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The document outlines installation and operating instructions for an All Makes Bench EUI/EUP Kit.

The document provides instructions for installing and operating the cambox kit and its components, as well as information on systems, principles of operation, and safety.

The document mentions to avoid eye splashes and extended skin contact with calibration fluid, not to ingest it, and to use protective clothing when handling it.

All Makes Bench EUI/EUP Kit

(HK1400)
Patents Pending: PCT/EP2015/068583 & EP15180772.4

Installation and Operating Manual

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


HARTRIDGE LIMITED HK1400 All Makes Bench EUI/EUP

CONTENTS
FOREWORD..................................................................................................................................................................... 7

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


1.1 GENERAL ........................................................................................................................................................... 11
1.1.1 Features .................................................................................................................................................... 11
1.2 HOST BENCH REQUIREMENTS ............................................................................................................................ 11
1.2.1 Host Bench Recommended / Minimum Specifications .............................................................................. 12
1.3 SPECIFICATION ................................................................................................................................................... 12
1.3.1 Cambox Hardware .................................................................................................................................... 12
1.3.2 Electrical supply........................................................................................................................................ 12
1.3.3 Fluids ........................................................................................................................................................ 12
1.3.4 Programmable parameters: ...................................................................................................................... 12
1.3.5 Measured parameters ................................................................................................................................ 12
1.3.6 Definition of Terms and Abbreviations ..................................................................................................... 12
2 INSTALLING THE KIT ....................................................................................................................................... 13
2.1 CAMBOX INSTALLATION .................................................................................................................................... 13
2.1.1 Injector access position ............................................................................................................................. 14
2.1.2 Injector access guard ................................................................................................................................ 14
2.1.3 Coupling guard ......................................................................................................................................... 15
2.1.4 Cambox Mounting ..................................................................................................................................... 16
2.1.5 Safety interlock connection ....................................................................................................................... 18
2.2 COMPUTER / USER INTERFACE ................................................................................................................. 21
2.2.1 Computer hardware .................................................................................................................................. 21
2.2.2 Computer software .................................................................................................................................... 21
2.2.3 Software Data Installation ........................................................................................................................ 23
2.2.4 Computer IP Address ................................................................................................................................ 24
3 SYSTEMS AND PRINCIPLE OF OPERATION ............................................................................................... 31
3.1 GENERAL PRINCIPLES ........................................................................................................................................ 31
3.2 SAFETY INTERLOCK AND OVERLOAD PROTECTION............................................................................................. 31
3.2.1 Safety interlock .......................................................................................................................................... 31
3.2.2 Thermal overload protection ..................................................................................................................... 31
3.2.3 Cambox overload protection ..................................................................................................................... 32
3.3 SUPPLEMENTARY KITS ...................................................................................................................................... 32
3.4 PRINCIPLES FOR TESTING ................................................................................................................................... 32
4 OPERATION .......................................................................................................................................................... 35
4.1 GUIDELINES FOR SAFE WORKING PRACTICE ...................................................................................................... 35
4.2 GENERAL OPERATION ........................................................................................................................................ 36
4.2.1 Cam Removal (if already fitted) ................................................................................................................ 36
4.2.2 Cam Fitment .............................................................................................................................................. 38
4.3 EUI FITMENT AND HYDRAULIC CONNECTIONS ................................................................................................. 42
4.4 EUP FITMENT AND HYDRAULIC CONNECTIONS................................................................................................. 44
4.5 PRELOAD ADJUSTMENT ...................................................................................................................................... 45
4.5.1 Electrical connections ............................................................................................................................... 47
4.6 SOFTWARE ......................................................................................................................................................... 49
4.6.1 Menu tree .................................................................................................................................................. 49
4.6.2 Message box .............................................................................................................................................. 50
4.6.3 Main Test Screen ....................................................................................................................................... 50
4.6.4 Testplan Screen ......................................................................................................................................... 52
4.6.5 Results (Saving) Screen ............................................................................................................................. 53
4.6.6 Results (Loading) Screen .......................................................................................................................... 54
4.6.7 Diagnostic Screen ..................................................................................................................................... 54
4.6.8 Owner Detail Screen ................................................................................................................................. 56
4.6.9 Logon Dialogue ......................................................................................................................................... 57
4.6.10 Injector Details Screen .............................................................................................................................. 58
4.7 LOADING A TESTPLAN ....................................................................................................................................... 58
4.7.1 Edit an existing testplan ............................................................................................................................ 59
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HK1400 All Makes Bench EUI/EUP HARTRIDGE LIMITED

4.8 STARTING THE TESTPLAN DISPLAYED ON THE MAIN SCREEN ........................................................................... 60


4.8.1 Injector response ...................................................................................................................................... 61
4.8.2 In edit mode .............................................................................................................................................. 61
4.8.3 Test step results ........................................................................................................................................ 61
4.8.4 Measuring the Coil Resistance (coil injectors only) ................................................................................. 61
4.8.5 Measuring fuel delivery ............................................................................................................................ 61
4.9 SAVING RESULTS .............................................................................................................................................. 62
4.10 VIEWING RESULTS ............................................................................................................................................ 62
4.11 EXAMPLE RESULTS SHEET ................................................................................................................................. 63
4.12 ASSESSING THE INJECTOR UNDER TEST ............................................................................................................. 63
5 MAINTENANCE .................................................................................................................................................... 65
5.1 REGULAR MAINTENANCE ................................................................................................................................. 65
5.1.1 Inspect nosepiece O-Ring ......................................................................................................................... 66
5.2 TROUBLESHOOTING .......................................................................................................................................... 67
6 SPARES ................................................................................................................................................................... 69
6.1 CONSUMABLES.................................................................................................................................................. 69
6.2 GENERAL SPARES ............................................................................................................................................. 70
APPENDIX A - CIRCUIT DIAGRAMS ....................................................................................................................... 71

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

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HARTRIDGE LIMITED HK1400 All Makes Bench EUI/EUP

LIST OF FIGURES
Figure 2.1 125mm centre height (e.g. Bosch) ................................................................................................13
Figure 2.2 246mm centre height (e.g. Hartridge) ...........................................................................................13
Figure 2.3 Injector access position ..................................................................................................................14
Figure 2.4 Injector access guard .....................................................................................................................15
Figure 2.5 Coupling guard ...............................................................................................................................15
Figure 2.6 Coupling Drive Engagement ..........................................................................................................16
Figure 2.7 Coupling Drive Clearance ..............................................................................................................17
Figure 2.8 Coupling Clamp Screws .................................................................................................................17
Figure 2.9 Securing Cambox to Bedplate .......................................................................................................18
Figure 2.10 Drive Coupling Rotational Check .................................................................................................18
Figure 2.11 Interlock Connector ......................................................................................................................19
Figure 2.12 Safety interlock connector ............................................................................................................20
Figure 2.13 User Account Control Dialog ........................................................................................................21
Figure 2.14 Magmah Installer Language Selection .........................................................................................22
Figure 2.15 Magmah Software Installer Welcome Screen ..............................................................................22
Figure 2.16 Magmah Software Installer Components Screen ........................................................................22
Figure 2.17 Magmah Software Installer Progress Screen ..............................................................................23
Figure 2.18 Application Data Installer Warning Screen ..................................................................................23
Figure 2.19 Windows XP Start Menu ..............................................................................................................24
Figure 2.20 Windows XP Control Panel ..........................................................................................................24
Figure 2.21 Windows XP Network Connection Screen ...................................................................................25
Figure 2.22 Windows XP LAN Properties Screen ...........................................................................................25
Figure 2.23 Windows XP IP Address Configuration Screen ...........................................................................26
Figure 2.24 Windows 7 Start Menu .................................................................................................................26
Figure 2.25 Windows 7 Control Panel .............................................................................................................27
Figure 2.26 Windows 7 Network and Internet Screen .....................................................................................27
Figure 2.27 Windows 7 Network and Sharing Screen ....................................................................................28
Figure 2.28 Windows 7 Network Connections Screen ....................................................................................28
Figure 2.29 Windows 7 LAN Properties Screen ..............................................................................................29
Figure 2.30 Windows 7 IP Address Configuration Screen ..............................................................................29
Figure 4.1 Draining Oil from Cambox ...............................................................................................................36
Figure 4.2 Cam Cover and Cam Removal .......................................................................................................37
Figure 4.3 Cam Removal from Camshaft Spline ..............................................................................................37
Figure 4.4 Cam Fitment ....................................................................................................................................38
Figure 4.5 Cam Nut, Spring Washer and Load Washer Fitment......................................................................38
Figure 4.6 Cam Nut Torque Procedure ............................................................................................................39
Figure 4.7 Cambox Cover Fitment ...................................................................................................................40
Figure 4.8 Tappet Breather Oil Fill Location.....................................................................................................41
Figure 4.9 Drain/Level Pipe Oil Fill Location ....................................................................................................41
Figure 4.10 EUI Fixturing ..................................................................................................................................42

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HK1400 All Makes Bench EUI/EUP HARTRIDGE LIMITED

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


Figure 4.12 EUP Fixturing .............................................................................................................................. 44
Figure 4.13 EUP Hydraulic connections ......................................................................................................... 45
Figure 4.14 Preload ......................................................................................................................................... 46
Figure 4.15 Cable Connections ...................................................................................................................... 47
Figure 4.16 Launch Screen ............................................................................................................................ 49
Figure 4.17 Clickable Tabs ............................................................................................................................. 49
Figure 4.18 Menu Tree ................................................................................................................................... 49
Figure 4.19 Message Box ............................................................................................................................... 50
Figure 4.20 Main Test Screen ........................................................................................................................ 50
Figure 4.21 Testplan Screen .......................................................................................................................... 52
Figure 4.22 Results (Saving) Screen .............................................................................................................. 53
Figure 4.23 Results (Loading) Screen ............................................................................................................ 54
Figure 4.24 Diagnostic Screen ....................................................................................................................... 55
Figure 4.25 Owner Details Screen.................................................................................................................. 56
Figure 4.26 Logon Dialogue ........................................................................................................................... 57
Figure 4.27 Injector Type Screen ................................................................................................................... 58
Figure 4.28 Testplan Selection drop down boxes .......................................................................................... 58
Figure 4.29 Drive direction .............................................................................................................................. 60
Figure 4.30 View Results ................................................................................................................................ 62
Figure 4.31 Results File .................................................................................................................................. 63
Figure 5.1 Inspect Nosepiece O-Ring ............................................................................................................ 66
Figure 6.1 Consumables ................................................................................................................................. 69
Figure 6.2 General spares .............................................................................................................................. 70

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HARTRIDGE LIMITED HK1400 All Makes Bench EUI/EUP

Foreword

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

Warranty Statement
The equipment is covered by the Hartridge™ Ltd standard Terms and Conditions of Sale or Supply. Section
7, 8 and 9 of these Terms and Conditions of Sale or Supply relate to guarantee. ‘The Company’ refers to
Hartridge Limited. A complete copy of the Terms and Conditions of Sale or Supply is available on request.
Please note that all guarantees and warranties are limited to use of the equipment with software installed as
supplied and expressly exclude the correct operation of, or any interaction between the kit software and, any
software and/or hardware supplied by a third party and installed on the Machine. Such software and/or
hardware shall be considered as an accessory as defined in Section 7c of the Terms and Conditions of Sale
or Supply and installation of third party software may be considered as misuse of the equipment as defined
in Section 9(a).
Similarly it is vital that the equipment is operated correctly and in accordance with the instructions and
messages displayed on the Host Machine and EUI/EUP control software. Failure to do so may be treated as
misuse under section 9b (iii) of the Terms and Conditions of Sale and Supply and particular attention must
be paid to closing the Machine down where it is vital the specified procedure is followed.
More specifically, the following are excluded from any express or implied warranties relating to the
equipment:
 Damage caused by poor mains supply quality.
 Damage caused by improper electrical connection of injectors.
 Damage caused by improper hydraulic connection of the cambox to the test bench.
 Damage caused by incorrect connection of the safety interlock into test benches.
It is the Client’s responsibility to ensure that any third party accessories (e.g. modem or network card)
installed on the Host Machine by the Client or at the Client’s request are compatible with the equipment and
will not detract from its correct operation.

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HK1400 All Makes Bench EUI/EUP HARTRIDGE LIMITED

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

WARNING!
INDICATES THAT A SITUATION MAY BE HAZARDOUS TO PERSONNEL.
INSTRUCTIONS ARE PROVIDED FOR AVOIDING PERSONAL INJURY.
CAUTION! Indicates that conditions exist that could result in damage to equipment. Instructions are
provided to prevent equipment damage.
NOTE Indicates additional information for clarification where there may be confusion.

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

Safety glasses must be worn when working on this equipment for the following
reasons:
1.The EUI/EUP base cambox kit is capable of producing high pressure fluid jets or
sprays which can cause severe eye injury in the event of a malfunction.
2.The test stand uses calibration fluid which is harmful to the eyes.
Make sure any rotary machinery is stationary before opening any access panels
or removing fixed panels.
Ensure the cambox drive coupling guard is in place before starting the test bench
drive.

Use extreme care to avoid being drawn in to the test stand. Check that all clothing,
especially sleeves and ties, and hair is safe and cannot be caught in revolving
parts. Check that hoses connected to the injector cannot chafe or become
entangled in the drive, thus causing a hazard.
Ensure the cambox drive coupling guard is in place before starting the test bench
drive
Make sure there is adequate ventilation. Oil vapour may be released from hot
fixtures or high pressure leaks. The specific directions in Health & Safety Data
Sheets must be adhered to.

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

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HARTRIDGE LIMITED HK1400 All Makes Bench EUI/EUP

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

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

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

Severe injury can be caused by slipping on spilt oils or fluids. All spillages of fluids
in the test area must be dealt with immediately. These can be mopped up and
mineral absorbent material spread over the affected area.
Ensure that any cables between the cambox and the EUI/EUP control box are
safely routed and do not present a trip hazard.
Use calibration fluid and lube oil of the correct specification only. Obtain the
manufacturers Health & Safety Data Sheets and follow the advice given therein.
Prolonged and repeated contact with oil products, ingestion or excessive and
prolonged inhalation of oil mists can be detrimental to health. Use an appropriate
barrier cream.

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

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

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

Accidents can occur to unauthorised personnel during testing. Untrained


person(s) must not be present in the test area when the equipment is operating.
Only qualified personnel are to operate this equipment.

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

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HK1400 All Makes Bench EUI/EUP HARTRIDGE LIMITED

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

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

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

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

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

Always start the system running at a low speed, check for correct injector function
and visually check for any leaks before setting higher speeds/pressures.
This particularly applies having just mounted a system, or having just replaced a
component.

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

At the end of its useful life, please ensure your Hartridge product(s) is disposed of in
accordance with national regulations.

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HARTRIDGE LIMITED HK1400 All Makes Bench EUI/EUP

1 Introduction & Specification

1.1 General
The kit is designed to be connected to traditional diesel test benches to enable testing of EUI/EUP
fuel injection equipment. A typical system for a specific application would consist of:-
 Cambox and controller
 Application kit for injector type (fuel sleeve, nose piece, cable, cam and pushrod)
 Computer/software
The kit consists of a single cam cambox and basic tooling. Injectors are mounted to the cambox
using existing components from the Hartridge catalogue, and the cambox is mechanically driven by
the host test bench. Fuel supply and delivery measurement will be via the host test bench. A control
box drives the injectors electrically, results are read from the host test bench and manually entered
into the computer software for results display and analysis.
The control box may be installed in a generic 19” rack or used free standing on a desk top.

1.1.1 Features
 Single cam for all low speed applications
 Single cam for all high speed applications
 Compatible with 125mm and 246mm* drive line centre heights to suit a range of machines
 Adjustable injector plunger lift
 Adjustable injector plunger pre-load
 Guard for protection from moving parts and high temperatures
 Volt free interlock contact for connection into host bench drive control circuit
 12V, 24V, 50V and 90V coil injector actuator capability
 185V piezo injector actuator capability
 Dual injector actuator capability (angle/time overlapping) for E3 injectors
 Nozzle response time measurement
 Automatic Injector voltage selection via injector cable
 Thermal overload protection (refer to section 3.2.2)
 Cambox overload protection (refer to section 3.2.3)
*Requires additional components to adapt cambox centre height (refer to section 2.1)

1.2 Host Bench requirements


The host test bench is to provide:-
 Drive speed and direction control
 Fuel supply & return
 Injected quantity measurement
All fittings to the test bench are to be provided by the customer as these are specific to the host test
bench, which are beyond Hartridge control.

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HK1400 All Makes Bench EUI/EUP HARTRIDGE LIMITED

1.2.1 Host Bench Recommended / Minimum Specifications


Min Max Engineering Units
Drive Power 10 Hp
Drive inertia *1 Kgm2
0.5
Drive coupling stiffness *1
ISO4008
Fuel supply pressure *2 *2 Bar
3 7
Fuel supply temperature *3 *3 °C
35 45
Fuel supply flow rate 2 10 Litres/min
*1
Recommend specification for RPM stability and test repeatability. It is possible to use the HK1400 EUI/EUP
cambox with a host bench which has a drive inertia lower than stated, however depending on application being
tested low speed stability and test repeatability could be affected.
*2
Dependent upon application being tested, refer to application sheets within HK1400 software.
*3
Recommended specification for test repeatability.
NOTE : The HK1400 cambox is not compatible with Hartridge VDM electronic metering systems.

1.3 Specification
1.3.1 Cambox Hardware
 Max speed 2400rpm.
 Max cam lift 18 mm.
 Injector clamp load up to 1.5 tonnes applied using load screw
 Weight of dry cambox assembly without application kit fitted - 26kg.

1.3.2 Electrical supply


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

1.3.3 Fluids
 Test oil – ISO 4113 Calibration Fluid
 Lubrication oil – 10W – 40W or Similar

1.3.4 Programmable parameters:


 Injector coil drive peak current, peak current duration and hold current
 Injector piezo charge & discharge current.
 Injector pulse duration.
 Injector cam timing.
 Maximum & minimum limits for injected quantity, response time and coil resistance
measurements

1.3.5 Measured parameters


 Drive shaft speed.
 Injector response time.
 Solenoid resistance.

1.3.6 Definition of Terms and Abbreviations


ECU Electronic (engine) Control Unit EUI Electronic (controlled) Unit Injector
EUP Electronic (controlled) Unit Pump NOP Nozzle Opening Pressure (bar)
NCV Nozzle Control Valve SCV Spill Control Valve
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HARTRIDGE LIMITED HK1400 All Makes Bench EUI/EUP

2 Installing the Kit

SWITCH OFF POWER SUPPLIES BEFORE STARTING THE INSTALLATION


PROCEDURE.

2.1 Cambox Installation (Refer to TB450_39)


To install the cambox on a host test bench which has a 125mm drive centre height, perform the following:
1) Install the keyway into the base of the cambox with the 3 retaining bolts, torque to 10Nm.
2) Lift the cambox onto the host test bench and secure to the bedplate using suitable clamps.

125mm

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

To install the cambox on a host test bench which has a 246mm drive centre height, perform the following:
1) Install the keyway into the base of the cambox as instructed above.
2) Locate APB224 onto the host test bench bedplate and secure using clamps APB220.
3) Install adapter plate A242A127 onto APB244 upper face using the 2 retaining bolts, torque to
100Nm.
4) Lift the cambox onto adapter plate A242A127 and ensure the cambox key is located within the
adapter plate keyway.
5) Install 2 retaining bolts through the cambox mounting holes into adapter plate A242A127 and torque
tighten to 100Nm.

246mm

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


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HK1400 All Makes Bench EUI/EUP HARTRIDGE LIMITED

2.1.1 Injector access position


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

2
D
A
25Nm

Figure 2.3 Injector access position

2.1.2 Injector access guard


A clear polycarbonate guard is provided, to enclose the Injector under test. The guard is intended to
prevent operator contact with:-
 Parts which develop high temperatures under test conditions
NOTE : High temperatures will also be present on components, pipes and fittings outside of
the guard.
 Electrical contacts of Injectors under test
 Potential pinch points during tests
If the Safety Interlock Connection has been wired into the host test bench as instructed, the test
bench drive will also be prevented from starting, or will be stopped if the cover is removed during
tests.
Referring to figure 2.4, fit the injector access guard by resting it on the base of the fixed interlock
cover (Figure 2.4A). Rotate and push the guard forward, ensuring the interlock key (Figure 2.4B) is
aligned with the interlock body (Figure 2.4C) and the guard clips (Figure 2.4D) click into position on
the support pillars (Figure 2.4E).

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HARTRIDGE LIMITED HK1400 All Makes Bench EUI/EUP

Click D

C E

B
A

Figure 2.4 Injector access guard

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

2.1.3 Coupling guard


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

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

Test bench Barring over


operating position position

Figure 2.5 Coupling guard

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HK1400 All Makes Bench EUI/EUP HARTRIDGE LIMITED

2.1.4 Cambox Mounting


Hartridge recommend the use of trolley HM1053 for safe easy mounting of the cambox assembly to
Hartridge test benches. If the trolley is used, align the trolley with the bedplate, secure it to the
machine using the clamp, release the cambox clamp and carefully slide the cambox onto the
bedplate.
If the Hartridge APB244, APB220 and A242A127 are utilised the cambox can be mounted on the
Hartridge trolley, otherwise the cambox must be lifted by a crane and strap around the top pressure
plate of the cambox.

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

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

Figure 2.6 Coupling Drive Engagement

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

Figure 2.7 Coupling Drive Clearance

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

Figure 2.8 Coupling Clamp Screws

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

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HK1400 All Makes Bench EUI/EUP HARTRIDGE LIMITED

Figure 2.9 Securing Cambox to Bedplate

The cambox MUST be adequately secured to the test bed.

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

Figure 2.10 Drive Coupling Rotational Check

2.1.5 Safety interlock connection


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

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


maximum operator safety

The interlock is available via the 3 pin DIN connector on the cambox junction box. To wire the
connector:-
1. Remove the central retaining screw
2. Use a 3mm flat blade screwdriver to unclip the connector cover
3. Thread the cable/wire from the test bench through the connector entry gland/grommet. The
maximum cable diameter allowed is 6mm.
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

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Note: When the interlock is wired into the host bench and the Cambox is not being used then
Cambox Interlock Link Assembly A242P010 can be used to enable normal operation of the
host bench.

1 2
Typical installation example

Figure 2.12 Safety interlock connector

For connection into a Hartridge AVM2-PC machine, contact Hartridge Customer Support –
Email: support@hartridge.com
Tel: +44 (0)1280 825650

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2.2 COMPUTER / USER INTERFACE


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

Item Description
Operating System Windows XP or 7 Standard / Pro (x86 or x64)
Locale Restriction Western, non-ideographic language (i.e. not Chinese, Arabic, Japanese
etc.).
Processor Intel dual-core 1.8GHz
RAM 4 GB RAM
Video Display Output VGA or DVI, resolution of 1280 x 768 @ 60fps minimum specification
Mass Storage Disc storage 120 GByte; (500 Mbyte for application and libraries)
USB interface 1x USB2 port
Network Port 1x 10/100 Mbps Ethernet

2.2.2 Computer software


The Magmah software is included on the USB memory device included within the HK1400 kit, part
number: A242A603.
It is recommended to copy the setup files from the USB memory device to the computer and run the
following installation program:

HK1400-EUI-EUP-Setup.exe

Please note that the installer makes changes to the computers registry. If more than one user
account is to use the software then the software must be installed by each user under their account
log in.
1. If the following message appears when installing, just accept by pressing “yes”.

Figure 2.13 User Account Control Dialog

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

Figure 2.14 Magmah Installer Language Selection


3. Select next to continue the installation.

Figure 2.15 Magmah Software Installer Welcome Screen


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

Figure 2.16 Magmah Software Installer Components Screen

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6. A dialogue displays the progress of the installation

Figure 2.17 Magmah Software Installer Progress Screen

7. Press close. The application is installed

2.2.3 Software Data Installation


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

HK1400-EUIEUP-Data-Setup.exe

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

Figure 2.18 Application Data Installer Warning Screen

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

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only so that the user cannot over write modified versions of them but can save modified copies under
a different name.
Selecting “yes” will over write the existing test plans with those from the data. Only the read only test
plans will be over written, any customer generated test plans with a different name will not be over
written.

2.2.4 Computer IP Address


The HK1400 EUI/EUP software communicates with the AE65/1 Control Box via an Ethernet
connection.
For Windows XP
The IP address of the host COMPUTER must be set manually as defined below:
1. Click the ‘Windows Start Icon’ and select ‘Control Panel’.

Figure 2.19 Windows XP Start Menu

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

Figure 2.20 Windows XP Control Panel


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

Figure 2.21 Windows XP Network Connection Screen

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

Figure 2.22 Windows XP LAN Properties Screen

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5. Select ‘Use the following IP address’ and define the parameters as stated below:
IP Address = 192.168.42.1
Subnet mask = 255.255.255.0

Figure 2.23 Windows XP IP Address Configuration Screen

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

For Windows 7

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

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

Figure 2.24 Windows 7 Start Menu

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

Figure 2.25 Windows 7 Control Panel

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

Figure 2.26 Windows 7 Network and Internet Screen

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

Figure 2.27 Windows 7 Network and Sharing Screen

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

Figure 2.28 Windows 7 Network Connections Screen

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

Figure 2.29 Windows 7 LAN Properties Screen

7. Select ‘Use the following IP address’ and define the parameters as stated below:
IP Address = 192.168.42.1
Subnet mask = 255.255.255.0

Figure 2.30 Windows 7 IP Address Configuration Screen

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

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3 Systems and Principle of Operation

3.1 General Principles


EUI/EUP equipment used on current applications are controlled using variable voltages and currents
from the engine ECU. In general, the injector is initially supplied with a short duration high current
that closes the high pressure spill control valve (SCV) as quickly as possible. The current is then
reduced and this is held until the required duration of injection event is complete.
Closing the SCV allows the fuel to be compressed by the plunger until the pressure is sufficient to lift
the needle off its seat and the fuel is injected. Opening the SCV allows the needle to re-seat and the
injection ends.
For unit injectors that have dual actuator control, i.e. E3 injectors, there is a Nozzle Control Valve
(NCV) in addition to the SCV. Closing the SCV allows the fuel to be compressed as for a single valve
injector, but injection cannot occur until the NCV is activated and the pressurised fuel is applied to
the nozzle needle. This means that fuel pressure can be pumped up to a much higher level before
the NCV is activated to allow the nozzle needle to open, providing a means of substantially
increasing the NOP and level of injection pressure during injection
The correct definition of the injector currents and voltages are essential for an injector to be tested
correctly.
The injector test plan is controlled using special EUI/EUP software. This enables the correct
parameters to be precisely entered, the machine controlled within safe limits and the test data saved
and used as required.
Mounting requirements
 The injector must be rigidly mounted with a fixture strong enough to withstand the injection
forces.
 It must be operated using a cam with the correct profile, i.e. the correct lift and timing.
 The electrical signal to the injector must be accurately timed relative to the cam profile. The
combination of the speed, cam profile, tappet and pushrod are critical to give a correct
installation and performance.

3.2 Safety Interlock and overload protection


3.2.1 Safety interlock
When fully and correctly installed the Cambox kit is safety-interlocked so that:
 The drive cannot be started if the guard is open (subject to the safety interlock being wired
into the host test bench).
 The drive will stop if the guard is opened whilst it is running (subject to the safety interlock
being wired into the host test bench).

3.2.2 Thermal overload protection


The software will calculate the thermal load and turn off the injector when this value reaches a
maximum.
The main screen displays a live thermal load value as a percentage of the maximum allowable.
The setting screen displays the following values:
 Heating factor
 Cooling factor
 Sample time interval.
An error message will be displayed on screen to inform the operator that the thermal load has
exceeded the maximum.

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3.2.3 Cambox overload protection


The overload protection is based on the maximum injector firing angle. Each injector type has a
separate maximum injector firing angle, derived from tests and stored in software.
This value is used to check that the angle is not exceeded during test plan editing and also prior to
setting the pulse width when running a test.
The injector type screen will allow the entry of the following parameters which will be stored and read
from the existing injector type files:
 Maximum pulse angle (actuator 1) (SCV) 0 – 360°
 Minimum overlap angle (actuator 1 - 2) 0 – 360°
An error message will be displayed on screen to inform the operator that the maximum angle has
been exceeded or the overlap angle is too small.

3.3 Supplementary Kits


In general each EUI/EUP type requires:
 The correct cam set to the correct position in the cambox to suit the injector type.
 A nosepiece that collects the injected oil that is piped to the host machine’s injected quantity
measuring system. The nosepiece incorporates a piezo transducer used to measure the
response of the injector,
 A fuelling sleeve to provide supply and return test oil flow and form part of the EUI/EUP
clamping system,
 A push rod/spacer that axially positions the EUI/EUP plunger in the correct position relative
to the cam
An extensive range of application kits is available. Contact your local distributor for further details.

3.4 Principles for Testing


The kit is capable of operating over a wide range of conditions but to obtain maximum use and
efficiency it is important that the testing is carried out in a controlled and consistent way.
As a result of extensive testing and development at Hartridge Ltd. it is recommended that the
following procedure is followed;
1. Fit a ‘master’ EUI/EUP to the cambox following the instructions within the application data
sheet, which can be accessed when starting the test plan within the HK1400 software.
2. Connect test oil supply and test oil return and electrical connections.
3. Rotate the drive by hand to ensure full 360 degree rotation.

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

4. Run the unit at the “Purge” test step until repeatable delivery readings are obtained. If
delivery is not obtained then refer to section 5.2 to determine possible faults.
5. Select a performance test step, i.e. idle, max power, max torque, and run the test for at least
30 seconds for the delivery and response time to stabilise before recording the values.
6. Repeat the process until all test points have been performed.
7. Stop the machine.
8. Save the results.
9. Generate ‘master’ pass / fail limits.
10. Remove the EUI/EUP.
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11. Test all subsequent EUI/EUP’s against the ‘master’ limits.


This process will ensure the fastest warm-up and will give the most consistent results. Longer time at
the maximum speed/delivery condition will give more stability but at the expense of test time. Ensure
that all EUI/EUP units are tested in exactly the same way so that meaningful comparisons can be
made.
Note: The EUI/EUP resistance is only measured when executing the first test step, therefore once
measured the value will be locked until the test is restarted.

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4 Operation
WARNING! HIGH PRESSURE FLUID SPRAYS CAN CAUSE SERIOUS
INJURY OR DEATH.
DO NOT ATTEMPT TO BY-PASS THE GUARD SAFETY INTERLOCK

4.1 Guidelines for Safe Working Practice

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

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

CAUTION:
The injectors produce high internal pressures that give high temperatures of
injector, fixture and pipes.
Use protective gloves when loading and unloading or adjusting the fixture.

CAUTION:
Do not unclamp the injector while oil is still being supplied to the injector.
The injector may be forced out of the sleeve by the pressure and a major spillage
will occur.

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

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4.2 General Operation


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

4.2.1 Cam Removal (if already fitted)


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

Figure 4.1 Draining Oil from Cambox

CAUTION:
High Temperature Oil
After running the cambox the oil temperature could reach high temperatures.

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G
F

B E
D

A
C

Figure 4.2 Cam Cover and Cam Removal

2. Remove the 4 cam cover retaining bolts (Figure 4.2A) and pull off the cam cover (Figure 4.2B).
NOTE If extraction assistance is required, remove the centre bolt (Figure 4.2C), and use the supplied
M8 x 70 jacking bolt.
3. Lock the drive shaft to prevent it from turning using the holes provided in the drive coupling (D).
4. Remove the cam nut (Figure 4.2E), using a suitable 1/2inch square drive, spring washer (Figure
4.2F), load washer (Figure 4.2G).
5. Remove the cam (Figure 4.3H) from the splined camshaft.
NOTE On initial use the cam may be tight on the camshaft splines, this tightness will reduce with
continued use.

Figure 4.3 Cam Removal from Camshaft Spline

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4.2.2 Cam Fitment


1. Line up the required cam position number with the indented hole in the camshaft (Figure 4.4),
refer to the application datasheet for the correct cam position number for the EUI/EUP being
tested.
2. Push cam onto camshaft splines, ensuring it is fully located.
NOTE On initial use the cam may be tight on the camshaft splines, this tightness will reduce with
continued use.

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.

Figure 4.4 Cam Fitment

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

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
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4. Lock the drive shaft to prevent it from turning using the holes provided in the drive coupling.
5. Using a 1/4in square drive torque wrench, torque the cam nut to 125Nm (Figure 4.6).

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

Figure 4.6 Cam Nut Torque Procedure

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6. Remove the extraction bolt (Figure 4.7A) from the cambox cover (if previously fitted).
7. Replace the cambox cover and torque tighten the 4 x cover retaining bolts to 20Nm.
8. Fit the cambox cover removal blanking plug (Figure 4.7B).

A 4

20Nm

Figure 4.7 Cambox Cover Fitment

9. Fill the cambox with 1 litre of lubrication oil 10W – 40W or Similar. The cambox can be filled with
oil in the following locations:
o Tappet housing breather hole (Figure 4.8) – requires removal of the EUI/EUP and
pushrod.
o Drain/Level pipe (Figure 4.9) - using a suitable funnel.

CAUTION:
Oil Level
Ensure the oil level is above the minimum mark as indicated on the cambox, if not add
more oil. Inadequate oil level will cause premature wear to the cambox bearings and
possible damage to the cam and tappet assembly.
Oil level should only be checked when the cambox is static and in an upright position
The oil level should be checked before starting a new EUI/EUP test.

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Figure 4.8 Tappet Breather Oil Fill Location

Figure 4.9 Drain/Level Pipe Oil Fill Location

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4.3 EUI Fitment and Hydraulic Connections


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

1. Select the correct fuel sleeve (Figure 4.10A) according to the application datasheet. Push the
EUI fully into the fuel sleeve.
2. Select the correct nose piece (Figure 4.10B) according to the application datasheet. Locate the
nose piece over EUI and fuel sleeve.
3. Locate the fuel sleeve and nose piece assembly into the base fixture (Figure 4.10C). Check the
alignment of the EUI within the cambox fixturing, the EUI electrical connector should not be
touching any part of the HK1400 fixturing.
4. Tighten the clamp screw (Figure 4.10D) to the correct torque, as indicated on the application
data sheet.

B D

Figure 4.10 EUI Fixturing

5. Connect the check valve assembly (Figure 4.11C), A242C003, to the nose piece quick release
port*
6. Connect the supplied ALP339 delivery pipe to the outlet of the check valve assembly, the other
end of the ALP339 delivery pipe should be connected to the host test bench metering system**.

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

C
B

ALP339
A

Figure 4.11 EUI Hydraulic connections

*It is important to ensure that check valve assembly, A242C003, is connected to the nose piece,
failure to do this will result in unstable response times.
** It may be necessary to modify the hydraulic components provided to suit the host test bench.
Connection to the host test bench is the responsibility of the end user; no parts are supplied for this.

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4.4 EUP Fitment and Hydraulic Connections


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

1. Select the correct fuel sleeve (Figure 4.12A) according to the application datasheet. Push the
EUP fully into the fuel sleeve.
2. Locate the fuel sleeve and EUP assembly into the base fixture (Figure 4.12C). Check the
alignment of the EUP within the cambox fixturing, the EUP retaining points should be in line with
the HK1400 cambox uprights.
3. Select the correct EUP clamp plate and clamping pins (Figure 4.12B) according to the
application datasheet. Screw the clamp pins within the EUP clamp plate and then locate the
clamp pins within the EUP retaining holes.
4. Tighten the clamp screw (Figure 4.12D) to the correct torque, as indicated on the application
data sheet.
5. Fit the EUP injector mounting assembly to the cambox base fixture using the 2 retaining bolts,
torque to 5Nm.

D
B
E

5Nm

Figure 4.12 EUP Fixturing

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6. Fit the flexible HP pipe (Figure 4.13F) between the EUP and test injector and torque as indicated
on the application data sheet
7. Connect the supplied ALP339 delivery pipe to the outlet of the injector assembly, the other end
of the ALP339 delivery pipe should be connected to the host test bench metering system**.
8. The fuel sleeve (Figure 4.13A) contains 2 x quick release connectors which provide the fuel
supply and fuel return to the EUP being tested, using the supplied connectors, 8924266, and
configure the hydraulic pipe for connection to the host test bench**.
Note: EUP fuel sleeves will be marked / etched to identify “IN” for supply fuel and “OUT” for return
fuel.

ALP339

Figure 4.13 EUP Hydraulic connections

4.5 Preload adjustment


1. Fit the correct pushrod (Figure 4.14A) for the application, as instructed by the application
datasheet.
2. Adjust the gap (Figure 4.14C) according to the application datasheet and lock into position with
the lock nut (Figure 4.14B).

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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.

Figure 4.14 Preload

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

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4.5.1 Electrical connections

85-264Va.c. Host Computer Ethernet


Connection

Ref 2.1.5

AE66/…

Figure 4.15 Cable Connections

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Do not try to force the connectors together, this may cause irreparable damage. Always
ensure the lugs are lined up correctly before attempting to push the two parts together.
Route the cables tidily between the control box and the test bench, ensuring that they do
not present a trip hazard, are clear of rotating parts and that there is adequate access to
the machine.

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

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

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

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

Figure 4.16 Launch Screen

4.6.1 Menu tree


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

Figure 4.17 Clickable Tabs

MAIN SCREEN (Tab Selection)

Main TestPlan Results Diagnostic Settings Injector type

Test & Measurement Owner Details


Results File
- Edit/Save Test step Production Setup
- Selection
- Start/Stop Test - Display/Print - Admin logon
- User Measurement
entry
- Live test data view Control Box Edit/Save Injector File
Testplan
Diagnostics (Password protected)
Load/Save

Figure 4.18 Menu Tree

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4.6.2 Message box


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

Figure 4.19 Message Box


4.6.3 Main Test Screen
The initial main screen displays the last test plan used on the machine.
If the testplan shown on screen matches the EUI/EUP to be tested, Read Section 4.8 and proceed.

Figure 4.20 Main Test Screen


Main Test Screen Overview

Starts and stops a test.


Loads a test plan
Edit / Disable edit button: used to allow / prevent
test parameters and limits from being changed.
a
Provides functionality to Save / Delete the test plan
which is loaded (only activated when a test plan is
loaded and in EDIT mode)
Used to display previously captured results.

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Fuel supply pressure and test bench controlled


temperature these values set for the whole test. They
are stored in the test plan and are the values to be
manually set on the bench before starting a test
(these values can be changed when editing a test
b plan).
The thermal load is calculated and is displayed as a
percentage of the maximum thermal load allowable.
When it reaches 100% the injector is disabled to
prevent damage.

Displays the speed from the 1 pulse per revolution


into the EUI/EUP control box. The minimum and
c
maximum speed limits are also displayed.
Displays the limits and the measured coil resistance
values.
Test step select buttons (maximum of ten). If the
button contains text then it is possible to select it and
run the test step.
The green tick indicates that all the test step
parameters have passed (red cross indicates a failed
d
test step).
When a test step is selected the parameters appear in
the bottom grid section. In edit mode the set points
and test parameter limits can be changed otherwise
they can only be observed.

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.

The results grid area displays the results of all


completed test steps for the whole test plan.
Results are shown in green if the test is in limits
(pass) or red if out of limits (fail).
The currently running test step is shown in the lower
f grid area.
When the test step has completed the delivery value
3
can be entered in the lower grid either as: cm (cc)
(graticule metering systems) where the software
3
converts the value to mm /st using the shot count, or
3
directly as mm /st (for automatic metering systems).

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4.6.4 Testplan Screen

Figure 4.21 Testplan Screen

Testplan Screen overview

Loads a test plan


Saves an edited test plan
Deletes the current loaded test plan
When confirmation of a test plan save or delete is
required cancel continues without taking any
action.
a
If the user has access rights then the test plan can
be edited, otherwise the log on dialogue is
displayed to allow the user to change access
rights.
Used to confirm overwrite of an existing test plan.

This dialogue is displayed when edit is selected


and the user does not have access rights.
b
It allows the user to log on / off.

Drop down list boxes are used to select the


c
required test plan to load, run, delete.

d In edit mode these list boxes allow the data units to


be selected, otherwise they display the current
units from the test plan.

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Displays the file name and the test plan


description. When saving a test plan in edit mode
the filename field is used to change the file name of
the current loaded file (save as), creating a
e separate file.
The test plan description text can be changed in
edit mode.
Displays the test plan time and date.

4.6.5 Results (Saving) Screen


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

Figure 4.22 Results (Saving) Screen

Results (Saving) Screen overview

Saves a results file.


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

Displays the test plan settings used for the results


b being saved.

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Displays the generated default file name for the


results which consists of a concatenation of :
Test plan, serial number, customer ref, year,
month, day, hours, minutes and seconds.
This can be modified as required.
c
Allows the operator to enter a comment which will
be stored in the results file for displaying and
printing.
The time and date of the results to be stored in the
file is displayed.

Data entered into these fields is included in the


results file.
The default results file name consists of a
d
concatenation of :
Test plan , serial number, customer ref, year ,
month , day, hours, minutes, seconds.

4.6.6 Results (Loading) Screen


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

Figure 4.23 Results (Loading) Screen

4.6.7 Diagnostic Screen


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

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

Figure 4.24 Diagnostic Screen

Diagnostic Screen overview

Changes to fields are sent to the EUI/EUP control


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

The current EUI/EUP control box status is


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

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Machine Settings
This page provides configuration values which set
the operating environment.

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

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

4.6.8 Owner Detail Screen


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

Figure 4.25 Owner Details Screen

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4.6.9 Logon Dialogue


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

Figure 4.26 Logon Dialogue

There are two user access modes:


<Workshop>
1) Provides the ability to modify test plan set conditions and limits on the “Main Test” screen:
a. Parameter Name
b. Drive Speed Demand
c. SCV Pulse Width Demand
d. NCV Pulse Width and NCV Delay Demand (only applicable for dual actuator products, i.e.
E3 EUI)
e. Response Time Limits
f. Delivery Limits
g. Resistance Limits
2) Provides the ability to save and delete a test plan on the “TestPlan” screen
3) Provides the ability to modify the “Owner Details” screen information
4) Provides the ability to modify the network settings parameters within the “Machine Settings” screen.

<Admin>
1) Provides all the functionality of the <Workshop> user access mode.
2) Unlocks the “Injector Type” screen so the injector configuration can be changed.

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4.6.10 Injector Type Screen


The injector type screen displays data which is specific to the injector type being tested such as: the
current and voltage drive values for the injector; the maximum speed the injector can be driven. It is
possible to change these values and create new injector types only by logging on and gaining
access rights.
WARNING!
MODIFYING THE DEFAULT VALUES OR CREATING NEW INJECTOR TYPES
REQUIRES KNOWLEDGE OF THE EUI/EUP AND IN DEPTH KNOWLEDGE OF
THE HARTRIDGE EQUIPMENT TO PREVENT INJURY; DAMAGE TO THE
EUI/EUP CONTROL BOX AND DAMAGE TO THE INJECTOR.

Figure 4.27 Injector Type Screen

4.7 Loading a Testplan


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

Figure 4.28 Testplan Selection drop down boxes


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 Select the Manufacturer from the drop down list.


 Select the Injector Type.
 Select the testplan required and click the ‘Load’ button.
 If required the application datasheet can be viewed which details the equipment required to fit the
EUI/EUP being tested, select the “Show Instructions” button.

4.7.1 Edit an existing testplan


 Load a testplan as described above.
Refer to Figure 4.21
 Click on the edit button and log on if necessary.
 Select the correct units for temperature and timing from the drop down list box.
 Select the main screen using the tab at the top of the screen.
Refer to Figure 4.20
 Select the test step to edit using the step select buttons at the side of the main grid.
 The test step data will appear in the lower grid this can be edited by selecting the fields and
typing in the correct values.
 If the test step name is blank a name must be entered because a test a blank name indicates that
there are no more test steps in the test plan. It is also important that test steps are filled from the
top to the bottom and any unused test steps (those which do not have a name) are at the bottom
of the table of test step buttons.
 Test step limit values can be changed while the test step is running.
 To change the test step setting values when the test step is running, it is necessary to abort the
test step first.
 The supply pressure and temperature fields at the top of the screen can be set at any time in
editing mode.
 When testplan editing is complete select the Testplan tab at the top of the screen. It is then
possible to save the test plan by pressing the save button, a confirmation message appears.
To overwrite the existing test plan press save again to create a new test plan.
Type in a new name in the filename field.

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

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

CAUTION:
There is no way to recover a deleted test plan.

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4.8 Starting the Testplan Displayed on the Main Screen


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

Ensure that the test bench drive rotation selection is correct before starting.
Correct rotation is indicated by the arrow on the cambox coupling guard.
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.

Figure 4.29 Drive direction

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

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4.8.1 Injector response


Injector response time is measured continually and the value is updated in the current test step grid
towards the bottom of the screen. The response time value is stored when the OK button is pressed
at the end of the delivery measurement.
The timing sensor detects the pressure rise in the nozzle adaptor as fuel flows from the injector
nozzle. The sensor signal is affected by the drive speed and the delivery value. Readings are quite
different from slow speed to high speed and injectors should be compared at the same running
condition to determine if injectors are satisfactory.

4.8.2 In edit mode


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

4.8.3 Test step results


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

4.8.4 Measuring the Coil Resistance (coil injectors only)


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

4.8.5 Measuring fuel delivery


The test bench measuring system measures the delivery. The test bench is configured by the
operator to capture a set number of delivery shots (revolutions of the drive).
The delivery result from the host test bench can be entered into the HK1400 cambox software in
3
units for mm /str or in cc. If a cc value is entered then the number of counts selected on the test
bench must also be entered into the HK1400 cambox software and in turn the software will
3
automatically calculate the mm /str value.

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4.9 Saving Results


Refer to Figure 4.22
 At the end of a test when the stop test is pressed the results save screen is displayed.
 Enter EUI/EUP serial number and customer name.
 Enter customer reference number and/or customer name.
 Enter other relevant fields.
 The results file name is generated from the test plan name, serial number, customer
reference, the current date and time. The generated default file name can be modified to suit
user’s preference by typing in the filename field.

4.10 Viewing Results


Refer to Figure 4.30
 Click Results from the Tab at the top of the screen.
 Choose the results file to open.
 Click ‘Open’. Internet explorer will be launched and the test results file will be loaded to view.
The file can be printed on a printer attached to the test bench computer if required, using the
internet explorer ‘File/Print…’ function.

Figure 4.30 View Results

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4.11 Example results sheet

Figure 4.31 Results File

4.12 Assessing the injector under test


There are no parts programmes or test plan information published by the injection equipment
manufacturers. Hence the recommended procedure for setting the acceptance criteria for a particular
injector type is to use a known master injector as the benchmark and to characterise that injector to
establish the performance.
In general, unless more detailed information is available, Hartridge recommend that the injector is
tested at a cranking speed, idle speed, maximum torque and maximum power conditions. A typical
test programme is programmed into the software and can be used as a template for new test plans.
Information about the speeds can be found from engine data and the pulse widths required to
achieve the typical deliveries can be found by experiment on the ‘master’ injector. Resistance
measurement and the timing performance of both the overall injector and the electrical coil can also
be established from the ‘master’ injector.
Further test information will be distributed when it is available.

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5 Maintenance
WARNING!
DO NOT RUN THE CONTROL BOX WITHOUT ALL THE COVERS FITTED.
ALWAYS ISOLATE THE CONTROL BOX AT THE MAIN VOLTAGE SUPPLY
SWITCH ON THE WALL, BEFORE REMOVING ANY COVERS.

HIGH VOLTAGE!
ACCESS TO THE ELECTRICAL ENCLOSURES SHOULD ONLY BE ALLOWED
SUITABLY QUALIFIED PERSONNEL.
ISOLATE AND LOCK THE ELECTRICAL SUPPLY OFF BEFORE PERFORMING
ANY MAINTENANCE OPERATIONS. DO NOT WORK ON ELECTRICAL
EQUIPMENT WHILE VOLTAGE IS SUPPLIED.
WARNING!
ALWAYS ISOLATE AND LOCK OFF THE TEST BENCH ELECTRICAL SUPPLY
WHEN PERFORMING MAINTENANCE TASKS ON THE CAMBOX.

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

5.1 Regular Maintenance


.
Operation Frequency of Check
Change Cambox oil Every 4 months or 250 test hours
Inspect nosepiece O-Ring After every 20 units tested

Table 5.1 Maintenance Schedule

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5.1.1 Inspect nosepiece O-Ring


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

Figure 5.1 Inspect Nosepiece O-Ring

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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

5. No delivery displayed EUI/EUP fault Check pipe to metering unit


connected
Metering not operating
Check correct line is selected on host
Leaks machine’s metering system.

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.

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6 Spares

6.1 Consumables

Item Description Part Number


A Fuse 2 Amp Anti-surge, 250V 9842588
B O-Ring (Fuel Sleeve, Nosepiece) Refer to Application datasheets
TB450_35, TB450_36

Figure 6.1 Consumables

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6.2 General Spares

Item Description Part Number


A Cam follower assembly A242A002
B Piezo sensor P2 AE38/1
C Cambox electrical connection assembly A242B110 (includes part E, A242P006)
D Cable assembly 1/Rev A242P005
E Guardswitch assembly A242P006
F Roller Bearing Plate Assembly HS398
G Cover Plate Assembly A242C002
H Spring Washer 9371130
I Friction Disc A242A139
J Cam Nut A242A137
K Cover Plate Assembly O-Ring BS 4518_0995_30

E
G
J
I A

D
K H

Figure 6.2 General spares

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Appendix A - Circuit diagrams

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Appendix B: Health and safety data sheet

HEALTH & SAFETY DATA SHEET DATE Pub. No.


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

PRODUCT WARNING
CALIBRATION FLUID (ISO 4113) SEEK IMMEDIATE MEDICAL ATTENTION IF
INGESTED
USE CLASSIFICATION
TEST FLUID FOR DIESEL INJECTORS, FLAMMABLE
INJECTION PUMPS & OTHER DIESEL EQUIPMENT
PRODUCT DESCRIPTION - COMPOSITION
THESE FLUIDS ARE PETROLEUM BASED PRODUCTS CONTAINING SIGNIFICANT PROPORTIONS OF THE
MORE VOLATILE PETROLEUM FRACTIONS AND OTHER SOLVENTS USED FOR LUBRICATION, ANTI-
CORROSION AND DERMATITIC INHIBITION.
SAFE HANDLING ADVICE (Protection - Usage, Storage & Transport)
USAGE: 1) Avoid eye splashes and extended skin contact.
2) Do NOT take internally.
3) Keep mist generated by machinery to a minimum, also avoid where possible vapours caused by elevated
temperatures.
4) Protective clothing to be regularly laundered.
STORAGE: These are flammable products which should be stored in closed containers away from heat in a well ventilated area.

EMERGENCY & FIRST AID PROCEDURE (Eyes, skin, ingestion, inhalation)


INGESTION: Do NOT induce vomiting. Give a glass of water and get immediate medical attention at Hospital.
EYES: Flush with large amounts of water for 15 minutes. Seek medical help if irritation persists.
SKIN: Wash thoroughly with soap & water. Seek medical help if irritation or skin rashes occur. Remove any contaminated
clothing.
INHALATION: Inhalation includes oil mists or vapours. Remove victim to fresh air. Seek medical help if affliction persists.

FIRE HAZARDS & PROTECTION (Flash point, spillage)


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

ENVIRONMENTAL PROTECTION (Spillage land / water, disposal)


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

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

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

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© Hartridge™ Limited, 2015

The Hartridge Building, Network 421, Radclive Road


Buckingham, MK18 4FD United Kingdom

Tel: +44(0) 1280 825 600 Fax: +44(0) 1280 825 601
Email: support@hartridge.com www.hartridge.com

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