Delphi YDT-35 Owner's manual

YDT-35
CR Injector Function Tester
Operating and Servicing Manual
HL066(EN) ISSUE 1, 05/2015
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DELPHI YDT-35
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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.
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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.
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YDT-35 Operating and Servicing Manual
HL066(EN) ISSUE 1, 05/2015 11
The equipment should be mounted on a bench suitable for maintaining correct operator
posture.
Make sure there is adequate ventilation. Fluid vapour may be released from hot fixtures
or high pressure leaks and a mist may develop from the spray chamber. The specific
directions in Health & Safety Data Sheets must be adhered to.
This equipment uses Viton (fluoroelastomer) seals. If these seals are exposed to high
temperatures, they decompose into a corrosive substance which is extremely harmful
and will contaminate skin. Do not touch Viton seals or the sealing surfaces if they have
been burnt or exposed to temperatures in excess of 400ºC.
Keep the machine clear of debris, tools and rags. Ensure that all fittings, particularly the
high pressure pipes and back leakage connectors are clean and not exposed to
potential contaminants.
Ear defenders or ear plugs must be worn by all personnel in the test area. High noise
levels will damage the inner ear and cause deafness.
At the end of its useful life, please ensure your Hartridge product(s) is disposed of in
accordance with national regulations.
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YDT-35 Operating and Servicing Manual
12 HL066(EN) ISSUE 1, 05/2015
1 Introduction & Specification
1.1 General
The YDT-35 is a simple function testing machine for common rail diesel injectors. It is designed with
the vehicle repair workshop in mind and is aimed at providing a means to make an initial assessment
of an injector’s functional state as a part of the initial vehicle diagnostic process.
The YDT-35 is not designed to enable the detailed assessments necessary to pin-point problems
with injectors at a level that enables components within the injector to be identified for potential repair
or replacement; nor for example is it able to provide delivery measurements for detailed analysis.
In order to be completely sure that an injector is performing exactly as it should according to the
operating specifications that it was designed for, an injector must be sent to a specialist diesel
workshop with the appropriate equipment, knowledge and training, such as an approved Delphi
Diesel Centre.
The YDT-35 is most effectively used to complement the existing capability of a repair workshop
when using other equipment such as ODB diagnostic interface tools and Oscilloscopes. When used
within a workshop’s existing processes to diagnose faults, an injector or set of injectors can be easily
and quickly positively identified as being obviously faulty. This is the YDT-35’s main strength.
The YDT-35 also allows the workshop operative to be able to focus on the most likely cause of the
vehicle problems being reported by customers, and in many cases avoids the unnecessary sending
off of injectors for testing and repair, instead focusing the search in other areas. In these scenarios
faults can be found earlier than they would have been and the vehicle can be fixed and returned to
the customer more quickly. This has the effect of reducing productivity bottlenecks and improves job
throughput for workshops.
The YDT-35 unit consists of a:-
Steel fabricated chassis
Pressure source
Universal injector fixtures
Delivery spray chamber
Digital pressure gauge
2 micron filtration
Safety operating guard
Additional Note: Piezo Injectors.
The YDT-35 is designed to take the operator through a specific path of fixed test steps that start with
electrical testing and end with spray pattern observation. In order to avoid potential critical damage to
the circuit board, the YDT-35 is designed to halt the test process if any Piezo type injector fails the
electrical test. For this reason, it is highly unadvisable to attempt to force the machine to conduct a
spray pattern function test if it is known that a Piezo injector has an electrical fault.
If a YDT-35 unit is returned under warranty and the software data logs show that this has been the
case then the warranty maybe deemed void at that point and the unit maybe returned to the
customer unrepaired.
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YDT-35 Operating and Servicing Manual
HL066(EN) ISSUE 1, 05/2015 13
1.2 Specification & Site Requirements
Dimensions
Height 750mm
Width 680mm
Depth 440mm
Weight
Dry Weight 30 kg
Electrical supply
Single phase, 100 –250Vac, 2 Amp, 50 / 60 Hz
Air supply
Clean, dry air
Minimum pressure 5 bar (72.5 psi)
Maximum 10 bar (145 psi)
Minimum flow rate 100L/min.
Max hydraulic operating pressure
1000 Bar
Measurement
Back leakage measurement (optional)
0 34 ml/min Back leakage
Universal injector clamping
Clamping diameter –17mm 30.5mm
Filtration
Replaceable 2 micron filter (test fuel tank)
Screen filter (backleak)
Fluid tank volume
3 Litres
Compatible test fluid
ISO 4113 (See Health & Safety Datasheet prior to use)
1.3 Definition of Terms and Abbreviations
CAP Capacitance (Piezo Injector Only)
CR Common Rail
IND Inductance (Coil Injector Only)
IPM Injections per Minute
ISF Injector Spray Function Test
uS Injector Pulse Width (Micro Seconds)
NOP Nozzle opening pressure (bar)
OHM Resistance (Coil Injector Only)
PCB Printed Circuit Board
RFM Return (Backleak) Flow Measurement Test
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YDT-35 Operating and Servicing Manual
HL066(EN) ISSUE 1, 05/2015 15
2 Machine Overview
Figure 2.1 Overview (front)
1
Tank Filling Cap
8
Back Leak Hose
2
High Pressure Connection Port
9
Injector Driver Cable
3
Spray Chamber
10
Back Leakage Port
4
Injector Clamp
11
Backleak (Return) Flow Measurement
Device (optional)
5
Injector Under Test (not included)
12
Control Panel
6
High Pressure Hose
13
Fuel Pressure Regulator
7
Protective Guard Cover
2
8
6
5
4
7
1
3
11
9
10
12
13
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YDT-35 Operating and Servicing Manual
16 HL066(EN) ISSUE 1, 05/2015
Figure 2.2 Overview (rear)
14
Tank Drain Tap
18
Spray Chamber Filter
15
Fuel Filter
19
Spray Chamber Drain Tap
16
Compressed Air Input Port
20
Fuel Level Indicator
17
Rear Panel (removable for service)
21
Mains electrical inlet and On/Off switch
15
16
17
18
22
19
20
14
15
16
17
21
20
18
19
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YDT-35 Operating and Servicing Manual
HL066(EN) ISSUE 1, 05/2015 17
3 Installation
3.1 Installing the machine
Machine dry weight is 30kg. Ensure the machine is handled in accordance with manual
handling guidelines.
Ensure the allocated work surface is capable of supporting the weight of the machine.
1. Remove the YDT-35 unit from the packaging and place on the allocated working surface.
Refer to Figure 3.1
Figure 3.1 YDT-35
2. Fit the 4 x machine feet to the base of the YDT-35 unit by screwing clockwise (refer to Figure
3.2 ). Ensure the YDT-35 unit is stable and adjust the height of the feet as required.
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YDT-35 Operating and Servicing Manual
18 HL066(EN) ISSUE 1, 05/2015
Figure 3.2 Levelling Feet
3.2 Electrical connections
The electrical supply MUST have a grounded (Earth) connection.
The cable connected to the YDT-35 MUST carry a grounded (Earth) conductor.
1. Make the electrical connection but do not switch the power on (refer to Figure 3.3).
Figure 3.3 Mains Electrical Connection
3.3 Air Services connection
NOTE: Ensure the air supply connected to the YDT-35 meets the required technical specification.
Clean, dry air
Minimum pressure 5 bar (72.5 psi)
Maximum 10 bar (145 psi)
Minimum flow rate 100L/min.
Hose Dimensions: 8mm inlet hose diameter.
100-250Vac
50/60Hz
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YDT-35 Operating and Servicing Manual
HL066(EN) ISSUE 1, 05/2015 19
Connect a suitable air supply hose into the push fit air connection on the back of the machine (Figure
3.4, item 1).
Do not fill the lower bowl (Figure 3.4, item 2) with lubrication oil; this is a water trap
for the air inlet. If filled with oil, this will result in irreversible damage to the
pneumatic components fitted to the machine and invalidate the product warranty.
Figure 3.4 Air Supply Connection
3.4 Initial setup and power-up
When handling ISO4113 calibration fluid, refer to the guidelines on the Health &
Safety datasheet in the appendices.
1. Ensure the fuel filter is fitted (Figure 3.5, item 1) and the fuel drain valve is turned off with the
valve parallel to the rear panel (Figure 3.5, item 2).
2. Ensure the spray chamber filter is fitted (Figure 3.5, item 3) and the spray chamber drain
valve is turned off with the valve parallel to the rear panel (Figure 3.5, item 4).
3. Lift open the guard door and locate the fuel filling port (Figure 3.5, item 5), remove the dust
cap fitting and using the supplied funnel fill with 3 litres of ISO 4113 calibration fluid. Verify
that the fuel is visible in the tank level indicator on the left side panel of the unit (Figure 3.5,
item 6). Re-fit the dust cap on the fuel filling port.
1
2
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YDT-35 Operating and Servicing Manual
20 HL066(EN) ISSUE 1, 05/2015
Figure 3.5 Tank Filling
4. Remove the rubber blanking plug located in the top of the fuel spray chamber (Figure 3.6,
item 1). Using a suitable tool, remove the injector O-ring from the top of the fuel spray
chamber (Figure 3.6, item 2).
Figure 3.6 Spray Chamber
5. Fit the supplied funnel into the top of the spray chamber and using the injector clamp, secure
the funnel in position. Ensure the funnel nose is tight against the opening within the spray
chamber (Figure 3.7, item 1). Carefully fill the spray chamber with ISO4113 fluid until the
chamber is full (Figure 3.7, item 2).
2
1
1
2
5
6
3
4
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