ANCEL AJ400 User manual

AJ400 GDI
Injector Cleaner & Tester
ANCEL
AJ400 GDI Injector Cleaner & Tester

AJ400 GDI
Injector Cleaner & Tester
ANCEL
General Notice & Disclaimer
All rights reserved! Any company or individual person shall not copy or ackup 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 y our company, which shall not assume any responsi ility 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 assumes no responsi ility for device damages or pro lems resulted from the usage of other parts or consuma les,
rather than original products of us or products approved y the company.
Important Safety Instructions
• Please read this manual carefully efore using the equipment.
• Be careful when touching high temperature parts of the equipment or engine.
• Please do NOT touch hot parts or rotating fan lades.
• If use a low-quality power cord, it may cause overheating.
• The device should e cooled completely efore storage and the line should e wound up.
• The cleaning agent for the device is a flamma le and weakly volatile liquid. Smoking and lighting fires are strictly
prohi ited during the cleaning process.
• The instrument should e placed in a room that is not exposed to direct sunlight and is well ventilated, and signs
“Smoking and lighting fires strictly for idden” and “Danger warning of inflamma les” should e posted.
• The operator’s hair, clothes, fingers and other parts of the ody should e 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 descri ed in the manual. Use accessories recommended y the manufacturer.
• It is strictly for idden to open the ultrasonic system under the circumstances that ultrasonic cleaning agent has not
een added into the ultrasonic cleaning pool. Otherwise, the ultrasonic equipment may e damaged easily.
• The housing of the device must e relia le and grounded.
• Automo ile exhaust contains a variety of toxic and harmful gases (such as car on monoxide, hydrocar on, nitrogen
oxide and etc.). During the test, the exhaust should e directed outdoors and the room should e well ventilated.
• The temperature of the exhaust pipe and water tank of the automo ile’s engine is high. Do not touch them to
prevent urns.
• Please pull up the hand rake of the vehicle to e cleaned, shift the transmission to neutral position and lock the
front wheel efore free disassem ly 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 y
fuel gushing out and causing fires.
• Test solution is used y the main unit of the device uses, and 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 operating.

AJ400 GDI
Injector Cleaner & Tester
ANCEL
Content
I. INT ODUCTION TO INJECTO CLEANE & TESTE .................................................................................................. 1
1.1 B RIEF I NTRODUCTION ............................................................................................................................................................ 1
1.2 F UNCTIONS AND F EATURES ................................................................................................................................................... 1
1.3 W ORKING CONDITIONS & S PECIFICATIONS ............................................................................................................................ 2
II. ST UCTU E OF INJECTO CLEANE & TESTE ........................................................................................................ 3
2.1 O VERVIEW ............................................................................................................................................................................. 3
2.2 C ONTROL P ANEL .................................................................................................................................................................... 3
III. INSTALLATION ................................................................................................................................................................... 4
3.1 I NSTALLATION OF GDI AND TOP - SUPPLY INJECTORS (EFI/MPI/SFI) .................................................................................... 4
3.2 I NSTALLATION OF SIDE - SUPPLY INJECTORS ............................................................................................................................ 5
IV. OPE ATING P OCEDU ES .............................................................................................................................................. 5
4.1 P REPARATION ........................................................................................................................................................................ 5
4.2 C LEANING & TESTING SEQUENCES ......................................................................................................................................... 5
4.3 P ROCEDURE AFTER WORK OPERATION ................................................................................................................................... 5
V. OPE ATION ........................................................................................................................................................................... 6
5.1 R ESISTANCE T EST .................................................................................................................................................................. 6
5.2 U LTRASONIC C LEANING ........................................................................................................................................................ 6
5.3 U NIFORMITY /S PRAYABILITY T EST ......................................................................................................................................... 6
5.4 L EAKAGE T EST ...................................................................................................................................................................... 7
5.5 I NJECTING F LOW T EST ........................................................................................................................................................... 8
5.6 W ORKING MODES TEST .......................................................................................................................................................... 8
5.7 O N -V EHICLE C LEANING ........................................................................................................................................................ 8
VI. T ANSPO TING AND STO ING ...................................................................................................................................... 9
6.1 T RANSPORTING ...................................................................................................................................................................... 9
6.2 S TORING .............................................................................................................................................................................. 10
6.3 I NSTALLATION E NVIRONMENT ............................................................................................................................................. 10
VII. T OUBLESHOOTING & P ECAUTIONS ..................................................................................................................... 10
7.1 T ROUBLESHOOTING ............................................................................................................................................................. 10
7.2 P RECAUTIONS ...................................................................................................................................................................... 10

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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 of changing product design and
specifications, the actual configuration according to the packing list.
I. Introduction to Injector Cleaner & Tester
Welcome to use Injector Cleaner & Tester equipment. It is a mechatronic product that com ines ultrasonic cleaning
technology with microprocessor fuel pressure control cleaning and testing technology.
1.1 Brief Introduction
The User Manual is applica le to the serial Injector Cleaner & Tester equipment.
1.2 Functions and Features
Main functions
 Ultrasonic cleaning:
To clean injectors to remove the car on deposition on them completely.
 esistance test
To test the resistance of 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 acklight.
 Leakage test:
To test the sealing and dri ling 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 disassem ly-free cleaning connectors, the device can e used to perform on-vehicle
cleaning and maintenance for various vehicle models.
 Low resistance injectors test function
Through the dedicated mother oard, it supports the full and long test of low resistant fuel injector such as 1
ohm.
 Multi items Setting:
Set different parameters of the device, including the uzzer sound level, display rightness, and acklight
rightness.
 Version information:
to check the software version information of the current device.
Main Features
 The special structure design makes the disassem ly and assem ly of the fuel separator easier and greatly
improves the work efficiency.
 With the resistance test of the injectors one y one, get to know the condition of the injectors
 The ultrasonic cleaner is integrated on the machine, which makes the operation easier and more efficient.
 With the dedicated mother oard, it can support the full and long test of low resistant fuel injector such as
1 ohm.
 The unique fuel circuit depressurization technology can make the machine automatically depressurize in the
case of sudden shutdown, avoiding equipment damage or personal injury.
 The rightness of the screen and acklight, and the level of the uzzer can e manually set and saved.
 The product adopts fuel pressure adjustment and control technology y microcomputer, which can ensure sta le
fuel pressure and wide adjusta le range. It is applica le to vehicles equipped with a variety of gasoline injection
systems. Meanwhile, the automation of injectors’ cleaning and testing processes can e realized.
 Thanks to the adoption of microcomputer automatic control and digital display technologies, the cleaning and
testing processes can e controlled automatically, and the parameters of the main status can e monitored in
real time.
 Adopting humanization design can make the system pressure fast restored to the default values.

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1.3 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: 0.1 Ω
 Simulated RPM range:100～9900rpm, step:10rpm
 Time range: 5～300s, step:5s
 Pulse width: 0.1～25ms,step: 0.1ms
 Fuel tank capacity: 2000ml
 Work pressure: 0-7 ar

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II. Structure of Injector Cleaner & Tester
2.1 Overview
1-Pulse line; 2-Fuel separator assem ly; 3-O servation window tu e; 4-Control panel; 5- Fuel pressure gauge;
6-Fuel outlet pipe; 7- Ultrasonic cleaner ; 8- Ultrasonic cleaner switch; 9- Liquid level indicator tu e (test liquid
drain tu e) ; 10-Cleaning liquid drain port; 11- Test liquid addition port; 12-Fuel tank; 13-Power switch
• Attention: there may be slight difference between the illustrations in this manual and the actual product. Subject
to actual product.
2.2 Control Panel
Key Function Description [en, es, ru, pt]
GDI injector test mode
F->1
Ultrasonic cleaning
F->2
Uniformity & Spray a ility test
-
>1
RPM
10
9
1
2
8
1
1
3
7
4
5
1
2
6
13

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-
>2
Pulse width
-
>3
Time
-
>4
No. / Mode
F->3
Leakage test
F->4
Injecting flow test
F->5
Working m
ode
s
test
-
>1
Mode 1 (Acceleration test)
-
>2
Mode 2 (Deceleration test)
-
>3
Mode 3 (Acceleration+ Deceleration test)
F->6
On
-
Vehicle cleaning
Fuel pressure + / -
Resistance test
Backlight on / off
Setting
p. 0-8: Buzzer sound level
dl. 1-7: Display rightness
l. 0-15: Backlight rightness
sa.0/1: 0-Not save as default. 1- Save as default
Run / Stop
III. Installation
3.1 Installation of GDI and top-supply injectors(EFI/MPI/SFI)
1) Choose the adapters according to the fuel top-supply injector from the coupler ox and mount a proper O-ring
on it. Remem er to apply a little lu ricating fuel on the O-ring.
2) The adapters for fuel top-supply injector are 4 types:
Thread sealing type: here are with coarse thread and fine thread.
O-ring sealing type: here are with ig hole and small hole.
3) If the injectors cannot e fixed ecause of the hole eing igger than the injector, need to sue the auxiliary support.
4) Need to adjust the relative position etween the Knurled nut and adjusta le screw so that the injectors can e fixed well
on the unit.
(Installation of EFI/MPI/SFI/GDI injectors)

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3.2 Installation of side-supply injectors
1) Choose proper couplers for side-supply injectors and proper O-rings, and mount them together.
2) Before fixing, est to apply a little lu ricating fuel on the O-ring.
3) If some cylinder is not used, need to install the plug.
(Installation of side-supply injectors)
IV. Operating Procedures
4.1 Preparation
1) Remove the injector from the motorcycle engine to check the o-rings inside for damage. If it is e damaged
need to replace it. Put the outside of injector in gasoline or detergent, and wipe them with soft cloth after
cleaning the outside fuel sludge carefully.
2) Check the test liquid level to e sure there are enough test liquid inside tank. Pouring 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, filled the liquid
up to 1/2 of the tank capacity.
3) Turn on the power switch on the right of the Ca inet.
4) Pour ultrasonic detergent into the ultrasonic cleaning asin so that the needle valve of the injector is covered y
the detergent.
5) Connect the injectors with the right couplers.
• The main unit of the de ice uses test solution for uniformity / sprayability 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.
4.2 Cleaning & testing sequences
Recommended to carry out the complete cleaning and testing procedures as the following order.
 Ultrasonic cleaning;
 Uniformity / Spraya ility test;
 Leakage test;
 Injecting flow test;
 Working modes test.
4.3 Procedure after work operation
1) Drain test solution to a fuel container.
2) Switch off the power switch and unplug the power plug.
3) Use a fuel header to suck all cleaning agent in the ultrasonic cleaning pool, and wipe the pool with a soft dry
cloth.
4) Wipe the ta le top of the machine with a soft dry cloth.
5) To avoid volatilization, all the test solution in the fuel tank should e discharged. If it can e used again, store it
in a safe place. If it is dirty and cannot e used any more, dispose it according to relevant regulations.

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V. Operation
Important reminder: Before any operation, choose the correct injector type for proper operating. Press the GDI key
with the indicator light ON for GDI injectors. For general top-feed or side-feed injectors, no need to press this
key.
5.1 esistance 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 e 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.
5.2 Ultrasonic Cleaning
Injector Cleaner takes advantage of the penetra ility and cavitation impact wave caused y ultrasonic wave traveling
through the medium to provide powerful cleaning on o jects with complex shapes, cavities and pores, so that the
stu orn car on deposits can e 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 ultrasonic cleaner so that the liquid level is a out 20mm a ove the needle
valve of injectors / whole pump.
3) Plug the pulse signal wire to injector / pump respectively.
4) Select ultrasonic cleaning function and then set the time.
5) Press RUN 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 eeper rings.
8) Turn off the ultrasonic cleaning switch on the left side of the machine after cleaning procedure.
9) Take the injector / pump out of the launder and wipe them with a dry soft cloth. Get ready for next operation.
Note:
1) It is strictly for idden to open the ultrasonic system under the circumstances that cleaning agent has not een added
into the ultrasonic cleaning pool. Otherwise, the ultrasonic equipment may e damaged easily.
2) It is strictly prohi ited to immerse the pulse signal line connector along with the injector into the ultrasonic pool
for cleaning. Otherwise, the pulse signal line connector can e damaged easily.
3) ATTENTION: Make sure to turn off the ultrasonic cleaning switch on the left side of the machine after cleaning
procedure.
5.3 Uniformity/Sprayability Test
Uniformity test is to find out the difference of the injectors injecting at the same working condition. This test can
indicate the comprehensive influences on the injector caused y electrical nature, ore variation and clogging. Spray
a ility test is to inspect the spraying performance y o serving 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 forward direction (Apply a little lu ricating grease on the O-ring.)
3) Install the fuel separator with injector onto the plate of the test tu e.
4) Connect the injector pulse signal wire.
5) Before doing this test, drain the test liquid from the measuring cup if there is any.
6) Select Uniformity/Spraya ility test function, set corresponding parameters (consult the appendix for pressure
setting, consult vehicle manuals for other parameters as needed), and then press RUN key to start the test.
7) When the test is completed, the equipment will auto stop with the ring of the uzzer.
Note:
1) The system pressure can e adjusted y pressing + or – at testing.

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2) During operating, 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 ut no jet. Otherwise, replace the injector.
4) In the spraya ility test, a special electrical parameter--the minimum injection pulse width of injector--can e 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 (o served with the help
of acklight). The value set at this moment is the minimum injection pulse width, so the difference of minimum
injection pulse width among these injectors could e o served.
Backflushing
Backflushing is limited to the top-supply injector y connecting the ackflushing connector under uniformity /
spraya ility test. Test solution enters from the outlet of the injector and flows out from the inlet during ackflushing.
Backflushing can wash away the dirt inside the injector and dirt attached to the filter.
1）Find the ackflushing connector (and select a supporting “O” ring to install it on the connector) installed elow
the fuel separator;
2）Install the top-supply injector in reverse direction (outlet up, inlet down);
3）Select the corresponding coupling element under the injector according to the shape of injector;
4）Adjust the screws to fix the fuel separator and injector assem ly in the fuel filler hole of the upper cover according
to the height of injector and tighten the compression screws ( lack) on oth sides evenly;
5）It is recommended to drain the remaining fuel in the transparent tu e to avoid overflow of test solution efore
ackflushing.
6）Connect the pulse signal line of the injector properly; set the operating parameters and press Run key to execute
ackflushing function; the system pressure can e adjusted y + and – keys on the control panel during ackflushing.
7）The system will stop automatically after completion of the cleaning.
(Installation for ackflushing)
5.4 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 dri ling
Procedures
Installation refer to Uniformity/ Spraya ility Test.
1) Before doing leakage test, please drain the rudimental residual test liquid from the measuring cup.
2) Select Leakage Test function and press un key to start.
At this time the system pressure can e adjusted y pressing + and – key to o serve dri ling from the injector
the pressure is adjusted prefera ly 10% higher than manufacturer’s specifications.
3) When the test is over, the equipment will automatically stop and the uzzer will ring simultaneously.
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.

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5.5 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:
Installation refer to Uniformity/ Spraya ility Test.
1) Before this test, drain the test liquid from the measuring cup if there is any.
2) Choose Injecting Flow Test function and press un key to start the test.
Adjust the fuel pressure y pressing + or – key according to the injector specification.
3) When the test is over, the equipment will stop automatically at the ring of the uzzer.
5.6 Working modes test
Working modes test contains three working status simulation tests(Acceleration, Deceleration, Acceleration+
Deceleration test)). This function can test more comprehensive performance of injectors y simulating the various
engine working conditions.
Procedures:
Installation refer to Uniformity/ Spraya ility Test.
1) Before the test, drain all the test liquid in the measuring cups if there is any.
2) Select Modes function and choose the mode needed , then press Run key to start the test.
3) Adjust the fuel pressure y pressing + or – keys.
4) When the test is over, the equipment will auto stop at the ring of the uzzer.
5.7 On-Vehicle Cleaning
After the motorcycle engine has een in operation for a period of time, its fuel flow may e locked or ecome un-
smooth owing to uildup of dust and impurities in fuel channel. In addition, the car on deposits and gum made y
com ustion can easily adhere to the injectors, inlet and outlet ports, inlet and outlet hoses, throttle and com ustion
cham er. So the fuel supply system, com ustion cham er and injector of the engine must e cleaned on a timely asis.
Com ustion Cham er cleaning is a solution that can save your time and la or.
Procedures:
1) Please check if there is test liquid or detergent inside the fuel tank efore on-vehicle cleaning. If 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 een shown in “Connecting” elow.
4) Select On-Vehicle Cleaning function and set the cleaning time.
5) Press un key to start the function, adjust the fuel pressure y pressing + or – keys.
6) Start the engine to egin cleaning.
Connecting
There are two cases for the line connection: one is the connection with 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 corresponding return hose and outlet hose of the device.
2) Connect the two other disconnected ends (A, D) with a proper hose, or remove the fuel pump fuse, or disconnect
the power ca le of engine fuel pump.

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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 suita le 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)
or remove the fuse of fuel pump or disconnect the power ca le of 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 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 “Leakage test” item and press RUN key to run the device for a out 2∼3
minutes. After the running has stopped, drain the test solution from fuel tank and dispose 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 effecti e fire extinguisher.
Be sure that all lines are well connected and there is no leakage before performing cleaning.
VI. Transporting and Storing
6.1 Transporting

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1) Before eing packed, the liquid inside the fuel tank should e drained completely to avoid overflowing as
transporting.
2) Move only y hand or lift with soft elt.
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 ase seat and in the packing case during
transportation. Firstly pack the unit with the matter similar with plastic strip and add the filling material (such as
foam or sponge, etc.) etween the unit and packing case to avoid scratching the surface when the unit shakes.
5) Make sure that the maximum incline angel does not exceed 45℃. Do not place the unit up-side-down.
6.2 Storing
1) Store only in dry area and keep away from water efore the unit is unpacked.
2) Store the machine in well-ventilated area and do not expose it to direct sun shine or rain.
6.3 Installation Environment
1) Keep a distance of no less than 200mm etween the unit and any wall or other su stance. The unit should e put
in well-ventilated area. Make sure the temperature is within -10℃+40℃.
2) The unit has een well grounded for safety operation. Please confirm that the power socket is also well
grounded.
VII. Troubleshooting & Precautions
7.1 Troubleshooting
1) The unit does not correspond when it is switched on.
2) Check the fuse at lower right side of the unit and replace it if it is damaged or roken.
3) There is leakage in the fuel separator coupler.
4) Fuel leaked at coupling element of fuel separator. Please check whether the “O” ring installed matches and if it deformed or
damaged. If it does not match or is damaged, please change it. The two lack adjusting screws should not e too tight, which
may also cause the coupling element of fuel separator to leak fuel.
5) The used machine has not een used for a long time a out several months, and it is found that the pump cannot work normally.
6) The type of test liquid used is not suita le, 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.
7.2 Precautions
1) In order 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 een connected to ground well.
3) Do not operate equipment with a damaged cord or if the equipment has een dropped or damaged until it has een examined
y qualified service personnel.
4) Equipment use is strictly prohi ited fireworks, and posted “No smoking” and “Flamma le hazard warning” signs.
5) Please operate the unit according to the operation procedures in the manual. Only use the accessories recommended y the
manufacturer.
6) ALWAYS WEAR SAFETY GOGGLES. Common used glasses are NOT safety glasses.