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YDT-35 Operating and Servicing Manual

14

HL066(EN) ISSUE 1, 05/2015

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THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016

Any technical intervention requires certified Hartridge training. Contact Hartridge Ltd for details.

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Summary of Contents for YDT-35

Page 1: ...r Operating and Servicing Manual HL066 EN ISSUE 1 05 2015 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016 Any technical intervention requires certified Hartridge training C...

Page 2: ...THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016 Any technical intervention requires certified Hartridge training Contact Hartridge Ltd for details...

Page 3: ...DELPHI YDT 35 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016 Any technical intervention requires certified Hartridge training Contact Hartridge Ltd for details...

Page 4: ...page intentionally left blank THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016 Any technical intervention requires certified Hartridge training Contact Hartridge Ltd for det...

Page 5: ...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...

Page 6: ...tation 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...

Page 7: ...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 tra...

Page 8: ...e 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 ex...

Page 9: ...so 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...

Page 10: ...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 T...

Page 11: ...contaminate skin Do not touch Viton seals or the sealing surfaces if they have been burnt or exposed to temperatures in excess of 400 C Keep the machine clear of debris tools and rags Ensure that all...

Page 12: ...s 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...

Page 13: ...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...

Page 14: ...14 HL066 EN ISSUE 1 05 2015 This page intentionally left blank THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016 Any technical intervention requires certified Hartridge train...

Page 15: ...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 Protecti...

Page 16: ...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 THIS IS AN...

Page 17: ...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 screw...

Page 18: ...n 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 Min...

Page 19: ...ilter 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 t...

Page 20: ...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 cha...

Page 21: ...acket and push the top of backleak measurement device into the quick fit port Figure 3 9 item 1 Locate the backleak injector hose from the application kit and fit this into the backleak lower quick fi...

Page 22: ...front of the machine is wound fully anti clockwise Figure 3 10 Figure 3 10 Fuel Pressure regulator 9 Close the guard door 10 Switch on the test stand via the back panel switch Figure 3 11 2 1 THIS IS...

Page 23: ...ing 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 12 Using the buttons on the Control Panel naviga...

Page 24: ...24 HL066 EN ISSUE 1 05 2015 This page intentionally left blank THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016 Any technical intervention requires certified Hartridge train...

Page 25: ...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 cham...

Page 26: ...t 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 4 2 4 Injector D...

Page 27: ...dard Injector Connector Delphi EU3 4 Type Figure 4 4 Delphi EU5 Injector Connector Figure 4 5 Bosch CRIN Injector Connector VE Connector Pin VE Connector Pin THIS IS AN UNCONTROLLED DOCUMENT downloade...

Page 28: ...R FIGURE 4 2 ARE CONNECTED AS ILLUSTRATED BELOW 4 2 5 1 Bosch Piezo 0445 115 xxx 0445 116 xxx 0445 117 xxx Figure 4 6 Bosch Piezo Connector Orientation 4 2 5 2 VDO Piezo 5WSxxxxx A2C595xxxxx Figure 4...

Page 29: ...015 29 4 2 5 3 Denso Piezo 295900 xxxx Figure 4 8 Denso Piezo Connector Orientation THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016 Any technical intervention requires cert...

Page 30: ...xxx 0445 120 xxx Coil Bosch CRIN fig 4 5 Continental VDO 77550 Piezo VDO Piezo fig 4 7 5WS4xxxx A2C595xxxxx Delphi EJBRxxxxxx Coil Standard fig 4 3 EJDRxxxxxx EMBRxxxxxx Standard fig 4 3 or Delphi EU...

Page 31: ...lator 4 3 1 Menu Navigation Navigate through the screens and functions using the arrow keys select via the Start and Stop keys 4 3 1 1 Home Screen Refer to Figure 4 10 This is the YDT 35 start up scre...

Page 32: ...s the following options some options are password protected to restrict access to authorised personnel Tank Filter Timers Displays the number of test hours remaining before the Tank Filter and Test Fl...

Page 33: ...selected will be displayed Injector Profile Brand Type Code DELPHI DFi EJBR Coil Max Pressure 1000 bar Press STOP when Done Figure 4 12 Injector Profile Screen To select a different Injector brand ty...

Page 34: ...tward 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 4 4 Tests Refer...

Page 35: ...then pressing the Start key to access it 4 4 1 Electrical Test Ohm Inductance Capacitance Refer to Figure 4 15 Depending on the Injector Type and Profile the YDT 35 will perform a Resistance Inductanc...

Page 36: ...110 START Test STOP Next Figure 4 17 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 displaye...

Page 37: ...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 ca...

Page 38: ...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 previou...

Page 39: ...reen 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 acc...

Page 40: ...s the START key Refer to Figure 4 24 A 180 second test timer appears at the bottom of the screen RFM EJBR Please consult the Operating Manual START Test STOP Next 180 Bar 0010 Figure 4 24 RFM Test Ins...

Page 41: ...est 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 fai...

Page 42: ...ing an injector 4 5 1 Removing the Injector from the Spray Chamber 1 Disconnect the high pressure pipe the electrical connector and the back leak hose from the injector under test 2 Loosen the Injecto...

Page 43: ...HL066 EN ISSUE 1 05 2015 43 This page intentionally left blank THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016 Any technical intervention requires certified Hartridge train...

Page 44: ...ot be regulated Refer to section 4 2 6 and select the correct profile for the injector installed If problem persists contact customer support E300 Injector pulse error Reboot the system by powering un...

Page 45: ...tor and the machine Piezo injector fails to inject Incorrect electrical connection faulty injector Check the injector connection is correct as described in section 4 2 5 Try a known good injector Inco...

Page 46: ...ure 5 1 Replacing Fuse ISF EJBR ERROR S FOUND Press START to Continue Figure 5 2 Error Screen THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016 Any technical intervention req...

Page 47: ...nce Schedule 6 1 1 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...

Page 48: ...ations Figure 6 1 Spray Chamber Drain Valve 6 1 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...

Page 49: ...d sooner than the recommended interval Refer to Figure 6 3 Figure 6 3 Spray Chamber Filter 1 Disconnect the spray chamber filter from the rear of the machine Drain any excess fluid into a suitable con...

Page 50: ...empty the tank 2 Close the drain valve and refill the tank with clean fluid as described in section 3 4 3 Discard the fluid in accordance with local waste disposal regulations 4 Reset the Fuel Timer f...

Page 51: ...rn Filter Change Every 12 months or 100 operating hours whichever is sooner the backleak return filter should be changed to ensure correct level of filtration If the injectors being tested are excessi...

Page 52: ...m fitting 1 8999004 CRIN Injector electrical harness extension 1 8999008 DENSO CRI Back Leak fitting 1 8999009 O ring for use with 8999018 1 8999010 BOSCH VDO CRI CRIN Back Leak fitting 1 8999011 O ri...

Page 53: ...ection chamber O ring 7mm 1 8999015 Screen Filter 1 8999023 Fuel Filter 1 Reference Part Number Description Qty 8999017 Test Fuel Funnel 1 8999018 High Pressure Hose M14x1 5 M12x1 5 750mm 1 8999021 YD...

Page 54: ...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 Remo...

Page 55: ...HL066 EN ISSUE 1 05 2015 55 This page intentionally left blank THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016 Any technical intervention requires certified Hartridge train...

Page 56: ...1280 825 659 Fax 44 0 1280 825 601 Email techsupport hartridge com https support hartridge com Hartridge Limited 2015 THIS IS AN UNCONTROLLED DOCUMENT downloaded by Lukas Matuska on 16 Feb 2016 Any te...

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