Delphi YDT-35 Owner's manual

YDT-35
CR Injector Function Tester
Operating and Servicing Manual
HL066(EN) ISSUE 1, 05/2015
THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016
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THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016
Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.

DELPHI YDT-35
THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016
Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.

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THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016
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YDT-35 Operating and Servicing Manual
HL066(EN) ISSUE 1, 05/2015 5
CONTENTS
FOREWORD.....................................................................................................................................................................8
1INTRODUCTION & SPECIFICATION .............................................................................................................12
1.1 GENERAL ...........................................................................................................................................................12
1.2 SPECIFICATION &SITE REQUIREMENTS.............................................................................................................13
1.3 DEFINITION OF TERMS AND ABBREVIATIONS.....................................................................................................13
2MACHINE OVERVIEW.......................................................................................................................................15
3INSTALLATION.....................................................................................................................................................17
3.1 INSTALLING THE MACHINE.................................................................................................................................17
3.2 ELECTRICAL CONNECTIONS ...............................................................................................................................18
3.3 AIR SERVICES CONNECTION...............................................................................................................................18
3.4 INITIAL SETUP AND POWER-UP ...........................................................................................................................19
3.5 POWERING DOWN THE MACHINE ........................................................................................................................23
4OPERATION..........................................................................................................................................................25
4.1 BEFORE TESTING ...............................................................................................................................................25
4.2 FITTING &CONNECTING AN INJECTOR FOR TESTING ..........................................................................................25
4.2.1 Mounting an injector.................................................................................................................................25
4.2.2 High Pressure Supply Pipe .......................................................................................................................25
4.2.3 Return Backleak Connection.....................................................................................................................26
4.2.4 Injector Driver Cable Connection.............................................................................................................26
4.2.5 Piezo Injector Polarity ..............................................................................................................................28
4.2.6 Injector Cable Reference Table.................................................................................................................30
4.3 CONTROL PANEL................................................................................................................................................31
4.3.1 Menu/Navigation.......................................................................................................................................31
4.4 TESTS.................................................................................................................................................................34
4.4.1 Electrical Test (Ohm / Inductance / Capacitance)....................................................................................35
4.4.2 Injector Spray Function Test (ISF) ...........................................................................................................37
4.4.3 Backleak (Return) Flow Measurement Test (RFM) –Option ...................................................................39
4.5 DISCONNECTING &REMOVING AN INJECTOR .....................................................................................................42
4.5.1 Removing the Injector from the Spray Chamber.......................................................................................42
5TROUBLESHOOTING.........................................................................................................................................44
5.1 SOFTWARE ERROR CODES .................................................................................................................................44
5.2 TROUBLESHOOTING GUIDE................................................................................................................................45
6MAINTENANCE ...................................................................................................................................................47
6.1 REGULAR MAINTENANCE ..................................................................................................................................47
6.1.1 General clean/inspection...........................................................................................................................47
6.1.2 Check spray chamber fluid........................................................................................................................48
6.1.3 Check Tank Fluid Level.............................................................................................................................48
6.1.4 Air Filter Drain.........................................................................................................................................48
6.1.5 Spray Chamber Filter Change..................................................................................................................49
6.1.6 Fluid Change.............................................................................................................................................50
6.1.7 Fuel Filter Change....................................................................................................................................50
6.1.8 Backleak (Return) Filter Change..............................................................................................................51
6.1.9 High Pressure Pipe Change......................................................................................................................51
7SPARES...................................................................................................................................................................52
7.1 ACCESSORIES SUPPLIED WITH THE MACHINE......................................................................................................52
7.2 CONSUMABLES ..................................................................................................................................................53
7.3 GENERAL SPARES ..............................................................................................................................................53
8APPENDIX 1 - HEALTH AND SAFETY DATA SHEET .................................................................................54
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YDT-35 Operating and Servicing Manual
6HL066(EN) ISSUE 1, 05/2015
LIST OF FIGURES
Figure 2.1 Overview (front)............................................................................................................................. 15
Figure 2.2 Overview (rear).............................................................................................................................. 16
Figure 3.1 YDT-35 .......................................................................................................................................... 17
Figure 3.2 Levelling Feet ................................................................................................................................. 18
Figure 3.3 Mains Electrical Connection.......................................................................................................... 18
Figure 3.4 Air Supply Connection................................................................................................................... 19
Figure 3.5 Tank Filling ..................................................................................................................................... 20
Figure 3.6 Spray Chamber .............................................................................................................................. 20
Figure 3.7 Spray Chamber Filling.................................................................................................................... 21
Figure 3.8 Injector O-Ring ............................................................................................................................... 21
Figure 3.9 Backleak (Return) Flow Measurement Option ............................................................................... 22
Figure 3.10 Fuel Pressure regulator................................................................................................................ 22
Figure 3.11 Mains Electrical Switch................................................................................................................. 23
Figure 4.1 Injector Connections....................................................................................................................... 26
Figure 4.2 Standard Injector Connector (Generic Type) ................................................................................. 27
Figure 4.3 Standard Injector Connector (Delphi EU3/4 Type)......................................................................... 27
Figure 4.4 Delphi EU5 Injector Connector....................................................................................................... 27
Figure 4.5 Bosch CRIN Injector Connector ..................................................................................................... 27
Figure 4.6 Bosch Piezo Connector Orientation ............................................................................................... 28
Figure 4.7 VDO Piezo Connector Orientation ................................................................................................. 28
Figure 4.8 Denso Piezo Connector Orientation............................................................................................... 29
Figure 4.9 Control Panel.................................................................................................................................. 31
Figure 4.10 Start Up Screen............................................................................................................................ 32
Figure 4.11 Settings Screen............................................................................................................................ 33
Figure 4.12 Injector Profile Screen.................................................................................................................. 33
Figure 4.13 Injector Selection Screen ............................................................................................................. 34
Figure 4.14 Test Screen .................................................................................................................................. 35
Figure 4.15 Ohm/Ind/Cap Instruction Screen.................................................................................................. 35
Figure 4.16 ‘Injector Connected’ Symbol......................................................................................................... 36
Figure 4.17 Ohm/Ind/Cap Start Test Screen................................................................................................... 36
Figure 4.18 Ohm/Ind/Cap Test Completed Screen......................................................................................... 37
Figure 4.19 ISF Test Instruction Screen.......................................................................................................... 38
Figure 4.20 ISF Test Step Start Screen .......................................................................................................... 38
Figure 4.21 ‘Injection’ Symbol.......................................................................................................................... 39
Figure 4.22 Pump Symbol............................................................................................................................... 39
Figure 4.23 RFM Test Instruction Screen 1..................................................................................................... 40
Figure 4.24 RFM Test Instruction Screen 2..................................................................................................... 40
Figure 4.25 RFM Test Start Screen................................................................................................................. 41
Figure 4.26 RFM Test in Progress................................................................................................................... 41
Figure 4.27 Injector Removal........................................................................................................................... 42
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YDT-35 Operating and Servicing Manual
HL066(EN) ISSUE 1, 05/2015 7
Figure 5.1 Replacing Fuse ...............................................................................................................................46
Figure 5.2 Error Screen....................................................................................................................................46
Figure 6.1 Spray Chamber Drain Valve ...........................................................................................................48
Figure 6.2 Air Filter Drain .................................................................................................................................49
Figure 6.3 Spray Chamber Filter......................................................................................................................49
Figure 6.4 Tank Filter/Drain Valve....................................................................................................................50
Figure 6.5 Backleak (Return) Filter ..................................................................................................................51
Figure 7.1 YDT-35 Adaptor Kit.........................................................................................................................52
* These are original instructions and are not translated.
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YDT-35 Operating and Servicing Manual
8HL066(EN) ISSUE 1, 05/2015
Foreword
Copyright
Hartridge™ Ltd. reserves the copyright of all information and illustrations in this publication which is supplied
in confidence and which may not be used for any other purpose other than that for which it was originally
supplied. The publication may not be reproduced in part or in whole without the consent in writing of this
company.
© Hartridge™Ltd.
Warranty Statement
The equipment is covered by the Hartridge™ Ltd standard Terms and Conditions of Sale or Supply. Section
7, 8 and 9 of these Terms and Conditions of Sale or Supply relate to guarantee. ‘The Company’ refers to
Hartridge Limited. A complete copy of the Terms and Conditions of Sale or Supply is available on request.
Please note that all guarantees and warranties are limited to use of the equipment with software installed as
supplied and expressly exclude the correct operation of, or any interaction between the kit software and, any
software and/or hardware supplied by a third party and installed on the Machine. Such software and/or
hardware shall be considered as an accessory as defined in Section 7c of the Terms and Conditions of Sale
or Supply and installation of third party software may be considered as misuse of the equipment as defined
in Section 9(a).
Similarly it is vital that the equipment is operated correctly and in accordance with the instructions and
messages displayed on the Machine and in this document. Failure to do so may be treated as misuse under
section 9b (iii) of the Terms and Conditions of Sale and Supply and particular attention must be paid to
closing the Machine down where it is vital the specified procedure is followed.
More specifically, the following are excluded from any express or implied warranties relating to the
equipment:
Damage caused by poor mains supply quality.
Damage caused by improper electrical connection of injectors.
Damage caused by improper hydraulic connection.
Damage caused by unauthorised adjustment of the pressure regulator fitted to the air
preparation unit.
It is the Client’s responsibility to ensure that any third party accessories installed on the Host Machine by the
Client or at the Client’s request are compatible with the equipment and will not detract from its correct
operation.
Further warranty information can be found on the Hartridge Support website via the following link:
https://support.hartridge.com/ydt35.php
Safety Information
Warnings, Cautions and Notes
The precautionary notes in this publication, indicated by the words WARNING, CAUTION, or NOTE provide
information about potential hazards to personnel or equipment. Ignoring these notes may lead to serious
injury to personnel and/or damage to equipment. These notes appear as follows:
WARNING!
INDICATES THAT A SITUATION MAY BE HAZARDOUS TO PERSONNEL.
INSTRUCTIONS ARE PROVIDED FOR AVOIDING PERSONAL INJURY.
CAUTION! Indicates that conditions exist that could result in damage to equipment. Instructions are
provided to prevent equipment damage.
NOTE Indicates additional information for clarification where there may be confusion.
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YDT-35 Operating and Servicing Manual
HL066(EN) ISSUE 1, 05/2015 9
General and Operational Warnings
WARNING!
HIGH PRESSURE FLUID SPRAYS CAN CAUSE SERIOUS INJURY OR DEATH.
COMMON RAIL SYSTEMS OPERATE AT EXTREMELY HIGH PRESSURES. IF
USED AS INSTRUCTED THE MACHINE WILL RELEIVE ANY HIGH PRESSURE
WHENEVER THE GUARD DOOR IS OPENED.
DO NOT ATTEMPT TO BYPASS THE GUARD DOOR SAFETY INTERLOCK.
WARNING!
HIGH MAGNETIC FIELDS MAY BE PRESENT. PACEMAKERS OR OTHER SIMILAR
IMPLANTED DEVICES MAY BE AFFECTED
WARNING!
INVERSE POLARITY MAY DAMAGE PIEZO INJECTORS. ENSURE ALL PIEZO
INJECTORS USING THE GENERIC TYPE CONNECTOR ARE CONNECTED
CORRECTLY
Safety glasses conforming to standard BS EN 166:1996 must be worn when working on
this equipment for the following reasons:
1. The test equipment is capable of producing high pressure fluid jets or sprays which
can cause severe eye injury in the event of a malfunction.
2. The test equipment uses fluid which is harmful to the eyes.
Gloves conforming to standard BS EN 407:1994 should be worn if regular contact with
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.
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
covers, are dropped.
High Voltage!
Isolate the electrical supply by removing the mains lead 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.
Do not open the guard while the system is running. Wait for the machine to stop before
opening the guard.
Do not attempt to remove the rear cover of the machine while the system is running.
Wait for the machine to stop, ensure the pressures have decayed to zero and the
machine is isolated from the services before opening.
It is mandatory to clean injectors in an ultrasonic tank/device before installing on the
YDT-35. Failure to do so may cause contamination of the fuel system on the YDT-35.
THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016
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YDT-35 Operating and Servicing Manual
10 HL066(EN) ISSUE 1, 05/2015
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.
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.
Ensure good levels of lighting for safe, efficient equipment operation.
CAUTION
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.
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.
Arc welding equipment must not be operated within 5 metres of the kit. The electrical
supply to welding equipment must be provided from a remote isolating transformer. Arc
welding can disturb the electronics.
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.
There must be no naked flames. Potentially flammable vapours are present in the
equipment and ignition is possible although unlikely. Smoking in the vicinity of the
equipment is strictly forbidden.
Use fluid of the correct specification only. Obtain the manufacturers Health & Safety
Data Sheets and follow the advice given therein. Prolonged and repeated contact with
oil products, ingestion or excessive and prolonged inhalation of oil mists can be
detrimental to health. Use an appropriate barrier cream.
THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016
Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.