ANCEL AJ600 GDI Piezo User manual

AJ600 GDI Piezo Injector Cleaner & Tester
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AJ600 GDI Piezo Injector Cleaner & Tester

AJ600 GDI Piezo Injector Cleaner & Tester
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General Notice & Disclaimer
All rights reserved! Any com any or individual erson shall not co y or backu this user manual in any format
(electronic, mechanical, hotoco ying, recording or other formats) without written ermission from us. The manual is
for the use of the roducts manufactured by our com any, which shall not assume any res onsibility for the
consequences arising from the use of it to guide the o erations of other equi ment.
The device is intended for the use of rofessional technicians or maintenance and re air ersonnel.
We assumes no res onsibility for device damages or roblems resulted from the usage of other arts or consumables,
rather than original roducts of us or roducts a roved by the com any.
Important Safety Instructions
• Please read this manual carefully before using the equi ment.
• Be careful when touching high tem erature arts of the equi ment or engine.
• Please do NOT touch hot arts or rotating fan blades.
• If use a low-quality ower cord, it may cause overheating.
• The device should be cooled com letely before storage and the line should be wound u .
• The cleaning agent for the device is a flammable and weakly volatile liquid. Smoking and lighting fires are strictly
rohibited during the cleaning rocess.
• The instrument should be laced in a room that is not ex osed to direct sunlight and is well ventilated, and signs
“Smoking and lighting fires strictly forbidden” and “Danger warning of inflammables” should be osted.
• The o erator’s hair, clothes, fingers and other arts of the body should be ke t away from the o erating arts of
the equi ment.
• To revent electric shocks, do you touch the o erating equi ment in wet areas or o erate it in the rain.
• Please o erate the device as described in the manual. Use accessories recommended by the manufacturer.
• It is strictly forbidden to o en the ultrasonic system under the circumstances that ultrasonic cleaning agent has not
been added into the ultrasonic cleaning ool. Otherwise, the ultrasonic equi ment 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 and etc.). During the test, the exhaust should be directed outdoors and the room should be well ventilated.
• The tem erature of the exhaust i e and water tank of the automobile’s engine is high. Do not touch them to
revent burns.
• Please ull u the handbrake of the vehicle to be cleaned, shift the transmission to neutral osition and block the
front wheel before free disassembly cleaning.
• Wear safety glasses when o erating. Daily wear glasses are not safety glasses.
• When disconnecting a ressurized fuel i e union, lease cover the union with a towel to avoid getting hurt by
fuel gushing out and causing fires.
• Test solution is used by 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.

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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 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 A UTO . T EST ........................................................................................................................................................................... 8
5.7 O N -V EHICLE C LEANING ........................................................................................................................................................ 8
VI. T ANSPO TING AND STO ING .................................................................................................................................... 10
6.1 T RANSPORTING .................................................................................................................................................................... 10
6.2 S TORING .............................................................................................................................................................................. 10
6.3 I NSTALLATION E NVIRONMENT ............................................................................................................................................. 10
VII. T OUBLESHOOTING & P ECAUTIONS ..................................................................................................................... 11
7.1 T ROUBLESHOOTING ............................................................................................................................................................. 11
7.2 P RECAUTIONS ...................................................................................................................................................................... 11

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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 equi ment. It is a mechatronic roduct that combines ultrasonic cleaning
technology with micro rocessor fuel ressure control cleaning and testing technology.
1.1 Brief Introduction
The User Manual is a licable to the serial Injector Cleaner & Tester equi ment.
1.2 Functions and Features
Main functions
 Ultrasonic cleaning:
To clean injectors to remove the carbon de osition on them com letely.
 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 s raying status of each injector
with the hel of backlight.
 Leakage test:
To test the sealing and dribbling conditions of injectors under system ressure.
 Injecting flow test:
To check the injecting amount of the injector in 15 seconds of constant injection.
 Auto. test:
To test injectors by reset rogram conditions.
 On-Vehicle Cleaning:
Coming with a variety of disassembly-free cleaning connectors, the device can be used to erform on-vehicle
cleaning and maintenance for various vehicle models.
 Low resistance injectors test function
Through the dedicated motherboard, it su orts the full and long test of low resistant fuel injector such as 1
ohm.
 Multi items Setting:
Set different arameters of the device, including the buzzer sound level, dis lay brightness, and backlight
brightness.
 Version information:
to check the software version information of the current device.
Main Features
 This device supports the cleaning and testing of Piezo injectors, GDI injectors and traditional
injectors.
 The s ecial structure design makes the disassembly and assembly of the fuel se arator easier and greatly
im roves the work efficiency.
 With the resistance test of the injectors one by one, get to know the condition of the injectors
 With the dedicated motherboard, it can su ort the full and long test of low resistant fuel injector such as
1 ohm.
 The unique fuel circuit de ressurization technology can make the machine automatically de ressurize in the
case of sudden shutdown, avoiding equi ment damage or ersonal injury.
 The back door of the cabinet o ens or closes with one touch.
 The brightness of the screen and backlight, and the level of the buzzer can be manually set and saved.
 The machine has a strong ultrasonic cleaning ability, which can remove carbon de osits and im urities on the
fuel injection nozzle to the greatest extent.
 The roduct ado ts fuel ressure adjustment and control technology by microcom uter, which can ensure stable
fuel ressure and wide adjustable range. It is a licable to vehicles equi ed with a variety of gasoline injection
systems. Meanwhile, the automation of injectors’ cleaning and testing rocesses can be realized.
 Thanks to the ado tion of microcom uter automatic control and digital dis lay technologies, the cleaning and

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testing rocesses can be controlled automatically and the arameters of the main status can be monitored in real
time.
 Automatic fuel drain during a certain test can be realized via a routine, owing to the ado tion of automatic fuel
drain control technology. Start or [Sto ] fuel drainage via the [Drain] button on the control anel in running or
sto state..
 Ado ting humanization design can make the system ressure fast restored to the default values.
1.3 Working conditions & Specifications
Working conditions:
 Tem erature: -10~+40℃ Relative humidity: ＜85%
 Intensity of outer magnetic field: ＜400A/m
 No naked flame within 2m.
Specifications:
 Main unit ower su ly: AC220V±10% 50Hz/60Hz or AC110V±10% 60Hz
 In ut ower: 230W
 Ultrasonic cleaner ower: 100W
 Resistance test accuracy: 0.1 Ω
 Simulated RPM range:100～9900r m, ste :10r m
 Time range: 5～300s, ste :5s
 Pulse width: 0.1～25ms,ste : 0.1ms
 Fuel tank ca acity: 2000 ml
 Work ressure: 0-7bar

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II. Structure of Injector Cleaner & Tester
2.1 Overview
1-Pulse line; 2-Fuel se arator assembly; 3-Observation window tube; 4-Control anel; 5- Fuel ressure gauge;
6-Fuel outlet hose; 7- Ultrasonic cleaner ;8-Test liquid addition ort; 9-Fuel tank
• 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]
F->1
Ultrasonic cleaning
F->2
Uniformity & S ray ability test
-
>1
RPM
-
>2
Pulse width
-
>3
Time
2
1
3
7
8
9
6
5
4

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-
>4
No. / Mode
F->3
Leakage test
F->4
Injecting flow test
F->5
Automatic test
-
>1
Mode 1 (Acceleration test)
-
>2
Mode 2 (Deceleration test)
-
>3
Mode 3 (Acceleration+ Deceleration test)
F->6
On
-
Vehicle cleaning
Fuel ressure + / -
[12V]: Conventional injector.
[GDI]: GDI injector.
[Piezo]: Piezo injector.
[
]
: Resistance test
Backlight on / off
Drain test solution
Setting
b . 0-8: Buzzer sound level
dl. 1-7: Dis lay brightness
bl. 0-15: Backlight brightness
sa.0/1: 0-Not save as default. 1- Save as default
Run / Sto
III. Installation
3.1 Installation of top-supply injectors (EFI/MPI/SFI)
1) Choose the ada ters according to the fuel to -su ly injector from the cou ler box and mount a ro er O-ring on
it. Remember to a ly a little lubricating fuel on the O-ring.
2) The ada ters for fuel to -su ly injector are 4 ty es:
Thread sealing ty e: here are with coarse thread and fine thread.
O-ring sealing ty e: here are with big hole and small hole.
3) If the injectors cannot be fixed because of the hole being bigger than the injector, need to sue the auxiliary su ort.
4) Need to adjust the relative osition between the Knurled nut and adjustable screw so that the injectors can be fixed well
on the unit.
(Installation of EFI/MPI/SFI/GDI/PIEZO injectors)

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3.2 Installation of side-supply injectors
1) Choose ro er cou lers for side-su ly injectors and ro er O-rings, and mount them together.
2) Before fixing, best to a ly a little lubricating fuel on the O-ring.
3) If some cylinder is not used, need to install the lug.
(Installation of side-su ly 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 be damaged
need to re lace it. Put the outside of injector in gasoline or detergent, and wi e them with soft cloth after
cleaning the outside fuel sludge carefully.
2) Check the test liquid level to be sure there are enough test liquid inside tank. Pouring test liquid from the ort
at the to left side of the unit and watch the liquid level in the fuel level viewer. In most cases, filled the liquid
u to 1/2 of the tank ca acity.
3) Turn on the ower 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 cou lers.
• 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 com lete cleaning and testing rocedures as the following order.
 Ultrasonic cleaning;
 Uniformity / S rayability test;
 Leakage test;
 Injecting flow test;
 Auto. test.
4.3 Procedure after work operation
1) Press [Drain] button on the control anel to drain test solution to a fuel container.
2) Switch off the ower switch and un lug the ower lug.
3) Use an fuel header to suck all cleaning agent in the ultrasonic cleaning ool, shown in Figure 4.2, and wi e the
ool with a soft dry cloth.

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4) Wi e the table to of the machine with a soft dry cloth.
5) To avoid volatilization, all the test solution in the fuel tank should be discharged. If it can be used again, store it
in a safe lace. If it is dirty and cannot be used any more, dis ose it according to relevant regulations.
V. Operation
Important reminder: Before the test o eration, Press the key to choose the correct injector ty e for ro er
o erating. When test the Piezo injector, MAKE SURE TO USE THE “Piezo Cable” FOR TESTING. There will
be an E1 error on the screen for wrong cable, and an E2 error when connect non-Piezo injectors on Piezo test mode.
Safety reminder: During the testing or cleaning rocess of the iezoelectric fuel injector, IT IS FORBIDDEN TO
DIRECTLY PLUG AND UNPLUG THE PULSE SIGNAL LINE WITHOUT STOPPING THE OPERATION. Be
sure to sto running first！
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 ress the key until the light of the key is ON. Press t he RUN key and the
resistance value will be dis layed on the screen.
3) If needed, measure several times to confirm the measured value.
4) After the measurement is com leted, remove the fuel injector and the resistance measurement line.
5.2 Ultrasonic Cleaning
Injector Cleaner takes advantage of the enetrability and cavitation im act wave caused by ultrasonic wave traveling
through the medium to rovide owerful cleaning on objects with com lex sha es, cavities and ores, so that the
stubborn carbon de osits can be removed from the injectors.
Procedures
1) Place the injector/ um which has gone through surface cleaning in the launder.
2) Add enough injector detergent into ultrasonic cleaner so that the liquid level is about 20mm above the needle valve
of injectors / whole um .
3) Plug the ulse signal wire to injector / um res ectively.
4) Select ultrasonic cleaning function and then set the time.
5) Press RUN key to start the rocedure.
6) When the time is u , it will sto automatically as the bee er rings.
7) Take the injector / um out of the launder and wi e them with a dry soft cloth. Get ready for next o eration.
Note:
1) It is strictly forbidden to o en the ultrasonic system under the circumstances that cleaning agent has not been added
into the ultrasonic cleaning ool. Otherwise, the ultrasonic equi ment may be damaged easily.
2) It is strictly rohibited to immerse the ulse signal line connector along with the injector into the ultrasonic ool
for cleaning. Otherwise, the ulse signal line connector can be damaged easily.
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 com rehensive influences on the injector caused by electrical nature, bore variation and clogging. S ray
ability test is to ins ect the s raying erformance by observing the injectors.
Installing and testing procedures for injectors
1) Choose a ro er ada tor according to the injector ty e and mount it to the fuel se arator.
2) Install the injectors in forward direction (A ly a little lubricating grease on the O-ring.)
3) Install the fuel se arator with injector onto the late of the test tube.
4) Connect the injector ulse signal wire.
5) Before doing this test, ress DRAIN icon to drain the test liquid from the measuring cu if there is any.

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6) Select Uniformity/S rayability test function, set corres onding arameters (consult the a endix for ressure
setting, consult vehicle manuals for other arameters as needed), and then ress RUN key to start the test.
7) When the test is com leted, the equi ment will auto sto with the ring of the buzzer.
Note:
1) While testing, it can drain fuel by ressing DRAIN icon. At default, solenoid valve is set at the closed state.
Uniformity test can be done at this state. When DRAIN icon is ressed, solenoid valve will drain fuel.
2) The system ressure can be adjusted by ressing + or – at testing.
3) During o erating, the user can select arameter, such as RPM or PW, and then ress or key to achieve the
status of the simulation.
4) Good injectors may have identical injecting angle, uniform s raying but no jet. Otherwise, re lace the injector.
5) In the s rayability test, a s ecial electrical arameter--the minimum injection ulse width of injector--can be
tested, to com are the injectors on the same engine. That is to set cylinder No., start the test from minimum
injection ulse width, and then gradually increases the ulse width till the injector starts injection (observed with
the hel of backlight). The value set at this moment is the minimum injection ulse width, so the difference of
minimum injection ulse width among these injectors could be observed.
Backflushing
Backflushing is limited to the to -su ly injector by connecting the backflushing connector under uniformity /
s rayability 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 su orting “O” ring to install it on the connector) installed below
the fuel se arator;
2) Install the to -su ly injector in reverse direction (outlet u , inlet down);
3) Select the corres onding cou ling element under the injector according to the sha e of injector;
4) Adjust the screws to fix the fuel se arator and injector assembly in the fuel filler hole of the u er cover according
to the height of injector and tighten the com ression screws (black) on both sides evenly;
5) It is recommended to ress [Drain] button to drain the remaining fuel in the trans arent tube to avoid overflow
of test solution before backflushing.
6) Connect the ulse signal line of the injector ro erly; set the o erating arameters and ress Run button to
execute backflushing function; the system ressure can be adjusted by + and – buttons on the control anel
during backflushing.
7) The system will sto automatically after com letion of the cleaning.
(Installation for backflushing)
5.4 Leakage Test
Leakage test is to ins ect the sealing conditions of the injector needle valve under system ressure and to find out if
the injector is dribbling