World Leaders in Diesel Fuel Injection Test Equipment. Series AVM2-PC. Diesel Pump Test Stand. Installation & Start Up Operating & Maintenance

World Leaders in Diesel Fuel Injection Test Equipment Series AVM2-PC Diesel Pump Test Stand Installation & Start Up Operating & Maintenance RefNoHL032 (EN) Issue 9, AT2329

Installation & Start-Up

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Installation & Start-Up 1 2 3 4 WARNINGS 5 Warranty Statement 9 Introduction 11 Installation 13 41 Site Requirements 13 42 Installing the Test Stand 14 43 Remove Transit Fittings 15 431 Injector Mount 15 432 Test Stand Bed 15 433 Console 16 44 Connecting Services to the Test Stand 16 441 Water Supply 16 442 Air Supply 16 45 Test Stand 3 Phase Electrical Supply 17 451 380-480V Supply 18 452 Test stand transformer primary setting and 50/60Hz selection 19 46 PC Single Phase Electrical Supply, Keyboard and Mouse 20 47 Filling the Oil Tanks 21 471 Test Oil 21 472 Lube Oil (option) 22 48 Connecting a Printer, Modem or Network Card 23 49 Installation Check List 23 5 Starting-Up the Test Stand 27 51 Power 27 511 Electrical supplies 27 512 Switching the 3 phase supply OFF 27 513 Switching the PC ON 27 514 Switching the PC OFF 27 52 Emergency Stop 28 53 Initial Power On 28 54 Changing Owner Details 29 55 Changing Date and Time 29 56 Adjusting the Monitor 30 57 Start the Fuel Pump 32 58 On Line Help 32 6 Circuits 33 61 62 63 64 65 66 Test Oil and Cooling Water Supply Circuit 33 Pneumatic Circuit 34 Lube Option Circuit 35 AVM2-PC Metering Circuit 36 Index to Hydraulic, Pneumatic and Cooling Water Circuits 37 Electrical Circuits 39 7 Start-up Problem Solving 49 71 72 73 Test Stand Serial Plate 49 Software Version Information 50 Fuse Locations 52 3

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1 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, eg 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 Do not adjust any test stand components (including pumps under test) while they are moving 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 5

INSTALLATION & START UP 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 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 (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 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 6

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 Low frequency noise may damage the inner ear and cause deafness NOISE HAZARD WARNING Noise levels at the operator position, ie 1 metre from the central axis of the test stand at a height of 16 metres from the floor with an injection pump running, are variable dependent on the size and speed of the unit under test Test have been shown that personnel at the operator position can be exposed to sound pressure levels in excess of 80dB(A) while the injector pump is running Under certain operating conditions; high pump speeds, high injection deliveries, rates and pressures and pumps with multiple cylinders, a mean sound pressure level in excess of 95dB(A) has been measured This is equivalent to a sound power level in excess of 100dB(A) With the fuel system running and the test stand drive rotating at its maximum possible speed, the sound power level is less than 90dB(A) With only the fluid system running this level drops to below a sound power level of 75dB(A) NOTE: Warning in accordance with the Essential Health & Safety Requirements of the Machinery Directive Annex I 174(f) 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 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 7

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2 Warranty Statement The AVM2-PC range of test benches is covered by the Hartridge Limited standard Terms and Conditions of Sale or Supply Section 7, 8 and 9 of these Terms and Conditions of Sale or Supply relate to guarantee The Company refers to Hartridge Limited A complete copy of the Terms and Conditions of Sale or Supply is available on request Please note that on the AVM2-PC (the Machine) all guarantees and warranties are limited to use of the Machine with software installed as supplied and expressly exclude the correct operation of, or any interaction between the Machine software and, any software and/or hardware supplied by a third party and installed on the Machine Such software and/or hardware shall be considered as an accessory as defined in Section 7c of the Terms and Conditions of Sale or Supply and installation of third party software may be considered as misuse of the Machine as defined in Section 9 (a) Similarly it is vital that the Machine is operated correctly and in accordance with the instructions and messages displayed on the Machine Failure to do so may be treated as misuse under section 9c of the Terms and Conditions of Sale and Supply and particular attention must be paid to closing the Machine down where it is vital the specified procedure is followed More specifically, the following are excluded from any express or implied warranties relating to the Machine: - damage caused by poor mains supply quality - wear and damage to the disposable keyboard protective cover other than that arising through faulty manufacture or workmanship; - damage to the keyboard for example through oil or dirt ingress and arising through a damaged or worn keyboard protective cover; - wear and damage to the mouse or other pointing device other than arising through faulty manufacturing or workmanship; - damage to the printer (optional) as a result of test oil / workshop dirt ingress or other misuse It is the Client s responsibility to ensure that any third party accessories (eg modem or network card) installed on the Machine by the Client or at the Client s request are compatible with the Machine and will not detract from its correct operation The personal computer (PC) installed within the Machine is manufactured by Dell and is covered by their standard warranty terms Dell offer a range of extended warranty options on their PC equipment, details are available direct from the Dell Distributor Network Any such warranty is completely independent of, and separate from, any warranties or guarantees offered by Hartridge Limited 9

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3 Introduction This manual provides information about the safety, installation, operating and routine maintenance of the AVM2-PC test stand Make sure you have read and understand the information contained before attempting to install and use the test stand More detailed information is available in the Technical Service Bulletins (TSB) available from your local agent The AVM2-PC range of test stands will (depending on the power specified) test most in-line and rotary diesel pumps in use for on-highway and industrial applications AVM2-PC 11

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4 Installation 41 Site Requirements Refer to Figure 41 OR Allow 1 metre around the front & side of the test stand for access A clean, level and dust-free floor capable of supporting the test stand weight Supply of clean water at 20 C maximum with flow available of 8 litres/min minimum pressure 2 bar (30psi), maximum pressure 6 bar (90psig) Well ventilated to dissipate heat Supply of clean dry air - minimum pressure 6 bar (90psig), maximum 8 bar (120psig) Lift the test stand from underneath using a fork lift or from above using slings placed under the test stand base Use a spreader bar on the slings to prevent damage to test stand panels 3 Phase & Earth electrical supply = 380-480V (33Amp - 10hp/54A - 20hp) 3 Phase & Earth electrical supply = 190-240V (66Amp - 10hp/108A - 20hp) using stepup transformer (only required on low voltage test stands) 1 phase & Earth electrical supply = 110V OR 220V 50 / 60Hz (5Amp) for PC Figure 41 AVM2-PC 13

42 INSTALLATION & START UP Installing the Test Stand Refer to Figure 42 1 2 3 14 Position the test stand on site Place a spirit level on the top surface of a suitable side panel (arrowed) Level the test stand by inserting suitable metal shims (1) (95mm x 95mm not supplied) between the rubber feet (2) and the test stand

43 Remove Transit Fittings 431 Injector Mount See Figure 43 Remove the four bolts (1) securing the orange transit bracket to the ring bracket and the injector mount 432 Test Stand Bed See Figure 44 1 Remove the left hand upper side panel 2 Remove the bolts (2) and both orange spacers between the bed and the base at the rear of the test stand 3 Remove the left and right hand trays at the front of the test stand 4 Remove the bolts (3) and both orange spacers between the bed and the base 5 Refit the left and right hand trays and the left hand upper side panel Figure 43 Injector Mount transit Fittings 15

433 INSTALLATION & START UP Console 1 2 Remove the bolts (4) in the top of the console cover and tilt the cover back Remove both bolts (5) locking the console to the test stand Figure 4 5 Console Transit Fittings 44 Connecting Services to the Test Stand 441 Water Supply Connect water supply (1) and return (2) pipes using 3/8" BSP fittings 442 Air Supply 1 Connect air supply (3) using 1/4" BSP fittings 2 Set MU air regulator to 3 bar and is not to be adjusted 3 Check/drain water trap every 20 hours 16

45 Test Stand 3 Phase Electrical Supply 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 earthing 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 The earth current is greater than 20mA due to filter capacitors between power lines and earth Failure to earth the test stand before applying mains power can cause a fatal electric shock The equipment CANNOT be used with a mains supply protected by a 'standard' Earth Leakage Circuit Breaker (ELCB) as the earth current is above a 'standard' ELCB trip level If local regulations state that an ELCB must be used, use a variable ELCB with a minimum current setting of 30mA and a minimum time delay setting of 50-100ms (this is available from the equipment supplier) The variable ELCB should always be set to the minimum current and time delay which will allow the test stand to run NOTE: The fuel pump motor used on the test stand is phase rotation sensitive Correct rotation of the pump can be checked by following the procedure given in 57 17

INSTALLATION & START UP 451 380-480V Supply Refer to Figure 47 Figure 47 Test Stand Isolator ox and 3 Phase/Earth Terminals 1 2 3 4 5 18 Ensure the test stand isolator and incoming supply isolator switches are off Remove the test stand isolator panel (4) Feed the 3 phase wires and Earth from the main electrical supply through the grommet hole (1) located above the isolator switch on the back panel of the test stand Connect each phase to the isolator switch (2) Connect the Earth wire to the earth stud (3)

452 Test stand transformer primary setting and 50/60Hz selection Refer to Figure 48 Figure 48 Internal Transformer 1 2 3 4 5 6 7 8 Ensure the test stand isolator is set to OFF Remove the test stand isolator panel Switch on the incoming electrical supply and measure the voltage between 2 phases on the input side of the test stand isolator switch (see Figure 47) Switch off the incoming supply Remove the clear plastic protective cover secured by 3 screws (small arrows) to gain access to the transformer Move wire 304 to the primary tapping nearest to the voltage measured above 50/60Hz selection (see inset): for 50Hz supply ensure SCB2 terminals 116 and 117 are linked For 60Hz supply ensure SCB2 terminals 116 and 118 are linked Refit all panels 19

46 INSTALLATION & START UP PC Single Phase Electrical Supply, Keyboard and Mouse Refer to Figure 49 1 2 3 4 5 6 7 Select the correct voltage on the switch (9) at the back of the PC Ensure the ON / OFF switch (14) on the rear of the console is set to OFF Plug the cable into the IEC socket (16) on the rear of the console and ensure the plug is locked by the wire clip Push the keyboard and mouse cables through the holes (11 and 17) at the back of the keyboard tray; if necessary, remove the keyboard tray to gain access Connect the keyboard lead to the connector with a keyboard symbol (2) on the back of the PC Connect the mouse lead to the connector with a mouse symbol (3) on the back of the PC Refit the console cover NOTE: Any PC compatible mouse, tracker ball or glide point can be used instead of the standard device if desired 20

47 Filling the Oil Tanks 471 Test Oil Refer to Figure 410 1 2 3 Remove the access panels on the left side of the stand to gain access to the tanks Fill the TEST OIL tank through the level indicator tube (3) or directly by removing the tank cover plate (2) (oil required is 58 litres/15 US gallons) Ensure the oil level is up to the top of the level indicator tube The following ISO specification test oil fluids are recommended: Castrol 4113 Shell 4113 (UK) or 59365 Viscor 1487 Silkolene Shell-Berre Normafluid (France) Brugarolas Califluid 2 (Spain) WARNING! Diesel fuel used in vehicles must not be used due to health and safety implications Figure 410 TEST & TUBE OIL tanks showing filling /level tubes 21

INSTALLATION & START UP 472 Lube Oil (option) Refer to Figures 410 and 411 Use SAE10-20 specification lube oil 1 2 3 22 Remove the access panels on the left side of the stand to gain access to the LUBE OIL level indicator (1) (see Figure 410) Fill the LUBE OIL tank through the table return pipe (see Figure 411) (oil required is 25 litres/7 US gallons) Ensure the oil level is up to level indicator window (1)

48 Connecting a Printer, Modem or Network Card Refer to Figures 49 and 413 All PC compatible black and white and colour printers with a parallel interface can be used with the AVM2-PC Grommet plates (35) are located at the back of the console for cables to be fed through to the PC Connect all peripheral devices to an external power supply CAUTION Do not connect these devices to the multi-way block inside the console NOTE: Printers, modems and network cards should be installed by qualified personnel to prevent conflicts with the AVM2-PC software as the PC will need configuring to support these devices 49 Installation Check List Before starting the test stand, check: levels Transit brackets are removed Water and air are connected Test oil (and lube oil if system fitted) have been added to tanks to correct Internal transformer voltage is correctly set All access panels and fixed covers are fitted Check that the drive coupling guide support is fitted to the centre of the coupling PC supply voltage selector switch is correctly set 23

INSTALLATION & START UP Figure 412 Test Stands Controls and Connections (Front View) 24

Figure 413 Test Stand Controls and Connections (back view) 25

N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 26 INSTALLATION & START UP Description Monitor PC Access door Keyboard Emergency stop Button Advance Gauge Connection 1ppr output Air Outlet Power supply A (+) Power supply B (+) Power supply B (-) Power supply A (-) Fuel supply outlet Pressure phasing outlet (80 bar) Backleak temperature Connection Lube oil supply Aux 2 (11bar) Phasing control knob Aux 1 (7 bar) Lube oil control knob Oil return to tank Supply oil suction connection Supply pressure control valve Backleakage connection Boost Control Knob Boost Supply Analogue trim Drive stop button Fuel Supply stop button Fuel supply start button Drive start button Analogue trim on/off Drive nudge button Single phase supply Serial plate Gland plate Electrical power isolator Cooling water inlet Cooling water outlet Air supply inlet

5 Starting-Up the Test Stand 51 Power 511 Electrical supplies Because the test stand runs Microsoft Windows NT software which takes some time to load and shutdown, the PC has an electrical supply independent of the test stand 3 phase supply This allows the PC to be left on overnight if required to avoid waiting for the PC to power up or shut down The 3 phase supply can be switched ON or OFF in any sequence (see 512) See 513 for instructions on switching OFF the PC supply 512 Switching the 3 phase supply OFF Use the main electrical supply isolator switch (35) on the back of the AVM2-PC to apply or disconnect the 3 phase power to the test stand See Figure 413 CAUTION The 3 phase supply should never be switched off while the drive is running as this can cause permanent damage to the drive controller 513 Switching the PC ON Connect the power cord to the connector (33) on the rear of the console ensuring the plug is secured by the wire clip Set the red power switch to ON [I] Highlight the 'Windows NT Workstation Version 400' Press the 'Enter' key on the keyboard The system will automatically select this after a short period anyway Wait for the AVM2-PC screen to be displayed (see Figure 51) and the function key characters on the screen to go black The PC is now ready to run 514 Switching the PC OFF CAUTION Do not switch the PC off without shutting down Windows first, otherwise data may be lost To shut Windows down, use one of the following three methods: Use the Shut Down AVM2 function key on the Main Screen Reveal the Windows 'task bar' by moving the mouse pointer to the top of the screen Click on Start using the left mouse button and then click on the 'Shut Down' option Select the 'Shutdown Operating System' option then click OK With any AVM2-PC screen displayed, click on the symbol in the top right hand corner using the left mouse button Wait until the display informs you it is safe to switch the PC off Switch off power to the PC using the red on/off (I/O) switch at the back of the console OR OR 27

52 INSTALLATION & START UP Emergency Stop Refer to Figure 412 1 2 53 In the case of an emergency, press either of the E-Stop buttons (4) to stop the fuel system and drive Twist the button to release the E-Stop Initial Power On 1 2 3 4 5 6 Ensure all panels and covers are fitted to the test stand Switch on the main electrical power isolator (36) to apply 3 phase power Switch on power to the PC (see 513) Check that the AVM2-PC screen is displayed Refer to Figure 51 Move the mouse and check that the pointer moves around the screen Check that the Setup screen can be selected using the 'F1' function key Refer to Figure 52 Figure 51 AVM2-PC Screen 28

Figure 52 Set up Screen NOTE: If the language is not correct, change by clicking on the Help menu and then select 'Change Language' in the pull down menu Refer to Figure 53 If the alternative language is still not correct, install the CD-ROM supplied with the test stand and select 'Custom Install' 54 Changing Owner Details With the 'Setup Screen' selected, press the Owner Details function key (F10) and enter the name and address of the test stand owner 55 Changing Date and Time Set the clock to local time a b c d e f Reveal the Windows 'Taskbar' Click on the 'Start' button Select the 'Date & Time' tab A calendar and clock will be displayed Select 'Settings' Select 'Control Panel' Double-click on the 'Date/Time' icon 29

INSTALLATION & START UP Figure 53 Setup screen with Change Language Selected 56 Adjusting the Monitor Refer to Figure 54 1 2 Select the function using button (3) Use the up (1) or down (2) arrow buttons to change the setting Figure 54a - Monitor Adjustment Controls (mod standard A G) 30

Figure 54b - Monitor Adjustment Controls (mod standard H onwards) 31

57 INSTALLATION & START UP Start the Fuel Pump 1 2 3 Ensure test oil and 80 bar oil pipes are fitted, ie the connections are not open to atmosphere Start the fuel pump by pressing the fuel start (I) button (Figure 412 item 29) Check for correct pump operation by: Setting a positive pressure on the Supply Pressure gauge by adjusting the supply pressure control valve (22) OR Visually checking that the fuel pump motor inside the test stand is running clockwise (viewed from front of test stand) If the above are not correct, stop the pump drive using the (O) button (Figure 412 item 28), switch off the 3 phase supply to the test stand and change over any two of the incoming 3 phase supply wires Repeat the above test (step 3) NOTE: The oil level in the tanks will drop when the system first runs as the pipework in the system fills with oil This may cause a low tank level warning Top up the tanks if necessary 58 On Line Help To assist the user, on line help can be accessed by clicking on the start button and selecting 'AVM2-PC MANUAL ENGLISH' from the menu list 32

6 Circuits 61 Test Oil and Cooling Water Supply Circuit 33 INSTALLATION & START UP

62 34 INSTALLATION & START UP Pneumatic Circuit

63 35 INSTALLATION & START UP Lube Option Circuit

64 36 INSTALLATION & START UP AVM2-PC Metering Circuit

65 37 INSTALLATION & START UP Index to Hydraulic, Pneumatic and Cooling Water Circuits

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66 INSTALLATION & START UP Electrical Circuits AVM2-PC Electrical Circuit Diagram Index 39

INSTALLATION & START UP AVM2-PC Electrical Circuit - Sheet 2 40

INSTALLATION & START UP AVM2-PC Electrical Circuit - Sheet 3 41

INSTALLATION & START UP AVM2 PC Electrical Circuit Sheet 4 42

INSTALLATION & START UP AVM2-PC Electrical Circuit Sheet 5 43

INSTALLATION & START UP AVM2-PC Electrical Circuit Sheet 6 44

INSTALLATION & START UP AVM2-PC Electrical Circuit - Sheet 7 45

INSTALLATION & START UP AVM2-PC Electrical Circuit - Sheet 8 46

INSTALLATION & START UP AVM2-PC Electrical Circuit - Sheet 9 47

INSTALLATION & START UP AVM2-PC Electrical Circuit Sheet 10 48

INSTALLATION & START UP 7 Start-up Problem Solving 71 Test Stand Serial Plate The serial plate is fixed to the back panel Always quote the full product number and serial number in any correspondence 49

72 INSTALLATION & START UP Software Version Information Always quote the PC Software version number in any correspondence The PC Software version number can be accessed from the AVM2-PC 'Diagnostics' screen 1 2 3 Select the 'Diagnostics' function key (F6) from the AVM2-PC [Main Menu] screen (see Figure 51) Select the 'Version Information' function key (F3) from the AVM2-PC [Diagnostics] screen (see Figure 72) A 'Version Information' window will appear with System Version Numbers displayed (see Figure 73) The PC Software version shown here is 'AVM2 Version 21309' Figure 72 AVM2-PC (Diagnostics) Screen 50

INSTALLATION & START UP Figure 73 AVM2-PC (Diagnostics) Screen showing Version Information Window 51

73 INSTALLATION & START UP Fuse Locations Figure 74 Fuse Locations Electrical Equipment Chassis (access panel removed) 52

Operating & Maintenance

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Operating & Maintenance 8 Operating the Test Stand 57 81 Menu Tree 57 82 Display, keyboard and Mouse 58 821 Keyboard Variations 58 822 Data Entry Boxes 58 823 Red Status Light 59 9 Pump Mounting 60 91 General 60 92 Mounting a Pump to the Test Stand 60 921 Injector Mount 61 922 Mounting a Rotary Pump 61 923 Mounting an In-Line Pump 64 924 Pump Connections 67 10 Pump Testing 68 101 Select the Metering Screen 68 102 Selecting/De-selecting Injectors 68 1021 Individual Injector Selecting and De-selecting 69 1022 Group Injector Selecting and De-selecting 69 103 Starting a Test 69 1031 Levels of Testing 70 104 Starting the Fuel Systems 72 105 Speed Control 73 1051 F12 Function Key 74 1052 Drive Direction 74 1053 Analog Trim potentiometer 74 1054 Speed Display Colours 74 106 Starting the Drive 74 107 During a Test 74 1071 Printing / Storing result 75 1072 Limits and Units 75 108 Stopping a Test 76 109 Auto Step Sequence and Results Storage Locations 77 1010 Printing Results Files 78 111 Metering Modes 80 112 Pump Ratio and Temperature Selection 81 113 Metering Injector Symbol Colours 81 12 Advance (Option) 82 13 Static and Dynamic Phasing/Advance 83 131 Static Phasing 83 132 Dynamic Phasing Datum Injector (Option) 84 133 Dynamic Advance 84 134 Phasing Injector Symbol Colours 84 14 Variable Voltage Outlets 85 15 External Calibrator 87 151 Select the Number of Turns 88 1511 Start Count 88 1512 Dump 88 16 Test Sequence Editor 89 161 Creating a New Sequence 89 55

162 Creating a New Step 90 163 Test Sequence Editor Commands 91 1631 Operator Message 91 1632 Set Speed 91 1633 Set Voltage A and Set Voltage B 91 1634 Set Datums 91 1635 Time Delay 91 1636 Set Limits 91 1637 Measure Deliveries 92 1638 Measure Advance 92 1639 Measure Phasing 92 16310 Parameters Common to All Commands 92 16311 Parameters Common to All Measure Commands 92 164 Microsoft Windows Commands 92 165 Saving a Sequence 92 166 Running a Sequence 93 17 Routine Maintenance 94 171 Removing Access Panels 95 172 Calibration and Routine Maintenance 96 Routine Servicing Schedule 96 1721 20 Hours Servicing 96 1722 100 Hours Servicing 97 1723 500 Hours Servicing 97 173 Metering System Auditing 99 1731 Audit 1 - Every 20 hours or weekly (whichever occurs first) 100 1732 Audit 2 - Every 20 hours or weekly (whichever occurs first) 100 1733 Audit 3 - Every 20 hours or weekly (whichever occurs first) 100 18 Specifications 102 181 Main Drive 102 182 Calibrating fluid Supply System 102 183 Lube Oil Supply System (Optional) 102 184 Metering System 103 185 Auxiliary Features 103 186 Measured Parameters 103 19 Consumables 105 20 Spare Parts 106 201 Services 106 2011 Pneumatic System 106 2012 Water System 106 202 Power Distribution 106 203 Fuel (Test Oil) System 107 204 Lube Oil System (Option) 108 205 Drive System 108 206 Metering System 108 207 General Requirements 109 56

8 Operating the Test Stand It is recommended that the user obtains some basic personal computer training before attempting to use the test stand 81 Menu Tree AVM2 PC Screen Main Menu Set Up Metering Phasing F1 F2 F3 Main Menu Drive Direction Speed Limit Set Supply Temp Set Volts A Set Volts B Set Volts A & B Limits/Units Timing Offset Owner Details F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 Main Menu Start Test Print Datum Dynamics Datum Injection Zero Static Limits/Units Zero Advance Phasing Limits Set Up Main Menu Start Test Print Metering Mode T40/1:1 Common Rail Limits/Units Zero Advance Metering Limits Set Up F1 F2 F4 F5 F6 F7 F8 F9 F10 F11 Advance Timing F4 F1 F2 F4 F5 F6 F7 F8 F9 F10 F11 Main Menu Start Test Print Advance Offset Offset Limits/Units Zero Advance Limits Timing External Calibrator F5 Main Menu No of Turns Start Count Dump Limits/Units F1 F2 F4 F5 F6 F7 F8 F9 F10 F11 Diagnostics F6 F1 F2 F3 F4 F8 Testplan Editor F7 Limits/ Units F8 Reset AVM2 F9 Shut Down AVM2 F10 CPEditor Window Main Menu Analog Channel Version Information General Information Start Audit 1 Start Audit 2 Start Audit 3 Zero Filter Hours F1 F2 F3 F4 F6 F7 F8 F9 Return Temp Units Flow Units Advance Units Pressure Units Boost Units Metering Units F1 F2 F3 F4 F5 F6 F7 mm3/st cc/50 cc/100 cc/125 cc/200 cc/250 cc/300 cc/500 Minimum Maximum Units Figure 81 Menu Structure NOTE: Operating the F12 key in any screen brings up the Speed Control Box 57

82 Display, keyboard and Mouse All PC screen buttons are operated by the LEFT mouse button OR keyboard keys Where more than one button appears on a screen, one of these will be highlighted with a black border This indicates the button is 'active' and will function A highlighted button can also be operated using the 'Enter' key on the keyboard 821 Keyboard Variations The legends used on keyboards can vary The table below lists common variations: 822 Data Entry Boxes Data can be entered into boxes on many screens Some screens have more than one box To move between boxes use the 'Tab' or 'Shift+Tab' keys The selected box will be highlighted in blue or have a dotted outline To enter data into a box with a dotted outline, press the space bar Figure 82 Pop-up Screen Showing Data Boxes 58

823 Red Status Light System errors are indicated by a small box with a Red Status Light at the bottom of the screen To clear this, click on the Red Status Light, note the error(s) listed and click on the 'Clear All' button NOTE: A Red Status Light will appear if the 3 phase supply is turned off and the PC is left on This is normal 59

9 Pump Mounting NOTE: The 'Nudge' control (see Figure 412) allows the operator to rotate the drive round to any position in small steps This is useful for positioning the drive to allow coupling fixing screws to be tightened or loosened with ease 91 General This section of the manual contains general information about mounting typical pumps on the test stand Accessory packages are available for mounting and testing most common rotary and in-line pumps 92 Mounting a Pump to the Test Stand CAUTION! The operator must ensure the correct pump mounting plates / brackets, injectors and high pressure pipes are used Incorrect setting of the drive can cause pump seizure Operating Tips For best results minimise run-out of the test stand drive coupling When using the pump coupling with 10mm thick drive dogs, use the 1mm spacer (1) opposite the clamping screw 12mm and 20mm thick dogs do not need a spacer When the pump drive is connected to the test stand drive make sure the drive dogs are horizontal and slide the pump coupling into the correct slot in the drive Leave a 05mm to 1mm gap between the pump and test stand couplings Shake the test stand coupling to settle it into a concentric position and then tighten the clamping screws to 25Nm You can use the Nudge facility to help rotate the pump to achieve this easily Figure 91 Drive Coupling with Spacers 60

921 Injector Mount The AVM can be supplied with a range of different injectors which may be fitted using the appropriate accessories 922 Mounting a Rotary Pump The anti-backlash coupling fitted to this test stand will accept pumps with both supported and unsupported shafts First determine the pump type CAUTION: Incorrect setting of the anti-backlash coupling is likely to cause damage to the pump and may result in drive shaft seizure 9221 Unsupported Drive Pumps Refer to Figure 92 CAUTION: Fit drive guide Part No 182-18-17 before testing unsupported drive pumps The majority of rotary pumps may be secured with the quick release clamps, however the adaptor plate has a hole pattern which will allow pumps to be bolted directly to the plate 9222 Supported Drive Pumps CAUTION: DO NOT fit the central guide when testing supported drive pumps The antibacklash coupling must allow the drive to float If a central guide is already fitted, insert a 8 mm threaded screw into the central guide, as shown in Figure 92 and withdraw the guide Refer to Table 41 to select the appropriate mounting plate for the pump to be tested Fit the mounting plate and clamp plates as shown in Figure 93 NOTE: Couplings such as ADC 223 have screws in their outer diameter ADC 240 is a safety guard as well as an adaptor It is designed to trap the screws if they come loose and must be used for any coupling of this nature 61

Figure 92 Drive Guide Application Table 91 Selection of Mounting Plate 62

Mounting Plates/Accessories Mounting Plate 68 mm dia Mounting Insert 46 mm dia Mounting Insert 50 mm dia Dog Drive 17 dia Taper Dog Drive 20 dia Taper Peugeot Spline Drive Coupling Quill Shaft Drive coupling Ring Bracket Pump Clamping Components Base Clamp DPA APB 250/1 APB 250/2 APB 250/3 ADC 239 ADC 95/1 ADC 186 ADC 223 APB 245 APB 250 APB 244 APB 220 DPC DPS Bosch VA/VE Diesel Kiki DPA Hub Dependent on type of pump Must be used Mount the pump to be tested on the mounting assembly as shown in Figure 94 Figure 94 Mounting a Rotary Pump 63

With reference to Table 91, select the appropriate pump drive accessories for the pump to be driven Then proceed for the different pumps as follows: i) Detachable Engine Drive Coupling Types Remove the coupling from the pump and fit the appropriate dog drive to the pump shaft Secure using nut If a 10 mm dog drive is used, fit a 1 mm spacer opposite the clamping screw in each 12 mm slot in the anti-backlash coupling Slide the pump towards the test stand drive and locate the dog drive in the appropriate slot in the anti-backlash coupling then tighten the clamping screws to a torque setting of 25Nm ii) Integral Spline Types Bolt the appropriate spline drive hub to the anti-backlash coupling Slide the pump towards the test stand drive, and locate the pump spline in the drive hub iii) Detachable Quill Shaft Types Bolt the appropriate spline drive hub to the anti-backlash coupling, and fit the quill into the pump, Slide the pump towards the test stand drive and locate the quill in the splined drive hub NOTE: When mounting pumps, ensure that there is a small (05 mm) gap between the pump coupling and the anti-backlash coupling This ensures that the pump shaft is not impacted 923 Mounting an In-Line Pump When testing in-line pumps the anti-backlash coupling must be set to drive supported pumps ie the drive guide must be removed to allow the drive to float 9231 Flange Mounted In-Line Pumps With reference to Table 92 select the appropriate mounting plate for the pump to be tested Fit the mounting plate as shown in Figure 95 NOTE: Some plates are slotted Figure 95 Flange Mounted In-Line Pump Mounting Assembly Mount the pump to the mounting plate as shown in Figure 96 64

Figure 96 Mounting a Flange Mounted In-Line Pump 65

Table 92 Pump Mounting Requirements Mounting Plates Accessories CAV ABN Mounting Bracket Assembly Clamp Mounting Plate 68 mm 4 mm Packing Piece 9 mm Packing Piece APB 283/1 APB 220 APB 243 APB 283/2 APB 283/3 16 mm Packing Piece Holding Down Bolt Quick Action Clamp Assembly Dog Drive 20 mm Taper Dog Drive 25 mm Taper APB 283/4 AFB 54 APB 12 ADC 95/1 AFP 383 Dog Drive 30 mm Taper Dog Drive 35 mm Taper ADC 156 ADC 235 Dependent on type of pump Bosch PEA Bosch PEP Bosch PES Must be used 9232 Base Mounted In-Line Pumps With reference to Table 92 select the appropriate accessories for mounting the pump on to the test stand WARNING: If the pump to be mounted has pumping elements which are 10 mm or greater, use the pump body bolts, not quick action clamps Mount the pump as shown in Figure 97 Figure 97 Mounting a Base-Mounted In-Line Pump When the pump has been mounted, select from Table 92 the appropriate accessories to enable the pump to be driven 66

924 Pump Connections If the pump to be tested has its own lift pump, connect it to the suction connection If the pump to be tested requires a pressurised supply of test oil, connect the test oil supply pipe to the pump Connect the test oil return from the pump to the return connection CAUTION: Before connecting the pressure phase pipe to the pump to be tested, check that the test oil/pressure phase valve is set to its minimum pressure (fully counterclockwise) If the pump requires a pressure phase supply, connect the pressure phase pipe to the pump If the pump requires a supply of lubrication oil, connect the lubrication oil supply pipe to the pump If the pump requires a supply of boost air, connect it to the turbo boost connection If a backleakage connection is required, connect a pipe between the pump and the backleakage connection CAUTION: Check that the high pressure pipes are free from any restriction before connecting to the pump Use the high pressure pipes specified in the pump testplan Refer to the AVM & PGM Accessories Catalogue for the relevant pipe part numbers NOTE: The high pressure pipes can be mounted in the most convenient order, as the test stand will automatically learn the pump firing order Two auxiliary gauges are provided, these may be used for connection to the transfer pressure connection etc on rotary pumps and hydraulic governors Connections for the auxiliary gauges are Aux 1 and Aux 2 Four 4 mm terminals on the front of the test stand provide two variable dc supplies (channel A and channel B) These may be used to operate pump solenoids The terminals will accept standard 4 mm plugs, however they are cross drilled and will accept plain wires WARNING! Spline drive pumps using drive couplings such as ADC223 must be used with the guard ADC240 for safety reasons 67

10 Pump Testing The system has been designed to guide you through the steps required to ensure the results are complete, repeatable and traceable There will be prompts to enter information relevant to the test, so that the results can be analysed and traced at a later date Once a pump is mounted, proceed as follows: 101 Select the Metering Screen From the Main Screen, press the 'Metering' function key Figure 101 Metering Screen 1 2 3 1 Select Pump Gearing / Temperature correction mode (eg 1:1 / T40) 2 Set Metering Mode to Average initially 3 Select Metering Units (eg mm3/st) 102 Selecting/De-selecting Injectors 68 The pump can be connected to any of the 8 or 12 injectors, but the PC must be told which ones are connected before running a test Injectors can be selected / de-selected at any time, individually or in groups Sometimes this is useful to get results faster, particularly when adjusting the output on one line of an in-line pump

Figure 102 Selecting Injectors Individually or in Groups using Mouse or Keyboard 1021 Individual Injector Selecting and De-selecting Hold down the 'Ctrl' key and press the desired function keys (F1 to F12) OR Click on the buttons next to the injector symbols on screen with the left mouse button 1022 Group Injector Selecting and De-selecting Hold down the 'Shift' key and press the two function keys corresponding to the first and last injectors in the group eg Shift+F9 and Shift+F12 will select or de-select injectors 9 to 12 OR Hold down the 'Shift' key and using the mouse, click on the two buttons next to the injector symbols on the screen corresponding to the first and last injectors in the group eg Shift+button 1 and Shift+button 6 will select or de-select injectors 1 to 6 as shown in Figure 102 NOTE: Selected injectors will turn grey initially and then blue when their firing position is learnt 103 Starting a Test Press the 'Start Test' function key Enter details relevant to the test such as: Drive direction Speed limit Temperature demand Vehicle details 69

Figure 103 Start Test pop-up window Of particular importance if results are to be filed are: Pump Model Pump Part Number Pump Serial Number These are used along with the Date and Time to create a unique result file name: PUMP-MODEL_PUMP-SERIAL-NUMBER_DATE_TIME 1031 Levels of Testing Three levels of testing can be selected by clicking on one of the radio buttons: Manual Manual Mode Leopard Semi Automatic NOTES: 1 2 3 70 'Manual Mode Leopard' and 'Semi Automatic' require a testplan name to be entered See 10311 to 10313 for detailed explanation of these three options When the required details have been entered, select 'OK' The Start Test function key will change to a Stop Test function key and the Print function key changes to a Store function key

Figure 104 Screen Showing Stop Test and Save function keys 10311 Manual At this level, the operator sets the speed, temperature, volts, limits and selection of screens Results can be printed and/or stored at any time during testing When pump testing is complete, press the 'Stop Test' button on the control panel 10312 Semi Automatic Selecting this level will load and run an Auto Step Test Sequence from disk All manual controls are still available to adjust demands, eg the speed can be adjusted by a few rpm to obtain the correct advance reading At the end of the Auto Step Test Sequence, 'Stop Test' will occur automatically NOTE: See section 16 for information on creating Auto Step Test Sequences 71

104 Starting the Fuel Systems Figure 105 Test Oil, Lube Oil and Phasing Oil Controls 1 Set Test Oil (2), Lube Oil (3) and Phasing Oil (1) control knobs to minimum (fully anticlockwise) 2 3 Start the fuel pumps by pressing the Fuel Start button (Figure 106, item 1) Rotate the Test Oil (2) and Lube Oil (3) control knobs to give the required pressures on the gauges displayed on the PC screen Check for leaks 4 72

105 Speed Control Speed can be changed in two ways: F12 function key Analog Trim potentiometer Figure 107 Speed Pop-Up Window 73

1051 F12 Function Key Selecting this function key pops up a window that allows the following information to be entered into the boxes displayed: Speed demand Speed in rpm Trim +/- rpm from speed demand Ramp rate Acceleration / Deceleration rate Preset Speeds Preset speeds are stored on function keys To copy a speed stored on a function key to the Speed Demand box, select the function key, ie F1 etc To copy a speed from the 'Speed Demand' box onto a function key, select 'Alt+F1' etc 1052 Drive Direction This changes the direction of rotation of the drive to L (pump) or R (pump) 1053 Analog Trim potentiometer To adjust the speed using the Analog Trim potentiometer, set the switch (Figure 106 item 3) to the position 1054 Speed Display Colours The colour of the speed display has the following meanings: Colour Speed Displayed Drive Condition Grey Target Speed Stopped Blue Actual Speed Orange Actual Speed Red Actual Speed Speed within 1 rpm of demand Ramping or Analog Trim Active Outside of low/high limits 106 Starting the Drive 1 Set the drive speed to a minimum, eg 100rpm 2 Press the 'Drive Start' button (Figure 106 item 2) 3 Check for coupling alignment See 92 'Mounting a Pump to the Test Stand' 107 During a Test The following controls are available during pump testing: 74 Printing/Storing Result Limits and Units Advance, Phasing, Metering, External Calibrator and Variable Voltage Outlets

1071 Printing / Storing result Results can be Printed or stored at any time during a test by pressing the STORE key You will be prompted to enter optional details as follows: Test Type (eg Cranking delivery test) Comments (eg Had to fit 002mm shims) This information will be stored with the displayed results 1072 Limits and Units Figure 108 Screen Showing Units and Limits Display General limits and units can be set using the Units / Limits function key from any of the measuring screens To return to the 'Metering' screen, press the Return function key Metering limits and engineering units can be set using the Metering Units function key from the 'Metering' screen 75

Figure 109 Screen Showing Metering Units and Limits Display 108 Stopping a Test 1 2 Press the 'Stop Test' button to stop a test once pump testing is completed or to abort a test Enter a result file name* and some overall test comments, eg Deliveries set 10% high at request of customer Figure 1010 Stop Test Pop-up Window NOTE: *The filename defaults to: PumpsPartNo_PumpSerialNo_YearMonthDayHoursMinutesSeconds 3 4 76 Select OK when finished entering the above information The results are stored to disk (see section 16)

109 Auto Step Sequence and Results Storage Locations Test sequences and result files are stored on the drive and directory specified in the Owner Detail screen Figure 1011 Owner Detail Screen 77

1010 Printing Results Files The complete results of a previously filed test can be printed using the 'Print' button (F4) You will be prompted to enter a file name (the default name is that of the last test filed) Figure 1012 Print Pop-up Window 78

11 Metering Figure 111 Metering screen 79

111 Metering Modes Table 111 Metering Mode Summary Metering Mode When used Relative display update rate Relative accuracy of results Results displayed Firing sequence must be learnt? Number of lines measured together (note 3) Overcheck Calibrate Average Total Sequential Overcheck General use Final check Governor cut-off test or when average only result is sufficient (see Note 8) SPM or CR pumps Automatically selected by test stand (note 2) High Medium (note 4) Very high Very High Medium (note 4) Medium (note 4) Very High Very high Medium Medium (note 4) 1 Each line 2 Average of selected lines 3 <Q>(note 7) 1 Each line 2 Average of selected lines 3 <Q>(note 7) Average only (can also 1 Line results 2 Total of lines display History) Yes (note 2) Desirable Desirable (note 5) (note 5) 1 (in turn) All selected lines together 1 to 12 (note 6) 1 Each line 2 Average of selected lines 3 <Q>(note 7) No No All selected lines together 1 (in turn) NOTES: 1 The firing sequence has been learnt when the injector symbols at the top of the metering screen selected are blue If the firing sequence cannot be learnt in Overcheck mode, Sequential Overcheck mode 2 will be automatically selected Reducing the number of selected lines, increases the display update rate in all modes, eg 3 Selecting each line in turn when adjusting each element of an in-line pump gives a fast and accurate display update 4 HIGH if only 1 line selected 5 Accuracy of results will be improved if firing sequence HAS been learnt 6 7 8 80 The number of lines measured together is selected automatically dependant on pump speed and delivery DELTA Q (<Q>) This is the difference between the highest and lowest line readings It provides a quick guide to the balance of the pump deliveries TOTAL mode is used when SPM is fitted to the machine and high deliveries from single line pumps are being tested or with AVM2 metering when high Common Rail pump flows are being tested using more then one metering line

112 Pump Ratio and Temperature Selection It is possible to select or de-select temperature correction for standard delivery pumps and for pumps with one delivery every two shaft revolutions The following symbols are displayed: o 1:1 T40 1:1 T0 Standard pump with metering results corrected to 40 C Standard pump with metering results corrected to injected oil temperature* 2:1 T40 Pumps with one delivery stroke every two shaft revolutions with metering o results corrected to 40 C Pumps with one delivery stroke every two shaft revolutions with metering results corrected to injected oil temperature* 2:1 T0 * Injected oil temperature correction provides correlation with test stands which inject directly into open graduated collectors The temperature sensor fitted to the test stand MUST be clipped onto one of the injectors connected to the pump under test when running in 'T0' mode Refer to Figure 112 NOTE: The correct 1:1 or 2:1 mode must be selected otherwise the test stand will not be able to learn the firing order Figure 112 Sensor Clipped to injector 113 Metering Injector Symbol Colours The injector states are represented on the screen by colour codes: 81

12 Advance (Option) Figure 121 Advance Screen 1 2 3 4 Set up the advance probe on the pump to be tested Select the Advance option on the Main Menu screen Select the units for reading - mm for Bosch, DPA or DPC for Lucas, or Stanadyne, etc Set the reading to zero as defined by the testplan using the zero button This can also be done from the 'Metering' screen OR Set the reading offset by pressing the up/down buttons NOTE: Using the 'Alt' key will multiply the Advance Offset by 10 on the Advance screen 82

13 Static and Dynamic Phasing/Advance Figure 131 Phasing Screen 131 Static Phasing WARNING! Do not run the drive while using the high pressure supply Rotate the pump by hand when static phasing 1 2 3 4 5 6 Set up the pump for static phasing Select the phasing option on the Main Menu screen - the screen shows the static phasing angle of the drive Set the supply pressure for phasing Rotate the pump by hand to the datum position Zero the reading using the 'Zero Static' button F7 Rotate the pump by hand to other positions - record the angles and adjust the pump as required 83

132 Dynamic Phasing Datum Injector (Option) 1 2 3 Select the injectors to be tested Select the datum injector - press the Datum Injector function key F6 followed by 'Ctrl+F1' for example All other angles will be relative to this injector Run the pump so it is delivering fuel The phasing angles will be displayed NOTE: If no datum injector is selected, the angles will be relative to the Static zero angle 133 Dynamic Advance The dynamic phasing screen can be used to give an INDICATION of pump advance as follows: 1 2 3 4 Ensure no datum injector is selected Set the pump reference speed, eg Idle Zero the dynamic phasing angles, press the 'Datum Dynamic' function key F5 Change the pump speed The advance angles will be displayed 134 Phasing Injector Symbol Colours The injector states are represented on the screen by colour codes: Four 4 mm terminals are fitted to the front facia of the test stand These provide two variable dc voltage supplies for pump electrical devices The terminals will accept standard 4 mm plugs, but they are cross drilled so that they will accept plain wires 84

14 Variable Voltage Outlets Four 4 mm terminals are fitted to the front facia of the test stand These provide two variable dcvoltage supplies for pump electrical devices The terminals will accept standard 4 mm plugs, but they are cross drilled so that they will accept plain wires 85

The arrangement of the variable voltage terminals allows parallel connection to increase the current supplied to the component (see Figure 143) Figure 143 Voltage Terminal Connections 86

15 External Calibrator Single cylinder pumps can be tested using a single cylinder cambox and single cylinder calibrator Information on mounting and piping up the single cylinder cambox and calibrator is contained in Technical Information Bulletins 160/13 and 160/3 respectively Electrical control of the calibrator is from the auxiliary socket on the front facia (Figure 412 item 6) Select 'External Calib' from the Main Menu to display the 'External Calibrator' screen Figure 151 External Calibrator Screen 87

151 Select the Number of Turns The operator can select the number of turns over which fuel is to be metered NOTE: The 'Turns' screen allows the operator to either select or store eight commonly used number of turns Alternatively the number of turns may be entered using the keyboard 1 2 3 4 Press the key below 'Turns' To select the commonly used/stored number of turns, select the key below the number of turns required To store a number of turns, enter the number of turns required, eg 125 With the number of turns displayed in the screen, press one of the eight keys below the screen This number of turns (125) will be stored in memory and displayed above the appropriate key Enter the number of turns required 1511 Start Count To start metering the fuel output from the pump, press the 'Start Count' function key F3 1512 Dump To drain the fuel from the calibrator press the 'Dump' function key F4 88

16 Test Sequence Editor A Test Sequence Editor is included with the test stand This enables the operator to create auto stepping test sequences A mouse is required for all functions of the editor All testplan settings are defaults which can be over-written by the operator during a test The Test Sequence Editor software can be installed onto any PC running Windows NT v400 or later This will enable test sequences to be created away from the test stand To open the editor, select the 'Testplan Editor' function button (F7) on the Main Screen 161 Creating a New Sequence Figure 161 Editor Screen Click on the Clean sheet icon A test sequence template will be displayed with two steps already inserted This forces you to enter certain parameters such as units, speed limit, drive direction etc 89

162 Creating a New Step 1 2 3 In the Command box of a blank line, click on the arrow in the grey box to pull down a list of possible commands Select a command eg Set Speed Enter the data required in the following columns Figure 162 Template Screen Showing Command Box 90

163 Test Sequence Editor Commands An overview of each command is shown in the following: 1631 Operator Message Enables the operator to type a message for display in the text window, eg instructions to the operator before and during testing Leaving the 'message' blank will clear a previous message 1632 Set Speed Enables the operator to set the drive speed NOTE: For safety reasons speed changes of more than 100 rpm require confirmation by the operator before proceeding Incremental = Go to the absolute speed entered in the 'Speed demand' column = Add the 'Speed increment' to the current speed Speed Demand Absolute speed demand Speed Increment Incremental speed change (+/-) Ramp Rate Acceleration/deceleration rate 1633 Set Voltage A and Set Voltage B Voltage Demand Set the voltage demand 1634 Set Datums Advance Value Set the advance reading to this value Dynamic Phasing Datum Line Select which one of the 12 lines is the datum 1635 Time Delay The time delay in seconds before moving onto the next step Useful for stabilisation 1636 Set Limits Set the limits of parameters which are also measured when one of the following commands is performed: Measure Deliveries Measure Advance Measure Phasing Set Low and High limits for: Speed Return Flow Aux 2 Pressure Phasing Pressure Supply Temperature Supply Pressure Boost Pressure Return Temperature Aux 1 Pressure Lube Pressure 91

1637 Measure Deliveries Look Back = Use low and high limits from this step Look Back Step = Use low and high limits from step defined by 'Look Back Step' column Step number of look back step Metering Mode Select from pull down list Metering Units Select from look down list Low Limit Low delivery limit High Limit High delivery limit Delta Q Limit Take Result After x Readings Maximum Delta Q limit 'Limits', 'Save' (if selected) and 'Proceed' will be effective after x metering results 1638 Measure Advance Low Rack/Advance Low limit High Rack/Advance High limit 1639 Measure Phasing Low and High Lines 1-12 Limits for each line 16310 Parameters Common to All Commands The following information can be entered for each step: Test Title This describes the step and will be saved alongside the result of the step It could be a description or a test code from the manufacturers testplan Auto Proceed = Wait for operator to press 'proceed' before moving onto next step = Proceed to next step without waiting for operator (see also section 1632) 16311 Parameters Common to All Measure Commands Save Results Save results of step and all background parameters (see section 1636) 164 Microsoft Windows Commands The Editor uses the following standard Microsoft Windows commands File New, Open, Close, Save, Save As, Print, Print Setup Edit - Copy, Cut, Paste, Insert New Step Before, Insert New Step After, Delete Step, Undo View Toolbar, Status Bar Window - New, Cascade, Tile, Arrange Icons Help - Help Topics, About CPE Editor 165 Saving a Sequence 1 Select 'File' in the toolbar and select 'Save' or 'Save As' 2 A window appears requiring a file name to be entered 3 Give the Test Sequence a suitable name, eg pump part number 4 Select OK 5 Close the editor to return to the AVM2-PC screen 92

Figure 163 Main Screen with File selected and Save highligted 166 Running a Sequence Start a test, enter the 'Testplan Name' and select the 'Semi-Automatic' option For further details refer to section 103 'Starting a Test' 93

17 Routine Maintenance WARNING! Do not run the test stand without any of the access panels fitted Always isolate the test stand at the main voltage supply switch on the wall, before removing any access panels Figure 171 Removing Access Panels 94

171 Removing Access Panels NOTE: Panels, items 1 and 3 are not shown These panels are the left-hand equivalents of items 2 and 4 1 Left Lower Panel Remove the two hex socket screws and lift panel to gain access to the test oil (calibrating fluid) drain pipe and lube oil drain pipe, if fitted 2 Right Lower Panel Remove the two hex socket screws and lift panel to gain access to the electrical components and the pneumatic control valve 3 Left Upper Panel Remove the two hex socket screws and lift panel to gain access to the main drive motor, test oil pump and motor, blower unit and the test oil/lube oil tanks 4 Right Upper Panel Remove the two hex socket screws and lift panel to gain access to the drive control unit and the system control board 5 Console Cover Remove the two screws and lift the cover to gain access to the PC and monitor connections 6 Right Middle Panel Remove the right middle lower panel and the right upper panel Remove the four hex head screws and remove panel to gain access to the fuses 7 Services Panel Remove the seven hex socket screws and remove the panel to gain access to the rear of the test stand 8 Isolator Panel Remove the knob from the mains isolator then remove the four hex socket screws and remove the panel to gain access to the mains isolator 9 Motor Access Panel Remove the four hex socket screws and remove the panel to gain access to the rear of the main motor 10 Left Surround Remove the four hex socket screws and remove the panel to gain access to the anti-vibration mount and water pipes 11 Right Surround Remove the four hex socket screws and remove the panel to gain access to the anti-vibration mount and the water pipes 12 Front Surround Remove the left surround and the right surround then remove the four hex socket screws and remove the panel to gain access to the pipes leading to the injector mount 13 Anti-backlash Coupling Cover Remove the two Durlock bolts and remove the complete guard to gain access to the emergency brake mechanism 95

172 Calibration and Routine Maintenance HartridgeTM Ltd recommends that the condition of the AVM2-PC and accessories used with the machine are regularly audited and certified by competent, authorized personnel The safety and operational functions and the calibration accuracy of the transducers in the machine should be checked every 1500 running hours or every year whichever is sooner Owners should contact their local Hartridge distributor for details of the certification service offered Routine Servicing Schedule Operation 20 Hr* 100 Hr* 500 Hr* Ref Check fluid levels 17211 Check emergency stop 17212 Generally clean 17213 Audit 1 1731 Audit 2 1732 Audit 3 1733 Check fuel injectors 17221 Change test oil and filter 17231 Change metering filters Change lube oil and filter (if fitted) 17232 17233 1721 NOTE: *Hours displayed on Diagnostics screen (see Figure 72) 20 Hours Servicing 17211 Check Fluid Levels Remove the lower left panel and check that the test oil (calibrating fluid) level (2) and the lube oil level (1) (if fitted) are visible in the sight tube windows Top up as necessary using the correct specification of fluid Refit the lower left panel 96

Figure 172 Fluid Level Indicators and Table Drain Plug 17212 Check the Emergency Stop Operation 1 With the test stand switched on, press the left Emergency Stop button Check that the Emergency Stop fault message is displayed on the screen Check that the test oil system cannot be started Check that the anti-backlash coupling cannot be rotated by hand 2 Reset the Emergency Stop button and check that the anti-backlash coupling can be rotated freely 3 Repeat the procedure with the right Emergency Stop button 17213 General Cleaning The test stand is a precision instrument and should be kept clean An antistatic cleaner may be used to clean the PC screen 1722 100 Hours Servicing 17221 Check Test Injectors 1 Remove the test injectors from their mount 2 Attach each in turn to a Hartridge injector tester, eg Poptest 3 Perform dry seat, backleakage and pressure setting test on each injector at a setting of 175 bar +2 bar -00 bar and re-set as necessary 1723 500 Hours Servicing 17231 Change the Test Oil (Calibrating Fluid) Check the viscosity of the test oil to determine whether or not the oil should be changed Technical Service Bulletin TSB160/14 details the equipment required to test the viscosity of the test oil To change the test oil: 1 2 3 4 5 Remove the left lower panel from the test stand Remove the test oil pipe (2) from the clip and hold the pipe over a suitable container (minimum capacity 45 litres) and allow the oil to drain out of the tank Remove the test oil filter from inside the tank Wipe out the inside of the tank with a clean dry absorbent cloth Fit a new test oil filter and fit the test oil pipe into the clip Fill the tank with the correct oil NOTE: At the same time, drain the waste oil in the table drain tank Remove the plug (Figure 172, item 3) and drain the oil into a suitable container Refit the drain plug 17232 Change the Metering Filters Refer to Figures 173, 174 and 175 With the fuel system switched off, remove the filters from the metering unit manifold and the filter mounted in the inlet to the metering unit Fit new filters When the inlet filter (fig 175) has been refitted loosen the three fixing 97

screws as shown to allow the blocks to realign Tighten to 3Nm Figure 173 Removal of Cover to Gain Access to the Metering Unit Figure 174 Changing the Metering Filters ( filters at the back of the filter block are shown, the remaining filters are at the front) 98

Figure 175 Location of Inlet metering Filter 17233 Change the Lube Oil (if fitted) 1 2 3 4 5 6 7 Remove the lube oil pipe from the clip and allow the oil to drain into a suitable container (minimum capacity 14 litres) Remove the lube oil filter from inside the tank Wipe out the inside of the tank with a clean dry absorbent cloth Fit a new lube oil filter and refit the lube oil pipe into the clip Refill the lube oil tank with the correct oil Fit the left lower panel Change the filter fitted in the backleakage connection located on the lower facia panel (Figure 412, item 23) The filter is a sliding fit within the bore of the fitting Disconnect the pipe connection Thread an M8 bolt into the filter bore and withdraw the filter Insert a new filter 173 Metering System Auditing Carry out the following metering system audit procedures each week in the order given CAUTION! The metering unit is a precision assembly and must only be serviced by qualified personnel Never run the test stand with any filter removed The audit procedures should be carried out with MCB4 temperature below 35 C and the deliveries restricted as follows: 99

1731 Audit 1 - Every 20 hours or weekly (whichever occurs first) Refer to Figure 73 Diagnostic Screen Audit 1 detects leaks in the metering unit and must be carried out with the metering unit temperature below 35 C 1 Connect all the lines of the pump being used 2 Select Audit 1 test on Diagnostic screen 3 Follow the instructions on the screen NOTE: The leak rate must be less than 02mm/min Causes of leakage which can be rectified by the maintainer include: Metering Unit Drain Solenoid Metering Unit Filter Plug Piezo Transducer O-ring If the problem is not resolved by these actions contact your local agent or Hartridge Limited in Buckingham 1732 Audit 2 - Every 20 hours or weekly (whichever occurs first) Audit 2 detects leaks in each metering line This test must be carried out only after Audit 1 and with Metering Unit temperature below 35 C 1 Connect all the lines of the pump being used 2 Select Audit 2 test on Diagnostic screen 3 Follow the instructions on the screen NOTE: The leak rate must be less than 08 mm/min Causes of leakage which can be rectified by the maintainer include: Injector adaptors Quick Release Couplings Braided pipes Injector Solenoid Valves Injector Filter Plugs If the problem is not resolved by these actions contact your local agent or Hartridge Limited in Buckingham 1733 Audit 3 - Every 20 hours or weekly (whichever occurs first) This test checks restrictions in each line and metering unit 1 Fit a pump to SOME of the lines 2 Remove injectors from unconnected lines which will be tested 100

3 Select Audit 3 on the Diagnostic screen 4 Follow the instructions on the screen NOTE: The value should be greater than 35 mm/sec If the measured value is greater than 35 (-35 on the screen) the filter is OK Causes of restriction which can be rectified by the maintainer include: Metering Unit Filter Injector Filter Braided pipes If the problem is not resolved by these actions contact your local agent or Hartridge Limited in Buckingham 101

18 Specifications 181 Main Drive Power 75kW (10HP) or 15kW (20hp) continuous Max Torque 65Nm or 150Nm continuous Speed range 30 to 4000 rpm clockwise and anticlockwise Speed control Full closed loop control by digital input into the PC keyboard with ±5 to 250rpm analogue speed trim using potentiometer Acceleration rate Selectable up to 400 rpm/second Flywheel inertia 1 kgm² (24lbft²) Drive Coupling Suitable for 75, 90 and 120mm diameter dog drives Stiffness: 600mm/st (ISO4008 rating) 182 Calibrating fluid Supply System Pump Capacity Low pressure 550l/hr (660l/hr for 60 Hz) High pressure 108 l/hr (130l/hr for 60Hz) Pressure Low pressure -1 to 7 bar (-14 to 101psi) High pressure 8 to 80bar (120 to 1200psi) Tank 45 litres nominal (12 US Gallons) Fitted with: Suction filter Over-temperature thermostat Low oil level protection Level indicator and drain pipe Sludge and magnetic particle traps Temperature control 25 to 65 C±2 C using electric heater and water / oil heat exchangers 183 Lube Oil Supply System (Optional) Pump Capacity 250l/hr (300l/hr for 60 Hz) Pressure Tank 0 to 4 bar (0 to 60psi) 14 litres nominal (37 US Gallons) Fitted with: Suction filter Low oil level protection Level indicator and drain pipe Sludge and magnetic particle traps Oil drain direct from table 102

184 Metering System 185 Auxiliary Features dc power: two supplies 0 to 25V 3A maximum or 6A in parallel Socket for single cylinder calibrator operation Socket for measurement of Advance & rack movement (optional) Air supply connector Hours counters for Drive, Fuel Pumps and Fuel Filter (software f6 from Main Screen) 186 Measured Parameters Parameter Units Display Range Resolution Accuracy rpm 1 30 to 4000 ±1 C 01 0 to 80 ±05 F Return Temperature C 01 0 to 80 ±05 F Return flow cc/min 1 22 to 1200 ±10% bar 001-1 to 7 ±1% fso Turbo Boost 0001 0 to 3 Mbar, psi, kg/cm² Aux 1 001 0 to 7 MPa, hpa, kpa Aux 2 001 0 to 15 mmhg Phasing 01 0 to 100 Lube 01 0 to 4 V 01 0 to 25 ±01 Static deg 01 0 to 360 Operator dependent Dynamic deg 01 0 to 360 ±02* mm³/st 01 0 to 500 ±(04%+01mm³) mm³/st 01 0 to 500 ±(04%+01mm³) Speed Other selectable units Calibrating Fluid Inlet Temperature l/min, l/hr, cc/1000st, cc/10sec Electronic Pressures Inlet DC Power Supply Phasing Angles Fuel Metering Calibrate mode Overcheck mode cc/50st, cc/100st, cc/125st, cc/200st, cc/250st, cc/300st, cc/500st, cc/min, l/min, l/hr cc/50st, cc/100st, cc/125st, cc/200st, cc/250st, cc/300st, cc/500st cc/min, l/min, l/hr 103

Average mode Advance (Option) mm³/st 01 0 to 500 ±(04%+01mm³) mm 01 20 ±01 cc/50st, cc/100st, cc/125st, cc/200st, cc/250st, cc/300st, cc/500st, cc/min, l/min, l/hr DPA Adv Box, DPC, STANadyne, mmr(ack) o DP200 Cam ring o DP200 Adv Box o DPS Adv Box o DPS Srv Adv mma(dvance) NOTES: fso = Full Scale Output * = Typical for pump delivery 100mm³/st at 200rpm 104

19 Consumables Description Cct Ref Part No Fig Item Filter element, 5 micron (Lube Oil) 4 OH20/2/21/11 201 6 Filter Element, 5 micron (Test Oil) 4 8850072 201 7 Filter (9 or 13 off) Filter, Backleakage Connection Fuse, Semi-conductor 80A Fuse, 40A (for 10 HP) F4, F5, F6 F1, F2, F3 8850073 UC6/2/17 8683018 9844181 204 206 202 202 4 4 16 15 Fuse, 50A (for 20 HP) Fuse, GEC NS10, 10A Fuse, 20 x 5 2A A/S F1, F2, F3 F7, F8, F9 FS2, FS4 9844182 9844184 9842588 202 202 202 15 14 13 9842591 9842595 8689617E 202 202 201 12 17 12 8689617U 180-34-16 201 204 12 7 Fuse, 20 x 5 3A A/S Fuse, 20 x 5 10A A/S Keyboard skin (except USA) Keyboard skin (USA only) Injector Locking Pin Assembly (8 or 12) FS1 FS3-105

20 Spare Parts 201 Services 2011 Pneumatic System Description Cct Ref Part No Fig Item Air Service Assembly 26 167-11-46 202 2 Valve boost m/assy (Optional) Pressure transducer (Boost) Brake m/assy 31 32-189-13-00 134-93-14 182-18-69 206 206 206 1 1 9 182-18-71 206 9-182-18-23 R8022111 8848017 206 206 9 7 Cct Ref Part No Fig Item 1 8681170 202 6-8868013 201 9 Description Cct Ref Part No Fig Item Isolator switch (3 phase) 8680325 203 2 Fuse, Semi-conductor 80A Fuse, 40A (for 10 HP) F4, F5, F6 F1, F2, F3 8683018 9844181 202 202 16 15 Fuse, 50A (for 20 HP) Fuse, GEC NS10, 10A Fuse, 2A 20 x 5 HRC ceramic Transformer F1, F2, F3 F7, F8, F9 F11, F12-9844182 9844153 9842599 134-92-19 202 202 202 202 15 14 21 9 Brake pad m/assy Diaphragm (Modified) H/Press nylon pipe, blue, 6mm x 1 mm Air connector CB7821/50 (Bayonet skt) - 2012 Water System Description Cooler solenoid valve 1263290 110V 50/60 SV Cooler Matrix 202 Power Distribution Blower 220V 50/60Hz (with capacitor) - 8686452 201 1 Fuse 20 x 5 2A A/S Fuse 20 x 5 3A A/S FS2, FS4 FS1 9842588 9842591 202 202 13 12 Fuse 20 x 5 10A A/S Power Supply Variable E/A Emergency Stop operator (red) FS3 PSU ESTOP 9842595 116-13-00 8685017 202 202 201 17 8 11 106

203 Fuel (Test Oil) System Description Contactor Overload 4A (High voltage stands) (Fuel) Pump-Gear (with lube) Cct Ref Part No Fig Item M101 M102 8 8682035 8682260 8920115 202 202 201 20 19 (Fuel) Pump-Gear (without lube) (Heater) relay, sstate, 480V 25A Element-Heater, 220V 1250W, Switch, float, vertical Pressure Control Valve M/Asy (4 Bar) Thermistor (25m long) (for fuel temp) Bobbin, Loading (4 bar) Spindle (Left Hand thread) Gasket O-ring RM0081-16 VA75, 81 x 16 O-ring RM0321-16 VA75, 321 x 16 8 5 6 11 8920118 8681591 8689151 8687354 160-39-12 201 202 201 203 203 4 4 18 8 1 6 9 174-02-42 205 1 11 205 205 205 205 205 205 3 7 9 8 4 O-ring RM0156-24 VA75, 156 x 24 Pressure Control Valve M/Asy (7 Bar) Thermistor (25m long) (for fuel temp) Bobbin, Loading (4 bar) Spindle (Left Hand thread) Gasket O-ring RM0081-16 VA75, 81 x 16 O-ring RM0321-16 VA75, 321 x 16 O-ring RM0156-24 VA75, 156 x 24 Thermostat, tank temp Filter element, 5 micron Flow transducer S8011R 160-39-03 160-39-05 160-39-10 9700033 9700113 9700203 160-39-30 203 5 6 9 174-02-42 205 1 3 4 10 160-39-03 160-39-05 160-39-10 9700033 9700113 9700203 8687310 8850072 8687365 205 205 205 205 205 205 202 201 205 3 7 9 8 4 5 4 7 6 Pressure Transducer - Supply Pressure Transducer - Aux 1 Pressure Transducer - Aux 2 Pressure Transducer - Pressure Phase 14 14 14 14 134-93-15 134-93-17 134-93-18 134-93-19 201 201 201 201 5 5 5 5 Thermistor (Return Flow) 9 167-11-35 204 7 Motor, Fuel Pump 075kW, Dual V & Hz Pipe, High Pressure, black rubber Pipe, Low Pressure 18 x 4 Blanking plug (Fluid connections) 7-8910228A ALP 206 167-11-02 E190/42 201 206 206 206 4 5 3-107 6

204 Lube Oil System (Option) Description Cct Ref Part No Fig Item 6 8687354 203 1 Filter Element, 5 micron 4 OH20/2/21/11 201 6 Pump-Gear (Lube oil pump) 33 8920115 201 2 Control, Valve, Pressure m/assy 34 160-39-12 203 6 Pressure Transducer - Lube 14 134-93-16 201 5 Lube Oil Control Valve Assy Switch, Float, Vertical 34 160-39-17 203 7 Bobbin, Loading(4 bar) - 160-39-03 205 3 Spindle(left handed thread) - 160-39-05 205 7 Gasket - 160-39-10 205 9 O-ring RM0081-16 VA75, 81 x 16-9700033 205 8 O-ring RM0321-16 VA75, 321 x 16-9700113 9700203 205 205 4 5 Cct Ref Part No Fig Item O-ring RM0156-24 VA75, 156 x 24 205 Drive System Description Contactor 590 DC Drive Controller SSD System Control PCB Safety Relay Coupling, A/backlash m/assy Encoder, rotary M102 SSD 590 ---(SCB2) 8682026 101-06-01 137-82-00 8682559 182-18-76 HS348 Cct Ref Part No 202 202 202 202 206 203 21 10 11 19 2 3 206 Metering System Description PCB Metering No 3 E/Assy Metering Unit - AVM12 M/Assy Metering Unit - AVM8 M/Assy Transducer, Linear Thermistor (25mm long) Filter (9 or 13 off) Piezo transducer E/Assy 331-VLO121H valve body Coil, 110V, 50Hz Quick connector B-QF4-B-4PM (8 or 12 off) Metering Unit Pipe (8 or 12 off) Spring, gas (750N/40)(mounted in upper swing arm tube) Transducer, Temperature 108 43 43 38 9 40 39 39 35 36 -- Fig Item 106-25-00 174-14-20 174-14-21 8687212 174-02-42 8850073 180-30-60 8681053 8681012A 8924265 180-34-17 8905113 202 204 204 204 204 204 204 204 204 204 204 204 1 5 5 3 4 1 2 2 8 4 11 8687109 204 10

207 General Requirements Description Cct Ref Part No Fig Item - UC6/2/17 206 4 135-12-01 - - - 203 5 - HS229 8684332 HS298 203 4 Keyboard (Finland) - 8689616A 201 13 Keyboard (Netherlands) Keyboard (UK) - 8689616D 8689616E 201 201 13 13 8689616F 201 13-8689616G 8689616I 8689616P 201 201 201 13 13 13 8689616S 8689616U 8689617E 8689617U 201 201 201 201 13 13 12 12 Filter, Backleakage Connection CD-ROM (AVM2 Application) PC Monitor - up to mod standard G use upgrade kit - mode standard H onwards PC Keyboard (France) Keyboard (Germany) Keyboard (Italy) Keyboard (Portugal) Keyboard (Spain) Keyboard (USA) Keyboard skin (except USA) Keyboard skin (USA only) 109

Figure 201 Test Stand Left View 110

Figure 202 Test Stand Right View 111

Figure 203 Test Stand Rear View 112

Figure 204 Injector Mount 113

1 Item 1 only used on Fuel Control Valve Figure 205 Fuel/Lube Pressure Control Valve 114