start the CR pump, after the initial starting sequence the pressurising system is enabled. The motor will not start if the injector is not clamped. 4. CR pump motor stop Press O to stop the CR pump motor Figure 3.4 Controls 25

28 3.9 Circuits The Electrical, Hydraulic, Pneumatic and Water circuit diagrams are included here for reference. 26 A29A800 Electrical circuit diagram 2 sheets A29A70 Hydraulic circuit diagram sheet A29A702 Pneumatic circuit diagram sheet A29A703 Water circuit diagram sheet

29 Electrical Circuit, sheet, MOD STD A-C 27

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31 Electrical Circuit, sheet, MOD STD D DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP 29

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33 Electrical Circuit, sheet, MOD STD H ONWARD 3

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35 Electrical Circuit, sheet 2, DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP 33

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37 Electrical Circuit, sheet 3, DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP 35

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43 Electrical Circuit, sheet 4, MOD STD H ONWARD 4

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55 Electrical Circuit, sheet 0, 53

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59 Electrical Circuit, sheet 2, 57

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61 Electrical Circuit, sheet 2, MOD STD H ONWARD 59

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63 Hydraulic Circuit, MOD STD A-G DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP Hydraulic Circuit 6

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65 Hydraulic Circuit, MOD STD H 63

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67 Pneumatic Circuit, MOD STD A-G DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP Pneumatic Circuit 65

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69 Pneumatic Circuit, MOD STD H 67

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71 DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP Water Circuit 69

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73 4. Operation WARNING! DO NOT ATTEMPT TO OPERATE THE TEST STAND BEFORE ALL PROCEDURES IN SECTION 2 (INSTALLATION) HAVE BEEN CARRIED OUT. WARNING! HIGH PRESSURE FLUID SPRAYS CAN CAUSE SERIOUS INJURY OR DEATH. COMMON RAIL SYSTEMS OPERATE AT EXTREMELY HIGH PRESSURES. IF USED AS INSTRUCTED THE TEST STAND WILL RELIEVE ANY HIGH PRESSURE WHENEVER THE GUARD DOORS ARE OPENED. DO NOT ATTEMPT TO BYPASS THE PRESSURE DUMP VALVE OR THE SAFETY INTERLOCK. 4. Recommended Test Sequence The recommended test sequence for Common Rail injectors is as follows:. Initial Check Use a Testmaster (HH70) and Signal Unit (HK85x) to check the basic operation of the injector and the nozzle spray pattern. 2. Cleaning and Repair If required, clean the nozzle in an ultrasonic tank, or dismantle the injector and replace faulty components. Any dismantling and reassembly should be done in a clean environment. 3. Repeat initial Check Re-check the injector on a Testmaster after cleaning/repair. 4. Final Test Carry out a full delivery, backleak, and response time test on the injectors using the CR Injector Test Stand. 7

74 4.2 Software Overview The test bench is controlled through Magmah software. At power-up the Main Screen is displayed (refer to Figure 4.). The screen is divided into sections as described below. Further screens and dialogs are accessed via the function keys. Click the relevant on-screen key. Alternate menu Figure 4. Main Screen 4.2. Function keys (Main Menu) F Start Test: Refer to Figure 4.7 Has to be pressed before any injections will take place. Pulls up a start test dialog which will have non mandatory fields to fill in (operator name, serial numbers etc.). Also has drop down boxes for Testplan selection and selection for automatic or semi-auto mode. F2 F3 Previous Step Next Step: In Manual Test mode these allow the user to step forward and back through test steps of a previously loaded testplan (will be greyed out otherwise). No action on these steps will be taken unless F4 Apply Step is also pressed. F4 Apply Step: Will apply test step. (Will also need to be pressed if the pressure demand, injection speed etc are changed manually) 72

75 F6 Testplan editor: Refer to Figure 4.2 Launches the MAGMAH parameter editor which is used to generate / modify testplans. For further details of the parameter editor refer to section 4.5. F7 Print: Refer to Figure 4.3 Displays a dialog to print. A drop down menu allows selection of the printer to be used -either the optional internal strip printer or an externally mounted desktop printer (not supplied). The type of printout can be selected, either a short summary report or a full report. F8 Results viewer: Refer to Figure 4.4 Displays a results screen where previous results can be loaded / viewed. F9 Measure Resistance Refer to Figure 4.9 Enables the resistance of the injector coil to be measured and displayed on screen. The appropriate resistance test cable should be connected for this. NOTE Resistance measurement is only valid for solenoid coil injectors, not for piezo injectors. F0 Status / diagnostic: Refer to Figure 4.4 Displays the status dialog each status box will display a red cross if there is a fault. F Reset: Resets the software as per power up. F2 Alternate Menu: Toggles between the main and alternate key functions Function keys (Alternate Menu) F7 (alternate menu) Production setup: Refer to Figure 4.6 Displays the Production Setup Dialogue. This is shown for reference only. All settings here are locked and require a log-on password to enable alteration. F8 (alternate menu) Owner details: Refer to Figure 4.5 Displays the Owner Details Dialogue. F0 (alternate menu) Backleak audit: Refer to Figure 5.5 Displays the Backleak audit screen that enables the HK90 Backleak Flow Module (if fitted) to be audited. F (alternate menu) Metering audit: Refer to Figure 5.4 Displays the Metering audit screen that enables the metering unit to be audited Main Screen Areas Area : Basic injector characteristics Shows the testplan loaded, the injector type loaded and the basic electrical characteristics: Supply Voltage; Hold Current; Pull-in Current and Maximum Pull-in Pulse Width. Also indicates if the fixture is clamped and if the drive motor is running. Area 2: Test conditions - 73

76 Shows the current step of the testplan plus any comments associated with the current step, also the conditions applied to the injector for that step: Fluid Supply Temperature; (Rail) Pressure Demand; Injection Speed; Pulse Width and Backleak Pressure Demand. The Live measured Supply Temperature and Rail Pressure are displayed too. Area 3: Measured / calculated parameters Shows the current measured parameters for the test step: Supply temp; Injector coil resistance; Rail pressure; Injector response time; Injector response variation; Backleak flow; Backleak temperature; Backleak pressure; Injector delivery and Injector delivery variation Status/Diagnostic Screen If the F0 function key turns red a problem has been detected with the system. Clicking the F0 key will open the Status/diagnostic screen. On this screen the status of all machine interlocks & controls plus the pump and injector control boards can be observed. An interlock fault will stop certain machine functions from operating and the cause should be investigated. indicates that the interlock or control board is OK. A indicates that the interlock or control board has tripped. Note that a against an item in the machine status window does not necessarily indicate a A fault, it simply indicates that particular item is not active at the present time. A tripped Pump PCB or Injector PCB can be reset by clicking the appropriate Reset button on-screen. 74

77 Figure 4.2 Testplan Editor Figure 4.3 Print 75

78 Figure 4.4 Status / Diagnostic Screen Figure 4.5 Owner Details 76

79 4.2.5 Red Status Indicator System errors are indicated by a small box with a Red Status indicator at the bottom of the screen. To clear this, click on the Red Status indicator, note the error(s) listed and click on the 'Clear All' button. NOTE: A Red Status Indicator will appear if the 3 phase supply is turned off and the PC is left on. This is normal. Figure 4.6 Red Status Indicator 4.3 Test Setup and Method The basic parameters that will establish the condition of a CR injector are: Spray Pattern (checked on Testmaster) Delivery vs. pressure vs. pulse width Backleak flow (dynamic and static) Response Time Example testplans are provided for each manufacturer. These contain the basic electrical characteristics for that manufacturer s injector and typical demand settings for various conditions. They do not contain expected results values as these will be specific to each injector part number. Example testplans can be used as a basis for creating dedicated testplans for specific injectors Load a Testplan When you first enter the CR Injector Test screen it will be mainly blank. You must load a testplan to start testing. To load a testplan for the relevant injector manufacturer, first press F (Start Test). This will display the Start Test dialog (Figure 4.7). 77

80 If you want to save the test results you can enter your name, a customer reference, and the injector serial number. You have the option of skipping the resistance test by checking the Skip Resistance Test box. This will prevent the need to do a resistance check before each injector test (clicking F9 from the main screen will allow a resistance test to be performed when required). If a resistance test is required before each injector test, leave the box unchecked Select the injector Manufacturer / Type and the Testplan / Part Number required, then select either Manual or Automatic test & then click OK. NOTE: Example test plans will be provided for each manufacturer. These give typical test parameters but do not give test result limits. The example test plans can be used to help create individual test plans for specific injector part numbers. See Section 4.5. Figure 4.7 Start Test Dialog Measure Injector Coil Resistance (if selected in the Start Test dialog). Refer to Figures 4.8 and 4.9. The injector solenoid resistance should be measured before any other tests to help avoid system trips due to faulty solenoids. This test should always be the first test step of all testplans. On-screen dialogs will prompt the operator to connect the resistance measurement cable for the specific type of injector to the lower socket () in the Injector test area (4 way connector). NOTE Resistance measurement is only valid for solenoid coil injectors, not for piezo injectors.

81 2 Figure 4.8 Injector Connectors Figure 4.9 Resistance Check If the resistance measured is within acceptable limits disconnect the resistance cable from the injector and proceed as follows Install Injector in the Clamping Fixture & Clamp Refer to Figure 4.0 Figure 4.0 shows a general schematic of the injector installation. The exact parts required will depend on the injector type - full details are given in Technical Bulletin 95/. Select the right parts for the injector you have and mount as shown. NOTE: Kit numbers given in Technical Bulletin 95/must be given the suffix /C e.g. HK9xx/C. kits with suffix /C have sufficient parts for injector. Kits without the suffix have parts for 4 injectors and are used for AVM2-PC and 4-line CRi-PC machines. NOTE: Remove any sealing washers from the injector nozzle and use the seals supplied in the relevant Nosepiece Adaptor Kit. The clamp block screws A should be tightened to a torque of 25Nm. NOTE: The clamping load is set by the distance D between the upper and lower blocks. For the majority of injectors a 9kN clamp load is recommended, therefore the 9kN Spacer NTA5002 should be fitted unless advised otherwise. 79

82 NTA5002 Figure 4.0 Clamping Arrangement When the injector is ready to be clamped, close the guard door and then press the clamp pushbutton on the control panel. Clamping will not occur if the safety door is open. The clamping mechanism should move upward towards the injector as long as the clamp button is held down. At the end of the clamping stroke the fixture clamped checkbox on the main screen should have a and the button may then be released. The fixture clamped checkbox should remain checked after the button has been released. The guard door can be opened and the backleak pipe and the high pressure pipe from the rail to the injector connected. NOTE: The height of the test rail is adjustable using the two screws into the cross strut. For the majority of injectors the rail should be left in its lowest position. For Delphi injectors (where one pipe is used for the different injector lengths) the rail height should be adjusted as required. After the Resistance Test the Connect Injector dialog appears (Figure 4.). Connect the Injector test cable suitable for the type of injector under test. Select the appropriate cable and plug it into the upper circular connector (Figure 4.8 item 2) in the injector test area. NOTE: Selection of the correct cable is very important as the connector for each type is internally wired to inform the system which injector will be tested, and therefore what voltage and current to apply. The injector is now ready to test. 80

83 Figure 4. Connect Injector Start the CR pump Press the CR pump motor start button (I). The motor will start, run up to full speed and the Drive motor running checkbox on the main screen should have a Run the Test Steps Ensure that the Injector test cable appropriate for the type of injector under test is connected as prompted on the screen after the Resistance test. Pressing [OK] then puts the software into testing mode; on the main screen F changes to Stop Test. Manual tests In manual tests the operator can click Next Step and Apply Step to go through the testplan step by step. When a test step is initiated the test stand is allowed a stabilisation time in the new test conditions (if, for example, the rail pressure has been increased). This stabilisation time is shown on the screen as the Wait for start parameter. When the parameter has been counted down to zero the test measurements for the step are taken. During a test step several metering measurements are taken and the average of these readings is the displayed result for the step. Each metering reading is an average of 0 injections. The Averaging readings parameter on the screen shows a countdown of the number of metering readings being taken. When the countdown reaches zero the average is displayed and the next step in the testplan can be executed or the last step repeated by selecting the relevant function key. When a test step is completed results are frozen unless the continuous reading button is pressed. During a manual test the operator may set a different injection speed (IPM) or pressure demand etc. by typing directly into the box for that parameter on the screen and pressing F4 twice to stop the step and then apply the new settings. If the step fails for any reason (any of the parameters going outside tolerance) the Overall Test Pass/Fail will display a and the parameter that failed will also have a shown next to it. The operator may click Apply Step to retry the current step or continue to the next step by clicking Next Step. At the end of the manual test, after all steps have been run, the test stand stays in the running conditions of the final step until the operator clicks Stop Test. Automatic tests In automatic mode the test steps are run through automatically, with no operator intervention (except the initial resistance test, where the operator has to connect cables to the injector). If any step fails the results are still saved and the testplan continues. At the end of an automatic test the testplan is stopped, the injections are stopped and a low rail pressure is demanded. The CR pump continues to run as the software has no control over this. The operator must press the motor Stop button to halt the CR pump. 8

84 The example testplans will typically follow this format: Resistance Check The first test of any testplan, to determine the condition of the injector coil. Failure to do this may trip the injector control circuit. 2 Leak Check A startup condition at low pressure so that you can visually check for leaks before going on to higher pressures. 3 Purge A higher injection speed and higher pressure condition; run to purge any air from the system (wait for stable deliveries to register before continuing), and while waiting for the system to reach temperature. 4 Idle Speed Sets the injector demands at typical idle speed settings. 5 Mid Load Sets the injector demands at typical mid load settings. 6 Full Load Sets the injector demands at typical full load settings. 7 Static Backleak Sets high pressure and switches the injectors off to measure the inherent backleak through the injectors. Go through the test steps in the order shown (steps 2 and 3 are for preparation and warm up, steps 4 to 7 are the main tests) Injector removal To remove the injector: Ensure the rail pressure has fully decayed. Open the guard door and disconnect the high pressure pipe, the backleak pipe and any electrical connector. Press the unclamp pushbutton until the clamping fixture has moved fully down. The guard must be closed to enable unclamping. Interpretation of Results The best way to use the Test Stand is as a comparator against new injectors. The demand settings in the example testplans supplied should give delivery results for the majority of injectors however there may be some test conditions that do not (particularly the idle speed step). We recommend that these testplans are used as a base to create specific testplans for individual injector part numbers (see Section 4.5). With experience you will build up knowledge of injector operation and possible faults. The following general guidelines apply if you are testing an unknown injector Response Time The faster the response time the better. Any injector whose response time is more than 00μs longer than the norm is likely to cause engine problems Delivery On a vehicle, engine management systems may compensate for small variations in injector delivery by trimming the pulse width to individual injectors. Therefore on the test bench you may well see slight differences between injectors at a given test point (depending on the delivery volume) Backleakage Common Rail injectors have inherently higher backleak than traditional injectors as a volume of fuel is expelled every time the injector valve operates (see Section 3). Typically for a good injector this dynamic backleak volume is of the same order of magnitude as the delivered volume. 82

85 The Static Backleak test focuses purely on the inherent tightness of the injector in a static condition and so gives an indication of the condition of the injector valve seats and clearances. This is similar to testing backleak on a traditional injector and is measured over time (mm³/sec). For both the dynamic and static backleak tests, any injector with a significantly higher flow (and temperature) than the norm should be regarded as suspect. NOTE: Backleak tests must be run with at least 20 seconds stabilisation time to ensure a reading is obtained Summary In general when testing a batch of injectors the faulty injector(s) will have: higher response time lower delivery higher backleakage flow 83

86 4.5 Creating/Editing/Saving Testplans 4.5. General Pressing F6 in the main screen will call up the Testplan Editor (Figure 4.2). The Editor uses the following standard Microsoft Windows commands. File - New, Open, Close, Save, Save As, Print, Print Setup, Print Preview, Exit, Find/Replace Edit Undo, Cut, Copy, Paste View - Toolbar, Status Bar Window New Window, Cascade, Tile, Arrange Icons Help - Help Topics, About CPE Editor To create a new testplan, open one of the example testplans, then use the Save As command to save with a different filename. The test step values can then be changed as required. NOTE: We advise you NOT to change the example testplans supplied as this will maintain a consistent base to refer back to if needed. Selecting one of the numbered test steps in the left hand column and then clicking the right hand mouse button will display the Insert/Delete menu. From this a new step may be inserted before or after the selected step or the selected step may be deleted. Refer to Figure 4.2. Figure 4.2 Insert/Delete Menu Parameters Refer to Figure 4.3. Scrolling horizontally to the right reveals the parameters that cannot be seen on the screen (column 6 onwards).

87 NOTE: Column widths can be resized similar to an Excel spreadsheet. The first 5 steps of the testplan configure the machine for that particular type of injector and should not be altered. They are Step Test Plan Comment Here the user may enter a note, comment about the testplan. Step 2 - Injector Setup The injector manufacturer is selected. A checkbox to select if the injector is a piezo type. The supply voltage for the injector. The current limit for the injector. The holding current for the injector. The pull-in current for the injector. The pull-in current pulse width. Step 3 Supply Temperature A checkbox to select whether the testplan waits for the temperature to be within tolerance before commencing the tests. A temperature demand setting. A minimum temperature setting. A maximum temperature setting. The units of the temperature display, either C or F. Step 4 Measure Resistance The minimum resistance for the injector coil (Ohms). The maximum resistance for the injector coil (Ohms). Step 5 Test Units The units for the display of Backleak flow. The units for the display of injector delivery flow. Step 6 onward Test Step Step 6 onward can be configured for the injector test conditions. The parameters available for each step are A checkbox to select whether the testplan waits for the temperature to be within tolerance before commencing the step. A timeout period for the wait for in limits parameter (secs). A title for the step. A comment area for the step. The stabilisation time (seconds). The number of metering updates. The rail pressure demand (bar). 85

88 The injection speed (injections per minute IPM). The injection pulse width (μsecs). The backleak pressure setting (mbar) (not available at this time). The minimum rail pressure. The maximum rail pressure. The minimum response time (μsecs). The time between the injector coil being energised and the fluid being injected. The maximum response time (μsecs). The minimum response variation (μsecs). The maximum response variation (μsecs). The minimum backleak flow. The maximum backleak flow. The minimum backleak temperature. The maximum backleak temperature. The minimum backleak pressure (mbar) (not available at this time). The maximum backleak pressure (mbar) (not available at this time). The minimum injector delivery. The maximum injector delivery. The minimum injector delivery variation. The maximum injector delivery variation. Figure 4.3 Example Parameters 86

89 4.6 Viewing and Printing Saved Results To view or print previously saved results press F8 Results viewer. This will open the main Results Viewer screen (Figure 4.4). When first opened the screen will show the results from the test just carried out. Figure 4.4 Results Viewer Clicking the F button on the main Results Viewer screen opens a dialog with a drop-down list of previously saved results files (Figure 4.5). Select the required results file and press [OK]; the software will load it into the Viewer screen. Figure 4.5 Load Results Dialogue The results from any step of a testplan can be viewed by clicking the Previous and Next Step buttons on the Viewer screen. Results can be printed by using F7, or return to the live data screen by pressing F2 Return. A drop down menu allows selection of the printer to be used -either the optional internal strip printer or an externally mounted desktop printer (not supplied). 87

90 The type of printout can be selected, either a short summary report or a full report (refer to Figure 4.3). Figure 4.6 Production Setup Dialogue 88

91 5. Calibration and Maintenance WARNING! DO NOT RUN THE TEST STAND WITHOUT ALL THE ACCESS PANELS FITTED. ALWAYS ISOLATE THE TEST STAND AT THE MAIN VOLTAGE SUPPLY SWITCH ON THE WALL, BEFORE REMOVING ANY ACCESS PANELS. 5. Calibration & Audit TM Hartridge recommend that the condition of the CRi is regularly audited and certified by competent independent personnel. The safety and operational functions and the calibration accuracy of the transducers used for measurement on the Cri-PC should be checked at least every year or every 500 hours in use whichever is sooner. Operators should contact their local Hartridge distributor for details of the certification service offered. 5.2 Removing Access Panels Electrical Enclosure High Voltage! Access to the electrical enclosure should only be allowed by 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. Refer to figure 5.. The enclosure door will not open with the main electrical isolator switch () in the ON position. Ensure the isolator is set to the OFF position. 2. Use the key tool provided to open the door locks (2). The door can then be swung open. 3. When closing the door check that the isolator switch handle is still in the OFF position, to prevent possible damage as it closes on the operating shaft. 89

92 2 2 2 Figure 5. Electrical Enclosure Access Rear panel Refer to Figure 5.2 This panel allows access to the CR Pump and the test fluid tanks. Release the five panel securing nuts (arrowed). The panel may then be lifted and removed. WARNING! HIGH FLUID PRESSURES MAY EXIST WITHIN THE TEST STAND. DO NOT REMOVE ACCESS PANELS UNTIL THE MOTOR HAS BEEN STOPPED, RAIL PRESSURE HAS DECAYED TO A LOW LEVEL AND THE MACHINE SWITCHED OFF. FLUID SPRAYS, ESPECIALLY FROM LEAKING HIGH PRESSURE PIPES AND SEALS, WILL CAUSE HIGH PRESSURE INJECTION THROUGH THE SKIN WHICH CAN RESULT IN FATAL INJURY. 90

93 Figure 5.2 Rear Panel Side panel The procedure for removing the side access panel is described in section 2.6. The side panel allows access to the magnetic debris filter in the main tank, the clean tank and allows access for filling with test fluid. Lower front panel Refer to Figure 5.3 The lower front panel allows access to the clamping cylinder, the pneumatic solenoids, the tank thermostat and the cooling water solenoids. Loosen the panel screws arrowed A and remove the panel screws arrowed B. The panel lifts off, leave screws A in position as these will help to locate the panel when it is replaced. A A B B B B A B B 9

94 Figure 5.3 Lower Front Panel 5.3 Regular Maintenance Frequency of checks Machine Hrs Operation 20 Hr* Pump Use Hrs 20 Hr* 500 Hr* Ref. Check emergency stop Check pressure dump valve Generally clean Metering Audit tests Backleak Audit test (if fitted) Change test fluid & filters, clean magnet filter Change metering unit filter NOTE: *Hours displayed on Status / Diagnostic dialog (see Figure 4.4) Check Emergency stop Every 20 hours of machine use or sooner. Switch on the test stand. 2. Press the Emergency Stop button and check it is latched in. 3. Check the motor cannot be started. 4. Check the air pressure reading on the pressure gauge at the rear of the injector test area reads zero. 5. Rotate the Emergency Stop button clockwise to unlatch it. 6. Check the air pressure gauge reads pressure (approx 3 bar). 7. Load an injector and start the CR pump motor. Note the common rail pressure. 92

95 8. Press the Emergency Stop button and check the motor stops. Check the common rail pressure has been dissipated Check pressure dump valve Every 20 hours of machine use or sooner. Switch on the test stand. 2. Start a test and set a low Common Rail pressure ( bar). Check the pressure is displayed on the monitor. 3. Open the Injector access door SLIGHTLY and check that the CR pump motor stops & the Common rail pressure is dissipated Generally Clean The test stand is a precision instrument and should be kept clean. An anti-static cleaner may be used to clean the PC screen. Check that the ventilation panels on the electrical enclosure at the rear of the test stand are clear of debris and unobstructed. NOTE: Use only soapy water to clean the clear plastic guard door. Do not use chemical or abrasive cleaners as this may damage the plastic and compromise safety. 93

96 5.3.4 Metering Audit Tests Refer to Figure 5.4 Figure 5.4 Metering Audits (Leak Test) The Start function keys at the bottom of the window will start the audit tests as listed in the window. The Previous Step Apply Step Next Step Stop Metering Stop Test keys provide the following functions:- Metering audits 2, 3, and 4 should be run using the audit testplan provided. Load the Metering Audit testplan for the injector type fitted, e.g. "Bosch_MeteringAudit.cpf". Before starting any audit, run the "PURGE" condition for a couple of minutes to ensure the system is clear of air and the firing order has been learnt. Then select the "AUDIT" condition to run audits 2, 3 and 4. 94

97 Audit - Mass Overcheck This audit is for the use of Hartridge personnel only and should not be accessed by the operator. Audit 2 Leak check The Leak test detects leaks in the metering unit and the fluid path between the injector nozzle & the metering unit. The test must be carried out with the machine at ambient temperature to help eliminate fluid cooling and contraction as a cause of errors. To perform a Leak Test it is necessary to first have an injector running.. Start an injector test and apply a step that causes the injector to fire. 2. Select F2 from the Main Screen to change to the Alternate Menu and then select F from the Alternate Menu to bring up the Metering Audit dialogue box. 3. The metering piston position is displayed in mm. Pressing the Start Audit 2 function key will stop the injections and perform a Leak Test at certain positions within the range of the piston displacement. If the position is out of range injections will continue (the dialogue displays Finding Position ) until in range and then the Leak Test will begin automatically. 4. When the Leak Test has started the dialogue displays Waiting Stability. The system will wait for 30 seconds after stopping the injections before measuring the leak rate. 5. During measurement the dialogue will display Leak Test. The leak rate is measured over a 30 second period and then the resulting Leak Rate (mm per minute) is displayed. The leak rate must be less than 0.2mm/min. 6. Pressing the Start function again at this point will result in the Stability and Leak Test being performed again from the current piston position (injector not fired again). 7. To end the Leak Test press click the Stop Test function button. Causes of leakage which can be rectified by the maintainer include: The injector and the bonded seal washer in the nozzle adaptor Metering Unit Drain Solenoid Metering Unit Filter Plug Piezo Transducer O-ring (on the injector clamping fixture). Injector adaptors The braided pipe between the Injector and the metering unit If the problem is not resolved by these actions contact Hartridge or your national distributor. Audit 3 Audit 3 is only valid for a 4 line Cri-PC test bench and should not be attempted on the single line Cri-PC test bench. Audit 4 Flush Test This test measures restrictions in the metering unit particularly of the sintered filter. With the injector working as for Audit test 2, click the Start Audit 4 Key to begin the test. The software will automatically control the injector and the metering unit. When prompted by the software, press the fixture unclamp button. The filter is OK if the result is greater than 35 (-35 on the screen) mm/sec. Causes of restriction which can be rectified by the maintainer include: Metering Unit Filter blocked; see section for instructions on replacing the filter 95

98 Braided pipes If the problem is not resolved by these actions contact Hartridge or your national distributor Backleak Audit With Magmah v9.0 onwards (If optional backleak measurement unit is fitted) Refer to figure 5.5 Specific note for pressurised backleak units: Before starting an audit the following should be disconnected: th a) the extraction tube hydraulic connection (5 port; disconnect the 6mm pipe from the 90 degree push-fit elbow) a These must be re-connected after the audit. A single (CRi -line) or set of four (CRi 4-line) good injector(s) should be used for the backleak unit audit. The purpose of the audit is to check the following three features of the backleak unit: - measurement line transducer offsets (step 2) - measurement line max fill calibration values (step 4) - measurement system leakage (step 5) If the audit indicates a problem in any of these areas, please contact Hartridge for further assistance.. Select F0 from the Alternate Menu to bring up the Backleak Audit dialog box. 2. Select [Load Testplan] and load any testplan for the injector type fitted. 3. Start the main motor and then press [Start] to start Step of the audit. This applies the pressure, pulse width, and speed demands shown in the dialog box. 96

99 Figure 5.5 Backleak Audit 4. Wait for the backleak temperatures to rise to between 50 and 60 C. The default demands can be altered if the temperatures are taking a long time to increase (these demands can only be changed during step of the audit, thereafter they are disabled). The audit will not proceed unless the backleak temperatures are within limits. 5. Press [Next] to go to Step 2, Permanent Drain Mode. This switches off the backleak metering valve to empty the measurement tubes, and switches off the injectors. Backleak Raw Value mv values will now be shown; wait a few seconds for them to stabilise (as the tubes drain). Values in the range of 500 to 2500 are acceptable. 6. Press [Next] to go to Step 3, Zero Readings. This records the mv offset readings and then zeroes the mv values (the values will fluctuate at 0 +/-2mV). 7. Press [Next] to go to Step 4, Permanent Fill Mode. This energises the backleak metering valve so that the measurement tubes start filling, and switches on the injectors. The mv values will increase until the measurement tubes are full; wait until the values stop increasing (this should be at values around 800 values between 784 and 86 are acceptable). 8. Press [Next] to go to Step 5, Leak Check. This records the max fill values, and prompts to stop the motor. 9. Once the motor is stopped, the audit waits for 0 seconds for stability, and then records the values at the start and end of a -minute leak check time. The difference between the leak test start and end readings is shown on the Back Leak Rate line and should be less than 0 mv/min. 0. At the end of the audit, press [Save] to save the audit log file. This is useful to keep for your own records and may also be requested by Hartridge to assist in diagnosing problems. The default filename and location is: C:\CRiPC\Log\BackleakAudit_date_time.txt. 97

100 5.3.6 Change test fluid & filter, clean magnet filter Check the viscosity of the test fluid to determine whether or not the oil should be changed. Otherwise, routinely change the test fluid after each 500 hours of test stand use. The current elapsed hours can be viewed on the Status / Diagnostics screen (Figure 4.4). Technical Service Bulletin TSB60/4 details the equipment required to test the viscosity of the test oil. Empty the tank. Switch off the electrical supply to the test stand and remove the left side access panel as described in section 2.6 and Figure Refer to Figure 5.6. Remove the main tank drain pipe () from its bracket, hold the pipe over a suitable container (minimum capacity 45 litres) and allow the fluid to drain out of the tank. 3. Release the clean tank drain pipe (2) from the clip, hold the pipe over the container and allow the fluid to drain out of the tank. 4. Wipe out the inside of the main tank with a clean dry absorbent cloth. 5. Refit the drain pipes to their respective bracket/clip. 2 Figure 5.6 Tank Drain Pipes Clean the magnet filter 6. Lift the magnet filter bracket out of the tank and wipe debris from the magnets using a soft lint free cloth (Figure 5.7). 7. Refit the magnet bracket. 98

101 Figure 5.7 Magnet Filter Change the Test Fluid Filter (Hartridge Number ) 8. Open the injector access door to access the test fluid filter (Figure 5.8). The filter hangs on an aperture to the right of the injector clamp. To remove the filter, simply lift the filter up and away from the aperture. Figure 5.8 Fluid Filter in Situ 9. Remove the pipe loop (L) (Figure 5.9) and fit it to the new filter. 0. Disconnect the inlet pipe from the pump (I) and connect it to the correct port on the new filter - identified with a green dot (I).. Disconnect the outlet pipe (O) and connect it to the correct port on the new filter. 99

102 2. Hang the new filter on the filter bracket. O I L Figure 5.9 Fluid Filter Connections Change the pump suction filter (Hartridge Number A29C23) 3. Open the side panel (see section 5.) to access the test fluid filter. The filter is pressed on to the suction pipe and hangs in the oil at the back right hand side of the tank. Pull off and replace. Fill with test fluid 4. Refill the tank as described in section 2.6 with clean test fluid to ISO43 specification. 5. Switch on the test stand and ensure the air supply is connected. The fluid circulation pump should start. Check around the filter for leaks. 00

103 5.3.7 Change metering filter (Hartridge Number ) Refer to Figures 5.0 and 5. Remove the filter from the metering unit inlet block (arrowed). Remove the orifice from the old filter and fit to the new filter Fit the new filter with the orifice towards the metering unit body and the O ring between filter and plug. Figure 5.0 Metering Filter Location Figure 5. Changing the Metering Filter 0

104 5.4 Troubleshooting WARNING: ONLY QUALIFIED SERVICE PERSONNEL SHOULD ATTEMPT DIAGNOSTICS WITH POWER APPLIED General The procedures given in this section assume that the test stand has been installed, prepared and commissioned correctly to the information given in the Installation section of the manual. The procedures also assume that the test stand has been powered up and operated correctly, as detailed in the Operating section of the manual. If a failure is suspected or indicated, repeat/recheck the appropriate instructions before attempting troubleshooting procedures. If a fault is suspected and/or displayed, carry out the following procedure before attempting further diagnosis:. Switch off power to the test stand and remove access covers. 2. Carry out a visual inspection, to ensure that there are no obvious signs of damage, for example: a. Loose, trapped or unterminated wires, connectors or pipework. b. Air or fluid leaks. c. Blown fuses. CAUTION: For the next check electrical power needs to be applied to the test stand. Note the warning at the top of this section. Take all necessary precautions to ensure the safety of personnel. These include, but are not limited to:- erecting signs warning of the electrical hazard; placing barriers/chains around the hazardous area; ensuring that metal items (such as jewellery) are removed before accessing the hazardous area. d. Check the voltage supplies are satisfactory (check secondary voltages on the main transformer are correct to within 0% as detailed in Table 5.). e. Check the dc voltage on the power supply at bottom left of the electrical cabinet (refer to Figure 5.2). the voltage should be 24V dc on wire 850 with respect to wire Ensure power is switched off and repair any visible defects. 4. Replace access covers, switch the test stand on and recheck. 02

105 Winding Nominal Voltage (a.c.) Acceptable Range (a.c.) 24V With reference to wire V 29V With reference to wire V 4.5V With reference to wire V 22V With reference to wire V 5V With reference to wire V 27V With reference to wire V 45V With reference to wire V 97V With reference to wire V 22V With reference to wire V Table 5. Transformer Secondary Voltages Figure 5.2 DC Power Supply Computer / monitor If the monitor screen appears to be dead check the following:. Open the hinged computer access door (Figure 2. item 2). Check that the computer is switched on, indicated by the power switch being illuminated. 2. Check the integrity of the connections to the rear of the monitor screen. 3. Is the power connected to the single phase socket at the rear of the test stand and the red power switch in the ON position? (Figure 2.4 item 4) 4. Is the red power switch illuminated? If not a. Check the main electrical supply at the wall is on. b. Switch off the electrical supply. Open the electrical cabinet and check the two 0A fuses on the power socket strip below the computer (Figure 2. item 4). 03

106 5.4.3 Fault indicators In the event of one of the interlock indicators on the Status screen showing a checks in table 5.2. Interlock Emergency Stop Active Main Tank Level Low Main Tank Thermostat Air Pressure Low Clean Tank Level Low Action Check that the emergency stop button has not been pressed. Check the test fluid level through the aperture in the left side panel, if the fluid is not visible or is low in the window top up the level as required. If the level appears to be ok suspect a faulty or obstructed float switch in the main tank. Check for evidence of leaks on the floor under / around the test stand and determine the source. Check the indicated supply temperature on the main screen. If the indicated temperature is lower than the setpoint (normally 40 C) suspect that the flow of fluid from the main tank into the clean tank is insufficient check the integrity of the fluid circulation system as for a Clean Tank Level Low fault. If the indicated temperature is much higher than the setpoint check that cooling water is switched on and entering the test stand (maximum temperature 20 C) and that warmer water is exiting the test stand. If the cooling water solenoid works but the water is not flowing though the test stand, suspect a contaminated / stuck solenoid valve or water supply pressure problem. If the main tank does not feel hot remove the front lower access panel and check that the two wires (red and grey) on the thermostat are still in place (the thermostat can be seen attached to the outer surface of the main tank). If the status indicator for the Cooler Circulation On is on and the cooling water circuit seems to function correctly suspect a problem with the heater control solid state relay (K2) on the electrical chassis. Indicates that the air supply pressure is too low or that the air is not connected. Check that the air supply to the test stand is connected, switched on and is at least 6.5 bar. Check that the air shut off valve (Figure 2.8 item ) is open and that air pressure is shown on the pressure gauge. Indicates that the clean fluid supply to the CR pump has failed (low level). 04 follow the Check that the fluid circulation pump is

107 operating correctly. Motor Circuit Breaker Main Guard Open Check the filter between the circulation pump and the clean tank is not blocked. Check the filter between the main tank and the circulation pump is not blocked. Check for any leaks around the circulation pump and any associated pipes. Check for any blockages or restrictions in the fluid circulation pipes. Indicates that the circuit breaker supplying the CR pump drive motor has tripped. Check the overload is set correctly for the electrical supply to the test stand (refer to the circuit diagram, sheet 4, thermal trip settings). Check for causes of motor overload eg: CR pump seized, excessive rail pressure due to faulty feedback from the pressure sensor on the dump valve or restricted motor cooling fan. Indicates that the test area door is not closed. This is only an indication of a fault if it is believed that the door is closed. The machine cannot be run without the guard door closed. Check the guard is closed. If OK suspect a faulty guard interlock switch Table 5.2 Interlock Status Indicators 05

108 5.4.4 Injector control WARNING: THE INJECTOR CONTROL PCB CONTAINS HIGH VOLTAGES. SWITCH OFF THE ELECTRICAL SUPPLY TO THE TEST STAND BEFORE OPENING THE ELECTRICAL CABINET. ONLY QUALIFIED SERVICE PERSONNEL SHOULD ATTEMPT DIAGNOSTICS WITH POWER APPLIED. Status Indicators The injector control status indicators on the Status/diagnostic screen (Figure 4.4) give the following indications: Injector PCB Trip Volts Low Pulse Too Great Default Injector Setting Injector PCB Trip Condition Two conditions could cause the system to trip:- high current (meaning that the current delivered is not controlled at the demand value), or extended pulse (meaning that the pulse has not turned off at the required width). Switching off the power supply to the system, waiting a few seconds, and then switching back on should reset the fault. This is achieved by pressing the Reset key in the Injector PCB area of the Status screen. If the system still trips switch off the test stand, disconnect the injector cable, then switch back on. If the system appears to be ok the trip could be caused by a faulty injector coil or piezo. Try a different injector to establish if it is a test stand fault or a problem with one injector. Otherwise a fault within the injector control PCB may be suspected. If you suspect a problem with the injector control PCB, contact your local Hartridge distributor. Other Faults Check the fuses on the control board. The injector control PCB receives its 22V power supply from the main transformer. This is protected by a 3.5A anti-surge fuse (FS) on the PCB (Figure 5.3). The injector coil control is powered by various combinations of voltages from the main transformer, the combination depends on the type of injector being tested. The coil circuit is protected by a 6.3A anti-surge fuse (FS2) on the PCB (Figure 5.3). For any more complex problems contact your national Hartridge distributor. Please give as much information as possible on the conditions when the fault occurred, e.g. 06 The injector type under test The test speed (injections per minute - IPM) The solenoid current(s) applied The pulse width applied

109 FS2 6.3A A/S FS 3.5A A/S Figure 5.3 Injector Controller Fuses CR pump control Status Indicator The Pump control status indicator on the Status/diagnostic screen (Figure 4.4) gives the following indication Pump Drive PCB trip. The Trip Condition The trip is set if the combined current load from both outputs exceeds 5A for more than 5 seconds. Switching off the power supply to the system, waiting a few seconds, and then switching back on should reset the fault. This is achieved by pressing the Reset key in the Pump Control PCB area of the Status screen. Short circuit or damaged pump solenoid coils may cause the trip. Any solenoid resistance below 2Ω should be regarded as suspect. Other Faults Check the fuse on the control board. The CR pump control PCB receives its 4V power supply from the main transformer. This is protected by a 6.3A anti-surge fuse (FS) on the PCB (Figure 5.4). 07

110 In the event of a problem, check this fuse first. For more complex problems contact your national Hartridge distributor. Please give as much information as possible on the conditions when the fault occurred, e.g. The test speed The pressure applied FS 6.3A A/S Figure 5.4 CR Pump Controller Fuse 08