Page 1 Common Rail Injector Test Stand 4 Line Operating and Servicing Manual HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 2 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 3 CRi-PC Operating and Servicing Manual Hartridge CRi-PC – 4 line HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 4 CRi-PC Operating and Servicing Manual HARTRIDGE LIMITED This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 5: Table Of Contents
Delivery ............................92 4.4.3 Backleakage ..........................92 4.4.4 Summary ............................92 HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 6 ........................... 123 ONSUMABLES ..........................124 ENERAL PARES 7.APPENDICES ............................... 127 HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 7: Foreword
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.
Page 8 Arc welding can disturb the measuring circuit. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 9 3 phase supply and may therefore still be powered when the test stand 3 phase supply is switched off. At the end of its useful life, please ensure your Hartridge product(s) is disposed of in accordance with national regulations.
Page 10 CRi-PC Operating and Servicing Manual HARTRIDGE LIMITED This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 11: Introduction
CRi-PC Operating and Servicing Manual 1. Introduction The Common Rail Injector Test Stand (CRi-PC) is designed to enable testing of Common Rail injectors. The stand accommodates currently available injectors from Bosch, Delphi, Denso and Siemens. Fixture components are available for testing specific injector types.
Page 12 CRi-PC Operating and Servicing Manual HARTRIDGE LIMITED This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 13: Installation
Serial port 2 for optional printer (if fitted) Serial port 3 (cable 51) Serial port 4 (cable 50) HL038, Issue16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 14 (if applicable). Figure 2.1 Fitting the Computer HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 15: Water & Air Connection
Ensure the pipe is not trapped by the side cover when it is refitted. HL038, Issue16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 16 CRi-PC Operating and Servicing Manual HARTRIDGE LIMITED Figure 2.3 Oil & Water Drainage HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 17: Electrical Connection
2. Ensure the connector retaining clip (4) is in place. Figure 2.4 Electrical Connections HL038, Issue16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 18: Setting For The Correct Supply Voltage
If the voltage supply frequency is 60Hz, the link must be wired between terminals 3 and 4. Figure 2.5 Supply Settings HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 19: Test Oil
Replace the tank access panel and the left side panel. HL038, Issue16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 20 CRi-PC Operating and Servicing Manual HARTRIDGE LIMITED Figure 2.6 Tank Filling HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 21: Initial Power-Up
(Fig. 2.6). Top up the fluid level in the main tank as required. 5. Switch ON the red illuminated power switch at the rear of the machine to power-up the computer, check that the monitor screen comes on and the Hartridge™ Magmah software starts.
Page 22 Figure 2.7 Clockwise Motor Rotation Figure 2.8 Air preparation HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 23: Systems And Principle Of Operation
HL038, Issue16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 24: Piezo Valves
HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 25: Pneumatic System
3. High pressure safety dump valve. Air is supplied through a separate regulator that is set and locked at Hartridge. This controls the maximum pressure in the high pressure hydraulic circuit. The regulator setting must not be adjusted or the machine safety will be compromised.
Page 26: Injector And Cr Pump Control
For further information on injector control see sections 3.1 & 3.2. 3.6.2 CR pump control The CR pump control electronics is based on the Hartridge™ AE31 All Makes CR Pump Test box. The CR pump generates the high pressure in the Common Rail.
Page 27: Controls
CR pump motor stop – Press ‘O’ to stop the CR pump motor Figure 3.4 Controls HL038, Issue16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 28: Circuits
A129A712  Water circuit diagram – 1 sheet A129A713 HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 29 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 1, MOD STD ‘A-C’ HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
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Page 31 Electrical Circuit, sheet 1, MOD STD ‘D’ DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
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Page 33 Electrical Circuit, sheet 1, MOD STD ‘E’ DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 34 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 35 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 1, MOD STD ‘H’ HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 36 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 37 CRi-PC Operating and Servicing Manual Electrical Circuit, sh eet 1, MOD STD ‘K’ HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 38 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 39 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 2, HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 40 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 41 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 3, HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 42 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 43 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 4, MOD STD ‘A-C’ HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 44 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 45 DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP    HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 46 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 47 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 4, MOD STD ‘H’ ONWARD HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 48 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 49 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 5, HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 50 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 51 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 6, HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 52 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 53 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 7, MOD STD ‘A-D’ HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 54 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 55 Electrical Circuit, sheet 7, MOD STD ‘E’ DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 56 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 57 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 8, HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 58 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 59 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 9, HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 60 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 61 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 10, HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 62 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 63 Electrical Circuit, sheet 11, DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 64 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 65 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 12, MOD STD ‘A-E’ HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 66 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 67 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 12, MOD STD ‘H’ HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 68 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 69 CRi-PC Operating and Servicing Manual Electrical Circuit, sheet 13, MOD STD ‘K’ HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 70 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 71 DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP Hydraulic Circuit HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 72 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 73 CRi-PC Operating and Servicing Manual Hydraulic Circuit, MOD STD ‘H’ HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 74 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 75 DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP Pneumatic Circuit HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 76 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 77 CRi-PC Operating and Servicing Manual Pneumatic Circuit, MOD STD ‘H’ HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
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Page 79 DO NOT USE FOR MANUFACTURE WITHOUT AUTHORISING STAMP Water Circuit HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 80 CRi-PC Operating and Servicing Manual This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 81: Operation
Carry out a full delivery, backleak, and response time test on the injectors using the CR Injector Test Stand. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 82: Software Overview
Click the relevant on-screen key. Alternate menu Figure 4.1A Main Screen (Limits) HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 83 Figure 4.1B Main Screen (Inj1 - 4) Figure 4.1C Main Screen (Histogram) HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 84: Function Keys (Main Menu)
Refer to Figure 4.5 Displays the Owner Details Dialogue. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 85: Main Screen Areas
HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 86 A tripped Pump PCB or Injector PCB can be reset by clicking the appropriate Reset button on-screen. Figure 4.2 Testplan Editor Figure 4.3 Print HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 87 Figure 4.4 Status / Diagnostic Screen Figure 4.5 Owner Details HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 88: Red Status Indicator
When you first enter the CR Injector Test screen it will be mainly blank. You must load a testplan to start testing. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 89: Measure Injector Coil Resistance (If Selected In The 'Start Test' Dialog)
Resistance measurement is only valid for solenoid coil injectors, not for piezo injectors. NOTE HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 90 If the resistance measured is within acceptable limits disconnect the resistance cable from the injector and proceed as follows. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 91: Install Injector In The Clamping Fixture & Clamp
The guard door can be opened and the backleak pipe and the high pressure pipe from the rail to the injector connected. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 92: Start The Cr Pump
HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 93: Injector Removal
HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 94: Response Time
 lower delivery  higher backleakage flow HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 95: Creating/Editing/Saving Testplans
Scrolling horizontally to the right reveals the parameters that cannot be seen on the screen (column 6 onwards). HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 96 The number of metering updates.  The rail pressure demand (bar). HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 97 The maximum injector delivery variation. Figure 4.13 Example Parameters HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 98: Viewing And Printing Saved Results
Clicking the ‘Backleak ‘ button will display the screen shown in Figure 4.14D. This screen displays a histogram of the Backleak delivery. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 99 (Inj 1 - 4) Figure 4.14C Results Viewer (Injection Delivery & Backleak) HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 100 The type of printout can be selected, either a short summary report or a full report (refer to Figure 4.3). HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 101 CRi-PC Operating and Servicing Manual Figure 4.16 Production Setup Dialogue HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 102 CRi-PC Operating and Servicing Manual HARTRIDGE LIMITED This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 103: Calibration And Maintenance
CRi is regularly audited and certified by competent independent personnel. The safety and operational functions and the calibration accuracy of the transducers used for measurement on the Cri-PC should be checked at least every year or every 1500 hours in use whichever is sooner.
Page 104 HIGH PRESSURE INJECTION THROUGH THE SKIN WHICH CAN RESULT IN FATAL INJURY. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 105 The panel lifts off, leave screws ‘A’ in position as these will help to locate the panel when it is replaced. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 106: Regular Maintenance
7. Load an injector and start the CR pump motor. Note the common rail pressure. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 107: Check Pressure Dump Valve
HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 108: Metering Audit Tests
Then select the "AUDIT" condition to run audits 2, 3 and HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 109 HARTRIDGE LIMITED CRi-PC Operating and Servicing Manual Audit 1 - Mass Overcheck This audit is for the use of Hartridge personnel only and should not be accessed by the operator. Audit 2 – Piston leak check The Leak test detects leaks in the metering unit.. The test must be carried out with the machine at ambient temperature to help eliminate fluid cooling and contraction as a cause of errors.
Page 110 Metering Unit Filter blocked; see section 5.2.7 for instructions on replacing the filter  Braided pipes If the problem is not resolved by these actions contact Hartridge™ or your national distributor. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015...
Page 111: Backleak Audit With Magmah V9.01 Onwards (If Optional Backleak Measurement Unit Fitted)
‘max fill’ calibration values (step 4) measurement system leakage (step 5) If the audit indicates a problem in any of these areas, please contact Hartridge for further assistance. 1. Select F10 from the Alternate Menu to bring up the Backleak Audit dialog box.
Page 112 10. At the end of the audit, press [Save] to save the audit log file. This is useful to keep for your own records and may also be requested by Hartridge to assist in diagnosing problems. The default filename and location is: C:\CRiPC\Log\BackleakAudit_date_time.txt.
Page 113: Change Test Fluid & Filter, Clean Magnet Filter
(Figure 5.7). 7. Refit the magnet bracket. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 114 11. Disconnect the outlet pipe and connect it to the correct port on the new filter (O). HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 115: Change Metering Filter ( Hartridge Number 8850073)
Fit a new filter with open end towards the metering unit. Fit the‘O’ ring between the blanking plug (2) and the filter. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 116 Figure 5.10 Metering Filter Location Figure 5.11 Changing the Fuel Cap Metering Filter HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 117: Troubleshooting
4. Replace access covers, switch the test stand on and recheck. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 118: Computer / Monitor
10A fuses on the power socket strip below the computer (Figure 2.1 item 4). HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 119: Fault Indicators
(low level).  Check that the fluid circulation pump is HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 120 Table 5.2 Interlock Status Indicators HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 121: Injector Control
Try a different injector to establish if it is a test stand fault or a problem with one injector. Otherwise a fault within the injector control PCB may be suspected. If you suspect a problem with the injector control PCB, contact your local Hartridge™ distributor.
Page 122: Cr Pump Control
This is protected by a 6.3A anti-surge fuse (FS1) on the PCB (Figure 5.14). HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 123 CRi-PC Operating and Servicing Manual In the event of a problem, check this fuse first. For more complex problems contact your national Hartridge™ distributor. Please give as much information as possible on the conditions when the fault occurred, e.g. ...
Page 124 CRi-PC Operating and Servicing Manual HARTRIDGE LIMITED This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 125: Spares
6.3A A/S 20 x 5 Pump controller 350-8109 6.3A A/S 20 x 5 HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 126: General Spares
PC, configured 338-4137 Relay, backleak overflow threshold Mod Standard K+ HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 127 Fluid circulation pump A129C007 Pump assembly (Mod Std. A-G) HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 128 For ALL applications please refer to TB195/11 This can be viewed on:- www.hartridge.com/products/commonrail/commonrail.htm HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 129: Appendices
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. HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 130 CRi-PC Operating and Servicing Manual HARTRIDGE LIMITED This page intentionally left blank HL038 (EN), Issue 16, AT2829, 09/15 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 131 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.
Page 132 Tel: +44 (0)1280 825 600 Fax: +44 (0)1280 825 601 Email: support@hartridge.com www.hartridge.com © Hartridge Ltd., 2015 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Antonio Nunes on 30 Dec 2015 Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.

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