LTR GDPD 400 Manuale utente

OPERATING INSTRUCTIONSOPERATING INSTRUCTIONS

High-pressure tester

for GDI systems (digital)

GDPD

- 2 - GDPD400_V0.3_0920

Manufacturer

LEITENBERGER GmbH, Bahnhofstraße 32/33

72138 Kirchentellinsfurt

Germany

Legal notice

This work is protected by copyright. All associated rights remain with LEITENBERGER GmbH. Reproduc-

tion of the work or parts thereof is permitted only within the limits of the statutory provisions of copyright

law. Any modication, abridgement or translation of the work without the express written consent of

LEITENBERGER GmbH is prohibited. We reserve the right to make product changes with respect to

appearance, dimensions, weights, functionality, properties and performance in the course of improvement

and adaptation to the state of the art. No right to correction or subsequent delivery of already delivered

products is thereby implied. Deletions may be made at any time without any right to a legal claim arising.

All information on use and safety are non-binding. They do not replace any legal provisions or regulations

of the employers' liability insurance association. The brand names mentioned in this document are the

property of their respective owners.

This document is a translation of the original LEITENBERGER GmbH document.

Described product

GDPD 400 – High-pressure tester for GDI systems (digital)

- 3 -

GDPD400_V0.3_0920

Contents

1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Safety notes and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3. Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.5 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2. Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Device versions / delivery scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. Prior to commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Check the scope of delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Prepare the high-pressure tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 Connect the high-pressure tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5. Handling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.1 Care and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.2 Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.3 Environmentally friendly disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6. Technicaldata,specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

- 4 - GDPD400_V0.3_0920

1. Safety

1.1 Safety notes and regulations

To ensure safe and reliable work with the high-pressure tester and to protect the user from inju-

ries, the following points are to be observed:

- Read the operating instructions carefully.

- Read and follow the operating instructions for digital pressure gauge DM 80.

- The high-pressure tester may only be operated and installed in systems by

trained motor vehicle specialists who possess the necessary expertise and

qualications to perform these tasks, and who are familiar with the applicable

standards, regulations and requirements of the eld of application.

- The operating instructions are part of the high-pressure tester. Store the

operating instructions in a safe location so that you can quickly nd the desired

information if necessary.

- The legal provisions and regulations as well as those of the vehicle manufacturer

are generally to be observed.

- Prior to commissioning, perform a check to ensure that the high-pressure tester,

along with all its components, is in faultless condition. Do NOT operate the

high-pressure tester if damaged.

- Never kink or pinch pressure lines.

- With daily use, the pressure lines must be replaced after max. 6 years.

- No technical modications may be made to the high-pressure tester or its com-

ponents.

- Do not subject the high-pressure tester or its components to any extreme tem-

peratures, direct sunlight, extreme humidity or moisture.

- Protection class according to DIN 60529: The ambient conditions at the place

of use must not exceed the requirements for the specied protection class (see

Technical data, DM 80 operating instructions).

- Never exceed the maximum measurement range end values of the high-pressure

tester.

- Repairs on the high-pressure tester may only be carried out by the manufacturer.

- Use only original spare parts and accessories.

- Non-specied use of the product or failure to observe the safety and operating

notes may lead to severe malfunctions as well as personal injury and property

damage.

- The discharge of media or hot liquids that are under pressure may cause injuries.

- Pressurised systems may burst and cause parts to be ejected.

- When working on the fuel system, the special safety regulations for ammable

liquids must be observed.

- Wear personal protective equipment, such as protective goggles, gloves, safety

shoes, etc. when working on pressurised systems and components.

- 5 -

GDPD400_V0.3_0920

1.2 Explanation of symbols

Warning notices and important information are marked in this document with symbols for better

identication.

The notices begin with signal words that indicate the extent of the danger. You must absolutely comply

with these notices and information and handle the device with care to prevent accidents and avoid per-

sonal injury and property damage.

DANGER

Notice indicating a dangerous situation which, if not avoided,

will result in death or severe injury.

WARNING

Notice indicating a dangerous situation which, if not avoided,

could result in death or severe injury.

CAUTION

Notice indicating a dangerous situation which, if not avoided,

could result in minor to moderate injury.

Attention

Notice indicating a dangerous situation which, if not avoided,

could result in property damage.

Note

Notice including useful tips, recommendations and information for efcient

and trouble-free operation of the digital pressure gauge.

1.3 Intended use

The GDPD 400 high-pressure tester is used for static and dynamic fuel pressure measurements on Otto

direct injection systems within the permitted ranges with the vehicle at a standstill and the engine cold.

WARNING

Danger from improper use.

Any improper use and failure to observe safety and operating notices can result in serious

malfunctions as well as personal injury and property damage.

– Only use the GDPD 400 high-pressure tester in accordance with its intended use.

– All information in the operating instructions and safety data sheets must be strictly complied with.

1.4 Disclaimer

Failure to comply with the intended use will immediately void any warranty and guarantee claims against

the manufacturer. No liability is accepted for damage or malfunctions caused by improper use, assembly

errors or failure to observe the operating instructions.

1.5 Ambient conditions

The GDPD 400 high-pressure tester is only to be used in commercial workshops.

The climatic requirements correspond to the conditions typically prevailing in Central Europe. Optimum

function is ensured between -10 °C and +45 °C. The device must be stored within a temperature range of

-20 °C to + 60 °C.

The GDPD 400 high-pressure tester and its components must be secured against falling.

- 6 - GDPD400_V0.3_0920

2. Product description

The GDPD 400 high-pressure tester is a testing unit for static and dynamic fuel pressure testing of the

high-pressure circuit on GDI (Gasoline Direct Injection) engines. For example, for static testing of the

pressure pump when starting the engine or for dynamic system pressure testing at changing speeds

while idling.

2.1 Device versions / delivery scope

GDPD 400 – High-pressure tester for GDI systems (digital)

Item Component Quantity

①Test block with digital pressure gauge (with rubber protection cap),

NG 80, measurement range 0...400 bar 1

②Flexible pressure line M14 x 1.5 (length 0.7 m) 2

③Adapter, M14 x 1.5 to M12 x 1.5 2

Plastic case (not shown) 1

- 7 -

GDPD400_V0.3_0920

3. Prior to commissioning

3.1 Check the scope of delivery.

3.2 Prepare the high-pressure tester.

Depending on the desired measurement method, connect the pressure line(s) to the test block:

For static measurements:

Connect a pressure line (2) to the test block connection (without sealing cap).

Screw the sealing cap (on the chain) onto the second test block connection.

Tighten the measuring hose screw connection and the cap to 25 Nm.

For dynamic measurements:

Connect both pressure lines (2) to both test block connections and tighten to 25 nm.

3.3 Connect the high-pressure tester.

CAUTION

– Risk of injury due to leaking liquids or gases.

– The discharge of liquids that are under pressure may cause injuries.

Before switching on the ignition or starting the engine, examine the ttings for damage and

check that they are properly tightened.

– Risk of injury due to ejected parts.

– Pressurised systems may burst and cause parts to be ejected.

Never open pressurised ttings.

Wear personal protective equipment, such as protective goggles, gloves and safety shoes

when working on pressurised systems.

– Risk of injury due to ammable liquids.

– Leaking liquids may ignite.

Only attach and remove the high-pressure tester when the engine is cold.

Observe the specications and instructions of the vehicle manufacturer

Attention

Follow the instructions and specications of the vehicle manufacturer regarding the

tightening torque of the ttings.

Use the high-pressure tester only for temporary measurements at a standstill. Do not leave

the unit in the engine compartment.

Connecting the high-pressure tester (static measurement)

Remove the high-pressure fuel line from the high-pressure pump according to the vehicle manufacturer's

specications. Attach the exible pressure line of the tester to the high-pressure pump and tighten accord-

ing to the vehicle manufacturer's specications. Use a reducing adapter (3) if necessary.

Connecting the high-pressure tester (dynamic measurement)

Connect the tester using the two exible pressure lines (2) between the high pressure pump and the rail

pipe and tighten according to the vehicle manufacturer's specications. Use a reducing adapter (3) if

necessary.

Before the measurement, the device must be completely vented bubble-free using the vent screw.

Make sure that the vent screw is closed, briey actuate the ignition or starter, connect the collection

container to the vent screw, slowly open the vent screw and vent the high-pressure tester. A correct

display is only possible when the high-pressure tester is lled bubble-free.

- 8 - GDPD400_V0.3_0920

4. Operation

Switch on the digital pressure gauge

(see operating instructions DM 80)

The high-pressure tester is ready

Static measurement:

Briey actuate the ignition to measure.

Observe the display as the pressure builds

and read off the measurement value.

Dynamic measurement:

Let the engine idle briey to measure. Observe the

display and read off the measurement value.

Before removing the high-pressure tester, the residual pressure must be released via the vent screw. To

do this, connect the collection container to the vent screw, slowly open the vent screw and release the

residual pressure, then loosen the exible pressure line(s) from the pump and remove the tester.

Restore the original condition of the engine/vehicle.

- 9 -

GDPD400_V0.3_0920

5. Handling instructions

5.1 Care and storage

To enable effective working, we designed the high-pressure tester to be low maintenance. Nevertheless,

you should still observe a few notes. This helps to ensure trouble-free operation and to preserve the value

of the technology.

Note:

Damage to the high-pressure tester or individual components caused by aggressive

cleaning agents or solvents. Do not use aggressive or abrasive cleaning agents, solvents or

similar chemicals for cleaning.

– Keep the high-pressure tester and its components free of dust and dirt.

– Clean the device and components after each use.

– Store your product in a dry, dust-protected environment.

Avoid places with higher temperatures and moisture or places which can become wet, also for main-

tenance.

– Keep the original packaging to avoid damage during transportation.

5.2 Maintenance and repair

–Regularly check the tightness and accuracy of the tester (30 seconds at 200/300 bar)

5.3 Environmentally friendly disposal

Recycling according to WEEE (EU Directive 2002/96 EC)

You can optionally return the high-pressure tester to us for disposal.

The high-pressure tester or its components must not be disposed of as normal waste.

If you prefer not to return the high-pressure tester to us for disposal, you are required to bring the device

to a specialised centre for the separate collection and disposal of hazardous and special waste.

- 10 - GDPD400_V0.3_0920

6. Technicaldata,specications

Feature Unit Description

Burst pressure, pressure line bar 800

Ambient temperature °C -10…+45°C

Storage temperature °C -10…45°C,

Media temperature °C -20…+80°C

Maximum relative humidity % RH <85% RH without condensation

Connection thread, pressure line mm M14x1.5

Thread adapter mm M14 x 1.5 to M12 x 1.5

Weight kg 3.1

Dimensions L x W x H mm 420 x 520

Feature Unit Measurement range (pressure gauge*)

Measurement range relative bar 0 … 400

Measurement range relative psi 0 … 5800

Overpressure Pmax bar 800

Accuracy % FS ±0.5

*For complete pressure gauge specications, see the pressure gauge description/operating instructions

(DM 80)

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