HL070 (En)

Common Rail Injector Tester
Operating and Servicing Manual
Original Instructions
HL070 (EN), Issue 2, 04/2017 AT3227

HARTRIDGE LTD Sabre CRi Master Operating and Servicing Manual
Hartridge Sabre CRi Master
HL070 (EN), Issue 2, 04/2017 AT3227 3

Sabre CRi Master Operating and Servicing Manual HARTRIDGE LTD
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4 HL070 (EN), Issue 2, 04/2017 AT3227

CONTENTS
FOREWORD..................................................................................................................................................................... 9
COPYRIGHT .................................................................................................................................................................... 9
WARRANTY STATEMENT ........................................................................................................................................... 9
DEFINITION OF TERMS AND ABBREVIATIONS ................................................................................................. 15
1. INTRODUCTION ................................................................................................................................................... 17
1.1 SPECIFICATION ................................................................................................................................................... 17
1.1.1 Injector Control Features.......................................................................................................................... 17
1.1.2 Physical ..................................................................................................................................................... 17
1.1.3 Injector Measurements .............................................................................................................................. 17
1.1.4 Test Control Parameters ........................................................................................................................... 17
1.1.5 Test Fluid System ...................................................................................................................................... 18
1.1.6 Machine Performance / Operating Envelopes .......................................................................................... 18
2. INSTALLATION .................................................................................................................................................... 23
2.1 SITE REQUIREMENTS.......................................................................................................................................... 23
2.2 SITING THE MACHINE ........................................................................................................................................ 24
2.3 LEVELLING THE MACHINE ................................................................................................................................. 25
2.4 ELECTRICAL CONNECTION ................................................................................................................................. 26
2.5 INITIAL MACHINE POWER-UP............................................................................................................................. 27
2.6 TABLET LANGUAGE CONFIGURATION................................................................................................................ 28
2.7 MAGMAH SOFTWARE CONFIGURATION – LICENCING ........................................................................................ 31
2.7.1 Product and Warranty Registration .......................................................................................................... 31
2.7.2 Licencing Activation – First Time Use ...................................................................................................... 32
2.7.3 Licencing Activation.................................................................................................................................. 33
2.7.4 Licencing Activation – Additional Features .............................................................................................. 38
2.8 MAGMAH USER INFORMATION DEFINITION ....................................................................................................... 39
2.9 TABLET KEYBOARD ........................................................................................................................................... 40
2.10 TEST FLUID ........................................................................................................................................................ 40
2.11 MACHINE SHUT DOWN ...................................................................................................................................... 44
3. MACHINE OVERVIEW ....................................................................................................................................... 47
3.1 MACHINE CONTROLS AND CONNECTIONS.......................................................................................................... 47
3.1.1 Controls and Connections – Front ............................................................................................................ 47
3.1.2 Controls and Connections – Rear ............................................................................................................. 47
3.1.3 Controls – Software................................................................................................................................... 48
4. OPERATION .......................................................................................................................................................... 49
4.1 PREPARATION FOR TEST .................................................................................................................................... 49
4.2 INJECTOR MOUNTING ........................................................................................................................................ 49
4.2.1 Mechanical Connection............................................................................................................................. 49
4.2.2 Hydraulic Connection ............................................................................................................................... 52
4.2.3 Electrical Connection ................................................................................................................................ 54
4.2.4 Visual Leak Check ..................................................................................................................................... 55
4.3 SOFTWARE OVERVIEW ....................................................................................................................................... 56
4.3.1 Welcome Animation................................................................................................................................... 56
4.3.2 Header and footer ..................................................................................................................................... 56
4.3.3 Common action and navigation icons/buttons .......................................................................................... 57
4.3.4 Icon colours............................................................................................................................................... 57
4.3.5 Injector selection screen ............................................................................................................................ 58
4.3.6 Test / Results screen .................................................................................................................................. 59
4.4 INJECTOR REMOVAL .......................................................................................................................................... 65
4.4.1 Electrical Disconnection ........................................................................................................................... 66
4.4.2 Hydraulic Disconnection........................................................................................................................... 66
4.4.3 Mechanical Disconnection ........................................................................................................................ 66
5. ADVANCED SOFTWARE FUNCTIONS ............................................................................................................ 69
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5.1 DIAGNOSTICS .................................................................................................................................................... 69

5.2 CREATING/EDITING A TESTPLAN ...................................................................................................................... 71
5.2.1 Create New Testplan ................................................................................................................................ 71
5.2.2 Adding % limits using a reference injector .............................................................................................. 72
5.2.3 Adding limits manually ............................................................................................................................. 76
5.2.4 Edit existing testplan ................................................................................................................................ 78
5.2.5 Delete a testplan ....................................................................................................................................... 78
6. MAINTENANCE ................................................................................................................................................... 79
6.1 CALIBRATION & AUDIT ..................................................................................................................................... 79
6.2 MOVING THE MACHINE FOR ACCESS.................................................................................................................. 79
6.3 REGULAR MAINTENANCE .................................................................................................................................. 80
6.3.1 Check guard door and pressure dump...................................................................................................... 80
6.3.2 Generally clean ........................................................................................................................................ 80
6.3.3 Change test fluid, filters ........................................................................................................................... 83
7. TROUBLESHOOTING ......................................................................................................................................... 85
7.1 DIAGNOSTIC SCREEN INTERLOCKS .................................................................................................................... 85
7.2 BASIC TROUBLESHOOTING GUIDE...................................................................................................................... 86
8. SPARES .................................................................................................................................................................. 89
8.1 CONSUMABLES.................................................................................................................................................. 89
8.1.1 Fuses......................................................................................................................................................... 89
8.1.2 Filters ....................................................................................................................................................... 89
8.2 GENERAL .......................................................................................................................................................... 89
8.2.1 General Spares ......................................................................................................................................... 89
8.2.2 Electrical .................................................................................................................................................. 90
8.2.3 Fluid system .............................................................................................................................................. 90
8.2.4 Metering systems ...................................................................................................................................... 90
8.2.5 Accessories supplied with the machine..................................................................................................... 91
8.2.6 Injector drive cables (All adaptor cables are additional options) ............................................................ 92
APPENDIX A: HEALTH AND SAFETY DATA SHEET ......................................................................................... 99
APPENDIX B: INTERPRETATION OF RESULTS ............................................................................................... 101
Response Time ........................................................................................................................................................ 101
Delivery .................................................................................................................................................................. 101
Backleakage ........................................................................................................................................................... 101
Summary ................................................................................................................................................................. 101
LIST OF FIGURES
Figure 1.1 Hydraulic Flow Operating Envelope ............................................................................................... 18
Figure 1.2 Operating Response Time Envelope ............................................................................................. 19
Figure 1.3 Fluid Cooling Performance ............................................................................................................. 20
Figure 1.4 Injected Delivery Repeatability ....................................................................................................... 21
Figure 1.5 Backleak Flow Repeatability .......................................................................................................... 22
Figure 2.1 Lifting the Machine ......................................................................................................................... 24
Figure 2.2 Transit Fittings ................................................................................................................................ 25
Figure 2.3 Electrical Connection ...................................................................................................................... 26
Figure 2.4 External step-up Transformer ......................................................................................................... 27
Figure 2.5 Power-up ........................................................................................................................................ 27
Figure 2.6 Sabre CRi Master Software Launch Icon ....................................................................................... 28
Figure 2.7 Windows 10 Desktop ...................................................................................................................... 28
Figure 2.8 Windows 10 Keyboard - English .................................................................................................... 28
Figure 2.9 Windows 10 Keyboard.................................................................................................................... 29
Figure 2.10 Windows 10 Language Configuration .......................................................................................... 29
Figure 2.11 Windows 10 Language Selection ................................................................................................. 30
Figure 2.12 Windows 10 Language Configuration .......................................................................................... 30
Figure 2.13 Windows 10 Keyboard.................................................................................................................. 31
Figure 2.14 Windows 10 Keyboard – Alternative Language ........................................................................... 31
Figure 2.15 Sabre CRi Master Software Launch Icons ................................................................................... 32
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Figure 2.16 No Licence Message .....................................................................................................................32

Figure 2.17 Feature License Status .................................................................................................................33
Figure 2.18 Choose Language .........................................................................................................................33
Figure 2.19 Licence Activation Screen .............................................................................................................34
Figure 2.20 Accept Terms & Conditions ...........................................................................................................34
Figure 2.21 Feature Activation User Code 1 & 2..............................................................................................35
Figure 2.22 Hartridge Software Portal – Home Page .......................................................................................35
Figure 2.23 Hartridge Software Portal – Activate Licence Page ......................................................................36
Figure 2.24 Hartridge Software Portal – Input Customer Information ..............................................................36
Figure 2.25 Hartridge Software Portal – Enter User Code 1 & 2 .....................................................................37
Figure 2.26 Hartridge Software Portal – Activation Code ................................................................................37
Figure 2.27 CRi Sabre Master - Input Activation Code ....................................................................................37
Figure 2.28 Select Diagnostics Screen ............................................................................................................38
Figure 2.29 Select Licence Manager Launch Icon ...........................................................................................38
Figure 2.30 Select Diagnostics Screen ............................................................................................................39
Figure 2.31 Select Owner Details .....................................................................................................................39
Figure 2.32 Workshop Owner’s Details ............................................................................................................40
Figure 2.33 Tablet Keyboard Activation ...........................................................................................................40
Figure 2.34 Filter and Drain Plug .....................................................................................................................41
Figure 2.35 Filling the Tank ..............................................................................................................................41
Figure 2.36 Tank Fluid Level Indicator .............................................................................................................42
Figure 2.37 Tank Drain Plug.............................................................................................................................43
Figure 2.38 Machine Shut Down ......................................................................................................................44
Figure 2.39 Depleted Tablet Battery ................................................................................................................45
Figure 3.1 Operator Controls ............................................................................................................................47
Figure 3.2 HDMI Connection ............................................................................................................................47
Figure 3.3 Circuit Breakers ...............................................................................................................................48
Figure 4.1 Nozzle Sealing Cap .........................................................................................................................49
Figure 4.2 Nozzle Sealing Cap Assembly ........................................................................................................50
Figure 4.3 Delivery Chamber Assembly ...........................................................................................................50
Figure 4.4 Injector Fitment................................................................................................................................51
Figure 4.5 Injector Mounting Fixture .................................................................................................................52
Figure 4.6 High Pressure Pipe Tightening .......................................................................................................53
Figure 4.7 Backleak Connection/s ....................................................................................................................53
Figure 4.8 Typical Injector Installation ..............................................................................................................54
Figure 4.9 Hydraulic Start Button .....................................................................................................................55
Figure 4.10 HP Visual Leak Points ...................................................................................................................55
Figure 4.11 Welcome Animation ......................................................................................................................56
Figure 4.12 Header and Footer ........................................................................................................................56
Figure 4.13 Injector Selection Screen ..............................................................................................................58
Figure 4.14 Injector Reference Number ...........................................................................................................58
Figure 4.15 Test Results Screen ......................................................................................................................59
Figure 4.16 End of Test ....................................................................................................................................63
Figure 4.17 Results Comment Text Box ..........................................................................................................64
Figure 4.18 Results Comment Text Box Keyboard Enter ................................................................................64
Figure 4.19 View Results Screen .....................................................................................................................65
Figure 4.20 Stop Button ....................................................................................................................................65
Figure 4.21 Disconnecting Electrical Cable ......................................................................................................66
Figure 4.22 Removing Hydraulic Connections .................................................................................................66
Figure 4.23 Removing Injector .........................................................................................................................67
Figure 4.24 Delivery & Backleak Bulkhead QR Disconnection ........................................................................67
Figure 5.1 Diagnostics Screen .........................................................................................................................70
Figure 5.2 Injector Selection Screen ................................................................................................................71
Figure 5.3 Testplan Name Dialog .....................................................................................................................72
Figure 5.4 Main Test Screen ............................................................................................................................73
Figure 5.5 Percentage Limits Dialog Box .........................................................................................................73
Figure 5.6 Feedback min/max limit ..................................................................................................................74
Figure 5.7 Testplan Save Screen .....................................................................................................................75
Figure 5.8 Overwrite option ..............................................................................................................................75
Figure 5.9 Feedback min/max limit ..................................................................................................................76
Figure 5.10 Exit edit mode................................................................................................................................77
Figure 5.11 Abort Test Screen .........................................................................................................................77
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Figure 5.12 Abort Warning Message ............................................................................................................... 77

Figure 5.13 Delete a Testplan ......................................................................................................................... 78
Figure 6.1 Rear Machine Feet - Static ............................................................................................................. 79
Figure 6.2 Rear Machine Feet - Rolling ........................................................................................................... 80
Figure 6.3 Machine Cleaning ........................................................................................................................... 82
Figure 6.4 Tank Drain ...................................................................................................................................... 83
Figure 6.5 Changing the Filters ....................................................................................................................... 84
Figure 8.1 Spares diagram 1 ........................................................................................................................... 93
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Foreword
Copyright
TM
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.
TM
© Hartridge Ltd.
Warranty Statement
The equipment is covered by the Hartridge™ Ltd standard Terms and Conditions of Sale or Supply. Section
7, 8 and 9 of these Terms and Conditions of Sale or Supply relate to guarantee. ‘The Company’ refers to
TM
Hartridge Limited. A complete copy of the Terms and Conditions of Sale or Supply is available on request.
Please note that all guarantees and warranties are limited to use of the equipment with software installed as
supplied and expressly exclude the correct operation of, or any interaction between the Machine software
and, any software and/or hardware supplied by a third party and installed on the Machine. Such software
and/or hardware shall be considered as an accessory as defined in Section 7c of the Terms and Conditions
of Sale or Supply and installation of third party software may be considered as misuse of the equipment as
defined in Section 9(a).
Similarly it is vital that the equipment is operated correctly and in accordance with the instructions and
messages displayed on the Host Machine. Failure to do so may be treated as misuse under section 9b (iii) of
the Terms and Conditions of Sale and Supply and particular attention must be paid to closing the Machine
down where it is vital the specified procedure is followed.
More specifically, the following are excluded from any express or implied warranties relating to the
equipment:
• Damage caused by poor mains supply quality.
• Damage to the touch screen caused by use of sharp, hard or improper implements.
• Damage to the touch screen caused by ingress of oil.
• Damage caused by incorrect injector cable selection.
• Damage caused by ingress of dirt particles from uncleaned injectors.
It is the Client’s responsibility to ensure that any third party accessories (e.g. keyboard, mouse, modem or
network card) installed on the Machine by the Client or at the Client’s request are compatible with the
equipment and will not detract from its correct operation.
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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 STAND WILL RELIEVE ANY HIGH
PRESSURE WHENEVER THE GUARD DOOR IS OPENED.
DO NOT ATTEMPT TO BYPASS THE SAFETY INTERLOCK.
WARNING!
HIGH MAGNETIC FIELDS MAY BE PRESENT. PACEMAKERS OR OTHER
SIMILAR IMPLANTED DEVICES MAY BE AFFECTED
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 motor
to stop and for the rail pressure to decay to a low level before opening the guard.
Do not attempt to open any machine covers while the system is running. Wait for
the test bench motor to stop and for the rail pressure to decay to a low level before
opening.
Safety glasses conforming to standard BS EN 166:1996 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.
Ear defenders or ear plugs must be worn by all personnel in the test area. Low
frequency noise may damage the inner ear and cause deafness.
NOISE HAZARD WARNING
Noise levels at the operator position, i.e. 1 metre from the central axis of the test
stand at a height of 1.6 metres from the floor with injectors running, are variable
dependent on the test conditions and type of injector.
Personnel at the operator position may be exposed to sound pressure levels in
excess of 80dB(A) in some operating conditions.
HL070 (EN), Issue 2, 04/2017 AT3227 11

General Warnings
Machine dry weight is 145kg (160kg wet weight). Care needs to be taken when
lifting the product.
Ensure the allocated work surface is capable of supporting the weight of the
machine.
Ensure good levels of lighting for safe, efficient equipment operation.
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.
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.
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 (during loading or unloading) or
test stand covers are dropped.
Burns will occur to the hands if certain parts of the test stand or equipment under
test are touched. Keep hands away from the interior of the calibration fluid tanks
and injector or high pressure pipes after periods of extended running.
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.
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.
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Arc welding equipment must not be operated within 5 metres of the test stand.
The electrical supply to welding equipment must be provided from a remote
isolating transformer. Arc welding can disturb the measuring circuit.
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.
High fluid pressures exist within the test stand. Do not run the test stand without
all cover panels fitted.
Fluid sprays, especially from leaking high pressure pipes and seals, will cause
high pressure injection through the skin which can result in fatal injury.
Use test 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.
Make sure there is adequate ventilation. Test fluid vapour may be released from
hot fixtures or high pressure leaks. The specific directions in Health & Safety Data
Sheets must be adhered to.
High Voltage!
Isolate and lock the electrical supply off before performing any maintenance
operations. Do not work on electrical equipment while voltage is supplied.
Be aware that there are two electrical mains supply connections to the machine.
Disconnect both before opening the electrical control enclosure panels.
Stored Voltage!
Wait at least 180 seconds after switching off the machine before removing any
panels to access the electrical control enclosure or working on the motor. The
motor controller must be allowed to fully discharge.
Use only clean, oil free implements, gloves or fingers on the touch screen. Ingress
of oil from improper use can lead to damage or failure of the screen.
At the end of its useful life, please ensure your Hartridge product(s) is disposed of
in accordance with national regulations.
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14 HL070 (EN), Issue 2, 04/2017 AT3227

Definition of Terms and Abbreviations

CR Common Rail
FCV Flow control valve
FERT Full Event Response Time
HDMI High definition multimedia interface
HP High pressure
I/P Input
IPM Injections per minute
LED Light emitting diode
O/P Output
PC / Tablet Compatible PC / Tablet
PCB Printed circuit board
PCV Pressure control valve
RS232 Serial communications
S/W Software
TIB Technical Information Bulletin
UUT Unit under test
VCV Volume control valve
V Volts
Vac Volts (alternating current)
A Amps
kg Kilogram
mm Millimetre
mH Millihenry
µF Microfarad
µs Microsecond
mL Millilitre
°C Degrees Celsius
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16 HL070 (EN), Issue 2, 04/2017 AT3227

1. Introduction
The Sabre CRi Master test machine is designed to enable comprehensive diagnostic of electronically
controlled injectors using pressures up to 1800 bar (180MPa). The machine is able to test a wide range
of injector applications, covering both solenoid and piezo, from various OE manufacturers.
Application tooling is available for testing specific injector types.
1.1 Specification
1.1.1 Injector Control Features
 Single channel injector drive circuit, suitable for a wide range of solenoid injectors and piezo
injectors.
 Drive Voltage 0-185V
 Drive Current (Solenoid) 0-23A
 Charge Current (Piezo) 0-25A
 Current Drive Profile Adjustable
1.1.2 Physical
 Dry weight 145kg
 Envelope dimensions W 610mm, D 610mm, H 1100mm
1.1.3 Injector Measurements

 Coil resistance 0 - 200 Ω
 Inductance (coil injectors only) 0 - 20 mH
 Capacitance (piezo injectors) 0 - 12 µF
 Response time measurement 0 - 999 µs (refer to section 1.1.6)
 Backleak flow measurement 0 - 290 mL/min (refer to section 1.1.6)

3
Delivery measurement 0 – 400 mm /str (refer to section 1.1.6)
 Backleak temperature 0 – 180°C
1.1.4 Test Control Parameters

 Rail Pressure 0* – 1800 bar
 Injection Speed 120 – 3000 ipm
 Pulse Width 0 – 4000 µS
 Time Delay 0 – 600 seconds
*0 bar actual pressure only when machine is at rest; when machine motor is running there will be a
minimum of at least 15bar present.
HL070 (EN), Issue 2, 04/2017 AT3227 17

1.1.5 Test Fluid System

 Fluid compatibility ISO4113
The Sabre CRi Master generates high pressure by using a vehicle CR pump which is
driven by a 1.5kW drive motor at 1500RPM. ISO4113 calibration fluid is specifically
designed as a substitute to EN590 Diesel to ensure enhanced lubricity and viscosity at
high pressure and temperatures.
It is extremely important that only ISO4113 calibration fluid is used with the Sabre CRi
Master otherwise the CR pump and associated hydraulic components durability and
performance could be affected.
 Tank capacity 10 litres

 Tank Filtration 2 μm (MANN WK712-2 or compatible)
 Metering unit filtration 60 μm
 Backleak filtration 60 μm
 High Pressure Flow 600 – 250 cc/min (refer to section 1.1.6)
 Fluid Cooling Air to Oil heat exchangers (refer to section 1.1.6)
1.1.6 Machine Performance / Operating Envelopes
1.1.6.1 High Pressure Flow

Refer to Figure 1.1
The Sabre CRi Master uses patented technology to control the CR Pump flow output based on the
available motor power using closed loop control, ensuring that maximum hydraulic flow is available
across the rail pressure operating range. The flow vs operating envelope, Figure 1.1, demonstrates the
available hydraulic flow available at different rail pressures.
Available Flow (cc/min)
Rail Pressure (bar)

Figure 1.1 Hydraulic Flow Operating Envelope
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When operating the machine without authorised Hartridge test plans, the Injection Speed, IPM, may
need to be reduced to ensure there is enough hydraulic flow available at high rail pressures. This
can be calculated by using the equation below:
Converted Injector Delivery (cc/min) = Injector Delivery (mm/str) x Injection Speed (ipm) / 1000
Total Flow (cc/min) = Converted Injector Delivery (cc/min) + Injector Backleak (mL/min)
The calculated Total Flow (cc/min) value can then be compared against Figure 1.1.
If the calculated Total Flow (cc/min) is outside the coloured area, i.e. above, then it is outside the
machines flow capability and the injections per min (ipm) should be reduced accordingly.
1.1.6.2 Response Time

Refer to Figure 1.2
The Sabre CRi Master utilises a piezo (knock) sensor to measure the injector response time which is
a fundamental characteristic of electronically controlled injectors to ensure correct injection timing.
The piezo (knock) sensor is positioned below the nozzle assembly to measure the full event
response timing, FERT, from the start of the electrical pulse to the exact time of injection from the
injector nozzle.
The Sabre CRi Master has the following response time characteristics based on rail pressure and
injector delivery.
Response Time Repeatability (uS)
Injected Delivery (mm/str)
Figure 1.2 Operating Response Time Envelope
Referring to Figure 1.2

If the injector being tested has the following characteristics: Injected Delivery <5 mm/str (and/or) Rail
Pressure <400 bar then the repeatability of the response time measurement cannot be guaranteed and
in most cases the Sabre CRi Master will return a “0” value.
If the injector being tested has the following characteristics: Injected Delivery =10 mm/str (and) Rail
Pressure =1200 bar then the expected repeatability of the response time measurement will be +/-6uS.
HL070 (EN), Issue 2, 04/2017 AT3227 19

If the injector being tested has the following characteristics: Injected Delivery =300 mm/str (and) Rail
Pressure =1600bar then the expected repeatability of the response time measurement will be +/- 3uS.
Note: The response time repeatability is dependent upon the condition of the injector being
diagnosed and it is normal to expect a small drift in response time as the injector temperature
increases.
1.1.6.3 Fluid Cooling Performance

Refer to Figure 1.3
The Sabre CRi Master is fitted with an air to oil heat exchanger assembly to regulate the hydraulic
temperature of the machine. There are 3 heat exchange paths within this assembly which regulate the
following hydraulic circuits:
 Injected Delivery
 Injector Backleak Flow
 Rail Pressure Control Valve
This enables the machine to operate at high duty cycles for extended periods of time without overheating
and requiring a rest period between injector tests.
For reference, Figure 1.3 demonstrates the fluid cooling performance with and without the air to oil heat
exchanger.
Hydraulic Temperature (°C)
Time (Minutes)
Figure 1.3 Fluid Cooling Performance
The machine was operated at 1800bar with a high flow injector producing between 230-235mm3/str.
Tests performed with an ambient temperature of 28°C. It was operated at this condition continuously
until the machines fluid temperature safety limit was reached (70°C).
Without Air to Oil Heat Exchanger = 12 minutes
With Air to Oil Heat Exchanger = 28 minutes
Using authorised Hartridge test plans the machine will operate throughout a 10 hour day
continuously without the requirement for a cooling period.
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1.1.6.4 Injected Delivery Repeatability
Refer to Figure 1.4

The Sabre CRi Master uses a high precision metering unit to measure injected delivery. The
expected delivery repeatability is dependent upon the quantity of fuel being delivered by the injector;
this is shown in Figure 1.4
.
Injected Delivery Repeatability (mm/str)
Injected Delivery (mm/str)
Figure 1.4 Injected Delivery Repeatability
The nozzle delivery tolerance map shows the nozzle delivery flow tolerances which can be expected
from the machine. The tolerances are shown as mm/str at several delivery flows rates, with all areas
outside the red band being deemed as achievable limits. A tolerance within the red band would not be
expected from the machine.
For example, a tolerance of +/- 0.1mm3/str at a nozzle delivery of 5mm3/str would not be achievable,
the expected tolerance at this flow rate would be +/-0.25mm3/str.
Note: The injected delivery repeatability is dependent upon the condition of the injector being
tested and it is normal to expect a small drift in delivery as the injector temperature increases.
HL070 (EN), Issue 2, 04/2017 AT3227 21

1.1.6.5 Backleak Flow Repeatability
Refer to Figure 1.5

The backleak flow tolerance map highlights the tolerances which can be expected from the machine
with regards to injector backleak/spill flow measurement unit. Backleak flow is measured in mL/min,
with the data being plotted over a range of 4-290 mL/min.
For example, with a backleak (return) flow of 10mL/min, a tolerance of +/- 1.75mL/min could be
expected.
Note: The injector backleak repeatability is dependent upon the condition of the injector being
tested and it is normal to expect a small drift in backleak as the injector temperature increases.
Backleak Flow Repeatability (mL/min)
Backleak Flow (mL/min)
Figure 1.5 Backleak Flow Repeatability
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2. Installation
2.1 Site Requirements
 Allow a minimum of 0.5 metres around the front, rear and right hand side of the test stand for
access and the motor air inlet vents. There must be adequate space to allow removal of the
mains electrical supply sockets on the rear of the machine.
 Allow adequate space above the machine to allow escape of heat and maximum efficiency of
the test fluid cooling system
 The site/bench-top must be clean, level and capable of supporting the fully loaded test stand
weight (160kg).
 The site should be well ventilated to dissipate heat and test oil vapour.
 Electrical Supply according to machine variant (high or low voltage); refer to machine serial plate
and section 2.4. Two supplies are required for the machine; in 100-120V countries the total
current may be higher than 15 Amps. Therefore, each of the two plugs must have their own
mains wall socket and not run off the same socket as another piece of equipment.
o Supply 1 (IEC C14 – Machine Controls):
Single Phase 100-120Vac or 200-240Vac, 50/60Hz, supply to be capable of 10 Amps.
In low voltage supply countries the voltage must be between 100 – 120V
In high voltage supply countries the voltage must be between 200 – 240V
or
o Supply 2 (IEC C20 – Motor Control):
Single Phase 200-240Vac, 50/60Hz.
Supply to be capable of 10 Amps in 200-240V countries.
In 100-120V countries this supply to be via an external step-up transformer, provided by
Hartridge. 100-120V supply to be capable of 15 Amps.
DANGER!
This machine is only suitable for use on single phase TT or TN-S supplies
which include an earth connection point.
Definitions:-
 TT systems (Earthed)
In a TT system, the protective earth connection of the consumer is provided
by a local connection to earth, independent of any earth connection provided
by the electricity generator. This type of system is suitable for the Sabre
CRi Master machine.
 TN−S systems (Earthed)
In a TN-S system, the PE (protective earth) and N (neutral) are separate
conductors that are connected together only near the power source (building
distribution point or local electricity generating transformer). This type of
system is suitable for the Sabre CRi Master machine.
 IT systems (Non-Earthed)
In an IT system the electrical distribution system has no connection to earth at
all, or it has only a high impedance connection. This type of system is not
suitable for the Sabre CRi Master machine.
HL070 (EN), Issue 2, 04/2017 AT3227 23

2.2 Siting the Machine

Refer to Figure 2.1
1. Remove the Sabre CRi Master from its packaging and position it on a suitable work bench,
using the lifting eyes supplied on top of the machine (A). This will require the use of an
engine hoist, capable of lifting the machine’s weight to a minimum clearance height of 1
meter beneath the machine. A minimum space of 0.5 metres must be left around the
machine.
Figure 2.1 Lifting the Machine
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Refer to Figure 2.2

2. Remove the transit fittings A258D170 (A). There is one transit fitting on each side of the
machine and can be removed using a 17mm spanner.
A A
Figure 2.2 Transit Fittings
2.3 Levelling the Machine

The machine must be levelled in both horizontal planes and stable, with weight evenly distributed on
the four feet before use.
1. Place a spirit level on the top of the test stand.
2. If the machine is not level adjust the levelling feet as required to achieve support on all four
feet.
The rear feet contain bearings to enable the machine to be rotated for servicing, refer to
section 6.2.
Care must be taken when levelling the machine to ensure the rear roller bearings are not
exposed during normal operation.
HL070 (EN), Issue 2, 04/2017 AT3227 25

2.4 Electrical Connection

WARNING
The electrical supplies must be in accordance with the specifications in section
Error! Reference source not found. of this document.
Do not attempt to connect a 100-120V voltage to a 200-240V machine or a
200-240V voltage to a 100-120V machine.
WARNING
The two electrical supply cables must each have their own mains wall socket and
must not run off the same socket as another piece of equipment.
Refer to Figure 2.3 and Figure 2.4

1. Ensure the machine isolator switch is set to the OFF (O) position.
2. Connect the two mains power cables. Each of the two cables must have their own mains
wall socket and not run off the same socket as another piece of equipment.
3. In low voltage countries (100-120V) a step-up transformer must be used to supply the 200-
240V the machine requires for the IEC C19/20 connection. This will be included in the
machine kit. Refer to Figure 2.4 for this connection.
4. Secure the C13 connector using the retaining clip (A) and the C19 connector using the
screwed clamp (B).
A
B
IEC C13/14
100-120V IEC C19/20
(Low voltage 200-240V
countries)
(Low and High
200-240V voltage countries)
(High voltage
countries)
Figure 2.3 Electrical Connection
Ensure the power cables are retained using the clip and clamp provided.
Ensure the power cables are routed safely between the machine and the power source
to avoid a tripping hazard.
26 HL070 (EN), Issue 2, 04/2017 AT3227

100-120V
TO IEC
C19
Figure 2.4 External step-up Transformer
2.5 Initial Machine Power-up
WARNING
If the machine power is switched from ON to OFF, wait at least 20 seconds before
switching ON again.
Refer to Figure 2.5

1. Apply power to the machine by switching ON the isolator switch at the front panel (A).
2. Turn on the PC / Tablet by pressing on the rocker switch (B). The ‘linx’ logo should appear after a
few seconds(C).
A Figure 2.5 Power-up C
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3. Once the PC / TABLET has loaded Windows 10, the Hartridge ‘Magmah’ software will start
automatically.
Note: If the Magmah software fails to start automatically, click the Hartridge icon within the Windows taskbar.
Figure 2.6 Sabre CRi Master Software Launch Icon
2.6 Tablet Language Configuration

The Sabre CRi Master is powered by Windows 10 and therefore has the ability to manage local
language support. The language configuration of the tablet can be changed as defined below:
1. Press the keyboard icon (bottom right on the taskbar)
Figure 2.7 Windows 10 Desktop
2. Once the keyboard is displayed, press the keyboard icon (bottom right within the keyboard).
Note: As default this will be configured to English.
Figure 2.8 Windows 10 Keyboard - English
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3. Press “Language Preferences”
Figure 2.9 Windows 10 Keyboard
4. On the background screen select the “Languages” section and press the ADD icon to “Add a
Language”
Figure 2.10 Windows 10 Language Configuration
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5. Select a language from the main language selection screen. Once loaded, this will be displayed
within the “Languages” screen.
Figure 2.11 Windows 10 Language Selection
6. Press the keyboard icon (bottom right on the taskbar).
Figure 2.12 Windows 10 Language Configuration
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7. Once the keyboard is displayed, press the keyboard icon (bottom right within the keyboard).
8. Select the loaded language from step 6.
Figure 2.13 Windows 10 Keyboard
The keyboard will now update and display the local regional settings.
Figure 2.14 Windows 10 Keyboard – Alternative Language
2.7 Magmah Software Configuration – Licencing

2.7.1 Product and Warranty Registration
The Sabre CRi Master is automatically registered as soon as you activate the Magmah software
using the step by step process detailed in section 2.7.2.
Once you have registered your product, the 12 month Hartridge Warranty, as outlined in Warranty
Statement, will also be activated. Please be sure to supply us with a valid email address as we may
use this to send you confirmation of your warranty activation and its initial expiry date. We may also
use it to remind you when your optional annual maintenance licence is due to expire. This is free of
charge for the first 12 months following software activation. This enables you to have full access to
the latest test plan updates and any Magmah software revisions and updates that are released. After
12 months Hartridge may charge for this service and so in order to continue receiving the latest
testplans and software updates the maintenance licence will need to be renewed. If this service
continues to be free of charge, then your licence will be automatically renewed and we may inform
you of this by email, using the email address you supply.
You can notify us of any change to your email address at any time by contacting Hartridge customer
support.
HL070 (EN), Issue 2, 04/2017 AT3227 31

2.7.2 Licencing Activation – First Time Use

The Magmah Sabre CRi Master software contains a dedicated licencing module which activates and
deactivates various features and options. Before the machine can be used the software must be
licenced to activate the base level functionality by following the guide below:
1. Launch the Sabre CRi Master software from the Windows taskbar or desktop by pressing the icons
highlighted below:
Figure 2.15 Sabre CRi Master Software Launch Icons
2. If the Sabre CRi Master software is not licenced the following message will be displayed, click the
tick icon to continue and proceed to section 2.7.3.
Note: If this message is not displayed then it indicates that the Sabre CRi Master software is licenced,
proceed to section 2.7.4.
Figure 2.16 No Licence Message

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2.7.3 Licencing Activation

The licence screen will be displayed showing the available licences which are available to activate.
Figure 2.17 Feature License Status
3. If required, select an alternative display language by pressing the “Choose Language” button and
then selecting the required language from the language dropdown menu.
Figure 2.18 Choose Language
4. Press “Activate” next to the selected feature licence text, as shown below:
HL070 (EN), Issue 2, 04/2017 AT3227 33

Figure 2.19 Licence Activation Screen
5. A dialog box will appear which defines the terms and conditions of the licence being activated. Read
the text included and continue by pressing “Accept”.
Note: if “Decline” is selected then the message box will close and return to the main licence menu
screen.
Figure 2.20 Accept Terms & Conditions
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6. A dialog box will appear showing user code 1 and user code 2.
Figure 2.21 Feature Activation User Code 1 & 2
7. Using an internet connected PC / Tablet go to the following website address:

https://sw.Hartridge.com/
Select the icon highlighted below to enter the portal.
Figure 2.22 Hartridge Software Portal – Home Page
8. The following webpage is displayed. The Sabre CRi Master test bench is supplied with a paper
licence document which contains a LicenceID and Password which is unique. Enter these details
below:
Note: If you have misplaced or cannot find the licence document then contact Hartridge customer
support for further guidance.
HL070 (EN), Issue 2, 04/2017 AT3227 35

Figure 2.23 Hartridge Software Portal – Activate Licence Page
9. The following webpage will be displayed which displays the licence information. To complete this
step the customer information is required to proceed.
Note: The fields highlighted with a red asterisk are mandatory and must be completed correctly; this
data will be used for warranty validation and product support.
Note: The following fields are not required for the Sabre CRi Master, leave these blank.
o PC Type
o PC Service Tag
o Software Version
10. Once all data is entered select “Next >>”
Figure 2.24 Hartridge Software Portal – Input Customer Information
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11. The following webpage is displayed. The final stage of activation is to define User code 1 and user
code 2 which have been generated by the Sabre CRi Master licence module. Type these codes into
the cells within the web page and then select “Next >>”.
Figure 2.25 Hartridge Software Portal – Enter User Code 1 & 2
12. The webpage will display a Licence Schedule which defines activation codes which must be entered
into the licence manager software on the Sabre CRi Master.
Figure 2.26 Hartridge Software Portal – Activation Code
13. Once the activation code is entered, press “Activate” then select “Close” on the licence manager
software.
The licence manager will return to the main licencing screen and if licencing was successful the
indicator will display GREEN.
Note: If any errors occur during licencing then contact Hartridge customer support.
To activate other licences and associated features, repeat steps 5 – 14.
Figure 2.27 CRi Sabre Master - Input Activation Code

HL070 (EN), Issue 2, 04/2017 AT3227 37
2.7.4 Licencing Activation – Additional Features

If the Magmah Sabre CRi Master software is already licenced then it is possible to activate additional
features licences at a later date by following the guide below:
1. Start the Sabre CRi Master software.
2. Select the Diagnostics screen (A).
Figure 2.28 Select Diagnostics Screen
3. Select the licence launch icon (B) to launch the licence manager application.
Figure 2.29 Select Licence Manager Launch Icon
4. Refer to section 2.7.3 to continue licencing additional features.
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2.8 Magmah User Information Definition

Upon start up, enter the workshops details in the Owner’s details screen. This can be found as
follows:-
1. Select the Diagnostics screen (A).
Figure 2.30 Select Diagnostics Screen
2. Select the Owner Details screen (B).
Figure 2.31 Select Owner Details
3. Enter Owner details.

Select the relevant text box to enable a pop-up keyboard. If the pop-up keyboard does not
appear, refer to section 2.9.
Once all the details have been entered, press the ‘Save’ Button on the screen to store the
information (C).
4. If required, the screen language can also be changed via the drop down box (D).
HL070 (EN), Issue 2, 04/2017 AT3227 39

Figure 2.32 Workshop Owner’s Details
2.9 Tablet Keyboard

Refer to Figure 2.33
In order to activate the Windows 10 built-in keyboard, the keyboard icon in the windows toolbar must
be selected. This can be found in the bottom right hand side of the tablet screen. Once pressed, the
built in windows keyboard will appear.
Figure 2.33 Tablet Keyboard Activation
2.10 Test Fluid

The test fluid tank should be filled with CLEAN ISO 4113 calibration test fluid.
The Sabre CRi Master generates high pressure by using a vehicle CR pump which is
driven by a 1.5kW drive motor at 1500RPM. ISO4113 calibration fluid is specifically
designed as a substitute to EN590 Diesel to ensure enhanced lubricity and viscosity at
high pressure and temperatures.
It is extremely important that only ISO4113 calibration fluid is used with the Sabre CRi
Master otherwise the CR pump and associated hydraulic components durability and
performance could be affected.
NOTE: When the machine fluid system is powered on the fluid level will drop as the system
components fill with fluid. Top up the fluid level as necessary.
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Ensure the fuel filter is fitted securely (A) and the fuel drain plug is fitted correctly (B).
Figure 2.34 Filter and Drain Plug

Fill the fluid tank with 9.5 litres of ISO4113 specification test fluid. This can be done using either the
front filling point (C) or the rear filling point (D)
Figure 2.35 Filling the Tank
HL070 (EN), Issue 2, 04/2017 AT3227 41

Ensure the filling point is clear of debris before filling the tank. Otherwise the debris can be flushed
down into the tank or block the filling point.
Caution must be taken to ensure the filling point is not overfilled leading to a leak.
Caution must be taken to not overfill the test fluid tank (>10 litres) as this will cause a
leak from each side of the machine.

The fluid level indicator on the Diagnostics screen should be monitored during filling of the fluid tank.
The fuel level gauge should display approx. 9.5L and be green in colour.
If the fuel tank level is displaying “0”, then do not continue to fill the machine with test
fluid. Review the trouble shooting guide in section 7 or contact Hartridge customer
support for guidance.
Figure 2.36 Tank Fluid Level Indicator
If the fuel level is red then this indicates that the fuel tank has been overfilled, drain a small quantity
of fuel from the tank by doing the following:
Remove the tank drain plug (A) and the yellow drain pipe from under the front right corner of the
machine.
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Figure 2.37 Tank Drain Plug
 Drain the test fluid into a suitable container until the fuel level is green.
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2.11 Machine Shut Down

To shut down the machine, proceed as follows:-
1. Press the software ON/OFF button in the top right corner of the screen.
2. When the ‘Close Application’ window appears, select the icon to confirm.
3. Press the windows Icon in the bottom left of the screen, press Power and then select shut
down (A).
4. Switch OFF the front panel isolator (B)
Figure 2.38 Machine Shut Down
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If the PC / tablet is not shut down, and the IEC C13/14 power source is disconnected,
then the PC / tablet will continue to operate using its battery. If the battery depletes then
upon restart it can take 5-10 minutes for the tablet battery to recharge before the system
can be started.
It is recommended that whenever the machine is switched off and the IEC C13/14 power
source is disconnected that the tablet is always shut down.
Figure 2.39 Depleted Tablet Battery
HL070 (EN), Issue 2, 04/2017 AT3227 45

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3. Machine Overview
3.1 Machine Controls and Connections
3.1.1 Controls and Connections – Front
Refer to Figure 3.1
1. Main isolator switch (A) – Operating the switch OFF will cut all power to the machine
controls. The PC / tablet will remain powered. This switch should only be operated OFF
when the user has finished using the machine. It may also be used for emergency situations.
2. Fluid system start (B) – press green hydraulic START button to start the fluid system pump
and the high pressure pump, after the initial starting sequence the pressurising system is
enabled. The motor will not start if the fluid levels are outside limits or the injector access
guard is open.
3. Fluid system stop (C) – Press red hydraulic STOP button to stop the fluid system and high
pressure pump. If there is an issue with the machine (i.e. a leak etc.), then the red button
must be used in order to remove power from the motor and the fluid system pump.
4. PC / Tablet ON/OFF (D) – Press to switch on the PC / tablet display
5. USB ports (E) - Can be used to connect external devices such as a keyboard, mouse,
printer or memory devices for transferring data.
D
A B
Figure 3.1 Operator Controls
3.1.2 Controls and Connections – Rear

Refer to Figure 3.2 and Figure 3.3.
1. HDMI Port (F): The PC / Tablet has the capability to output the display to a remote monitor
using the HDMI port at the rear of the machine.
Figure 3.2 HDMI Connection
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Figure 3.3 Circuit Breakers
2. Circuit Breakers (G): (Rating will depend on machine voltage variant). Centre of breaker will
pop out when breaker has tripped; push back in to reset.
3.1.3 Controls – Software

A touchscreen provides the main operator interface with the test stand. All operator controlled
functions of the test stand (other than motor Start/Stop) are accessed by soft keys on the
touchscreen. The touchscreen keys can be operated by finger or glove. Information which needs to
be typed into the screen is entered via an on-screen keyboard.
The software control and interface is defined in section 4.3.
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4. Operation
This section defines how to operate the Sabre CRi master machine on a day to day basis.
4.1 Preparation for Test

It is thoroughly recommended to clean the injector in an ultrasonic device
before installing on the Sabre CRi Master. Failure to do this may shorten the
service life of the machine and lead to component failures which may not be
covered by machine warranty.
4.2 Injector Mounting

4.2.1 Mechanical Connection
Refer to Figure 4.1

There are 2 different nozzle sealing cap options; one suits a nozzle diameter of 7mm and the other
9mm (NTA7200 and NTA7201 respectively).
Figure 4.1 Nozzle Sealing Cap

The correct sealing cap must be installed into the injector clamp base block prior to installing an injector.
To do this, firstly select the appropriate nozzle sealing cap by referring to the application datasheet, TIB
243, contained on the USB memory stick or alternatively refer to the printed version which is provided
with the machine.
Note: Application datasheet, TIB243, will be updated on a regular basis with new application
information. It is important to ensure that the correct contact email address has been provided during
machine / product licencing so Hartridge can communicate directly via. email when updates are
available. Updates to TIB243 will be available to download from the Hartridge support website.
Refer to Figure 4.2, Figure 4.3, Figure 4.4, Figure 4.5
Note: Before fitment ensure both sealing O-rings on the sealing cap are in a good working condition.
1. Slide the nozzle sealing cap (Figure 4.2A) into the tooling fixturing using the slots on the
horizontal clamping plate.
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Figure 4.2 Nozzle Sealing Cap Assembly
2. Install the delivery chamber onto the sealing cap assembly:

a. Locate the delivery chamber assembly so the locating pins are engaged within the
sealing cap locating grooves. (Figure 4.3B)
b. Rotate the delivery chamber clockwise using the control arm. (Figure 4.3C)
c. The locating pins will follow the profile of the locating grooves to locate and seal the
chamber.
Figure 4.3 Delivery Chamber Assembly
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3. Insert the injector under test into the clamp, ensuring that the injector body is concentric with the
nozzle sealing cap. Refer to Figure 4.4.
4. Push the injector fully into the nozzle sealing cap.
Figure 4.4 Injector Fitment
The Injector Clamp is adjustable horizontally to fit injectors with a body diameter of between 10-
49mm.
HL070 (EN), Issue 2, 04/2017 AT3227 51

The height block (Figure 4.5D) and clamping plate (Figure 4.5E) can be moved from left or right to
ensure that the injector is concentric with the nozzle sealing cap.
Figure 4.5 Injector Mounting Fixture

NOTE:- If the injector body is not concentric it could cause the injector to push upwards and
break the O’ring seal during testing.
5. Lock the injector in place via the threaded bar (Figure 4.5F).
6. Connect the delivery pipe into the delivery quick release fitting (Figure 4.5G).
4.2.2 Hydraulic Connection
Refer to Figure 4.6

1. Install the correct high pressure (HP) pipe (Figure 4.6H) to suit the thread on the injector’s high
pressure port (M12 or M14).
2. Tighten both ends of the HP pipe to 35Nm. A spanner may be required to hold the injector
steady whilst torqueing the pipe (this will vary between injector types).
52 HL070 (EN), Issue 2, 04/2017 AT3227

35Nm
Figure 4.6 High Pressure Pipe Tightening
Refer to Figure 4.7

3. Connect the backleak hose to the injector. One end clips directly into the quick release
bulkhead fitting (K) on the rear of the chamber and the other end onto the injector’s back leak
port (J).
4. An additional adaptor may be required to fit onto the injector’s backleak port. For further
information, please refer to the injector specific technical information bulletin (TIB).
Figure 4.7 Backleak Connection/s
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4.2.3 Electrical Connection

Refer to Figure 4.8
1. Connect the electrical cable to suit the injector type and model. The electrical cable is made up
of two parts, the base cable (M) and the injector adaptor cable (L). There are two types of
base cables, one for coil injectors and one for piezo injectors. A range of adaptor cables is
available, to accommodate injectors from different manufacturers.
The correct cable assembly must be used otherwise the injector will not work.
This may also lead to irreversible damage to the injector and/or the machine,
which will not be covered by the machine warranty.
Figure 4.8 Typical Injector Installation
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4.2.4 Visual Leak Check

Once the injector is fitted into the machine it is recommended to perform a visual leak check to
ensure the HP connections have been corrected assembled. This can be performed as defined
below:
1. Close the front door and engage the lock.
2. Press the green hydraulic START button on the front panel. (Figure 4.9)
Figure 4.9 Hydraulic Start Button
3. Visually check for leaks around the HP hose connection points. (Figure 4.10)
Figure 4.10 HP Visual Leak Points
Note: This check is performed at low pressure / maximum flow conditions, it is recommended to
perform the same check at high pressure conditions during injector testing.
HL070 (EN), Issue 2, 04/2017 AT3227 55

4.3 Software overview

The majority of operator interface with the test machine is via the touchscreen. Information is
presented with associated graphics and screen navigation is via on-screen icons/buttons. The
various operator interface screens share some common elements.
4.3.1 Welcome Animation

On initial power up of the software, a welcome animation will appear. To clear this, double tap
anywhere on the screen and this will take you to the main injector selection screen.
Figure 4.11 Welcome Animation
4.3.2 Header and footer

The header contains the name of the screen and an icon/ button indicating the machine/comms
status. A red icon indicates an error, touch the icon to access the Diagnostics Screen.
The top area of the footer contains a fixed area of round icons/buttons which control the actions
required for the various screens.
Figure 4.12 Header and Footer
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4.3.3 Common action and navigation icons/buttons
Return to previous screen Got to next screen
Print New testplan
Delete testplan View results PDF
Start test Automatic test
Pause test Manual test
Edit/create reference testplan Stop test
Yes/accept Save changes
No/delete OK proceed
Backleak flow Tank fluid level
Calibrate Rail pressure
Comms settings Clear machine errors
End of test and auto save results Home (Injector select screen)
Reset service hours
4.3.4 Icon colours

The colours of icons on screen indicate the status of that function
Function available Function selected Function disabled
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4.3.5 Injector selection screen

Select the injector manufacturer/type and the testplan to be used via the relevant drop down boxes.
The injector reference number should also be entered. To do this, press on the empty box next to
reference number (A), the tablet keyboard will appear. Enter the desired text and press ‘X’ to
remove the keyboard (B).
Create/edit testplan (5.2) View results (4.3.6.6)
Figure 4.13 Injector Selection Screen
Figure 4.14 Injector Reference Number
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Automatic or manual mode can now be selected. The selected mode will be highlighted, once
selected, select the next arrow (C) which will navigate to the main test screen.
4.3.6 Test / Results screen

If running in automatic mode, once the start test icon is selected, the testplan will run through all the
test steps (from top down) without any intervention. If at any point the testplan needs to be stopped,
the stop icon can be selected.
If running in manual mode, the test steps can be ran in any order or a single test step can be run.
Refer to Figure 4.15.

The main operating screen is split into sections.
Test step settings (4.3.6.1) Acquired values (4.3.6.3) Diagnostics (5.1)
Stored values Acquired flow values View results

Test steps (4.3.6.2) (4.3.6.5) (4.3.6.4) (4.3.6.6)
Figure 4.15 Test Results Screen
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4.3.6.1 Test step settings

This area indicates the test step settings as entered into the testplan.
Pressure demand Pulse width

0 - 1800 bar 0/150 – 4000 µs
Injection speed Test step duration

120 – 3000 ipm 0 – 600 secs
4.3.6.2 Test steps

A typical test plan sequence is shown below. The test step buttons are in a column at the left of the
test results screen:-
Resistance/Inductance/Capacitance
The first test of any test plan, to determine the
condition of the injector electrical actuator.
Sets the injector demands at typical full load

settings.
Sets the injector demands at typical mid load

settings.
Sets the injector demands for ‘pre injection’

conditions, high pressure but very low delivery.
Sets the injector demands at typical idle speed

settings.
Sets high pressure and switches the injector

actuator off to measure the inherent backleak
through the injector.
Refer to
Indicates the various elements of a testplan, the colour of the element show the status of the test.
Test step passed
Test step failed
Test step selected
Test step to be done
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4.3.6.3 Acquired values

The following data will be acquired for each test step. The acquired data will be tested against pre-
defined limits and a pass/fail flag set. The colour of the acquired value will be red if outside limits and
green if inside limits.
Upper pass limit
Resistance (Ω)
Pass Fail
Lower pass limit
Rail pressure (bar)
Response time (µs)
Inductance (mH)
Capacitance (µF)
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4.3.6.4 Metered flow values

Metered values of injector flow quantity/temperature and backleak flow/temperature.
Injected flow Injection temperature

quantity bar graph (after cooling)
Backleak flow Backleak temperature

quantity bar graph (pre cooling)
4.3.6.5 Test step stored values

The stored flow values for previous steps of the present testplan are displayed here
Test step Injected quantity Backleak flow Test step value
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4.3.6.6 End of test

After a test has finished, the green finish flag will appear.
Figure 4.16 End of Test
Refer to Figure 4.17, Figure 4.18

Once the finish icon is selected, a text box will appear in the middle of the screen which will enable
comments to be added to the test results. For instance, if the test has failed due to an external leak
between the injector body and capnut this comment can be added to the printed report.
The tablet keyboard will appear once this has been selected. Once the desired comment text has
been entered, the enter button on the keyboard must be selected.
Note: If you do not wish to enter a comment just simply select the enter button on the keyboard.
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Figure 4.17 Results Comment Text Box
Figure 4.18 Results Comment Text Box Keyboard Enter
The software will navigate to the results page.

4.3.6.7 View results
Historical test results can be viewed in .PDF format. The form can be printed to a USB, WIFI or
Bluetooth attached printer or saved to a USB stick for printing/viewing away from the machine.
The results filename consists of the testplan name/Injector part number followed by the year, month,
day, hour, minute and second that the file was saved.
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The latest test will always be loaded into the results viewer automatically; however any results can
be viewed by using the drop down selection box (A).
Figure 4.19 View Results Screen
4.4 Injector Removal

After the injector has been tested the injector should be removed as follows:
1. Press the red hydraulic STOP button on the front panel (A)
Figure 4.20 Stop Button
Note: Wait 5 seconds to allow the drive motor to fully stop before proceeding to the next step.
2. Open the front door.
The injector enclosure and injector itself may be hot and therefore it is
mandatory to wear protective gloves when removing the injector after testing.
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4.4.1 Electrical Disconnection

1. Disconnect the electrical connection from the injector.
Figure 4.21 Disconnecting Electrical Cable
4.4.2 Hydraulic Disconnection

1. Disconnect the HP hose from the injector.
2. Disconnect the backleak hose / connection from the injector.
Figure 4.22 Removing Hydraulic Connections
4.4.3 Mechanical Disconnection

1. Release the threaded bar to unclamp the injector.
2. Pull the injector upwards from the Nozzle Sealing Cap.
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3. Remove the injector from the spray chamber area.
Figure 4.23 Removing Injector
Note: It is recommended that if the machine is not being used for 30 minutes after injector removal then the
delivery and backleak bulkhead QR connections are disconnected to prevent oil scavenging from the
hydraulic circuit. See Figure 4.24.
If this is not performed then it is normal to expect 25-40% longer purge times for the next injector being
tested.
Figure 4.24 Delivery & Backleak Bulkhead QR Disconnection
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5. Advanced Software Functions

5.1 Diagnostics
Refer to Figure 5.1
The diagnostics screen shows the status of the machine and the software/hardware versions. The
screen is split into sections
A. Interlock status
A tick indicates that interlock input is active; A cross indicates the interlock input is inactive.
B. Analogue values
Displays the live readings of analogue machine parameters.
C. Error monitoring
An error is indicated by the text turning red.
Any machine errors detected can be cleared via the ‘Clear error’ icon.
The diagnostics screen allows access to the Ethernet network communications

settings between the PC / TABLET and the PCB via the ‘Comms’ icon. These
should not be altered by the user.
Access to machine sensor calibration is via the ‘Calibration’ icon.
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Reset service hours

(6.3)
Calibration (6.1)
Figure 5.1 Diagnostics Screen
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5.2 Creating/Editing a Testplan
Users cannot overwrite testplans ending in ‘.Hart’. These are injector part
specific testplans which have been developed by Hartridge.
NOTE Some of the procedures described below may be password protected, with access only
available to authorised personnel.
5.2.1 Create New Testplan
Refer to Figure 5.2

Whilst on the Injector selection screen
1. Select the correct injector manufacturer type and injector type using one of the existing test
plans, then select the ‘Create testplan’ Icon as shown below.
Create testplan
Figure 5.2 Injector Selection Screen
2. Refer to Figure 5.3

A pop up box will appear, enter a testplan name. This can be anything however using the
injector number is preferred. Once entered, select the ‘Enter’ button, this will then automatically
take the user to the main test screen.
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Figure 5.3 Testplan Name Dialog

Enter
5.2.2 Adding % limits using a reference injector
Refer to Figure 5.4

The drive parameters and limits for each test step must be specified prior to running the test. Start
the process at the electrical test step and work down through the list until each test step has been
defined.
For the electrical test step, the drive parameters (Pressure, pulse width, Speed and duration) are all
fixed and cannot be adjusted. On the other 5 test steps, the drive parameters are adjustable
however the durations are included on the suggested testplan limits documents
1. To enable testplan creation mode, the ‘reference injector’ icon must be selected. This will
highlight in light blue once selected. Once this icon has been selected, parameters and limits
can be edited. The simplest and quickest way is to set the drive parameters and limits for
one test step at a time.
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Drive parameter (Pressure)
Percentage
limits
Reference injector
Play
Figure 5.4 Main Test Screen
Once this icon has been selected, parameters and limits can be edited.
2. The drive parameters (Pressure, pulse width, speed and duration) can be set via selecting
the box where the relevant parameter is located (Refer to Figure 5.4 ). A pop up dialog box
will appear in the middle of the screen and a figure can be inputted. Once the figure is
inputted, select enter to save the parameter (Refer to Figure 5.5 for the location of ‘enter’).
3. The percentage feature will add a minimum and maximum limit to whatever the new injector
produces. This percentage is inputted by the user via selecting the digit % under/next to
each feedback. (Refer to Figure 5.4). This will bring up a dialog box (Refer to Figure) where
the user can input a percentage (0-100%).
Enter
Figure 5.5 Percentage Limits Dialog Box

HL070 (EN), Issue 2, 04/2017 AT3227 73
4. Once a figure has been entered, select ‘Enter’ to bring back the main test screen.
This works in the following way, for example:

If a percentage is applied to the nozzle delivery of 10%, this will give a minimum limit of the n-10%
and a maximum of n+10%, where n is the new injector nozzle delivery’. So if a 10% limit is applied,
and an injector delivers 50mm3/str; the software will give a minimum limit of 45mm3/str and a
maximum limit of 55mm3/str. This method can be applied to the following feedback points:
 Nozzle Delivery
 Injector backleak/Return
 Nozzle response time
 Inductance (Coil injectors only)
 Resistance (Coil injectors only)
 Capacitance (Piezo injectors only)
 Rail Pressure feedback
Apply a percentage limit to each of the above parameters however the electrical factors can only be
applied on the electrical test step.
5. Navigate through the test steps using the left hand side of the screen and selecting the
required test step.
6. Once the drive parameters and feedback percentage limits have been set for all test steps,
start the motor via the green button on the front of the machine.
7. Start the test via selecting the ‘play’ icon.
The software will cycle through each test step, starting at the electrical test step and ending with the
static leak step. Once all test steps have been completed, the save button will appear and the green
finish flag Icon will appear.
8. Save the testplan via the ‘floppy disc save’ Icon (Refer to Figure 5.6). This will open up
another screen, giving the choice to re-name or overwrite the current testplan (Refer to
Figure 5.7).
Save testplan
Figure 5.6 Feedback min/max limit
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Save testplan
Figure 5.7 Testplan Save Screen
9. The name of the testplan can be edited by selecting the’ Testplan’ Box. This will bring up a
keyboard and a new name can be entered. Then select enter and select the ‘Floppy disc’
save Icon.
10. If overwriting a testplan, after the save icon is selected, a warning message will appear
stating if that the testplan file already exists and asking if the user wants to overwrite (Refer
to Figure 5.8).
Figure 5.8 Overwrite option
11. Select the ‘’ to overwrite the existing file with the new limits, or select ‘x’ to cancel.
12. Only when the ‘’ is selected, can the user press the save testplan Icon.
HL070 (EN), Issue 2, 04/2017 AT3227 75

13. Once the testplan has been saved, the software will revert back to the main test screen.
The back arrow or home button can then be used to revert back to the injector selection
screen.
Once saved, the testplan and its limits can be checked by re-loading the testplan from the injector
selection screen and scrolling through each test step ensuring the limits are all present.
5.2.3 Adding limits manually
This method allows for a minimum and maximum limit to be entered\adjusted manually. To use this
method, follow the above steps in section 5.2.2 until step 3, and then complete the following:
1. Select the minimum or maximum limit within the relevant feedback box. (Refer to Figure 5.9)
A dialog box will appear in the middle of the screen.
Minimum feedback limit Maximum feedback limit
Figure 5.9 Feedback min/max limit
2. Enter a value and select enter. This will put the selected limits into the testplan.
3. Once all limits and drive parameters have been set, save the testplan via the ‘floppy disc
save’ icon. This will bring up another screen, allowing the user to overwrite or rename the
testplan.
4. The name of the testplan can be edited by selecting the’ Testplan’ Box. This will bring up a
keyboard and a new name can be entered. Then select enter and select the ‘Floppy disc’
save Icon.
5. If overwriting a testplan, after the save icon is selected, a warning message will appear
stating if that the testplan file already exists and asking if the user wants to overwrite.
6. Select the ‘’ to overwrite the existing file with the new limits, or select ‘x’ to cancel.
7. Only when the ‘’ is selected, can the user press the save testplan Icon.
8. Once the testplan has been saved, the software will revert back to the main test screen.
Select the ‘x’ to exit edit mode (Refer to Figure 5.10)
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Figure 5.10 Exit edit mode
The testplan has now been created and saved for future use.
If, during the testplan creation phase, an abort is required, select the red ’x’ icon on the main test screen
(Refer to Figure 5.11. This will bring up a dialog box with an abort warning (Refer to Figure 5.12). Select the
tick if an abort is required and this will take you back to the main selection screen or the ‘x’ if an abort is not
required.
Abort
Figure 5.11 Abort Test Screen
Figure 5.12 Abort Warning Message
HL070 (EN), Issue 2, 04/2017 AT3227 77

5.2.4 Edit existing testplan

Refer to 5.2.1
The method to editing an existing testplan is very similar to creating a new testplan, with the only
difference being using an existing testplan as a base to modify instead of creating a new one.
Once specific functions have been adjusted, save the testplan as mentioned in section 5.2.1.
5.2.5 Delete a testplan
CAUTION! Deletion of a testplan is irreversible

From the Injector Select screen, select Manufacturer, Injector type and Testplan.
Press the Delete Testplan button.

The Delete pop-up appears, refer to Figure 5.13
Press the tick to delete the testplan. OR
Press X to close the pop-up and retain the testplan.
Figure 5.13 Delete a Testplan
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6. Maintenance
WARNING!
DO NOT RUN THE MACHINE WITHOUT ALL THE ACCESS PANELS FITTED.
DO NOT RUN THE MACHINE WHEN LOWERED ONTO THE ROLLER BEARING
FEET
ALWAYS ISOLATE THE MACHINE AT THE MAIN VOLTAGE SUPPLY
SWITCHES/PLUGS ON THE WALL, BEFORE REMOVING ANY ACCESS PANELS.
6.1 Calibration & Audit

TM
Hartridge recommend that the condition of the Sabre CRi Master 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 Sabre CRi Master should be checked at
least every year or every 1500 hours in use whichever is sooner.
Operators should contact their local Hartridge distributor for details of the certification service
offered.
6.2 Moving the machine for access

To ensure safe working, the Sabre CRi Master is equipped with two feet which can be raised or
lowered onto roller bearings contained within the feet. When the machine is resting on the roller
bearing caps, it is difficult for the machine to move and the machine must only be operated when the
feet are in this state.
Figure 6.1 Rear Machine Feet - Static
In order to rotate the machine to access the rear electrical components, the feet must be adjusted so
the machine is sitting on the roller bearings. To do this, the use of a 19mm spanner is required.
Rotate the nut anti-clockwise until the machine is sitting on the roller bearings. The machine can
now be moved by either pushing or by slightly lifting the front of the machine and rotating using the
roller bearings.
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Figure 6.2 Rear Machine Feet - Rolling
Caution must be taken to ensure all 4 of the feet are always above the work surface at all times to
eradicate the risk of a falling machine.
6.3 Regular maintenance
Operation 20 Hr* 500 Hr* Ref.

Check guard door and pressure  6.3.1
dump
Generally clean  6.3.2
Change Nozzle delivery and  6.3.3

Backleak filters
Change test fluid & tank filter.  6.3.3
NOTE: *Hours displayed on Diagnostics screen

6.3.1 Check guard door and pressure dump
Every 20 hours of machine use or sooner -
 Switch on the test stand.
 Open the injector access door.
 Check the high pressure pump motor cannot be started.
 Load an injector, close the injector access door.
 Check the fluid system and high pressure pump motor can be started.
 Set a low rail pressure (300 bar).
 Enter the diagnostics menu screen.
 Open the injector access door. Check the high pressure pump motor stops and the rail
pressure decays rapidly to near zero.
6.3.2 Generally clean

The machine is a precision instrument and should be kept clean.
Refer to Figure 6.3
80 HL070 (EN), Issue 2, 04/2017 AT3227
Tool tray and injector test chamber

Keep the tool tray (A) and the injector test chamber (B) clear of debris. Any debris present may get
washed into the test fluid tank.
Machine air vents

Check the machine ventilation slots (C) on the top of the machine (plus one on the rear hydraulics
access panel and one on the left side panel) are clear of debris and unobstructed. Wipe any
accumulated dust away from the vents with a soft dry cloth.
Guard door
Use only soapy water to clean the clear plastic guard door (D). Do not use chemical or abrasive
cleaners as this may damage the plastic and compromise safety. Ensure that the door is open and
an absorbent mat is placed into the tool tray and do not use excessive amounts of water whilst
cleaning, to help prevent water dripping into the test fluid tank.
Touch screen
For safety reasons, switch off the mains power supply to the machine at the wall before cleaning.
Do not rub the screen (E) with a hard object.
Never use any of the following strong solvents, these will damage the LCD screen
 Thinner
 Benzene
 Abrasive cleaner
 Spray type cleaner
 Wax
 Acid or alkaline solvent
Clean the LCD screen surface with a soft dry cloth. Do not use tissue paper etc. because these will
damage the screen.
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C
C
Figure 6.3 Machine Cleaning
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6.3.3 Change test fluid, filters

CAUTION!
Dispose of or recycle waste fluids and components safely and in accordance with local
environmental regulations.
Routinely change the test fluid after each 500 hours of machine use. The current elapsed hours can
be viewed on the Diagnostics screen.
Part numbers of filters can be found in the Spares section of this manual.
6.3.3.1 Empty/clean the tanks

Switch off the electrical supply to the test stand. This is to prevent the possibility of starting the fluid
system pump as the tanks are drained.
Refer to Figure 6.4
 Remove the tank drain plug (A) and the yellow drain pipe from under the front right corner of
the machine and drain the test fluid into a suitable container (minimum capacity 20 litres).
Refit the main tank drain plug and pipe.
Figure 6.4 Tank Drain
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6.3.3.2 Changing the filters

Refer to Figure 6.5
 Using a Counter-Clockwise motion remove the old fluid filter (D) and dispose of correctly.
 Using a Clockwise motion install a new fluid filter.
 Remove the two filter caps (E) on the left and right hand side of the injector test chamber.
 Remove and replace the two 60μm filter elements (F) ensuring that the two O-rings (G) of
each filter are installed correctly.
 Replace the filter caps (E) tightening to 8Nm.
E E
D
G
Figure 6.5 Changing the Filters
6.3.3.3 Fill with test fluid

 Refill the tank as described in section 2.9 with clean test fluid to ISO4113 specification.
 Switch on the test stand. Run the fluid system and check around the filters for leaks.
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7. Troubleshooting
WARNING:
ONLY QUALIFIED SERVICE PERSONNEL SHOULD ATTEMPT DIAGNOSTICS
WITH POWER APPLIED.
For anything not covered in this section, or if the checks listed do not solve the problem, refer to your
Hartridge distributor or Hartridge customer support.
7.1 Diagnostic screen interlocks

In the event of one of the indicators on the Status screen showing a  follow the checks below.
Indication Checks
 Tank Temperature  If the main tank does not feel hot (touch from beneath) the over-temperature
sensor may have a wire break or be faulty.
 Tank Level  Check the fluid level in the tank

Observe the tank level indicator
Top up the fluid as necessary

 Check for evidence of leaks on the floor under / around the test stand and
determine the source.
 Motor Start Button  It is normal for the motor start button indicator to showif the motor stop
button has been pressed. In the event that pressing the motor start button
does not change the status of this parameter then contact your Hartridge
distributor or Hartridge customer support.
 Guard  Check the guard is closed and the door handle is in the closed position. If
OK suspect a faulty guard interlock switch.
Do not attempt to bypass the guard switch or operate the machine with
the guard open. Contact your Hartridge distributor or Hartridge
customer support.
 PSU OK  Check the condition of the left most circuit breaker at the rear of the
machine.
 Otherwise suspect 12V power supply overload or fault.
 Motor Running  Check condition of the two right-most circuit breakers at the rear of the
machine.
 Check the injector test settings are inside the operating envelope specified in
the product manual
 Further diagnosis requires machine panels off to view the motor controller
status – Contact your Hartridge distributor or Hartridge customer support.
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 Pump overload Clear the error and try again. If fault persists:
 Ensure filters have been changed and test fluid replaced in accordance with
the maintenance schedule in the product manual. Pump overload can be
caused by blocked filters or poor quality test fluid.
 Check the injector test settings are inside the operating envelope specified in
the product manual.
 Contact your Hartridge distributor or Hartridge customer support.
 Cooling Clear the error and try again. If fault persists:

 Contact your Hartridge distributor or Hartridge customer support.
 System Comms  Contact your Hartridge distributor or Hartridge customer support.
 Motor Stop Button  Contact your Hartridge distributor or Hartridge customer support.
 Lift Pump Pressure  It is normal for the lift pump pressure to show 
if the motor start button has
not been activated. In the event that pressing the motor start button does
not change the status of this parameter then contact your Hartridge
distributor or Hartridge customer support.
 Motor over current

(Diagnostic screen error) Clear the error and try again. If fault persists:
 Ensure filters have been changed and test fluid replaced in accordance with
the maintenance schedule in the product manual. Motor overload can be
caused by the high pressure pump seizing or having impaired performance
caused by blocked filters or poor quality test fluid.
 If the issue continues to re-occur contact your Hartridge distributor or

Hartridge customer support.
7.2 Basic troubleshooting guide

Fault Reason Corrective Action
Blank Screen Mains supply disconnected Secure cable to left socket at the rear of the
machine
Screen in sleep mode Momentarily press the screen power reset
button to the right of the screen
Depleted battery Ensure IEC power mains cable is plugged in
and wait 10 minutes
Screen is on, PC / Tablet running on battery power with Secure cable to left socket at the rear of the
machine is not mains supply disconnected machine
PC / Tablet running on stored battery Switch on the mains isolator to the left of the
power with mains isolator switched off screen
Circuit breaker / fuse trip Reset circuit breaker (back of machine)
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Motor will not Mains supply disconnected Secure cable to right socket at the rear of the
start machine
Fuel level below minimum tank level Review fuel level within diagnostic screen, fill
as required
Door not closed Close door
Door interlock faulty - open circuit Contact your Hartridge distributor or Hartridge
customer support for advice
Safety relay fault Contact your Hartridge distributor or Hartridge
Motor seized Contact your Hartridge distributor or Hartridge
Motor circuit breaker / fuse trip Reset circuit breaker (back of machine)
Lift pump failure Contact your Hartridge distributor or Hartridge
Motor circuit HP pump seized Contact your Hartridge distributor or Hartridge
breaker / fuse customer support for advice
trip Drive motor seized Contact your Hartridge distributor or Hartridge
LP pump seized Contact your Hartridge distributor or Hartridge
No Ethernet cable disconnected Contact your Hartridge distributor or Hartridge
communication customer support for advice
Incorrect LAN address defined (software Reconfigure LAN address
configuration)
USB port disabled Enable USB port
USB to LAN device failure Contact your Hartridge distributor or Hartridge
Software issue Tablet freezing Shut down software and relaunch
Comms error message Reset in diagnostics screen
Shut down software and relaunch
Old version software Update to the latest version
Leak from Plug missing from drain pipe Replace plug
under the Tank overfilled Check fuel level on diagnostic screen
machine
Injector Excessive backpressure within injector Remove orifice from delivery chamber and
pushed out of chamber check for blockage
assembly Excessive backpressure within injector Remove delivery filter and check for blockage
chamber
Excessive backpressure within injector Remove metering unit check valve and check
chamber pressure setting
Damaged injector O-ring Inspect O-ring for damage and replace.
Injector not clamped securely within Clamp injector correctly
fixture
No rail Loose high pressure connector in bulk Torque both ends of high pressure pipe to
pressure head 35Nm
Faulty injector Test a known good injector
Blockage in main filter Replace filter as recommended in manual
Test step will Motor not started Start motor
not execute / Incorrect cable type fitted Fit correct cable type (refer to TIB document)
start
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Injector not Incorrect manufacture selected Select correct manufacture file

firing Incorrect injector type selected Select correct injector type
Incorrect injector cable fitted Fit correct injector cable
Faulty injector Test a known good injector
Leak from Damaged O-ring Replace O-ring
delivery
chamber
No response Minimum delivery and/or rail pressure not Refer to response time operating envelope
time achieved
Piezo sensor faulty (on delivery chamber) Replace sensor
Piezo sensor not plugged into bulkhead Plug connector into bulkhead connector
connector
Delivery chamber orifice removed Replace delivery orifice
Metering unit check valve fault (low Remove metering unit check valve and check
pressure) pressure setting
No metering Metering unit not purged Ensure metering unit is purged:
results 1) extend time delay
2) Increase pulse width
Metering unit check valve fault (no Remove metering unit check valve and check
pressure) pressure setting
Linear encoder stuck / seized Contact your Hartridge distributor or Hartridge
Leak from delivery chamber Rectify leak
Metering pipe not connected to delivery Connect metering pipe to delivery port
port
Metering pipe connected to flushing port Connect metering pipe to delivery port
Backleak not SPM error message Reset in diagnostics screen
measuring Shut down software and relaunch
Excessive flow (Faulty Injector) Test a known good injector
Backleak unable to drain fuel. Contact your Hartridge distributor or Hartridge

Fuel evident
from backleak
Contact your Hartridge distributor or Hartridge
overflow pipe
Metering unit piston over travel fault Restart machine and see if issue re-occurs.
Fuel evident
If so, contact your Hartridge distributor or
from metering
Hartridge customer support for advice
unit overflow
Seal failure within metering unit Contact your Hartridge distributor or Hartridge
pipe
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8. Spares
Please quote the serial number of the machine when enquiring about spares.
The term LV refers to components used on Low Voltage supply machines (100-120V). The term HV
refers to components used on High Voltage supply machines (200-240V).
8.1 Consumables
8.1.1 Fuses
No. Reference Part Number Description Qty
1 Figure 8.1 9842529 Fuse 500mA A/S 1
2 Figure 8.1 9842503 Fuse 250mA QB 1
8.1.2 Filters
3 Figure 8.2 8999023 Fluid filter 1
4 Figure 8.2 8850073 Metering unit filter, 60 μm 1
5 Figure 8.2 8850073 Backleak unit filter, 60 μm 1
8.2 General
8.2.1 General Spares
6 Figure 8.2 A245E150 Backleak hose assembly, 300mm 1

7 Figure 8.2 9700254 O Ring (Injector sealing cap assembly) 1
8a 9550190 Internal O Ring to suit 7mm Nozzle

1
sealing cap
Figure 8.2
8b 9550194 Internal O Ring to suit 9mm Nozzle
1
sealing cap
9 Figure 8.2 9700188 O Ring (Metering and backleak filter) 2
10 Figure 8.2 9700083 O Ring (metering and backleak filter) 2
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8.2.2 Electrical
15 Figure 6.1 A262G020 Inverter, programmed 1
16 Figure 6.1 A258A900 Printed Circuit Board 1
17 Figure 6.1 440R-N23114 Emergency stop safety relay 1
18 Figure 8.6 8910238 High pressure pump motor, 1.5kW 1
19 Figure 8.4 OTP017 Fluid system pump 1
20 Figure 8.7 100-6780 Fluid level switch 1
21 Figure 8.7 16238399 Fluid level sensor 1
22 Figure 8.7 229-5884 Thermostat 1
23 Figure 8.7 174-02-42 Temperature sensor (tank) 1
24 Figure 8.3 A262D014 Tablet assembly 1
25 Figure 8.2 A262P180 Piezo Sensor 1
8.2.3 Fluid system

30 Figure 8.4 A262D009 Cooler Assembly 1
31 Figure 8.6 A262D100 Rotex coupling 1
32 Figure 8.6 28470303 High pressure pump 1
33 Figure 8.5 R9144Z240A High Pressure rail (incl. pressure sensor & 1
pressure control valve)
34 Figure 8.5 A245E111 Temperature sensor (pre-cooler) 1
35 Figure 8.7 9109-904 Backleak venturi 1
36 Figure 8.5 A262D121 Lift Pump Pressure Switch 1
8.2.4 Metering systems

40 Figure 8.5 A262D017 Metering unit – low capacity (backleak) 1
40a Figure 8.5 174-02-42 Temperature sensor (backleak) 1
40b Figure 8.5 307-0254 Solenoid valve (backleak) 1
40c Figure 8.5 24123177 Fluid sensor (backleak) 1
41 Figure 8.5 A262D005 Metering unit assembly 1
41a Figure 8.5 174-02-42 Temperature sensor (metering)
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8.2.5 Accessories supplied with the machine
Part Number Description Qty
NTA7200 Injector sealing cap assembly – 7mm 1
NTA7201 Injector sealing cap assembly – 9mm 1
NTA7202 Delivery chamber assembly 1

A245E150 Backleak hose assembly 300mm 1
AHP5065 Pipe assy – 1.6x400x14x12 Straight 1
AHP5066 Pipe assy – 1.6x400x14x14 1
HK1206 Sabre backleak adaptor kit 1
*A258G010 Step up transformer assembly 1
Cable assembly – drive power (transformer
*A258P005 1
to IEC inlet)
A262A603 USB Memory Stick 1
* ONLY SUPPLIED ON CRi180-B VARIANTS
HL070 (EN), Issue 2, 04/2017 AT3227 91

8.2.6 Injector drive cables (All adaptor cables are additional options)
A range of Injector drive cables are available. The cables are optional and are not supplied with the
base machine. The part numbers and cable details are listed here for reference.
AE69/7 CR Driver cable adaptor - Conti PZO type 1
AE69/1 CR Base driver cable - PIEZO
AE69/8 CR Driver cable adaptor - Conti PZO type 2
AE69/9 CR Driver cable adaptor - Denso PZO type 1
AE69/10 CR Driver cable adaptor - Bosch PZO type 1
AE69/11 CR Driver cable adaptor - Bosch PZO type 2
AE69/4 CR Base driver cable - COIL AE69/14 CR Driver cable adaptor - Denso coil type 2
AE69/15 CR Driver cable adaptor – Bosch coil type 1

/Denso coil type 1
AE69/16 CR Driver cable adaptor - Bosch coil type 2

/ Denso coil type 3
AE69/17 CR Driver cable adaptor - Delphi coil type 1
92 HL070 (EN), Issue 2, 04/2017 AT3227

1 2 17 16
15
Figure 8.1 Spares diagram 1
HL070 (EN), Issue 2, 04/2017 AT3227 93

9 4 5 10
8a/8b
25
7
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24
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30
19
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41a
33
41
40
34
40b
36
40c
40a
HL070 (EN), Issue 2, 04/2017 AT3227 97

31
18
32
21
35
23
22 20
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Appendix A: Health and safety data sheet
HEALTH & SAFETY DATA SHEET DATE Pub. No.

Information regarding the safe handling & storage of the named product. MAR 97
Applicable to employees and customers.
PRODUCT WARNING
CALIBRATION FLUID (ISO 4113) SEEK IMMEDIATE MEDICAL ATTENTION IF
INGESTED
USE CLASSIFICATION
TEST FLUID FOR DIESEL INJECTORS, FLAMMABLE
INJECTION PUMPS & OTHER DIESEL EQUIPMENT
PRODUCT DESCRIPTION - COMPOSITION
THESE FLUIDS ARE PETROLEUM BASED PRODUCTS CONTAINING SIGNIFICANT PROPORTIONS OF THE
MORE VOLATILE PETROLEUM FRACTIONS AND OTHER SOLVENTS USED FOR LUBRICATION, ANTI-
CORROSION AND DERMATITIC INHIBITION.
SAFE HANDLING ADVICE (Protection - Usage, Storage & Transport)
USAGE: 1) Avoid eye splashes and extended skin contact.
2) Do NOT take internally.
3) Keep mist generated by machinery to a minimum, also avoid where possible vapours caused by elevated
temperatures.
4) Protective clothing to be regularly laundered.
STORAGE: These are flammable products which should be stored in closed containers away from heat in a well ventilated area.
EMERGENCY & FIRST AID PROCEDURE (Eyes, skin, ingestion, inhalation)

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

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

SPILLAGE: Advise authorities if product has entered or may enter sewers, water courses or extensive land areas.
DISPOSAL: All waste should be put into identified containers and stored at a specific disposal point.
Arrange for off site disposal in accordance with local regulations for notified waste.
HARTRIDGE LTD
Network 421, Radclive Rd, Buckingham,
MK18 4FD, England.
THE INFORMATION AND RECOMMENDATIONS IN THIS PUBLICATION ARE TO THE BEST OF OUR KNOWLEDGE INFORMATION AND BELIEF ACCURATE
AT THE TIME OF PUBLICATION NOTHING HEREIN TO BE CONSTRUED AS A WARRANTY, EXPRESS OR IMPLIED IN ALL CASES. IT IS THE
RESPONSIBILITY OF THE USERS TO DETERMINE THE SUITABILITY OF ANY PRODUCTS FOR THEIR OWN PARTICULAR PURPOSE. RECOMMENDATIONS
FOR HANDLING, PROTECTION ETC. ARE ADVISORY ONLY.
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Appendix B: Interpretation of results
The best way to use the machine is as a comparator against new injectors. The demand settings in
the injector part number specific testplans were developed using known good or new injectors and
therefore should enable an injector to deliver useable results. For any injector part numbers which do
not have a testplan, It is recommended that a similar testplan is used as a base to create specific
testplan for that injector part number (see Section 5.2).
With experience, the user can build up a sound knowledge of injector operation and their common
faults.
The following general guidelines apply if testing an unknown injector.
Response Time
The faster the response time, the quicker the injector injects fuel. Any injector whose response time
is more than 100μs longer than a known good injector is likely to cause engine problems.
Delivery
On vehicle, engine management systems may 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).
Backleakage
Common Rail injectors have inherently higher backleak than traditional injectors as a volume of fuel
is expelled every time the injector valve operates.
The Static Leak 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.
For both dynamic and static backleak tests: - Any injector with a significantly higher flow (and
temperature) than a known good injector should be regarded as suspect.
NOTE: Backleak tests must be run over sufficient time to ensure a stable, valid reading is obtained.
Summary
In general when testing a batch of injectors the faulty injector(s) will have:
 Very fast or very slow response time
 Abnormally low or high delivery
 Excessive backleakage flow
HL070 (EN), Issue 2, 04/2017 AT3227 101

102 HL070 (EN), Issue 2, 04/2017 AT3227

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: support@Hartridge.com www.Hartridge.com

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Common Rail Injector Tester

Operating and Servicing Manual

HL070 (EN), Issue 2, 04/2017 AT3227

Hartridge Sabre CRi Master

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5.1 DIAGNOSTICS .................................................................................................................................................... 69

Figure 2.16 No Licence Message .....................................................................................................................32

Figure 5.12 Abort Warning Message ............................................................................................................... 77

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

Accidents can occur to unauthorised personnel during testing. Untrained

This equipment contains electrostatic sensitive devices. Observe the necessary

Gloves conforming to standard BS EN 407:1994 must be worn when handling

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14 HL070 (EN), Issue 2, 04/2017 AT3227

Definition of Terms and Abbreviations

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16 HL070 (EN), Issue 2, 04/2017 AT3227

1.1.3 Injector Measurements

1.1.4 Test Control Parameters

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1.1.5 Test Fluid System

 Tank capacity 10 litres

1.1.6 Machine Performance / Operating Envelopes

1.1.6.1 High Pressure Flow

Rail Pressure (bar)

18 HL070 (EN), Issue 2, 04/2017 AT3227

1.1.6.2 Response Time

Injected Delivery (mm/str)

Figure 1.2 Operating Response Time Envelope

Referring to Figure 1.2

HL070 (EN), Issue 2, 04/2017 AT3227 19

1.1.6.3 Fluid Cooling Performance

Figure 1.3 Fluid Cooling Performance

20 HL070 (EN), Issue 2, 04/2017 AT3227

1.1.6.4 Injected Delivery Repeatability

Refer to Figure 1.4

Injected Delivery (mm/str)

Figure 1.4 Injected Delivery Repeatability

HL070 (EN), Issue 2, 04/2017 AT3227 21

1.1.6.5 Backleak Flow Repeatability

Refer to Figure 1.5

Backleak Flow (mL/min)

Figure 1.5 Backleak Flow Repeatability

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2.2 Siting the Machine