MS 300 Automotive Fuel Injector Cleaner and Tester User Manual

MS 300 Automotive Fuel Injector Cleaner and Tester User Manual

Disclaimer

• To take full advantage of the unit, you should be familiar with the vehicle engine working principle.
• All information, illustrations, and specifications contained in this manual are based on the latest information available at the time of publication. The manufacturer resume the right of modify this manual and the machine itself with no prior notice.

Safety Precautions

Read all service procedures and precautions, installation instructions and equipment operating manuals thoroughly. Failure to observe these precautions, or the improper use of equipment, could result in property damage, serious injury or death. Never allow improperly trained personnel to perform these procedures or operate the equipment.

• Read the operating instructions before attempting to operate the unit. Keep this manual with the unit at all times.
• Care must be taken as burns can occur from touching hot parts of the equipment or in the engine.
• 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.
• Do not hang cords over the edge of the table, bench or counter, or come in contact with hot manifolds or moving fan blades.
• If an extension cord is needed, a cord with a rated current equal to or greater than that of the equipment should be used. Cords rated for lower current than that of the equipment may overheat.
• Always unplug equipment from electrical outlet when the machine is not in use. Never pull the cord when unplugging from the outlet.
• Make sure the equipment cools down completely before putting it away. Loop cord loosely around the equipment when storing.
• To protect against risk of fire, do not operate the equipment in the vicinity of open container containing flammable liquid (gasoline).
• Make sure that the unit is in the well-ventilation area when operating the fuel engine.
• Keep lighted cigarettes, sparks, flames or other ignition sources away from fuel systems at all times.
• Keep hair, clothes, fingers or the other body parts away from the running parts of the unit.
• In order to avoid electric shock, keep away from the damp part of a working unit and avoid exposing it to the rain.
• Please operate the unit according to the operation procedures in the manual. Only use the accessories recommended by the manufacturer.
• Do not switch on the ultrasonic system when there is no ultrasonic detergent in the ultrasonic cleaning chamber. Otherwise, damage to the ultrasonic cleaner can be resulted.
• Keep the unit well grounded.
• Provide ventilation through an exhaust gas removal system, ventilation fans or large doors. Carbon monoxide gas, which is odorless and colorless, can cause serious illness, injury or death.
• Avoid contacting hot surfaces such as exhaust pipes, radiator, etc.
• Before testing vehicles, put the transmission lever in NEUTRAL position, apply the parking brake, and block the front wheels.
• ALWAYS WEAR SAFETY GOGGLES. Common used glasses are NOT safety glasses.
• When disconnecting any connector of the pressurized fuel hose, wrap the connector with towel to prevent the fuel from spurting out. Spurted fuel may cause personal injury or fire.
• Test liquid is used by the main unit. Detergent is used for on-vehicle cleaning. The ultrasonic cleaning uses specified ultrasonic detergent.

Note: Specifying operations that require attention when operating the equipment.

Warning: Specifying a possible hazard that could result in damage to the machine or personal injury.

Functions

• Ultrasonic cleaning: To perform simultaneous cleaning on several injectors and to remove the carbon deposits on the injector completely.
• Uniformity/Spray-ability 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. This test is also for reverse flush.
• 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.
• Automatic test: To test injectors by simulating different working conditions.
• On-vehicle cleaning: The unit is equipped with various adapters and couplers that facilitate cleaning on the injectors on vehicle.

Features

• Adopting the powerful ultrasonic cleaning technology, the equipment offers complete cleaning to the injectors.
• Fuel pressure control through microcomputer offers stable pressure control and large adjustable range, which is suitable for all EGI vehicles and can help to achieve automatic cleaning and testing of injectors.
• With the help of microcomputer control and digital display, the equipment makes possible automatic cleaning, testing injectors and real-time monitoring of the dynamic values.
• Automatic fuel draining through preset programs for some test items. Test liquid/detergent can also be drained by pushing a button on the control panel after the test.
• Adopting humanization design can make the system pressure fast restored to the default values. Specifications.

Working conditions:

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

Specifications

• Main unit power supply: AC 110/220V+10%, 50/60Hz
• Main unit power: 150W
• Dimension of main unit: 27cm x 31 cm x 34cm
• Ultrasonic cleaner power: 60W;
• Fuel pressure: 0-10bar
• Simulated RPM range: 20~ 10000rpm;
• Pulse width: 0.5~25ms; step 0.1 ms;
• Uniformity/Spray-ability test duration: 1~20min
• Leakage test duration: 1~30min
• Injecting flow test duration: 3~120s
• Automatic drain: 60s
• Pressure unit: Bar, Psi, Kpa, mmHg, Kg/cm2
• Delivery dimension: 300x340x400mm
• Delivery Weight: 12kg (Varies according to configuration)

Structure

Overview
The Injector Cleaner& Tester structure has been shown in Fig.01.

A-Power socket & ON/OFF Switch & Fuse
For introduce AC power into the unit, and there’s a fuse socket, and a ON/OFF switch to turn on/off the unit.
B-Control/display panel
All the data will be shown on this touch screen, and adjustment of parameter could be done by finger tap. Refer to the Control Panel section for details
C-Control knob
Fast Navigation and control knob, turn left/right to switch between parameters and press to confirm.
D-Fuel filler port
For refill of test fuel. The fuel reservoir capacity is 2100ml, always refer to the Fuel level indicator while refill.
E-Fuel level indicator
Note the fuel level at refilling, and before testing. The fuel level shall be checked at a regular basis, always make sure the fuel level over MIN line, otherwise, pump faulty could be resulted.
F-Fuel drain port
If the fuel becomes dirty, drain the fuel, pour the fuel through a strainer and refill it back in from the Fuel filler port.
G-Fuel supply hose
Used to introduce fuel to the Fuel distributor.
H- Fuel distributor assembly
Different type of fuel distributor assembly may come with the unit according to changes of hardware configuration. The Fuel distributor assembly is used to distribute fuel into mounted injectors for testing.
I-Return fuel connector
Used for introduce return fuel from the vehicle at on-vehicle-testing function.
J-Sockets for pulse signal cable
Standalone Sockets for injector drive signal, note the index of the signal socket.

Note: The illustrations in this manual may be slightly different from the actual product!

Control Panel

All control of the unit is finished on a single touch LCD and a knob, which can be turned left/right to select and press to confirm.
All explanation with a >>> means its a menu item.
All explanation with a * mark, means its editable, and a window as below would pop up while tap the entry.

A-Decrease; B-Increase; C-Drag up to increase and drag down to decrease; D-Actual value Close the pop All control of the unit is finished on a single touch LCD and a knob, which can be turned left/right to select and press to confirm. All explanation with a >>> means its a menu item. E- All explanation with a * mark, means its editable, and a window as below would pop up while tap the entry.up window.

Main Screen

A-Control Knob; B-Ultrasonic Pulse Driver>>>; C-Uniformity/Spray-ability Test>>>; D-LeakageTest>>>; E-Injecting Flow Test>>>; F-Automatic Test>>>;G-On- Vehicle Test>>>;H-Fuel Drain>>>; |-Setting>>>.

Ultrasonic Pulse Driver

A-Status Icon; B-Duration*; C-Drain Fuel Button; D-Start/Stop Button; E-Return to Main Screen.

Uniformity/Spray-ability test

A-Status Icon; B-Pressure Indication; C-RPM ; D-Pulse ; E-Duration of the Test ; F-Injector Index( 0 means all injectors, while 1~6 refer to signal socket 1 to 6.) ; G-Pressure Level*; H-Drain Fuel Button; |-Start/Stop button; J-Return to Main Screen.

Leakage test

A-Status Icon; B-Pressure Indication; C-Duration of the test; D-Pressure Level; E-Drain Fuel Button; F-Start/Stop button; Return to Main Screen.

Injecting flow test

A-Status Icon; B-Pressure Indication; C-Duration of the test; D-Pressure Level; E-Drain Fuel Button; F-Start/Stop button; Return to Main Screen.

Automatic Test

A-Status Icon; B-Pressure Indication; C-Mode; D-Pressure Level; E-RPM (Status); F-Time Stamp (Status); G-Injection Countdown (status); H-Drain Fuel Button; |-Start/Stop Button; J-Return to Main Screen.

Mode

Mode 1|
Injecting for 8 seconds, Halt for 30 seconds, Drain 60 seconds, Injecting for 1500 times at 650rpm, 2.8ms, Halt for 30 seconds, Drain 60 seconds, Injecting for 1500 times at 6000rpm, 2.8ms, Halt for 30 seconds, Drain 60 seconds.
---|---
Mode 2 (3 working cycles)|
600rpm -6000rpm step 50rpm, at every checkpoint, inject 3 times, respective at Duty Ratio 30%, 15% and 2%. Halt for 30 seconds, Drain 60 seconds.
Mode 3| Mode1+Mode2(one working cycle)

On-Vehicle Test

A-Status Icon; B-Pressure Indication; C-Duration of the Test ; D-Pressure Level ; E-Drain Fuel Button; F-Start/Stop Button; G-Return to Main Screen.

Fuel Drain

A-Status Icon; B-Duration *; C-Start/Stop Button; D-Return to Main Screen.

Setting

The setting page is used to setup the default value while the unit every time start up.

A-Status Icon; B-Default RPM; C-Default Pulse; D-Default Spray-test Duration; E-Default Leakage Duration; F-Default Injecting Flow Duration; G-Default On-Vehicle Testing Duration; H-Default Pressure Level; I-Default pressure Unit.; J-Save the setting; K-Decrease/Switch back; L-Increase/Switch forward; M-Return to Main Screen.

Installation

• Move the machine onto the workbench after unpacking and loosen the strips on the outlet hoses.
• Mount the pulse signal cables onto the sockets on the top right side of the machine.
• Take the two adjusting bolts out from the kit and install them to the press plate on the top of the glass tube.
• Take the two knurled nuts from the kit and install them on the adjusting bolts.
• Take the fuel distributor from the kit and install it on the knurled nuts and tighten them with the pressing bolts.
• Take the power cables out from the kit and insert it into the input socket at the bottom of the unit.
• Take the power cables out from the kit and insert it into the input socket of the ultrasonic cleaner.

Operating Procedures

Preparation

• Remove the injector from the vehicle engine to check the o-rings for damage. Replace the damaged O ring with another same type O-ring to avoid leakage during testing. Put the outside of injectors in gasoline or detergent, and wipe them with soft cloth after cleaning the outside oil sludge carefully.
• Check the liquid level and refill test liquid when necessary. Fill the test liquid through the filler on the side of the unit and observe the liquid level in the fuel level viewer.Do NOT exceeding the Max line.
• Turn on the power switch on the left side of the Cabinet.
• Fill ultrasonic detergent into the ultrasonic cleaning launder so that the needle valve of the injector is covered by the detergent.
• Connect the injectors with the correct couplers.

Note:
Test liquid and detergent won’’t be provided by the manufacturer.

Cleaning & testing sequences
A complete cleaning and testing sequence shown below should be followed:

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

Select the corresponding parameter and set up according for various tests. For detailed operations, please refer to Operation and Control Panel section.

Tidy up after operating
Tidy-up should be done after cleaning and testing is completed:

• Press [Drain] button to drain the test liquid into fuel tank.
• Switch off the power.
• Drain the injector detergent to its original bottle and then wipe the ultrasonic cleaner with soft cloth.
• Clean the Injector Cleaner & Tester control panel with soft cloth.
• Drain the test liquid from the tank into a container to avoid volatilization. Store the test liquid in a safe place if it can be used again, or dispose of it in accordance with relevant regulations if it is too dirty.

Operation

Ultrasonic Cleaning
Injector Cleaner takes advantage of the penetrability and cavitation impact wave caused by ultrasonic wave 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

• Connect the power supply: connect one end of the power cable to the power socket on ultrasonic cleaner and the other end to power socket.
• Place the injectors which have gone through surface cleaning in a launder.
• Add enough injector detergent into ultrasonic cleaner so that the liquid level is about 20mm above the needle valve of injectors.
• Plug the injector pulse signal wires to injectors respectively then turn on the power switch of the ultrasonic cleaner.
• Tap icon on the main screen. Tap the time to set the timer (1~60min, and 10 minutes by default) then tap the button.
• When the time is up, Injector Cleaner & Tester will stop automatically.
• Turn off the power of the ultrasonic cleaner, take the injectors out of the launder and wipe them with a dry soft cloth. And they are ready for next operation.

Note:

• Never operation the ultrasonic cleaner when the tank’s empty, otherwise, damage may be incurred.
• Do not dip the pulse signal cables plug and the injector’s body into the detergent.

Uniformity/Spray-ability Test
Uniformity test is to find out if the flow of different injectors meets the requirement or specifications under the same working condition. This test can reflect the comprehensive influences on the injector caused by electrical nature, bore variation and clogging. Spray-ability test is to inspect the spraying performance by observing the injectors.

Installing and testing procedures for top-supply injectors

• Choose the fuel distributor stopper (4) from the coupler box and mount a proper O-ring on it.
  Remember to apply a little lubricating grease on the O-ring. Mount the fuel distributor stopper (4) onto the top-supply fuel distributor.

• Mount the crescent plate (3) and tighten it with a plate bolt (1).

• Choose a proper adaptor (5) according to the injector type and mount it to the corresponding coupler under the top-supply fuel distributor.

• Install the injectors in forward direction (Apply a little lubricating grease on the O-ring.)

• Install the top-supply fuel distributor and the injector on the fuel distributor supporter with a proper adjustable screw and knurled nuts, and tighten two riffle screws (black). See Fig. 05.

• Connect the injector pulse signal wire.

• Before doing this test, tap button to drain the test liquid from the measuring tube if there is any.

• Tap <Uniformity/Spray ability test> icon on the control panel, set corresponding parameters (consult the appendix for pressure setting, consult vehicle manuals for other parameters as needed), and then press button to start the test.

• When the test is completed, the equipment will auto stop with the ring of the buzzer.

Fig. 05 For fuel top-supply injector

1-Plate bolt; 2-Riffle screw; 3-Crescent plate; 4-Fuel distributor stopper; 5-Adapter for fuel top-supply injector; 6-Injector;7-Knurled nut; 8-Adjustable screw

Installing and testing procedures for side-supply injectors

• Choose proper couplers for side-supply injectors (3) and proper O-rings, and mount them together.
  (Remember to apply a little lubricating grease.)

• Mount the injectors on the couplers and install them onto the side-supply fuel distributor.

• Mount the cross plate (1) and tighten it with bolts.

• Mount the fuel distributor and injectors onto the fuel distributor supporter, and tighten them with two rifle screws (black). See Fig. 06.

• Connect the injector pulse signal wire.

• Before doing this test, tap button to drain the test liquid from the measuring cup if there is any.

• Tap <Uniformity/Sprayability test> on the control panel, set the corresponding parameters and tap button to start the testing.

• When the testing is finished, Injector Cleaner & Tester will stop.

1-Cross plate; 2-Fuel side-supply injector; 3- Coupler for fuel side-supply injector; 4,5-O-ring; 6-Side-supply fuel distributor.

Note:

• While testing, Injector Cleaner & Tester can drain fuel by tap key at anytime. At default, solenoid valve is set at the closed state. Uniformity test can be done at this state. When key is pressed, solenoid valve will drain oil for 60 seconds.
• The default cylinder number of the system is 0, which means that all injectors are working when Injector Cleaner & Tester is running. A specific cylinder can be selected by setting the number of the cylinder.
• The System Pressure, RPM, Pulse can be adjusted during testing.
• Keep the fuel level to at least 30 ml while testing. Foam will be produced in the liquid during injection. In order to prevent spillover, set the related parameter with reference to the following formula :Pulse width(ms)xtime(s)xspeed(rpm) / 120<18000.
• This function is for checking the uniformity of each cylinder. Injecting difference of all injectors on one vehicle should be kept within 2% during uniformity testing.

Reverse flush
Injector Cleaner & Tester can also perform reverse flush by connecting with flush-back adaptor at [Uniformity/Spray-ability test] mode. Reverse flush is a way to clean the injectors with the test liquid flowing from the outlet to the inlet of the injector. Reverse flush may remove the dirt inside the injector or the injector Strainer (Only for the top fuel supply injector).

Procedures:

• Choose a reverse flush coupler and proper O-ring, and mount them under the fuel distributor.
• Install the injectors in reverse direction (outlet upward, and inlet downward).
• Choose a proper coupler according to the shape of the injector and put it under the injector.
• Install the fuel distributor and the injector on the fuel distributor supporter with a proper adjustable screw and knurled nuts, and tighten two riffle screws (black). See Fig. 07.
• Connect the injector pulse signal wire.
• Tap icon, and tap [Run] button to start cleaning.
• When the cleaning is over, Injector Cleaner & Tester will automatically stop.

Note:

• The system pressure can be adjusted when performing reverse flush.
• It is advised to tap key to avoid spillover of test liquid during reverse flush.

1-Plate bolt; 2-Crescent plate; 3-Fuel distributor stopper; 4-Reverse adaptor; 5-Injector; 6-Knurled nut; 7-Adjustable screw; 8-Riffle screw; 9,10,11-O-ring; 12-Fuel distributor; 13-O-ring; 14-Couplers.

Leakage Test
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 (For installation refer to Uniformity/Sprayability Test):

• Before doing leakage test, please press [Drain] button to drain the rudimental residual test liquid from the measuring cup.
• Select icon on the main screen. tap key, the machine will work. At this time the system pressure can be adjusted to observe dribbling from the injector, the pressure is adjusted preferably 10% higher than manufacturer’s specifications.
• When the test is over, the equipment will automatically stop.

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

Injecting Flow Test

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

Procedures (For installation refer to Uniformity/Sprayability Test):

• Before this test, tap button to drain the test liquid from the measuring tube if there is any.
• Tap icon on the main screen, and tap button to start the test. Adjust the fuel pressure according to the injector specification.
• When the test is over, Injector Cleaner & Tester will stop.

Automatic Test
Automatic Test contains all above-mentioned tests (15-second injecting test, idle speed, middle speed, high speed, varying acceleration, varying deceleration, changing pulse width test). This function can test more comprehensive performance of injectors by simulating the various engine working conditions.

Procedures (For installation refer to Uniformity/Sprayability Test):

• Before the test, tap button to drain all the test liquid in the measuring cups if there is any.
• Tap mode on the Main Screen and set up the pressure value according to the injector specifications, select the test mode (mode 1, 2, or 3 are all available), and then tap button to start the test.
• Adjust the fuel pressure when testin.
• When the test is over, Injector Cleaner & Tester will stop.

Note: Please refer to the Control Panel section for Mode explanation.

On-Vehicle Cleaning

• Please check if there is test liquid or detergent inside the fuel tank before on-vehicle cleaning. If test liquid is in the tank, replace it with detergent. The detailed procedure to be followed: remove the level indicator on the left of the main unit, and drain the test liquid inside fuel tank into a container. If the drained test liquid contains lots of impurities and can not be reused, please dispose it in the proper way and fill with new test liquid. If the drained test liquid is clean, please store it for later using.
• Blend the detergent with the fuel at a certain ratio, and fill the mixture into the fuel tank. (Consult the user’s manual of detergent for blending ratio.) Refer to the following table for filling amount, as shown in the following table:
  **** No. of cylinders| 4 cylinder| 6/8 cylinder
  ---|---|---
  Amount| about 800~1000ml| about 1500ml
• The connection of engine fuel pipes has been shown in “Connecting” below.
• Tap icon on the control panel, and set the time and tap button to start the test, and then start the engine with park gear applies.
• Refer to specifications required by various vehicle types to adjust system pressure.

1- Fuel-return connector; 2- Fuel-return hose from engine; 3-Fuel-inlet hose to engine.

Connecting

The hose line connection of the engine with return hose is shown as in Fig.09.

• Disconnect the connections of fuel supply hoses (C. D) and fuel return hoses (A. B) of the engine fuel system (wrap the connector with towel when disconnecting the connector). Choose proper connectors and connect them to the B end and C end separately, and then connect the other ends to corresponding return hose and outlet hose of the unit. See Fig.09.
• Connect the disconnected other ends (A. D) with proper hose, or remove the fuel pump fuse, or disconnect the power cable of 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- Auto fuel pump; 9-Auto tank.

Without return hose connecting:

The hose line connection of the engine without return hose is shown as in Fig.10.

• Disconnect the fuel supply hoses (E, F) of engine fuel system (wrap the connector when disconnecting the connector), and then choose a proper connector and connect it to the E end. Reconnect the fuel outlet hose of the unit well and make the fuel return hose hanging. See Fig.10.
• Stop the other end of the disconnected end (F) with a proper stopper, (use when the fuel pump has the fuel return function only) or remove the fuse of fuel pump or disconnect the power cable of fuel pump.

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

Note:

1. When cleaning, care must be taken as the detergent is inflammable. Prepare for a fire extinguisher.
2. Be sure that all hose lines are well connected and there is no leakage on the hose lines before performing cleaning.

Appendix 1: Pressure Gauge of Injection System

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