World Leaders in Diesel Fuel Injection Test Equipment.

Pumpmaster Electronic
Test Stands
PM1008 & PM2012

User Manual

Ref. No. HL002GB

HARTRIDGE LIMITED USER MANUAL

Pumpmaster Electronic
Test Stands
PM1008 & PM2012

CONTENTS

Foreword iii
Safety Information iv
Introduction and Specification Section 1
Installing Section 2
Systems Section 3
Operating Section 4
Maintenance Section 5
Spares List Section 6
Speed and Graphics System (Option) Appendix 1
Internal Chiller System (Option) Appendix 2
PGM Calibrator (Option) Appendix 3
Internal Lube System (Option – PM2012 only) Appendix 4

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Foreword
The equipment has been designed and manufactured to give maximum performance. Regular maintenance and
servicing will ensure maximum service life.
Worldwide service and support facilities are provided by Hartridge Ltd, The Hartridge Building, Network 421,
Radclive Road, Buckingham, MK18 4FD, U.K., which may be contacted if any difficulty is experienced.
It is essential to quote the MODEL and SERIAL NUMBER of the machine in all communications.

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

Warranty
The Pumpmaster range of test stands is covered by the Hartridge Ltd. standard Terms and Conditions of Sale or
Supply. Details of warranty may be obtained from Hartridge Ltd. The use of replacement parts or lubrication oils
not supplied or approved by Hartridge Ltd. can lead to expensive failures which will not be covered by warranty.
Consult Hartridge Ltd., The Hartridge Building, Network 421, Radclive Road, Buckingham, MK18 4FD, U.K. for
advice if any doubt exists.

Maintenance
To ensure continued, trouble-free operation of the equipment, it is important that periodic servicing is carried out
in accordance with the information contained in this publication.
Use only the replacement parts recommended by Hartridge Ltd. when carrying out routine maintenance,
overhaul or repair.
When handling, operating and/or performing maintenance or repair, personnel are expected to use safe
engineering practices and to observe all relevant national and local safety regulations.
Work requiring electrical and mechanical competence must be carried out by suitably skilled personnel.

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Safety Information
Most accidents involving equipment operation and maintenance are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognising potentially hazardous situations
beforehand. The equipment is designed to be intrinsically safe whenever possible. Guards are fitted to afford
optimum operator protection.
Read and understand all warning, caution, prohibition and mandatory notices and labels on the equipment
before operation or carrying out any maintenance or servicing.
If in doubt - ASK!

Warnings, Cautions and Notes

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

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

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

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

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Warning Symbols

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.

Ensure the coupling guard is fitted over the coupling during operation. Ensure
the guard sleeve is fully extended to completely cover the drive coupling.

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.

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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 (during loading or
unloading) or test stand covers, are dropped.

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

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

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

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

There must be no naked flames. Potentially flammable vapours are present in

the test stand and ignition is possible although unlikely. Smoking whilst
operating the equipment is strictly forbidden.

Accidents can occur to unauthorised personnel during testing. Untrained

person(s) must not be present in the test area when the equipment is operating.
Only qualified personnel are to operate this equipment.

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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.

CAUTION

Care must be taken to ensure that the correct speed and the correct rotation are
selected for the pump under test. Always return the speed control to minimum
before switching off the test stand.

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.

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1. Introduction
This manual provides information about the safety, installation, operating and routine maintenance of
the Hartridge Pumpmaster PM1008 and PM2012 test stands which are designed to test diesel fuel
injection pumps. Where information is different depending on the model, this will be clearly indicated.
Troubleshooting information is also provided to assist the user to solve simple problems.
Make sure you have read and understand the information contained in this manual before attempting
to install and use the test stand.

1.1 Test Stand General Arrangement

Figure 1.1 shows the general arrangement of the PM1008 test stand. This is fitted with a 10 h.p. d.c.
drive motor and eight graduates. The PM2012 is fitted with a 20 h.p. d.c. drive motor and twelve
graduates.

Figure 1.1 Test Stand General Arrangement

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1.2 Specifications

Electrical Supply Standard: 380/480 V a.c. 3 phase 50/60 Hz (no neutral required)
Other voltage supplies require an optional external transformer
PM1008 PM2012
Current: 40 Amps 63 Amps
Weight: Gross: 855 kg. 980 kg
Net: 670 kg. 775 kg
Dimensions Refer to Fig 1.1.
Width (W): 825 mm 860 mm
Length (L): 1635 mm 1860 mm
Height (H): 1761 mm 1761 mm
Calibration Fluid Type: ISO4113
Capacity: 50 litres (tank) 55 litres (system)
Refer to Health and Safety Data Sheet for Calibration Fluid (ISO 4113)
Air Supply Clean, dry
Pressure: minimum 6 bar (90 lbf/in²)
maximum 8 bar (115 lbf/in²)
Flow rate: maximum 2.35 litre/min (5 ft³/min.)
Water Supply Clean, free of contaminant
Temperature: maximum 20°C (68°F)
Flow: 3 litres/min.
Pressure: minimum 4 bar (58 lbf/in²)
maximum 7 bar (100 lbf/in²)
Lube oil (Option – PM2012 only)
Capacity: 20 litres (tank) 22 litres (system)

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Health and Safety Data Sheet for Calibration Fluid (ISO 4113)
HEALTH & SAFETY DATA SHEET DATE Pub. No.
Information regarding the safe handling & storage of the named product. MAR 97

Applicable to employees and customers.

PRODUCT WARNING
CALIBRATION FLUID (ISO 4113) SEEK IMMEDIATE MEDICAL ATTENTION
IF INGESTED
USE CLASSIFICATION
TEST FLUID FOR DIESEL INJECTORS, FLAMMABLE
INJECTION PUMPS & OTHER DIESEL EQUIPMENT

PRODUCT DESCRIPTION - COMPOSITION

THESE FLUIDS ARE PETROLEUM BASED PRODUCTS CONTAINING SIGNIFICANT PROPORTIONS OF
THE MORE VOLATILE PETROLEUM FRACTIONS AND OTHER SOLVENTS USED FOR LUBRICATION,
ANTI-CORROSION AND DERMATITIC INHIBITION.

SAFE HANDLING ADVICE (Protection - Usage, Storage & Transport)

USAGE: 1) Avoid eye splashes and extended skin contact.
2) Do NOT take internally.
3) Keep mist generated by machinery to a minimum, also avoid where possible vapours
caused by elevated temperatures.
4) Protective clothing to be regularly laundered.
STORAGE: These are flammable products which should be stored in closed containers away from heat in a
well ventilated area.

EMERGENCY & FIRST AID PROCEDURE (Eyes, skin, ingestion, inhalation)

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

FIRE HAZARDS & PROTECTION (Flash point, spillage)

SPILLAGE: Contain spillages with sand or mineral absorbent material. Mop up and clean floor to remove oil
residue.
FLASH POINT: Above 55°C.
FIRE: (Extinguisher media)
Use carbon dioxide, dry chemical powder or foam extinguishers. Do NOT use water jets.

ENVIRONMENTAL PROTECTION (Spillage land / water, disposal)

SPILLAGE: Advise authorities if product has entered or may enter sewers, water courses or extensive land
areas.
DISPOSAL: All waste should be put into identified containers and stored at a specific disposal point.
Arrange for off site disposal in accordance with local regulations for notified waste.

ASSEMBLY TECHNOLOGY & TEST LTD

Tingewick Road, Buckingham,
MK18 1EF, England.
THE INFORMATION AND RECOMMENDATIONS IN THIS PUBLICATION ARE TO THE BEST OF OUR KNOWLEDGE INFORMATION
AND BELIEF ACCURATE AT THE TIME OF PUBLICATION NOTHING HEREIN TO BE CONSTRUED AS A WARRANTY, EXPRESS OR
IMPLIED IN ALL CASES. IT IS THE RESPONSIBILITY OF THE USERS TO DETERMINE THE SUITABILITY OF ANY PRODUCTS FOR
THEIR OWN PARTICULAR PURPOSE. RECOMMENDATIONS FOR HANDLING, PROTECTION ETC. ARE ADVISORY ONLY.

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2. Installation
2.1 Positioning the Test stand
Refer to Figure 2.1. Observe the following when transporting and positioning the test stand:

• Swivel the metering unit assembly (3) to the front of the test stand.
• Tighten the captive bolt (1) to secure the metering unit assembly in position.
• Ensure the lifting equipment is capable of carrying the weight of the test stand.
• A lifting eye is supplied with the test stand. This is located inside the rear of the test stand on the
main motor support bar. Unscrew the plastic plug from the threaded hole at the front of the control
panel enclosure and screw in the lifting eye (4). A lifting rope can be tied to the eye and attached to
the pump mounting bed as shown in Figure 2.1.
• Place protective material (2) between the rope and the body of the test stand to prevent the rope
damaging the paintwork.
• Avoid pushing the test stand for a long distance when installing. Do not push against the metering
unit assembly (3) or the control enclosure (5).

• The test stand is designed to be free standing on a solid level floor. Using a spirit level, check that
the bedplate is horizontal in both planes by adjusting the four levelling feet in the baseframe as
required.

Figure 2.1 Lifting the Test Stand

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2.2 Connecting the Air Supply

Refer to section 1.2 for specification. Connect the air supply to the 8mm diameter barb connector
(Fig 3.6 item 12) located at the rear of the test stand beneath the electrical equipment enclosure door.
NOTE:
The display on the Central Control Unit will not illuminate if the air supply is not connected.

2.3 Connecting the Cooling Water

Refer to section 1.2 for specification. Connect the cooling water supply (Fig.3.8 item 5) and return
(Fig.3.8 item 6) pipes to the two 10mm diameter barb connectors located at the rear of the test stand
beneath the electrical equipment enclosure door.

2.4 Filling the Test Fluid Tank

The test stand uses ISO4113 test fluid (see Calibrating Fluid Data Sheet in section 1). Remove the
small left hand side panel which provides access to the test fluid tank. Lift off the tank lid and fill the
tank to the maximum level shown by the sight level gauge. The tank capacity is approximately 50 litres.
Check that the tank thermostat is set to 60°C. Replace the tank lid and access panel.
NOTE:
The display on the Central Control Unit will not illuminate if the tank level is below the minimum level.
Keep the tank well above the minimum level as indicated on the level gauge.

2.5 Filling the Lube Oil Tank (If Fitted)

Refer to section 1.2 for specification, and Appendix 4 for layout and description. This is an optional
system, available at build on PM2012 models only.

2.6 Electrical Installation

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.

2.6.1 Set the Internal Transformer Voltage

Ensure that the primary tapping (wire number 56) on the internal transformer (Fig 3.3 item 14) is set to
the voltage closest to the incoming supply voltage.

2.6.2 Connect the Test Stand

WARNING!
THE INCOMING MAINS CABLE MUST BE CAPABLE OF CARRYING THE
TOTAL LOAD CURRENT OF THE TEST STAND.

The following minimum cable sizes should be used . PM1008: 6 mm² section.
PM2012: 10 mm² section.
CAUTION
Do not use cables longer than 20 m to connect the test stand to the mains power.
Refer to Fig 2.2.
1. Feed the cables through the holes provided in the base of the test stand.
2. Connect the cables to the connection box at the back of the test stand (Figure 3.3 item 16).
3. Connect the ground wire to the special connector provided.

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4. Check the rotation of the test fluid pump motor. Switch on the test stand power using the mains
isolator switch (Fig 3.3 item 11). Start the test fluid pump using the Test Fluid Supply Pump
ON/OFF button (Fig. 4.1 item 6). Adjust the test fluid pressure control valve (Fig. 3.6 item 8) to
give a positive pressure on the gauge (Fig. 3.5 item 3). If a positive pressure cannot be achieved,
the pump rotation is incorrect. In this case, switch off and isolate the test stand. Change over the
connections of any two of the three incoming phase wires.
NOTES:
a. If the power supply exhibits voltage fluctuations, contact your nearest dealer for assistance.
b. Refer to the Troubleshooting section of this manual to solve simple problems experienced during
operation. Contact your nearest dealer if you cannot identify and solve the problem using this
manual.

Figure 2.2 Electrical Connections

CAUTION
After the test stand is installed, slacken the captive bolt (Fig 2.1 item 1) until the metering unit
assembly is able to move freely. Do not to loosen the bolt completely.
NOTE:
The glycerin filled pressure gauges have a cap in the body top to allow the glycerin to ‘breathe’ and
avoid condensation. As soon as the test stand is installed, loosen the caps slightly to prevent
condensation. Do not remove the caps.

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2.7 Installation Checklist

Before starting the test stand, check:

• Test stand correctly positioned and level

• Air supply connected
• Cooling water connected
• Test fluid tank filled to correct level (and lube oil tank if system fitted)
• Internal transformer voltage correctly set
• Electrical connector box connected to incoming mains
• Metering unit captive bolt slackened
• Glycerin filled pressure gauge caps loosened slightly
• Test fluid pump motor rotation checked
• Tank thermostat set to 60°C
• All access panels and fixed covers fitted and all doors closed

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3. Systems
3.1 Pressure Gauges, Pressure Controllers and Bulkhead Connections
Refer to Figure 3.1.

Figure 3.1 Pressure Gauges, Pressure Controllers and Bulkhead Connections

KEY TO FIGURE 3.1
1 Transfer Pressure Reading Group 6 Air Supply Connection
2 Auxiliary Pressure Reading Group 7 Test Fluid Supply Connection
3 Air Pressure Control Group 8 Flowmeter Return Connection
4 High Pressure Control Group 9 Direct Tank Connection
5 Supply Pressure Control Group 10 High Pressure Supply Connection

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3.2 Electrical Equipment

Refer to Figures 3.2, 3.3 and 3.4.
Control Button Group (1)
Buttons in group (1) operate the fluorescent lamp, temperature control, temperature set point and test
fluid pump. Refer also to section 3.7 and Fig 3.10.
Control Display (2)
Gives readout of speed, temperature, drive direction, shot count and temperature control status.
Speed Control Potentiometer (3)
This manually operated potentiometer is used to set the speed of the main drive motor. The Speed
range is from approximately 50 rpm to 4000 rpm.
Control Button Group (4)
Buttons in group (4) operate the metering system shot count, main drive direction of rotation and main
drive motor. Refer also to section 3.7 and Fig 3.10.
Selector Switch 12/24 Volt d.c. (5)
Used to select either 12 or 24 V d.c.
12/24 Volt d.c. Reset Push-button (6)
Resets the supply should the voltage trip out.
Socket 12/24 Volt d.c. Supply (7)
Connection socket for the 12/24 V d.c. supply.
Temperature Sensor - Test Fluid Supply (8)
This temperature sensor senses the temperature of the test fluid supply and sends the signal to the
Central Control Unit. The test fluid supply temperature is controlled to the set temperature.
Calibrator Lamp (9)
A 15 W fluorescent lamp is provided to assist the operator in viewing the graduates.
Auxiliary Socket (10)
This socket provides an output signal from the encoder for external calibrating equipment. The
encoder generates 60 pulses of 5 Volt amplitude per revolution.
Mains Isolater Switch (11)
Used to switch the test stand on and off. The switch isolates the test stand from the incoming mains
electrical supply.
Main Motor (12)
Refer to 3.2.1 for specification. The flywheel is directly coupled to the main motor.
Encoder (13)
An encoder is mounted on the back of the main motor and picks up a signal as the motor is running.
The signal is used to control the speed of the main motor.
Transformer (14)
Regulates the internal test stand voltage.
Electronic Equipment Enclosure (15)
Houses the test stand electronic equipment.
Mains Supply Connection Box (16)
Connection box for 3 phase supply.

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Cooling System Solenoid (17)

The test stand uses water to control the test fluid temperature. Water is circulated through the cooling
coil inside the tank. The central control unit operates the solenoid valve to allow cooling water to pass
through the cooling coil when required.
Test Fluid Tank Low Level Switch (18)
When the switch is actuated the main drive and test fluid supply pump are switched off and the test
stand electrical equipment is disabled. The display is also switched off.
Heater (19)
The 1500 W heater is located in the test fluid tank.
Test Fluid Tank Over- temperature Thermostat (20)
If the test fluid system temperature rises above 60ºC the thermostat will switch off the power to the test
fluid tank heater.
Air Low Pressure Switch (21)
If the inlet air falls below 5.5 bar the switch will stop the main drive, test fluid supply pump and will
disable the test stand electrical equipment except for the main motor cooling fan.
Temperature Sensor - Test Fluid Return (22)
This temperature sensor senses the temperature of the test fluid return and sends the signal to the
Central Control Unit.
Emergency Stop Buttons (23)
These are situated on each side of the control console. Pressing either will stop the main drive, test
fluid supply pump and disable the test stand electrical equipment. The display is switched off.
NOTE:
The Air Low Pressure switch (21) and the Test Fluid Tank Low Level switch (18) act in the same way
as the Emergency Stop buttons. The main motor fan is not disabled when an Emergency Stop button
is operated.
Turn the Emergency Stop button clockwise to unlatch the button and restore the electrical supply to the
control console.
Metering Shutter Actuator (24)
This operates the metering shutter.
Main Motor Cooling Fan (25)
The cooling fan provides cooling air for the motor.
Brake Actuator Solenoid (26)
This controls the air brake that stops the main drive when an Emergency Stop button is pressed.
Pneumatic Valve (27)
Test Fluid Supply Pump/Motor (28)
The transfer pump is run by a 1.5 hp/1.1 kW a.c. motor.

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Figure 3.2 Electrical Equipment (front view)

KEY TO FIGURES 3.2, 3.3 & 3.4

1 Control Button Group - Left 15 Electronic Equipment Enclosure
2 Control Display 16 Mains Supply Connection Box
3 Speed Control Potentiometer 17 Cooling System Solenoid
4 Control Button Group - Right 18 Test Fluid Tank Low Level Switch
5 Selector Switch 12/24 V d.c. 19 Heater
6 12/24 V d.c. Reset Push-button 20 Test Fluid Tank Over-temperature Thermostat
7 Socket 12/24 V d.c. Supply 21 Air Low Pressure Switch
8 Temperature Sensor – Test Fluid 22 Temperature Sensor – Test Fluid
Supply Return
9 Calibrator Lamp 23 Emergency Stop Buttons
10 Auxiliary Socket 24 Metering Shutter Actuator
11 Mains Isolater Switch 25 Main Motor Cooling Fan
12 Main Motor 26 Brake Actuator
13 Encoder 27 Pneumatic Valve
14 Transformer 28 Test Fluid Supply Motor

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Figure 3.3 Electrical Equipment (side view)

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Figure 3.4 Electrical Equipment (rear view)

3.2.1 Electrical Circuit Description
Refer to the electrical panel layout (Fig 3.13), electrical circuits (Figs 3.14, 3.15, 3.16, 3.17) and the
electrical component layout drawings (Figs 3.2, 3.3, 3.4). Numbers in brackets refer to Figs 3.2, 3.3,
and 3.4 unless otherwise stated.
Power circuits
Incoming power is 3 phases (50 or 60 Hz, 380 to 480 V a.c.) and earth via connection box (16) - no
neutral is used. Any supplies outside the range 380 to 480 V require an external transformer.
The isolator switch (11) on the side of the machine disconnects the 3 phase input supply. The 3
phases pass through the machine main trips F1 to F3 which sense overload in any phase and then trip
all three phases. They are manually reset.
All low voltage supplies are derived from a control transformer (14) mounted inside the machine,
powered from 2 phases via trip F4. This trip is manually reset. The input wire 56 should be connected
to the tapping which is nearest in value to the supply voltage into the machine.
The fuel pump motor runs when contactor K1 is energised. An overload trip (with reset by pressing a
button) is attached to the contactor for protection.
The heater is powered when RL2 is energised. Overload trip F5 protects the circuit. A thermostat, set
to 60°C, breaks the heater power circuit if the tank oil is too hot.
The heater consists of 2 elements connected in series. Each element has a resistance between 50
and 60 ohms. Current is 3 to 4 amps. An indicator lamp located next to the thermostat turns on when
there is voltage across one of the elements.
For cooling, a 220 V a.c. solenoid (17) is energised to allow water to flow through cooling coils in the
test oil tank. There is no internal pump; supply pressure defines the water flow. If a chiller unit is used,
this has its own pump to circulate the water.

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Interlocks
The 2 emergency stop buttons (23), tank level switch (18), air pressure switch (21), and fuel pump
motor overload trip T1 are wired in series to connect 24 V a.c. to the emergency stop relay RL1. If any
of these switches operate, then power is removed from the Control Panel, and the drive and fuel pump
will stop.
The drive and temperature control cannot be started unless the fuel system has been switched on.
Both are switched off if the fuel system is switched off. This logic is performed in the microcontroller
circuit board.

Temperature Control and Measurement

A temperature sensor is located in the fuel return port of the pressure control valve. The sensor
outputs its signal as digital pulses to the microcontroller board in the control panel. An LED illuminates
on this board to indicate that the sensor is generally working.
The supply temperature is normally shown on the display (Fig 4.1 item 19).
If the temperature control system is switched on, this temperature is compared to the set demand. If
the temperature is rising, the heater switches off when the temperature equals the set demand. If the
temperature is falling, the heater switches on when the temperature is one degree less than the set
demand.
The cooler solenoid energises when the temperature is one degree above the set demand. It switches
off when the temperature equals the set demand.
LEDs on the display (Fig 4.1 items 25, 26, 27) indicate the temperature control status.
To turn the heater on, the microcontroller board energises a relay on the Relay board. This relay in
turn energises the heater relay RL2 to power the heater.
To turn the cooler on, the microcontroller board energises a relay on the Relay board. This relay in
turn energises the cooler solenoid.
A second identical temperature sensor, located in the bulkhead connection to the flowmeter, is used to
measure the temperature of the back leakage return oil. An LED illuminates on the microcontroller
board to indicate that the sensor is generally working.
The back leakage temperature is displayed in place of the supply temperature if the set temperature
button (Fig 4.1 item 3) is pressed while the drive is running. Back leakage temperature cannot be
viewed when the drive is off.

Drive system
The drive system consists of:
DC motor: PM1008: 10 hp at 3000 rpm (400 V armature). Maximum speed
4000 rpm by field weakening. Armature current 23 A
(torque 24 Nm). Field current 2 A.
PM2012: 20 hp at 2500 rpm (400 V armature). Maximum speed
4000 rpm by field weakening. Armature current 45 A
(torque 57 Nm). Field current 2 A.
Encoder: 2 channels of 60 pulse per rev. Mounted directly on the back of the motor.
Speed demand: Single turn 10 K potentiometer with a large diameter marked speed dial.
Speed PCB: Compares the speed demand to the encoder pulse rate and produces a
torque demand signal according to the difference.
Potentiometers on the board allow adjustment for ramp rate, drive stability,
minimum speed, and calibration of the speed dial.
Located in the Control Panel.

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DC Drive: Adjusts the voltage across the armature to produce armature current
proportional to the torque demand from the speed board.
Also supplies controlled field current and automatically weakens the field
above 3000 rpm (PM1008) or 2500 rpm (PM2012) to keep the armature
volts at 400V.
Contactors: Two contactors for clockwise or counter clockwise rotation by swapping over
the armature wires.
Interlocks: Drive on/off and direction controls on the front panel input to the
microcontroller board, which then operates the drive contactors and brake
as required.
Air operated brake: Operates to brake the flywheel when the emergency stop relay is de-
energised or the drive button is pressed to stop the drive.
Braking remains on until one second after the motor has stopped.
The operation of the drive contactors is controlled by the microcontroller board independently of the
status of the drive unit or speed board.
The speed board outputs 0 to 10 V to demand current from the drive.
The output is raised if the speed demand is greater than the speed measured from the encoder pulse
rate. The output is clamped low when the contactor is not energised.
Armature voltage from the drive is compared to the speed measured by the board to check for loss of
feedback pulses. A red indicator on the speed board latches on for a speed feedback loss condition,
reset when the drive run indicator is off. The speed board also has an A/D converter to measure drive
current. This is output in digital form to the microcontroller board to display as the main motor current.
Speed measurement
One channel of the 60 pulse per rev encoder output is connected to the microcontroller board. An
indicator on the microcontroller board flashes for each pulse input. Pulses are counted over 1 second
to give the speed in rpm. This pulse input is also used for the stroke countdown control.
Stroke system
The microcontroller board energises the stroke relay and LED on the relay board to operate the
mechanism which deflects the injected oil into the graduates. The stroke board requires a 24 V a.c.
supply. The board outputs a positive pulse to drive the stroke 12 V d.c. motor to the metering position,
and a negative pulse for back. The red indicator on the board shows that 24 V a.c. supply power is
present. The green indicator turns on to show metering. Note that the output is a pulse through a
capacitor, and is therefore difficult to check with a voltmeter.
Fuse and overload settings
Refer to Fig 3.13.

Description Reference PM1008 PM2012

Setting Setting
Main Overload Trip F1, F2, F3 40 A 63 A
Control Transformer Trip F4 16 A 16 A
Heater Trip F5 6A 6A
Fuel Pump Motor Overload Trip T1 2.2 A 2.2 A
Lube Oil Pump Motor Overload Trip (PM2012 – if fitted) T2 n/a 2.2 A
Relay board 24 V a.c. fuse (20 mm x 5 mm) S1 (on board) 2.5 A 2.5 A
Relay board 220 V a.c. fuse – cooling solenoid (20 mm x 5 mm) S2 (on board) 0.2 A 0.2 A
Relay board 220 V a.c. fuse – DC motor fan (20 mm x 5 mm) S3 (on board) 2.5 A 2.5 A
Relay board S4 (on board) not used not used
Relay board 220 V a.c. fuse – transformer (20 mm x 5 mm) S5 (on board) 1A 1A
DC Supply (Adapter) Board fuse (20 mm x 5 mm) - 5A 5A

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Relay board yellow indicators

The nine relays on the relay board are driven by the microcontroller board. A yellow indicator LED
(located to the left and slightly above each relay) shows when the relay is energised. From top to
bottom the functions are:
Brake Energised while the motor is stopping.
Motor direction Energised for anti-clockwise direction.
Drive Energised for drive on.
Fuel pump Energised for fuel pump on.
Lube oil PM1008: n/a.
PM2012: energised for lube oil pump on (if fitted).
Stroke Energised for metering of injected fuel.
Cooler Energised for cooling water solenoid energised.
Heater Energised for heater turned on.
Calibrator lamp Energised for lamp on.

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3.3 Test Fluid and Pneumatic Equipment

Refer to Figures 3.5 and 3.6.
Air Pressure Control Valve (1)
Used to adjust the air supply pressure.
High Pressure Phasing Gauge (2)
Measures up to a maximum pressure of 100 bar.
Supply Pressure Gauge (3)
Measures the supply pressure of the test fluid from –1 to 4 bar.
Transfer Pressure Gauge (4)
Measures up to 14 bar.
Auxiliary Pressure Gauge (5)
Measures up to 6 bar.
Air Pressure Gauge (6)
Measures from 0 to 2.5 bar.
Flowmeter (7)
The flowmeter measures test fluid return flow. For accurate measurement the test fluid should be
certified ISO4113. Refer to the Data Sheet for Calibration Fluid ISO4113 in section 1.
Test Fluid Pressure Control Valve (8)
Test fluid pressure can be adjusted up to a maximum of 3 bar for pump feed pressure, as indicated on
pressure gauge (3). Further adjustment of the regulator provides a pressure phasing pressure of up to
50 bar as indicated on the gauge (2).
NOTE:
It is recommended that the pressure be reduced to a minimum after a pump has been tested.
Waste Fluid Tank and Drain Valve (9)
The waste fluid tank collects any spilt test fluid and lubrication oil mixture from the drip tray. A drain tap
mounted below the tank inside the test stand is used to drain the waste tank.
Test Fluid Filter (10)
The filter is placed in its own section of the tank to prevent aeration.
Test Fluid Supply Pump (11)
The gear type pump supplies test fluid up to a maximum of 9 lt./min.
Air Inlet (12)
Test stand air supply connector.

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Figure 3.5 Test Fluid and Pneumatic Equipment (rear view)

KEY TO FIGURES 3.5 & 3.6
1 Air Pressure Control Valve 7 Flowmeter
2 0 - 100 bar High Pressure Gauge 8 Test Fluid Pressure Control Valve
3 -1/+4 bar Test Fluid Supply Pressure Gauge 9 Waste Fluid Tank and Drain Valve
4 0 - 14 bar Transfer Pressure Gauge 10 Test Fluid Filter
5 0 - 6 bar Auxiliary Pressure Gauge 11 Test Fluid Supply Pump
6 0 - 2.5 bar Air Pressure Gauge 12 Air Inlet

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Figure 3.6 Test Fluid and Pneumatic Equipment (side view)

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3.4 Metering System

Refer to Figure 3.7.
The metering unit assembly is mounted on a rotating arm and can be moved around to the front or
either side of the test stand. Height adjustment is also provided by operating handle (5).
Graduates (2 & 3)
The capacities of the graduates in the different models are as follows:

PM1008 PM2012
3 3
Small Graduates 26 cm 38 cm
3 3
Large Graduates 120 cm 260 cm

Test Injectors (6)

The injector mount assembly can accommodate most common types of test injectors by fitting suitable
adapters.

Figure 3.7 Metering System Equipment

KEY TO FIGURE 3.7
1 Shutter Actuator 7 Spray Chambers
2 Large Graduate 8 Flow Needle
3 Small Graduate 9 Large Graduate Holder
4 Metering Unit Assembly 10 Small Graduate Holder
5 Height Adjustment Handle 11 Position Lock
6 Injector

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3.5 Cooling System

Refer to Figure 3.8.
The cooling system operates in conjunction with the heater as part of the integrated temperature
control system. The test stand Central Control Unit monitors the temperature of the test fluid via a
temperature sensor and operates the solenoid valve to allow a flow of the cooling water to the cooling
coils when required. The cooling system consists of a cooling coil (1) mounted in the test fluid tank and
a water inlet solenoid valve (2).
Refer to Appendix 2 if the optional chiller system is fitted.

Figure 3.8 Cooling System Layout

KEY TO FIGURE 3.8
1 Cooling Coils 4 Water Supply Line
2 Supply Inlet Solenoid Valve 5 Supply Connector
3 Water Return Line 6 Return Connector

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3.6 Emergency Stop Braking System

Refer to Figure 3.9.
The brake system uses a friction type mechanical brake to stop the drive. The brake is active when the
power to the test stand is off. Operating an Emergency Stop button applies the brake to stop the drive
in an emergency.

Figure 3.9 Braking System Layout

KEY TO FIGURE 3.9
1 Brake Pads 5 Connector Rod
2 Brake Spring 6 Air Piston
3 Brake Arm 7 Air Pressure Regulator
4 Brake Cam 8 Air Pressure Gauge

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3.7 Central Control Unit

Figure 3.10 Central Control Unit

KEY TO FIGURE 3.10
1 Digital/LED Display 6 Speed Interface PCB
2 Left Touch Button Group 7 Emergency Stop Button
3 Speed Control Potentiometer 8 Display PCB
4 Right Touch Button Group 9 Central Control Unit PCB
5 Transformer

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3.8 Pneumatic Circuit

Figure 3.11 Pneumatic Circuit

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3.9 Hydraulic Circuit

Figure 3.12 Hydraulic Circuit

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3.10 Electrical Equipment Enclosure Layout

Figure 3.13 Electrical Equipment Component Locations

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3.11 Electrical Circuit Diagram

Figure 3.14 Electrical Circuit Diagram (1 of 4)

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Figure 3.15 Electrical Circuit Diagram (2 of 4)

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Figure 3.16 Electrical Circuit Diagram (3 of 4)

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Figure 3.17 Electrical Circuit Diagram (4 of 4)

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4. Operating the Test Stand

IMPORTANT NOTE
Read and understand all warning, caution, prohibition and mandatory notices and labels on the
equipment before operating the test stand.
WARNING!
MAKE SURE THE COUPLING GUARD IS FITTED OVER THE COUPLING
DURING OPERATION. A DAMAGED COUPLING MAY CAUSE SERIOUS
PERSONAL INJURY AND DAMAGE TO THE TEST STAND.

4.1 Before Testing

Refer to Fig 4.1. The numbers in brackets ( ) refer to items in Fig 4.1, unless otherwise stated.
1. Switch on the test stand power using the mains isolator switch on the R/H side of the test stand
(Fig 3.3 item 11).
2. Switch on the calibrator lamp, if required, using button (1).
3. Mount and connect the pump to be tested. Refer to Section 4.5 for mounting arrangements, and
to Fig 3.1 for the pump connections, i.e. supply, return etc. The various adapters and brackets
used to mount different pumps are given in Section 4.4.
4. Check the drive direction of rotation by looking at which indicator (20 or 22) is illuminated. Set the
direction of rotation for the pump being tested by pressing button (12).
5. Press button (6) to start the test fluid supply pump, the indicator (23) will illuminate. Pressing
button (6) again will stop the supply pump,
6. Adjust the test fluid supply pressure using control valve (Fig 3.6 item 8) monitoring the pressure
displayed by gauge (Fig 3.5 item 3). The maximum supply pressure is approximately 3 bar
(45 lbf/in²).
7. Screwing the test fluid supply regulator (Fig 3.6 item 8) in further will supply a high pressure of up
to 50 bar for pressure phasing to the connection on the front bulkhead. The pressure set can be
seen on the 0 - 100 bar gauge (Fig. 3.5 item 2).
8. View the fuel temperature demand by pressing button (3). Adjust if necessary using the up and
down arrow buttons (4 and 5). Press button (3) again to accept the set demand and return to the
supply temperature display.
NOTES:
a. The temperature demand can be set between 26°C and 50°C.
b. Pressing button (3) while the drive is running displays the backleak temperature. This is shown
in the display (19), prefixed by ‘b’. Pressing button (3) again returns the display to the supply
temperature.
9. Turn on the temperature control system by pressing button (2), indicator (25) will illuminate. If the
heater is on, indicator (26) will illuminate. If the cooling system is on, indicator (27) will illuminate.
NOTE:
The heater will not operate unless the test fluid pump is on.
10. Set the speed to minimum by turning the speed control knob (7) fully anti-clockwise.
11. Start the main motor by pressing button (13), the indicator (21) will illuminate.

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4.2 Pump Delivery

1. To select a pump delivery, measured as a number of strokes, press button (9). The number of
strokes selected is displayed on the ‘Stroke’ display (16).
2. Each press of button (9) increases the measured stroke count by 100 strokes up to 1000 strokes
maximum. After 1000 strokes, the setting returns to 100.
3. Start the delivery measurement by pressing button the Start Count button (10).
4. Abort the measurement if required by pressing the ‘ESC’ button (11).
5. To select a pump delivery measured as a unit of time press button (8). The time selected is
displayed on the ‘SEC’ display (17). Each press of button (8) increases the measured time by 10
seconds up to 100 seconds maximum.
6. Start the delivery measurement by pressing button Start Count button (10).

4.3 Auxiliary Voltage Supply

A 12V d.c. or 24V d.c. supply is available to energise pump solenoids. Push-button (Fig 3.2 item 5)
selects the voltage. Push-button ‘ESC’ (Fig 3.2 item 6) resets the voltage to the supply socket (Fig 3.2
item 7).
1. Unscrew the protective cap from the supply socket.
2. Screw in the Connection Cable (Part No. AP1245) supplied with the test stand.
3. Connect the + and – leads to the pump to be tested.

Figure 4.1 Control Panel

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TABLE 4.1 KEY TO FIGURE 4.1

1 Lamp ON/OFF 15 Speed Display in RPM
2 Temperature Control ON/OFF 16 Stroke Display
3 Temperature Set Mode/Store 17 Second Display
4 Temperature Set Point - up 18 Main Motor Current Display
5 Temperature Set Point - down 19 Test Fluid Temperature Display
6 Test Fluid Supply Pump ON/OFF 20 Main Motor CLOCKWISE Rotation Indicator
7 Speed Control 21 Main Motor On Indicator
8 Time Select 22 Main Motor ANTICLOCKWISE Rotation
Indicator
9 Stroke Select 23 Test Fluid Supply Pump On Indicator
10 Start Count 24 Lube Oil Pump On Indicator
11 Cancel Count 25 Temperature Control System On Indicator
12 Main Motor Direction 26 Heater ON Indicator
13 Main Motor ON/OFF 27 Cooling System On Indicator
14 Lube Oil Pump ON/OFF

NOTE:
Button (14) and indicator (24) will be present on the machine even if the Lube Oil option is not fitted.

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4.4 Pump Mounting Table

The following table lists the Part Numbers of the mounting components that can be used to mount
rotary and in-line pumps to enable them to be tested on the Pumpmaster. The mounting components
are described in 4.5 Mounting Pumps to the Test Stand.
Pump Main Bracket(s) / Mounting Plate / Adapter (if Coupling
Clamps Drive Hub required)
Rotary Pumps
Lucas DPA AA1996 Plate AA2012 AA2010 or AA1195 or 3-hole
(supported) AA2011
Lucas DPA AA1996 Hub AA1205 or AA1185 AA1209 or AA1216
(unsupported) AA1213
Lucas DPC AA1996 Plate AA1186 or AA2010 AA1193, AA1194, or AA1195
AA2012
Lucas DPS AA1996 Plate AA2012 AA2010 AA1193 or AA1195
Lucas DP200 AA1996 Plate AA1186 or AA2010 AA1195
AA2012
Bosch EPVE AA1996 Plate AA1186 or AA2010 AA1193, AA1194, or AA1195
AA2012
In-Line Pumps
Bosch P type AA1996 and AA1998 AA1592 n/a AA1376 or AA1377
Other Bosch AA1991 and AA1999 n/a n/a AA1376
(2 of each)
Simms AA1992 and AA1999 n/a n/a AA1375 or AA1376
(2 of each)

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4.5 Mounting Pumps to the Test Stand

4.5.1 In-Line Pump Mounting Brackets (Part Numbers AA1991 and AA1992)
Two sets of pump mounting brackets with different height dimensions enable most common in-line
pumps to be fitted to the Pumpmaster test stand. These brackets are bolted to the T slot in the test
stand mounting bed.

Figure 4.2 In-Line Pump Mounting Brackets

4.5.2 Quick-Action Clamps for In-line Pumps (Part No. AA1999)
Two quick-action clamps are used to secure in-line pumps to the mounting brackets.
1. Fit the pump to be tested to the correct mounting bracket.
2. Align the pump with the anti-backlash coupling before bolting the pump down to the T slot.
3. Place the quick action clamps in the T slot of the mounting bed, at each end of the pump.
4. Bolt the clamps to the T slot.
5. Place the clamp jaws on top of the pump body.
6. Tighten the knurled rings by hand.
7. Turn the clamping levers, at the base of the clamp, clockwise to lock the pump to the mounting
brackets.

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Figure 4.3 Quick-Action In-line Pump Clamp

4.5.3 Bosch P Flange Adapter Plate (Part No. AA1592)
This flange adapter plate, which is bolted to the horseshoe shaped Rotary Pump Mounting Bracket
(see 4.4.4), accepts Bosch P pumps with a flange diameter of 107 mm. A tail support (Part No.
AA1998) supports the governor end of the pump.

4.5.4 Rotary Pump Mounting Bracket (Part No. AA1996)

This horseshoe shaped bracket accommodates the two drive hubs (Part Numbers AA1205 and
AA1213) and the range of available adapter plates.
The bracket is normally bolted to the T slot of the test stand bed to ensure alignment with the anti-
backlash drive coupling.

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4.5.5 Rotary Pump Drive Hub with Supported Bearing and 18 mm Driveshaft (Part No. AA1205)
Refer to Figure 4.4. This drive hub (1), complete with 3 hole mounting plate, incorporates a female
spline rotating in a bearing.
NOTE:
Lubricate the fuel pump male 18 mm quill drive shaft (3) with a light oil, before fitting the pump.
A separate quill drive shaft (Part No. AA1209) and spring (2) are included within the standard
accessories.
An adapter ring (Part No. AA1185) is used to convert the spigot diameter of the drive hub (Part No.
AA1205) from 46 mm to 50 mm.

Figure 4.4 Adapter for Pumps with 18mm Quill Drive

4.5.6 Rotary Pump Drive Hub with Supported Bearing and 36 mm Splined Drive (Part No. AA1213)
This drive hub complete with 3 hole mounting plate incorporates a female spline rotating in a bearing
and enables uprated drive rotary pumps with a 50 mm spigot to be mounted and driven.
A large male splined quill shaft (Part No. AA1216) is supplied which fits on to the pump to be tested.

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4.5.7 Pump Mounting Adapter Plate with 4 Pump Fixing Holes (Part No. AA1188)
This mounting plate is used to mount rotary and small In-line pumps with internal bearings requiring a
4-hole adapter plate. The plate (2) is bolted to the Rotary Pump Mounting Bracket (1) (Part No.
AA1996).
Rotary and small in-line pumps with a spigot diameter of 68 mm, 85 mm and 92 mm can be fitted to
this type of bracket and mounting plate. Two types of adapter ring insert reduce the spigot diameter
from 92 mm to 85 mm (Adapter Ring Part No. AA1190) and 92 to 68 mm (Adapter Ring Part No.
AA1189).

Figure 4.5 Adapter Plate (Part No. AA1188)

4.5.8 Rotary Pump Adapter Plate with 9 Pump Fixing Holes (Part No. AA1187)
This adapter plate enables a wide variety of rotary pumps having either a 2, 3 or 4 hole fixing to be
mounted. The plate is bolted to the Rotary Pump Mounting Bracket (Part No. AA1996).
Two ring inserts are supplied to reduce the spigot diameter to 50 mm (Part No. AA2010) and 46 mm
(Part No. AA2011). This allows rotary pumps manufactured by Lucas, Bosch, Denso, Zexel and
Stanadyne to be mounted.

Figure 4.6 Adapter Plate (Part No. AA1187)

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4.5.9 Rotary Pump Adapter Plate with 3 Pump Fixing Holes (Part No. AA1186)
This mounting plate has a 68 mm spigot diameter for mounting DPS type pumps. The mounting plate
is bolted to bracket (Part No. AA1220).

4.6 Test Injectors and High Pressure Pipes

Refer to the relevant testplan for the pump to be tested to determine the correct test injectors and high
pressure pipes. A wide range or test injectors and high pressure pipes suitable for use on Pumpmaster
Test Stands is available from Hartridge Test Products. Refer to catalogue Ref. No. XCB510(EN).

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5. Maintenance
WARNING!
BEFORE CARRYING OUT ANY MAINTENANCE, ISOLATE THE TEST
STAND AT THE SWITCH ON THE WALL. MAKE SURE ALL PANELS ARE
FITTED AND DOORS ARE CLOSED BEFORE SWITCHING THE TEST
STAND ON AFTER CARRYING OUT ANY MAINTENANCE.

5.1 Daily Checks

5.1.1 Check the Tank Test Fluid Level
1. Remove the small left hand side panel.
2. Check the test fluid level using the sight level gauge.
3. If required, top up to the maximum level mark.
4. Refit the side panel.

5.1.2 Check the Air Supply

1. Open the rear cabinet door.
2. Check the supply pressure is correct (6 bar).
3. Check the air separator bowl for water.
4. If required, drain the water separator bowl into a container by pushing in the button on the bottom
of the bowl.
5. Close the rear cabinet door.

5.2 Every 300 Running Hours

5.2.1 Drain the Test Fluid Tank
1. Remove the small panels on each side of the test stand.
2. Drain the test fluid into a suitable container by removing the drain plugs on the rear facing side of
the tank.
3. After the tank is completely empty, wipe out the inside of each section of the tank with a clean dry
absorbent cloth.
4. Change the test fluid tank suction filter at the same time (see 5.2.2).
5. Refit the drain plugs.
6. Re-fill the tank to the full level with the correct specification test fluid.

5.2.2 Change the Test Fluid Tank Filter

1. When the test fluid tank is drained, remove the suction filter by unscrewing the knurled nut and
pulling the filter from the stud.
2. Discard the old filter.
3. Fit a new filter.

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5.2.3 Empty the Waste Oil Tank

1. Remove the small panel on left hand side of the test stand. The waste oil tank is situated above
the test fluid tank.
2. Open the waste oil tank drain valve and drain the waste oil into a suitable container.
3. Change the waste tank filter at the same time (see 5.2.4).
4. When the tank is empty, close the drain valve.

5.2.4 Change the Waste Oil Tank Filter

1. Lift the test area drip tray out.
2. Clean out the drip tray sump.
3. Unscrew the waste oil tank filter from the drip tray sump.
4. Discard the old filter.
5. Fit a new filter in the drip tray sump.

5.2.5 Check the Test Injectors

1. Remove the test injectors from the metering console.
2. Carry out dry seat, back leakage and pressure setting tests on each injector. These should
normally be set to either 125 +3/-0 or 172 +3/-0 dependent on the pump to be tested. Refer to the
testplan provided by the pump manufacturer.
3. Re-set the injectors as necessary.
4. Refit to the metering console.

5.3 Every 500 Running Hours

5.3.1 Check the Motor Brushes
1. Check the brushes of the main motor by removing the side cover opposite the main motor cooling
fan (Fig 3.4 item 25).
2. If there are black traces of brush material and sparks are observed while the motor is running, the
brushes must be changed.
3. Your nearest dealer can provide assistance in changing the brushes.

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5.4 Fault finding

Fault: DC motor fan does not run when the isolator is switched on.
Check:
• 380 to 480 V a.c. between each pair of phases at the connection box.
• Trips F1 to F4 are set on.
• Fuse S3 on the relay board is OK.
• 220 V a.c. across terminals TB130/131 (wires 24/8) on the electrical chassis.
Fault: No displays illuminated on the control panel
Is the red indicator in RL1 off?
Yes: Check:
• The two emergency stop buttons are released.
• Oil level in the tank is above the level switch.
• Air is connected and is greater than 6 bar.
• Fuel pump overload is reset.
• Trips F1 to F4 are set on.
• Fuse S1 on the relay board is OK.
No: Check:
• Fuse S5 on the relay board is OK.
• 220 V a.c. on the Control Unit transformer input.
• 15 V and 18 V a.c. on the Control Unit transformer outputs.
• Change the microcontroller board and display.
Fault: No supply fuel pressure
Does the fuel pump motor run?
Yes Check the direction of rotation is correct (correct direction is clockwise as viewed
from the front of the machine). If incorrect, swap over any two of the three
incoming phase connections.
th
No: Does the 4 yellow indicator down on the relay board turn on/off as the fuel button
is pressed?
No: Check
• cable 46 between the microcontroller and relay boards.
• 15 V and 18 V a.c. on the Control Unit transformer outputs.
• Change the microcontroller board.
• Change the relay board.
• Change the left control button group panel.
Yes: Check
• If contactor K1 does not operate with the above relay, check the
wiring to the contactor and check for 24 V a.c. across the contactor
coil.
• If the contactor operates but the fuel pump does not run, check a.c.
voltage at the fuel pump motor is within 10% of the nominal supply.
Fault: Drive does not run.

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Note that the drive will only operate when the fuel system is running.
Does drive contactor F or R pull in/drop out each time the drive start button is pressed?
rd
No: Does the 3 yellow indicator down on the relay board turn on/off?
No: check:
• Cable 46 between the microcontroller and relay boards.
• Change the microcontroller board.
• Change the relay board.
• Change right control button group panel.
Yes: check:
• Wiring from relay board to contactors.
• Change the relay board.
Yes The relay & microcontroller boards are OK.
• Check for 10V across drive terminals 10 (brown wire) and 7 (green
wire).
• Check the drive displays:
• If this voltage is near zero, the problem is with the speed board.
• DRIVE READY flashing indicates a drive fault. Press RESET to try
to clear. If the fault repeats, report the fault, noting the error
indicated on the flashing upper display.
Fault: Drive runs but lacks power.
Check field current is 2 A.
Measure the armature current under load. (A d.c. clamp on meter is best). If the armature
current is 25 to 30 A (PM1008) or 45 to 55 A (PM2012), and the field current is correct, then
the system is operating correctly, giving its maximum power. If the motor load indicator on
the display differs significantly from measured armature current the error could be on the
speed board or microcontroller board.
Fault: Drive runs away to between 500 & 1000 rpm and cuts out.
Pressing the drive button to stop, then again to start repeats the runaway. This indicates loss
of speed feedback pulses from the encoder.
If there is a display of speed during runaway, this indicates loss of the second channel of
pulses only from the encoder to the speed board.
Check for the speed board pulse indicator showing 2 flashes for every one flash on the
microcontroller board.
Check wiring from encoder to speed board.
Change encoder.
Change speed board.
Fault: Drive runs away to a high speed
Check the speed potentiometer.
As the speed demand is increased from zero, a green indicator on the speed board turns on.
This indicates that the speed potentiometer input is generally OK.
Check the voltage between TB 24 & 23 increases from 0V to 10 V for 0 to 4000 rpm.
Change the speed pot. if incorrect.
Check wires to TB23 to 25 of the speed board.
Change the speed board.

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Fault: Stroke shutter does not operate.

Note that the shutter will only operate when the drive is running.
th
Does the 6 yellow indicator down on the relay board turn on for the count period?
No:
• Check cable 46 between the microcontroller and relay boards.
• Change the microcontroller board.
• Change the right control button group panel.
• Change the relay board.
Yes:
• Check that the stroke board red indicator is always on (24 V a.c.) and the green indicator
is on for the count time.
• Check that the mechanism is free to move in and out of the stroke motor.
• Check the motor by very briefly applying 12 V d.c. from a battery. Swap wires to drive
back by again very briefly applying 12 V d.c.
• Change the stroke board.

Fault: Temperatures not correct.

Check the temperatures when the machine is cold. The temperatures displayed should be
the same as ambient temperature.
If one sensor operates, but not the other, swap over the green wires in terminals 13 and 14 of
the microcontroller PCB. If the fault stays with the display, change the microcontroller PCB.
Otherwise change the sensor.
If the temperature is too low:
Check that the set demand is at the level required.
Check that the temperature control is turned on and demanding heat.
Check if the indicator next to the thermostat is on (indicating heating).
Check if RL1 operates, F5 trip is set, and heater current is 3 to 4 A.
Check that, if cooling water is connected, it is not flowing through the cooler solenoid
(solenoid stuck open).
Check each heater element has a resistance about 60 ohm.
Check that oil is passing through the return from the pressure controller direct to tank (over
the temperature sensor).

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6. Spares List
The following list of parts are those which are likely to have a limited life and require replacement.

When ordering spares, always quote the product type and serial number. This information is provided
on the identification plate fixed to the back of the test stand.
6.1 Electrical Spares
Description Fig. Item Ref. Part No.
Touch Button Group - Left 6.1 1 BJ1011
Control Display (Lexan Sticker) 6.1 2 BJ1010
Speed Control Potentiometer 6.1 3 KO1026
Touch Button Group - Right 6.1 4 BJ1009
12/24 V d.c. Reset Button/Selector Switch 6.1 5, 6 AR1176
Socket 12/24 V d.c. 6.1 7 AR1172
Temperature Sensor - Supply/Return 6.2/6.3 8/22 AA1489
Calibrator Lamp 6.2 9 YP1016
External Calibrator Socket 6.2 10 AR1172
Mains Isolator Switch 6.2 11 AP1053
Main Motor (PM1008 only) 6.2 12 AL1029
Main Motor (PM2012 only) 6.2 12 AL1028
Encoder 6.2 13 AR1130
Main Transformer 6.2 14 AP1284
Cooling Solenoid 6.2 17 AP1019
Tank Low Level Switch 6.2 18 BA1071
Heater 6.2 19 AP1280
Tank Thermostat 6.2 20 AP1192
Air Pressure Switch 6.2 21 BA1084
Emergency Stop Buttons 6.3 23 AP1032
Metering Shutter Actuator 6.3 24 AP1003
Main Motor Cooling Fan 6.3 25 AL1003
Brake Actuator Solenoid 6.3 26 BA1077
Pneumatic Valve 6.3 27 BA1099
Test Fluid Supply Motor 6.3 28 AL1027
Main Trip (3 x 40 A) (PM1008 only) 3.13 F1, F2, F3 AP1020
Main Trip (3 x 63 A) (PM2012 only) 3.13 F1, F2, F3 AP1151
Control Transformer Trip (16 A) 3.13 F4 AP1023
Heater Trip (6 A) 3.13 F5 AP1007
Drive Direction Contactors (PM1008 only) 3.13 F, R AP1233
Drive Direction Contactors (PM2012 only) 3.13 F, R AP1133
Pump Motor Contactor 3.13 K1, K2 AP1116

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Description Fig. Item Ref. Part No.

Emergency Stop Relay 3.13 RL1 AP1139
Heater Relay 3.13 RL2 AP1231
Motor Overload Trip 3.13 T1, T2 AP1221
Mentor II Drive 3.13 - AR1298

6.2 Test Fluid & Pneumatic System Spares

Description Fig. Item Ref. Part No.
Hose - tank to bulkhead 6.4 1 BM 1008
Hose - valve to bulkhead (HP) 6.4 2 BR 1032
Hose - valve to bulkhead (LP) 6.4 3 BR 1033
Air Pressure Control Valve 6.4 4 BA 1004
Pipe - high pressure gauge connection 6.4 5 BN 1001
0 - 100 bar Pressure Gauge 6.4 6 BB 1025
Hose - fluid low pressure gauge connection 6.4 7 BM 1001
Hose - fluid low pressure gauge connection 6.4 8 BM 1001
-1/+4 Supply Pressure Gauge 6.4 9 BB 1021
0-14 bar Transfer Pressure Gauge 6.4 10 BB 1022
0 - 6 bar Auxiliary Pressure Gauge 6.4 11 BB 1023
Hose - fluid low pressure gauge connection 6.4 12 BM 1001
0 - 2.5 bar Air Pressure Gauge 6.4 13 BB 1024
Hose - air pressure gauge connection 6.4 14 BM 1022
Flowmeter 6.4 15 KO 1037
Hose - bulkhead to flowmeter 6.4 16 BM 1006
Hose - flowmeter to tank 6.4 17 BM 1008
Hose - pump to valve 6.5 18 BR 1031
Waste Oil Tank Drain Tap 6.5 19 BH 1005
Supply Pressure Control Valve 6.5 20 AA 1900
Hose - calibrator to tank 6.5 21 BM 1007
Hose - Waste fluid drain 6.5 22 BM 1008
Hose - control valve to tank 6.5 23 BM 1021
Test Fluid Filter 6.5 24 BA 1003
Hose - tank to pump 6.5 25 BR 1030
Test Fluid Supply Pump 6.5 26 BA 1006
Hose - air supply 6.5 27 BM 1022
Air Pressure Switch 6.5 28 BA 1084
Air Filter 6.5 29 BA 1042

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6.3 Metering System Spares

Description Fig. Item Ref. Part No.
Shutter Actuator 6.6 1 AP1003
Graduate – 120 cc 6.6 2 BC1009
Graduate – 26 cc 6.6 3 BC1010
Injector 6.6 6 KO1038
Spray Chamber 6.6 7 BE1003
Graduate – 38 cc 6.6 3 BC1015
Graduate – 260 cc 6.6 2 BC1013
Graduate Holder – 260 cc 6.6 9 BC1010
Flow Needle 6.6 8 BE1004
Graduate Holder – 120 cc 6.6 9 BE1009
Graduate Holder – 26/38 cc 6.6 10 BE1008
Position Lock 6.6 11 AA1936

6.4 Cooling System Spares

Description Fig. Item Ref. Part No.
Cooling Coils 6.7 1 KO1033
Supply Inlet Solenoid Valve 6.7 2 AP1019
Supply/Return Line 6.7 3, 4 BM1008
Supply/Return Connection 6.7 5, 6 AA1528

6.5 Braking System Spares

Description Fig. Item Ref. Part No.
Brake Pads and Spring 6.8 1, 2 BA1010
Brake Arm 6.8 3 AA1413
Brake Cam 6.8 4 AA1411
Connector Rod 6.8 5 AA1706
Air Piston 6.8 6 BA1077
Air Pressure Regulator 6.8 7 BA1042
Pressure Regulator Gauge 6.8 8 BA1058

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USER MANUAL HARTRIDGE LIMITED

6.6 Central Control Unit Spares

Description Fig. Item Ref. Part No.
Display (Lexan Sticker) 6.9 1 BJ1010
Touch Button Group - Temperature 6.9 2 BJ1011
Speed Control Potentiometer 6.9 3 KO1026
Touch Button Group - Metering 6.9 4 BJ1009
Console Transformer 6.9 5 AP1265
Speed Interface PCB 6.9 6 AR1302
Emergency Stop Button 6.9 7 AP1032
Display PCB 6.9 8 AR1023-2
Central Control Unit PCB 6.9 9 AR1274

6.7 Accessories Supplied with Test Stand

Description Quantity
Part No. Comments
Injectors / Pipes
KO1038 Test Injector plus ISO4010 8 or 12
nozzle
BN1004 Test Line 6*2*600 8 or 12 connections: 12*1.5 pump,
14*1.5 inj
BN1005 Test Line 6*2*600 8 or 12 connections: 14*1.5 pump,
14*1.5 inj
BN1006 Test Line 6*2*840 8 or 12 connections: 12*1.5 pump,
14*1.5 inj
Brackets / Clamps
AA1996 Horseshoe Bracket 1
AA1991 Support Bracket (Height 97 2
mm)
AA1992 Support Bracket (Height 104 2
mm)
AA1999 Quick Action Clamp 2
AA1998 Tail Support 1
Mounting Plates
AA1186 Mounting Plate 3-hole, 1 Fits onto Horseshoe Bracket
68 mm dia AA1996
AA2012 Mounting Plate 9-hole 1 Fits onto Horseshoe Bracket
AA1996
AA1188 Mounting Plate 4-hole, 1 Fits onto Horseshoe Bracket
92 mm dia AA1996
AA1592 Mounting Plate 105 mm dia 1 Fits onto Horseshoe Bracket
AA1996
Drive Hubs (for unsupported pumps)

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AA1205 Drive Hub 18 mm spline, 46 1 Fits onto Horseshoe Bracket

mm spigot AA1996
AA1213 Drive Hub 36 mm spline, 1 Fits onto Horseshoe Bracket
50 mm spigot AA1996
Adaptor
s
AA1185 Adaptor Plate 50 mm 1 Converts AA1205 to a 50 mm
spigot
AA1189 Ring Insert 68 mm 1 Converts AA1188 to a 68 mm
spigot
AA1190 Ring Insert 85 mm 1 Converts AA1188 to an 85 mm
spigot
AA2010 Ring Insert 50 mm 1 Converts AA2012 to a 50 mm
spigot
AA2011 Ring Insert 46 mm 1 Converts AA2012 to a 46 mm
spigot

6.7 Accessories Supplied with Test Stand (continued)

Description Quantity
Part No. Comments
Couplings
AA1193 Coupling (DPS - dog drive) 1
AA1194 Coupling 17 mm dia. 1
AA1195 Coupling 20 mm dia. 1
AA1375 Coupling 22 mm dia. 1
AA1376 Coupling 25 mm dia. 1
AA1377 Coupling 30 mm dia. 1
Pump-related Connectors / Tools
BA1007 Banjo Connector 2
AA1271 Test Oil Return Connection 2
AA1272 Cambox Pressure 1
Connection
AA1277 Inlet Screw - M14 1
AA1278 Inlet Screw - M12 1
AA1330 Pressure Adjusting Screw 1
AP1245 Pump Solenoid Connector 1
Cable
Miscellaneous
AA1899 Leg base for Test Stand 4
AA1209 Quill Shaft 18 mm 1 Fits AA1205

Ref. No. HL002GB Issue 1 6.5

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AA1216 Quill Shaft 36 mm 1 Fits AA1213

AA1257 Small Coupling Puller 1
AA1276 Flywheel Turning Bar 1
AA1379 Large Coupling Puller 1
AA1473 Coupling Spanner 1
AR1172 Encoder Connection Plug 1
BR1001 Hose, Pneumatic 4 x1 2
KO1041 Hose for air connection with 1
banjo end
KO1039 Hose, Transparent, Supply 2
and Return
KO1040 Hose 3/8 High Pressure 1
AA1337 Anti-backlash Coupling 1 PM1008 only
96 mm
AA1891 Coupling Cover Small 1 PM1008 only
AA1384 Anti-backlash Coupling 1 PM2012 only
110 mm
AA1897 Coupling Cover Large 1 PM2012 only

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6.8 Optional Accessories

Description Part No.
External wheel-up Chiller System HB355
External Wheel-up Lube Oil System HB359
Injector Adapter Kit (ISO Nozzles) HF1038
Injector Adapter Kit (Orifice Plate Nozzles) HF1039
Anti-backlash Spline Drive for Rotary Pumps ADC223
Pump Solenoid Variable Power Supply Tester TBA
Attachment for testing Rotary Pumps with short Injector HP pipes TBA
External Transformer - Low Voltage Supplies, see 1.2 (PM1008 only) 8688118
External Transformer – Low Voltage Supplies, see 1.2 (PM2012 only) 8868119

The following options are only available factory-fitted, pre-delivery.

Description Part No.
Internal Chiller System HB356W
Internal Lube Oil System (PM2012 only) HB357W
Speed and Graphics System HB358W
Positive Graduate Metering (PGM) Calibrator (PM1008 only) HB360W
Positive Graduate Metering (PGM) Calibrator (PM2012 only) HB361W

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Figure 6.1 Electrical Equipment (front view)

KEY TO FIGURES 6.1, 6.2 & 6.3

1 Control Button Group - Left 15 Electronic Equipment Enclosure
2 Control Display 16 Mains Supply Connection Box
3 Speed Control Potentiometer 17 Cooling System Solenoid
4 Control Button Group - Right 18 Test Fluid Tank Low Level Switch
5 Selector Switch 12/24 V d.c. 19 Heater
6 12/24 V d.c. Reset Push-button 20 Test Fluid Tank Over-temperature
Thermostat
7 Socket 12/24 V d.c. Supply 21 Air Low Pressure Switch
8 Temperature Sensor – Test Fluid Supply 22 Temperature Sensor – Test Fluid Return
9 Calibrator Lamp 23 Emergency Stop Buttons
10 Auxiliary Socket 24 Metering Shutter Actuator
11 Mains Isolater Switch 25 Main Motor Cooling Fan
12 Main Motor 26 Brake Actuator
13 Encoder 27 Pneumatic Valve
14 Transformer 28 Test Fluid Supply Motor

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Figure 6.2 Electrical Equipment (side view)

Ref. No. HL002GB Issue 1 6.9

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Figure 6.3 Electrical Equipment (rear view)

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Figure 6.4 Test Fluid and Pneumatic Equipment (rear view)

KEY TO FIGURES 6.4 & 6.5
1 Hose - tank to bulkhead 16 Hose - bulkhead to flowmeter
2 Hose - valve to bulkhead (HP) 17 Hose - flowmeter to tank
3 Hose - valve to bulkhead (LP) 18 Hose - pump to valve
4 Air Pressure Control Valve 19 Waste Oil Tank Drain Tap
5 Pipe - high pressure gauge connection 20 Supply Pressure Control Valve
6 0 - 100 bar Pressure Gauge 21 Hose - calibrator to tank
7 Hose - fluid low pressure gauge connection 22 Hose - Waste fluid drain
8 Hose - fluid low pressure gauge connection 23 Hose - control valve to tank
9 -1/+4 Supply Pressure Gauge 24 Test Fluid Filter
10 0-14 bar Transfer Pressure Gauge 25 Hose - tank to pump
11 0 - 6 bar Auxiliary Pressure Gauge 26 Test Fluid Supply Pump
12 Hose - fluid low pressure gauge connection 27 Hose - air supply
13 0 - 2.5 bar Air Pressure Gauge 28 Air Pressure Switch
14 Hose - air pressure gauge connection 29 Air Filter
15 Flowmeter

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Figure 6.5 Test Fluid and Pneumatic Equipment (side view)

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Figure 6.6 Metering System Equipment

KEY TO FIGURE 6.6
1 Shutter Actuator 7 Spray Chamber
2 Large Graduate 8 Flow Needle
3 Small Graduate 9 Large Graduate Holder
4 Metering Unit Assembly 10 Small Graduate Holder
5 Height Adjustment Handle 11 Position Lock
6 Injector

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Figure 6.7 Cooling System Layout

KEY TO FIGURE 6.7
1 Cooling Coils 4 Water Supply Line
2 Supply Inlet Solenoid Valve 5 Supply Connector
3 Water Return Line 6 Return Connector

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Figure 6.8 Braking System Layout

KEY TO FIGURE 6.8
1 Brake Pads 5 Connector Rod
2 Brake Spring 6 Air Piston
3 Brake Arm 7 Air Pressure Regulator
4 Brake Cam 8 Air Pressure Gauge

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Figure 6.9 Central Control Unit

KEY TO FIGURE 6.9
1 Digital/LED Display 6 Speed Interface PCB
2 Left Touch Button Group 7 Emergency Stop Button
3 Speed Control Potentiometer 8 Display PCB
4 Right Touch Button Group 9 Central Control Unit PCB
5 Transformer

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Appendix 1 Speed & Graphics System (Option)

A1.1 Speed & Graphics Control Panel

Figure A1.1 Optional Speed & Graphics Control Panel

KEY TO FIGURE A1.1
1 LCD Display 10 Drive Start/Stop
2 Left ControlGroup 11 Speed Up/Down
3 Speed Selection 12 Start Count
4 Shot Count Selection 13 Cancel Count
5 Temperature Control Selection 14 Right Control Group
6 Numerical Keys 15 Temperature Control On/Off
7 Enter key 16 Calibrator Lamp On/Off
8 Central Control Group 17 Lube Oil On/Off
9 Drive Direction 18 Test Oil On/Off

A1.3 Operating the Test Stand using the Speed & Graphics System
The following describes the optional Speed & Graphics system and the changes in operating
procedure specific to the optional system. For all other operating instructions, refer to section 4 in the
main body of the manual.
The control panel contains the LCD display and 3 separate control groups (see Figure A1.1):
Left Control Group Used for entering/changing the speed, temperature demand and stroke
count
Central Control Group Used for starting/stopping the drive, changing the drive direction, carrying out
incremental speed adjustments and starting/cancelling the shot count.
Right Control Group Used for controlling the test oil supply, lube oil supply, temperature and the
calibrator lamp.
Figure A1.2 shows the layout of the LCD display and gives an explanation of the data displayed.

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Figure A1.2 Speed & Graphics LCD Display

A1.3.1 Speed Control
Speed can be controlled in three different ways:

• Direct Speed Entry

• Using Preset Values
• Incremental Adjustment
NOTE: The speed range of the bench is 45 to 4000rpm
Direct Speed Entry
The desired speed can be set directly using the numerical keypad in the Left Control Group. Press the
[RPM] button. The speed display will change to ‘----’ which indicates input mode. Key in the desired
speed, then press [↵
↵] (Enter).
Preset Values
The bench can hold up to ten preset values, shown in the lower left corner of the LCD display
alongside the numbers 1 to 9 and 0.
To set the speed to an existing preset value, press [↵
↵] followed by the number corresponding to the
desired speed.
To assign new values to the presets, hold down the [↵ ↵] button (Left Control Group) for 5 seconds, until
the first preset is highlighted. The presets are highlighted in sequence, pressing [↵
↵] to pass from one
to the next. To store a new value, highlight the preset, then key in the desired speed and press [↵ ↵]. If
you do not wish to change the existing value, press [↵ ↵] to pass on to the next. Pressing [↵↵] after the
tenth preset ends the input mode.
Incremental Adjustment
With the drive running, the speed can be adjusted incrementally using the RPM [


] and [
] buttons.

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A1.3.2 Shot Count

The following 14 shot count values are preset within the machine: 50, 100, 150, 200, 250, 300, 350,
400, 500, 600, 700, 800, 900, 1000.
To select a value, press the shot count button, [N] (Left Control Group). With each press of the button
the value will step up sequentially from 50 to 1000. To start the measurement, press the counter start
button, [1] (Central Control Group). To stop the count part way through, press the [ESC] button.
NOTE:
The speed cannot be changed while a shot count is in process.

A1.3.3 Measuring Delivery Against Time

This feature enables the operator to measure delivery against a certain time. Press and hold the shot
count button [N] for more than 3 seconds, until the ‘sec’ mode is highlighted and the seconds display
changes to ‘---’ which indicates the input mode. Key in the desired time and press [↵
↵] (Enter). To start
the measurement, press the counter start button [1] (Central Control Group).

A1.4 Spares
Description Fig Item Ref Part No.
LCD Screen A1.1 1 AR1021
Touch Button Group – Left A1.1 2 BJ1015
Touch Button Group – Centre A1.1 8 BJ1016
Touch Button Group – Right A1.1 14 BJ1014
Display PCB - - AR1361
Central Control Unit PCB - - AR1362
Power Supply PCB - - AR1363

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App 1.4 Ref. No. HL002GB Issue 1

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Appendix 2 – Internal Chiller System (Option)

CAUTION
The chiller system uses R22 (Freon 22) gas as a refrigerant – refer to the Health and Safety Data
Sheet given on page App2.3.

The layout and spares for the chiller system are given in Figure A2.1.
The gas is pumped through the coils in the fuel tank, increasing the cooling capacity as compared to
the standard machine, and therefore giving a more rapid temperature control mechanism. The
machine switches the system on/off automatically when required (as described in section 3.2.1).
Figure A2.2 gives the hydraulic circuit. Refer to Figure 3.16 for the electrical circuit connections.

Figure A2.1 Internal Chiller System

KEY TO FIGURE A2.1

Item Description Part No.

1 Copper Pipe - 3/8" BP1023
2 Copper Tube - Hair Thin BP1024
3 Radiator BL1003
4 Cooling Fan BL1002
5 Chiller Unit BL1001
6 Gas Insert Tap BL1005
7 Dryer BL1004

Ref. No. HL002GB Issue 1 App 2.1

USER MANUAL HARTRIDGE LIMITED

8 Copper Pipe 5/16" BP1022

9 Exchanger Coil KO1005

Figure A2.2 Chiller System Hydraulic Circuit

KEY TO FIGURE A2.2

Item Description Part No.

1 Exchanger Coil KO1005
2 Level Gauge BP1025
3 Chiller Unit BL1001
4 Cooling Radiator BL1003
5 Cooling Fan BL1002
6 Dryer BL1004

App 2.2 Ref. No. HL002GB Issue 1

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Ref. No. HL002GB Issue 1 App 2.3

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Appendix 3 – PGM Calibrator (Option)

A3.1 Introduction
The layout of the PGM (Positive Graduate Metering) Calibrator is given in Figure A3.1.
WARNING
DO NOT remove the Safety Screen (3) if the air supply is on. The air supply must be turned off
prior to removal of the screen and must not be turned on at any time before the screen is
refitted.
3 3
The glass graduates are calibrated from 0 to 60cm in divisions of 0.2cm . The PGM calibrator
operates in three modes as follows:
1) Metering: injected fuel passes into the graduates for the duration of the shot count. When the shot
count finishes, the machine automatically passes into the next mode.
2) Reading Held: the fuel injected during the shot count is held in the graduates to enable the
operator to read the volumes. Fuel injected during this mode bypasses the graduates to return to the
tank. The machine will stay in this mode until instructed otherwise by the operator (either by activating
a further shot count, or by activating the drain mode).
3) Draining: the injected fuel is forced out of the graduates by increased air pressure acting on the
bottom of the pistons.
The delivery of fuel (when not metering) can be seen through the windows in between each pair of
graduates.

Figure A3.1 PGM Calibrator

KEY TO FIGURE A3.1

1 PGM Calibrator Assembly 4 Injector Mounting Block
2 Graduate Drain Button 5 Injector Tray Width Adjustment
3 Safety Screen

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A3.2 Operation
In the majority of aspects, using the test bench with a PGM calibrator is the same as described for
open graduates in Section 4 in the manual. This includes:
shot count selection (button 9, Fig.4.1)
shot count start (button 10, Fig.4.1)
shot count abort (button 11, Fig.4.1)
The only difference is the way in which the graduates are drained. This is achieved via the illuminated
button next to the graduates (Fig. A3.1, item 2). Press and hold this button until all the pistons are
pushed back up to the zero point.
Note: this button is inactive while the shot count is in progress.

A3.3 Maintenance
Replacing a Graduate
Refer to Figure A3.2. The graduates are fitted in between the valve block/reservoir block assembly
and the dump air manifold. To remove a graduate:
i) Start and run the fuel pump, then press and hold the drain key to drain all fuel from the
graduates.
ii) Turn off the air supply to the test stand.
iii) Remove the safety screen from in front of the graduates.
iv) Slacken off the zeroing nut (1) and screw it back to the valve block (3).
v) Screw down the graduate adjuster (4) and the manifold (5), to release the graduate (2).
vi) Raise the graduate until the bottom edge completely clears the graduate adjuster (4).
vii) Manoeuvre the graduate gently sideways to release it from the graduate insert (6), then remove
the graduate.
Replacement graduate assemblies are supplied as tested items complete with pistons. Component
parts should not be interchanged. To fit a new graduate assembly:
i) Inspect the two ‘O’ ring seals in the adjuster (4) and the ‘O’ ring seal in the graduate insert (6);
replace seals if they show signs of wear or damage.
ii) Using a suitable tool, push the piston down into the graduate until it is beyond the zero line, off
the scale.
iii) Screw the adjuster (4) fully down, then fit the graduate and piston, in the reverse order to
removal.
With the new graduate installed, zero the piston as follows:
i) Gradually screw the adjuster (4) upwards to raise the graduate, until the red cursor line on the
piston is aligned with the zero mark on the graduate scale. The piston will remain against the insert
(6).
ii) When adjustment is correct, screw down the zeroing nut (1) to lock the graduate in position.
iii) If the graduate is screwed up too far (ie an initial reading is displayed) withdraw the graduate
and repeat the setting procedure.
Ensure that the safety screen is fitted to the front of the console before reconnecting the air supply.

App 3.2 Ref. No. HL002GB Issue 1

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Figure A3.2 Graduate Adjustment / Removal

Ref. No. HL002GB Issue 1 App 3.3

USER MANUAL HARTRIDGE LIMITED

Fig. A3.2 Graduate Adjustment / Removal

Replacing the Fuel Inlet Filter
Refer to Figure A3.3. If any metal particles are thought to have entered the delivery system (e.g. a test
injector fault) the filters in the valve block may require replacement.
Remove the back cover of the calibrator.
Release each delivery pipe in turn at its coupling (1).
Unscrew the union adapter (2), and withdraw the nylon filter (3) from its holder (4).
Renew each filter as necessary.

Figure A3.3 Inlet Filter Replacement

App 3.4 Ref. No. HL002GB Issue 1

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A3.4 Spares

Figure A3.4 PGM Calibrator – rear view

Ref. No. HL002GB Issue 1 App 3.5

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Description Figure Item Part No.

Graduate Insert and Nut (includes O rings) A3.2 1 171-01-12
Graduate (with piston and datum ring) A3.2 2 171-01-13
Adjuster A3.2 4 171-01-37
Air Manifold (2 graduates) A3.2 5 171-01-38
Air Manifold (2 graduates plus inlet connector)) A3.2 5 171-01-39
O ring (adjuster - top) A3.2 7 9700073
O ring (adjuster - bottom) A3.2 8 9550156
Fuel Inlet Filter A3.3 3 UC6/2/17
Gasket (PM1008 only) A3.4 1 171-03-15
Gasket (PM2012 only) A3.4 1 171-01-26
Diaphragm A3.4 2 171-01-27
Valve body A3.4 4 8681054
Coil A3.4 4 tba
Bypass Valve A3.4 8 171-01-11

The following service kits are available:

YDB703 Manifold Kit. Contains air manifolds and screws for up to 12 graduates.
YDB704 Graduate Spares Kit. Contains Adjusters, Inserts, Zeroing Nuts, and O Rings for 4
graduates (graduates to be ordered separately).
YDB705 Diaphragm Kit. Contains diaphragms and plungers for 1 valve block (4graduates).

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Ref. No. HL002GB Issue 1 App 3.7

HARTRIDGE LIMITED USER MANUAL

Appendix 4 – Internal Lube System (Option – PM2012

only)
The layout and spares for the lube system are given in Figure A4.1. Refer to Figure 3.15 for the
electrical circuit connections.

Figure A4.1 Internal Lube System

KEY TO FIGURE A4.1

Item Description Part No.
1 Lube Oil Pressure Gauge BB 1027
2 Pipe 4x2 - DIN 74324 BM 1001
3 Rubber Hose -Valve to Bulk Head Conn. BR 1034
4 Return Hose 5/8" - Transparent BM 1025
5 Return Hose 14 x 2,5 - Transparent BM 1008
6 Transparent Hose - Return from Check Valve BM 1008
7 Check Valve - 5 Bars AA 1596
8 Rubber Hose - Pump to Feed Valve BR 1035
9 Lube Oil Pressure Control Valve AA 1979
10 Return Hose 5/8" - Transparent BM 1025
11 Transfer Pump BA 1006
12 Rubber Hose - Tank to Pump BR 1036
13 Filter BA 1026
14 Transfer Pump Motor AL 1027

Ref. No. HL002GB Issue 1 App 4.1

USER MANUAL HARTRIDGE LIMITED

Operation
Connect the pump to the relevant bulkhead connections – see Figure A4.2. The following hoses for
connecting the pump to the bulkhead are supplied:

Description Quantity Part No.

Oil Supply/Return Hose 2 KO1039
Coupling Leak Return Hose 1 BR1047

Switch on the lube oil pump using button 14 (Figure 4.1). Adjust the pressure using the control valve
(item 9, Figure A4.1), referring to the pressure gauge (item 1, Figure A4.1). The lube oil pressure can
be adjusted up to 10 bar.

Figure A4.2 Lube Oil Bulkhead Connections

KEY TO FIGURE A4.2

1 Lube Oil Supply Connection
2 Lube Oil Return Connection
3 Lube Oil Return Connection

Maintenance
The lube oil tank filter (item 13, Figure A4.1) should be replaced every 300 running hours.

App 4.2 Ref. No. HL002GB Issue 1

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