ANCEL AJ400 GDI Injector Cleaner and Tester Instruction Manual

ANCEL AJ400 GDI Injector Cleaner and Tester

Specifications

• Product Name: ANCEL AJ400 GDI Injector Cleaner & Tester
• Intended Users: Professional technicians or maintenance and repair personnel
• Safety: Follow the important safety instructions provided in the user manual

Product Information

Introduction to Injector Cleaner & Tester
The ANCEL AJ400 GDI Injector Cleaner & Tester is a device designed for cleaning and testing GDI (Gasoline Direct Injection) injectors. It is intended for professional technicians or maintenance and repair personnel.

Installation

Installation of GDI and Top-Supply Injectors (EFI/MPI/SFI)
To install GDI and top-supply injectors, follow the instructions provided in the user manual. Make sure to use original products from the manufacturer or approved products.

Installation of Side-Supply Injectors
To install side-supply injectors, refer to the user manual for detailed instructions.

Operating Procedures
The operating procedures for the ANCEL AJ400 GDI Injector Cleaner & Tester are explained in detail in the user manual. Follow the instructions carefully to ensure proper usage of the device.

Operation
The operation of the injector cleaner and tester involves the following steps:

1. Connect the device to a power source.
2. Prepare the GDI injectors for cleaning and testing.
3. Follow the instructions on the control panel to select the desired cleaning and testing functions.
4. Initiate the cleaning and testing process.
5. Monitor the cleaning and testing progress through the display  or indicator lights.
6. Once the process is complete, disconnect the device from the power source.

Important Safety Instructions

• Please read this manual carefully before using the equipment.
• Be careful when touching high-temperature parts of the equipment or engine.
• Please do NOT touch hot parts or rotating fan blades.
• If use a low-quality power cord, it may cause overheating.
• The device should be cooled completely before storage and the line should be wound up.
• The cleaning agent for the device is a flammable and weakly volatile liquid. Smoking and lighting fires are strictly prohibited during the cleaning process.
• The instrument should be placed in a room that is not exposed to direct sunlight and is well-ventilated, and signs “Smoking and lighting fires strictly forbidden” and “Danger warning of inflammable” should be posted.
• The operator’s hair, clothes, fingers, and other parts of the body should be kept away from the operating parts of the equipment.
• To prevent electric shocks, do you touch the operating equipment in wet areas or operate it in the rain?
• Please operate the device as described in the manual. Use accessories recommended by the manufacturer.
• It is strictly forbidden to open the ultrasonic system under the circumstances that an ultrasonic cleaning agent has not been added to the ultrasonic cleaning pool. Otherwise, the ultrasonic equipment may be damaged easily.
• The housing of the device must be reliable and grounded.
• Automobile exhaust contains a variety of toxic and harmful gases (such as carbon monoxide, hydrocarbon, nitrogen oxide, etc.). During the test, the exhaust should be directed outdoors and the room should be well-ventilated.
• The temperature of the exhaust pipe and water tank of the automobile’s engine is high. Do not touch them to prevent burns.
• Please pull up the handbrake of the vehicle to be cleaned, shift the transmission to a neutral position, and block the front wheel before free disassembly cleaning.
• Wear safety glasses when operating. Daily wear glasses are not safety glasses.
• When disconnecting a pressurized fuel pipe union, please cover the union with a towel to avoid getting hurt by fuel gushing out and causing fires.
• A test solution is used by the main unit of the device, and an ultrasonic cleaning agent is used for ultrasonic cleaning.

INDICATES WHERE ATTENTION SHOULD BE PAID WHEN OPERATING THE DEVICE.

Indicates the possibility of product damage and personnel injury during operation.

Special note:
This user’s manual is an introduction to the structure, functions, operations, cautions, maintenance, and troubleshooting for the proper use of the equipment, we retain the right to change product design and specifications, the actual configuration according to the packing list.

Introduction to Injector Cleaner & Tester
Welcome to useusingjector Cleaner & Tand test equipment. It is a mechatronic product that combines ultrasonic cleaning technology with microprocessor fuel pressure control cleaning and testing technology.

Brief Introduction
The User Manual applies to the serial Injector Cleaner and tester equipment.

Functions and Features

Main functions

• Ultrasonic cleaning:
  To clean injectors to remove the carbon deposition on them completely.

• Resistance test
  To test the resistance of the fuel injector

• Uniformity / Sprayability test:
  To test the uniformity of injecting amount of each injector, and to monitor the spraying status of each injector with the help of backlight.

• Leakage test:
  To test the sealing and dribbling conditions of injectors under system pressure.

• Injecting flow test:
  To check the injecting amount of the injector in 15 seconds of constant injection.

• Working modes test:
  To test injectors under different working conditions.

• On-Vehicle Cleaning:
  Coming with a variety of disassembly-free cleaning connectors, the device can be used to perform on-vehicle cleaning and maintenance for various vehicle models.

• Low resistance injectors test function
  Through the dedicated motherboard, it supports the full and long test of low- resistant fuel injectors such as 1 ohm.

• Multi items Setting:
  Set different parameters of the device, including the buzzer sound level, display brightness, and backlight brightness.

• Version information:
  to check the software version information of the current device.

Main Features

• The special structure design makes the disassembly and assembly of the fuel separator easier and greatly improves work efficiency.
• With the resistance test of the injectors one by one, get to know the condition of the injectors
• The ultrasonic cleaner is integrated into the machine, which makes the operation easier and more efficient.
• With the dedicated motherboard, it can support the full and long test of low-resistant fuel injectors such as 1 ohm.
• The unique fuel circuit depressurization technology can make the machine automatically depressurize in the case of a sudden shutdown, avoiding equipment damage or personal injury.
• The brightness of the screen and backlight and the level of the buzzer can be manually set and saved.
• The product adopts fuel pressure adjustment and control technology by microcomputer, which can ensure stable fuel pressure and wide adjustable range. It applies to vehicles equipped with a variety of gasoline injection systems. Meanwhile, the automation of injectors’ cleaning and testing processes can be realized.
• Thanks to the adoption of microcomputer automatic control and digital display technologies, the cleaning and testing processes can be controlled automatically, and the parameters of the main status can be monitored in real-time.
• Adopting a humanization design can make the system pressure quickly restored to the default values.

Working Conditions & Specifications

Working conditions:

• Temperature : -10~+40℃ Relative humidity: ＜85%
• Intensity of outer magnetic field : ＜400A/m
• No naked flame within 2m.

Specifications:

• Main unit power supply: AC220V±10% 50Hz/60Hz or AC110V±10% 60Hz
• Input power: 230
• Ultrasonic cleaner power: 100W
• Resistance test accuracy: 0.1Ω
• Simulated RPM range: 100～9900rpm, step:10rpm
• Time range: 5～300s, step:5s
• Pulse width: 0.1～25ms,step: 0.1ms
• Fuel tank capacity: 2000 ml
• Work pressure : 0-7bar

Structure of Injector Cleaner & Tester

Overview

1. Pulse line;
2. Fuel separator assembly;
3. Observation window tube;
4. Control panel;
5. Fuel pressure gauge;
6. Fuel outlet pipe;
7. Ultrasonic cleaner ;
8. Ultrasonic cleaner switch;
9. Liquid level indicator tube (test liquid drain tube) ;
10. Cleaning liquid drain port;
11. Test liquid addition port;
12. Fuel tank;
13. Power switch

Attention:
there may be a slight difference between the illustrations in this manual and the actual product. Subject to actual product.

Control Panel

Installation

Installation of top-supply injector(EFI/MPI/SFI)

1. Choose the adapters according to the fuel top-supply injector from the coupler box and mount a proper O-ring on it. Remember to apply a little lubricating fuel on the O-ring.
2. The adapters for fuel top-supply injectors are of 4 types:
3. Thread sealing type: here are with coarse thread and fine thread.
4. O-ring sealing type : here are with big holes and small holes.
5. If the injectors cannot be fixed because of the hole being bigger than the injector, need to use the auxiliary support.
6. Need to adjust the relative position between the Knurled nut and adjustable screw so that the injectors can be fixed well on the unit.

Installation of side-supply injectors

1. Choose proper couplers for side-supply injectors and proper O-rings, and mount them together.
2. Before fixing, best to apply a little lubricating fuel on the O-ring.
3. If some cylinder is not used, need to install the plug.

Operating Procedures

Preparation

1. Remove the injector from the motorcycle engine to check the o-rings inside for damage. If it is damaged need to replace it. Put the outside of the injector in gasoline or detergent, and wipe it with a soft cloth after cleaning the outside fuel sludge carefully.
2. Check the test liquid level to be sure there is enough test liquid inside the tank. Pour test liquid from the port at the top left side of the unit and watch the liquid level in the fuel level viewer. In most cases, the liquid is up to 1/2 of the tank capacity.
3. Turn on the power switch on the right of the Cabinet.
4. Pour ultrasonic detergent into the ultrasonic cleaning basin so that the needle valve of the injector is covered by the detergent.
5. Connect the injectors with the right couplers.

The main unit of the device uses a test solution for uniformity/playability test, leakage test, injecting flow test, and auto. test. The ultrasonic cleaner uses the cleaning agent. Test solution and cleaning agent are not included in the standard configuration and can be purchased separately.

Cleaning & testing sequences
Recommended to carry out the complete cleaning and testing procedures in the following order.

• Ultrasonic cleaning;
• Uniformity / Sprayability test;
• Leakage test;
• Injecting flow test;
• Working modes test.

Procedure after work operation

1. Drain the test solution into a fuel container.
2. Switch off the power switch and unplug the power plug.
3. Use a fuel header to suck all cleaning agents in the ultrasonic cleaning pool, and wipe the pool with a soft dry cloth.
4. Wipe the tabletop of the machine with a soft dry cloth.
5. To avoid volatilization, all the test solutions in the fuel tank should be discharged. If it can be used again, store it in a safe place. If it is dirty and cannot be used anymore, dispose of it according to relevant regulations.

Operation

Resistance Test

1. Connect one end of the resistance measurement line to the interface on the right side of the device, and the other end to the two electrodes of the fuel injector.
2. Start the machine, and press the key. The resistance value will be displayed on the screen.
3. If needed, measure several times to confirm the measured value.
4. After the measurement is completed, remove the fuel injector and the resistance measurement line.

Ultrasonic Cleaning
Injector Cleaner takes advantage of the penetrability and cavitation impact wave caused by ultrasonic waves traveling through the medium to provide powerful cleaning on objects with complex shapes, cavities, and pores so that the stubborn carbon deposits can be removed from the injectors.

Procedures

1. Place the injector/pump which has gone through surface cleaning in the launder.
2. Add enough injector detergent into the ultrasonic cleaner so that the liquid level is about 20mm above the needle valve of the injectors / whole pump.
3. Plug the pulse signal wire into the injector/pump.
4. Select the ultrasonic cleaning function and then set the time.
5. Press the UN key to start the procedure.
6. Turn on the ultrasonic cleaning switch on the left side of the machine.
7. When the time is up, it will stop automatically as the beeper rings.
8. Turn off the ultrasonic cleaning switch on the left side of the machine after the cleaning procedure.
9. Take the injector / pump out of the launder and wipe them with a dry soft cloth. Get ready for the next operation.

Note:

1. It is strictly forbidden to open the ultrasonic system under the circumstances that a cleaning agent has not been added to the ultrasonic cleaning pool. Otherwise, the ultrasonic equipment may be damaged easily.
2. It is strictly prohibited to immerse the pulse signal line connector along with the injector into the ultrasonic pool for cleaning. Otherwise, the pulse signal line connector can be damaged easily.
3. ATTENTION: Make sure to turn off the ultrasonic cleaning switch on the left side of the machine after the cleaning procedure.

Uniformity/Sprayability Test
The uniformity test is to find out the difference between the injectors injecting at the same working condition. This test can indicate the comprehensive influences on the injector caused by electrical nature, bore variation, and clogging. The spray ability test is to inspect the spraying performance by observing the injectors.

Installing and testing procedures for injectors

1. Choose a proper adaptor according to the injector type and mount it to the fuel separator.
2. Install the injectors in the forward direction (Apply a little lubricating grease on the O-ring.)
3. Install the fuel separator with the injector onto the plate of the test tube.
4. Connect the injector pulse signal wire.
5. Before doing this test, use a manual switch to drain the test liquid from the measuring cup if there is any.
6. Select the Uniformity/Sprayability test function, set corresponding parameters (consult the appendix for pressure setting, consult vehicle manuals for other parameters as needed), and then press the RUN key to start the test.
7. When the test is completed, the equipment will auto-stop with the ring of the buzzer.

Note:

1. The system pressure can be adjusted by pressing + or – at testing.
2. During operation, the user can select parameter, such as RPM or PW, and then press or key to achieve the status of the simulation.
3. Good injectors may have identical injecting angle, uniform spraying but no jet. Otherwise, replace the injector.
4. In the playability test, a special electrical parameter–the minimum injection pulse width of injector–can be tested, to compare the injectors on the same engine. That is to set cylinder No., start the test from minimum injection pulse width, and then gradually increases the pulse width till the injector starts injection (observed with the help of backlight). The value set at this moment is the minimum injection pulse width, so the difference in minimum injection pulse width among these injectors could be observed.

Backflushing
Backflushing is limited to the top-supply injector by connecting the backflushing connector under a uniformity/playability test. Test solution enters from the outlet of the injector and flows out from the inlet during backflushing. Backflushing can wash away the dirt inside the injector and dirt attached to the filter.

1. Find the backflushing connector (and select a supporting “O” ring to install it on the connector) installed below the fuel separator;
2. Install the top-supply injector in the reverse direction (outlet up, inlet down);
3. Select the corresponding coupling element under the injector according to the shape of the injector;
4. Adjust the screws to fix the fuel separator and injector assembly in the fuel filler hole of the upper cover according to the height of the injector and tighten the compression screws (black) on both sides evenly;
5. It is recommended to use a manual switch to drain the remaining fuel in the transparent tube to avoid overflow of the test solution before backflushing.
6. Connect the pulse signal line of the injector properly; set the operating parameters and press the Run button to execute the backflushing function; the system pressure can be adjusted by the + and – buttons on the control panel during backflushing.
7. The system will stop automatically after the completion of the cleaning.

Leakage Test
The leakage test is to inspect the sealing conditions of the injector needle valve under system pressure and to find out if the injector is dribbling

Procedures
Installation refers to the Uniformity/ Sprayability Test.

1. Before doing the leakage test, please use the manual switch to drain the rudimental residual test liquid from the measuring cup.
2. Selethe ct Leakage Test function and press the Run key to start. At this time the system pressure can be adjusted by pressing the + and – keys to observe dribbling from the injector the pressure is adjusted preferably 10% higher than the manufacturer’s specifications.
3. When the test is over, the equipment will automatically stop and the buzzer will ring simultaneously.

Note:
In general, the drip of the injector should be less than 1 drop within 1 minute (or by the specifications). The default time of the system is 1 minute.

Injecting Flow Test
The injecting flow test is to check if the injecting flow in 15 seconds meets the specifications for the injecting amount. The deviation reflects the wear or clogging in the injector, instead of electrical parameter variation.

Procedures:
Installation refers to the Uniformity/ Sprayability Test.

1. Before this test, use a manual switch to drain the test liquid from the measuring cup if there is any.
2. Choose the Injecting Flow Test function and press the Run key to start the test. Adjust the fuel pressure by pressing the + or – key according to the injector specification.
3. When the test is over, the equipment will stop automatically at the ring of the buzzer.

Working modes test
The working modes test contains three working status simulation tests(Acceleration, Deceleration, and Acceleration+ Deceleration test)). This function can test the more comprehensive performance of injectors by simulating the various engine working conditions.

Procedures:
Installation refers to the Uniformity/ Sprayability Test.

1. Before the test, use a manual switch to drain all the test liquid in the measuring cups if there is any.
2. Select the Modes function and choose mode no. , then press the Run key to start the test.
3. Adjust the fuel pressure by pressing the + or – keys.
4. When the test is over, the equipment will auto-stop at the ring of the buzzer.

On-Vehicle Cleaning
After the motorcycle engine has been in operation for some time, its fuel flow may be blocked or become un-smooth owing to the buildup of dust and impurities in the fuel channel. In addition, the carbon deposits and gum made by combustion can easily adhere to the injectors, inlet and outlet ports, inlet and outlet hoses, throttle, and combustion chamber. So the fuel supply system, combustion chamber, and injector of the engine must be cleaned on a timely basis. Combustion Chamber cleaning is a solution that can save you time and labor.

Procedures:

1. Please check if there is test liquid or detergent inside the fuel tank before on-vehicle cleaning. If the test liquid is in the tank, replace it with detergent.
2. Blend the detergent with the fuel at a certain ratio, and fill the mixture into the fuel tank.
3. The connection of engine fuel pipes has been shown in “Connecting” below.
4. Select the -Vehicle Cleaning function, and set the cleaning time.
5. Press The un key to start the function, and adjust the fuel pressure by pressing the + or – keys.
6. Start the engine to begin cleaning.

Connecting
There are two cases for the line connection: one is the connection with the fuel-return hose and the other is the connection without the fuel-return hose.

Connection with fuel-return hose:

1. Disconnect the fuel supply hoses (C, D) and fuel return hoses (A, B) of the engine fuel system (when disconnecting the fuel line connectors, cover them with towels). Choose proper connectors and connect them to the B end and C end separately, and then connect the other ends to the corresponding return hose and outlet hose of the device.
2. Connect the two other disconnected ends (A, D) with a proper hose, remove the fuel pump fuse, or disconnect the power cable of the engine fuel pump.

1.  Injector Cleaner & Tester;
2. Engine;
3. Fuel-return hose from engine;
4. Fuel-inlet hose to engine;
5. Auto filter;
6. Engine fuel supply hose;
7. Engine fuel return hose;
8. Fuel pump;
9. Fuel tank

Connection without fuel-return hose:

1. Disconnect the fuel supply hoses (E, F) of the engine fuel system (when disconnecting the fuel line connectors, cover them with towels), and then choose a suitable connector, connect it to the E end, and reconnect the fuel outlet hose of the device. Hang the fuel return hose.
2. Block the other end of the disconnected end (F) with a stopper (for fuel pump with fuel return function only) remove the fuse of the fuel pump or disconnect the power cable of the engine fuel pump.

1.  Injector Cleaner & Tester;
2. Engine;
3. Stopper;
4. Fuel-inlet hose to engine;
5. Fuel tank;
6. Fuel filter;
7. Engine fuel supply hose;
8. Fuel pump

Tidy up after cleaning

1. After the on-vehicle cleaning is completed, turn off the ignition switch of the vehicle. Restitute the hose connection, start the engine, and accelerate properly to check if there is any fuel leakage at the connectors or in the hoses.
2. Please clean the fuel tank and the lines of the device with test solution at the end of the on-vehicle cleaning, the specific procedures are: drain the detergent left in the fuel tank first and dispose of it according to its cleanliness. Add a small amount of test solution into the fuel tank, connect the fuel outlet hose of the device to the fuel return port, and power on the device. Select the “Leakage test” item and press the RUN button to run the device for about 2∼to 3 minutes. After the running has stopped, drain the test solution from the fuel tank and dispose of the drained liquid according to relevant regulations.
3. Clean up the site and tidy up the washing machine for later use.

Note :
When cleaning, care must be taken as the detergent is inflammable. Prepare at least one effective fire extinguisher. Be sure that all lines are well connected and that there is no leakage before performing the cleaning.

Transporting and Storing

Transporting

1. Before being packed, the liquid inside the fuel tank should be drained completely to avoid overflowing as transporting.
2. Move only by hand or lift with a soft belt.
3. No package no lifting tools or long-distance transportation.
4. To prevent the unit from shocking and knocking, make sure it is on the base seat and in the packing case during transportation. Firstly pack the unit with the matter similar to a plastic strip and add the filling material (such as foam or sponge, etc.) between the unit and packing case to avoid scratching the surface when the unit shakes.
5. Make sure that the maximum incline angle does not exceed 45℃. Do not place the unit upside-down.

Storing

1. Store only in a dry area and keep away from water before the unit is unpacked.
2. Store the machine in a well-ventilated area and do not expose it to direct sunshine or rain.

Installation Environment

1. Keep a distance of no less than 200mm between the unit and any wall or other substance. The unit should be put in a well-ventilated area. Make sure the temperature is within -10℃+40℃.
2. The unit has been well grounded for safety operation. Please confirm that the power socket is also well grounded.

Troubleshooting & Precautions

Troubleshooting

1. The unit does not correspond when it is switched on.
2. Check the fuse at the lower right side of the unit and replace it if it is damaged or broken.
3. There is a leakage in the fuel separator coupler.
4. Fuel leaked at the coupling element of the fuel separator. Please check whether the “O” ring installed matches and if it is deformed or damaged. If it does not match or is damaged, please change it. The two black adjusting screws should not be too tight, which may also cause the coupling element of the fuel separator to leak fuel.
5. The machine has not been used for a long time about several months, and it is found that the pump cannot work normally.
6. The type of test liquid used is not suitable, which will lead to poor internal signal of the pump after a long time of non-use. Use the electrical shock method and tap the pump as needed to resume normal operation.

Precautions

1. To avoid electric shock, keep away from the damp part of a working unit and avoid exposing it to the rain.
2. To ensure operation safety, please make sure that equipment has been connected to the ground well.
3. Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged until it has been examined by qualified service personnel.
4. Equipment use is strictly prohibited fireworks and posted “No smoking” and “Flammable hazard warning” signs.
5. Please operate the unit according to the operation procedures in the manual. Only use the accessories recommended by the manufacturer.
6. ALWAYS WEAR SAFETY GOGGLES. Commonly used glasses are NOT safety glasses.

General Notice & Disclaimer

All rights reserved!

Any company or person shall not copy or backup this user manual in any format (electronic, mechanical, photocopying, recording, or other formats) without written permission from us. The manual is for the use of the products manufactured by our company, which shall not assume any responsibility for the consequences arising from the use of it to guide the operations of other equipment. The device is intended for the use of professional technicians or maintenance and repair personnel. We assume no responsibility for device damages or problems resulting from the usage of other parts or consumables, rather than our original products or products approved by the company.

FAQ’s

Can I use the ANCEL AJ400 GDI Injector Cleaner & Tester for non-GDI injectors?

No, the device is specifically designed for GDI injectors and may not be compatible with non-GDI injectors.

Can I use aftermarket cleaning solutions with the injector cleaner and tester?

It is recommended to use the cleaning solutions provided by the manufacturer or approved alternatives. Using unauthorized cleaning solutions may affect the performance of the device.

How often should I clean and test my GDI injectors?

The frequency of cleaning and testing depends on various factors such as vehicle usage and maintenance. Refer to the vehicle manufacturer's recommendations or consult a professional technician for guidance.

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