user manual - auto kelly · adelphi diesel systems ltd. reserva o direito de alterar...

2010

USER MANUALIRIS

USER MANUAL

IRIS

DDNX329B(EN)

DDNX329B(EN)

Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd., maisla société décline toute responsabilité légale à cet égard. Delphi Diesel Systems Ltd. poursuit un programme intensif de conception et de développement

qui peut entraîner la modification des spécifications des produits. Delphi Diesel Systems Ltd. se réserve le droit de modifier les spécifications, sans pré- avis et si cela est nécessaire, pour assurer les performances optimales de sa gamme de produits.

Tous droits réservésToute reproduction, mémorisation dans un système informatique ou transmission sous quelle que forme que ce soit, ou par tout moyen électronique,

mécanique, par photocopie, enregistrement ou autre de cette publication est interdit sans l'autorisation préalable de Delphi Diesel Systems Ltd.

Ainda que se tenha lido o máximo cuidado na compilação da informação contida nesta publicação, a Delphi Diesel Systems Ltd., não pode aceitar qualquerresponsabilidade legal por inexactidões. ADelphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento qe pode porventuraualterar as especificações do produto. ADelphi Diesel Systems Ltd. reserva o direito de alterar especificações sem aviso e sempre que seja necessario

para assegurar um desempeho óptimo da sua linha de produtos.Todos os direitos reservados.

Nenhuma parte desda publicação pode se reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou porquaisquer meios, electrónico, mecânico, de fotocópia, gravação ou outros, sem autorização antecipada de Delphi Diesel Systems Ltd.

Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies.Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd.

reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its productrange. All Rights Reserved

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying,recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.

Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicación, Delphi Diesel Systems Ltd. no acepta ninguna responsabilidad legalpor inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd. se sigue un programa intensivo de diseño e investigación el cual podríaen cualquier momento alterar la especificación de los productos. Delphi Diesel Systems Ltd. se reserva el derecho de alterar las especificaciones

sin notificación previa y siempre que esto sea necesario para asegurar el mejor funcionamiento posible de sus productos.Todos los Derechos Reservados

No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicación de ninguna forma o medio electrónico, mecánico, de fotocopia, grabación o cualquier otro, sin autorización previa de Delphi Diesel Systems Ltd.

Bei der Zusammenstellung der in dieser Veröffentlichung enthaltenen Informationen wurde mit größtmöglicher Sorgfalt vorgegangen. Delphi Diesel SystemsLtd. kann jedoch rechtlich nicht für etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. führt ein forlaufendes Designund Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produkdaten ändern. Delphi Diesel Systems Ltd. behält sich das Recht vor, ohne

Vorankündigung Spezifikationen jederzeit zu ändern, um die optimale Leistung seiner Produkte sicherzustellen.Alle Rechte vorbehalten.

Kein Teil dieser Veröffentlichung darf ohne vorherige Genehmigung durch Delphi Diesel Systems Ltd. abgedruckt, in einem Datenverarbeitungssystemgespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopiren, Aufzeichnen oder auf sonstige Art,

übertragen werden.

Anche se ogni cura è stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilità pereventuali imprecisioni. Delphi Diesel Systems Ltd. svolge un intenso programma di progettazione e sviluppo che potrebbe modificare le specifiche del prodotto.Delphi Diesel Systems Ltd. si riserva il diritto di modificare le specifiche senza preavviso e ogniqualvolta lo ritenga necessario ai fini assicurare le prestazioni

ottimali dalla sua gamma di prodotti.Tutti i diritti riservati

Nessuna parte di questa pubblicazione può essere riprodotta, memorizzata in un sistema elettronico o trasmessa in qualsiasi forma o con qualsiasi mezzo,elettronico, di fotocopiatura, di registrazione o altro, senza previa autorizzazione di Delphi Diesel Systems Ltd.

Porter un appareil de protectiondes yeux / du visage.

Wear eye/face protection. Use protecção da face/olhos.

Veiligheidsbril/-masker gebruiken.Úsese protección para los ojos/la cara.

Proteggersi gli occhi/la faccia.Schutzbrille/Gesichtsschutz tragen.

Porter des gants appropriés.

Wear suitable gloves. Use luvas apropriadas.

Aangepaste veiligheidshandschoenendragenUsen guantes adecuados.

Usare guanti adatti.Geeignete Schutzhandschuhe tragen.

Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux provenant des fuites de tuyaux et des joints soumis à la haute pression. Le liquide sous haute pression injecté sous la peau peut causer des blessures mortelles. En cas d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de santé et de sécurité du gazole.

Do not put your skin into the fuel jets under pressure, especially those due to pressurepipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injectionunder the skin, contact a doctor immediately. Please refer to the health and security fuel documents.

Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos afugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar ferimentosmortais. No caso de injecção subcutânea, consulte imediatamente um médico. Consulte or favor a documentação respeitante a saúde e segurança de combustíveis.

Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione, specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.

dheids-en veiligheidsfiche met betrekking tot de brandstof.z

Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralenonder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de gezon-

Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores, tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel, consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y Seguridad.

Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie soforteinen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.

Conserver à l'écart de toute flamme ousource d'étincelles - Ne pas fumer.

Keep away from sources of ignition- No smoking.

Mantenha afastado de fontes de ignição - Proibido fumar.

Conservare lontano da fiammee scintille - Non fumare.

Von Zündquellen fernhalten- Nicht rauchen.

Ver van open vuur en ontstekingsbronnenhouden - Niet reken.

Conservar alejado de toda llamao fuentede chispas - No fumar.

1. PRESENTATION1.1 Machines........................................................................................................................................................................1-1

2. SOFTWARE INSTALLATION2.1 INSTALLATION..............................................................................................................................................................2-1

3. ACTIVATION CODE AND LICENSE NUMBER3.1 ACTIVATION CODE.......................................................................................................................................................3-1

3.2 HOW TO REGISTER AND GET A LICENSE NUMBER.................................................................................................3-1

3.3 LICENSE ERROR............................................................................................................................................................3-4

4. TEST PLANS4.1 LOAD AND UPGRADE...................................................................................................................................................4-1

5. PDF INFORMATION FILES5.1 UPDATING THE PDF INFORMATION FILES................................................................................................................5-1

6. SOFTWARE UNINSTALL6.1 UNINSTALL....................................................................................................................................................................6-1

7. INSTALLATION AND CONFIGURATION OF THE DYMO PRINTER7.1 DYMO PRINTER.............................................................................................................................................................7-1

7.1.1 INSTALLATION.............................................................................................................................................7-1

7.1.2 CONFIGURATION OF THE PRINTER...........................................................................................................7-8

8. HOW TO USE IRIS SOFTWARE8.1 INJECTORS TEST WITH IRIS........................................................................................................................................8-1

8.1.1 GENERAL PRESENTATION.........................................................................................................................8-1

8.1.2 TEST OF AN INJECTOR...............................................................................................................................8-1

8.1.3 RESULTS AND ARCHIVES.........................................................................................................................8-11

8.2 ELECTRONIC UNIT INJECTOR / PUMP TEST WITH IRIS.........................................................................................8-15

8.2.1 GENERAL PRESENTATION.......................................................................................................................8-15

8.2.2 TEST OF AN ELECTRONIC UNIT INJECTOR / PUMP..............................................................................8-16

8.2.3 CONTINUING A PREVIOUS TEST.............................................................................................................8-25


8.3 CR PUMP TEST WITH IRIS..........................................................................................................................................8-31

8.3.1 GENERAL PRESENTATION.......................................................................................................................8-31

8.3.2 TEST OF A COMMON RAIL PUMP............................................................................................................8-32


8.4 OTHER SOFTWARE FUNCTIONALITIES....................................................................................................................8-45

8.4.1 DESCRIPTION OF THE MENUS.................................................................................................................8-45

8.4.2 LIST OF ERRORS LINKED TO THE TEST OF AN INJECTOR...................................................................8-48

8.4.3 LIST OF ERRORS LINKED TO THE TEST OF AN EUI / EUP.....................................................................8-58

8.4.4 LIST OF ERRORS LINKED TO THE TEST OF A POMPE...........................................................................8-60

TABLE OF CONTENTS

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TABLE OF CONTENTS

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1.1 Machines

PRESENTATION

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For a better use of the IRIS software, it is important to read carefully this document.

The IRIS software (Injection Repair Integrated Solution) is an interface allowing to carry out the diagnostic and

characterisation of Delphi Common Rail injectors using the Cri-PC test bench, and diagnostic and adjustment of Electronic

Unit Injectors (EUI) using the AVM2-PC test bench. Using a local OPC link, IRIS talks directly to the MAGMAH software

which drives the test bench.

To activate the IRIS software, it is necessary to connect the USB dongle (reference: YDT486).

In order to print the C2I/C3i labels for Common Rail Injectors, it is necessary to use the DYMO LabelManager PC printer.

Its installation and configuration are detailed in this document.

The PC on which IRIS will be installed is supplied with the test bench (CRi-PC, AVM2PC, CRpPC).

The purpose of this manual is to explain the installation of IRIS and how to use it to test the range of Delphi products

PRESENTATION

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2.1 INSTALLATION

Note:The user is advised to close all the running applications before launching the software installation process.

The following installation guide can be used for either CRi-PC or AVM2-PC test machines. Please ensure the lastest

version of MAGMAH software is installed before starting the IRIS installation.

• CRi-PC: V9.01 (or later)

• AVM2PC: Magmah Plus / V40.02 (or later)

• CRpPC: Magmah / V2.50 (or later)

When installing the MAGMAH software ensure the OPC Core Install option is selected to be installed.

For the installation, please respect the following procedure:

• Step 1: Insert the IRIS CD-Rom. The installation

should run automatically. You may need to wait a

few seconds for the Setup to load.

If this is not launched automatically, open the Windows

Explorer, click on the CD-Rom drive, then double-click on

DDA-Setup.exe to launch the install.

• Step 2: Choose the language.

SOFTWARE INSTALLATION

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• Step 3: click "I Agree" to accept the license contract

terms.

• Step 4: Choose the elements to install.

• Step 5: click "Install" to launch the IRIS install

process. The default directory proposed is C:

\Delphi \DDARepair


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• Step 6: If a previous version is already installed, it

is proposed to update it. click "Yes" to peform the

upgrade.

• Step 7: At the end of the install process, click "Yes"

to reboot the system.


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3.1 ACTIVATION CODEThe activation code is supplied either with the IRIS CD or separately as a scratch card.

This code is an authorisation to run a given application (CR injector, EUI, CR pump...). It includes an expiry date and is

specific to each application. It is then necessary to register once a year and for each application you want to run.

3.2 HOW TO REGISTER AND GET A LICENSE NUMBER

A license number is required to be able to run a test plan. To get this license number, you need to register with the

Dongle ID and the Activation Code supplied for the given application.

• Connect the Dongle to the PC and launch IRIS from

Magmah screen.

• On the IRIS main screen, click the "Licenses"

button.

• The following screen should appear. If no product

has been registered before, no code should be

present. Click on “Register Product”.

ACTIVATION CODE AND LICENSE NUMBER

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The registration module is then launched as shown.

• Enter the Activation Code supplied by Delphi for

the application you want to run. The Dongle

number is read automatically.

• Fill-in all your coordinates.

• If the PC is connected to Internet, click on

“Automatic” button to get the license number.

Then “Close” button to return back to IRIS. At this

step your product is registered and the test plans

for the selected application can be run.

• If the machine PC is not connected to Internet, click

on “Manual” button and follow the instructions

below.

• Step 1: Save your details on a USB stick. Use “Save

as” button.


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• Step 2: Connect the USB stick to a PC connected to

Internet. Click on www.delphiiris.com and select

the *.retreg file saved on the USB stick.

• Click on “Register” button and “OK”.

• The registration details screen appears and

summarizes the all the data enetered.

• Click “Save the license information” button and

select the USB stick to save the new file

“licence.rtealic”.

• Close the web page. Disconnect properly the USB

stick and go back to the machine PC.

• On the following screen, continue with Step 3. Click

on “Open” button and select the “licence.rtealic”

from the USB stick.


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• The following screen displays the licence number

• Close this screen to go back to the IRIS “License

Information” message box as shown. Then click

“OK”.

Note:The codes may not be displayed before having

closed and reopened the dialog box.

Your product is now registered and IRIS can run the test plans for the selected application.

Note:The Test Plans need to be loaded in order to be able to run a test. See the following section.

If the Test Plans are not loaded, the list of products references is empty.

3.3 LICENSE ERROR

When IRIS is launched, the following licensing screen

may be displayed.

This screen shows a valid expiry date, but the license number is in red.


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When starting a new test, the following screen is

displayed.

This message is due to the fact that the dongle used to

launch the software is different from the one that has

been used to register the product.

The user has 2 options to resolve this problem :

• Reuse the original dongle to launch the IRIS test,

OR

• Register with the new dongle and the activation

code provided by Delphi for this product. In this

case, the license number is different, but the expiry

date remains the same.


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4.1 LOAD AND UPGRADEThe test plans can be distributed by different means (CD, e-mail ...).

CAUTION

It is important to note that the test plans update procedure overwrites all the existing test plans on the machine.

Procedure to follow when a test plan update is received :

• Launch the IRIS software.

• Select "New test" or "Continue a previous tes". The following page is then displayed:

• Select "Import", then "Test Plan".

• Select the path where the test plans will be imported from.

• click "Done"

TEST PLANS

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The test plans are then updated.

TEST PLANS

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5.1 UPDATING THE PDF INFORMATION FILESFor the IRIS EUI / EUP and CRp application various help and information PDF files are displayed at different points during

the test plans. The information files offer advice and guideance on how to rectify various test plan and test equipment

errors and also provide helpful product adjustment information.

To ensure the latest release of PDF information files are installed on the computer, please do the following:

Open the directory of the IRIS CD-ROM (normally the D:

\ directory)

Locate the folder named "PDF Files"

Double click on the executable file to install the files for

the different languages.

PDF INFORMATION FILES

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Select the install language and follow the instructions

displayed.

The PDF Information files are now updated.

PDF INFORMATION FILES

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6.1 UNINSTALLThe instructions below explain how to uninstall properly the IRIS software, when necessary.

• Step 1: From " Start \ Settings\ Control Panel",

double-click on "Add or remove programmes" and

select "IRIS" in the programmes list.

• Step 2: Select the language.

• Step 3: click "Uninstall" to start the uninstall

procedure.

SOFTWARE UNINSTALL

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At the end of the procedure, click "OK", then close the "Control panel" window.

SOFTWARE UNINSTALL

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7.1 DYMO PRINTER

7.1.1 INSTALLATION

WINDOWS XP: Connect your printer to the PC using

the supplied USB cable.

Select the option "Install from a list or specific

location (Advanced)" then click "Next".

Insert the CD-ROM supplied with the printer (DYMO

LabelMANAGER PC) and click "Next".

INSTALLATION AND CONFIGURATION OF THE DYMO PRINTER

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CAUTION

When the CR-ROM is inserted, the LabelMANAGERsoftware may be executed automatically. It is not

necessary to install the software to use the printerwith IRIS. To quit the install programme, click

"Finish".

The printer drivers are searched automatically.

In the list of the drivers found, select the english

version. Make sure to select the line containing

"english\lmpc.inf" in the location column. click

"Next".


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The driver is installed automatically.

Once the installation finished, the following screen

is displayed. click "Finish".

WINDOWS 2000 : Connect the printer to the PC

using the supplied USB cable. The following screen

is displayed :


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"Add new hardware" screen is displayed. click

"Next".

click "Next" to search for the new driver.


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Insert the CD-ROM supplied with the printer and tick

"Specific location". The other options mustn't be

selected. click "Next" to continue.

CAUTIONWhen the CR-ROM is inserted, the LabelMANAGER

software may be executed automatically. It is not

necessary to install the software to use the printer

with IRIS. To quit the install programme, click

"Finish".


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Select the CD-ROM drive, then "English" directory.

click "Open". The driver is then searched. Select

"Next".

The driver installation is then executed.


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Once the installation finished, the following screen

is displayed. Select "Finish".


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7.1.2 CONFIGURATION OF THE PRINTER

2 printer types can be met : LabelManagerPC or LabelManagerPC II.

The LabelManagerPC printer requires the configuration of the label width. If this printer is installed, follow the

instructions below to configure it :

WINDOWS XP : Select "Start" then "Printers and

faxes".


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From the list of the printers available, right-click on

the "DYMO LabelMANAGER PC I" and select

"Properties".

WINDOWS 2000 : Select "Start" then "Parameters

\Printers".


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From the list of the available printers, right-click on

the printer "DYMO LabelMANAGER PC" and select

"Properties".

Select the "Landscape" option then click

"Advanced".


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Select the format "12 mm (1/2")" in the "Label width"

list.

• Select "Small Pendaflex" in the "Paper size"

list and click "OK".

• click "OK" to close the "Printing Options"

window.


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• Select "Device settings" and "Small

Pendaflex" in the drop-down list.

• click "OK" to close the "Properties" window.

CAUTION

For the printer to be ready to use, you need to select

its type in IRIS. Go to "Display" menu then "Printer

information" and select the printer type & the tape

width as shown in the picture.

CAUTION

It is compulsory to use a tape adapted to the engine environment and compatible with the DYMO printers

described above.

Delphi recommendation: D1 permanent polyester white tapes with a width of 12 mm (DYMO reference: 16959)

and a width of 19 mm (DYMO reference: 16960).


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8.1 INJECTORS TEST WITH IRIS

8.1.1 GENERAL PRESENTATION

NEW TESTThis function allows to launch a new test (Electrical test, Diagnostic, Characterisation)

CONTINUE PREVIOUS TESTThis function allows to load and continue an existing test.

MACHINE CALIBRATIONThis function allows to calibrate the bench and generate a target for a given injector family.

INJECTOR ARCHIVEThis function gives access to the list of the archived files, the files in the "Pending" directory and to the target files.

8.1.2 TEST OF AN INJECTOR

4 types of tests can be done:

• Machine calibration: this test allows to generate the target for the reference of the injector to test. This target

is necessary in order to be able to complete a diagnostic and / or a characterisation test.

• Electrical test: this test consists in measuring the coil resistance and in checking the valve vibration when

the injector is driven.

• Diagnostic: this test allows to diagnose the state of the injector installed on the bench.

HOW TO USE IRIS SOFTWARE

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• Correction: this test allows to generate the C2I of the injector. It includes the electrical test, the static leak,

the dynamic leak and the characterisation test.

The first test to do must be the "Machine calibration" in order to generate the target. The results of this test are

saved on the machine in the target directory. Each target remains valid only during a certain time calibrated in

the software. It is possible to check the remaining validity time of each target by looking in the Targets table in

the "Injector Archives".

A) Calibration of the machine

CAUTION

It is compulsory to use a new injector to generate the target. If this condition is not respected, the reliability of

the reference data is not guaranteed. It is the same for the C2I and the diagnostic results.

There are 3 different ways to generate the target :

1. Case 1: generate the target from the "Start Menu".

2. Case 2: generate the target when a new injector test is launched.

3. Case 3: generate the target from the "Injector Archives".

CASE 1• In the "Start Menu" screen, select "Machine

calibration".

• Enter the requested information and select

the injector reference to use for the target

generation.


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• Select the line on which the injector will be

installed. Enter the serial number and the C2I

of the injectors, then click "OK".

In cas eof a 4-line machine, it is possible to generate

the target on any line.

CAUTION

The line selected in the software must correspond

to the one on which the injector is installed. The line

N°1 is the one on the left of the fixture.

The test plan corresponding to the reference

selected is automatically loaded.

• Install the injector on the fixture using the right clamp blocks and respecting the installation

recommendations.

• Clamp the injectors and launch the motor.

• Use the button "Start" to launch the test.

The test starts automatically and the software indicates the percentage completed.

At the end of the test, the target file is generated and saved.


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CASE 2• It is assumed that a diagnostic or

caracterisation test has been launched from

the following menu:

• Select the reference of the injector to test.

Enter its serial number and C2I.

The test plan is automatically loaded. click "Start" to

launch the test.


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• If the target doesn't exist or if its date has

expired, the error code 20001 is raised.

• IRIS proposes then to generate the missing

target. click "Yes" to generate the target.

• IRIS displays the list of injectors belonging to

the same family as the injector under test.

Select the reference of the NEW injector that

will be used to generate the target.


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• Enter the serial number and the C2I of the new

injector. click "OK" to validate.

• The following screen is displayed. click "Start"

to launch the target generation routine.

CASE 3From the Archives screen, it is possible to view the status of the different targets present on the machine. The

expired targets are indicated in red.

To generate a target from the Archives screen, follow the instructions below:


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• Select the expired target.

• In the list of actions located in the "Options"

column on the left, select "Machine

calibration".

• IRIS displays the list of references that can be

used to generate the target (same family).

Select the reference of the NEW injector that

will be used.

• Enter the different information requested

(Operator / Manufacturer / Serial Number /

C2I) and click "OK" to validate.

• The following screen is displayed. Select

"Start" to launch the target generation routine.


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B) Electrical test

• In the screen "Injector test type", select

"Electrical test".

• Follow the software instructions.

• Connect the injector to the resistance measurement cable.

• If the resistance is within the tolerances, it is proposed to connect the injector to the line N°1 in order to test

the valve. A this step, it is neither necessary to clamp the injector nor to connect it to the backleak flowmeter.

This electrical test allows to select only the injectors that can be hydraulically diagnosed.

• Save the results file.

By default, the file is saved in the "Pending" directory. It can be accessed from the "Archives".

C) Diagnos tic

• In the screen "Start test", select "Diagnostic test"

• Enter the information requested for the

injector to test: serial number and C2I. The

injector reference is selected in the drop-

down list. click "OK" to validate.


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In case of a 4-line machine, it is possible to diagnose

up to 4 injectors.

CAUTION

The line selected in the software must correspond

to the one on which the injector is installed. The line

N°1 is the one on the left of the fixture.

When the reference of the injector is selected, the

corresponding test plan is loaded automatically.

• Install the injector in the fixture using the appropriate clamp blocks and respecting the fitting

recommendations.

• Clamp the injectors and start the motor.

• Select the "Start" button to launch the test.

The test runs automatically and the software

indicates the percentage of completion.

For the nozzle leaks test, it is requested to use

the nosepieces with the oblong hole.

For the dynamic backleak test and the injected

deliveries test, it is requested to use the

standard nosepieces.


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• At the end of the test, save the file.

D) Cor rection• In the screen "Start test", select "Correction test".

• Enter the information requesed for the injector to test: Reference, Manufacturer, Serial Number and C2I.

click "OK" to validate.

In case of a 4-line machine, it is possible to characterise up to 4 injectors.

When the injector reference is selected, the corresponding test plan is loaded automatically.

CAUTION

The line selected in the software must correspond to the one on which the injector is installed. The line N°

1 is the one on the left of the fixture.

• Install the injector on the fixture using the appropriate clamp blocks and respecting the fitting

recommendations.

• Clamp the injectors and start the motor.

• Select "Start" button.

In this routine, the electrical tests as well as

the static leaks and the dynamic leaks tests are

also done. In fact, after having repaired the

injector, it is necessary to check these

characteristics are within the tolerances.

For the nozzle leaks test, it is requested to use the nosepieces with the oblong hole.

For the dynamic backleak test and the injected deliveries test, it is requested to use the standard nosepieces.


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• At the end of the test, save the file.

The results file contains the new C2I generated for the repaired injector.

8.1.3 RESULTS A ND A RCH IVE S

A) Results

The results of the different tests can be viewed in

the screen "Results and Analysis". There are 2

different ways to view a results file:

- From "Results and Analysis" screen. The

instructions are explained below.

- From "Injector Archives" screen. See "Archive

\ Test results" section hereafter.

• Select the screen "Results and Analysis".

• Select the line in which the results will be viewed.

• Select the "Load results" button, or click F1.

The results files can be either in the "Pending" directory, or in the "Results" directory.

The "Pending"directory contains the electrical results and the diagnostic results.

The "Results" directory contains all the "complete" results that is to say the files including the electrical tests,

the diagnostic test and the characterisation test.

CAUTION

It is possible to archive manually the files containing only the electrical results or diagnostic results. The

effect of this is to move these files from the "Pending" directory to the "Results" directory.

The file searched has a name with the following structure: REFERENCE_SERIALNUMBER_DATE_TIME. For

example EJBR01701Z_1000FV06W7_20070611_103248

• Select the data type to display: "Correction data" or "Diagnostic data".

Correction data : if the loaded file corresponds to a characterisation test, the software displays the new C2I

calculated after repair. It is possible to view the graph of the delivery curve against pulse widths for different

pressures.

Diagnostic data : if the loaded file corresponds to the diagnostic test, only the old C2I is diplayes.

The software allows to view the overall pass / fail status as well as the detailed result for each test step (electrical

test, static test, dynamic test, injected deliveries ...).

In case of test failure, it is necessary to analyse the results in detail in order to determine the cause of the failure.

It is possible to print the results and / or the C2I.


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CAUTION

It is compulsory to clearly identify the injector onwhich the printed C2I label will be stuck. Check that

the serial number of the repaired injector and theserial number that appears in the results file are

identical.

B) Archives

The "Archives" contain all the results generated on the machine:

• Injector test results: electrical, diagnostic or characterisation.

• Targets recored on the machine.


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Test resultsAs mentioned above, there are 2 directories wherethe results files can be recorded: "Pending" and

"Results".

• Select the appropriate directory to view the

list of the results files.

It is possible to sort the files by Type, Date of

modification, C2I, Serial number or reference.

click on the column title (Status, Last saved,

C2I, Serial Number, Injector reference).

• Select a results test file.

• In the column "Options", click on the file

selected. An actions list is displayed:

• No action

• Delete : this command allows to delete

the file.

• Archive : this command allows to

archive the selected file, that is to say,

move it from the "Pending" directory to

the "Results" one.

This command is possible only when

the "Pending" directory has been

selected on the top-left hand corner of

the table.

• Continue test : this command allows to

continue an electrical test or a

diagnostic test.

• View results : this command allows to

view the detailed results contained in

the selected file. When this command is

used, the software asks to enter a line

number (1 to 4). It is then necessary to

go back to the "Results and Analysis" to

view the results.

• Display filename : this command allows

to display the complete name of the file

selected (with a .DRF extention).


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TargetsThe targets table gathers all the targets that have been generated on the machine. A validity status is associated

to each target :

• Valid : when a target is still valid, a number between brackets is associated to indicate the number of days

remaining before it expires.

• Error : it refers to an incorrect target that cannot be used in the calculations. This error can be due to corrupted

data or to a structure problem in the file.

• Expired : this status refers to a target which is no more valid. The expired targets generate the error 20000

when the software is launched.


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8 .2 ELECTRONIC UNIT INJECTOR / PUMP TEST WITH IRIS

8. 2. 1 GE NE RA L PRESENTATIO N

NEW TESTThis function allows to launch a new test (Electrical test, Diagnostic, Adjustment)

CONTINUE PREVIOUS TESTThis function allows to load and continue an existing test.

MACHINE CALIBRATIONThis function is not used when testing an Electronic Unit Injector or Electronic Unit Pump

RESULTS ARCHIVEThis function provides access to view the results in the Pending and Archive folders.


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8 .2 . 2 TEST OF A N EL ECTRONIC U NI T INJE CT OR / PU MP

Select "New Test" from the main IRIS menu

3 types of tests can be done:

• Electrical Test: this test consists in measuring the coil resistance and in checking the valve vibration when

the EUI/EUP is driven.

• Diagnostic: this test allows to diagnose the state of the EUI / EUP installed on the bench.

• Adjustment: this test allows adjustment of the EUI / EUP by providing technical information during the test

and also provides a new correction code if the test is sucessful.


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A) Electr ical tes t

In the screen "EUI/EUP test type", select "Electrical

test".

Note:It is not essential to connect the fuel supply and

return hoses to the EUI / EUP fuelling sleeve while

conducting the electrical test module

The apprioprate part number must be selected

before the test can be started.

The part number is selected by clicking the drop

down menu within the "EUI/EUP Part Number"

dialog box.

Once the test plan is selected click OK. The relevent setup and safety instructions will be displayed.

The electrical test module checks the resistance and control valve assembly of the actuator.

The result file is not automatically saved when the test sequence is complete, if the result needs to be saved select

the FILE and SAVE function.

By default, the file is saved in the "Pending" directory. It can be viewed by selecting the "Results and Analysis"

tab.


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B) Diagnostic Test

In the screen "EUI/EUP Test Type", select

"Diagnostic Test"

Enter the information requested to start the test.

1) Operator Name

2) EUI/EUP Part Number

3) Old Correction Code

4) Serial Number (S/N)

5) Metering Line

CAUTION

Before clicking the O.K button, please ensure the correct metering line is selected for testing. The selected metering

line should be the one which the EUI / EUP is connected to.


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Since there are various types of EUI / EUP which can be tested using IRIS the product specific setup information

is displayed at the beginning of the test.

• Press the "Start" button

A message box will be displayed asking if you

would like to see the test equipment list and test

conditions?. The message box has two selection

options "Yes" and "No".

If the "No" button is selected the test will continue

as normal.

If the "Yes" button is selected a seperate PDF

viewing window will be opened which shows the

relevant setup information for the EUI.

CAUTIONTo continue the test, the PDF viewing window must be closed

Once the EUI / EUP is fully installed into the EUI base kit, start the fuel supply and drive Motor by pressing the

green buttons next to the AVM2-PC monitor.


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At the end of the test a message box will be shown

which highlights if the diagnostic test has passed,

failed or has been aborted..

The result file is automatically saved into the

"Pending" folder and loaded into the "Results and

Analysis" viewer.

Click the "Results and Analysis" tab to review the

measured data from the test.


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Note:If the EUI / EUP passes all of the test modules in the diagnostic test then the original grading code can be reused.

C) Adjustment

In the screen "EUI/EUP Test Type", select

"Adjustment Test".

Enter the information requested to start the test.

1) Operator Name

2) EUI/EUP Part Number

3) Serial Number (S/N)

4) Metering Line

CAUTION

Before clicking the O.K button, please ensure the correct metering line is selected for testing. The selected metering

line should be the one which the EUI / EUP is connected to.


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Since there are various types of Electronic Unit Injector which can be tested using IRIS the product specific setup

information is displayed at the beginning of the test.

• Press the "Start" button

A message box will be displayed asking if you

would like to see the test equipment list and test

conditions?. The message box has two selection

options "Yes" and "No".

If the "No" button is selected the test will continue

as normal.

If the "Yes" button is selected a seperate PDF

viewing window will be opened which shows the

relevant setup information for the EUI.

CAUTIONTo continue the test, the PDF viewing window must be closed

Once the EUI / EUP is fully installed into the EUI base kit, start the fuel supply and drive Motor by pressing the

green buttons next to the AVM2-PC monitor.


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During the test if any product related errors are

raised then IRIS will automatically display an error

report and stop the test.

Advice and guideance is provided for each error and

this can be viewed by clicking the appropriate "Info"

button.

The "Info" button opens a seperate viewing window

and the appropriate help file is loaded into the

viewer.

The viewer contains a very simple and easy to use

interface. The page displayed can be changed by

clicking the "next" or "previous" page arrows.


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CAUTION

During the adjustment test the information included in the PDF file might specify that the EUI / EUP might needdismantling and inspecting. If the PDF file specifies an adjustment of a shim or replacement of a component it is

advisable than the PDF viewer should be "Minimized" and the results of the test reviewed before any adjustment

is completed.

• Hide the PDF viewer by clicking the "Minimize" button in the top right hand corner of the PDF viewer window.

• Select "End Testing" from the original error report message box

• Click the "Results and Analysis" tab to review the measured data during the test.

• Open the PDF viewer by clicking the "Restore" button on the windows taskbar.

Review the adjustment information.

If the EUI / EUP passes all of the test modules a new

grading code should be provided in the "New Code"

column within the "Results and Analysis" viewer.

If the EUI / EUP passes all of the test modules but

does not generate a new grading code, then open

the error report by clicking the "Display" tab on the

top of the IRIS display. Then select "Error Report" to

display any errors raised during the test.


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8. 2. 3 CONTINUI NG A PREVIOUS T EST

The continue previous test functionality can be performed in two ways:

• From the IRIS main menu when selecting "Continue Previous Test"

• From the "Results Archive" when selecting a result file from the pending folder

A) Main Menu - Continue Previous Test

Select "Continue Previous Test" from the Start

Menu

• Select diagnostic or adjustment test to display

the EUI/EUP Information box

• Click the icon next to the Serial Number (S/N)


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• Highlight the result file that you want to load

and click OK

Note:The file searched has a name with the following structure: REFERENCE_SERIALNUMBER_DATE_TIME. For

example BEBE4020345_203450344_20090521_232122

Once the file is loaded the EUI/EUP part number and serial number (S/N) will be preloaded into the EUI/EUP

information box

• Before clicking OK ensure the correct

Metering Line is selected for testing and if

required enter the Operator Name


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B) Results Archive - Continue Previous Test

• Open the "Results Archive" from the IRIS main menu or selection tab

• Locate the result file which you want to

continue from the Pending Folder

• Click the left hand column (by default "No

Action" is selected)

• Select "Contiue Test" from the list

• Open the EUI/EUP Test Type screen and select either diagnostic or adjustment test

• The EUI/EUP part number and serial number (S/N) will be preloaded into the EUI/EUP information box


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• Before clicking OK ensure the correct

Metering Line is selected for testing and if

required enter the Operator Name

8 .2 .4 RESULTS AND ARCHIVES

A) Res ults

The results of the different tests can be viewed in

the screen "Results and Analysis". There are 2

different ways to view a results file:

- From "Results and Analysis" screen. The


- From "Result Archives" screen. See "Archive \

Test results" section hereafter.

• Select the screen "Results and Analysis".

• Select the "Load Results" button, or click F1.

The results files can be either in the "Pending" directory, or in the "Results" directory.

The "Pending"directory contains the electrical results and the diagnostic results.

The "Results" directory contains all the "complete" results that is to say the files including the electrical tests,

the diagnostic test and the adjustment test.

CAUTION

It is possible to archive manually the files containing only the electrical results or diagnostic results. The

effect of this is to move these files from the "Pending" directory to the "Results" directory.

The file searched has a name with the following structure: REFERENCE_SERIALNUMBER_DATE_TIME. For

example BEBE4020345_203450344_20090521_232122

• Select the data type to display: "Diagnostic data" or "Adjustment data".

Diagnostic data : if the loaded file corresponds to the diagnostic test, only the old grading code is diplayed.


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Adjustment data : if the loaded file corresponds to a Adjustment test, the software displays the new grading

code calculated after repair.

The software allows to view the overall pass / fail status as well as the detailed result for each test step.

In case of test failure, it is necessary to analyse the results in detail in order to determine the cause of the failure.

It is possible to print the report and / or the screen

CAUTION

Check that the serial number of the repaired EUI/

EUP and the serial number that appears in the

results file are identical. This is to ensure the new

grading code is linked to the correct EUI/EUP.


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B) Archives

The "Results Archive" contain all the results generated on the machine:

Test resultsAs mentioned above, there are 2 directories where

the results files can be recorded: "Pending" and

"Results".


list of the results files.

It is possible to sort the files by Type, Date of

modification, New correction grade, Serial

number or reference. click on the column title

(Status, Last saved, New Correction Grade,

Serial Number, Part Number).

• Select a results test file.

• In the column "Options", click on the file

selected. An actions list is displayed:

• No action

• Delete : this command allows to delete

the file.

• Archive : this command allows to

archive the selected file, that is to say,

move it from the "Pending" directory to

the "Results" directory.

This command is possible only when

the "Pending" directory has been

selected on the top-left hand corner of

the table.

• Continue Test : this command allows to

continue an electrical test , diagnostic

test or adjustment test.

• View Results : this command allows to

view the detailed results for the selected

result file.

• Display filename : this command allows

to display the complete name of the file

selected (with a .DRF extention).


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8 .3 CR PUMP TEST WITH IRIS

8. 3. 1 GE NE RA L PRESENTATIO N

NEW TESTThis function allows to launch a new test (Diagnostic, Recheck)

CONTINUE PREVIOUS TESTThis function is not used in the "CR pump application".

MACHINE CALIBRATIONThis function is not used in the "CR pump application".

RESULTS ARCHIVEThis function allows to access the results saved in the "Pending Results" or "Results Archived" directories.


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8 .3 .2 TEST OF A COM MON RAIL PUM P

Select "New Test" in the main menu.

2 types of tests can be carried out :

• Diagnostic: this tests allows to diagnose the pump fitted on the bench.

• Recheck: it allows to verify that the repaired pump satisfies the Delphi specifications.


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A) Diagnostic

Select "Diagnostic" in the screen "CRp Test Type".

Enter the requested information to launch the test.

1) Operator name

2) Pump reference

3) Serial number

4) Line number (in case of AVM2PC)


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CAUTION

In case of the AVM2PC, before clicking "OK", make sure the line number is correct. The selected line must be theone the pump is connected on.


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Clicking the "START" button, the complete list of

test modules is displayed. IRIS proposes to select

the modules the user doesn't want to test.

CAUTION

Delphi recommends to run ALL the modules to

know precisely the state of the pump.

CAUTIONThe cleanliness test, using the YDT378 tool, is very

important as it prevents a contaminated pump from

introducing pollution in the measurement system.

Note:This option allows the user to test only some

modules, which may be useful in case of a quick

verification after the replacement of a particular

component or when a pump component is

suspected.

As several pump types can be tested with IRIS, the information specific to each product are displayed at the

beginning of the test.

• Tick the modules to skip and click "OK".

• Confirm the selection by validating the warning message displayed by IRIS.

IRIS displays a dialog box asking whether the user

wants to view the list of the required equipement

and the test conditions. This dialog box has 2

options: "YES" and "NO".

If "NO" is selected, the test continues as normal.


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If "YES" is selected, a window is open displaying a

PDF file with the product information.

Use the arrows in top left-hand corner to view the

other pages of the document.

CAUTION

To continue the test, the PDF window must be closed.

Once the pump completely fitted on the bench, start the fuel supply and run the motor using the green button of

the CRpPC or AVM2PC.

Follow the instructions displayed by the IRIS

software. The test starts automatically and the

percentage completed is indicated in the bottom

right-hand corner.


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At the end of the test, a dialog box is displayed

indicating whether the diagnostic test has been

completed or aborted.

The results file is automatically saved in the

"Pending" directory and is loaded by the results

viewer (Results and Analysis tab).

Select the "Results and Analysis" tab to view the

measurements recorded during the test.


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Note:If the pump has passed ALL the Diagnostic modules, it can be fitted on the vehicle.

B) Recheck

Select "Recheck" in the "CRp Test Type" screen .

Enter the requested information to run the test.

1) Operator name

2) Pump reference

3) Serial number

4) Line number (in case of AVM2PC)

CAUTION

In case of the AVM2PC, before clicking "OK", make sure the line number is correct. The selected line must be the

one the pump is connected on.


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Clicking the "START" button, the complete list of

test modules is displayed. IRIS proposes to select

the modules the user doesn't want to test.

CAUTION

Delphi recommends to run ALL the modules to

know precisely the state of the pump.

CAUTIONThe cleanliness test, using the YDT378 tool, is very

important as it prevents a contaminated pump from

introducing pollution in the measurement system.

Note:This option allows the user to test only some

modules, which may be useful in case of a quick

verification after the replacement of a particular

component or when a pump component is

suspected.

As several pump types can be tested with IRIS, the information specific to each product are displayed at the

beginning of the test.

• Tick the modules to skip and click "OK".

• Confirm the selection by validating the warning message displayed by IRIS.

IRIS displays a dialog box asking whether the user

wants to view the list of the required equipement

and the test conditions. This dialog box has 2

options: "YES" and "NO".

If "NO" is selected, the test continues as normal.


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If "YES" is selected, a window is open displaying a

PDF file with the product information.

Use the arrows in top left-hand corner to view the

other pages of the document.

CAUTION

To continue the test, the PDF window must be closed.

Once the pump completely fitted on the bench, start the fuel supply and run the motor using the green button of

the CRpPC or AVM2PC.

Follow the instructions displayed by the IRIS

software. The test starts automatically and the

percentage completed is indicated in the bottom

right-hand corner.


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During the test, if an error linked to the productbeing tested is raised, IRIS automatically displays

an error report and stops the test.

Information and recommendations are provided for

each error. They can be viewed by clicking the "Info"

button.

The "Info" button opens a window displaying the

appropriate help information.

The viewer is a simple and easy to use interface. The

displayed page can be changed using the "next" and

"previous" arrows.

• Select "Results" in the bottom left-hand corner

of the error report to open the "Results and

Analysis" screen.


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The table in the bottom of the "Results and Analysis"

screen displays all the pump results, including the

error codes shen the test step has failed. When a

measurement is out of tolerance, the related cell is

red.

The list in the top right-hand corner summarizes the

tested modules and their status (pass / fail).

• Select an error and view the related

information by clicking the "Info" button.

Review the error related information.


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If the pump passes ALL the test modules, it can be

refitted on vehicle.

8.3.3 RESULTS A ND A RCH IVE S

A) Results

The results from the different tests can be viewed

in the "Results and Analysis" screen. A results file

can viewed by 2 ways:

- From the "Results and Analysis" screen. The


- From the "Archives" screen. See the "Archives

\ Test Results" section below.

• Select the "Results and Analysis" screen.

• Use the "Load Results" button, or click F1.

The results files can be either in the "Pending" directory or in the "Results" directory.

The "Pending" directory includes the results files either from incomplete tests or from aborted tests.

The "Results" directory includes the files from complete tests.

The searched file has a filename with the following structure: REFERENCE_SerialNumber_DATE_TIME. For

instance 9044A071A_5634AYE67_20100521_232122

In case of a failed test, it is necessary to analyse the results in detail to determine the cause of the failure. Refer

to the measurements table in the bottom of the screen.

It is possible to print the report and / or the screen.


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B) Ar chives

The "Archives" include all the results that have been generated on the machine:

Test resultsAs mentioned above, the results can be saved either

in the "Pending" directory or in the "Results"

directory.


results files list.

It is possible to sort the files by Reference,

Serial number, Last saved, status. Click the

related column title.

• Select a results file.

• In the "Options" column, click the selected file.

An actions list is displayed :

• No action

• View the results: this command allows

to view the detailed results of the

selected file.

• View the filename: this command

allows to view the complete name of the

selected file (with .DRF extention)

8 .4 OTHER SOF TWARE FUNCTIONALITIES

8. 4. 1 DE SCRIPTION OF TH E M ENUS

4 main menus give access to supplementary functionalities :

• File menu : allows to manage the manual loading of the test plan, to save the test results, to export the

results, to import the new test plans, to start the test, to select the test mode (manual or automatic), to

reinitialise the application and to quit the software.

• Display menu : allows to display the test plan information, the list of injectors, the owner information, the

Dongle information, the diagnostic of the backleak pressure, the debug information, the printer information,

the OPC Client tool and the error report.

• Tools menu : allows to manage the functionalities linked to the calculation results (ignore the calculations

and / or the errors report), to select the demonstration mode, to force the OPC connection and to analyse

the results.

• Diagnostic menu: allows to diagnostic information such as APC temperature and pump outlet

temperature. It also allows to access the "head-to-head" functionality in case of a DFP3 pump.

• Help menu : allows to change the language and to access to the software information.

Only the main functionalities are described below :

A) File \ Import \ Test plan

This command is used to update the software with the new test plans.

CAUTION

The test plans update command overwrites all the previous test plans already existing on the machine.

Refer to the "Test Plans \ Load and uprgade" section in this document to import the new test plans.


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B) Display \ Injector list information

This function allows to access, for each family, to

the list of the injectors and to the version of the

corresponding test plans.

Some families are green ticked and others are with

a red cross :

• Green ticked families : this means the

associated target is valid. Moreover, the

reference of the injector that has been used to

generate this target is also green ticked.

• Families with the red cross : this means either

the target doesn't exist or it is expired or it is

not valid.

C) Dis play \ Pump lis t information

This function is available only in the "Pump" mode.

This function allows to access the list of the pump

references as well as the testplan version for each

family.


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D) Display \ Backleak pressure diagnostic

This function allows to display the status of the

parameters used to diagnose the backleak unit

HK901-P included in the HJ044 kit.

Parameter DescriptionNormal value in "Flowmeasurement" mode

Normal value in"Depression" mode

A Not used 0 9999

B Not used 0 9999

C Gives an indication on the internal leaks of th e unit 0 2220

DReflects the absolute value of the measured

depression0 300 ou 600

E) Display \ Printer information

This function is used to check and / or to select the

C2I printer configuration. Default margins are set in

the software, but it is possible to modify them using

this menu.


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F) Dis play \ Error report

The errors report describes the list of errors that

have been raised during the test. For each error, the

group, the fault code and the description are

displayed. For more details, refer to the errors list

at the end of this document.

G) Tools \ Result calculations

This function allows to ignore the errors linked to

the test and / or to the C2I calculation. If these

options are selected, the test runs normally, but no

calculations are done and no file is saved at the end.

H) Tools \ Analyse Results

This function allows to perform the calculations for a given results file. In case of a diagnostic file, it allows to

calculate the MDP, the delivery slope, the calibrated response time as well as the different parameters drifts. In

case of a correction file, it allows to calculate the C2I or the C3I.

8 .4 . 2 LIST OF E RRO RS LINKED TO TH E TE ST OF AN INJE CT OR

In order to give information on different potential anomalies linked to the multiple test situations, the error codes

below have been included in the application. These codes are specific to the Common Rail injector test.

In the table below, 2 fault groups appear. The group N°4 gathers the errors managed by the IRIS application. The

group N°5 gathers the errors managed by the calculation module.

Group (*) Category Errorcode

Name Description

5 Standard error 10000 File not found The data file is not found


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Group (*) CategoryErrorcode

Name Description

5 Standard error 10001 File not valid The results file is not valid

5 Standard error 10002 Undefined error The DLL cannot deliver the results because of an unknown error

5 Standard error 10003No data found in theresults file

The results file is not complete. The required data is not found in theresults file.

5 Standard error 10004No data found in thetarget file

The target file is not complete or is empty. The required data is notfound.

5 Standard error 10005 Divide by 0 Impossible to perform the calculations because of a division by 0.

4 Target 20000 Target expired The validity date of the target file for one or several families is expired.

5 Target 20001 Target dat not foundThe target file for the reference under test couldn't be found in thetargets directory.

5 Target 20002 Target empty The target file doesn't contain any data.

5 Target 20003Impossible togenerate the targetdata

The target file cannot be generated because of on e or more errorslinked either to the data measurement, or to the calculations, or tothe original C2I. This error code is raise d with other supplementaryerrors giving information on the status of the data or the calculations.

5 Measurements 30001Pulse dataincoherent

Pulse values negative or zero.

5 Measurements 30002Delivery dataincoherent The values of the measured deliveries are negative.

5 Measurements 30003 Opening delayincoherent

This fault is raised when the opening delay is strictly out of thetolerance 0 - 999 μs.

4 Measurements 30000 Delivery too low All the deliveries are below 0.2 mm3/sh at 230 ba r



4 Measurements 30003 Delivery too low All the deliveries are below 0.5 mm3/sh at 120 0 bar

4 Measurements 30004 Delivery too low All the deliveries are below 0.5 mm3/sh at the maximum pressure

4 Measurements 30005 Minimum deliveryhigher than expected

All the deliveries are higher than 2 mm3/sh at 230 bar

4 Measurements 30006Minimum deliveryhigher than expected







All the deliveries are h igh er than 4 mm3/sh at the maximum pressure

4 Measurements 30010Dlivery lower than 3mm3/shot

All the deliveries are lower than 3 mm3/sh at 23 0 bar


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Name Description

4 Measurements 30011Dlivery lower than 3mm3/shot All the deliveries are lower than 3 mm3/sh at 400 bar

4 Measurements 30012Dlivery lower than 3mm3/shot All the deliveries are lower than 3 mm3/sh at 800 bar

4 Mesures 30013 Dlivery lower than 3mm3/shot

All the deliveries are lower than 3 mm3/sh at 1200 bar

4 Measurements 30014 Dlivery lower than 3mm3/shot

All the deliveries are lower than 3 mm3/sh at the maximum pressure

4 Measurements 30015

Error in the lowdeliveries -Insufficient numberof me asurements

At 230 bar, number of measurements with a delivery between 0.2and 2 mm3/sh, lower than 2.






At 800 bar, number of measurements between 0.5 and 3 mm3/sh,lower tha 2.






At the maximum pressure, number of measurements with a deliverybetween 0.5 and 4 mm3/sh, lower than 2.


Error in the highdeliveries -Insufficient numberof me asurements

At 230 bar number of measurements with a delivery strictly higherthan 3 mm3/sh, lower than 2.








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Name Description


Error in the highdeliveries -Insufficient numberof measurements



Error in the highdeliveries -Insufficient numberof measurements

At the maximum pressure, number of measurements with a deliverystrictly higher than 3 mm3/sh, lower than 2.

4 Measurements 30025 Delivery too lowAll the deliveries are lower than Q1P3 mm3/sh at 800 bar (Q1P3depends on the injector refe rence)



4 Measurements 30028 Delivery too lowAll the deliveries are lower than Q1P4 mm3/sh at 1600 ba r (Q1P4depends on the injector refe rence)




All the deliveries are higher than Q2P3 mm3/sh at 80 0 bar (Q2P3depends on the injector refe rence)












Error in the lowdeliveries -Insufficient numberof measurements

At 800 bar, number of measurements with a delivery strictly betweenQ1P3 and Q2P3 mm3/sh, lower than 2.


Error in the lowdeliveries -Insufficient numberof measurements



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Name Description













5 Calculations 40001Pilot pulseincoherent

Pilot pulse negative or zero at 230 bar and/or at 400 bar and/or at800 bar and/or at 1200 bar and/or at the maximum pressure.

5 Calculations 40002Main pulseincoherent

Main pulse negative or zero at 230 bar and/or at 400 bar and/or at800 bar and/or at 1200 bar and/or at the maximum pressure.

5 Calculations 40003Delivery slopeincoherent

Slope negative or zero.

5 Calculations 40004Impossible tocalculate the deliveryslope

Denominator zero

5 Calculations 40005

Impossible tocalculate thecorrection d uring theoptimization

At 800 bar, the minimum delivery calculated during the optimizationprocess is zero



At 1600 bar, the minimum delivery calculated during the optimizationprocess is zero



At 1600 bar, the minimum delivery calcu la ted is equal to the maximumdelivery calculated



At 1600 bar, the maximum delivery calculated is equ al to Q4P4 (Q4P4depends on the injector reference)


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Name Description

4 C2I 50000Error in the originalC2I Number of characters lower than 16.

5 C2I 50001 Incorrect checksum The calculated checksum is not correct.

5 C2I 50002Incorrect checksummethod

The checksum method in the results file is different from 0 and 1.

5 C2I / C3I 50003The BETA parametercannot be calculated- Division by 0

Denominator zero

5 C2I / C3I 50004Paramètre Betaincohérent

Deta negative or zero

5 C2I / C3I 50005

The GAMMAparameter cannot becalculated - Divisionby 0

Denominator zero

5 C2I / C3I 50006 Incoherent GAMMAparameter

Gamma negative or zero

5 C2I / C3I 50007

The ALPHAparameter cannot becalculated - Divisionby 0

Denominator zero

5 C2I / C3I 50008ALPHA parametercannot be calculated Alpha negative or zero

5 C2I / C3I 50009Incoherent DELTAparameter Delta positive or zero

5 C2I 50020Impossible tocalculate thechecksum

The checksum method in the original C2I is not known.


Opening delay correction out of tolerances.


Byte 1 out of tolerances






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Name Description









5 C2I 50022

Impossible tocalculate the C2I -Offset 1 out oftolerances

5 C2I 50023


5 C2I 50024


5 C2I 50025


5 C2I 50026


5 C2I 50027


5 C2I 50028



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Name Description

5 C2I 50029


4 C3I 50030Error in the originalC3I

Number of characters lower than 20


Number of characters higher than 20


The entered characters are not alphanumeric.

5 C3I 50033 Incorrect checksum The checksum calculated is not correct


Checksum method in the result file is different from the expected onefor the injector tested.


Checksum method in the result file is different from the expected onefor the injector tested.


Response time correction offset out of tolerance

5 C3I 50037

Impossible tocalculate the C3I -Offset 1 out oftolerance

5 C3I 50038


5 C3I 50039


5 C3I 50040


5 C3I 50041


5 C3I 50042Impossible tocalculate the C3I -


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Name Description

Offset 6 out oftolerance

5 C3I 50043


5 C3I 50044


5 C3I 50045


5 C3I 50046

Impossible tocalculate the C3I -Offset 10 out o ftolerance

5 C3I 50047


5 C3I 50048


5 C3I 50049


5 C3I 50050


5 C3I 50051


5 MDP 60000Incoherent MDPvalue

MDP negative or zero


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Name Description

5 MDP 60001Incoherent MDPvalue MDP at 230 bar negative or zero

5 MDP 60002Incoherent MDPvalue MDP at 400 bar negative or zero

5 MDP 60003 Incoherent MDPvalue

MDP at 800 bar negative or zero

5 MDP 60004 Incoherent MDPvalue

MDP at 1200 bar negative or zero

5 MDP 60005Incoherent MDPvalue

MDP at the maximum pressure negative or zero

5 MDP 60006Impossible tocalculate MDP value

Division by 0 at 400 bar





5 C2I 70001Error in the originalC2I - Incorrect Length

Number of characters in the entered C2I different from 16.

5 C2I 70002Error in the originalC2I - Characters arenot Hexadecimal

The entered characters are not hexadecimal.

5 C2I 70003 C2I not valid The checksum recalculated for the original C2I is not correct.

5 C3I 70004 C3I not valid Incorrect length

5 C3I 70005 C3I not valid Incorrect length

4 Initialization 80000Error in constantsinitialization





4 Initialization 80005 Error in constantsinitialization

4 Initialization 80006 Error in constantsinitialization


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Name Description

4 In itialization 80007Error in constantsinitialization

4 In itialization 80009Error in constantsinitialization

4 In itialization 80010 Error in constantsinitialization

4 In itialization 80011 Error in constantsinitialization

5 Interpolation 95000 Interpolation error

5 Interpolation 95001 Missing step number The step number is missing in the result file

5 Interpolation 95002 Missing pulseThe pulse is missing in the result file to perform the interpolationcalculation

5 Interpolation 95003 Missing data The data is missing in the previous or next step number (result file).

8 .4 . 3 LIST OF E RRO RS LINKED TO TH E TE ST OF AN E UI / EUP

Group (*) Category Error code Name Description

5 Grading error 0 No Error Found

5 Grading error 13 Fuel 1 ZeroFuel DAQ value missing from data array or division value isequal to 0




5 Grading error 17 Fuel 5 Zero Fuel DAQ value missing from data array or division value isequal to 0

5 Grading error 21 Invalid Timing Offset - HighResponse time - T3 correction value not found within arraytable

5 Grading error 22 Invalid Timing Offset - LowResponse time - T3 correction value not found within arraytable

5 Grading error 23 Invalid Fuelling Offset - High Fuelling correction value not found within array table

5 Grading error 24 Invalid Fuelling Offset - Low Fuelling correction value not found within array table

5 Grading error 25 Average fuelling zeroFuel DAQ value missing from data array or division value isequal to 0

4 Standard error 10001 No Actuator Noise User defines "no noise emmited" within the IRIS interfaceduring the valve test


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4 Standard error 10002Fuel Supply Temperature outof limits

Fuel supply temperature out of limits (individual limits specificto IRIS test plan)

4 Standard error 10003Injector Line Temperature outof limits

Injector line temperature out of limits (individual limitsspecific to IRIS test plan)

4 Standard error 10004 Boost Pressure out of limitsBoost pressure out of limits (individual limits specific to IRIStest plan)

4 Standard error 10005Fuel Supply Pressure out oflimits

Fuel supply pressure out of limits (individual limits specific toIRIS test plan)

4 Standard error 10006 Drive Speed out of limitsAVM2-PC drive speed out of limits (individual limits specificto IRIS test plan)

4 Standard error 10007 Resistance out of limits Actuator Resistance out of limits (individual limits specific toIRIS test plan)

4 Standard error 10008 Fuel Delivery out of limits Measured fuel delivery out of limits (individual limits specificto IRIS test plan)

4 Standard error 10009 Base Load out of limitsBase load measurement out of limits (individual limits specificto IRIS test plan)

4 Standard error 10010Response Time - T3 out oflimits

Response time - T3 out of limits (individual limits specific toIRIS test plan)

4 Standard error 10011 Peak Pressure out of limitsPeak pressure out of limits (individual limits specific to IRIStest plan)

4 Standard error 10012Response Time - T4 out oflimits

Response time - T4 out of limits (individual limits specific toIRIS test plan)

4Calculation

error10013

Response Time - T3Calculation Error

Calculation data missing or corrupt within the IRIS test plan

4Calculation

error10014

Response Time - T4Calculation Error

Calculation data missing or corrupt within the IRIS test plan

4Calculation

error10015 Idle Grade Calculation Error Calculation data missing or corrupt within the IRIS test plan

5 Grading error 90021 Unknown Correction Method Correction method not specified before starting a test plan

5 Grading error 90030 T3 Correction out of limitsResponse time - T3 correction value not found within arraytable

5 Grading error 90031 T4 Correction out of limitsResponse time - T4 correction value not found within arraytable

5 Grading error 90032 Idle Correction out of limits Idle correction value not found within array table

5 Grading error 90040 Fuel Slope Calculation ErrorFuel DAQ value missing from data array or division value isequal to 0

5 Grading error 90041Average Delivery CalculationError

Fuel DAQ value missing from data array or division value isequal to 0

5 Grading error 90050 Correction ECUT4 out of limits ECUT4 correction value not found within array table


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5 Grading error 90051 Incorrect Serial NumberIncorrect serial number length specified before starting a testplan

8 .4 .4 LIST OF E RRO RS LINKED TO TH E TE ST OF A PO MPE

In order to give information on different potential anomalies linked to the multiple test situations, the error codes

below have been included in the application. These codes are specific to the Common Rail pump.

Code Module Parameter Description

10001 Temperaturestability

Pump temperature sensor Difference between the pump sensor temperature and the supplytemperature, higher than the maximum limit.

10002 Running-in Delta T Difference between the supply temperature and the returntemperature higher than a limit depending on the test point.10003 IMV test

10004 Performance test

10005 PLV test

10006 All Supply temperature Out of testplan tolerances

10007 Return temperature Out of testplan tolerances

10008 Pump temperature Out of testplan tolerances

20001 IMV test Hysteresis Hysteresis value higher than the limit.

20002 All IMV current IMV current out of tolerance

30001 IMV test Pump outlet flow Out of testplan tolerances. Value depending on the pump and on itstestpoint.30002 Performance test

30003 PLV test

30004 Internal leaks atlow pressure

30005 Internal leaks athigh pressure

30006 Regulator closed

30007 Regulator breakpressure

40001 Performance test Pump return flow Out of testplan tolerances. Value depending on the pump and on itstestpoint.40002 PLV test

40003 Internal leaks atlow pressure

40004 Internal leaks athigh pressure

40005 Regulator closed

40006 Regulator breakpressure


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Code Module Parameter Description

50001 Performance test Venturi depression Corrected dep ression value out of tolerance. The limits depend onthe pump and on the testpoint.

60001 Performance test Transfer pressure Transfer pressure value out of tolerance. The limits depend on thepump and on the testpoint.

60002 All Rail pressure Parameter out of testplan tolerances.

60003 All Supply pressure

60004 All Return pressure

70001 Head-to-headtest / DFP3 pump

Head contribution Difference between the minimum contribution and the maximumcontribution, higher than a limit depending on the pump type.

70011 DAQ400 internalparameters

Unknown error

70012 Failed to lo ad Head to Head User Interface

70013 File read/write

70014 Memory allocation

70015 Data acquisition software version

70016 Data acquisition hardware not found

70017 Data acquisition gain settings could not be set

70018 Data acquisition problem

70019 IIR filter

70020 Failed to read/write IIR Filter coefficients file

70021 Failed to read/write .INI file

70022 Failed to read/write Wavefo rms file

70023 Plotting e rror

70024 Feature not supported

70025 No data to analyse

70026 Pressure signal / Analysis failure / Cylinders incorrect

70027 Failed to read / write Config.ini file value

70028 Pulses per rev sign al fault / not enough revs

80001 All Pump speed Parameter out of testplan tolerances.


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Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd., maisla société décline toute responsabilité légale à cet égard. Delphi Diesel Systems Ltd. poursuit un programme intensif de conception et de développement

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Anche se ogni cura è stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilità pereventuali imprecisioni. Delphi Diesel Systems Ltd. svolge un intenso programma di progettazione e sviluppo che potrebbe modificare le specifiche del prodotto.Delphi Diesel Systems Ltd. si riserva il diritto di modificare le specifiche senza preavviso e ogniqualvolta lo ritenga necessario ai fini assicurare le prestazioni

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Nessuna parte di questa pubblicazione può essere riprodotta, memorizzata in un sistema elettronico o trasmessa in qualsiasi forma o con qualsiasi mezzo,elettronico, di fotocopiatura, di registrazione o altro, senza previa autorizzazione di Delphi Diesel Systems Ltd.

Porter un appareil de protectiondes yeux / du visage.

Wear eye/face protection. Use protecção da face/olhos.

Veiligheidsbril/-masker gebruiken.Úsese protección para los ojos/la cara.

Proteggersi gli occhi/la faccia.Schutzbrille/Gesichtsschutz tragen.

Porter des gants appropriés.

Wear suitable gloves. Use luvas apropriadas.

Aangepaste veiligheidshandschoenendragenUsen guantes adecuados.

Usare guanti adatti.Geeignete Schutzhandschuhe tragen.

Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux provenant des fuites de tuyaux et des joints soumis à la haute pression. Le liquide sous haute pression injecté sous la peau peut causer des blessures mortelles. En cas d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de santé et de sécurité du gazole.

Do not put your skin into the fuel jets under pressure, especially those due to pressurepipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injectionunder the skin, contact a doctor immediately. Please refer to the health and security fuel documents.

Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos afugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar ferimentosmortais. No caso de injecção subcutânea, consulte imediatamente um médico. Consulte or favor a documentação respeitante a saúde e segurança de combustíveis.

Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione, specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.

dheids-en veiligheidsfiche met betrekking tot de brandstof.z

Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralenonder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de gezon-

Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores, tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel, consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y Seguridad.

Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie soforteinen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.

Conserver à l'écart de toute flamme ousource d'étincelles - Ne pas fumer.

Keep away from sources of ignition- No smoking.

Mantenha afastado de fontes de ignição - Proibido fumar.

Conservare lontano da fiammee scintille - Non fumare.

Von Zündquellen fernhalten- Nicht rauchen.

Ver van open vuur en ontstekingsbronnenhouden - Niet reken.

Conservar alejado de toda llamao fuentede chispas - No fumar.

user manual - auto kelly · adelphi diesel systems ltd. reserva o direito de alterar...

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