YDT-35. CR Injector Function Tester. Operating and Servicing Manual

Transcription

1 YDT-35 CR Injector Function Tester Operating and Servicing Manual

2

3 DELPHI YDT-35

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5 CONTENTS FOREWORD... 8 INTRODUCTION & SPECIFICATION GENERAL... 2 SPECIFICATION & SITE REQUIREMENTS... 3 DEFINITION OF TERMS AND ABBREVIATIONS MACHINE OVERVIEW INSTALLATION INSTALLING THE MACHINE... 7 ELECTRICAL CONNECTIONS... 8 AIR SERVICES CONNECTION... 8 INITIAL SETUP AND POWER-UP... 9 POWERING DOWN THE MACHINE OPERATION BEFORE TESTING FITTING & CONNECTING AN INJECTOR FOR TESTING Mounting an injector High Pressure Supply Pipe Return Backleak Connection Injector Driver Cable Connection Piezo Injector Polarity Injector Cable Reference Table CONTROL PANEL Menu/Navigation TESTS Electrical Test (Ohm / Inductance / Capacitance) Injector Spray Function Test (ISF) Backleak (Return) Flow Measurement Test (RFM) Option DISCONNECTING & REMOVING AN INJECTOR Removing the Injector from the Spray Chamber TROUBLESHOOTING SOFTWARE ERROR CODES TROUBLESHOOTING GUIDE MAINTENANCE REGULAR MAINTENANCE General clean/inspection Check spray chamber fluid Check Tank Fluid Level Air Filter Drain Spray Chamber Filter Change Fluid Change Fuel Filter Change Backleak (Return) Filter Change High Pressure Pipe Change SPARES ACCESSORIES SUPPLIED WITH THE MACHINE CONSUMABLES GENERAL SPARES APPENDIX - HEALTH AND SAFETY DATA SHEET

6 LIST OF FIGURES Figure 2. Overview (front)... 5 Figure 2.2 Overview (rear)... 6 Figure 3. YDT Figure 3.2 Levelling Feet... 8 Figure 3.3 Mains Electrical Connection... 8 Figure 3.4 Air Supply Connection... 9 Figure 3.5 Tank Filling Figure 3.6 Spray Chamber Figure 3.7 Spray Chamber Filling... 2 Figure 3.8 Injector O-Ring... 2 Figure 3.9 Backleak (Return) Flow Measurement Option Figure 3.0 Fuel Pressure regulator Figure 3. Mains Electrical Switch Figure 4. Injector Connections Figure 4.2 Standard Injector Connector (Generic Type) Figure 4.3 Standard Injector Connector (Delphi EU3/4 Type) Figure 4.4 Delphi EU5 Injector Connector Figure 4.5 Bosch CRIN Injector Connector Figure 4.6 Bosch Piezo Connector Orientation Figure 4.7 VDO Piezo Connector Orientation Figure 4.8 Denso Piezo Connector Orientation Figure 4.9 Control Panel... 3 Figure 4.0 Start Up Screen Figure 4. Settings Screen Figure 4.2 Injector Profile Screen Figure 4.3 Injector Selection Screen Figure 4.4 Test Screen Figure 4.5 Ohm/Ind/Cap Instruction Screen Figure 4.6 Injector Connected Symbol Figure 4.7 Ohm/Ind/Cap Start Test Screen Figure 4.8 Ohm/Ind/Cap Test Completed Screen Figure 4.9 ISF Test Instruction Screen Figure 4.20 ISF Test Step Start Screen Figure 4.2 Injection Symbol Figure 4.22 Pump Symbol Figure 4.23 RFM Test Instruction Screen Figure 4.24 RFM Test Instruction Screen Figure 4.25 RFM Test Start Screen... 4 Figure 4.26 RFM Test in Progress... 4 Figure 4.27 Injector Removal

7 Figure 5. Replacing Fuse...46 Figure 5.2 Error Screen...46 Figure 6. 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...5 Figure 7. YDT-35 Adaptor Kit...52 * These are original instructions and are not translated. 7

8 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: 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 8 Indicates additional information for clarification where there may be confusion.

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 66:996 must be worn when working on this equipment for the following reasons:. 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 407:994 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. 9

10 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. 0

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.

12 Introduction & Specification. 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 Digital pressure gauge Pressure source 2 micron filtration Universal injector fixtures Safety operating guard Delivery spray chamber 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. 2

13 .2 Specification & Site Requirements Dimensions Height 750mm Width 680mm Depth 440mm Weight Dry Weight 30 kg Electrical supply Single phase, Vac, 2 Amp, 50 / 60 Hz Air supply Clean, dry air Minimum pressure 5 bar (72.5 psi) Maximum 0 bar (45 psi) Minimum flow rate 00L/min. Max hydraulic operating pressure 000 Bar Measurement Back leakage measurement (optional) 0 34 ml/min Back leakage Universal injector clamping Clamping diameter 7mm 30.5mm Filtration Replaceable 2 micron filter (test fuel tank) Screen filter (backleak).3 Fluid tank volume 3 Litres Compatible test fluid ISO 43 (See Health & Safety Datasheet prior to use) 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 3

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15 2 Machine Overview Figure 2. Overview (front) Tank Filling Cap 8 Back Leak Hose 2 High Pressure Connection Port 9 Injector Driver Cable 3 Spray Chamber 0 Back Leakage Port 4 Injector Clamp Backleak (Return) Flow Measurement Device (optional) 5 Injector Under Test (not included) 2 Control Panel 6 High Pressure Hose 3 Fuel Pressure Regulator 7 Protective Guard Cover 5

16 Figure 2.2 Overview (rear) 6 4 Tank Drain Tap 8 Spray Chamber Filter 5 Fuel Filter 9 Spray Chamber Drain Tap 6 Compressed Air Input Port 20 Fuel Level Indicator 7 Rear Panel (removable for service) 2 Mains electrical inlet and On/Off switch

17 3 Installation 3. 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.. Remove the YDT-35 unit from the packaging and place on the allocated working surface. Refer to Figure 3. Figure 3. YDT 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. 7

18 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.. Make the electrical connection but do not switch the power on (refer to Figure 3.3) Vac 50/60Hz 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. 8 Clean, dry air Minimum pressure 5 bar (72.5 psi) Maximum 0 bar (45 psi) Minimum flow rate 00L/min. Hose Dimensions: 8mm inlet hose diameter.

19 Connect a suitable air supply hose into the push fit air connection on the back of the machine (Figure 3.4, item ). 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. 2 Figure 3.4 Air Supply Connection 3.4 Initial setup and power-up When handling ISO43 calibration fluid, refer to the guidelines on the Health & Safety datasheet in the appendices.. Ensure the fuel filter is fitted (Figure 3.5, item ) 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 43 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. 9

20 Figure 3.5 Tank Filling 4. Remove the rubber blanking plug located in the top of the fuel spray chamber (Figure 3.6, item ). Using a suitable tool, remove the injector O-ring from the top of the fuel spray chamber (Figure 3.6, item 2). 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 ). Carefully fill the spray chamber with ISO43 fluid until the chamber is full (Figure 3.7, item 2). 20

21 2 Figure 3.7 Spray Chamber Filling 6. Remove the funnel and refit the injector O-ring into the top of the spray chamber (Figure 3.8). Figure 3.8 Injector O-Ring 7. Backleak (Return) Flow Measurement option Locate the backleak measurement device into the lower support bracket and push the top of backleak measurement device into the quick-fit port (Figure 3.9, item ). Locate the backleak injector hose from the application kit and fit this into the backleak lower quick-fit connector (Figure 3.9, item 2). If the Return Flow Measurement option is not used, connect the backleak injector hose directly into the quick-fit port. 2

22 2 Figure 3.9 Backleak (Return) Flow Measurement Option 8. Ensure that the system pressure regulator on the front of the machine is wound fully anticlockwise (Figure 3.0). Figure 3.0 Fuel Pressure regulator 9. Close the guard door 0. Switch on the test stand via the back panel switch (Figure 3.). 22

23 Figure 3. Mains Electrical Switch. On first injector test it will be necessary to run the injector for a minimum of 2 minutes to ensure the hydraulic system is completely purged of air before diagnosing any injectors refer to Section 4 for injector setup and system operation information. NOTE: the machine may produce a continuous beeping sound upon first start up. This can be cleared by selecting the correct injector type from the main menu based on the injector fitted to the machine. 2. Using the buttons on the Control Panel, navigate to Settings >> 5.Languages and select your preferred language. The machine is now fully installed and ready to use. 3.5 Powering down the machine. Stop any active test 2. Switch OFF the mains power switch on the rear of the machine. 23

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25 4 Operation 4. Before Testing It is mandatory to clean the injector 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. Always verify that the Spray Chamber is filled with fluid. In case it is empty or needs a top up, please refill with fluid using the funnel provided, or a syringe. 4.2 Fitting & connecting an injector for testing 4.2. Mounting an injector. Make sure the correct O-ring for the injector under test is fitted into the top of the spray chamber (Figure 3.8). 2. Mount the injector in the injector clamp. The Injector Clamp is adjustable for injectors from 7mm to 30.5mm. 3. Push the injector down onto the injector sealing O-ring in the top of the spray chamber Ensure the injector nozzle is immersed in the spray chamber fluid. 4. Tighten the injector clamp; the spray chamber adjusts automatically to centre on the injector High Pressure Supply Pipe Refer to Figure 4. Connect the flexible high pressure pipe (suitable for the injector to be tested) between the high pressure supply port (item ) and the Injector supply port (item 2). The diagram illustrates a typical injector, Injector port positions may vary depending on the manufacturer/type. Confirm the correct location of supply and backleak ports before connecting. Standard Fitting on Hose: M4x.5mm Extra Fitting available: M2x.5mm Tighten the fittings to 25-30Nm. 25

26 Figure 4. Injector Connections High Pressure Supply Port 4 Backleak (Return) Flow Measurement Port 2 Injector Supply Port 5 Injector Driver Cable Connection to YDT35 3 Injector Backleak (Return) Port 6 Injector Driver Cable Connection to Injector Return Backleak Connection Refer to Figure 4. Push the flexible pipe onto the injector backleak port (item 3) and the YDT-35 backleak port (item 4). The diagram illustrates a typical injector, Injector port positions may vary depending on the manufacturer/type. Confirm the correct location of supply and backleak ports before connecting. If the backleak measurement device option is not used, connect directly to the backleak port on the machine front panel Standard fitting (free Hose) for most injectors Extra fittings are available for Delphi and Bosch Piezo Injectors Injector Driver Cable Connection Refer to Figure 4. Connect the Injector drive cable (suitable for the injector to be tested) between the electrical connection on the front panel (item 5) and the injector solenoid/piezo connector (item 6). The diagram illustrates a typical injector; electrical connections vary depending on the manufacturer/type. Injector Harness: 26 Standard Connector: Delphi Euro 3/4 (Figure 4.3) and Generic type (Figure 4.2) Additional Connector: Delphi Euro 5 (Figure 4.4) Additional Connector: Bosch CRIN (Figure 4.5)

27 +VE Connector Pin -VE Connector Pin Figure 4.2 Standard Injector Connector (Generic Type) Figure 4.3 Standard Injector Connector (Delphi EU3/4 Type) Figure 4.4 Delphi EU5 Injector Connector Figure 4.5 Bosch CRIN Injector Connector 27

28 4.2.5 Piezo Injector Polarity WARNING! INVERSE POLARITY MAY DAMAGE PIEZO INJECTORS. MAKE SURE ALL PIEZO INJECTORS USING THE GENERIC TYPE CONNECTOR (FIGURE 4.2) ARE CONNECTED AS ILLUSTRATED BELOW Bosch Piezo ( xxx, xxx, xxx) Figure 4.6 Bosch Piezo Connector Orientation VDO Piezo (5WSxxxxx, A2C595xxxxx) Figure 4.7 VDO Piezo Connector Orientation 28

29 Denso Piezo ( xxxx) Figure 4.8 Denso Piezo Connector Orientation 29

30 4.2.6 Injector Cable Reference Table Injector Manufacture Injector Part Number Injector Type xxx Coil Standard (fig 4.2) Piezo Bosch Piezo (fig 4.6) Coil Bosch CRIN (fig 4.5) Piezo VDO Piezo (fig 4.7) Injector Connector Cable Connector Polarity Sensitive xxx xxx xxx Bosch xxx Continental / VDO 5WS4xxxx A2C595xxxxx EJBRxxxxxx Manual Ref Standard (fig 4.3) EJDRxxxxxx EMBRxxxxxx Delphi 282xxxxx Standard (fig 4.3) Coil or or or Delphi EU5 (fig 4.4) 283xxxxx Standard (fig 4.2) 284xxxxx xxxx Denso Standard (fig 4.2) Piezo Denso Piezo (fig 4.8) xxxx xxxx 30 Coil

31 4.3 Control Panel Figure 4.9 Control Panel Right Arrow key 6. Start / OK key 2. Left Arrow key 7. Stop / Back key 3. Injector Select key 8. Down Arrow key 4. Settings key 9. Pressure regulator 5. Up Arrow key Menu/Navigation Navigate through the screens and functions using the arrow keys, select via the Start and Stop keys. Home Screen Refer to Figure 4.0 This is the YDT-35 start up screen. The software (sw) and injector database (db) versions are displayed. 3

32 DELPHI YDT-35 CRi Function Tester sw: 3.0 / db:.6 Figure 4.0 Start Up Screen Settings Refer to Figure 4. By pressing the Settings key on the control panel from the Home Screen, the operator can access the following options (some options are password protected to restrict access to authorised personnel): 32 Tank / Filter Timers Displays the number of test hours remaining before the Tank Filter and Test Fluid are scheduled to be changed. Help Enable Allows help screens to be enabled or disabled. Language

33 SETTINGS. Tank/Filter TIMERS 2. Help Enable 3. Language sw: 3.0 / db:.6 Figure 4. Settings Screen Injector Selection Refer to Figure 4.2 By pressing the Injector button the operator can select a new injector profile from the database. The current Injector Profile selected will be displayed Injector Profile Brand: DELPHI Type : DFi Code :.EJBR-###### Coil Max Pressure: 000 bar Press STOP when Done... Figure 4.2 Injector Profile Screen To select a different Injector brand/type/code:refer to Figure 4.3 Use the up/down arrow keys to move the left side cursor to the item to change. Then press the Start key to access the list of options. 33

34 INJECTOR BRAND SELECTION BOSCH DENSO DELPHI VDO ALL Figure 4.3 Injector Selection Screen Use the up/down arrow keys to place the cursor next to the required option. Then press the Start key to select the option Pressure regulator Use the regulator to set the test pressure 4.4 Pull outward and twist Anti-Clockwise to decrease the high pressure supply. Pull outward and twist Clockwise to increase the high pressure supply. Push inward to lock the regulator in position. Tests Refer to Figure 4.4 To access the Test screen:from the YDT-35 Start-Up screen, Press the Start key. The Fluid and Filter hours will be displayed on screen - Press the Start key to continue. 34

35 Test: Ohm/Ind/Cap ISF RFM.EJBR-###### Figure 4.4 Test Screen The YDT-35 automatically performs the following tests in sequence: Electrical safety test (Ohm/Inductance/Capacitance) Injector Spray Function Test (ISF) Return Flow Metering Test (RFM) Optional The operator can skip to a specific test by using the up/down keys to select the required test and then pressing the Start key to access it Electrical Test (Ohm / Inductance / Capacitance) Refer to Figure 4.5 Depending on the Injector Type and Profile, the YDT-35 will perform a Resistance/Inductance or Capacitance test. Follow the on-screen instructions:- Ohm/Ind/Cap.EJBR-###### Connect the injector harness to the COIL injector. Also note that some injectors have Polarity. When ready press START. Figure 4.5 Ohm/Ind/Cap Instruction Screen 35

36 WARNING! INVERSE POLARITY MAY DAMAGE PIEZO INJECTORS. MAKE SURE ALL PIEZO INJECTORS USING THE GENERIC TYPE CONNECTOR (FIGURE 4.2) ARE CONNECTED CORRECTLY. When an Injector has been connected, the Injector symbol appears at the bottom of the screen (Figure 4.6). Figure 4.6 Injector Connected Symbol Refer to Figure 4.7. When ready to test, press the START Ohm/Ind/Cap O START=Test, key..ejbr-###### uh 60-0 STOP=Next Figure 4.7 Ohm/Ind/Cap Start Test Screen The test is fully automatic with both upper and lower tolerance limits shown on screen. On test completion, a PASS or FAIL is displayed on the test screen. Refer to Figure 4.8 In addition to a FAIL indication there may be other symbols such as: OC Open circuit SC Short circuit If the test fails, all subsequent tests are cancelled. When the test has been completed, press the Stop 36 key to move on to the ISF tests.

37 Ohm/Ind/Cap O.EJBR-###### uh START=Test, STOP=Next Figure 4.8 Ohm/Ind/Cap Test Completed Screen Injector Spray Function Test (ISF) PIEZO INJECTORS CAN OPERATE FOR A MAXIMUM OF 2 MINUTES AT EACH TEST CONDITION. OPERATING THE INJECTOR FOR ANY PERIOD LONGER MAY RESULT IN THE TEMPERATURE PROTECTION CIRCUIT BEING ACTIVATED. IF ACTIVATED, TESTS CAN BE RESTARTED AFTER A SHORT COOLING PERIOD. Each Injector profile carries a set of 4 different test loads:. Full Load 2. Mid-Low Load 3. Pre-Injection 4. Spray Condition. Refer to Figure

38 Follow the on-screen instructions:- ISF.EJBR-###### Make all necessary connections to the injector When ready press START. Figure 4.9 ISF Test Instruction Screen Refer to Figure When ready, press the Start key. The Spray chamber is illuminated to aid visual checks of the injector spray pattern during the test. Each test step runs automatically. The operator can perform the following functions during a test: Adjust the High Pressure using the regulator Advance to the next test step or repeat a previous step via left and right arrow keys Press STOP twice in order to cancel the ISF Test ISF >> IPM >>2 >>3.EJBR-###### >>4 us START=Test, STOP=Next Bar: 0800 Figure 4.20 ISF Test Step Start Screen 38

39 Press the START key The correct voltage for the injector is set and the test begins. When the ISF tests are running, the injection symbol flashes on screen, refer to Figure 4.2. Figure 4.2 Injection Symbol 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. The pump symbol appears on screen when injection tests are performed to indicate that the high pressure pump is active, refer to Figure 4.22 Figure 4.22 Pump Symbol The test assessment is purely visual*. There are no pass/fail indications on-screen that the injector is acceptable or not. The operator must determine by observation and comparison with a known good injector, whether the spray pattern and injector performance for all tests is acceptable. * If YDT-35 Backleak Measurement Unit (899902) is fitted, observe the flow measurement displayed on the backleak flow indicator. This backleak measurement is purely visual and the operator must determine by observation and comparison with a known good injector, whether the backleakage (return) flow is acceptable at each test step. When the test has been completed, press the Stop key to move on to the RFM test. Backleak (Return) Flow Measurement Test (RFM) Option If the backleak flow indicator option has been fitted to the machine the RFM test may be performed. 39

40 Refer to Figure Follow the on-screen instructions:- RFM.EJBR-###### If not yet performed, please install the Return Adapter Make all necessary connections to the injector When ready press START. Figure 4.23 RFM Test Instruction Screen When ready, press the START key. Refer to Figure A 80 second test timer appears at the bottom of the screen RFM.EJBR-###### Please consult the Operating Manual... START=Test, 80 STOP=Next Bar: 000 Figure 4.24 RFM Test Instruction Screen 2 When ready to test, press the START key. Refer to Figure Use the pressure regulator to set the maximum test pressure. 40

41 RFM.EJBR-###### Adjust to MAX Pressure. Press START when ready Bar: 000 Figure 4.25 RFM Test Start Screen When ready to start the test, press the START key. Refer to Figure The 80 second timer starts counting down; the elapsed test time is indicated at the bottom of the screen. RFM.EJBR-###### Please consult the Operating Manual... START=Test, 95 STOP=Next Figure 4.26 RFM Test in Progress The injector has maximum pressure applied, with no injection pulse. Observe the flow measurement on the backleak flow indicator. The test assessment is purely visual. There are no pass/fail indications on-screen that the injector is acceptable or not. The operator must determine by observation and comparison with a known good injector, whether the backleakage (return) flow is acceptable. In an ideal injector, the flow in this test would be zero. 4

42 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 followed. The pump symbol appears on screen when the return flow test is performed to indicate that the high pressure pump is active, refer to Figure 4.22 When the test has finished, press the Stop key twice to return to the YDT-35 Start up screen. Disconnecting & removing an injector Removing the Injector from the Spray Chamber. Disconnect the high pressure pipe, the electrical connector and the back leak hose from the injector under test. 2. Loosen the Injector Clamp. 3. Remove the injector from the spray chamber assembly by gently twisting the injector upwards until the nozzle is clear of the O-ring (Figure 4.27). Avoid pulling the injector upwards as this may cause fuel to exit the spray chamber. Figure 4.27 Injector Removal 4. If removed, make sure to refit the O-ring into the top of the spray chamber ready for the next injector test. 42

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44 5 Troubleshooting 5. Software Error Codes Software Error Code Error Description Possible cause/action E000 Error present on unit. Reboot the system if no other fault codes are listed on the display. E003 Protective guard cover open Close the cover and restart test. Faulty safety switches. Contact customer support. E00 Firmware/Database fault present Contact customer support. E0 PCB Over Temperature error Allow PCB to cool down before continuing test. E05 Error in Database file Contact customer support. E0 Incorrect Injector profile selected Refer to section and select the correct profile for the injector installed. E200 High Voltage cannot be regulated Refer to section and select the correct profile for the injector installed. If problem persists, contact customer support. E300 Injector pulse error Reboot the system by powering unit off/on. E400 Maximum pressure reached Reduce pressure within limits and repeat test. E900 System Error Reboot the system by powering unit off/on. If problem persists, contact customer support. Reboot the system by powering unit off/on. If problem persists, contact customer support. Reboot the system by powering unit off/on. If problem persists, contact customer support. Reboot the system by powering unit off/on. If problem persists, contact customer support. E90 E902 Error regulating voltage Injector High Voltage Error E903 E Software Error

45 5.2 Troubleshooting Guide Symptom Possible cause/action Display dead Mains supply fuse blown Refer to Figure 5. Check the mains inlet fuse, pinch the top and bottom tags of the fuse holder and pull to withdraw the fuse. There is one spare fuse supplied inside the holder. Remove the mains electrical supply connector before attempting to change the fuse Irregular clunking sound Pressure regulator set too high Irregular Injector firing Inconsistent/no injector firing Unwind the regulator until the indicated pressure is lower than 000 bar. Poor electrical connection/faulty injector Check Injector cable is connected correctly and is secure Try a known good injector Wrong injector type selected/faulty injector Check the correct injector Brand/Type/Code is selected Incorrect injector selection may damage both the injector and the machine. Piezo injector fails to inject Incorrect electrical connection/faulty injector Check the injector connection is correct as described in section Try a known good injector Incorrect Piezo injector connection may damage both the injector and the machine. ISF test fails to run (no spray pattern) OC on-screen (Ohm/Ind/Cap test) SC on-screen (Ohm/Ind/Cap test) Inadequate air supply/ inadequate high pressure Check the air supply is connected to the back on the machine and is within the specification described in section 0 Adjust the pressure regulator for adequate high pressure. Check there is adequate fluid in the tank Injector open circuit/faulty Check Injector cable is connected correctly Try a known good injector Injector short circuit/faulty Error(s) Found on-screen indication Refer to Figure 5.2 Try a known good injector Guard opened during a test Close the guard and restart the test 45

46 Figure 5. Replacing Fuse ISF.EJBR-###### ERROR(S) FOUND Press START to Continue Figure 5.2 Error Screen 46

47 6 Maintenance Prior to any maintenance ensure all services have been isolated. 6. Regular Maintenance Frequency Of Checks Operation 20 Hr 3 Mths 2 Mths 36 Mths Ref General Clean/inspection 6.. Check Spray Chamber Fluid 6..2 Check Tank Fluid Level 6..3 Air Filter Drain 6..4 Guard Door Safety Switches - Spray Chamber Filter Change 6..5 Fluid Change 6..6 Fuel Filter Change 6..7 Backleak (Return) Filter Change 6..8 High Pressure Pipe Change 6..9 Table 6. Maintenance Schedule 6.. General clean/inspection 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. Inspect all fittings before use and clean as necessary. Reliable operation of the machine is dependent on maintaining cleanliness. Displays, keypads, the guard and the metal casing may be cleaned using a soft, dry lint free cloth. Visually check the machine every 20 hours of use for leaks or signs of fatigue at the fluid connections. 47

48 6..2 Check spray chamber fluid Every 20 test hours or sooner. Check the spray chamber fluid level. If necessary top up using a syringe or funnel as described in section Visually check the fluid for cleanliness. If dirty or dark, change the fluid by opening the spray chamber drain valve on the rear of the machine and emptying the chamber (Figure 6.). 3. Refill the spray chamber as described in section Discard the fluid in accordance with local waste disposal regulations. Figure 6. Spray Chamber Drain Valve 6..3 Check Tank Fluid Level Every 20 test hours or sooner Check the tank fluid level through the tank level indicator on the left side panel of the machine. If there is no fluid visible, top up the tank as described in section Air Filter Drain Refer to Figure 6.2 Every 20 test hours or sooner if required the air filter should be drained of water. Place a suitable container under the filter (item ), loosen the drain screw (item 2) and allow any trapped water to drain away. Re-tighten the drain screw after draining. 48

49 2 Figure 6.2 Air Filter Drain 6..5 Spray Chamber Filter Change Every 3 months or 50 operating hours, whichever is sooner, the spray chamber filter should be changed to ensure the correct level of cleanliness. If the injectors being tested are excessively dirty a filter check must be carried out more frequently and the filter replaced sooner than the recommended interval. Refer to Figure 6.3 Figure 6.3 Spray Chamber Filter. Disconnect the spray chamber filter from the rear of the machine. Drain any excess fluid into a suitable container. 2. Open the filter assembly as illustrated above. Remove the filter and replace with a new one. 3. Reassemble the filter assembly and tighten the fittings. 4. Reconnect the filter assembly to the rear of the machine. 49

50 6..6 Fluid Change When handling calibration fluid, guidelines as stated on the safety data sheet in the appendix must be followed. Every 3 months or 50 operating hours, whichever is sooner, the test fluid should be changed to ensure the correct level of cleanliness. If the injectors being tested are excessively dirty the fluid check must be carried out more frequently and the fluid replaced sooner than the recommended interval. The internal Tank/Filter timer will flag up when a change is due. Refer to Figure Figure 6.4 Tank Filter/Drain Valve. Place a suitable container under the drain valve (item ). Open the drain valve and empty the tank. 2. Close the drain valve and refill the tank with clean fluid as described in section Discard the fluid in accordance with local waste disposal regulations. 4. Reset the Fuel Timer from the Settings >> Tank/Filter Timers. The password to access the timers is Fuel Filter Change When handling calibration fluid, guidelines as stated on the safety data sheet in the appendix must be followed. Every 2 months or 00 operating hours, whichever is sooner, the fuel filter should be changed to ensure correct level of filtration. If the injectors being tested are excessively dirty the filter check must be carried out more frequently and the fluid filter replaced sooner than the recommended interval. 50

51 The internal Tank/Filter timer will flag up when a change is due. Refer to Figure Place a suitable container under the drain valve (item ). Open the drain valve and empty the tank. 6. Remove the filter (item 2) as illustrated and replace with a new one. 7. Close the drain valve and refill the tank with clean fluid as described in section Discard the filter in accordance with local waste disposal regulations. 9. Reset the Filter Timer from the Settings >> Tank/Filter Timers. The password to access the timers is It is recommended to drain a small volume of fuel from the tank after replacing the filter, in order to avoid air gaps Backleak (Return) Filter Change Every 2 months or 00 operating hours, whichever is sooner, the backleak (return) filter should be changed to ensure correct level of filtration. If the injectors being tested are excessively dirty the filter check must be carried out more frequently and the fluid filter replaced sooner than the recommended interval. Refer to Figure 6.5. Unscrew the backleak (return) pipe connector (item ) using a 4mm A/F spanner. 2. Remove the filter (item 2) and replace with a new one. 2 Figure 6.5 Backleak (Return) Filter 6..9 High Pressure Pipe Change Repeated flexing of the pipe to suit different injectors will weaken the pipe over time. Every 36 months or more frequently if used regularly with tight bends, change the flexible high pressure pipe. 5

52 7 Spares Please quote the serial number of the machine when enquiring about spares. 7. Accessories supplied with the machine A kit of adaptors ( ) is supplied with the machine. The kit enables testing of most injectors and comprises:reference Part Number Description Qty BOSCH CRI Piezo Back Leak fitting DELPHI CRI Back Leak fitting M4x.5mm to M2x.5mm fitting CRIN Injector electrical harness extension DENSO CRI Back Leak fitting O ring - for use with BOSCH/VDO CRI/CRIN Back Leak fitting O ring - for use with M8x BOSCH CRIN / DENSO Back Leak fitting /8 BOSCH CRIN Back Leak fitting O ring - for use with & Injector Back Leak Fuel Return hose Delphi EU5 Injector electrical harness extension CRIN Injector Nozzle Spacer Figure 7. YDT-35 Adaptor Kit 52

53 7.2 Consumables Reference Part Number Description Qty Fuse, 3.5A quick blow* In-line Fuse (Protection circuit for PCB) Injection chamber O-ring 9mm Injection chamber O-ring 7mm Screen Filter Fuel Filter *One spare fuse is provided in the mains inlet fuse holder 7.3 General Spares Reference Part Number Description Qty Test Fuel Funnel High Pressure Hose YDT-35 Backleak Measurement Unit YDT-35 Injector PCB YDT-35 Injector Electrical Harness/Cable USB Flash Drive YDT-35 Manual 53

54 8 Appendix - Health and safety data sheet HEALTH & SAFETY DATA SHEET Information regarding the safe handling & storage of the named product. Applicable to employees and customers. DATE MAR 97 Pub. No. WARNING PRODUCT CALIBRATION FLUID (ISO 43) SEEK IMMEDIATE MEDICAL ATTENTION IF INGESTED USE CLASSIFICATION TEST FLUID FOR DIESEL INJECTORS, INJECTION PUMPS & OTHER DIESEL EQUIPMENT FLAMMABLE PRODUCT DESCRIPTION - COMPOSITION THESE FLUIDS ARE PETROLEUM BASED PRODUCTS CONTAINING SIGNIFICANT PROPORTIONS OF THE MORE VOLATILE PETROLEUM FRACTIONS AND OTHER SOLVENTS USED FOR LUBRICATION, ANTICORROSION AND DERMATITIC INHIBITION. SAFE HANDLING ADVICE (Protection - Usage, Storage & Transport) USAGE: ) Avoid eye splashes and extended skin contact. 2) Do NOT take internally. 3) Keep mist generated by machinery to a minimum, also avoid where possible vapours caused by elevated temperatures. 4) Protective clothing to be regularly laundered. STORAGE: These are flammable products which should be stored in closed containers away from heat in a well ventilated area. EMERGENCY & FIRST AID PROCEDURE (Eyes, skin, ingestion, inhalation) INGESTION: Do NOT induce vomiting. Give a glass of water and get immediate medical attention at Hospital. EYES: Flush with large amounts of water for 5 minutes. Seek medical help if irritation persists. SKIN: Wash thoroughly with soap & water. Seek medical help if irritation or skin rashes occur. Remove any contaminated clothing. INHALATION: Inhalation includes oil mists or vapours. Remove victim to fresh air. Seek medical help if affliction persists. FIRE HAZARDS & PROTECTION (Flash point, spillage) SPILLAGE: Contain spillages with sand or mineral absorbent material. Mop up and clean floor to remove oil residue. FLASH POINT: Above 75 C. FIRE: (Extinguisher media) Use carbon dioxide, dry chemical powder or foam extinguishers. Do NOT use water jets. ENVIRONMENTAL PROTECTION (Spillage land / water, disposal) SPILLAGE: Advise authorities if product has entered or may enter sewers, water courses or extensive land areas. DISPOSAL: All waste should be put into identified containers and stored at a specific disposal point. Arrange for off site disposal in accordance with local regulations for notified waste. HARTRIDGE LTD Network 42, Radclive Rd, Buckingham, MK8 4FD, England. THE INFORMATION AND RECOMMENDATIONS IN THIS PUBLICATION ARE TO THE BEST OF OUR KNOWLEDGE INFORMATION AND BELIEF ACCURATE AT THE TIME OF PUBLICATION NOTHING HEREIN TO BE CONSTRUED AS A WARRANTY, EXPRESS OR IMPLIED IN ALL CASES. IT IS THE RESPONSIBILITY OF THE USERS TO DETERMINE THE SUITABILITY OF ANY PRODUCTS FOR THEIR OWN PARTICULAR PURPOSE. RECOMMENDATIONS FOR HANDLING, PROTECTION ETC. ARE ADVISORY ONLY. 54

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56 Hartridge Limited, 205 The Hartridge Building, Network 42, Radclive Road Buckingham, MK8 4FD United Kingdom Tel: +44(0) Fax: +44(0)