Hartridge AVM2-PC

HARTRIDGE
AVM2 - PC
Diesel Pump Test Stand
Installation & Start-Up

INSTALLATION & START-UP HARTRIDGE
This page deliberately left blank
2 AVM2-PC MAN-01(GB)
HARTRIDGE INSTALLATION & START-UP
Installation & Start-Up

1. WARNINGS ............................................................................................................................. 5
2. Warranty Statement ............................................................................................................... 9
3. Introduction .......................................................................................................................... 11
4. Installation ............................................................................................................................ 13
4.1 Site Requirements ........................................................................................................ 13
4.2 Installing the Test Stand ............................................................................................... 14
4.3 Remove Transit Fittings ............................................................................................... 15
4.3.1 Injector Mount ................................................................................................. 15
4.3.2 Test Stand Bed ............................................................................................... 15
4.3.3 Console .......................................................................................................... 16
4.4 Connecting Services to the Test Stand ........................................................................ 16
4.4.1 Water Supply .................................................................................................. 16
4.4.2 Air Supply ....................................................................................................... 16
4.5 Test Stand 3 Phase Electrical Supply .......................................................................... 17
4.5.1 380 - 480V Supply .......................................................................................... 18
4.5.2 Test stand transformer primary setting and 50/60Hz selection ...................... 19
4.6 PC Single Phase Electrical Supply, Keyboard and Mouse .......................................... 20
4.7 Filling the Oil Tanks ...................................................................................................... 21
4.7.1 Test Oil ........................................................................................................... 21
4.7.2 Lube Oil (option) ............................................................................................. 22
4.8 Connecting a Printer, Modem or Network Card ........................................................... 23
4.9 Installation Check List................................................................................................... 23
5. Starting-Up the Test Stand ................................................................................................. 26
5.1 Power ........................................................................................................................... 26
5.1.1 Electrical supplies ........................................................................................... 26
5.1.2 Switching the 3 phase supply OFF ................................................................. 26
5.1.3 Switching the PC ON ...................................................................................... 26
5.1.4 Switching the PC OFF .................................................................................... 26
5.2 Emergency Stop ........................................................................................................... 27
5.3 Initial Power On ............................................................................................................ 27
5.4 Changing Owner Details ............................................................................................... 28
5.5 Changing Date and Time .............................................................................................. 28
5.6 Adjusting the Monitor .................................................................................................... 29
5.7 Start the Fuel Pump ..................................................................................................... 30
5.8 On Line Help ................................................................................................................. 30
6. Circuits ................................................................................................................................. 31
6.1 Test Oil and Water Supply Circuit ................................................................................ 31
6.2 Pneumatic Circuit ......................................................................................................... 32
6.3 Lube Option Circuit ....................................................................................................... 33
6.4 AVM2-PC Metering Circuit ........................................................................................... 34
6.5 Index to Hydraulic, Pneumatic and Cooling Water Circuits .......................................... 35
6.6 Electrical Circuits .......................................................................................................... 37
7. Start-up Problem Solving .................................................................................................... 47
7.1 Test Stand Serial Plate ................................................................................................. 47
7.2 Software Version Information ....................................................................................... 48
7.3 Fuse Locations ............................................................................................................. 50
AVM2-PC MAN-01(GB) 3
1. WARNINGS
Isolate the electrical supply before performing any maintenance operations. Do not
work on electrical equipment while voltage is supplied. If such cannot be avoided, e.g.
for measurements, tests or adjustments, have the action carried out by qualified
personnel only.
Safety glasses must be worn when working on this equipment for the following
reasons:
1. The 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.
Make sure any rotary machinery is stationary before opening any access panels or
removing fixed panels.
Use extreme care to avoid being drawn in to the test stand. Check that all clothing,
especially sleeves and ties, and hair is safe and cannot be caught in revolving parts.
Check that hoses connected to the injection pump cannot chafe or become entangled in
the drive, thus causing a hazard.
Do not adjust any test stand components (including pumps under test) while they are
moving.
Make sure there is adequate ventilation. Oil vapour may be released from hot fixtures or
high pressure leaks. The specific directions in Health & Safety Data Sheets must be
adhered to.
Keep hands and the body away from fluid sprays, especially injectors, leaking high
pressure pipes and seals. High pressure injection through the skin can result in fatal
injury. In the event of injection into the skin, seek urgent medical attention. Refer to the
Health & Safety Data Sheets.
Impervious gloves and overalls should be worn if regular contact with ISO4113 test fluid
is likely. Gloves should also be worn when handling fixture parts or injectors after
testing which may be hot. Refer to the Health & Safety Data Sheets.
Burns will occur to the hands if certain parts of the test stand or equipment under test
are touched. Keep hands away from the calibration fluid heater element and injector
or high pressure pipes after periods of extended running.
Safety footwear must be worn in the test area at all times. Injury to the feet may be
sustained in the event that, equipment under test (loading or unloading), or test stand
covers are dropped.
Severe injury can be caused by slipping on spilt oils or fluids. All spillages of fluids in
the test area must be dealt with immediately. These can be mopped up and mineral
absorbent material spread over the affected area.
Use calibration fluid and lube oil of the correct specification only. Obtain the
manufacturers Health & Safety Data Sheets and follow the advice given therein.
Prolonged and repeated contact with oil products, ingestion or excessive and prolonged
inhalation of oil mists can be detrimental to health. Use an appropriate barrier cream.
Ensure that the servicing requirements and intervals as set out in the Maintenance
section are adhered to. Operate and service this equipment only if competent to do so.
Carry out regular inspections to make sure all high pressure connections are tight and
safe.
Remove any tools, cleaning rags or other debris from the test stand before starting up.
Make sure the inching bar is not fitted to the test stand before starting up.
There must be no naked flames. Potentially flammable vapours are present in the test
stand and ignition is possible although unlikely. Smoking whilst operating the equipment
is strictly forbidden.
Accidents can occur to unauthorised personnel during testing. Untrained person(s) must
not be present in the test area when the equipment is operating. Only qualified
personnel are to operate this equipment.
Ensure good levels of lighting for safe, efficient equipment operation.
This equipment uses Viton (fluoroelastomer) seals. If these seals are exposed to high
temperatures, they decompose into a corrosive substance which is extremely harmful
and will contaminate skin. Do not touch Viton seals or the sealing surfaces if they have
been burnt or exposed to temperatures in excess of 400ºC.
Take care to ensure only recommended equipment is connected to the test stand
auxiliary power socket and that it is correctly earthed.
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 an injection pump running, are variable
dependent on the size and speed of the unit under test.
Test have been shown that personnel at the operator position can be exposed to sound
pressure levels in excess of 80dB(A) while the injector pump is running.
Under certain operating conditions; high pump speeds, high injection deliveries, rates
and pressures and pumps with multiple cylinders, a mean sound pressure level in
excess of 95dB(A) has been measured. This is equivalent to a sound power level in
excess of 100dB(A).
With the fuel system running and the test stand drive rotating at its maximum possible
speed, the sound power level is less than 90dB(A). With only the fluid system running
this level drops to below a sound power level of 75dB(A).
NOTE: Warning in accordance with the Essential Health & Safety Requirements of the
Machinery Directive Annex I. 1.7.4.(f).
CAUTION
Care must be taken to ensure that the correct speed limit and the correct rotation are
selected for the pump under test.
This equipment contains electrostatic sensitive devices. Observe the necessary

precautions for handling electrostatic discharge sensitive devices. Do not touch printed
circuit boards and associated electronic connections and components.
Arc welding equipment must not be operated within 5 metres of the test stand. The
electrical supply to welding equipment must be provided from a remote isolating
transformer. Arc welding can disturb the measuring circuit.
2. Warranty Statement
The AVM2-PC range of test benches is covered by the Lucas Aftermarket Operations
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 Lucas
Aftermarket Operations. A complete copy of the Terms and Conditions of Sale or Supply
is available on request.
Please note that on the AVM2-PC (the Machine) all guarantees and warranties are
limited to use of the Machine 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 Machine as defined in Section 9(a).
Similarly it is vital that the Machine is operated correctly and in accordance with the
instructions and messages displayed on the Machine. Failure to do so may be treated as
misuse under section 9c 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 Machine:
• damage caused by poor mains supply quality.
• wear and damage to the disposable keyboard protective cover other than that arising
through faulty manufacture or workmanship;
• damage to the keyboard for example through oil or dirt ingress and arising through a
damaged or worn keyboard protective cover;
• wear and damage to the mouse or other pointing device other than arising through
faulty manufacturing or workmanship;
• damage to the printer (optional) as a result of test oil / workshop dirt ingress or other
misuse.
It is the Client’s responsibility to ensure that any third party accessories (e.g. modem or
network card) installed on the Machine by the Client or at the Client’s request are
compatible with the Machine and will not detract from its correct operation.
The personal computer (PC) installed within the Machine is manufactured by Hewlett
Packard (HP) and is covered by their standard warranty terms. HP offer a range of
extended warranty options on their PC equipment, details are available direct from the
HP Distributor Network. Any such warranty is completely independent of, and separate
from, any warranties or guarantees offered by Lucas Aftermarket Operations.
3. Introduction
This manual provides information about the safety, installation, operating and routine
maintenance of the AVM2-PC test stand. Make sure you have read and understand the
information contained before attempting to install and use the test stand.
More detailed information is available in the Technical Service Bulletins (TSB) available
from your local agent.
The AVM2-PC range of test stands will (depending on the power specified) test most in-
line and rotary diesel pumps in use for on-highway and industrial applications.
AVM2-PC
4. Installation
4.1 Site Requirements
Refer to Figure 4.1.
• Allow 1 metre around the front & side of the test stand for access.
• A clean, level and dust-free floor capable of supporting the test stand weight.
• Supply of clean water at 20°C maximum with flow available of 8 litres/min. - minimum
pressure 2 bar (30psi), maximum pressure 6 bar (90psig).
• Well ventilated to dissipate heat.
• Supply of clean dry air - minimum pressure 6 bar (90psig), maximum 8 bar (120psig).
• Lift the test stand from underneath using a fork lift or from above using slings placed
under the test stand base. Use a spreader bar on the slings to prevent damage to
test stand panels.
• 3 Phase & Earth electrical supply = 380 - 480V (33Amp - 10hp/54A - 20hp).
OR
• 3 Phase & Earth electrical supply = 190 - 240V (66Amp - 10hp/108A - 20hp) using
stepup transformer (only required on low voltage test stands).
• 1 phase & Earth electrical supply = 110V OR 220V 50 / 60Hz (5Amp) for PC.
Figure 4.1 AVM2-PC
4.2 Installing the Test Stand

1. Position the test stand on site.
2. Place a spirit level on the top surface of a suitable side panel (arrowed).
3. Level the test stand by inserting suitable metal shims (1) (95mm x 95mm - not
supplied) between the rubber feet (2) and the test stand.
Figure 4.2 Levelling the Test Stand
4.3 Remove Transit Fittings

4.3.1 Injector Mount
See Figure 4.3.
Remove the four bolts (1) securing the
orange transit bracket to the ring bracket
and the injector mount.
4.3.2 Test Stand Bed

See Figure 4.4
1. Remove the left hand upper side
panel.
2. Remove the bolts (2) and both
orange spacers between the bed and
the base at the rear of the test stand.
3. Remove the left and right hand trays
at the front of the test stand.
4. Remove the bolts (3) and both
orange spacers between the bed and
the base.
5. Refit the left and right hand trays and
the left hand upper side panel.
Figure 4.3 Injector Mount Transit Fittings
2
3
Figure 4.4 Test Stand Base Transit Fittings
4.3.3 Console
1. Remove the bolts (4) in the top of the console cover and tilt the cover back.
2. Remove both bolts (5) locking the console to the test stand.
Figure 4. 5 Console Transit Fittings

4.4 Connecting Services to the Test Stand
Figure 4.6 Water and Air Supply Connections

4.4.1 Water Supply
Connect water supply (1) and return (2) pipes using 3/8" BSP fittings.
4.4.2 Air Supply

Connect air supply (3) using 1/4" BSP fittings.
4.5 Test Stand 3 Phase Electrical Supply

The connection of electrical supplies must comply with the local and national electrical
regulations. Make sure the connection of 3 phase electrical power is carried out by a
suitably qualified electrician.
WARNING!
The equipment must be hardwired and bonded to a protective earthing
system before the mains supply wires are connected. The earth wire must
be taken directly to earth instead of or as well as through a plug and
socket.
The earth current is greater than 20mA due to filter capacitors between
power lines and earth.
Failure to earth the test stand before applying mains power can cause a
fatal electric shock.
The equipment CANNOT be used with a mains supply protected by a
'standard' Earth Leakage Circuit Breaker (ELCB) as the earth current is
above a 'standard' ELCB trip level.
If local regulations state that an ELCB must be used, use a variable ELCB
with a minimum current setting of 30mA and a minimum time delay setting
of 50 - 100ms (this is available from the equipment supplier).
The variable ELCB should always be set to the minimum current and
time delay which will allow the test stand to run.
NOTE: The fuel pump motor used on the test stand is phase rotation sensitive. Correct
rotation of the pump can be checked by following the procedure given in 5.7.
4.5.1 380 - 480V Supply

Figure 4.7 Test Stand Isolator Box and 3 Phase/Earth Terminals

1. Ensure the test stand isolator and incoming supply isolator switches are off.
2. Remove the test stand isolator panel (4).
3. Feed the 3 phase wires and Earth from the main electrical supply through the
grommet hole (1) located above the isolator switch on the back panel of the test
stand.
4. Connect each phase to the isolator switch (2).
5. Connect the Earth wire to the earth stud (3).
4.5.2 Test stand transformer primary setting and 50/60Hz selection

Figure 4.8 Internal Transformer

1. Ensure the test stand isolator is set to OFF.
2. Remove the test stand isolator panel.
3. Switch on the incoming electrical supply and measure the voltage between 2 phases
on the input side of the test stand isolator switch (see Figure 4.7).
4. Switch off the incoming supply.
5. Remove the clear plastic protective cover secured by 3 screws (small arrows) to gain
access to the transformer.
6. Move wire 304 to the primary tapping nearest to the voltage measured above.
7. 50/60Hz selection (see inset): for 50Hz supply ensure SCB2 terminals 116 and 117
are linked. For 60Hz supply ensure SCB2 terminals 116 and 118 are linked.
7. Refit all panels.
4.6 PC Single Phase Electrical Supply, Keyboard and Mouse

Figure 4.9 PC Connections

NOTE: A locally sourced IEC cable is required for the PC.
1. Select the correct voltage on the switch (9) at the back of the PC.
2. Ensure the ON / OFF switch (14) on the rear of the console is set to OFF.
3. Plug the cable into the IEC socket (16) on the rear of the console and ensure the plug
is locked by the wire clip.
4. Push the keyboard and mouse cables through the holes (11 and 17) at the back of
the keyboard tray; if necessary, remove the keyboard tray to gain access.
5. Connect the keyboard lead to the connector with a keyboard symbol (2) on the back
of the PC.
6. Connect the mouse lead to the connector with a mouse symbol (3) on the back of the
PC.
7. Refit the console cover.
NOTE: Any PC compatible mouse, tracker ball or glide point can be used instead of the
standard device if desired.
4.7 Filling the Oil Tanks

4.7.1 Test Oil
1. Remove the access panels on the left side of the stand to gain access to the tanks.
2. Fill the TEST OIL tank through the level indicator tube (3) or directly by removing the
tank cover plate (2) (oil required is 58 litres/15 US gallons).
3. Ensure the oil level is up to the top of the level indicator tube.
The following ISO specification test oil fluids are recommended:
Castrol 4113
Shell 4113 (UK)
Viscor 1487 Silkolene
Shell-Berre Normafluid (France)
Brugarolas Califluid 2 (Spain)
WARNING!
Diesel fuel used in vehicles must not be used due to health and safety
implications.
Figure 4.10 TEST & LUBE OIL tanks showing filling/level tubes
4.7.2 Lube Oil (option)

Refer to Figures 4.10 and 4.11.
Use SAE10-20 specification lube oil.
1. Remove the access panels on the left side of the stand to gain access to the LUBE
OIL level indicator (1) (see Figure 4.10).
2. Fill the LUBE OIL tank through the table return pipe (see Figure 4.11) (oil required is
25 litres/7 US gallons).
3. Ensure the oil level is up to level indicator window (1).
Figure 4.11 Table Return Pipe
4.8 Connecting a Printer, Modem or Network Card

Refer to Figures 4.9 and 4.13.
• All PC compatible black and white and colour printers with a parallel interface can be
used with the AVM2-PC.
• Grommet plates (35) are located at the back of the console for cables to be fed
through to the PC.
• Connect all peripheral devices to an external power supply.
CAUTION
Do not connect these devices to the multi-way block inside the console.
NOTE: Printers, modems and network cards should be installed by qualified personnel to
prevent conflicts with the AVM2-PC software as the PC will need configuring to support
these devices.
4.9 Installation Check List

Before starting the test stand, check:
• Transit brackets are removed.
• Water and air are connected.
• Test oil (and lube oil if system fitted) have been added to tanks to correct levels.
• Internal transformer voltage is correctly set.
• All access panels and fixed covers are fitted.
• Check that the drive coupling guide support is fitted to the centre of the coupling.
• PC supply voltage selector switch is correctly set.
Figure 4.12 Test Stand Controls and Connections (Front view)
Figure 4.13 Test Stand Controls and Connections (Back view)
5. Starting-Up the Test Stand

5.1 Power
5.1.1 Electrical supplies
Because the test stand runs Microsoft® Windows NT™ software which takes some time
to load and shutdown, the PC has an electrical supply independent of the test stand 3
phase supply. This allows the PC to be left on overnight if required to avoid waiting for the
PC to power up or shut down. The 3 phase supply can be switched ON or OFF in any
sequence (see 5.1.2). See 5.1.3 for instructions on switching OFF the PC supply.
5.1.2 Switching the 3 phase supply OFF

Use the main electrical supply isolator switch (35) on the back of the AVM2-PC to apply
or disconnect the 3 phase power to the test stand. See Figure 4.13.
CAUTION
The 3 phase supply should never be switched off while the drive is running as this can
cause permanent damage to the drive controller.
5.1.3 Switching the PC ON

• Connect the power cord to the connector (33) on the rear of the console ensuring the
plug is secured by the wire clip.
• Set the red power switch to ON [I].
• Highlight the 'Windows NT Workstation Version 4.00'.
• Press the 'Enter' key on the keyboard.
The system will automatically select this after a short period anyway. Wait for the
AVM2-PC screen to be displayed (see Figure 5.1) and the function key characters on
the screen to go black.
• The PC is now ready to run.
5.1.4 Switching the PC OFF

CAUTION
Do not switch the PC off without shutting down Windows first, otherwise data may be lost.
To shut Windows down, use one of the following three methods:
• Use the “Shut Down AVM2” function key on the Main Screen.
OR
• Reveal the Windows 'task bar' by moving the mouse pointer to the top of the screen.
Click on using the left mouse button and then click on the 'Shut Down'
option. Select the 'Shutdown Operating System' option then click OK.
OR
• With any AVM2-PC screen displayed, click on the symbol in the top right hand
corner using the left mouse button.
• Wait until the display informs you it is safe to switch the PC off.
• Switch off power to the PC using the red on/off (I/O) switch at the back of the console.
5.2 Emergency Stop

1. In the case of an emergency, press either of the E-Stop buttons (4) to stop the fuel
system and drive.
2. Twist the button to release the E-Stop.
5.3 Initial Power On

1. Ensure all panels and covers are fitted to the test stand.
2. Switch on the main electrical power isolator (36) to apply 3 phase power.
3. Switch on power to the PC (see 5.1.3).
4. Check that the AVM2-PC screen is displayed. Refer to Figure 5.1.
5. Move the mouse and check that the pointer moves around the screen.
6. Check that the ‘Setup’ screen can be selected using the 'F1' function key. Refer to
Figure 5.2.
Figure 5.1 AVM2-PC Screen
Figure 5.2 Setup Screen

NOTE: If the language is not correct, change by clicking on the ‘Help’ menu and then
select 'Change Language' in the pull down menu. Refer to Figure 5.3. If the alternative
language is still not correct, install the CD-ROM supplied with the test stand and select
'Custom Install'.
5.4 Changing Owner Details

With the 'Setup Screen' selected, press the ‘Owner Details’ function key (F10) and enter
the name and address of the test stand owner.
5.5 Changing Date and Time

Set the clock to local time.
a. Reveal the Windows 'Taskbar'.
b. Click on the 'Start' button.
c. Select the 'Date & Time' tab. A calendar and clock will be displayed.
d. Select 'Settings'.
e. Select 'Control Panel'.
f. Double-click on the 'Date/Time' icon.
Figure 5.3 Setup Screen with 'Change Language' Selected
5.6 Adjusting the Monitor

1. Select the function using button (3).
2. Use the up (1) or down (2) arrow buttons to change the setting.
Figure 5.4 Monitor Adjustment Controls
5.7 Start the Fuel Pump

1. Ensure test oil and 80 bar oil pipes are fitted, i.e. the connections are not open to
atmosphere.
2. Start the fuel pump by pressing the fuel start (I) button (Figure 4.12 item 29).
3. Check for correct pump operation by:

Setting a positive pressure on the Supply Pressure gauge by adjusting the supply
pressure control valve (22).
OR
Visually checking that the fuel pump motor inside the test stand is running clockwise
(viewed from front of test stand).
If the above are not correct, stop the pump drive using the (O) button (Figure 4.12 item
28), switch off the 3 phase supply to the test stand and change over any two of the
incoming 3 phase supply wires. Repeat the above test (step 3).
NOTE:
The oil level in the tanks will drop when the system first runs as the pipework in the
system fills with oil. This may cause a ‘low tank level’ warning. Top up the tanks if
necessary.
5.8 On Line Help

To assist the user, on line help can be accessed by clicking on the button and
selecting 'AVM2-PC MANUAL ENGLISH' from the menu list.
6. Circuits
6.1 Test Oil and Cooling Water Supply Circuit
6.2 Pneumatic Circuit
6.3 Lube Option Circuit
6.4 AVM2-PC Metering Circuit
6.5 Index to Hydraulic, Pneumatic and Cooling Water Circuits
6.6 Electrical Circuits
A032 - CIRCUIT DIAGRAM INDEX

SHT. No. DESCRIPTION ISSUE FILE
100-29-
01 AVM ELECTRICAL SCHEMATIC INDEX 2 00A
02 AVM ELECTRICAL SCHEMATIC, INCOMING MAINS AND DRIVE 2 00B
03 AVM ELECTRICAL SCHEMATIC, FUEL PUMP MOTOR 2 00C
04 AVM ELECTRICAL SCHEMATIC, TRANSFORMER AND BLOWER
:
1
1
A
_
C
M
R
F
N
E
IG
0
2
3
1
S
O
T
S
A
C
U
L
-P
N
E
G
M
U
-S
.0
1
IT
D
E
1
N
E
G
I
O
N
A
C
.0
2
1
M
O
IS
2 00D
05 AVM ELECTRICAL SCHEMATIC, EM. STOP SAFETY CIRCUIT 2 00E
06 AVM ELECTRICAL SCHEMATIC, INSTRUMENTATION 2 00F
07 AVM ELECTRICAL SCHEMATIC, INTERLOCK AND METERING 2 00G
08 AVM ELECTRICAL SCHEMATIC, SPARE I/O, TERMINATIONS AND SCREENS 2 00H
09 AVM ELECTRICAL SCHEMATIC, OV DIAGRAM 2 00I
WIRE No. SERIES:- 100 - L1

AC MAINS
000 - 0VAC 200 - L2
415V
001 - 0VDC 300 - L3
002 - 0VDC (DRIVE) 700 - AC CONTROL (110V/132V)
800 - DC CONTROL (24VDC)
900 - 950 LOW VOLTS AC (14V, 27VAC)
951 - 999 LOW VOLTS DC (5VDC)
ISSUE 1
AVM2-PC Electrical Circuit Diagram Index

100 F1 101 BK 101 /3.1

63A MAIN ISOLATOR OPTION:-
200 F2 201 BK 201 /3.1
CUSTOMER SUPPLY 15kW
1 2 300 F3 301 BK 301 /3.1 F1 - F3 50A
LOW V=200,210,220, L1
230,240 3 4 50A F4 F5 F6 7.5kW F1 - F3 40A
L2 80A
HIGH V=346,380,390 ± 10% 5 6 (SEE OPTION) SEMICONDUCTOR
400,415,440, L3
E Q1 FUSE
460,480
3 PHASE 50/60Hz
102
202
302
CCW R1
3 WIRE & EARTH E1 10K
(NO NEUTRAL). 801
13 1 3 5
OPTIONAL 1:2 STEPUP K101 CONSOLE
TRANSFORMER, EXTERNAL
CW 4 1
ENCLOSED, FLOOR MAIN 14 2 4 6 /5.7
103
203
303
MOUNTED. SPEED
STUD TRIM S4 3 2
L1 L2 L3 SCB2
PE 110VAC
FILTER Z1
OR
BN
PK
E2
VI
[31] PE L1 L2 L3
/5.7
112
PART 1/3 D1 S5
705 RD
[22]
701 RD
000 RD
[22] [27]
PART 1/4 PART 1/2 MAIN PART 2/4 +10V 36 -10V 37 38 39 35
RD
BU
STUD [50] SCB2 DRIVE ON

0V BUS
CONSOLE 77 76 78 75 73
RD 21 149 150 80 RD PE L1 L2 L3 D8 D7 D5 D6
3 uP B6 HEALTHY 24V
85 BU AUX SUPPLY IN [27]
JOG
RD/BU
S3 Rl1/1 C4 JOG
BU 20 GN (110V AC) PART 2/2
84 ZERO
4 C3 START/RUN
GY
TQ
PK
GN 29 Rl1 79 YL SPEED
3 24VDC B5 .0
2
1
:
1
A
_
C
M
R
F
1
S
A
C
IU
1
0
2
3
1
S
O
T
N
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M
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G
-S
N
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.0
1
IT
D
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M
I
O
IS
O
PSU
START 86 WH B3 A6 B4 A2
S1 C5 ENABLE
DRIVE YL 28 INTERLOCKS 87 BK
C9 24V
4 OK
(IMAX)
(+10V)
WH BN
(SPEED
SET POINT)
27
(-10V)
1 81
B8 PROG STOP
STOP 82 VI LOGIC
S2 26 B9 COAST STOP
DRIVE BK ZERO SPEED
74 OR
2 &
FUEL ON
A1 0V RL1 SSD 590
DRIVE OV D.C. DRIVE
uP U1 CONTROLLER
DRIVE ON
BK
E-STOP OK Rx3+ 68 1
WT
Rx3- 69 [26] 4 ENCODER CARD
RS422 RD P2
Tx3+ 70 6 WAY 5
BU FCC DIG OUT 3 DIG IN 1 OV 5V -A A -B B
SCB2 Tx3- 71 6
PE A- A+ D3 D4 C1 C2 B7 C6 1 2 3 4 5 6
CABLE
WH
GN
BK
BK
RD
RD
BU
BU
D7 BK
YL
BK
[25]
E14 GN/YL 802
3 WAY IEC CONSOLE
ADAPTOR GN/YL
[51] [52] [53]
BK
-A 63 WH
-B 65 GN
5V 60 RD
BU
A 62 BK
110V/230V
B 64 YL
L L
59
1ø 50/60Hz PC MONITOR
0V 61
F1
N N SPARE 49 -M
SEPARATE E SUPPLY SUPPLY A1 A2 RD
48 M
E 7.5kW D6 GY
47 -B
SUPPLY OR [23]
BU
46 B
F2 YL
E11
E12
45 -A DRIVE 0V
15kW PK
N
44 A
L
GN 43 0V SCB2
ARMATURE FIELD THERMISTOR 1024 WH
/6.1
/6.1
/6.1
/6.1
/6.1
/6.1
42 5V
ROTARY BN
41 SCR
GN/YL
ENCODER ISSUE 1
AVM2-PC Electrical Circuit - Sheet 2

/2.7 101 BK 101

/2.7 201 BK 201
/2.7 301 BK 301
F7 F8 F9
10A
BK 104
/4.1
BK 304 /4.1
104
204
304
13 A1
1 3 5
K102
706 RD
000 RD
[22] A2
14 2 4 6
PART 3/4 [31]
PART 2/3
GN
YL
/7.5
HEATERS
105
205
305
0V BUS
CONSOLE INTERLOCKS 151 152 110 1250W 1250W
TQ
OK 220V 220V
22 1 3 5
21 F10
STOP
96
S5 E4 E5
95
1051
1051
2051
2 4 6
:
1
1
_A
C
M
FR
N
G
STIE
A
C
LU
1
.0
2
.0
1
1
0
2
3
1
S
O
-P
N
E
G
M
-SU
N
E
G
I
O
N
A
C
IT
D
E
M
IS
O
FUEL GY
105
23
22
+ ~
FUEL SSR
ON - ~
RD/BU 24 110VAC 1 3 4 5
13 0VDC
2
ETB3
START
S6
FUEL GN/RD FUEL ON
2051
14 uP
205
25
24VDC
SSR
107 WH
[30] 480V 25A
106 RD
307 BN
206 BU
207 BK
HEAT
306 YL
146 RD
145 BU + KHR
uP
-
24VDC 0VDC FUEL PUMP
MOTOR
COOL
1.1kW
136
RD [15]
+
SSR
uP -
110VAC COOLER E6 FLC 2.6A
SOLENOID
133
BU MAIN
SCB2 0VAC
STUD
AVM ELECTRICAL SCHEMATIC 100-29-00C

FUEL PUMP MOTOR SHEET 3 OF 9 ISSUE 1

104 BK
/3.10
/3.10 304 BK
104
108
104
304
1.3A RMS
0V 220V TAPPINGS, 220,346,380
AUTO 400,415,440,460,480V
PE T1
104
108
E7 10A 3A 1.5A 1.5A
0V 27V 0V 14V 0V 110V 132V
MAIN
900 RD
901 RD
902 RD
903 RD
000 RD
700 RD
702 RD
(50Hz) (60Hz)
STUD
110 BN
8uF
126 125 124 123 122 121 120 F11 F12

SCB2 FS4 FS1
:
1
1
_A
1
0
2
3
1
S
O
-P
1
C
M
FR
N
E
G
M
-SU
.0
1
.0
2
N
G
STIE
IT
D
E
M
IS
O
N
E
G
I
O
N
A
C
A
C
LU
FS3 FS2 2A
002 BU 105
E10
10A 3A 2A 2A
A/S A/S A/S A/S 6 7 8 9
DRIVE OVDC
ETB3
703 118 60Hz E
BU
BN
BK
132VAC 701 117 MAIN
50Hz
000 RD 108 110VAC 704 116 RD STUD
111
112
(0VAC) 0VAC 24VDC
E8 001 BU 104 24VDC 800 8

(0VDC) 0VDC 110/132VAC
34 U1 U2
18V
110/132VAC
14VAC 14VAC L N
0V BUS SCR 103 (N) (L) Z
110VAC
SPARE
SPARE
MAIN
172
188
174
173
127
132
131
139
115
128
129
113
SCR 130
M
STUD ~
S1
900 RD
904 RD
BLOWER
GN
RD
BU
YL
MAIN 220V
[29] 300W
STUD D2
9 10 11 50
49
001 BU (0VDC) (0VAC) (27VAC) (0VAC)
(110V/
51 132VAC)
001 BU
8 VARIABLE (14VAC)(L)
803 BU METERING CONTROL E15
6 SOLENOID PSU 52 BOARD No.4 54
804 BU 116-13-00 E9
7 (14VAC)(N) 106-19-00
METERING MAIN
BLOCK EARTH STUD
AVM ELECTRICAL SCHEMATIC 100-29-00D

TRANSFORMER AND BLOWER SHEET 4 OF 9 ISSUE 1

CONSOLE
806 BU
807 BU
11 21 11 21
\2.8
EMS1 EMS2
(LH) 12 22 (RH) 12 22
8061 BU 8071 BU
XC 1 2
WH/RD
RD/BN
RD/BK
YL/RD
[22]
PART 4/4 110VAC 30 32 ESTOP OK 24VDC 31 33 110/132VAC
111 90 92 95 94 91 93
SCB2 114
705 RD
701 RD
704 RD
WH
GN
RD
BU
BK
YL
805 BU E13
[28]
A1 S22 S33 S21 S33 34 33 S23 S12 13 23

0V +ve
PE
K1 BREAKS 30ms K2 K2
E. STOP BEFORE K2 & K3
SAFETY RELAY :
1
1
A
_
C
M
FR
1
0
2
3
1
S
O
1
TILU
-P
N
E
G
G
M
-SU
.0
1
.0
2
IT
D
E
M
IS
O
N
E
I
O
N
A
C
N
G
E
S
A
C
BD5987.03/001 KES K3 K3
DOLD
A2 X5 X6 14 24
707 RD
000 RD
808 BU
809 BU
[16]
RD
21
0V BUS
K101 A1
22 K101
A2
SV
000 RD
BU
0V BUS 0V BUS
BRAKE DRIVE
SOLENOID CONTACTOR
13 14
/2.3
21 22 5
AVM ELECTRICAL SCHEMATIC 100-29-00E

EM. STOP SAFETY CIRCUIT SHEET 5 OF 9 ISSUE 1

42
/2.3
/2.3
3 CORE
[37]
PS
2
Tx1 180 RD Rx
3
Rx1 179 BU Tx RS232
5
0V1 178 GN 0V
PC
RS232
ISOLATED
SCN 177
INSTALLATION & START-UP
3 CORE
PS
MONITOR
CONSOLE
S7
[36]
Tx5 176 RD 3 Rx
0V AC
Rx5 175 BU 2 Tx
SUPPLY
VARIABLE
SCN 171
SOLENOID
116-13-00
110VAC
FACIA 5 WAY DIN PROBE 5 WAY DIN
PLUG AND SOCKET PLUG AND SOCKET
S3
[38]
-
uP
+ P1 196 RD
BU S1 195 BU
137
S2 194 GN
24VDC
138
RD METER
P2 193 YL
ADVANCE PROBE
SCN 191
[48]
161
S4
1/2
PART
[21]
RD CHA/N ppr
RD WH
5V 16
162
BU 1 ppr BU GN
SIG 17
FLM
GN BN
0V 18
BACKLEAK
0V DC
158
1 2 3
FLOW METER
GN
ETB4
163
YL CHB 5V 10 YL
4
164
INLET
WH CHA T1 11 WH
5
0V DC
5V 12 BK
[34]
6
THERMISTORS
157
SCR T2 13 BN
BACK LEAK
14 WAY AUXILIARY SOCKET

SCN 9
8
4
RD 204PZ+ 5V 239 RD
3
- 238 YL
1
PT1
BU 203PZ- + 237 GN
BOOST
0V 236 BU

GN 202NLS+ SCN235 A1
[47]
4
5V 233 RD
3
YL 201NLS- - 232 YL
INSTRUMENTATION
1
PT2
+ 231 GN
SUPPLY
AVM ELECTRICAL SCHEMATIC

2
WH 200SPS+ 0V 230 BU
SCN229 A2
[46]
4
BK 199SPS- 5V 227 RD
3
- 226 YL
1
SCB2
PT3
+ 225 GN
AUX 1
[39]
2
0V 224 BU
SCN223 A3
[45]
4
5V 221 RD
3
- 220 YL
1
PT4
+ 219 GN
AUX 2
0V 218 BU
DIGITAL PRESSURE TRANSDUCERS
SCN217 A4
[44]
4
SHEET 6 OF 9
5V 215 RD
100-29-00F
3
- 214 YL
1
PT5
+ 213 GN
PHASE
0V 212 BU
SCN211 A5
[43]
4
5V 209 RD
3
- 208 YL
1
PT6
GN
LUBE
+ 207
2
0V 206 BU
SCN205 A6
[42]
HARTRIDGE
ISSUE 1
AVM2-PC MAN-01(GB)
INTERLOCKS SCB2
E-STOP OK 24VDC OK
24V MICROPROCESSOR BOARD

FAULT MONITOR INPUTS
CHA/N
0VDC
PIEZO
SCN
Rx4
Tx4
165
169
170
167
168
166
2 3 4 5 153 154 155156 148 147 6 7
RSF LINEAR ENCODER
[21]
OR
WH/GN
TQ
PK
GN/YL
VI
PART 2/2 [32] [31]
PART 3/3
WH
GN
[33]
RD
GY
BN
BK
PK
YL
ETB4 9 10 11 12
WH
RD
RD
BU
BU
BK
95
/3.7
INJECTOR METERING UNIT P F10 D5
TEMPERATURE M/U COOLING
96 [35] HEIDENHAIN LINEAR ENCODER
THERMISTOR THERMISTOR SOLENOID
LUBE FUEL FUEL AIR FUEL
WH
:
1
1
_A
C
M
FR
N
G
STIE
A
C
LU
1
0
2
3
1
S
O
-P
N
E
G
M
-SU
N
E
G
I
O
N
A
C
.0
1
1
.0
2
IT
D
E
M
IS
O
GN
TANK TANK TANK PRESSURE PUMP
RD
BU
YL
LEVEL LEVEL STAT OVERLOAD
[14] INTERLOCKS [40]

951
952
953
951
WH/GN
GN/YL
RD
BU
(5V) 18A BK
18B BK
BK
BK
+B 6 GN
0V 2 WH
8 GY
-A 5 RD
+A 4 BU
SCR
5V 1 BR
-REF9 PK
-B 7 YL
INT 3SCR
17
(5V) 18
21
22
CHA/N
Tx 64
Rx 65
59
55
63
EXT10
PIEZO
OVDC
+REF
RD
13
METERING CONTROL BOARD No 4 PIEZO
106-19-00 14
BU
15
25
26
37
38
27
28
39
40
29
30
41
42
31
32
43
44
33
34
45
46
35
36
47
48
23
24
[41]
[1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13]
RD
RD
RD
RD
RD
RD
RD
RD
RD
RD
RD
RD
RD
BU
BU
BU
BU
BU
BU
BU
BU
BU
BU
BU
BU
BU
1 2 3 4 5 6 7 8 9 10 11 12 13
METERING
BYPASS
INJECTOR SOLENOIDS SOLENOID
AVM ELECTRICAL SCHEMATIC 100-29-00G

INTERLOCK AND METERING SHEET 7 OF 9 ISSUE 1

44
Tx6 184
Rx6 183
SPARE
0V 182
RS232
SCN 181
RS232
ISOLATED
110VAC
Tx2+190
-
Tx2- 189
135
+ Rx2+188
SPARE
Rx2- 187
RS422
uP
0V 186
INSTALLATION & START-UP
SCN 185
OUT 1
136
+
24VDC
OUT 2
144
DIGOUT 1
143
DIGOUT 2
142
DIGOUT 3
0V DC
154 CHA/N2
14 5V
SPARE
15 T3
THERMISTOR
66 NOT CONNECTED
IS
O
M
IT
E
D
1
.0
2
1
.0
I
A
N
C
O
E
-SU
M N
G
SE
-P
ON
G
1
3
2
0
1
STIE
N
G LU
A
C
1FR
_A
C
M
:
1
72 DIG IN 1
88 DIG IN 2
96 DIG IN 3
97 ANALOG IN
98 ANALOG IN
99 ANALOG IN
SPARE
100 ANALOG IN SCN 1

TERMINATIONS
SCN 9
101 ANALOG IN SCN 19
SCN 35
102 ANALOG IN SCN 41
SCN 50

140 110V AC SCN 59
SCN 67
159 5VD SCN 73
AVM ELECTRICAL SCHEMATIC
SCN 83
SPARE I/O, TERMINATIONS AND SCREENS
192 12VS SCN 89

SCB2
SCN 103
198 18V SCN 119
SCN 127
SCREEN
TERMINATIONS
SCN 141
SCN 157
SCN 165
SCN 171
SCN 177
SHEET 8 OF 9
SCN 191
100-29-00H
SCN 197
SCN 205
SCN 211
SCN 217
SCN 223
SCN 229
SCN 235
HARTRIDGE
ISSUE 1
AVM2-PC MAN-01(GB)
DRIVE
FILTER SSD 590 ENCODER
MOTOR
PE PE PE
E14 0V
0V 0V
E2 D1 D7 D6 S6
[27] [25] HEATER 1 HEATER 2 [23] [23]
CONSOLE FUEL
VARIABLE E.STOP BLOWER
SPEED TRIM TRANSFORMER PUMP
PSU RELAY MOTOR
MOTOR
& P.BUTTON
E4 E5
0V
S5 E7 S7 D2 E13 E10 E6
[22] [36]
ADVANCE BACKFLOW BACK LEAK
METERING MCB4 PROBE METER TEMP.
MONITOR PC
UNIT LINEAR
S A
0V S S
PIEZO
A1GENTITLE0231GEN-POSGEN-SUMCANONII1.0EDITMISO1:11FRMC_A1LUCASTIT0231GEN-POSGEN-SUMCANONII1.0EDITMISO1:11
12.012.0
DIG 0V ANL 0V S3 D4 S4
E12 E11 D3 E9 [38] [21]
SCREENS
0V PT1 PT2 PT3 PT4 PT5 PT6

E15
D2 D3 D5 S2 AC1
[35] A1 A2 A3 A4 A5 A6
D1 D6 D7 D5 D4 S4 S5 S6
[27] [23] [25] [35] [21] 178 A1 A2 A3 A4 A5 A6 AC1 S2 S3 [21] [22] [23] S7 SCB2
ISOLATED 0V
DRIVE OV DIGITAL OV ANALOGUE 0V AC 0V SCREENS

002 001 000
E2 E4 E5 E6 E7 E9 E10 E13 E11 E12
OV BUS S1
E8
PROTECTIVE EARTH STUD SOCKET

E1 E0
CUSTOMER EARTH (3ø) CUSTOMER EARTH (1ø)
AVM ELECTRICAL SCHEMATIC 100-29-00I

0V DIAGRAM SHEET 9 OF 9 ISSUE 1

7. Start-up Problem Solving

7.1 Test Stand Serial Plate
Figure 7.1 Serial Plate Location

The serial plate is fixed to the back panel. Always quote the full product number and
serial number in any correspondence.
7.2 Software Version Information

Always quote the PC Software version number in any correspondence. The PC Software
version number can be accessed from the AVM2-PC 'Diagnostics' screen.
1. Select the 'Diagnostics' function key (F6) from the AVM2-PC [Main Menu] screen
(see Figure 5.1).
2. Select the 'Version Information' function key (F3) from the AVM2-PC [Diagnostics]
screen (see Figure 7.2).
3. A 'Version Information' window will appear with System Version Numbers displayed
(see Figure 7.3). The PC Software version shown here is 'AVM2 Version 213.09'.
Figure 7.2 AVM2-PC [Diagnostics] Screen
Figure 7.3 AVM2-PC [Diagnostics] Screen showing 'Version Information' window.
7.3 Fuse Locations
Figure 7.4 Fuse Locations - Electrical Equipment Chassis (access panel removed)
HARTRIDGE
AVM2 - PC
Diesel Pump Test Stand
Operating & Maintenance

OPERATING & MAINTENANCE HARTRIDGE
HARTRIDGE OPERATING & MAINTENANCE
Operating & Maintenance

8. Operating the Test Stand .................................................................................................... 55
8.1 Menu Tree .................................................................................................................... 55
8.2 Display, Keyboard and Mouse....................................................................................... 56
8.2.1 Keyboard Variations ........................................................................................ 56
8.2.2 Data Entry Boxes ............................................................................................ 56
8.2.3 Red Status Light ............................................................................................. 57
9. Pump Mounting .................................................................................................................... 58
9.1 General ......................................................................................................................... 58
9.2 Mounting a Pump to the Test Stand .............................................................................. 58
9.2.1 Injector Mount ................................................................................................. 59
9.2.2 Mounting a Rotary Pump ................................................................................. 59
9.2.3 Mounting an In-Line Pump............................................................................... 62
9.2.4 Pump Connections .......................................................................................... 65
10. Pump Testing ....................................................................................................................... 66
10.1 Select the Metering Screen ........................................................................................... 66
10.2 Selecting/De-selecting Injectors .................................................................................... 67
10.2.1 Individual Injector Selecting and De-selecting ................................................. 67
10.2.2 Group Injector Selecting and De-selecting ...................................................... 67
10.3 Starting a Test ............................................................................................................... 68
10.3.1 Levels of Testing ............................................................................................. 69
10.4 Starting the Fuel Systems ............................................................................................. 70
10.5 Speed Control ............................................................................................................... 71
10.5.1 F12 Function Key ............................................................................................ 72
10.5.2 Drive Direction ................................................................................................ 72
10.5.3 Analog Trim potentiometer............................................................................... 72
10.5.4 Speed Display Colours .................................................................................... 72
10.6 Starting the Drive .......................................................................................................... 72
10.7 During a Test................................................................................................................. 72
10.7.1 Printing / Storing result .................................................................................... 73
10.7.2 Limits and Units ............................................................................................... 73
10.8 Stopping a Test ............................................................................................................. 74
10.9 Auto Step Sequence and Results Storage Locations .................................................... 75
10.10 Printing Results Files .................................................................................................... 75
11. Metering ................................................................................................................................ 76
11.1 Metering Modes ............................................................................................................ 77
11.2 Pump Ratio and Temperature Selection ........................................................................ 78
11.3 Metering Injector Symbol Colours .................................................................................. 78
12. Advance (Option) ................................................................................................................. 79
13. Static and Dynamic Phasing/Advance ............................................................................... 80
13.1 Static Phasing ............................................................................................................... 80
13.2 Dynamic Phasing Datum Injector (Option) ..................................................................... 81
13.3 Dynamic Advance ......................................................................................................... 81
13.4 Phasing Injector Symbol Colours ................................................................................... 81
14. Variable Voltage Outlets...................................................................................................... 82
15. External Calibrator ............................................................................................................... 84
15.1 Select the Number of Turns .......................................................................................... 85
15.1.1 Start Count ...................................................................................................... 85
15.1.2 Dump .............................................................................................................. 85
16. Test Sequence Editor .......................................................................................................... 86

16.1 Creating a New Sequence ............................................................................................ 86
16.2 Creating a New Step ..................................................................................................... 87
16.3 Test Sequence Editor Commands ................................................................................. 88
16.3.1 Operator Message .......................................................................................... 88
16.3.2 Set Speed ....................................................................................................... 88
16.3.3 Set Voltage A and Set Voltage B ..................................................................... 88
16.3.4 Set Datums ..................................................................................................... 88
16.3.5 Time Delay ...................................................................................................... 88
16.3.6 Set Limits ........................................................................................................ 88
16.3.7 Measure Deliveries ......................................................................................... 89
16.3.8 Measure Advance ........................................................................................... 89
16.3.9 Measure Phasing ............................................................................................ 89
16.3.10 Parameters Common to All Commands ........................................................... 89
16.3.11 Parameters Common to All Measure Commands ............................................ 89
16.4 Microsoft® Windows® Commands ................................................................................ 89
16.5 Saving a Sequence ....................................................................................................... 90
16.6 Running a Sequence..................................................................................................... 90
17. Routine Maintenance ........................................................................................................... 91
17.1 Removing Access Panels .............................................................................................. 92
17.2 Servicing Schedule ....................................................................................................... 93
17.2.1 20 Hours Servicing .......................................................................................... 93
17.2.2 100 Hours Servicing ........................................................................................ 94
17.2.3 500 Hours Servicing ........................................................................................ 94
17.3 Metering System Auditing.............................................................................................. 97
17.3.1 Audit 1 - Every 20 hours or weekly (whichever occurs first)............................. 97
18. Specifications ....................................................................................................................... 99
18.1 Main Drive ..................................................................................................................... 99
18.2 Calibrating fluid Supply System ..................................................................................... 99
18.3 Lube Oil Supply System (Optional) ............................................................................... 99
18.4 Metering System ......................................................................................................... 100
18.5 Auxiliary Features ........................................................................................................ 100
18.6 Measured Parameters ................................................................................................. 101
19. Consumables ..................................................................................................................... 102
20. Spare Parts ......................................................................................................................... 103
20.1 Services ...................................................................................................................... 103
20.1.1 Pneumatic System ......................................................................................... 103
20.1.2 Water System ................................................................................................ 103
20.2 Power Distribution ....................................................................................................... 103
20.3 Fuel (Test Oil) System ................................................................................................. 104
20.4 Lube Oil System (Option) ............................................................................................ 104
20.5 Drive System ............................................................................................................... 105
20.6 Metering System ......................................................................................................... 105
20.7 General Requirements ................................................................................................ 106
8. Operating the Test Stand

It is recommended that the user obtains some basic personal computer training before
attempting to use the test stand.
8.1 Menu Tree
Figure 8.1 Menu Structure

NOTE:
Operating the F12 key in any screen brings up the Speed Control Box
8.2 Display, Keyboard and Mouse

All PC screen buttons are operated by the LEFT mouse button OR keyboard keys.
Where more than one button appears on a screen, one of these will be highlighted with a
black border. This indicates the button is 'active' and will function. A highlighted button can
also be operated using the 'Enter' key on the keyboard.
8.2.1 Keyboard Variations

The legends used on keyboards can vary. The table below lists common variations:
Description Possible variations
Enter
Shift
Ctrl Control
Tab ®|
Back Tab (Shift+Tab) |¬
8.2.2 Data Entry Boxes
Data can be entered into boxes on many screens. Some screens have more than one box.
To move between boxes use the 'Tab' or 'Shift+Tab' keys. The selected box will be
highlighted in blue or have a dotted outline.
To enter data into a box with a dotted outline, press the space bar.
Figure 8.2 Pop-up Screen Showing Data Boxes
8.2.3 Red Status Light

System errors are indicated by a small box with a Red Status Light at the bottom of the
screen. To clear this, click on the Red Status Light, note the error(s) listed and click on the
'Clear All' button.
NOTE: A Red Status Light will appear if the 3 phase supply is turned off and the PC is left
on. This is normal.
Figure 8.3 Screen Showing Red Status Light
9. Pump Mounting
NOTE:
The 'Nudge' control (see Figure 4.12) allows the operator to rotate the drive round to any
position in small steps. This is useful for positioning the drive to allow coupling fixing screws
to be tightened or loosened with ease.
9.1 General
This section of the manual contains general information about mounting typical pumps on
the test stand. Accessory packages are available for mounting and testing most common
rotary and in-line pumps.
9.2 Mounting a Pump to the Test Stand

CAUTION!
The operator must ensure the correct pump mounting plates / brackets, injectors and high
pressure pipes are used. Incorrect setting of the drive can cause pump seizure.
Operating Tips
• For best results minimise run-out of the test stand drive coupling.
• When using the pump coupling with 10mm thick drive dogs, use the 1mm spacer (1)
opposite the clamping screw. 12mm and 20mm thick dogs do not need a spacer.
• When the pump drive is connected to the test stand drive make sure the drive dogs are
horizontal and slide the pump coupling into the correct slot in the drive. Leave a 0.5mm
to 1mm gap between the pump and test stand couplings.
• Shake the test stand coupling to settle it into a concentric position and then tighten the
clamping screws to 25Nm. You can use the ‘Nudge’ facility to help rotate the pump to
achieve this easily.
Figure 9.1 Drive Coupling with Spacers
9.2.1 Injector Mount

The AVM can be supplied with a range of different injectors which may be fitted using the
appropriate accessories.
9.2.2 Mounting a Rotary Pump

The anti-backlash coupling fitted to this test stand will accept pumps with both supported
and unsupported shafts. First determine the pump type.
CAUTION:
Incorrect setting of the anti-backlash coupling is likely to cause damage to the
pump and may result in drive shaft seizure.
9.2.2.1 Unsupported Drive Pumps

CAUTION:
Fit drive guide Part No. 182-18-17 before testing unsupported drive pumps.
The majority of rotary pumps may be secured with the quick release clamps, however the
adaptor plate has a hole pattern which will allow pumps to be bolted directly to the plate.
9.2.2.2 Supported Drive Pumps

CAUTION:
DO NOT fit the central guide when testing supported drive pumps. The antibacklash
coupling must allow the drive to float.
If a central guide is already fitted, insert a 8 mm threaded screw into the central guide, as
shown in Figure 9.2 and withdraw the guide.
Refer to Table 4.1 to select the appropriate mounting plate for the pump to be tested. Fit
the mounting plate and clamp plates as shown in Figure 9.3.
NOTE:
Couplings such as ADC 223 have screws in their outer diameter. ADC 240 is a safety guard
as well as an adaptor. It is designed to trap the screws if they come loose and must be
used for any coupling of this nature.
Figure 9.2 Drive Guide Application
Tighten these
bolts first
Finally tighten
these bolts to
secure the
pump
Figure 9.3 Rotary Pump Mounting Assembly
Table 9.1 Selection of Mounting Plate
Mounting Plates/Accessories DPA DPC DPS Bosch Diesel DPA

VA/VE Kiki Hub
Mounting Plate 68 mm dia. APB 250/1 4 4 4 4 4 4

Mounting Insert 46 mm dia. APB 250/2 4 4 4
Mounting Insert 50 mm dia. APB 250/3 4 4 4 4 4 4
Dog Drive 17 dia. Taper ADC 239 4 4 4 4 4 4

Dog Drive 20 dia. Taper ADC 95/1 4 4 4 4 4 4
Peugeot Spline Drive Coupling ADC 186 4
Quill Shaft Drive coupling ADC 223 4
Ring Bracket APB 245 • • • • • •

Pump Clamping Components APB 250 • • • • • •
Base APB 244 • • • • • •
Clamp APB 220 • • • • • •
4 Dependent on type of pump • Must be used

Mount the pump to be tested on the mounting assembly as shown in Figure 9.4.
Figure 9.4 Mounting a Rotary Pump
With reference to Table 9.1, select the appropriate pump drive accessories for the pump to
be driven. Then proceed for the different pumps as follows:
i) Detachable Engine Drive Coupling Types.
Remove the coupling from the pump and fit the appropriate dog drive to the pump shaft.
Secure using nut. If a 10 mm dog drive is used, fit a 1 mm spacer opposite the
clamping screw in each 12 mm slot in the anti-backlash coupling. Slide the pump
towards the test stand drive and locate the dog drive in the appropriate slot in the anti-
backlash coupling then tighten the clamping screws to a torque setting of 25Nm.
ii) Integral Spline Types
Bolt the appropriate spline drive hub to the anti-backlash coupling. Slide the pump
towards the test stand drive, and locate the pump spline in the drive hub.
iii) Detachable Quill Shaft Types
Bolt the appropriate spline drive hub to the anti-backlash coupling, and fit the quill into
the pump, Slide the pump towards the test stand drive and locate the quill in the
splined drive hub.
NOTE:
When mounting pumps, ensure that there is a small (0.5 mm) gap between the pump
coupling and the anti-backlash coupling. This ensures that the pump shaft is not impacted.
9.2.3 Mounting an In-Line Pump

When testing in-line pumps the anti-backlash coupling must be set to drive supported
pumps i.e. the drive guide must be removed to allow the drive to float.
9.2.3.1 Flange Mounted In-Line Pumps.

With reference to Table 9.2 select the appropriate mounting plate for the pump to be tested.
Fit the mounting plate as shown in Figure 9.5.
NOTE:
Some plates are slotted.
Figure 9.5 Flange Mounted In-Line Pump Mounting Assembly

Mount the pump to the mounting plate as shown in Figure 9.6
Figure 9.6 Mounting a Flange-Mounted In-Line Pump
Table 9.2 Pump Mounting Requirements
Mounting Plates Accessories CAV ABN Bosch PE.A Bosch PE.P Bosch PE.S
Mounting Bracket Assembly APB 283/1 • • • •
Clamp APB 220 • • • •
Mounting Plate 68 mm APB 243 •
4 mm Packing Piece APB 283/2 4 • 4
Holding Down Bolt AFB 54 4 4
Quick Action Clamp Assembly APB 12 4 4 4
Dog Drive 20 mm Taper ADC 95/1 4 4 4
Dog Drive 25 mm Taper AFP 383 4 4 4
Dog Drive 30 mm Taper ADC 156 • 4 4 4
Dog Drive 35 mm Taper ADC 235 4 4
4 Dependent on type of pump • Must be used
9.2.3.2 Base Mounted In-Line Pumps

With reference to Table 9.2 select the appropriate accessories for mounting the pump on to
the test stand.
WARNING: If the pump to be mounted has pumping elements which are 10 mm or
greater, use the pump body bolts, not quick action clamps.
Mount the pump as shown in Figure 9.7.
Figure 9.7 Mounting a Base-Mounted In-Line Pump

When the pump has been mounted, select from Table 9.2 the appropriate accessories to
enable the pump to be driven.
9.2.4 Pump Connections

• If the pump to be tested has its own lift pump, connect it to the suction connection.
• If the pump to be tested requires a pressurised supply of test oil, connect the test oil
supply pipe to the pump.
• Connect the test oil return from the pump to the return connection.
CAUTION:
Before connecting the pressure phase pipe to the pump to be tested, check that
the test oil/pressure phase valve is set to its minimum pressure (fully counter-
clockwise).
• If the pump requires a pressure phase supply, connect the pressure phase pipe to the
pump.
• If the pump requires a supply of lubrication oil, connect the lubrication oil supply pipe to
the pump.
• If the pump requires a supply of boost air, connect it to the turbo boost connection.
• If a backleakage connection is required, connect a pipe between the pump and the
backleakage connection.
CAUTION:
Check that the high pressure pipes are free from any restriction before connecting
to the pump.
• Use the high pressure pipes specified in the pump testplan. Refer to the AVM & PGM
Accessories Catalogue for the relevant pipe part numbers.
NOTE:
The high pressure pipes can be mounted in the most convenient order, as the test stand
will automatically learn the pump firing order.
• Two auxiliary gauges are provided, these may be used for connection to the transfer
pressure connection etc. on rotary pumps and hydraulic governors. Connections for
the auxiliary gauges are Aux 1 and Aux 2.
• Four 4 mm terminals on the front of the test stand provide two variable d.c. supplies
(channel A and channel B). These may be used to operate pump solenoids. The
terminals will accept standard 4 mm plugs, however they are cross drilled and will
accept plain wires.
WARNING!
Spline drive pumps using drive couplings such as ADC223 must be
used with the guard ADC240 for safety reasons.
10. Pump Testing

The system has been designed to guide you through the steps required to ensure the
results are complete, repeatable and traceable. There will be prompts to enter information
relevant to the test, so that the results can be analysed and traced at a later date. Once a
pump is mounted, proceed as follows:
10.1 Select the Metering Screen

From the Main Screen, press the 'Metering' function key.
Figure 10.1 Metering Screen

NOTE:
Refer to section 11 for more information on Metering Screen Settings.
1. Select Pump Gearing / Temperature correction mode (e.g. 1:1 / T40).
2. Set Metering Mode to ‘Average’ initially.
3. Select Metering Units (e.g. mm3/st).
10.2 Selecting/De-selecting Injectors

• The pump can be connected to any of the 8 or 12 injectors, but the PC must be told
which ones are connected before running a test.
• Injectors can be selected / de-selected at any time, individually or in groups. Sometimes
this is useful to get results faster, particularly when adjusting the output on one line of
an in-line pump.
Figure 10.2 Selecting Injectors Individually or in Groups using Mouse or Keyboard

10.2.1 Individual Injector Selecting and De-selecting
Hold down the 'Ctrl' key and press the desired function keys (F1 to F12).
OR
Click on the buttons next to the injector symbols on screen with the left mouse button.
10.2.2 Group Injector Selecting and De-selecting

Hold down the 'Shift' key and press the two function keys corresponding to the first and last
injectors in the group.
e.g. Shift+F9 and Shift+F12 will select or de-select injectors 9 to 12.
OR
Hold down the 'Shift' key and using the mouse, click on the two buttons next to the injector
symbols on the screen corresponding to the first and last injectors in the group.
e.g. Shift+button 1 and Shift+button 6 will select or de-select injectors 1 to 6 as shown in
Figure 10.2.
NOTE:
Selected injectors will turn grey initially and then blue when their firing position is learnt.
10.3 Starting a Test

Press the 'Start Test' function key.
Enter details relevant to the test such as:
• Drive direction
• Speed limit
• Temperature demand
• Vehicle details
Figure 10.3 'Start Test' pop-up window

Of particular importance if results are to be filed are:
• Pump Model
• Pump Part Number
• Pump Serial Number
These are used along with the Date and Time to create a unique result file name:
PUMP-MODEL_PUMP-SERIAL-NUMBER_DATE_TIME
10.3.1 Levels of Testing

Three levels of testing can be selected by clicking on one of the ‘radio’ buttons:
• Manual
• Manual Mode Leopard
• Semi Automatic
NOTES:
1. 'Manual Mode Leopard' and 'Semi Automatic' require a testplan name to be entered.
See 10.3.1.1 to 10.3.1.3 for detailed explanation of these three options.
2. When the required details have been entered, select 'OK'.
3. The ‘Start Test’ function key will change to a ‘Stop Test’ function key and the ‘Print’
function key changes to a ‘Store’ function key.
Figure 10.4 Screen Showing 'Stop Test' and 'Save' function keys
10.3.1.1 Manual
At this level, the operator sets the speed, temperature, volts, limits and selection of screens.
Results can be printed and/or stored at any time during testing.
When pump testing is complete, press the 'Stop Test' button on the control panel.
10.3.1.2 Manual Mode Leopard

This is the same as ‘Manual’ but the testplan will be loaded from the LEOPARD CD and
displayed at the bottom of the screen for assistance.
10.3.1.3 Semi Automatic

Selecting this level will load and run an Auto Step Test Sequence from disk.
All manual controls are still available to adjust demands, e.g. the speed can be adjusted by
a few rpm to obtain the correct advance reading.
At the end of the Auto Step Test Sequence, 'Stop Test' will occur automatically.
NOTE: See section 16 for information on creating Auto Step Test Sequences.
10.4 Starting the Fuel Systems
Figure 10.5 Test Oil, Lube Oil and Phasing Oil Controls
1. Set Test Oil (2), Lube Oil (3) and Phasing Oil (1) control knobs to minimum (fully anti-
clockwise).
2. Start the fuel pumps by pressing the Fuel Start button (Figure 10.6, item 1).
3. Rotate the Test Oil (2) and Lube Oil (3) control knobs to give the required pressures on
the gauges displayed on the PC screen.
4. Check for leaks.
Figure 10.6 Fuel Control Panel
10.5 Speed Control

Speed can be changed in two ways:
• F12 function key
• Analog Trim potentiometer
Figure 10.7 Speed Pop-Up Window
10.5.1 F12 Function Key

Selecting this function key pops up a window that allows the following information to be
entered into the boxes displayed:
• Speed demand Speed in rpm
• Trim +/- rpm from speed demand
• Ramp rate Acceleration / Deceleration rate
Preset Speeds
Preset speeds are stored on function keys.
To copy a speed stored on a function key to the Speed Demand box, select the function
key, i.e. F1 etc.
To copy a speed from the 'Speed Demand' box onto a function key, select 'Alt+F1' etc.
10.5.2 Drive Direction

This changes the direction of rotation of the drive to L (pump) or R (pump).
10.5.3 Analog Trim potentiometer

To adjust the speed using the Analog Trim potentiometer, set the switch (Figure 10.6 item
3) to the position.
10.5.4 Speed Display Colours

The colour of the speed display has the following meanings:
Colour Speed Displayed Drive Condition

Grey Target Speed Stopped
Blue Actual Speed Speed within 1 rpm of demand
Orange Actual Speed Ramping or Analog Trim Active
Red Actual Speed Outside of low/high limits
10.6 Starting the Drive

1. Set the drive speed to a minimum, e.g. 100rpm.
2. Press the 'Drive Start' button (Figure 10.6 item 2).
3. Check for coupling alignment. See 9.2 'Mounting a Pump to the Test Stand'.
10.7 During a Test

The following controls are available during pump testing:
• Printing/Storing Result
• Limits and Units
• Advance, Phasing, Metering, External Calibrator and Variable Voltage Outlets
10.7.1 Printing / Storing result

Results can be Printed or stored at any time during a test by pressing the ‘STORE’ key.
You will be prompted to enter optional details as follows:
Test Type (e.g. Cranking delivery test)
Comments (e.g. Had to fit 0.02mm shims)
This information will be stored with the displayed results.
10.7.2 Limits and Units
Figure 10.8 Screen Showing Units and Limits Display

General limits and units can be set using the ‘Units / Limits’ function key from any of the
measuring screens. To return to the 'Metering' screen, press the ‘Return’ function key.
Metering limits and engineering units can be set using the ‘Metering Units’ function key
from the 'Metering' screen.
Figure 10.9 Screen Showing Metering Units and Limits Display

10.8 Stopping a Test
1. Press the 'Stop Test' button to stop a test once pump testing is completed or to abort a
test.
2. Enter a result file name* and some overall test comments, e.g. Deliveries set 10% high
at request of customer.
Figure 10.10 'Stop Test' Pop-up Window

NOTE: * The filename defaults to:
PumpPartNo_PumpSerialNo_YearMonthDayHoursMinutesSeconds.
3. Select OK when finished entering the above information.
4. The results are stored to disk (see section 16).
10.9 Auto Step Sequence and Results Storage Locations

Test sequences and result files are stored on the drive and directory specified in the
‘Owner Detail’ screen.
Figure 10.11 Owner Detail Screen

10.10 Printing Results Files
The complete results of a previously filed test can be printed using the 'Print' button (F4).
You will be prompted to enter a file name (the default name is that of the last test filed).
Figure 10.12 Print Pop-up Window
11. Metering
Figure 11.1 Metering Screen
11.1 Metering Modes

Table 11.1 Metering Mode Summary
Metering Mode
Overcheck Calibrate Average Sequential

Overcheck
(note 2)
When used General use Final check Governorcut-off Automatically

test or when selected by
average only result test stand (note 2)
is sufficient
Relative display High Medium (note 4) Very high Medium (note 4)

update rate
Relative accuracy Medium (note 4) Very High Very high Medium (note 4)
of results
Results displayed 1. Each line 1. Each line 1. Average only 1. Each line
2. Average of 2. Average of 2. Average of
selected lines selected lines selected lines
3. <Q>(note 7) 3. <Q>(note 7) 3. <Q>(note 7)
Firing sequence Yes (note 2) Desirable Desirable No

must be learnt ? (note 5) (note 5)
Number of lines
measured together 1 to 12 (note 6) 1 (in turn) All together 1 (in turn)
(note 3)
NOTES:
1 The firing sequence has been learnt when the injector symbols at the top of the ‘metering’ screen
selected are blue.
2 If the firing sequence cannot be learnt in ‘Overcheck’ mode, ‘Sequential Overcheck’ mode will be
automatically selected.
3 Reducing the number of selected lines, increases the display update rate in all modes,e.g. Selecting
each line in turn when adjusting each element of an in-line pump gives a fast and accurate display
update.
4 HIGH if only 1 line selected.
5 Accuracy of results will be improved if firing sequence HAS been learnt.
6 The number of lines measured together is selected automatically dependant on pump speed and
delivery.
7 DELTA Q (<Q>). This is the difference between the highest and lowest line readings. It provides
a quick guide to the ‘balance’ of the pump deliveries.
11.2 Pump Ratio and Temperature Selection

It is possible to select or de-select temperature correction for standard delivery pumps and
for pumps with one delivery every two shaft revolutions. The following symbols are
displayed:
1:1 T40 Standard pump with metering results corrected to 40oC.
1:1 T0 Standard pump with metering results corrected to injected oil temperature*.
2:1 T40 Pumps with one delivery stroke every two shaft revolutions with metering
results corrected to 40oC.
2:1 T0 Pumps with one delivery stroke every two shaft revolutions with metering
results corrected to injected oil temperature*.
* Injected oil temperature correction provides correlation with test stands which inject
directly into open graduated collectors.
The temperature sensor fitted to the test stand must be clipped onto one of the
injectors connected to the pump under test when running in 'T0' mode. Refer to
Figure 11.2.
NOTE: The correct 1:1 or 2:1 mode must be selected otherwise the test stand will not be
able to learn the firing order.
Figure 11.2 Sensor Clipped to Injector
11.3 Metering Injector Symbol Colours

The injector states are represented on the screen by colour codes:
Blue Firing order learnt

Grey Firing order un-learnt
White Injector/s not selected
12. Advance (Option)
Figure 12.1 Advance Screen

1. Set up the advance probe on the pump to be tested.
2. Select the ‘Advance’ option on the Main Menu screen.
3. Select the units for reading - mm for Bosch, DPA or DPC for Lucas, or Stanadyne, etc.
4. Set the reading to zero as defined by the testplan using the zero button. This can also
be done from the 'Metering' screen.
OR
Set the reading offset by pressing the up/down buttons.
NOTE: Using the 'Alt' key will multiply the Advance Offset by 10 on the Advance screen.
13. Static and Dynamic Phasing/Advance
Figure 13.1 Phasing Screen

13.1 Static Phasing
WARNING!
Do not run the drive while using the high pressure supply. Rotate the
pump by hand when static phasing.
1. Set up the pump for static phasing.
2. Select the phasing option on the Main Menu screen - the screen shows the static
phasing angle of the drive.
3. Set the supply pressure for phasing.
4. Rotate the pump by hand to the datum position.
5. Zero the reading using the 'Zero Static' button F7.
6. Rotate the pump by hand to other positions - record the angles and adjust the pump as
required.
13.2 Dynamic Phasing Datum Injector (Option)

1. Select the injectors to be tested.
2. Select the datum injector - press the ‘Datum Injector’ function key F6 followed by
'Ctrl+F1' for example. All other angles will be relative to this injector.
3. Run the pump so it is delivering fuel. The phasing angles will be displayed.
NOTE:
If no datum injector is selected, the angles will be relative to the ‘Static’ zero angle.
13.3 Dynamic Advance

The dynamic phasing screen can be used to give an INDICATION of pump advance as
follows:
1. Ensure no datum injector is selected.
2. Set the pump reference speed, e.g. Idle.
3. Zero the dynamic phasing angles, press the 'Datum Dynamic' function key F5.
4. Change the pump speed. The advance angles will be displayed.
13.4 Phasing Injector Symbol Colours

The injector states are represented on the screen by colour codes:
Blue Injector selected

Grey Datum injector
White Injector/s not selected
14. Variable Voltage Outlets
Figure 14.1 Voltage Pop-Up Screen
X°
Hartridge AVM2-PC
_ VA +
_ VB +
X°
_ VA +
_ VB +
Figure 14.2 Voltage Terminals
Four 4 mm terminals are fitted to the front facia of the test stand. These provide two
variable d.c. voltage supplies for pump electrical devices. The terminals will accept
standard 4 mm plugs, but they are cross drilled so that they will accept plain wires.
The arrangement of the variable voltage terminals allows parallel connection to increase
the current supplied to the component (see Figure 14.3).
Figure 14.3 Voltage Terminal Connections
15. External Calibrator

Single cylinder pumps can be tested using a single cylinder cambox and single cylinder
calibrator. Information on mounting and piping up the single cylinder cambox and calibrator
is contained in Technical Information Bulletins 160/13 and 160/3 respectively. Electrical
control of the calibrator is from the auxiliary socket on the front facia (Figure 4.12 item 6).
Select 'External Calib' from the Main Menu to display the 'External Calibrator' screen.
Figure 15.1 External Calibrator Screen
15.1 Select the Number of Turns

The operator can select the number of turns over which fuel is to be metered.
NOTE:
The 'Turns' screen allows the operator to either select or store eight commonly used
number of turns. Alternatively the number of turns may be entered using the keyboard.
1. Press the key below 'Turns'.
2. To select the commonly used/stored number of turns, select the key below the number
of turns required.
3. To store a number of turns, enter the number of turns required, e.g. 125. With the
number of turns displayed in the screen, press one of the eight keys below the screen.
This number of turns (125) will be stored in memory and displayed above the
appropriate key.
4. Enter the number of turns required.
15.1.1 Start Count

To start metering the fuel output from the pump, press the 'Start Count' function key F3.
15.1.2 Dump
To drain the fuel from the calibrator press the 'Dump' function key F4.
16. Test Sequence Editor

A Test Sequence Editor is included with the test stand. This enables the operator to create
auto stepping test sequences. A mouse is required for all functions of the editor. All testplan
settings are defaults which can be over-written by the operator during a test.
The Test Sequence Editor software can be installed onto any PC running Windows NT
v4.00 or later. This will enable test sequences to be created away from the test stand.
To open the editor, select the 'Testplan Editor' function button (F7) on the Main Screen.
16.1 Creating a New Sequence
Figure 16.1 Editor Screen

• Click on the ‘Clean sheet’ icon .
A test sequence template will be displayed with two steps already inserted. This forces you
to enter certain parameters such as units, speed limit, drive direction etc.
16.2 Creating a New Step

1. In the Command box of a blank line, click on the arrow in the grey box to pull down a list
of possible commands.
2. Select a command e.g. Set Speed.
3. Enter the data required in the following columns.
Figure 16.2 Template Screen Showing Command Box
16.3 Test Sequence Editor Commands

An overview of each command is shown in the following:
16.3.1 Operator Message
Enables the operator to type a message for display in the text window, e.g. instructions to
the operator before and during testing. Leaving the 'message' blank will clear a previous
message.
16.3.2 Set Speed
Enables the operator to set the drive speed.
NOTE:
For safety reasons speed changes of more than 100 rpm require confirmation by the
operator before proceeding.
Incremental = Go to the absolute speed entered in the 'Speed
demand' column.
= Add the 'Speed increment' to the current speed.
Speed Demand Absolute speed demand.

Speed Increment Incremental speed change (+/-).
Ramp Rate Acceleration/deceleration rate.
16.3.3 Set Voltage A and Set Voltage B

Voltage Demand Set the voltage demand.
16.3.4 Set Datums
Advance Value Set the advance reading to this value.
Dynamic Phasing Datum Line Select which one of the 12 lines is the datum.
16.3.5 Time Delay
The time delay in seconds before moving onto the next step. Useful for stabilisation.
16.3.6 Set Limits
Set the limits of parameters which are also measured when one of the following commands
is performed:
• Measure Deliveries
• Measure Advance
• Measure Phasing
Set Low and High limits for:
• Speed • Supply Temperature • Return Temperature
• Return Flow • Supply Pressure • Aux 1 Pressure
• Aux 2 Pressure • Boost Pressure • Lube Pressure
• Phasing Pressure
16.3.7 Measure Deliveries

Look Back = Use low and high limits from this step
= Use low and high limits from step defined by 'Look
Back Step' column.
Look Back Step Step number of look back step.
Metering Mode Select from pull down list.
Metering Units Select from look down list.
Low Limit Low delivery limit.
High Limit High delivery limit.
Delta Q Limit Maximum Delta Q limit.
Take Result After x Readings 'Limits', 'Save' (if selected) and 'Proceed' will be effective
after x metering results.
16.3.8 Measure Advance

Low Rack/Advance Low limit.
High Rack/Advance High limit.
16.3.9 Measure Phasing

Low and High Lines 1 - 12 Limits for each line.
16.3.10 Parameters Common to All Commands

The following information can be entered for each step:
Test Title This describes the step and will be saved alongside the
result of the step. It could be a description or a test code
from the manufacturers testplan.
Auto Proceed = Wait for operator to press 'proceed' before moving
onto next step.
= Proceed to next step without waiting for operator
(see also section 16.3.2).
16.3.11 Parameters Common to All Measure Commands

Save Results Save results of step and all background parameters (see
section 16.3.6).
16.4 Microsoft® Windows® Commands

The Editor uses the following standard Microsoft® Windows® commands.
File - New, Open, Close, Save, Save As, Print, Print Setup
Edit - Copy, Cut, Paste, Insert New Step Before, Insert New Step After, Delete Step, Undo
View - Toolbar, Status Bar
Window - New, Cascade, Tile, Arrange Icons
Help - Help Topics, About CPE Editor
16.5 Saving a Sequence

1. Select 'File' in the toolbar and select 'Save' or 'Save As'.
2. A window appears requiring a file name to be entered.
3. Give the Test Sequence a suitable name, e.g. pump part number.
4. Select OK.
5. Close the editor to return to the AVM2-PC screen.
Figure 16.3 Main Screen with 'File' selected and 'Save' highlighted
16.6 Running a Sequence

Start a test, enter the 'Testplan Name' and select the 'Semi-Automatic' option. For further
details refer to section 10.3 'Starting a Test'.
17. Routine Maintenance

WARNING!
Do not run the test stand without any of the access panels fitted.
Always isolate the test stand at the main voltage supply switch on the
wall, before removing any access panels.
Figure 17.1 Removing Access Panels
17.1 Removing Access Panels

NOTE: Panels, items 1 and 3 are not shown. These panels are the left-hand equivalents of
items 2 and 4.
1 Left Lower Panel
Remove the two hex socket screws and lift panel to gain access to the test oil
(calibrating fluid) drain pipe and lube oil drain pipe, if fitted.
2 Right Lower Panel
Remove the two hex socket screws and lift panel to gain access to the electrical
components and the pneumatic control valve.
3 Left Upper Panel
Remove the two hex socket screws and lift panel to gain access to the main drive
motor, test oil pump and motor, blower unit and the test oil/lube oil tanks.
4 Right Upper Panel
Remove the two hex socket screws and lift panel to gain access to the drive control unit
and the system control board.
5 Console Cover
Remove the two screws and lift the cover to gain access to the PC and monitor
connections.
6. Right Middle Panel
Remove the right middle lower panel and the right upper panel. Remove the four hex
head screws and remove panel to gain access to the fuses.
7. Services Panel
Remove the seven hex socket screws and remove the panel to gain access to the rear
of the test stand.
8 Isolator Panel
Remove the knob from the mains isolator then remove the four hex socket screws and
remove the panel to gain access to the mains isolator.
9 Motor Access Panel
Remove the four hex socket screws and remove the panel to gain access to the rear of
the main motor.
10 Left Surround
Remove the four hex socket screws and remove the panel to gain access to the anti-
vibration mount and water pipes.
11 Right Surround
Remove the four hex socket screws and remove the panel to gain access to the anti-
vibration mount and the water pipes.
12 Front Surround
Remove the left surround and the right surround then remove the four hex socket
screws and remove the panel to gain access to the pipes leading to the injector mount.
13 Anti-backlash Coupling Cover
Remove the two Durlock bolts and remove the complete guard to gain access to the
emergency brake mechanism.
17.2 Servicing Schedule

Operation 20 Hr* 100 Hr* 500 Hr* Ref.
Check fluid levels 4 17.2.1.1

Check emergency stop 4 17.2.1.2
Generally clean 4 17.2.1.3
Audit 1 4 17.3.1
Audit 2 4 17.3.2
Audit 3 4 17.3.3
Check fuel injectors 4 17.2.2.1
Change test oil and filter 4 17.2.3.1
Change metering filters 4 17.2.3.2
Change lube oil and filter (if fitted) 4 17.2.3.3
NOTE: *Hours displayed on Diagnostics screen (see Figure 7.2).
17.2.1 20 Hours Servicing

17.2.1.1 Check Fluid Levels
Remove the lower left panel and check that the test oil (calibrating fluid) level (2) and the
lube oil level (1)(if fitted) are visible in the sight tube windows.
Top up as necessary using the correct specification of fluid. Refit the lower left panel.
Figure 17.2 Fluid Level Indicators and Table Drain Plug
17.2.1.2 Check the Emergency Stop Operation

1. With the test stand switched on, press the left Emergency Stop button.
• Check that the ‘Emergency Stop’ fault message is displayed on the screen.
• Check that the test oil system cannot be started.
• Check that the anti-backlash coupling cannot be rotated by hand.
2. Reset the Emergency Stop button and check that the anti-backlash coupling can be
rotated freely.
3. Repeat the procedure with the right Emergency Stop button.
17.2.1.3 General Cleaning

The test stand is a precision instrument and should be kept clean. An anti-static cleaner
may be used to clean the PC screen.

17.2.2.1 Check Test Injectors
1. Remove the test injectors from their mount.
2. Attach each in turn to a Hartridge injector tester, e.g. Poptest.
3. Perform dry seat, backleakage and pressure setting test on each injector at a setting of
175 bar +2 bar -0.0 bar and re-set as necessary.

17.2.3.1 Change the Test Oil (Calibrating Fluid)
Check the viscosity of the test oil to determine whether or not the oil should be changed.
Technical Service Bulletin TSB160/14 details the equipment required to test the viscosity of
the test oil.
To change the test oil:
1. Remove the left lower panel from the test stand.
2. Remove the test oil pipe (2) from the clip and hold the pipe over a suitable container
(minimum capacity 45 litres) and allow the oil to drain out of the tank.
3. Remove the test oil filter from inside the tank. Wipe out the inside of the tank with a
clean dry absorbent cloth.
4. Fit a new test oil filter and fit the test oil pipe into the clip.
5. Fill the tank with the correct oil.
NOTE:
At the same time, drain the waste oil in the table drain tank. Remove the plug (Figure 17.2,
item 3) and drain the oil into a suitable container. Refit the drain plug.
17.2.3.2 Change the Metering Filters

Refer to Figures 17.3, 17.4 and 17.5. With the fuel system switched off, remove the filters
from the metering unit manifold and the filter mounted in the inlet to the metering unit. Fit
new filters.
Figure 17.3 Removal of Cover to Gain Access to the Metering Unit
Figure 17.4 Changing the Metering Filters

(filters at the back of the filter block are shown, the remaining filters are at the front)
Figure 17.5 Location of Inlet Metering Filter

17.2.3.3 Change the Lube Oil (if fitted)
1. Remove the lube oil pipe from the clip and allow the oil to drain into a suitable container
(minimum capacity 14 litres).
2. Remove the lube oil filter from inside the tank.
3. Wipe out the inside of the tank with a clean dry absorbent cloth.
4. Fit a new lube oil filter and refit the lube oil pipe into the clip.
5. Refill the lube oil tank with the correct oil.
6. Fit the left lower panel.
7. Change the filter fitted in the backleakage connection located on the lower facia panel
(Figure 4.12, item 23). The filter is a sliding fit within the bore of the fitting. Disconnect
the pipe connection. Thread an M8 bolt into the filter bore and withdraw the filter. Insert
a new filter.
17.3 Metering System Auditing

Carry out the following metering system audit procedures each week in the order given.
CAUTION!
The metering unit is a precision assembly and must only be serviced by qualified personnel.
Never run the test stand with any filter removed.
The audit procedures should be carried out with MCB4 temperature below 35°C and the
deliveries restricted as follows:
Number of Maximum delivery

lines selected per line (mm³/st)
4 150
6 100
8 75
12 50
17.3.1 Audit 1 - Every 20 hours or weekly (whichever occurs first)

Refer to Figure 7.3 Diagnostic Screen
Audit 1 detects leaks in the metering unit and must be carried out with the metering unit
temperature below 35°C.
1. Connect all the lines of the pump being used.
2. Select ‘Audit 1’ test on Diagnostic screen.
3. Follow the instructions on the screen.
NOTE:
The leak rate must be less than 0.2mm/min.
Causes of leakage which can be rectified by the maintainer include:
• Metering Unit Drain Solenoid
• Metering Unit Filter Plug
• Piezo Transducer O-ring
If the problem is not resolved by these actions contact your local agent or Lucas
Aftermarket Operations at Birmingham.

Audit 2 detects leaks in each metering line. This test must be carried out only after Audit 1
and with Metering Unit temperature below 35°C.
1. Connect all the lines of the pump being used.
2. Select ‘Audit 2’ test on Diagnostic screen.
3. Follow the instructions on the screen.
NOTE:
The leak rate must be less than 0.8 mm/min.
Causes of leakage which can be rectified by the maintainer include:

• Injector adaptors
• Quick Release Couplings
• Braided pipes
• Injector Solenoid Valves
• Injector Filter Plugs

This test checks restrictions in each line and metering unit.
1. Fit a pump to SOME of the lines.
2. Remove injectors from unconnected lines which will be tested.
3. Select Audit 3 on the Diagnostic screen
4. Follow the instructions on the screen
NOTE:
The value should be greater than 35 mm/sec. If the measured value is greater than 35 (-35
on the screen) the filter is OK.
Causes of restriction which can be rectified by the maintainer include:
• Metering Unit Filter
• Injector Filter
• Braided pipes
18. Specifications
18.1 Main Drive
Power 7.5kW (10HP) or 15kW (20hp) continuous
Max Torque 65Nm or 150Nm continuous
Speed range 30 to 4000 rpm clockwise and anticlockwise
Speed control Full closed loop control by digital input into the PC keyboard
with ±5 to 250rpm analogue speed trim using potentiometer.
Acceleration rate Selectable up to 400 rpm/second
Flywheel inertia 1 kgm² (24lbft²)
Drive Coupling Suitable for 75, 90 and 120mm diameter dog drives
Stiffness: 600mm/st (ISO4008 rating)
18.2 Calibrating fluid Supply System

Pump Capacity Low pressure 550l/hr (660l/hr for 60 Hz).
High pressure 108 l/hr (130l/hr for 60Hz)
Pressure Low pressure -1 to 4 bar (-14 to 60psi).
High pressure 8 to 80bar (120 to 1200psi).
Tank 45 litres nominal (12 US Gallons)
Fitted with: Suction filter
Over-temperature thermostat
Low oil level protection
Level indicator and drain pipe
Sludge and magnetic particle traps.
Temperature control 25 to 65°C±2°C using electric heater and water / oil heat
exchangers.
18.3 Lube Oil Supply System (Optional)

Pump Capacity 250l/hr (300l/hr for 60 Hz)
Pressure 0 to 4 bar (0 to 60psi)
Tank 14 litres nominal (3.7 US Gallons)
Fitted with: Suction filter
Low oil level protection
Level indicator and drain pipe
Sludge and magnetic particle traps
Oil drain direct from table.
18.4 Metering System

Metering unit Capacity 0 - 500mm³/stroke.
Water cooled for pumps with high temperature outputs
Pipe up in any order
Quick release injectors
18.5 Auxiliary Features

• d.c. power: two supplies 0 to 25V 3A maximum or 6A in parallel
• Socket for single cylinder calibrator operation
• Socket for measurement of Advance & rack movement (optional)
• Air supply connector
• Hours counters for Drive, Fuel Pumps and Fuel Filter

18.6 Measured Parameters

Parameter Units Display Range Accuracy Other selectable
Resolution units
Speed rpm 1 30 to 4000 ±1

Calibrating Fluid
Inlet Temperature °C 0.1 0 to 80 ±0.5 °F
Return Temperature °C 0.1 0 to 80 ±0.5 °F
Return flow cc/min 1 22 to 1200 ±10% l/min, l/hr,
cc/1000st, cc/10sec
Electronic Pressures
Inlet bar 0.01 -1 to 4 ±1% fso mbar
Turbo Boost 0.001 0 to 3 psi
Aux 1 0.01 0 to 7 kg/cm²
Aux 2 0.01 0 to 15 MPa
Phasing 0.1 0 to 100 HPa
Lube 0.1 0 to 4 kPa
mmHg
DC Power Supply V 0.1 0 to 25 ±0.1
Phasing Angles
Static deg 0.1 0 to 360 Operator
dependent
Dynamic deg 0.1 0 to 360 ±0.2*
Fuel Metering
Calibrate mode mm³/st 0.1 0 to 500 ±(0.4%+0.1mm³) cc/50st, cc/100st,
cc/125st, cc/200st,
cc/250st, cc/300st,
cc/500st
Overcheck mode mm³/st 0.1 0 to 500 ±(0.4%+0.1mm³) cc/50st, cc/100st,
cc/125st, cc/200st,
cc/250st, cc/300st,
cc/500st
Average mode mm³/st 0.1 0 to 500 ±(0.4%+0.1mm³) cc/50st, cc/100st,
cc/125st, cc/200st,
cc/250st, cc/300st,
cc/500st
Advance (Option) mm 0.1 20 ±0.1 DPA, DPC,
Stanadyne, Rack
NOTES:
fso = Full Scale Output
* = Typical for pump delivery 100mm³/st at 200rpm

19. Consumables
Description Cct. Ref. Part No. Fig Item
Filter element, 5 micron (Lube Oil) 4 8850072 20.1 6

Filter Element, 5 micron (Test Oil) 4 OH20/2/21/11 20.1 7
Filter (9 or 13 off) - 8850070 20.4 4
Filter, Backleakage Connection - UC6/2/17 20.6 4
Fuse, Semi-conductor 80A F4, F5, F6 8683018 20.2 16
Fuse, 40A (for 10 HP) F1, F2, F3 9844181 20.2 15
Fuse, 50A (for 20 HP) F1, F2, F3 9844182 20.2 15
Fuse, GEC NS10, 10A F7, F8, F9 9844184 20.2 14
Fuse, 20 x 5 2A A/S FS2, FS4 9842588 20.2 13
Fuse, 20 x 5 3A A/S FS1 9842591 20.2 12
Fuse, 20 x 5 10A A/S FS3 9842595 20.2 17
Keyboard skin (except USA) - 8689617E 20.1 12
Keyboard skin (USA only) - 8689617U 20.1 12
Injector Locking Pin Assembly (8 or 12) - 180-34-16 20.4 7

20. Spare Parts

20.1 Services
20.1.1 Pneumatic System
Air Service Assembly 26 167-11-46 20.2 2

Valve boost m/assy (Optional) 31 189-13-00 20.6 1
Pressure transducer (Boost) 32 134-93-14 20.6 1
Brake m/assy - 182-18-69 20.6 9
Brake pad m/assy - 182-18-71 20.6 9
Diaphragm (Modified) - 182-18-23 20.6 9
H/Press nylon pipe, blue, 6mm x 1 mm - R8022111 - -
Air connector CB7821/50 (Bayonet skt) - 8848017 20.6 7
20.1.2 Water System

Cooler solenoid valve 1 8681170 20.2 6

126.329.0 110V 50/60 SV
Cooler Matrix - 8868013 20.1 9
20.2 Power Distribution

Isolator switch (3 phase) - 8680325 20.3 2

Fuse, Semi-conductor 80A F4, F5, F6 8683018 20.2 16
Fuse, 40A (for 10 HP) F1, F2, F3 9844181 20.2 15
Fuse, 50A (for 20 HP) F1, F2, F3 9844182 20.2 15
Fuse, GEC NS10, 10A F7, F8, F9 9844153 20.2 14
Fuse, 2A 20 x 5 HRC ceramic F11, F12 9842599 20.2 21
Transformer - 134-92-19 20.2 9
Blower 220V 50/60Hz (with capacitor) - 8686452 20.1 1
Fuse 20 x 5 2A A/S FS2, FS4 9842588 20.2 13
Fuse 20 x 5 3A A/S FS1 9842591 20.2 12
Fuse 20 x 5 10A A/S FS3 9842595 20.2 17
Power Supply Variable E/A PSU 116-13-00 20.2 8
Emergency Stop operator (red) E.STOP 8685017 20.1 11

20.3 Fuel (Test Oil) System

Contactor M101 8682035 20.2 20

Overload 4A (High voltage stands) M102 8682260 20.2 19
(Fuel) Pump-Gear (with lube) 8 8920115 20.1 4
(Fuel) Pump-Gear (without lube) 8 8920118 20.1 4
(Heater) relay, s.state, 480V 25A - 8681591 20.2 18
Element-Heater, 220V 1250W, 5 8689151 20.1 8
Switch, float, vertical 6 8687354 20.3 1
Pressure Control Valve M/Asy 11 160-39-12 20.3 6
Thermistor (25m long) 9 174-02-42 20.5 1
(for fuel temp)
Bobbin, Loading - 160-39-03 20.5 3
Spindle (Left Hand thread) - 160-39-05 20.5 8
Gasket - 160-39-10 20.5 10
O-ring RM0081-16 VA75, 8.1 x 1.6 - 9700033 20.5 9
O-ring RM0321-16 VA75, 32.1 x 1.6 - 9700113 20.5 4
O-ring RM0321-24 VA75, 15.6 x 2.4 - 9700203 20.5 5
Thermostat, tank temp. 3 8687310 20.2 4
Filter element, 5 micron 4 8850072 20.1 7
Flow transducer S8011R 10 8687365 20.5 6
Pressure Transducer - Supply 14 134-93-15 20.1 5
Pressure Transducer - Aux 1 14 134-93-17 20.1 5
Pressure Transducer - Aux 2 14 134-93-18 20.1 5
Pressure Transducer - Pressure Phase 14 134-93-19 20.1 5
Thermistor (Return Flow) 9 167-11-35 20.4 7
Motor, Fuel Pump 0.75kW, Dual V & Hz 7 8910228A 20.1 4
Pipe, High Pressure, black rubber - ALP 206 20.6 5
Pipe, Low Pressure 18 x 4 - 167-11-02 20.6 3
Blanking plug (Fluid connections) - E190/42 20.6 6
20.4 Lube Oil System (Option)

Switch, Float, Vertical 6 8687354 20.3 1

Filter Element, 5 micron 4 OH20/2/21/11 20.1 6
Pump-Gear (Lube oil pump) 33 8920115 20.1 2
Control, Valve, Pressure m/assy 34 160-39-12 20.3 6
Pressure Transducer - Lube 14 134-93-16 20.1 5

20.5 Drive System

Contactor M102 8682026 20.2 21

590 DC Drive Controller SSD SSD 590 101-05-00 20.2 10
System Control PCB (SCB2) - 137-82-00 20.2 11
Safety Relay - 8682559 20.2 19
Coupling, A/backlash m/assy - 182-18-76 20.6 2
Encoder, rotary - 8687091 20.3 3
20.6 Metering System

PCB Metering No. 3 E/Assy - 106-25-00 20.2 1

Metering Unit - AVM12 M/Assy 43 174-14-20 20.4 5
Metering Unit - AVM8 M/Assy 43 174-14-21 20.4 5
Transducer, Linear 38 8687212 20.4 3
Thermistor (25mm long) 9 174-02-42 20.4 -
Filter (9 or 13 off) - 8850070 20.4 4
Piezo transducer E/Assy 40 180-30-60 20.4 1
331-VLO1.21H valve body 39 8681053 20.4 2
Coil, 110V, 50Hz 39 8681012A 20.4 2
Quick connector B-QF4-B-4PM 35 8924265 20.4 8
(8 or 12 off)
Metering Unit Pipe (8 or 12 off) 36 180-34-17 20.4 4
Spring, gas (750N/40)(mounted in - 8905113 20.4 11
upper swing arm tube)
Transducer, Temperature - 8687109 20.4 10

20.7 General Requirements

Filter, Backleakage Connection - UC6/2/17 20.6 4

CD-ROM (AVM2 Application) - 135-12-01 - -
PC Monitor - 8684329 20.3 5
PC - 8689283 20.3 4
Keyboard (Finland) - 8689616A 20.1 13
Keyboard (Netherlands) - 8689616D 20.1 13
Keyboard (UK) - 8689616E 20.1 13
Keyboard (France) - 8689616F 20.1 13
Keyboard (Germany) - 8689616G 20.1 13
Keyboard (Italy) - 8689616I 20.1 13
Keyboard (Portugal) - 8689616P 20.1 13
Keyboard (Spain) - 8689616S 20.1 13
Keyboard (USA) - 8689616U 20.1 13
Keyboard skin (except USA) - 8689617E 20.1 12
Keyboard skin (USA only) - 8689617U 20.1 12

Figure 20.1 Test Stand - Left View

Figure 20.2 Test Stand - Right View

Figure 20.3 Test Stand - Rear View

Figure 20.4 Injector Mount
Figure 20.5 Fuel Pressure Control Valve

110 Figure 20.6 Facia Services AVM2-PC MAN-01(GB)


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HARTRIDGE

Installation & Start-Up

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Installation & Start-Up

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

This equipment contains electrostatic sensitive devices. Observe the necessary

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Figure 4.1 AVM2-PC

4.2 Installing the Test Stand

Figure 4.2 Levelling the Test Stand

4.3 Remove Transit Fittings

4.3.2 Test Stand Bed

Figure 4.3 Injector Mount Transit Fittings

Figure 4.4 Test Stand Base Transit Fittings

Figure 4. 5 Console Transit Fittings

Figure 4.6 Water and Air Supply Connections

4.4.2 Air Supply

4.5 Test Stand 3 Phase Electrical Supply

4.5.1 380 - 480V Supply

Figure 4.7 Test Stand Isolator Box and 3 Phase/Earth Terminals

4.5.2 Test stand transformer primary setting and 50/60Hz selection

Figure 4.8 Internal Transformer

4.6 PC Single Phase Electrical Supply, Keyboard and Mouse

Figure 4.9 PC Connections

4.7 Filling the Oil Tanks

4.7.2 Lube Oil (option)

Figure 4.11 Table Return Pipe

4.8 Connecting a Printer, Modem or Network Card

4.9 Installation Check List

Figure 4.12 Test Stand Controls and Connections (Front view)

Figure 4.13 Test Stand Controls and Connections (Back view)

5. Starting-Up the Test Stand

5.1.2 Switching the 3 phase supply OFF

5.1.3 Switching the PC ON

5.1.4 Switching the PC OFF

5.2 Emergency Stop

5.3 Initial Power On

Figure 5.1 AVM2-PC Screen

Figure 5.2 Setup Screen

5.4 Changing Owner Details

5.5 Changing Date and Time

Figure 5.3 Setup Screen with 'Change Language' Selected

5.6 Adjusting the Monitor

Figure 5.4 Monitor Adjustment Controls

5.7 Start the Fuel Pump

3. Check for correct pump operation by:

5.8 On Line Help

6.2 Pneumatic Circuit

6.3 Lube Option Circuit

6.4 AVM2-PC Metering Circuit

6.5 Index to Hydraulic, Pneumatic and Cooling Water Circuits

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6.6 Electrical Circuits

A032 - CIRCUIT DIAGRAM INDEX

WIRE No. SERIES:- 100 - L1

AVM2-PC Electrical Circuit Diagram Index