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Diesel Information

TECHNICAL
COMMERCIALLY CONFIDENTIAL

June 06

DDGX198(EN)

YDT500 User Guide


EQUIPMENT: SUBJECT: YDT500 User Guide

1.

INTRODUCTION

In order to comply with the new Tier 3 standard which came into force at the beginning of 2004, numerous heavy duty vehicles now use common rail injection systems. Heavy duty: Agricultural and public works vehicles, heavy goods vehicles and generating sets. Therefore, Delphi has developed this new YDT500 kit to adapt the principle of the sealed rail kit to the special features of this new market. The principle of operation of the YDT500 kit is identical to that of the YDT278, the modifications relate to the means of connecting all of the equipment to the heavy duty applications which are, of necessity, different from the automobile applications. Therefore, the purpose of this manual is to present each component of the kit and its method of use. For the diagnostic methods, the procedures described in the user manual of the YDT278 kit must be followed. It is therefore necessary to read the DDRX208 manual carefully before reading this manual.

2.

PRESENTATION

Composition of the YDT500 kit

DELPHI Diesel Systems Ltd, Diesel Aftermarket, Spartan Close, Warwick, CV34 6AG, England. Tel: [44] [0] 1926 472 900 Fax: [44] [0] 1926 472 901

Delphi

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ID mark A B C

Description Sealed rail Collection bottle

Part number YDT272 YDT273

Quantity 2 2 1

Function Measurement of the pressure supplied by the HP pump Recovery of the backleak from the sealed rail Displays the pump pressure measured by the sealed rails (9 V battery not supplied) Connection of the sealed rail(s) to the pumps with M12 HP outlet(s) Connection of the sealed rail(s) to the pumps with M14 HP outlet(s) Measurement backleak of the injector

Dual output pressure YDT425 display M12-M14 HP connection pipe M14-M14 HP connection pipe Collection bottle injector return Delphi connectors short YDT269 short YDT411 for YDT412

D1 D2 E F G

2 2 2 2x4 2x6

injector YDT275

Connection of the backleak collection bottles to Delphi injectors Connection of the backleak collection bottles to Bosch / Siemens injectors Plugging of the various unions to prevent the entry of particles into the common rail system Connection of a YDT377 collection bottle (500 ml) to a quick fit female union Connection of a YDT377 collection bottle (500 ml) to a 6 mm push-on connector Connection of the YDT412 collection bottles to 6 mm push-on connector Collect the injector return with 10 mm banjo Collect the injector returns with 8 mm banjos Collect the injector returns on M12 or M14 threads

Bosch / Siemens injector YDT276 connectors Protection plug kit YDT416

Quick fit male / male YDT417 adaptor Quick fit male / 6 mm YDT418 adaptor Injector return adaptor M10 banjo M8 banjo M12 / M14 adaptors kit YDT419 YDT413 YDT414 YDT415

L M N P

8 1 8 1

3.

DIAGNOSTICS

Consult the DDNX208 manual

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4. 4.1

DESCRIPTION ID mark A / YDT272 / Sealed rail

The sealed rails are identical to those supplied in the YDT278 kit. The YDT500 kit contains two sealed rails to permit independent checking of the pressure on dual outlet pumps in a single test. Note:
4.2

Carefully check that the discharge screw is correctly tightened before starting a test.

ID mark B / YDT273 / Collection bottle

The bottles are identical to those supplied in the YDT278 kit. They must be connected to the sealed rail discharge push-on connector during the test. Note: During the test, if fuel is collected in a collection bottle even though a pressure of at least 1300 bar has not been reached, this indicates a malfunction of the sealed rail. Carry out the checks described in 7.1.5 of the DDNX208 manual.

4.3

ID mark C / YDT425 / Dual output pressure display

The YDT425 pressure display is presented in the same form as the YDT268 display. The difference lies with the dual connector. This design makes it possible to measure the pressure on two rails simultaneously for pumps fitted with two HP outlets. The operation is identical in all ways to that of the single output display. The pressures are displayed on two lines and are marked P1 and P2. The connectors are also identified by Laser marking.

P max 1 = 1250 bars P max 2 = 1260 bars


If this dual output display is used on a single rail, one value only will be displayed.

P max 1 = 1250 bars P max 2 = ------- bars


4.4 ID mark D1 / YDT269 / Short M12-M14 pipe

These HP pipes permit connection of the sealed rails to the dual M12 HP outlet pumps. During the test, the nuts on the tool pipes must be tightened to 20 Nm. The tightening torque is intentionally low to maintain their service life. Note: For refitting following the test, it is essential to use a new pump/rail HP pipe and comply with the manufacturer's recommendations for tightening.

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4.5

ID mark D2 / YDT411 / Short M14-M14 pipe

These HP pipes permit connection of the sealed rails to the dual M14 HP outlet pumps. During the test, the nuts on the tool pipes must be tightened to 20 Nm. The tightening torque is intentionally low to maintain their service life. Note: For refitting following the test, it is essential to use a new pump/rail HP pipe and comply with the manufacturer's recommendations for tightening.

4.6

ID mark E / YDT412 / Bottles for injectors return

These bottles permit measuring of the injectors backleak. The presentation in two banks of 4 bottles permits coverage of applications up to 8 cylinders.
4.7 ID mark F / YDT275 / Delphi injector connectors

These connectors permit connection to Delphi type injectors with click fit return connector. They are identical to those supplied in the YDT278 kit.
4.8 ID mark G / YDT276 / Bosch - Siemens injector connectors

These unions permit connection to Bosch and Siemens type injectors. They are identical to those supplied in the YDT278 kit.
4.9 ID mark H / YDT416 / Protection plug kit

This plug kit has the same function as that of the YDT278. Details of its composition and the destination of the plugs are identified on the sticker inside the case.
4.10 ID mark J / YDT417 / Quick fit male - male adaptor

This union permits the connection of a YDT377 500 ml bottle to the pump returns fitted with a 8 mm quick fit. This permits checking of the return flow and of the cleanness of the diesel fuel to highlight the presence of metal shavings or any other contamination.
4.11 ID mark K / YDT418 / Quick fit male - 6 mm adaptor

This union permits the connection of a YDT377 500 ml bottle to the pump returns or to the high pressure actuator returns fitted with a smooth hollow needle with an external diameter of 6 mm. Note: Details of Delphi high pressure actuator diagnostics will be indicated in the manual of the applications concerned.

4.12 ID mark L / YDT419 / Injector return adaptor

These unions permit connection of the YDT412 bottles to injector returns fitted with an external diameter of 6 mm. This configuration can be found in particular on John Deere applications fitted with the Denso system. The plugs supplied with these adaptors permit plugging of the fuel return rail during the test.
4.13 ID mark M / YDT413 / M10 banjo

This banjo permits collection of the injector backleak, when this is shared and is located at the end of the cylinder head. Therefore, the banjo is fitted in place of the vehicle's return banjo which can be plugged using the tool banjo's plug. This configuration can be found in particular on Renault Trucks applications.

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Referring to the manufacturer's methods, disconnecting each injector in turn (by means of the electronic diagnostics tool) and applying a comparative method, it is possible to identify a faulty injector.
4.14 ID mark N / YDT414 / M8 banjo

These banjos permit collection of the injector when these banjos are made via the intermediary with M8 banjo bolts. Therefore, the banjos are fitted in place of the vehicle's return banjos which can be plugged using the tool banjos' plugs. This configuration can be found in particular on Sisu Diesel applications. In order to be able to connect these banjos to the YDT412 bottle, the YDT419 connectors should be used.
4.15 ID mark P / YDT415 / M12 and M14 adaptors kit

These unions permit collection of the injector backleak when this is shared and the return pipe is of the injector pipe type with M12 or M14 nut. During the test, the unions of the YDT415 kit must be tightened to 20 Nm. The tightening torque is intentionally low to maintain their service life. In order to be able to connect these unions to the YDT412 bottles, the YDT419 connectors should be used. Note: For refitting following the test, it is essential to comply with the manufacturer's recommendations for tightening.