HK1400
HK1400
HK1400
(HK1400)
Patents Pending: PCT/EP2015/068583 & EP15180772.4
CONTENTS
FOREWORD..................................................................................................................................................................... 7
LIST OF FIGURES
Figure 2.1 125mm centre height (e.g. Bosch) ................................................................................................13
Figure 2.2 246mm centre height (e.g. Hartridge) ...........................................................................................13
Figure 2.3 Injector access position ..................................................................................................................14
Figure 2.4 Injector access guard .....................................................................................................................15
Figure 2.5 Coupling guard ...............................................................................................................................15
Figure 2.6 Coupling Drive Engagement ..........................................................................................................16
Figure 2.7 Coupling Drive Clearance ..............................................................................................................17
Figure 2.8 Coupling Clamp Screws .................................................................................................................17
Figure 2.9 Securing Cambox to Bedplate .......................................................................................................18
Figure 2.10 Drive Coupling Rotational Check .................................................................................................18
Figure 2.11 Interlock Connector ......................................................................................................................19
Figure 2.12 Safety interlock connector ............................................................................................................20
Figure 2.13 User Account Control Dialog ........................................................................................................21
Figure 2.14 Magmah Installer Language Selection .........................................................................................22
Figure 2.15 Magmah Software Installer Welcome Screen ..............................................................................22
Figure 2.16 Magmah Software Installer Components Screen ........................................................................22
Figure 2.17 Magmah Software Installer Progress Screen ..............................................................................23
Figure 2.18 Application Data Installer Warning Screen ..................................................................................23
Figure 2.19 Windows XP Start Menu ..............................................................................................................24
Figure 2.20 Windows XP Control Panel ..........................................................................................................24
Figure 2.21 Windows XP Network Connection Screen ...................................................................................25
Figure 2.22 Windows XP LAN Properties Screen ...........................................................................................25
Figure 2.23 Windows XP IP Address Configuration Screen ...........................................................................26
Figure 2.24 Windows 7 Start Menu .................................................................................................................26
Figure 2.25 Windows 7 Control Panel .............................................................................................................27
Figure 2.26 Windows 7 Network and Internet Screen .....................................................................................27
Figure 2.27 Windows 7 Network and Sharing Screen ....................................................................................28
Figure 2.28 Windows 7 Network Connections Screen ....................................................................................28
Figure 2.29 Windows 7 LAN Properties Screen ..............................................................................................29
Figure 2.30 Windows 7 IP Address Configuration Screen ..............................................................................29
Figure 4.1 Draining Oil from Cambox ...............................................................................................................36
Figure 4.2 Cam Cover and Cam Removal .......................................................................................................37
Figure 4.3 Cam Removal from Camshaft Spline ..............................................................................................37
Figure 4.4 Cam Fitment ....................................................................................................................................38
Figure 4.5 Cam Nut, Spring Washer and Load Washer Fitment......................................................................38
Figure 4.6 Cam Nut Torque Procedure ............................................................................................................39
Figure 4.7 Cambox Cover Fitment ...................................................................................................................40
Figure 4.8 Tappet Breather Oil Fill Location.....................................................................................................41
Figure 4.9 Drain/Level Pipe Oil Fill Location ....................................................................................................41
Figure 4.10 EUI Fixturing ..................................................................................................................................42
Foreword
Copyright
Hartridge™ Ltd. reserves the copyright of all information and illustrations in this publication which is supplied
in confidence and which may not be used for any other purpose other than that for which it was originally
supplied. The publication may not be reproduced in part or in whole without the consent in writing of this
company.
© Hartridge™ Ltd.
Warranty Statement
The equipment is covered by the Hartridge™ Ltd standard Terms and Conditions of Sale or Supply. Section
7, 8 and 9 of these Terms and Conditions of Sale or Supply relate to guarantee. ‘The Company’ refers to
Hartridge Limited. A complete copy of the Terms and Conditions of Sale or Supply is available on request.
Please note that all guarantees and warranties are limited to use of the equipment with software installed as
supplied and expressly exclude the correct operation of, or any interaction between the kit software and, any
software and/or hardware supplied by a third party and installed on the Machine. Such software and/or
hardware shall be considered as an accessory as defined in Section 7c of the Terms and Conditions of Sale
or Supply and installation of third party software may be considered as misuse of the equipment as defined
in Section 9(a).
Similarly it is vital that the equipment is operated correctly and in accordance with the instructions and
messages displayed on the Host Machine and EUI/EUP control software. Failure to do so may be treated as
misuse under section 9b (iii) of the Terms and Conditions of Sale and Supply and particular attention must
be paid to closing the Machine down where it is vital the specified procedure is followed.
More specifically, the following are excluded from any express or implied warranties relating to the
equipment:
Damage caused by poor mains supply quality.
Damage caused by improper electrical connection of injectors.
Damage caused by improper hydraulic connection of the cambox to the test bench.
Damage caused by incorrect connection of the safety interlock into test benches.
It is the Client’s responsibility to ensure that any third party accessories (e.g. modem or network card)
installed on the Host Machine by the Client or at the Client’s request are compatible with the equipment and
will not detract from its correct operation.
Safety Information
Warnings, Cautions and Notes
The precautionary notes in this publication, indicated by the words WARNING, CAUTION, or NOTE provide
information about potential hazards to personnel or equipment. Ignoring these notes may lead to serious
injury to personnel and/or damage to equipment. These notes appear as follows:
WARNING!
INDICATES THAT A SITUATION MAY BE HAZARDOUS TO PERSONNEL.
INSTRUCTIONS ARE PROVIDED FOR AVOIDING PERSONAL INJURY.
CAUTION! Indicates that conditions exist that could result in damage to equipment. Instructions are
provided to prevent equipment damage.
NOTE Indicates additional information for clarification where there may be confusion.
General Warnings
Isolate the electrical supply before performing any maintenance operations. Do
not work on electrical equipment while voltage is supplied. If such cannot be
avoided, e.g. for measurements, tests or adjustments, have the action carried out
by qualified personnel only.
Safety glasses must be worn when working on this equipment for the following
reasons:
1.The EUI/EUP base cambox kit is capable of producing high pressure fluid jets or
sprays which can cause severe eye injury in the event of a malfunction.
2.The test stand uses calibration fluid which is harmful to the eyes.
Make sure any rotary machinery is stationary before opening any access panels
or removing fixed panels.
Ensure the cambox drive coupling guard is in place before starting the test bench
drive.
Use extreme care to avoid being drawn in to the test stand. Check that all clothing,
especially sleeves and ties, and hair is safe and cannot be caught in revolving
parts. Check that hoses connected to the injector cannot chafe or become
entangled in the drive, thus causing a hazard.
Ensure the cambox drive coupling guard is in place before starting the test bench
drive
Make sure there is adequate ventilation. Oil vapour may be released from hot
fixtures or high pressure leaks. The specific directions in Health & Safety Data
Sheets must be adhered to.
Keep hands and the body away from fluid sprays, especially injectors, leaking high
pressure pipes and seals. High pressure injection through the skin can result in
fatal injury. In the event of injection into the skin, seek urgent medical attention.
Refer to the Health & Safety Data Sheets.
Impervious gloves and overalls should be worn if regular contact with ISO4113
test fluid is likely. Gloves should also be worn when handling fixture parts or
injectors after testing which may be hot. Refer to the Health & Safety Data Sheets.
Burns will occur to the hands if certain parts of the kit or equipment under test are
touched. Keep hands away from the injector or high pressure pipes after periods
of extended running.
Safety footwear must be worn in the test area at all times. Injury to the feet may be
sustained in the event that equipment under test (during loading or unloading) or
covers are dropped.
Severe injury can be caused by slipping on spilt oils or fluids. All spillages of fluids
in the test area must be dealt with immediately. These can be mopped up and
mineral absorbent material spread over the affected area.
Ensure that any cables between the cambox and the EUI/EUP control box are
safely routed and do not present a trip hazard.
Use calibration fluid and lube oil of the correct specification only. Obtain the
manufacturers Health & Safety Data Sheets and follow the advice given therein.
Prolonged and repeated contact with oil products, ingestion or excessive and
prolonged inhalation of oil mists can be detrimental to health. Use an appropriate
barrier cream.
Ensure that the servicing requirements and intervals as set out in the Maintenance
section are adhered to. Operate and service this equipment only if competent to
do so. Carry out regular inspections to make sure all high pressure connections
are tight and safe.
Remove any tools, cleaning rags or other debris from the test stand before starting
up. Make sure the inching bar is not fitted to the test stand before starting up.
There must be no naked flames. Potentially flammable vapours are present in the
test stand and ignition is possible although unlikely. Smoking whilst operating the
equipment is strictly forbidden.
This equipment uses Viton (fluoroelastomer) seals. If these seals are exposed to
high temperatures, they decompose into a corrosive substance which is extremely
harmful and will contaminate skin. Do not touch Viton seals or the sealing surfaces
if they have been burnt or exposed to temperatures in excess of 400ºC.
Ensure that the mains electrical supply to the EUI/EUP control box is correctly
earthed (grounded).
Ear defenders or ear plugs must be worn by all personnel in the test area. High
noise levels will damage the inner ear and cause deafness.
CAUTION
This equipment contains electrostatic sensitive devices. Observe the necessary
precautions for handling electrostatic discharge sensitive devices. Do not touch
printed circuit boards and associated electronic connections and components.
Arc welding equipment must not be operated within 5 metres of the kit. The
electrical supply to welding equipment must be provided from a remote isolating
transformer. Arc welding can disturb the measuring circuit.
Always start the system running at a low speed, check for correct injector function
and visually check for any leaks before setting higher speeds/pressures.
This particularly applies having just mounted a system, or having just replaced a
component.
Do not open the cambox injector guard while the system is running. Wait for the
test bench drive to stop and for the pressure to decay to a low level before
opening the guard.
At the end of its useful life, please ensure your Hartridge product(s) is disposed of in
accordance with national regulations.
1.1 General
The kit is designed to be connected to traditional diesel test benches to enable testing of EUI/EUP
fuel injection equipment. A typical system for a specific application would consist of:-
Cambox and controller
Application kit for injector type (fuel sleeve, nose piece, cable, cam and pushrod)
Computer/software
The kit consists of a single cam cambox and basic tooling. Injectors are mounted to the cambox
using existing components from the Hartridge catalogue, and the cambox is mechanically driven by
the host test bench. Fuel supply and delivery measurement will be via the host test bench. A control
box drives the injectors electrically, results are read from the host test bench and manually entered
into the computer software for results display and analysis.
The control box may be installed in a generic 19” rack or used free standing on a desk top.
1.1.1 Features
Single cam for all low speed applications
Single cam for all high speed applications
Compatible with 125mm and 246mm* drive line centre heights to suit a range of machines
Adjustable injector plunger lift
Adjustable injector plunger pre-load
Guard for protection from moving parts and high temperatures
Volt free interlock contact for connection into host bench drive control circuit
12V, 24V, 50V and 90V coil injector actuator capability
185V piezo injector actuator capability
Dual injector actuator capability (angle/time overlapping) for E3 injectors
Nozzle response time measurement
Automatic Injector voltage selection via injector cable
Thermal overload protection (refer to section 3.2.2)
Cambox overload protection (refer to section 3.2.3)
*Requires additional components to adapt cambox centre height (refer to section 2.1)
1.3 Specification
1.3.1 Cambox Hardware
Max speed 2400rpm.
Max cam lift 18 mm.
Injector clamp load up to 1.5 tonnes applied using load screw
Weight of dry cambox assembly without application kit fitted - 26kg.
1.3.3 Fluids
Test oil – ISO 4113 Calibration Fluid
Lubrication oil – 10W – 40W or Similar
125mm
To install the cambox on a host test bench which has a 246mm drive centre height, perform the following:
1) Install the keyway into the base of the cambox as instructed above.
2) Locate APB224 onto the host test bench bedplate and secure using clamps APB220.
3) Install adapter plate A242A127 onto APB244 upper face using the 2 retaining bolts, torque to
100Nm.
4) Lift the cambox onto adapter plate A242A127 and ensure the cambox key is located within the
adapter plate keyway.
5) Install 2 retaining bolts through the cambox mounting holes into adapter plate A242A127 and torque
tighten to 100Nm.
246mm
2
D
A
25Nm
Click D
C E
B
A
DANGER!
Do not attempt to bypass the interlock switch, remove the interlock or attempt to fit
the cover in alternate positions.
The guard MUST be returned to the fully extended (Test bench operating) position
when running the test bench, for operator safety.
The assembly is heavy and should not be manually lifted on/off the machine
by one person.
1. Slide the cambox assembly along the machine’s test bed and, with the drive dogs horizontal,
rotate the machine drive coupling to align with the cambox coupling, and then engage them
together. Refer to Figure 2.6.
2. Withdraw the cambox assembly until there is about 1mm gap between machine coupling
and cambox coupling. Refer to Figure 2.7.
3. Tighten the test bench coupling clamp screws to secure the cambox coupling. Refer to
Figure 2.8.
4. Secure the cambox to the test bed using APB220 clamps (for Hartridge standard 246mm
centre height test benches) or the generic test bed securing bolts used on other
manufacturer test benches. Refer to Figure 2.9.
5. Rotate the machine drive manually to ensure the cambox coupling is symmetrically engaged
with the machine coupling. Refer to Figure 2.10.
The interlock is available via the 3 pin DIN connector on the cambox junction box. To wire the
connector:-
1. Remove the central retaining screw
2. Use a 3mm flat blade screwdriver to unclip the connector cover
3. Thread the cable/wire from the test bench through the connector entry gland/grommet. The
maximum cable diameter allowed is 6mm.
2
4. Connect wires to the screw terminals. The terminal capacity is 0.75mm maximum wire
cross sectional area.
The connector pinout is –
Pin 1 Contact IN
Pin 2 Contact OUT
Pin E Not connected
The switching capacity of the interlock contact is 5 Amps maximum, 60V maximum (as designated
on the junction box label).
Correct connection into test benches other than the Hartridge AVM2-PC is the
responsibility of the end user. It is the responsibility of the end user to determine
whether the host test bench systems are suitable for integration of the safety
interlock. Consult your test bench product manual or manufacturer before wiring in
the safety interlock.
Hartridge Ltd. Accept no responsibility for improper connection into third party test benches.
A typical installation would involve wiring the interlock into the host test bench drive STOP control.
Click
1 2
Max
2
0.75mm
Max
4 wire
6mmØ
cable
Figure 2.11 Interlock Connector
Note: When the interlock is wired into the host bench and the Cambox is not being used then
Cambox Interlock Link Assembly A242P010 can be used to enable normal operation of the
host bench.
1 2
Typical installation example
For connection into a Hartridge AVM2-PC machine, contact Hartridge Customer Support –
Email: support@hartridge.com
Tel: +44 (0)1280 825650
Item Description
Operating System Windows XP or 7 Standard / Pro (x86 or x64)
Locale Restriction Western, non-ideographic language (i.e. not Chinese, Arabic, Japanese
etc.).
Processor Intel dual-core 1.8GHz
RAM 4 GB RAM
Video Display Output VGA or DVI, resolution of 1280 x 768 @ 60fps minimum specification
Mass Storage Disc storage 120 GByte; (500 Mbyte for application and libraries)
USB interface 1x USB2 port
Network Port 1x 10/100 Mbps Ethernet
HK1400-EUI-EUP-Setup.exe
Please note that the installer makes changes to the computers registry. If more than one user
account is to use the software then the software must be installed by each user under their account
log in.
1. If the following message appears when installing, just accept by pressing “yes”.
2. From the drop down list box select the language the installer will use.
HK1400-EUIEUP-Data-Setup.exe
Installation is the same as for the application. During installation the following dialogue may appear.
This is just to inform that the data or previous version of the data has already been installed.
Selecting “yes” will over write the Hartridge supplied test plans. These test plans are usually read
only so that the user cannot over write modified versions of them but can save modified copies under
a different name.
Selecting “yes” will over write the existing test plans with those from the data. Only the read only test
plans will be over written, any customer generated test plans with a different name will not be over
written.
5. Select ‘Use the following IP address’ and define the parameters as stated below:
IP Address = 192.168.42.1
Subnet mask = 255.255.255.0
For Windows 7
The IP address of the host computer must be set manually as defined below:
3. Select ‘Network Sharing Centre’ within the Network and Internet screen.
4. Select ‘Change adaptor settings’ from the left panel of the Network and Sharing Centre screen.
7. Select ‘Use the following IP address’ and define the parameters as stated below:
IP Address = 192.168.42.1
Subnet mask = 255.255.255.0
CAUTION:
Care should be taken when manually rotating the drive by hand as the EUI/EUP plunger
spring can cause the drive to rotate suddenly due to being compressed by the cam.
4. Run the unit at the “Purge” test step until repeatable delivery readings are obtained. If
delivery is not obtained then refer to section 5.2 to determine possible faults.
5. Select a performance test step, i.e. idle, max power, max torque, and run the test for at least
30 seconds for the delivery and response time to stabilise before recording the values.
6. Repeat the process until all test points have been performed.
7. Stop the machine.
8. Save the results.
9. Generate ‘master’ pass / fail limits.
10. Remove the EUI/EUP.
32 HL067(EN) Issue 2, 12/2015 (AT2903)
HARTRIDGE LIMITED HK1400 All Makes Bench EUI/EUP
4 Operation
WARNING! HIGH PRESSURE FLUID SPRAYS CAN CAUSE SERIOUS
INJURY OR DEATH.
DO NOT ATTEMPT TO BY-PASS THE GUARD SAFETY INTERLOCK
CAUTION:
Do not open the guard while the system is running. Wait for the test bench drive
to stop before opening the guard.
CAUTION:
Check that the fixture is correctly aligned and that the injector is clamped to the
correct load before running the machine.
CAUTION:
The injectors produce high internal pressures that give high temperatures of
injector, fixture and pipes.
Use protective gloves when loading and unloading or adjusting the fixture.
CAUTION:
Do not unclamp the injector while oil is still being supplied to the injector.
The injector may be forced out of the sleeve by the pressure and a major spillage
will occur.
CAUTION:
Support the injector when it is unclamped.
When the injector is unclamped and the supply and return pipes removed the
injector may fall out of the fixture and cause injury or damage.
CAUTION:
High Temperature Oil
After running the cambox the oil temperature could reach high temperatures.
G
F
B E
D
A
C
2. Remove the 4 cam cover retaining bolts (Figure 4.2A) and pull off the cam cover (Figure 4.2B).
NOTE If extraction assistance is required, remove the centre bolt (Figure 4.2C), and use the supplied
M8 x 70 jacking bolt.
3. Lock the drive shaft to prevent it from turning using the holes provided in the drive coupling (D).
4. Remove the cam nut (Figure 4.2E), using a suitable 1/2inch square drive, spring washer (Figure
4.2F), load washer (Figure 4.2G).
5. Remove the cam (Figure 4.3H) from the splined camshaft.
NOTE On initial use the cam may be tight on the camshaft splines, this tightness will reduce with
continued use.
CAUTION:
Cam Position
Incorrectly setting the cam positon could cause damage to the cambox or EUI/EUP.
Refer to the application data sheet to select the correct cam position number for the
application being tested.
3. Fit load washer (Figure 4.5A), spring washer (Figure 4.5Figure 4.5B) and cam nut (Figure 4.5C)
onto the camshaft. Ensuring the load washer is fitted with the tapered edge against the
camshaft splines.
CAUTION:
Load Washer
Ensure load washer is fitted with the tapered edge towards the camshaft splines to
prevent damaging the camshaft splines.
C
B
A
Figure 4.5 Cam Nut, Spring Washer and Load Washer Fitment
38 HL067(EN) Issue 2, 12/2015 (AT2903)
HARTRIDGE LIMITED HK1400 All Makes Bench EUI/EUP
4. Lock the drive shaft to prevent it from turning using the holes provided in the drive coupling.
5. Using a 1/4in square drive torque wrench, torque the cam nut to 125Nm (Figure 4.6).
CAUTION:
Cam Nut Torque
Ensure the cam nut is torqued to the correct value as specified to prevent the cam nut
becoming loose at high drive speeds. If the cam nut is not correctly tightened then
possible damage could be caused to the cambox bearings.
125Nm
6. Remove the extraction bolt (Figure 4.7A) from the cambox cover (if previously fitted).
7. Replace the cambox cover and torque tighten the 4 x cover retaining bolts to 20Nm.
8. Fit the cambox cover removal blanking plug (Figure 4.7B).
A 4
20Nm
9. Fill the cambox with 1 litre of lubrication oil 10W – 40W or Similar. The cambox can be filled with
oil in the following locations:
o Tappet housing breather hole (Figure 4.8) – requires removal of the EUI/EUP and
pushrod.
o Drain/Level pipe (Figure 4.9) - using a suitable funnel.
CAUTION:
Oil Level
Ensure the oil level is above the minimum mark as indicated on the cambox, if not add
more oil. Inadequate oil level will cause premature wear to the cambox bearings and
possible damage to the cam and tappet assembly.
Oil level should only be checked when the cambox is static and in an upright position
The oil level should be checked before starting a new EUI/EUP test.
1. Select the correct fuel sleeve (Figure 4.10A) according to the application datasheet. Push the
EUI fully into the fuel sleeve.
2. Select the correct nose piece (Figure 4.10B) according to the application datasheet. Locate the
nose piece over EUI and fuel sleeve.
3. Locate the fuel sleeve and nose piece assembly into the base fixture (Figure 4.10C). Check the
alignment of the EUI within the cambox fixturing, the EUI electrical connector should not be
touching any part of the HK1400 fixturing.
4. Tighten the clamp screw (Figure 4.10D) to the correct torque, as indicated on the application
data sheet.
B D
5. Connect the check valve assembly (Figure 4.11C), A242C003, to the nose piece quick release
port*
6. Connect the supplied ALP339 delivery pipe to the outlet of the check valve assembly, the other
end of the ALP339 delivery pipe should be connected to the host test bench metering system**.
7. The fuel sleeve (Figure 4.11A) contains 2 x quick release connectors which provide the fuel
supply (Figure 4.11E) and fuel return (Figure 4.11F) to the EUI being tested, using the supplied
connectors, 8924266, and configure the hydraulic pipe for connection to the host test bench**.
Note: Fuel supply is the upper connector, return is the lower for all EUI fuel sleeves.
C
B
ALP339
A
*It is important to ensure that check valve assembly, A242C003, is connected to the nose piece,
failure to do this will result in unstable response times.
** It may be necessary to modify the hydraulic components provided to suit the host test bench.
Connection to the host test bench is the responsibility of the end user; no parts are supplied for this.
1. Select the correct fuel sleeve (Figure 4.12A) according to the application datasheet. Push the
EUP fully into the fuel sleeve.
2. Locate the fuel sleeve and EUP assembly into the base fixture (Figure 4.12C). Check the
alignment of the EUP within the cambox fixturing, the EUP retaining points should be in line with
the HK1400 cambox uprights.
3. Select the correct EUP clamp plate and clamping pins (Figure 4.12B) according to the
application datasheet. Screw the clamp pins within the EUP clamp plate and then locate the
clamp pins within the EUP retaining holes.
4. Tighten the clamp screw (Figure 4.12D) to the correct torque, as indicated on the application
data sheet.
5. Fit the EUP injector mounting assembly to the cambox base fixture using the 2 retaining bolts,
torque to 5Nm.
D
B
E
5Nm
6. Fit the flexible HP pipe (Figure 4.13F) between the EUP and test injector and torque as indicated
on the application data sheet
7. Connect the supplied ALP339 delivery pipe to the outlet of the injector assembly, the other end
of the ALP339 delivery pipe should be connected to the host test bench metering system**.
8. The fuel sleeve (Figure 4.13A) contains 2 x quick release connectors which provide the fuel
supply and fuel return to the EUP being tested, using the supplied connectors, 8924266, and
configure the hydraulic pipe for connection to the host test bench**.
Note: EUP fuel sleeves will be marked / etched to identify “IN” for supply fuel and “OUT” for return
fuel.
ALP339
CAUTION:
EUI/EUP Preload
Failure to set the correct preload could cause damage to the EUI/EUP being tested, the
HK1400 cambox and/or the host test bench.
Rotate the drive by hand to ensure the set-up is correct and does not lock up. Check the
EUI/EUP does not move vertically; re-clamp if it does.
NOTE It is important to check the hydraulic connections for leaks, ensure the fuel supply and return
hydraulic pipes are connected to the fuel sleeve. Switch on the fuel supply via the host test
bench, configure the supply pressure as instructed by the application datasheet and check for
any leaks.
Ref 2.1.5
AE66/…
Do not try to force the connectors together, this may cause irreparable damage. Always
ensure the lugs are lined up correctly before attempting to push the two parts together.
Route the cables tidily between the control box and the test bench, ensuring that they do
not present a trip hazard, are clear of rotating parts and that there is adequate access to
the machine.
See the EUI/EUP specific Technical Bulletin (TB450) for details of the cable from control box to the
injector. EUI/EUP actuators / coils are not polarity sensitive so the crocodile clips of injector cables (if
present) can be fitted to either terminal.
The connectors on the front of the control box have bayonet coupling rings incorporating a metal
wave spring, which locks with an audible positive ‘click’. All connectors have locating lugs, line up the
lugs with the corresponding socket lugs and then push the plug into the socket. Rotate the outer
coupling ring clockwise until it reaches the end of its travel and a ‘click’ is felt, indicating the
connector is locked into position.
Switch the control box on using the red ON/OFF rocker switch on the front panel. The power switch
will illuminate to indicate power is connected.
4.6 Software
When the Magmah software is launched on a host computer, the program performs an initialisation
sequence. The EUI/EUP Control Box must already be powered up for the initialisation to complete
successfully. If the initialisation is unsuccessful, a warning is displayed that the software will not
function without the appropriate hardware.
On launching the software the main test screen is displayed.
This grid shows the test step set point values for up to
ten test steps.
The NCV values are only displayed for injectors which
e
have two actuators, such as Delphi E3.
In test plan edit mode these values can be edited for
the current selected test step in the lower grid area.
WARNING!
THE SETTING OF VALUES IS FOR HARTRIDGE PERSONNEL ONLY AS THIS
CAN POTENTIALLY CAUSE INJURY, DAMAGE TO THE CONTROL BOX AND
THE EUI/EUP.
Machine Settings
This page provides configuration values which set
the operating environment.
Language:
This selects the language to be used for operating
the software and for displaying the results data.
Note that exit and restart of the software is required
for this change to be effective.
Network:
This shows the network address and port number
for connection to the AE65 hardware. This is a
critical setting and must match the AE65 hardware
values or communication will not be achieved. A
login is required to change these values.
<Admin>
1) Provides all the functionality of the <Workshop> user access mode.
2) Unlocks the “Injector Type” screen so the injector configuration can be changed.
CAUTION:
If the original test plan is overwritten there is no way of recovering the
original.
Unwanted test plans can be deleted by pressing the delete key and when asked to confirm
pressing the delete key again.
CAUTION:
There is no way to recover a deleted test plan.
Ensure that the test bench drive rotation selection is correct before starting.
Correct rotation is indicated by the arrow on the cambox coupling guard.
Refer to Figure 4.29
The test bench can be run immediately if the test plan displayed on the Main Screen is suitable.
If the test plan is not suitable the parameters of an existing plan can be modified on the Main Screen,
see section 4.7.1 for details.
The EUI/EUP must be correctly installed: -
Check the EUI/EUP is clamped and the delivery, supply and return pipes are connected. Fuel
supply is the top connection and fuel return is the bottom connection.
Check the correct electrical cable is connected from the EUI/EUP control box to the EUI/EUP
electrical actuator refer to section 4.5.1
On the test bench select the metering line to which the injector delivery pipe is connected (if
applicable).
Start the test bench fuel supply pump and set the pressure.
Check the test bench drive is set to minimum speed (about 30 rpm) and start the main drive.
Check the drive rotation is correct.
Select a test step from the buttons to the left of the test settings grid on the main screen.
5 Maintenance
WARNING!
DO NOT RUN THE CONTROL BOX WITHOUT ALL THE COVERS FITTED.
ALWAYS ISOLATE THE CONTROL BOX AT THE MAIN VOLTAGE SUPPLY
SWITCH ON THE WALL, BEFORE REMOVING ANY COVERS.
HIGH VOLTAGE!
ACCESS TO THE ELECTRICAL ENCLOSURES SHOULD ONLY BE ALLOWED
SUITABLY QUALIFIED PERSONNEL.
ISOLATE AND LOCK THE ELECTRICAL SUPPLY OFF BEFORE PERFORMING
ANY MAINTENANCE OPERATIONS. DO NOT WORK ON ELECTRICAL
EQUIPMENT WHILE VOLTAGE IS SUPPLIED.
WARNING!
ALWAYS ISOLATE AND LOCK OFF THE TEST BENCH ELECTRICAL SUPPLY
WHEN PERFORMING MAINTENANCE TASKS ON THE CAMBOX.
Impervious gloves and overalls should be worn if contact with ISO4113 test fluid and
lubrication oil is likely. Gloves should also be worn when handling fixture parts or
injectors after testing which may be hot. Refer to the Health & Safety Data Sheets.
5.2 Troubleshooting
Installation issues
Problem Possible Cause Action
1. Drive will not rotate Incorrect EUI/EUP Check correct cam position and
fixture parts used – see Application
Incorrect cam position
Data Sheet
Incorrect pushrod
Incorrect preload
2. Injector moves in fixture Incorrect EUI/EUP Check top clamp bolt tight
when drive runs
Incorrect cam position Check correct fixture parts used – see
Application data sheet
Incorrect pushrod
Incorrect preload
Operational Problems
Problem Possible Cause Action
3. Drive will not run Safety interlock not Ensure the Injector Access Guard is
wired correctly/guard in position.
not fitted Check for correct wiring of the safety
interlock contact into the host test
bench (if used).
4. Injector does not fire Test oil not supplied Check supply and return pipes fitted.
Check correct supply pressure set.
Check injector spill ports not blocked.
Injector actuator not
Injector driver leads not fitted correctly
energising
Incorrect Injector driver lead used.
Injector access guard not fitted
6. Injector response not EUI/EUP actuator fault See sections and 4.6.1 and 4.9.1
displayed
Transducer not Check transducer connected to P2
detecting input lead at junction box.
Change operating condition – speed
or pulse width and retry.
Refer to your national Hartridge Distributor for any problems not covered by this guide.
6 Spares
6.1 Consumables
E
G
J
I A
D
K H
PRODUCT WARNING
CALIBRATION FLUID (ISO 4113) SEEK IMMEDIATE MEDICAL ATTENTION IF
INGESTED
USE CLASSIFICATION
TEST FLUID FOR DIESEL INJECTORS, FLAMMABLE
INJECTION PUMPS & OTHER DIESEL EQUIPMENT
PRODUCT DESCRIPTION - COMPOSITION
THESE FLUIDS ARE PETROLEUM BASED PRODUCTS CONTAINING SIGNIFICANT PROPORTIONS OF THE
MORE VOLATILE PETROLEUM FRACTIONS AND OTHER SOLVENTS USED FOR LUBRICATION, ANTI-
CORROSION AND DERMATITIC INHIBITION.
SAFE HANDLING ADVICE (Protection - Usage, Storage & Transport)
USAGE: 1) Avoid eye splashes and extended skin contact.
2) Do NOT take internally.
3) Keep mist generated by machinery to a minimum, also avoid where possible vapours caused by elevated
temperatures.
4) Protective clothing to be regularly laundered.
STORAGE: These are flammable products which should be stored in closed containers away from heat in a well ventilated area.
HARTRIDGE LTD
Network 421, Radclive Rd, Buckingham,
MK18 4FD, England.
THE INFORMATION AND RECOMMENDATIONS IN THIS PUBLICATION ARE TO THE BEST OF OUR KNOWLEDGE INFORMATION AND BELIEF ACCURATE
AT THE TIME OF PUBLICATION NOTHING HEREIN TO BE CONSTRUED AS A WARRANTY, EXPRESS OR IMPLIED IN ALL CASES. IT IS THE
RESPONSIBILITY OF THE USERS TO DETERMINE THE SUITABILITY OF ANY PRODUCTS FOR THEIR OWN PARTICULAR PURPOSE. RECOMMENDATIONS
FOR HANDLING, PROTECTION ETC. ARE ADVISORY ONLY.
Tel: +44(0) 1280 825 600 Fax: +44(0) 1280 825 601
Email: support@hartridge.com www.hartridge.com