Delphi DDNX300, DDNX300 EN GENERAL MANUAL
GENERAL MANUAL
ELECTRONIC UNIT PUMP - YUCHAI ENGINE 4112 / 6112 / 6113 DDNX300(EN)
2006
(D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn
Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche
Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie
sofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.
(E) Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores,
tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar
la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel,
consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y
Seguridad.
(EN) Do not put your skin into the fuel jets under pressure, especially those due to pressure
pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an
injection under the skin, contact a doctor immediately. Please refer to the health and
security fuel documents.
(F) Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux
provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous
haute pression injecté sous la peau peut causer des blessures mortelles. En cas
d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de
santé et de sécurité du gazole.
(IT) Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione,
specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione
possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare
immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.
(NL) Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen
onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder
hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als
de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de
gezondheids- en veiligheidsfiche met betrekking tot de brandstof.
(P) Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a
fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar
ferimentos mortais. No caso de injecção subcutânea, consulte imediatamente um
médico. Consulte por favor a documentação respeitante a saúde e segurança de
combustíveis.
(D) Schutzbrille/Gesichtsschutz tragen.
(E) Úsese protección para los ojos/la cara.
(EN) Wear eye/face protection.
(F) Porter un appareil de protection des yeux / du visage.
(IT) Proteggersi gli occhi/la faccia.
(NL) Veiligheidsbril/-masker gebruiken.
(P) Use protecção da face/olhos.
(D) Von Zündquellen fernhalten - Nicht rauchen.
(E) Conservar alejado de toda llama o fuente de chispas -No fumar.
(EN) Keep away from sources of ignition - No smoking.
(F) Conserver à l'écart de toute flamme ou source d'étincelles - Ne pas fumer.
(IT) Conservare lontano da fiamme e scintille - Non fumare.
(NL) Ver van open vuur en ontstekingsbronnen houden – Niet roken.
(P) Mantenha afastado de fontes de ignição – Proibido fumar.
(D) Geeignete Schutzhandschuhe tragen.
(E) Usen guantes adecuados.
(EN) Wear suitable gloves.
(F) Porter des gants appropriés.
(IT) Usare guanti adatti.
(NL) Aangepaste veiligheidshandschoenen dragen.
(P) Use luvas apropriadas.
SPECIAL FEATURES OF THE SYSTEM I
REMOVAL / REFITTING II
APPENDIX III
Produced and published by:
Delphi Diesel Systems Ltd
Delphi Diesel Aftermarket
Spartan Close
Warwick CV34 6AG Tel: +44 (0) 1926 472 900
Fax: +44 (0) 1926 472 901
© Delphi
TABLE OF CONTENTS
DDNX300(EN) - Issue 1 of 09/2006
i
1. ENGINE CHARACTERISTICS - 4112
1.1 Engine Characteristics..................................................................................................................................................1-1
1.2 Power and Torque Values............................................................................................................................................1-1
2. ENGINE CHARACTERISTICS - 6112
2.1 Engine Characteristics..................................................................................................................................................2-3
2.2 Power and Torque Values............................................................................................................................................2-3
3. ENGINE CHARACTERISTICS - 6113
3.1 Engine Characteristics..................................................................................................................................................3-5
3.2 Power and Torque Values............................................................................................................................................3-5
4. PARTS SUPPLIED BY DELPHI
4.1 General...........................................................................................................................................................................4-7
4.2 Electronic Unit Pump....................................................................................................................................................4-7
4.3 Injectors and Inlet Connector.......................................................................................................................................4-8
4.4 Sensors..........................................................................................................................................................................4-8
4.4.1 Crankshaft sensor.........................................................................................................................................4-8
4.4.2 Camshaft sensor...........................................................................................................................................4-9
4.4.3 Boost pressure sensor.................................................................................................................................4-9
4.4.4 Boost temperature sensor...........................................................................................................................4-9
4.4.5 Coolant temperature sensor......................................................................................................................4-10
4.4.6 Fuel temperature sensor............................................................................................................................4-10
4.5 Engine Control Unit (ECU)..........................................................................................................................................4-11
I SP E CIA L FEA T URE S OF THE S YST E M
TABLE OF CONTENTS
ii
DDNX300(EN) - Issue 1 of 09/2006
5. PRELIMINARY OPERATIONS
5.1 Preparation..................................................................................................................................................................5-13
6. HIGH PRESSURE PIPES
6.1 Removal Of A High Pressure Pipe.............................................................................................................................6-15
6.2 Refit Of A High Pressure Pipe.....................................................................................................................................6-15
7. INJECTOR
7.1 Removal Of An Injector...............................................................................................................................................7-17
7.2 Refit Of An Injector......................................................................................................................................................7-19
7.3 Bleeding The Low Pressure Fuel System..................................................................................................................7-20
8. SENSOR
8.1 Removal Of The Sensor..............................................................................................................................................8-21
8.2 Refit Of The Sensor.....................................................................................................................................................8-21
9. ELECTRONIC UNIT PUMP (EUP)
9.1 Removal Of The Electronic Unit Pump......................................................................................................................9-23
9.2 Refit Of The Electronic Unit Pump.............................................................................................................................9-24
9.3 Bleeding The Low Pressure Fuel System..................................................................................................................9-25
10. DIESEL CONTROL UNIT (DCU) OR ELECTRONIC ENGINE CONTROLLER (EEC)
10.1 Removal Of The Engine Control Unit......................................................................................................................10-27
10.2 Refit Of The Engine Control Unit.............................................................................................................................10-27
REM O VAL / RE F ITT I NG I I
TABLE OF CONTENTS
DDNX300(EN) - Issue 1 of 09/2006
iii
11. MISCELLANEOUS
11.1 Tightening Torques...................................................................................................................................................11-29
11.2 Resistance Values......................................................................................................................................................11-30
11.3 Tools...........................................................................................................................................................................11-31
11.4 Wiring Diagrams.......................................................................................................................................................11-32
11.5 Abbreviations Used In This Manual........................................................................................................................11-34
III A PPEN DIX
TABLE OF CONTENTS
iv
DDNX300(EN) - Issue 1 of 09/2006
1 ENGINE CHARACTERISTICS - 4112
1.1 Engine Characteristics
4112
Engine layout 4 or 6 cylinders in-line with direct injection
Engine capacity
5200 cm
3
Bore and stroke 112 x 132 mm
Compression ratio 17.8/1
Number of valves per cylinder 4
Drive Gear driven camshaft - overhead valve with push-rod actuation
1.2 Power and Torque Values
The 4112 engine is currently available in the following three specifications:
Specification Power Torque
4112 155kW @ 2200 erpm 820Nm @ 1500 erpm
4G220-30 132kW @ 2300 erpm 660Nm @ 1400 erpm
4G180-30 177 kW @ 2200 erpm 950Nm @ 1500 erpm
SPE C IAL F EAT U RES OF T H E S Y STEM I
ENGINE CHARACTERISTICS - 4112
DDNX300(EN) - Issue 1 of 09/2006
1-1
2 ENGINE CHARACTERISTICS - 6112
2.1 Engine Characteristics
6112
Engine layout 4 or 6 cylinders in-line with direct injection
Engine capacity
7800 cm
3
Bore and stroke 112 x 132 mm
Compression ratio 17.5/1
Number of valves per cylinder 2
Drive Gear driven camshaft - overhead valve with push-rod actuation
2.2 Power and Torque Values
The 6112 engine is currently available in the following three specifications:
Specification Power Torque
6112 199 kW @ 2200 erpm 1080Nm @ 1600 erpm
6G240-30 243 kW @ 2200 erpm 1280Nm @ 1400 erpm
6G270-30 228 kW @ 2200 erpm 1150Nm @ 1400 erpm
SPE C IAL F EAT U RES OF T H E S Y STEM I
ENGINE CHARACTERISTICS - 6112
DDNX300(EN) - Issue 1 of 09/2006
2-3
3 ENGINE CHARACTERISTICS - 6113
3.1 Engine Characteristics
6113
Engine layout 4 or 6 cylinders in-line with direct injection
Engine capacity
8424 cm
3
Bore and stroke 113 x 140 mm
Compression ratio 17.5/1
Number of valves per cylinder 4
Drive Gear driven camshaft - overhead valve with push-rod actuation
3.2 Power and Torque Values
The 6113 engine is currently available in the following four specifications:
Specification Power Torque
6113 206 kW @ 2200 erpm 1100Nm @ 1600 erpm
6L330-30
6L310-30
6L280-30
SPE C IAL F EAT U RES OF T H E S Y STEM I
ENGINE CHARACTERISTICS - 6113
DDNX300(EN) - Issue 1 of 09/2006
3-5
4 PARTS SUPPLIED BY DELPHI
4.1 General
DELPHI supplies the following original fitment parts:
• Electronic Unit Pump with tappet assembly
• Injector
• Inlet connector (4112 & 6113 engines only)
• Crankshaft sensor
• Camshaft sensor
• Boost Pressure sensor
• Boost Temperature sensor
• Coolant Temperature sensor
• Fuel Temperature sensor
• Engine Control Unit
4.2 Electronic Unit Pump
Specifications:
• Bore and stroke Ø11 x 16 mm
• Maximum Injection Pressure at Rated Speed : 2000
bar
• Fuel delivery (approx.):
-
190 mm
3
per stroke at Rated Speed
-
200 mm
3
per stroke at Peak Torque
• Operating condition and specification of solenoid :
- Electrical drive-EUP Nominal drive Voltage50
V
- Peak 10 A
- Hold 4.1-5.2 A (modulated)
• Tyco 2 pin harness plug connector
• Dot matrix trim code on connector
• External fuel filter
• Separate tappet assembly - location guide in
separate cambox
• EURO III & IV emissions capable
50V Electronic Unit Pump generates highly pressurised
fuel to achieve optimum injection consistency. On these
fuel systems it has proved beneficial to measure and
characterise individual assembly performance, to
communicate this data to the ECU and adjust the signal
outputs for each cylinder.
SPE C IAL F EAT U RES OF T H E S Y STEM I
PARTS SUPPLIED BY DELPHI
DDNX300(EN) - Issue 1 of 09/2006
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