All Makes Common Rail Injector Test Kit (AVM2) Operating ... · The HK900 Common Rail Injector Test Kit is designed to be fitted to the AVM2-PC Test Stand to enable testing of Common

HL030(EN), Issue 1, June 2005

World Leaders in Diesel Fuel Injection Test Equipment

HK900

All Makes Common Rail

Injector Test Kit (AVM2)

Operating Manual

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


HARTRIDGE LIMITED Operating Manual

HL030(EN), Issue 1, June 2005 1

CONTENTS

FOREWORD .........................................................................................................................................................3

1. INTRODUCTION .........................................................................................................................................7

1.1 SPECIFICATION ...............................................................................................................................................7 1.2 RELATED DOCUMENTS ...................................................................................................................................7 1.3 DEFINITION OF TERMS AND ABBREVIATIONS .................................................................................................7

2. INSTALLATION ..........................................................................................................................................9

2.1 FIXTURE INSTALLATION AND HYDRAULIC CONNECTIONS .............................................................................9 2.2 UPGRADE TO AE31 PUMP CONTROL UNIT ................................................................................................... 10 2.3 INJECTOR CONTROL UNIT ............................................................................................................................ 10

2.3.1 Fitting/Installation ............................................................................................................................... 10 2.4 ACCESSORY STORAGE.................................................................................................................................. 14

3. INTRODUCTION TO CR INJECTORS ................................................................................................. 15

3.1 CR INJECTOR OPERATION ............................................................................................................................ 15 3.2 INJECTOR VALVE TYPES .............................................................................................................................. 15

3.2.1 Solenoid Valves .................................................................................................................................... 15 3.2.2 Piezo Valves ......................................................................................................................................... 16

3.3 RECOMMENDED TEST SEQUENCE ................................................................................................................. 16

4. OPERATION .............................................................................................................................................. 17

4.1 GUIDELINES FOR SAFE WORKING PRACTICE ................................................................................................ 17 4.2 SOFTWARE OVERVIEW ................................................................................................................................. 17 4.3 TEST SETUP AND METHOD ........................................................................................................................... 19

4.3.1 Fit the Surrogate Pump ........................................................................................................................ 19 4.3.2 Load a Testplan .................................................................................................................................... 19 4.3.3 Measure Injector Coil Resistance ........................................................................................................ 20 4.3.4 Install Injectors in the Fixture .............................................................................................................. 20 4.3.5 Run the Test Steps ................................................................................................................................ 21 4.3.6 End of Test ........................................................................................................................................... 22

4.4 INTERPRETATION OF RESULTS ..................................................................................................................... 22 4.4.1 Response Time ...................................................................................................................................... 22 4.4.2 Delivery ................................................................................................................................................ 23 4.4.3 Backleakage (with HK901) .................................................................................................................. 23 4.4.4 Summary............................................................................................................................................... 23

4.5 CREATING/EDITING/SAVING TESTPLANS ..................................................................................................... 23 4.6 VIEWING AND PRINTING SAVED RESULTS.................................................................................................... 24

5. MAINTENANCE ........................................................................................................................................ 25

5.1 REGULAR MAINTENANCE ............................................................................................................................ 25 5.2 TROUBLESHOOTING ..................................................................................................................................... 25

5.2.1 Status Indicator Light ........................................................................................................................... 25 5.2.2 Other Faults ......................................................................................................................................... 25

6. SPARES ....................................................................................................................................................... 26


Operating Manual HARTRIDGE LIMITED

2 HL030(EN), Issue 1, June 2005

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Foreword

Copyright

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

© Hartridge Ltd.

Safety Information

Warnings, Cautions and Notes

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

WARNING! INDICATES THAT A SITUATION MAY BE HAZARDOUS TO PERSONNEL. INSTRUCTIONS ARE PROVIDED FOR AVOIDING PERSONAL INJURY.

CAUTION! Indicates that conditions exist that could result in damage to equipment. Instructions are provided to prevent equipment damage.

NOTE Indicates additional information for clarification where there may be confusion.

Operational Warnings

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

COMMON RAIL SYSTEMS OPERATE AT EXTREMELY HIGH PRESSURES. IF USED AS INSTRUCTED THE TEST KIT WILL RELIEVE ANY HIGH PRESSURE WHENEVER THE GUARD DOORS ARE OPENED.

DO NOT ATTEMPT TO BYPASS THE PRESSURE DUMP VALVE OR THE SAFETY INTERLOCK.

Safety glasses must be worn when working on this equipment for the following reasons:

1. The test equipment is capable of producing high pressure fluid jets or sprays which can cause severe eye injury in the event of a malfunction.

2. The test stand uses calibration fluid which is harmful to the eyes.

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

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




Impervious gloves and overalls should be worn if regular contact with ISO4113 test fluid is likely. The pump, high pressure control valve, and delivery lines to the metering unit will become very hot after running. Wear protective gloves if handling immediately after use. Refer to the Health & Safety Data Sheets.

General Warnings

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.

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

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

Severe injury can be caused by slipping on spilt oils or fluids. All spillages of fluids in the test area must be dealt with immediately. These can be mopped up and mineral absorbent material spread over the affected area.

Use calibration fluid and lube oil of the correct specification only. Obtain the manufacturers Health & Safety Data Sheets and follow the advice given therein. Prolonged and repeated contact with oil products, ingestion or excessive and prolonged inhalation of oil mists can be detrimental to health. Use an appropriate barrier cream.

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




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

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.








1. Introduction

The HK900 Common Rail Injector Test Kit is designed to be fitted to the AVM2-PC Test Stand to enable testing of Common Rail injectors. Additional mounting parts are available for testing specific injector types.

NOTE: The AVM2-PC must be fitted with the following items in order to use the HK900 (all available separately):

- HB378 Common Rail Base Kit - HF1130 Common Rail Pump Test Kit - Version 33 (or later) Magmah PC software

1.1 Specification

Refer to packing list for kit contents. The AE32 Injector Control Unit specification is as follows:

Power Supply 120/240V AC 50/60Hz Single Phase

Control Features 4-channel injector drive circuit, suitable for current Bosch, Delphi and Denso solenoid injectors, and Siemens piezo injectors.

Measurements Single channel solenoid resistance measurement.

4-channel response time measurement (via response time unit).

Auxiliary voltage measurement channel.

Miscellaneous Status reporting.

Interface to HK901 for 4-line backleak flow and temperature measurement.

1.2 Related Documents

This manual describes the general operation of the HK900 kit for testing Common Rail injectors. Bulletin TIB195/11 (also provided in this kit) outlines the accessories available and which injector applications they cover.

Please contact Hartridge, or visit www.hartridge.com for the latest availability of accessories and bulletins.

Users should also be familiar with the HB378 CR Base Kit manual (ref HL024), and HF1130 All Makes CR Pump Kit manual (ref HL025).

1.3 Definition of Terms and Abbreviations

CR Common Rail

FIE Fuel Injection Equipment

PCV Pressure Control Valve

IMV Inlet Metering Valve

FCV Flow Control Valve

VCV Volume Control Valve

3rd CYL Pump 3rd

Cylinder Solenoid (Bosch CP1 pumps)

PWM Pulse Width Modulation








2. Installation

SWITCH OFF POWER SUPPLIES BEFORE STARTING THE INSTALLATION PROCEDURE.

2.1 Fixture Installation and Hydraulic Connections

1. A threaded hole is required in the guard clamping blocks in order to fix the injector fixture (HB378 kits supplied after Jan 2005 will have this hole pre-drilled). If required, remove the two clamping blocks from the guard and add the M12 x 1.75 threaded hole as shown.

2. Fit the fixture bracket NTA5001 into the guard and secure with two M12 bolts into the threaded holes produced above.

3. Before fitting the main fixture assembly, ensure that the guard is clamped securely to the machine bedplate.

4. When you first receive the fixture assembly, remove the two screws from either side of the top block (to be used in step 5).




WARNING! THE MAIN FIXTURE ASSEMBLY NTA5000 WEIGHS 27KGS AND SHOULD NOT BE LIFTED BY ONE PERSON ALONE; USE 2 PEOPLE WHEN LIFTING ON OR OFF THE MACHINE.

5. Lift the fixture assembly onto the mounting bracket support post and slide into position. Secure with four screws through the side brackets (two each side).

6. Route the four delivery line hoses (numbered 1 to 4) through the guard and connect to the injector fixture lines and to four of the metering unit lines. We will use the convention of numbering the injector positions 1 to 4 from left to right as shown.

7. Connect the high pressure hose A079B112 from the guard dump valve to the rail entry port.

The fixture is now ready to accept the required injector-specific fitting accessories (see TIB195/11).

2.2 Upgrade to AE31 Pump Control Unit

The AE31 CR Pump Test Box (from the HF1130 kit) requires a software update to work with the injector test box. Refer to the separate instructions in kit HS239 (supplied).

2.3 Injector Control Unit

2.3.1 Fitting/Installation

The AE32 injector test box is designed to be fixed onto the AE31 pump test box.

1. Unscrew the three bottom feet from the AE31.

2. Offer up the AE32 and re-fit the feet (using the three longer M4 screws supplied) screwing through the holes in the extended rear panel.

1 2 3 4

AE31




3. On the front of the units, secure them together using the two link brackets supplied.

AE31

AE32




2.3.2 Connections

The features on the left hand side of the box are as follows:

1. Power/status indicator light (see section 5.2.1).

2. Power switch.

3. Connection for Injector cable.

4. Connection for Resistance measurement cable.

5. Connection for HK901 Backleak Unit, and two status indicator lights (these indicate the backleak unit status and will be explained in the HK901 manual).

6. Auxiliary 5V output and measurement channel (spare – for future use). 7. Flying lead for connection to the response time box (on fixture NTA5000).

Figure 2.2: Box Features (Left)

The features on the right hand side of the box are as follows:

8. Flying lead for connection to AE31.

9. Connection for communications loom A089E956 (to avoid confusion with the AE31 this loom has a RED D connector)

10. Push button for HK901 Backleak Unit diagnostics.

11. Single Phase power socket with 5A fuse, and voltage selector switch.

Figure 2.3: Box Features (Right)




Once the AE31 and AE32 boxes have been fitted together, hang on the right hand side of the test bench and connect as follows (the numbers in brackets refer to Figures 2.2 and 2.3 above):

CAUTION! The voltage selector switch must be set to the correct setting for your local single phase voltage (120/240V).

1. Set the voltage selector switch (11) to the correct value then plug in the single phase power lead.

2. Connect flying lead (8) to the spare socket on the right hand side of the AE31 unit.

3. Connect the red D plug on loom A089E956 to socket (9) on the AE32. Plug the other end of this loom into EXT2 on the rear of the AVM2. Plug the AE31 comms loom A086E913 into the spare flying socket on this new loom.

4. Connect the flying lead (7) to the response time unit on the fixture.

You are now ready to connect the main injector drive lead to socket (3) and the resistance cable to socket (4). These cables will depend on the injector type you are testing; see TIB195/11.




2.4 Accessory Storage

The kit includes an accessory panel that can be wall mounted to help store and organise the various accessory kits. The application/accessory bulletin TIB195/11 can be attached to the board for ease of reference (using the magnets supplied). Accessory kits will be supplied with the appropriate storage bins or clips to fit the panel.

Figure 2.4: Accessory Storage Panel

Further panels are available, part number NTA5050.




3. Introduction to CR Injectors

3.1 CR Injector Operation

One of the main differences between Common Rail injectors and traditional mechanical injectors is the introduction of electrical control; with Common Rail injectors the timing and duration of injection are controlled using an electrically-operated valve. There are currently two types of valve, described in section 3.2 below.

In terms of the hydraulic operation, high pressure fuel is supplied to the nozzle body and to a chamber on top of the control needle. The electrical valve opens/closes a leak off path from this chamber into the return circuit. When the valve is closed, the high pressure acting on top of the control needle keeps the injector firmly closed. Opening the valve relieves the high pressure from the top of the needle, opening the nozzle and starting the injection. Closing the valve re-establishes the high pressure on top of the control needle, quickly shutting off the injection.

The volume of fuel delivered is proportional to both the duration of the pulse (pulse width), and the applied pressure, as shown by the graph in Figure 3.1. Typical pulse widths are in the range of 200 to

2000s. There is a minimum pressure below which the injector will not open; this is typically around 200 bars.

s

mm

3/s

tk

b a r

Figure 3.1: Effect of Pressure and Pulse Width on Delivery

3.2 Injector Valve Types

3.2.1 Solenoid Valves

These are electromagnetic coil valves; Figure 3.2 gives a schematic of the drive signal (showing current against time). There is a higher “pull-in current” (Ip) to initially open the valve, followed by a lower “hold current” (Ih) to keep the valve open. The overall pulse width (T) is the combined width of the pull-in and hold phases. There is a maximum limit on the pull-in current to protect the solenoid.

Injectors with solenoid valves are currently manufactured by Bosch, Delphi, and Denso. Each of these manufacturers uses a different specification for operating voltage and current levels.




Ip

Ih

T

Figure 3.2: Solenoid Injector Drive Signal

3.2.2 Piezo Valves

These use the inherent properties of piezo crystals (that they deflect with applied voltage) to activate the valve. There is a positive current pulse (I) to switch the valve on, and a negative current pulse to switch the valve off. The overall pulse width (T) is the time between the positive and negative current pulses.

I

T

Figure 3.3: Piezo Injector Drive Signal

Siemens were the first manufacturer to introduce piezo injectors, the main advantage over solenoid valves being that piezo valves have a much faster response time.

3.3 Recommended Test Sequence

The recommended test sequence for Common Rail injectors is as follows:

1. Initial Check Use a Testmaster (HH701) and Signal Unit (HK85x) to check the basic operation of the injector and the nozzle spray pattern.

2. Cleaning and Repair If required, clean the nozzle in an ultrasonic tank, or dismantle the injector and replace faulty components. Any dismantling and reassembly should be done in a clean environment.

3. Re-do initial Check Re-check the injector on a Testmaster after cleaning/repair.

4. Final Test Carry out a full delivery, backleak, and response time test on the injectors using the HK900 and HK901kits.




4. Operation

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

COMMON RAIL SYSTEMS OPERATE AT EXTREMELY HIGH PRESSURES. IF USED AS INSTRUCTED THE TEST KIT WILL RELIEVE ANY HIGH PRESSURE WHENEVER THE GUARD DOORS ARE OPENED.

DO NOT ATTEMPT TO BYPASS THE PRESSURE DUMP VALVE OR THE SAFETY INTERLOCK.

WARNING! THE CONTROLS IN THE HK900 KIT HAVE BEEN DESIGNED TO WORK WITH ONE OF THE FOLLOWING CR PUMPS:

BOSCH CP1 (WITH PCV) OR SIEMENS

DO NOT ATTEMPT TO USE ANY OTHER TYPE OF PUMP WITH THE KIT.

4.1 Guidelines for Safe Working Practice

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

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

The pump, injectors, and delivery lines to the metering unit will become very hot after running. Wear protective gloves if handling immediately after use.

4.2 Software Overview

The HK900 kit is controlled through the AVM2 PC software; Magmah version 33 or later is required (a software upgrade kit must be ordered separately if your AVM2 does not have version 33).




The software automatically detects when the kit is fitted, and enables the Common Rail injector control features. Pressing F2 [Metering] from the Main Menu takes you to the new CR Injector Test screen. This is shown below and explanation of the key areas follows:

Figure 4.1: CR Injector Control Screen

1. Results File Information Shows results file information in results view.

2. Injector Characteristics Shows the injector type loaded and the basic electrical characteristics: Supply Voltage; Pull-in Current; Hold Current; and Maximum Pulse Width.

3. Testplan Section Drop-down list of up to 10 test steps. Each step has associated settings for: Pressure Demand, Speed, Pulse Width, Backleak Pressure, and can include limits values for Backleak flow, Delivery, and Pressure.

4. Injector Selection Click on the numbered button to turn on metering. Tick the box and press [Apply Step] to switch on the injector.

5. Resistance Results Injector resistance measurements in Ohms.

6. Response Time Injector response time measurements in microseconds.

7. Metering Line Selection Enter the number in the box for the metering line you are using for that injector.

8. Delivery Results Bar graph showing delivery metering results.

9. Backleak Results (Only if HK901 fitted). Backleak temperature reading in deg. C. Bar graph showing backleak flow results. NOTE: the inner grey bar is an instantaneous reading for indication only; the outer bar and the numerical value give the accurate result.

10. Speed Readings Pump and Engine Speeds.

11. Rail Pressure Actual rail pressure feedback (from Dump Valve pressure transducer).




12. Channel B Current Used to apply an open loop current demand to the second channel of the pump control box (only required when using a Siemens pump as the surrogate – see Section 4.3.1, otherwise set to 0 A).

The function key actions are as follows:

F1 Main Menu Returns to the Main Menu

F2 Testplan Menu Opens the Testplan Menu. From here you can Save changes to the current testplan, create a New testplan, load a different testplan, and edit the Testplan/Injector details. See Section 4.5.

F3 Not used.

F4 Start Test Start a test (with possibility to save results). See Section 4.3.5.

F5 View Results Opens a dialog where you can select previously saved results to view. See Section 4.7.

F6 T40 1:1 Metering mode temperature compensation (function key not enabled, this parameter is set in the testplan).

F7 Print Print (only enabled in Results View – see Section 4.6)

F8 Limits/Units Opens the standard Limits/Units screen.

F9 Metering Mode Toggles the metering mode between Overcheck and Calibrate. Calibrate is the more accurate mode and should be used for taking results.

F10 Metering Limits Opens the standard Metering Limits dialog.

4.3 Test Setup and Method

The basic parameters that will establish the condition of a CR injector are:

Spray Pattern (checked on Testmaster)

Delivery vs. pressure vs. pulse width

Backleak flow (dynamic and static)

Response Time

Example testplans are provided for each manufacturer. These contain the basic electrical characteristics for that manufacturer’s injector and typical demand settings for various conditions. They do not contain expected results values as these will be specific to each injector part number. These example testplans can be used as a basis for creating dedicated testplans for specific injectors.

The following instructions assume that the basic kit has been installed (see Section 2).

4.3.1 Fit the Surrogate Pump

Mount the surrogate pump (either a Bosch CP1 with PCV or a Siemens Pump), and connect to the Pump Control Unit (refer to HF1130 manual and associated bulletins).

NOTE If using a Siemens pump connect the cable the opposite way around to normal i.e. fit the connector labelled “FCV” to the pressure control valve, and fit the connector labelled “PCV” to the flow control valve. Additionally, set the “Channel B Current” to 2A (this applies 2A to the FCV so that it will deliver maximum flow).

4.3.2 Load a Testplan

When you first enter the CR Injector Test screen it will be mainly blank (as in Figure 4.1); you must load a testplan to start testing.

To load the example testplan for the relevant injector manufacturer, first press F2 to access the Testplan Menu (shown below), then select the Manufacturer and Part Number required, then click [Load Testplan], then [OK].




Figure 4.2: Testplan Menu

4.3.3 Measure Injector Coil Resistance

If you wish to measure the injector solenoid resistance this should be done before installing the

injectors in the fixture. Connect the resistance measurement cable to the AE32, then press the [] button and follow the on-screen instructions (a series of dialogs will appear asking you to connect one injector at a time to the resistance cable). When you press [OK] to go on to the next injector, the resistance value will be transferred to the main screen.

NOTE Resistance measurement is only valid for solenoid coil injectors, not for piezo injectors.

4.3.4 Install Injectors in the Fixture

Figure 4.4: Clamping Arrangement

Figure 4.4 shows a general schematic of the injector installation. The exact parts required will depend on the injector type - full details are given in Technical Bulletin 195/11. Select the right parts for the injector you have and mount as shown.

NOTE: Remove any sealing washers from the injector nozzle and use the seals supplied in the relevant Nosepiece Adaptor Kit.

The clamp block screws A should be tightened to a torque of 25Nm.

Tighten the main drawbar nut (24mm socket) to bring the lower section of the fixture up to clamp the injector. Tighten until you reach a dead stop (i.e. when the stop tube and spacer are clamped between the upper and lower blocks) – no torque setting is required.

NOTE: The clamping load is set by the distance D between the upper and lower blocks. For the majority of injectors a 9kN clamp load is recommended, therefore the 9kN Spacer NTA5002 should be fitted unless advised otherwise.

Now connect the high pressure pipes from the rail to the injectors, the backleak piping, and the electrical cable.

NOTE: The height of the test rail is adjustable via the two screws in the central pillar. For the majority of injectors the rail should be left in its lowermost position. For Delphi injectors

NTA5002

D

A A




(where one pipe is used for the different injector lengths) the rail height should be adjusted as required.

NOTE: Backleak pipe assembly NTA5003 is supplied which links all the outlets together for connection to the ‘tank return’ connection on the AVM2 bulkhead. If you have kit HK901, then additional pipes and instructions will be supplied.

You are now ready to run the injectors.

4.3.5 Run the Test Steps

If you want to save the test results you must put the software into “testing” mode. To do this press F4 [Start Test]. This opens the dialog below where you can enter your name, a customer reference, and the injector serial numbers.

NOTE: You can leave these fields blank and enter this information at the end of the test if more convenient (see 4.3.6).

Figure 4.5: Start Test Dialog

Pressing [OK] then puts the software into “testing” mode; on the main screen F4 changes to [Stop Test] and F5 to [Save Results]. Then during the test, press F5 whenever you want to save results.

NOTE: Only one set of results is saved per test step (the last set if F5 has been pressed more than once during a step).

The example testplans will typically follow the following format:

1 Leak Check A startup condition at low speed and low pressure so that you can visually check for leaks before going on to higher pressures.

2 Purge A higher speed and higher pressure condition; run for a couple of minutes to purge any air from the system (wait for stable deliveries to register before continuing), and while waiting for the system to reach temperature.

3 Idle Speed Sets the injector demands at typical idle speed settings.

4 Mid Load Sets the injector demands at typical mid load settings.

5 Full Load Sets the injector demands at typical full load settings.

6 Static Backleak Sets high pressure and switches the injectors off to measure the inherent backleak through the injectors.




Go through the test steps in the order shown (steps 1 and 2 are for preparation and warm up, steps 3 to 6 are the main tests). After changing the test conditions, allow a minute or so for the system to stabilise before taking results.

NOTE: For the most accurate metering results, use Calibrate mode.

4.3.6 End of Test

If you have been saving results, then at the end of the test press F4 [Stop Test]. This opens the dialog below (the same as the Start Test dialog with additional fields for the filename and comments). Complete the information required and select either [Save] or [Save and Print] (to get a printout at the same time).

Figure 4.6: Stop Test Dialog

4.4 Interpretation of Results

The best way to use the HK900 kit is as a comparator against new injectors. The demand settings in the example testplans supplied should give delivery results for the majority of injectors however there may be some test conditions that do not (particularly the idle speed step). We recommend that these testplans are used as a base to create specific testplans for individual injector part numbers (see Section 4.5).

With experience you will build up knowledge of injector operation and possible faults. The following general guidelines apply if you are testing a set of 4 unknown injectors:

4.4.1 Response Time

The faster the response time the better. Any injector whose response time is more than 100s longer than the others is likely to cause engine problems.

NOTE: During the metering cycle the backpressure in the delivery line will fluctuate slightly causing

the response time results to fluctuate by up to 10s. To view results under the most stable conditions, switch off delivery metering.




4.4.2 Delivery

On vehicle, engine management systems can compensate for small variations in injector delivery by trimming the pulse width to individual injectors. Therefore on the test bench you may well see slight differences between injectors at a given test point (depending on the delivery volume). The suggested maximum spread is 2mm

3 for deliveries up to 20mm

3/stk, and thereafter 10% of delivery.

4.4.3 Backleakage (with HK901)

Common Rail injectors have inherently higher backleak than traditional injectors as a volume of fuel is expelled every time the injector valve operates (see Section 3). Typically for a good injector this dynamic backleak volume is of the same order of magnitude as the delivered volume.

The Static Backleak test focuses purely on the inherent tightness of the injector in a static condition and so gives an indication of the condition of the injector valve seats and clearances. This is similar to testing backleak on a traditional injector and is measured over time (mm

3/sec).

For both the dynamic and static backleak tests, any injector with a significantly higher flow (and temperature) compared to the others should be regarded as suspect.

4.4.4 Summary

In general when testing a set of 4 injectors the faulty injector(s) will have:

higher response time

lower delivery

higher backleakage

4.5 Creating/Editing/Saving Testplans

In the Testplan Menu (Figure 4.2), pressing [New] creates a copy of the currently loaded testplan. You will be prompted for a new testplan name (we suggest that you use the injector part number as the testplan name), and then the following dialog box will appear with the general testplan/injector parameters.

Figure 4.7: Injector Parameters Dialog

Max Speed, Max Pulse Width, and Max Pressure are all safety limits which you can set at the maximum for the injector concerned (if then while running the testplan you type in a higher value the software will not allow it). You can set the speed ratio between engine and pump, and also select whether you want to set the speed in terms of Pump RPM or Engine RPM. T40 or T0 is the standard bench metering temperature compensation. In this dialog you can also set the limits for resistance and response time. When you are happy with the changes, press [OK] to go back to the Testplan Menu (you will be asked for confirmation to overwrite the testplan), then [OK] to return to the main screen.

NOTE: You can only edit testplan parameters for the testplan that is loaded (the [Edit Parameters] button will be greyed out otherwise).




To edit a testplan, load it into the main screen then simply change the required demand values or limits (by clicking in the appropriate box). Step names can also be changed using the [Edit Name] button.

NOTE: We advise you NOT to change the example testplans supplied as this will maintain a consistent base to refer back to if needed. Rather, create a copy of the example plan using the [New] button as described above, and then make the required changes to this new testplan.

To save the changes, open the Testplan Menu then click [Save Testplan].

NOTE: You are not able to create, edit, or delete Manufacturer information as this is restricted access.

4.6 Viewing and Printing Saved Results

To view or print previously saved results press F5 [View Results]. This opens a dialog with a drop-down list of previously saved results files. Select the required results file and press [OK]; the software will load it into the main screen.

The appearance of the results viewing screen is slightly different from the live data screen; most of the functions/areas are disabled (greyed out) as shown below. The results file information in the top left of the screen shows the date and time saved, the results filename and any comments saved with the results.

You can use the drop-down test step list to view the results from each test step (it also shows the demands and limits for that test step). You can print the results using F7, or return to the live data screen by pressing F5 [View Live].

Figure 4.8: Injector Screen in Results View




5. Maintenance

5.1 Regular Maintenance

The All Makes Injector Test Unit AE32 does not require any regular maintenance procedures.

5.2 Troubleshooting

THE AE32 CONTAINS HIGH VOLTAGES. SWITCH OFF AND REMOVE POWER CABLE BEFORE OPENING THE UNIT.

ONLY QUALIFED SERVICE PERSONNEL SHOULD ATTEMPT DIAGNOSTICS WITH POWER APPLIED.

5.2.1 Status Indicator Light

The AE32 power status light gives the following indications:

Condition Status

Off No power.

Mainly on, but flashing off every 5 seconds Normal (healthy) status

Flashing on/off every second The internal electrical protection has tripped – see below.

Fully on. Not normal operation; power is present but there is a fault.

The Trip Condition

Two conditions could cause the unit to trip: high current (meaning that the current delivered is not controlled at the demand value), or extended pulse (meaning that the pulse has not turned off at the required width).

To reset the unit switch off, wait a few seconds, and then switch back on. If the unit is still tripped, switch off and disconnect the injector cable, then switch back on. The trip could be caused by a faulty injector coil or piezo, or by a fault within the AE32. Try the injectors one at a time to establish if one is faulty.

If you suspect a problem with the AE32 unit, contact your local Hartridge distributor (see below).

5.2.2 Other Faults

The only other intervention that we advise is to check the 5A fuse in the single phase power connection unit.

For any more complex problems contact your national Hartridge distributor; we would recommend that the unit is returned to Hartridge for investigation and repair. Please give as much information as possible on the conditions when the fault occurred, e.g.

the injector type under test

the test speed

the solenoid current(s) applied

the pulse width applied




6. Spares

Part Numbers for the items in the kit are as follows:

Part No. Description

AE32 CR Injector Test Control Box

HS239 AE31 Software Update Kit

NTA5000 Base Fixturing Assembly

NTA5001 Fixturing Mount Bracket Assembly

NTA5002 Stop Tube Spacer – 9kN

NTA5003 4-Line Backleak Pipe Assembly

NTA5004 Delivery Pipe Set Lines 1-4

Individual delivery pipes (without numbered idents) are available as part number ALP339.

NTA5050 Accessory Panel

A069B261 Blanking Plug (M14)

A079B112 HP Hose – Dump Valve To Rail

A089E956 Comms/Interface Loom

8282177 Storage Bin Size 0 Blue

8282178 Storage Bin Size 1 Blue

8285002 Multi Bin Holder

8285015 Single Vertical Hook 75mm

8809019 Disc Magnets Dia.14 x 5 (Bag of 10)

For accessory kit spares, refer to the relevant packing list.



World Leaders in Diesel Fuel Injection Test Equipment.

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: [email protected] www.hartridge.com

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