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YDT-35 FIELD TRIAL TEST DOCUMENT
AMENDMENT HISTORY
Approved :
Number Issued 1.2
Iss.
No
Page Description of Change Date
1 NA First Issue (Marc Reynolds) 13 Nov 14
1.1 3-6 Revised Installation & Setup section (Lee Jacobs) 15 Dec 14
1.2 10-12 Piezo Injector Polarity (Marc Reynolds) 17 Dec 14
WARNING – FOR FIELD TRIAL SITES ONLY
WARNING COMMON RAIL SYSTEMS OPERATE AT EXTREMELY HIGH
PRESSURES. IF USED AS INSTRUCTED THE TEST KIT WILL RELEIVE
ANY HIGH PRESSURE WHENEVER THE GUARD DOOR IS OPENED.
DO NOT ATTEMPT TO BYPASS THE PRESSURE DUMP VALVE OR THE
SAFETY INTERLOCK.
EYE PROTECTION MUST BE WORN The test equipment is capable of producing high pressures which can cause
severe eye injury in the event of a malfunction.
The test stand uses fluid which may be harmful to the eyes.
HIGH FLUID PRESSURE EXISTS DURING TESTING OF THIS EQUIPMENT Do not operate without safety guard in place.
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1 CONTENTS
1 CONTENTS ........................................................................................................... 2 2 OVERVIEW OF FIELD TRIALS ......................................................................... 2
3 INSTALLATION .................................................................................................. 3 3.1 Installing the test stand .................................................................................... 3
3.2 Electrical Connection ...................................................................................... 4
3.3 Air Services Connection.................................................................................. 5
3.4 Initial Setup and Priming................................................................................. 6
4 HOW TO USE THE YDT35 MACHINE ........................................................... 10 4.1 Before Testing ............................................................................................... 10
4.2 Mounting an injector ..................................................................................... 10
4.2.1 Piezo Injector Polarity............................................................................ 11
4.3 Control Panel ................................................................................................. 13
4.3.1 MENU / Buttons ........................................................................................ 13
5 DAILY INJECTOR FUNCTION TESTS ........................................................... 16 6 WEEKLY RESULTS GATHERING .................................................................. 19
7 PROBLEM LOGGING ....................................................................................... 19 8 CONTACT WITH HARTRIDGE ....................................................................... 19 9 SPECIFICATIONS .............................................................................................. 20
10 MAINTENANCE ................................................................................................ 21
2 OVERVIEW OF FIELD TRIALS
This document specifies the tests that all Field Trial customers will be required to
complete as part of their agreements.
The Field Trial testing will last for a period up to 1 month, in which Hartridge will be
in weekly contact with the customer via email to collect all results gathered during
this period.
Customers will be asked to complete a number of daily and weekly tests, which are all
specified within this document. At the end of this document there is a test log
document where all tests performed should be recorded and returned to Hartridge.
Should the customer have any further questions regarding the field trial test period,
contact Hartridge via the contacts listed within Section 6 of this document.
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3 INSTALLATION
3.1 Installing the test stand
Machine dry weight is 30kgs. Care needs to be taken when handling the
machine 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 (fig 1).
Fig 1
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2. Fit the 4 x machine feet to the base of the YDT-35 unit by screwing
clockwise (Fig 2A & 2B). Ensure the YDT-35 unit is stable and adjust the
height of the feet as required.
Fig 2A
Fig 2B
3.2 Electrical Connection
1. Connect the power cable to the electrical connection but do not switch the
power on (fig 3).
Fig 3
100-240 Vac
50/60Hz
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3.3 Air Services Connection
Note: Ensure the air supply which you are connecting to the YDT-35 meets the
required technical requirements
Air Pressure: 5bar minimum to 10bar maximum.
Hose Dimensions: 8mm inlet hose diameter.
1. Connect a suitable air supply hose into the push fit air connection on the
back of the machine (Fig 4.1).
Do not fill the filter (Fig 4.2) with lubrication oil; this is an air filter
regulator. If filled with oil, this will result in irreversible damage to the
pneumatic components fitted to the YDT35 unit and invalidate the product
warranty.
Fig 4
1
2
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3.4 Initial Setup and Priming
When handling ISO4113 calibration fluid, guidelines as stated on the safety
data sheet must be followed.
1. Ensure the fuel filter is fitted (fig 4.1) and the fuel drain valve is turned off
with the valve parallel to the rear panel (fig 4.2). Lift open the guard door
and locate the oil fill port (fig 5.1), remove the dust cap fitting and using
the supplied funnel fill with 3 litres of ISO 4113 calibration test oil. Verify
that the oil is visible inside the tank level indicator on the left side panel of
the unit (fig 5.2). Re-fit the dust cap (fig 5.1).
Fig 4
Fig 5
1. Remove the rubber blanking plug located in the top of the fuel spray
chamber (fig 6.1). Using a suitable tool, remove the injector O-ring from
the top of the fuel spray chamber (fig 7.1). Fit the supplied funnel into the
top of the spray chamber and using the injector clamp secure the funnel
into position, ensure the funnel nose is tight against the opening within the
spray chamber (fig 8.1). Carefully fill the spray chamber with ISO4113
fluid until the chamber is full (fig 9).
1
2
1
2
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Fig 6
Fig 7
Fig 8
Fig 9
2. Remove the funnel and refit the injector O-ring into the top of the spray
chamber (Fig 10).
1
1
1
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Fig 10
3. Locate the backleak device into the lower support bracket and push the top
of backleak unit into the quick-fit port (Fig 11). Locate the backleak
injector hose from the application kit and fit this into the backleak lower
quick-fit connector. (Fig 12)
Fig 11
Fig 12
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4. Ensure that the system pressure regulator on the front of the machine is
fully unwound anti-clockwise (Fig 13).
Fig 13
5. Close the guard door.
6. Switch on the test stand via the back panel switch (Fig 14)
Fig 14
7. 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 before
diagnosing any injectors – refer to section 4.0 for injector setup and system
operation information.
Please 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.
The machine is now fully installed and ready to use.
100-240 Vac
50/60Hz
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4 HOW TO USE THE YDT35 MACHINE
4.1 Before Testing
It is mandatory to clean the injector in an ultrasonic device before installing on the
YDT-35, in order to assure no dirt particles enter the YDT-35.
4.2 Mounting an injector
Mounting an injector on the injector clamp, does not require any adapters, other than
the ones for the Fluid and Electrical connections.
The Injector Clamp is adjustable to fit injectors 17mm-30.5mm. The Spray Tube is
also adjusted to center on the injector – this can be adjusted by loosening the 4 clamp
bolts and centralising the spray chamber to suit.
Each injector requires the correct adapters/fittings to be mounted on the YDT-35.
Please use the provide adapters in the adapter’s kit in order to connect:
1. The High Pressure Supply Hose:
Standard Fitting on Hose: M14x1.5mm
Tighten both HP pipe unions to 30Nm.
2. The Return Back Leak Hose:
Standard fitting (free Hose) for most injectors.
Extra fittings in the adapters kit for Delphi and Bosch Piezo Injectors.
3. Injector Harness:
Standard Connector: Delphi Euro 3/4 and Generic type (Fig 15)
Additional Connectors: Delphi Euro 5
Fig 15
-VE
Connector Pin
+ VE
Connector Pin
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4.2.1 Piezo Injector Polarity
WARNING
INVERSE POLARITY MAY DAMAGE PIEZO
INJECTORS. MAKE SURE ALL PIEZO INJECTORS
USING THE GENERIC TYPE CONNECTOR (FIG
15) ARE CONNECTED AS THE ILLUSTRATED
BELOW.
Bosch Piezo (0445 115 xxx, 0445 116 xxx, 0445 117 xxx)
VDO Piezo (5WSxxxxx, A2C595xxxxx)
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4.3 Control Panel
The Control Panel provides a connection between the operator and the machine.
Through the control panel the operator can control the machine, test an injector and
adjust the high pressure.
i. Right Arrow Button
ii. Left Arrow Button
iii. Injector Selection Button
iv. Settings Button
v. Up Arrow Button
vi. START button
vii. Down Arrow Button
viii. STOP Button
ix. Pressure Regulator
4.3.1 MENU / Buttons
For Navigating through the screens and functions, the use of Left / Right / Up / Down
arrows and START / STOP buttons is required.
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Home This is the start-up screen of the YDT-35. It shows the Hardware and Database
versions.
DELPHI YDT-35
CRi Function Tester
sw: 2.6 / db: 1.3
Settings By pressing the “Settings” button on the control panel from the Home Screen, the
operator can access and navigate the Settings Menu. The following options are
available in the Settings Menu:
Manufacturer Menu
Service Menu
Tank / Filter Timers
Help Enable
Language
Injector Selection By pressing on the “Injector” button the operator can select a new injector profile
from the database.
Tests The Tests the YDT-35 can perform are the following and are sequenced
automatically. Please Note: If the electrical test fails then the rest of the tests will be
cancelled.
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Electrical Test (Ohm / Inductance / Capacitance)
Depending on the Injector Type and Profile, the YDT-35 will perform a
Resistance/Inductance Test or a Capacitance Tests. This test is fully automatic and the
operator receives a PASS or FAIL on the test screen. Symbols like OC or SC mean
Open Circuit and Short Circuit respectively.
ISF (Injector Spray Function)
Each Injector profile carries a set of 4 different test loads: Full Load / Mid-Low Load
/ Pre-Injection / Spray Condition. The operator can perform the following:
Adjust the High Pressure during the tests
Press STOP and START again to skip the current test plan
Press STOP twice in order to cancel the ISF Test
RFM (Return Flow Metering)
Perform a static high pressure backleak flow measurement to determine the backleak
from the injector under test. The value displayed on the RFM unit is an indication of
the backleak flow from the injector and should be used to compare injectors from an
engine set for variations.
Pressure Regulator
Pull outward and twist Counter Clockwise in order to decrease the high
pressure.
Pull outward and twist Clockwise in order to increase the high pressure.
Push inward in order to lock the regulator in position.
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5 DAILY INJECTOR FUNCTION TESTS
TOOLS & EQUIPMENT REQUIRED
1x CR Injector (to be used at the start of
each day during the field trial)
PROCEDURE
Connect the Master Injector to the YDT-35,
making sure the O-ring seal on the nozzle
block is seated correctly. Check the
following connections are made:
o High Pressure Pipe
o Back leak Pipe
o Electrical Connector (check polarity
if using Piezo Injector).
Select Start Test () on the keypad and load the correct injector settings for
the injector currently under test.
1. Select Exit Set-up () to enter the test options display.
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2. Use (↑) and (↓) to select Ohm/Ind/Cap test.
3. Perform test and record results on supplied Log Sheet.
4. Select Exit Set-up () to exit.
5. Use (↑) and (↓) to select ISF test.
6. Select Start Test () on the keypad and set the Injector pressure to read 600bar
on the display.
7. Perform test at all 4 steps for a minimum of 1 minute per step, using (←) and
(→) to move between test steps.
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8. Measure the back leak flow by viewing the level of the ball in the back leak
assembly. Record the data on the supplied Log sheet.
9. Select Exit Set-up () to exit.
10. Use (↑) and (↓) to select RFM test.
11. Select Start Test () on the keypad and set the Injector pressure to read
800bar on the display.
12. Select () to start the test process and record back leak data on the supplied
log sheet.
13. Daily testing is now completed.
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6 WEEKLY RESULTS GATHERING
At the end of every week, you will be contacted by Hartridge Support and will be
required to feedback all of the data obtained to for analysis. The data required by
Hartridge includes:
Field Trial Data Log Sheet
Record of each injector tested on the equipment.
Information concerning any problems encountered.
7 PROBLEM LOGGING
Should you encounter any problems during your Field Trial test period, then you will
be required to contact Hartridge support on either:
or
0044 (0)1280 825650
This will help Hartridge to keep an active log of all on-going problems encountered,
ensuring that we can work fast to resolve all issues and cause minimum delays to the
field trials.
8 CONTACT WITH HARTRIDGE
For any questions that you require answers for during the field trial period, the
following Hartridge personnel will be contactable to assist you:
Gavin Del Cuore – Technical Support
Hartridge Support – [email protected]
Hartridge Main Tel – 0044 (0)1280 825600
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9 SPECIFICATIONS
Description Value
Mains Supply
Voltage 100-250 AC
Frequency 50/60 Hz
Current / Fuse Max 2A / 3.5A
Test Oil
Fluid Compatibility ISO4113
Oil Tank Capacity 4 liters (Tank: 3.5l / Filter: 0.5l)
Tank Filter 2μm (MANN WK712-2 or compatible) Back Leak Filter Screen Filter
High Pressure
Max Static Output 1300 bar / 18850 psi
Air to Fluid Ratio 1:130
Maximum Fluid Flow 0.48 l/min
Pressure Control Manual
Pressure Control Range 50-1100 bar
Dimensions & Weight
Dry Weight 30kg
Envelope Dimensions (mm) 680x440x750 [WxDxH]
Envelope Weight 34kg
Notes Allow ½ meter around the machine for
access
Compressed Air
Input Pressure (bar) 5-10 bar
Connecting Hose inner diameter > 10mm
Notes Use of Air Purifier and Water Separator is
required
Injector Clamping Range 17mm-30.5mm
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10 MAINTENANCE
Replacing Test Oil 1. Power OFF the YDT-35
2. Drain the old Test Oil, using the drain valve on the rear of the YDT-35.
Always dispose of the test oil waste according to the country’s regulations.
3. Once all the oil has been drained, switch off the valve.
4. Remove the filling cap on the front of the YDT-35 and insert the provided
funnel
5. Fill with Test Oil according to the Specifications table. Verify that the Oil is
visible inside the tank level indicator.
6. Remove the funnel and install the filling cap back
7. Reset the Fluid Timer from the Settings >> Tank/Filter Timers
Replacing Filters 1. Power OFF the YDT-35
2. Drain the old Test Oil, using the drain valve on the rear of the YDT-35.
Always dispose of the test oil waste according to the country’s regulations.
3. Once all the oil has been drained, switch off the valve.
4. Using a Counter-Clockwise motion remove the old Test Oil Filter and dispose
of correctly.
5. Using a Clockwise motion install the New Test Oil Filter.
6. Remove the filling cap on the front of the YDT-35 and insert the provided
funnel
7. Fill with Test Oil according to the Specifications table. Verify that the Oil is
visible inside the tank level indicator.
8. Remove the funnel and install the filling cap back.
9. Reset the Fluid and Filter Timers from the Settings >> Tank/Filter Timers
10. In addition, it is recommended to drain a small volume of oil after replacing
the filter, in order to avoid air gaps.
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Contact: +44(0)1280 825650
or e-mail: [email protected]
Ω uH uFNozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Delphi 0.35 91 N/A 16 12 8 6
YDT-35 FIELD TRIAL DATA LOG SHEET_WEEK 1
Machine Serial No:
Please complete for all tests.
Example
ISF >>1 ISF >>2 ISF >>3 ISF >>4
Comments
13/11/2014 EJBR02201Z No Problems Present
Date:Injector
Manufacture:Injector Part No:
Test
Complete
Ohm/Ind/Cap
Customer Contact:
Document Reference: YDT-35/FT_Doc – Issue 1.2
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Contact: +44(0)1280 825650
or e-mail: [email protected]
Ω uH uFNozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Delphi 0.35 91 N/A 16 12 8 6
YDT-35 FIELD TRIAL DATA LOG SHEET_WEEK 2
Machine Serial No:
Please complete for all tests.
Example
ISF >>1 ISF >>2 ISF >>3 ISF >>4
Comments
13/11/2014 EJBR02201Z No Problems Present
Date:Injector
Manufacture:Injector Part No:
Test
Complete
Ohm/Ind/Cap
Customer Contact:
Document Reference: YDT-35/FT_Doc – Issue 1.2
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Contact: +44(0)1280 825650
or e-mail: [email protected]
Ω uH uFNozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Delphi 0.35 91 N/A 16 12 8 6
YDT-35 FIELD TRIAL DATA LOG SHEET_WEEK 3
Machine Serial No:
Please complete for all tests.
Example
ISF >>1 ISF >>2 ISF >>3 ISF >>4
Comments
13/11/2014 EJBR02201Z No Problems Present
Date:Injector
Manufacture:Injector Part No:
Test
Complete
Ohm/Ind/Cap
Customer Contact:
Document Reference: YDT-35/FT_Doc – Issue 1.2
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Contact: +44(0)1280 825650
or e-mail: [email protected]
Ω uH uFNozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Nozzle
Spray?
Backleak
(ml/min)
Delphi 0.35 91 N/A 16 12 8 6
Machine Serial No:
Please complete for all tests.
YDT-35 FIELD TRIAL DATA LOG SHEET_WEEK 4
Example
ISF >>1 ISF >>2 ISF >>3 ISF >>4
Comments
13/11/2014 EJBR02201Z No Problems Present
Date:Injector
Manufacture:Injector Part No:
Test
Complete
Ohm/Ind/Cap
Customer Contact: