Hartridge HM1023 Owner's manual

HL078 (EN), Issue 1, AT3376, 04/2018
HM1023
(AE72) Pressure Audit Kit
Operating and Servicing Manual

HARTRIDGE LIMITED HM1023 (AE72) Operating and Servicing Manual
HL078 (EN), Issue 1, AT3376, 04/2018 1
HM1023 (AE72) Pressure Audit Kit

HM1023 (AE72) Operating and Servicing Manual HARTRIDGE LIMITED
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CONTENTS
FOREWORD.....................................................................................................................................................................5
1. INTRODUCTION.....................................................................................................................................................7
1.1 KIT OVERVIEW ....................................................................................................................................................7
1.2 SPECIFICATION &SITE REQUIREMENTS...............................................................................................................7
2. PREPARATION & FITTING .................................................................................................................................9
2.1 PREPARING THE TEST BOX....................................................................................................................................9
2.2 CONNECTIONS......................................................................................................................................................9
3. SYSTEM DESCRIPTION......................................................................................................................................11
4. OPERATION ..........................................................................................................................................................11
4.1 GENERAL ...........................................................................................................................................................11
4.2 WARM UP AND LEAK CHECK.............................................................................................................................11
4.3 PRESSURE AUDIT (REFER TO THE HARTRIDGE AUDIT PROCESS DOCUMENT FOR THE HOST MACHINE ) ..............12
4.4 FAILED AUDITS..................................................................................................................................................12
4.5 END OF TEST......................................................................................................................................................12
5. MAINTENANCE....................................................................................................................................................13
5.1 REGULAR MAINTENANCE ..................................................................................................................................13
5.2 GENERAL CLEANLINESS ....................................................................................................................................13
6. SPARES...................................................................................................................................................................15
6.1 CONSUMABLES ..................................................................................................................................................15
6.2 GENERAL SPARES ..............................................................................................................................................15
LIST OF FIGURES
Figure 1.1 Kit Overview .....................................................................................................................................7
Figure 6.1 Spares............................................................................................................................................16

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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 & General Warnings
Do not open the guard on the host machine while the system is running. Wait for the
machine to stop before opening the guard.
Do not attempt to remove covers of the machine while the system is running. Wait for
the test bench to stop, the pressures to decay to zero before opening and to be
isolated from the services.
WARNING! HIGH PRESSURE FLUID SPRAYS CAN CAUSE SERIOUS INJURY OR
DEATH.
COMMON RAIL SYSTEMS OPERATE AT EXTREMELY HIGH PRESSURES.
DO NOT ATTEMPT TO BYPASS THE PRESSURE DUMP VALVE OR THE SAFETY
INTERLOCK.
Ensure good levels of lighting for safe, efficient equipment operation.
High Voltage!
Do not work on electrical equipment while voltage is supplied.
Safety glasses conforming to standard BS EN 166:1996 must be worn when using this
equipment for the following reasons:
The host machine is capable of producing high pressures which can cause severe eye
injury in the event of a malfunction.
The host machine uses fluid which may be harmful to the eyes.

HM1023 (AE72) Operating and Servicing Manual HARTRIDGE LIMITED
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Gloves conforming to standard BS EN 407:1994 must be worn when handling parts
after testing which may be hot.
Safety footwear must be worn in the test area at all times. Injury to the feet may be
sustained in the event that equipment under test is dropped (during loading or
unloading).
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 use this equipment.
This equipment contains electrostatic sensitive devices. Observe the necessary
precautions for handling electrostatic discharge sensitive devices. Do not touch printed
circuit boards and associated electronic connections and components.
There must be no naked flames. Smoking in the vicinity of the equipment is strictly
forbidden. Potentially flammable vapours are present in the test stand and ignition is
possible although unlikely.
Severe injury can be caused by slipping on spilt oils or fluids. All spillage of fluids in the
test area must be dealt with immediately.
Arc welding equipment must not be operated within 5 metres of the host machine . The
electrical supply to welding equipment must be provided from a remote isolating
transformer. Arc welding can disturb the electronics.
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..
Use fluid 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.
Do not adjust the dump valve air pressure regulator on the host machine, this is pre-set
and locked off prior to leaving Hartridge. If this is adjusted after leaving Hartridge by
unauthorised personnel, it will invalidate the warranty and may cause serious injury.
All injector electrical connectors not in use should be stowed away to prevent any
damage to connectors.

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1. Introduction
The HM1023 Pressure Audit Kit is designed to provide a means of checking the accuracy and
condition of Common Rail pressure transducers on Hartridge Sabre injector Tester, CRi-PC test
stands and AVM2-PC test benches fitted with the HB378 Common Rail Base Kit, HF1130 All Makes
Common Rail Pump Test Kit and the HK900 All Makes Common Rail Injector Test Kit.
1.1 Kit Overview
Refer to Figure 1.1. The kit consists of -
A281G200 - Pressure audit test box (1)
A281A200 - Test box transducer assembly (2)
A281A210 - Pressure audit test box case (3)
A281A202 –PTD simulator assembly (4)
A281P201 –Cable adaptor assembly (5)
Figure 1.1 Kit Overview
1.2 Specification & Site Requirements
The kit requires a host machine, either a Sabre CRi Master/Expert, CRi-PC or an AVM2-PC (fitted
with HB378 Common Rail Base Kit, HF1130 All Makes Common Rail Pump Test Kit and HK900 All
Makes Common Rail Injector Test Kit).
The AE72 Audit Test Box is powered by a 9V PP3 battery.
Display resolution is ± 1 bar.
Accuracy is within ± 6 bar of nominal pressure.
1
2
3
4
5

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2. Preparation & fitting
2.1 Preparing the test box
1. Connect the battery in the back of the AE72 Audit Test Box. Switch the AE72 Audit Test Box to
‘CAL’ mode
2. Check that the display shows a value of 5000 ±2
3. If the value is too low, fit a new 9V battery in the rear of the AE72 Audit Test Box
4. If the value is still out of tolerance the AE72 Audit Test Box must be returned to Hartridge Ltd for
recalibration.
2.2 Connections
Refer to Figure 2.1.
1. Switch off the host machine.
For Sabre Master / Expert
2. Connect the AE72 Audit Test Box Transducer Assembly to the high pressure port (1).
3. The transducer cable can enter the guarded area from the bottom of the guard door.
Ensure the hydraulic connection are tightened to a maximum torque of 35Nm.
For CRi-PC / AVM2-PC
2. Ensure there is one free outlet port on the common rail (2)
3. Connect the AE72 Audit Test Box Transducer Assembly to the free rail port (3).
The transducer cable can enter the guarded area from the bottom of the guard door on CRi-PC
or from beneath the guard on AVM2-PC.
Ensure hydraulic connections are tightened to a maximum torque of 35Nm.
4. Switch on the AE72 Audit Test Box and select ‘Overcheck’ mode.
Check the display shows 0000 ±2.
If the displayed value is out of tolerance the AE72 Audit Test Box must be returned to Hartridge
Ltd for recalibration.
5. Do not leave the AE72 Audit Test Box switched ON without using it for extended periods as the
battery has a finite life. A weak battery will affect the accuracy of any readings on the display.

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Figure 2.1 Connections
2
CRi-PC / AVM2-PC
CRi-PC / AVM2-PC
3
Sabre CRi Master / Expert
1

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3. System Description
The AE72 Audit Test Box provides a 5 Volt supply to a high pressure transducer. The voltage is
derived from the 9V battery. The transducer provides a ratiometric output voltage (between 10 –
90% of supply voltage), the output voltage is proportional to the applied pressure, where 0.5V is
equivalent to zero bar and 4.5V is equivalent to 2800 bar.
The AE72 Audit Test Box is calibrated to convert the transducer output voltage into a displayed
pressure. The AE72 Audit Test Box has two modes:-
CAL
Provides a reading of the 5V supply voltage to the transducer. The pressure reading is
dependent on an accurate supply voltage. It is important to periodically check the ‘CAL’ value
is within tolerance to ensure accurate readings.
Overcheck
Provides a reading of the applied pressure. With the paired transducer connected, but no
pressure applied, the reading should be zero.
The Pressure Transducer (PTD) Simulator provides a means of checking the calibration of the host
machine. A switch connects a simulated 0 bar or Maximum 2800 bar signal into the system. The
PTD Simulator connects to the AE72 Audit Test Box via the adaptor cable A281P201, provided in
the kit.
4. Operation
4.1 General
The following sections describe typical procedures for the use of the AE72 Pressure Audit Kit. In all
cases the correct audit process for the host machine must be followed.
Certificates of Compliance must be completed to confirm the host machine is within tolerance.
4.2 Warm Up and Leak Check
WARNING! HIGH PRESSURE FLUID SPRAYS CAN CAUSE SERIOUS INJURY OR
DEATH.
COMMON RAIL SYSTEMS OPERATE AT EXTREMELY HIGH PRESSURES.
ENSURE THAT ALL PANELS ARE FITTED TO THE HOST MACHINE.
1. Set up the host machine to run a test, using injectors capable of high pressures.
2. If a 4 line CRi-PC is used, ensure that unused injector positions are populated with injectors but
do not connect the injector control cable to the unused injectors.
3. On any host machine, ensure that unused connectors are stowed away to prevent damage to
them.
4. Start the host machine in Manual Mode, to allow control of rail pressure and injector parameters.
5. Set the rail pressure to 400 bar and check for leaks around the pressure transducer connections.
If a leak is present, stop the machine, ensure the rail pressure has been relieved, switch off the
machine and fix the leak.
6. When there are no visible leaks, run the host machine at approximately 1000 bar. Run for
several minutes to allow the system to purge air and the temperature to stabilise. Recheck for
leaks.

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4.3 Pressure Audit (Refer to the Hartridge audit process document for the host machine )
Stop the machine drive before attempting any adjustments. Ensure the rail pressure
has dissipated before attempting to remove pressure transducers.
High Voltage!
Only qualified personnel are to attempt adjustments while power is applied to the
machine. Observe all safety precautions including, but not limited to - erecting signs
warning of the electrical hazard; placing barriers/chains around the hazardous area;
ensuring that metal items (such as jewellery) are removed before accessing the
hazardous area.
1. Switch on the AE72 Audit Test Box.
2. Set into ‘CAL’ mode and check the displayed value is 5000 ± 2.
3. Set into ‘Overcheck’ mode.
4. Follow the audit procedure as described in the machine audit document.
This generally involves –
Checking host machine calibration with the PTD Simulator
Adjusting machine calibration if necessary
Adjusting the rail pressure on the host machine to the test pressures specified on the
audit Certificate of Compliance.
Confirming that AE72 readings at each point are within tolerance
4.4 Failed Audits
If the results are out of tolerance, the host machine transducer may be faulty or the host machine
pressure calibration may need adjustment. Always check that the AE72 ‘CAL’ value is within
specification before rejecting a transducer or adjusting machine calibration, if the ‘CAL’ value is
incorrect the pressure audit results are invalid.
4.5 End of Test
Stop the machine and switch off. Ensure the rail pressure has dissipated before
attempting to remove pressure transducers.
1. Switch OFF the AE72 Audit Test Box. Remove the AE72 pressure transducer from the machine.
2. Reconfigure the Host Machine for normal testing.
Ensure hydraulic connections are tightened to a maximum torque of 35Nm.
3. Start the Host Machine in Manual Mode.
Increase the rail pressure and check for leaks.

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5. Maintenance
5.1 Regular Maintenance
Each Use
1. Switch on the Audit Test Box and set into ‘CAL’ mode with a pressure transducer connected.
Ensure the reading is 5.000 ±2.
If the reading is out of tolerance, change the 9V battery in the rear of the Test Box.
Note -
Lithium batteries should generally give a longer life.
Consider carrying a spare battery.
Consider using rechargeable batteries (NiMH), ensure that the battery charger is
compatible with the type of rechargeable battery used. Also be aware that rechargeable
batteries self discharge even when not in use (20-25% per month).
Dispose of batteries with care, many types are toxic.
Use collection and recycling facilities where they exist.
2. Inspect sealing faces before fitting equipment to a machine.
Annually
The AE72 Audit Test Box and transducer must be re-calibrated as a pair against a master reference
held at Hartridge Ltd., and a calibration certificate issued. The PTD Simulator accuracy should also
be checked annually. Contact Hartridge Ltd customer support for further details.
5.2 General Cleanliness
The kit should be kept clean. Contamination on the sealing faces or threads can cause leaks,
degrade seals and enter the fuel systems of host machines, causing blockages and potential
damage to equipment.
1. Ensure that all threads and pressure ports are sealed when not in use with dust caps.
2. The display window of the Audit Test Box may be wiped clean with a damp, non abrasive cloth.
3. Keep the contacts of the PTD Simulator connector and the cable adaptor assembly clean to
avoid poor connection and inaccurate readings.

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6. Spares
Please quote the serial number of the unit when enquiring about spares.
Refer to Figure 6.1
6.1 Consumables
Reference
Part Number
Description
Qty
1
9842551
Internal fuse, 100mA, quick blow, 20 x 5
1
2
Source locally
Battery, 9V PP3
1
3
9832054
Sealing plug
1
6.2 General Spares
Reference
Part Number
Description
Qty
4
A281P201
Adaptor Cable Assembly
1
5
A155A117
Test Box Pipe Assembly
1
6
A155A116
HP Interface
1
7
A281P200
Cable Assembly
1
8
A281A202
PTD Simulator Assembly
1
Note: The transducer (9) is not a spares item as the AE72 Audit Test Box and transducer must be calibrated
as a pair, and a calibration certificate issued by Hartridge Ltd.

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Figure 6.1 Spares
5
9
6
7
4
3
8
1
2

The Hartridge Building, Network 421, Radclive Road,
Buckingham, MK18 4FD, United Kingdom
Tel: [phone] Fax: + 44 (0)1280 825 601
Email: [email protected] www.hartridge.com
© Hartridge Ltd., 2018