YDT-35 FIELD TRIAL TEST DOCUMENT - Hartridge Support · YDT-35 FIELD TRIAL TEST DOCUMENT AMENDMENT...

Document Reference: YDT-35/FT_Doc – Issue 1.2

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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


6

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


7

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


8

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)


12

Denso Piezo (295900-xxxx)


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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:

[email protected]

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

mailto:[email protected]

mailto:[email protected]


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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:


23

Contact: +44(0)1280 825650


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:


Example

ISF >>1 ISF >>2 ISF >>3 ISF >>4

Comments


Date:Injector


Test

Complete

Ohm/Ind/Cap

Customer Contact:


24

Contact: +44(0)1280 825650


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:


Example

ISF >>1 ISF >>2 ISF >>3 ISF >>4

Comments


Date:Injector


Test

Complete

Ohm/Ind/Cap

Customer Contact:


25

Contact: +44(0)1280 825650


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:



Example

ISF >>1 ISF >>2 ISF >>3 ISF >>4

Comments


Date:Injector


Test

Complete

Ohm/Ind/Cap

Customer Contact:

YDT-35 FIELD TRIAL TEST DOCUMENT - Hartridge Support · YDT-35 FIELD TRIAL TEST DOCUMENT AMENDMENT...

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