LTR GDPD 400 User manual

OPERATING INSTRUCTIONSOPERATING INSTRUCTIONS
High-pressure tester
for GDI systems (digital)
GDPD

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Manufacturer
LEITENBERGER GmbH, Bahnhofstraße 32/33
72138 Kirchentellinsfurt
Germany
Legal notice
This work is protected by copyright. All associated rights remain with LEITENBERGER GmbH. Reproduc-
tion of the work or parts thereof is permitted only within the limits of the statutory provisions of copyright
law. Any modication, abridgement or translation of the work without the express written consent of
LEITENBERGER GmbH is prohibited. We reserve the right to make product changes with respect to
appearance, dimensions, weights, functionality, properties and performance in the course of improvement
and adaptation to the state of the art. No right to correction or subsequent delivery of already delivered
products is thereby implied. Deletions may be made at any time without any right to a legal claim arising.
All information on use and safety are non-binding. They do not replace any legal provisions or regulations
of the employers' liability insurance association. The brand names mentioned in this document are the
property of their respective owners.
© LEITENBERGER GmbH. All rights reserved. Translation of the original document.
This document is a translation of the original LEITENBERGER GmbH document.
Described product
GDPD 400 – High-pressure tester for GDI systems (digital)

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GDPD400_V0.3_0920
Contents
1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Safety notes and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3. Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.5 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Device versions / delivery scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Prior to commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Check the scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Prepare the high-pressure tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Connect the high-pressure tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. Handling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.1 Care and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Environmentally friendly disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. Technicaldata,specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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1. Safety
1.1 Safety notes and regulations
To ensure safe and reliable work with the high-pressure tester and to protect the user from inju-
ries, the following points are to be observed:
- Read the operating instructions carefully.
- Read and follow the operating instructions for digital pressure gauge DM 80.
- The high-pressure tester may only be operated and installed in systems by
trained motor vehicle specialists who possess the necessary expertise and
qualications to perform these tasks, and who are familiar with the applicable
standards, regulations and requirements of the eld of application.
- The operating instructions are part of the high-pressure tester. Store the
operating instructions in a safe location so that you can quickly nd the desired
information if necessary.
- The legal provisions and regulations as well as those of the vehicle manufacturer
are generally to be observed.
- Prior to commissioning, perform a check to ensure that the high-pressure tester,
along with all its components, is in faultless condition. Do NOT operate the
high-pressure tester if damaged.
- Never kink or pinch pressure lines.
- With daily use, the pressure lines must be replaced after max. 6 years.
- No technical modications may be made to the high-pressure tester or its com-
ponents.
- Do not subject the high-pressure tester or its components to any extreme tem-
peratures, direct sunlight, extreme humidity or moisture.
- Protection class according to DIN 60529: The ambient conditions at the place
of use must not exceed the requirements for the specied protection class (see
Technical data, DM 80 operating instructions).
- Never exceed the maximum measurement range end values of the high-pressure
tester.
- Repairs on the high-pressure tester may only be carried out by the manufacturer.
- Use only original spare parts and accessories.
- Non-specied use of the product or failure to observe the safety and operating
notes may lead to severe malfunctions as well as personal injury and property
damage.
- The discharge of media or hot liquids that are under pressure may cause injuries.
- Pressurised systems may burst and cause parts to be ejected.
- When working on the fuel system, the special safety regulations for ammable
liquids must be observed.
- Wear personal protective equipment, such as protective goggles, gloves, safety
shoes, etc. when working on pressurised systems and components.

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GDPD400_V0.3_0920
1.2 Explanation of symbols
Warning notices and important information are marked in this document with symbols for better
identication.
The notices begin with signal words that indicate the extent of the danger. You must absolutely comply
with these notices and information and handle the device with care to prevent accidents and avoid per-
sonal injury and property damage.
DANGER
Notice indicating a dangerous situation which, if not avoided,
will result in death or severe injury.
WARNING
Notice indicating a dangerous situation which, if not avoided,
could result in death or severe injury.
CAUTION
Notice indicating a dangerous situation which, if not avoided,
could result in minor to moderate injury.
Attention
Notice indicating a dangerous situation which, if not avoided,
could result in property damage.
Note
Notice including useful tips, recommendations and information for efcient
and trouble-free operation of the digital pressure gauge.
1.3 Intended use
The GDPD 400 high-pressure tester is used for static and dynamic fuel pressure measurements on Otto
direct injection systems within the permitted ranges with the vehicle at a standstill and the engine cold.
WARNING
Danger from improper use.
Any improper use and failure to observe safety and operating notices can result in serious
malfunctions as well as personal injury and property damage.
– Only use the GDPD 400 high-pressure tester in accordance with its intended use.
– All information in the operating instructions and safety data sheets must be strictly complied with.
1.4 Disclaimer
Failure to comply with the intended use will immediately void any warranty and guarantee claims against
the manufacturer. No liability is accepted for damage or malfunctions caused by improper use, assembly
errors or failure to observe the operating instructions.
1.5 Ambient conditions
The GDPD 400 high-pressure tester is only to be used in commercial workshops.
The climatic requirements correspond to the conditions typically prevailing in Central Europe. Optimum
function is ensured between -10 °C and +45 °C. The device must be stored within a temperature range of
-20 °C to + 60 °C.
The GDPD 400 high-pressure tester and its components must be secured against falling.

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2. Product description
The GDPD 400 high-pressure tester is a testing unit for static and dynamic fuel pressure testing of the
high-pressure circuit on GDI (Gasoline Direct Injection) engines. For example, for static testing of the
pressure pump when starting the engine or for dynamic system pressure testing at changing speeds
while idling.
2.1 Device versions / delivery scope
GDPD 400 – High-pressure tester for GDI systems (digital)
Item Component Quantity
①Test block with digital pressure gauge (with rubber protection cap),
NG 80, measurement range 0...400 bar 1
②Flexible pressure line M14 x 1.5 (length 0.7 m) 2
③Adapter, M14 x 1.5 to M12 x 1.5 2
Plastic case (not shown) 1

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GDPD400_V0.3_0920
3. Prior to commissioning
3.1 Check the scope of delivery.
3.2 Prepare the high-pressure tester.
Depending on the desired measurement method, connect the pressure line(s) to the test block:
For static measurements:
Connect a pressure line (2) to the test block connection (without sealing cap).
Screw the sealing cap (on the chain) onto the second test block connection.
Tighten the measuring hose screw connection and the cap to 25 Nm.
For dynamic measurements:
Connect both pressure lines (2) to both test block connections and tighten to 25 nm.
3.3 Connect the high-pressure tester.
CAUTION
– Risk of injury due to leaking liquids or gases.
– The discharge of liquids that are under pressure may cause injuries.
Before switching on the ignition or starting the engine, examine the ttings for damage and
check that they are properly tightened.
– Risk of injury due to ejected parts.
– Pressurised systems may burst and cause parts to be ejected.
Never open pressurised ttings.
Wear personal protective equipment, such as protective goggles, gloves and safety shoes
when working on pressurised systems.
– Risk of injury due to ammable liquids.
– Leaking liquids may ignite.
Only attach and remove the high-pressure tester when the engine is cold.
Observe the specications and instructions of the vehicle manufacturer
Attention
Follow the instructions and specications of the vehicle manufacturer regarding the
tightening torque of the ttings.
Use the high-pressure tester only for temporary measurements at a standstill. Do not leave
the unit in the engine compartment.
Connecting the high-pressure tester (static measurement)
Remove the high-pressure fuel line from the high-pressure pump according to the vehicle manufacturer's
specications. Attach the exible pressure line of the tester to the high-pressure pump and tighten accord-
ing to the vehicle manufacturer's specications. Use a reducing adapter (3) if necessary.
Connecting the high-pressure tester (dynamic measurement)
Connect the tester using the two exible pressure lines (2) between the high pressure pump and the rail
pipe and tighten according to the vehicle manufacturer's specications. Use a reducing adapter (3) if
necessary.
Before the measurement, the device must be completely vented bubble-free using the vent screw.
Make sure that the vent screw is closed, briey actuate the ignition or starter, connect the collection
container to the vent screw, slowly open the vent screw and vent the high-pressure tester. A correct
display is only possible when the high-pressure tester is lled bubble-free.

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4. Operation
Switch on the digital pressure gauge
(see operating instructions DM 80)
The high-pressure tester is ready
Static measurement:
Briey actuate the ignition to measure.
Observe the display as the pressure builds
and read off the measurement value.
Dynamic measurement:
Let the engine idle briey to measure. Observe the
display and read off the measurement value.
Before removing the high-pressure tester, the residual pressure must be released via the vent screw. To
do this, connect the collection container to the vent screw, slowly open the vent screw and release the
residual pressure, then loosen the exible pressure line(s) from the pump and remove the tester.
Restore the original condition of the engine/vehicle.

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5. Handling instructions
5.1 Care and storage
To enable effective working, we designed the high-pressure tester to be low maintenance. Nevertheless,
you should still observe a few notes. This helps to ensure trouble-free operation and to preserve the value
of the technology.
Note:
Damage to the high-pressure tester or individual components caused by aggressive
cleaning agents or solvents. Do not use aggressive or abrasive cleaning agents, solvents or
similar chemicals for cleaning.
– Keep the high-pressure tester and its components free of dust and dirt.
– Clean the device and components after each use.
– Store your product in a dry, dust-protected environment.
Avoid places with higher temperatures and moisture or places which can become wet, also for main-
tenance.
– Keep the original packaging to avoid damage during transportation.
5.2 Maintenance and repair
–Regularly check the tightness and accuracy of the tester (30 seconds at 200/300 bar)
5.3 Environmentally friendly disposal
Recycling according to WEEE (EU Directive 2002/96 EC)
You can optionally return the high-pressure tester to us for disposal.
The high-pressure tester or its components must not be disposed of as normal waste.
If you prefer not to return the high-pressure tester to us for disposal, you are required to bring the device
to a specialised centre for the separate collection and disposal of hazardous and special waste.

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6. Technicaldata,specications
Feature Unit Description
Burst pressure, pressure line bar 800
Ambient temperature °C -10…+45°C
Storage temperature °C -10…45°C,
Media temperature °C -20…+80°C
Maximum relative humidity % RH <85% RH without condensation
Connection thread, pressure line mm M14x1.5
Thread adapter mm M14 x 1.5 to M12 x 1.5
Weight kg 3.1
Dimensions L x W x H mm 420 x 520
Feature Unit Measurement range (pressure gauge*)
Measurement range relative bar 0 … 400
Measurement range relative psi 0 … 5800
Overpressure Pmax bar 800
Accuracy % FS ±0.5
*For complete pressure gauge specications, see the pressure gauge description/operating instructions
(DM 80)

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GDPD400_V0.3_0920

Subject to technical modications. 09/2020
Leitenberger GmbH, Bahnhofstr. 33, 72138 Kirchentellinsfurt, Germany
GDPD400_V0.3_09.20