Carbon Zapp CRU.4R User manual

Operation Manual
For CRU, GDU, DS, GD, UIP, HUI, TBCR, DCD, ECMR Units “R” version
v201902

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Contact Information
Carbon Zapp
364 Varis –Koropiou Ave
Athens –Koropi / 19400
GREECE
Support / Sales Telephone: [phone]
Support email: [e-mail]
TeamViewer email: [e-mail]
Sales email: [e-mail]
URL: www.CarbonZapp.com

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Warranty
2 –Year Limited Warranty
Carbon Zapp company manufactures its equipment from new parts and components
that are in accordance with industry standard practices. Carbon Zapp warrants that the
equipment it manufactures will be free of defects in materials and workmanship.
The warranty terms are 2 years, beginning on the date of the Carbon Zapp invoice in
accordance with the following described:
This warranty does not cover damage due to external causes, including accident, abuse,
misuse, scratches on external components or surfaces, problems with electrical power
supply, servicing not authorized by Carbon Zapp, usage not in accordance with
machine’s operating manual, failure to perform required preventative maintenance,
failure to change the calibration oil and other ultrasonic cleaning or testing fluids
regularly, failure to change the main testing and flushing fluid (were applicable) filter
when needed, to permit machines fluid pump to sit or operate without fluid in it, usage
of improper testing or cleaning fluid in the machine, usage of improper ultrasonic
cleaning fluid in the ultrasonic bath, usage of ultrasonic fluid instead of testing fluid or
the opposite, usage of cleaning solvents and chemicals not provided or
indicated/approved by Carbon Zapp, use of parts and components not supplied or
approved by Carbon Zapp.
Note: Failure to clean injectors with Carbon Zapp’s ultrasonic device before any test is
performed on the test bench will void the warranty of the machine, if dirt particles from
the injectors or components tested enter the machine and valves.
Assure all inline screen filters and HD inline filters are mounted and replaced periodically
according to machine indications otherwise warranty is voided.
Carbon Zapp will repair or replace parts and components returned to manufacturer’s
facility. To request warranty service, contact Carbon Zapp within the warranty period. If
warranty service is required, you must ship the defective part or component in their
original or equivalent packaging, prepay shipping charges, and insure, or accept the risk
of loss or damage during shipment. Carbon Zapp will return the repaired or replacement
part or component freight prepaid. If Carbon Zapp repairs or replaces a part or
component, its warranty term is Not Extended.
Carbon Zapp does not accept liability beyond the remedies set forth in this warranty
statement or liability for incidental or consequential damages.
Machine serial number: _____________________________________
Signed by: Technical Department:_____________________________
Date: _____/_____/_________

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Contents
Contact Information ..........................................................................................................................2
Warranty...............................................................................................................................................3
General Information ..........................................................................................................................7
Warning and Safety symbols .......................................................................................................7
Definition of Terms and Abbreviations .....................................................................................7
Product Description .....................................................................................................................12
CRU.4R.........................................................................................................................................12
CRU.2R.........................................................................................................................................13
GDU.4R........................................................................................................................................14
GDU.2R........................................................................................................................................15
DS-R..............................................................................................................................................16
DSF-R ...........................................................................................................................................17
GD-R.............................................................................................................................................18
UIP-R............................................................................................................................................19
HUI-R ...........................................................................................................................................20
TBCR.............................................................................................................................................21
DCD ..............................................................................................................................................23
ECMR............................................................................................................................................24
Adapters..........................................................................................................................................25
Flush-Adapter ............................................................................................................................25
SPR ...............................................................................................................................................25
RSP ...............................................................................................................................................25
CRIN .............................................................................................................................................26
EUI................................................................................................................................................26
HEUI.............................................................................................................................................26
Commissioning .................................................................................................................................27
Installation .....................................................................................................................................27
Electrical Connections .................................................................................................................27

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Compressed Air Connections ....................................................................................................27
Attachment Unit Connections ...................................................................................................27
Filling the Tanks ............................................................................................................................29
Tank Level Sensors...................................................................................................................30
Degassing the system .............................................................................................................30
Filling the Spray Chamber ..........................................................................................................31
Switch On/Off the Control Panel / PC......................................................................................31
Software Setup..............................................................................................................................31
Language Selection..................................................................................................................31
Wi-Fi Setup .................................................................................................................................31
Printer setup..............................................................................................................................32
Personal Data / Accounts .......................................................................................................32
Connection to the PCB / DEMO Mode .................................................................................33
Software Orientation .......................................................................................................................34
HOME...............................................................................................................................................34
User Logins: ...............................................................................................................................35
SETTINGS ........................................................................................................................................36
INJECTOR/COMPONENT SELECTION .......................................................................................36
CUSTOMER DATA..........................................................................................................................37
COMPONENT DATA......................................................................................................................37
CFL 1/2/3.........................................................................................................................................38
ADJUST HP ..................................................................................................................................39
EUI................................................................................................................................................40
CRP ...............................................................................................................................................40
SELECT TESTS.................................................................................................................................41
MACC ...............................................................................................................................................42
TEST (###)......................................................................................................................................44
REPORTS .........................................................................................................................................46
REPORT VERSIONS....................................................................................................................47
SHARE ..........................................................................................................................................48
Save to USB ................................................................................................................................49
Operation ...........................................................................................................................................50
Before Testing ...............................................................................................................................50
Setting up the injector(s) / Pump .............................................................................................50

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Cleaning and Testing the Injector(s)........................................................................................50
Results and Reports .....................................................................................................................52
Maintenance......................................................................................................................................53
Regular Maintenance ..................................................................................................................53
Troubleshooting ...............................................................................................................................55
Technical Specifications ..................................................................................................................56

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General Information
Warning and Safety symbols
: CAUTION, High Pressures
: CAUTION, Hot Surface(s)
: Always wear protective gloves
: Always wear protective goggles
Definition of Terms and Abbreviations
Throughout the manual symbols or abbreviations are used to describe a test, a
function or something similar. Below is a list of the most commonly used:
: Symbol used for Testing Tank / Fluid / Fill Port / Drain Valve. Use only
specified fluid in Specifications area of this manual.
: Symbol used for MACC (Cleaning) Tank / Fluid / Fill Port / Drain Valve.
Use only specified fluid in Specifications area of this manual.
: Symbol used for Hydraulic Oil Tank / Fluid / Fill Port / Drain Valve. Use
only specified fluid in Specifications area of this manual. This tank is available
only in HUIr units.
: Injector Harness Connection. Use the provided harness(es) in the
adapters kit. Some units have additional cables to connect on the main harness,

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and provide adaptability to other, non-universal injector sockets. For multi slot
units, the making 1/2/3/4 is used to denote the slot #.
: Injector Sensor Connection. Use the provided harness(es) in the
adapters kit. Some units have additional cables to connect to other sensors like
BIP. For multi slot units, the making 1/2/3/4 is used to denote the slot #.
: Port for measuring the Discharge Volume of the Injector/Component.
For multi slot units, the making 1/2/3/4 is used to denote the slot #.
: Port for measuring the Return Volume of the Injector/Component. For
multi slot units, the making 1/2/3/4 is used to denote the slot #.
: For multi slot units, the making 1/2/3/4 is used to denote the slot #.
: The Common Rail output port(s). Connect appropriate HP Hoses,
approved by your Service Provider. Since it is a common rail, use HP Plugs to
plug the unused ports in a multi slot machine.
: The main are port for the machines. Always look in specifications
to adhere hose diameter, lengths and compressor power and capacity.
/: Attachment port/cable, used to connect a main unit to
the attachment unit.
: Mains Power Supply Plug.
: HUIr unit Hydraulic High Pressure Oil Port for connection to the
HEUI Adapter port.

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: HUIr unit Hydraulic Oil return port from the HEUI Adapter.
: Connect the Return Hose from the UI Adapter. Use
Position 1 or 2 depending on the injector type. Pos.1: Regulated Return (Most
commonly used), Pos.2: Free Return (VW PDE, CUMMINS, FORD
POWERSTROKE).
: Connect to the Feed port on the adapter of the UI injector. When 2
Ports on the adapter are horizontally aligned, the order is arbitrary, when the
ports are vertical, the Port marked with a DOT is the Feed Port.
: Use this indicator to adjust the CAM lift of the EUI
Injector Plunger.
: USB Port for connecting USB Stick/Drive, USB Printer, USB
Mouse/Keyboard.

Package version: Software version
APK version: Application version
ADB version: Database version
MDB version: Machine version

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AVR version: Firmware version
FPGA version: Hardware version
TeamViewer QS: A portal for internet support
: Back button, goes back one step
: Provides screen specific option
SLOT #: (On multi slot machines only) Activate/deactivate operation of specific
slot
MACC: Cleaning / Flushing Function
: Shows/Hides the the list of tests to be executed
R2LC: Electrical Test of component
aNOP: Automatic Nozzle Opening Pressure Test (RSP adapter needed)
RSP: Response test. Measure the Delay from injector actuation to injection (RSP
adapter needed)
BIP: Solenoid Delay test. Measures the Delay from injector actuation to solenoid
charge (BIP adapter needed)
iVM/DFi: Dynamic Volume Metering test. Measure Discharge and/or Return
Injection Volume
LKT: Static Volume Measuring of Return Volume.
mm3 VS mg: mm3 is Volume(V) and mg is Mass(m). Some machines have an
advanced measuring unit that measure mass. An approximation volume to
mass (as a dynamic, under HP pressure flow) would be “V=m/0.775”.
TP: Test Plan, a set of parameters for a specific test, comprising of Strokes,
Pulses, Pulse Width, Pressure etc.
STRK: Strokes per minute.
BRF is a backup and restore file, accessible inside the settings, to backup and
restore the Reports, UserDB and Personal info and Sensor Calibration Data, via
USB. Please note that this file is specific to each machine and it will not be
directly compatible when used in other units. All reports and DBs will be
completely replaced by the restored ones.

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CRG/BRG/DRG are Re-Generation Features for the Piezo stack for Conti, Bosch
and Denso Piezo injectors respectively. This feature will repair injector to
increase their injection volume.
CGL is Conti Gap Lift Feature that will diagnose the condition of the stack for
Conti injectors and provide information for its repair.

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Product Description
CRU.4R
Intended Use
This unit can automatically and fully Test up to 4 Common Rail Injectors
simultaneously. It has the capability to fit SPR and RSP adapters on Common Rail
injectors. In addition, it supports EUI (UIPR-A) and HEUI (HUIR-A) Attachment units,
that can perform testing of these Pump-Injectors 1-by-1 and also use RSP and BIP
adapters. This unit uses a Dynamic Mass Metering system and can do Coding on select
injectors.
Front View
Figure: CRU.4R
1. Diesel Injector (Not included)
2. Injector Harness Cables
3. Injector Clamp / Discharge Height Adjuster (iPSC mounted) with LED
4. Protective Hood
5. Control Panel / PC
6. USB Port
7. On/Off Switch for PC
8. Cushioned / Adjustable support pads
9. Air Vents
10. Carrying Handles
11. Test Oil level Indicator
12. Emergency Stop Switch
13. Test Oil Fill Port

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CRU.2R
Intended Use
This unit can automatically and fully Test and Clean up to 1 Common Rail Injector
simultaneously. It has the capability to fit SPR and RSP adapters on Common Rail
injectors. In addition, it supports EUI (UIPR-A) and HEUI (HUIR-A) Attachment units,
that can perform testing of these Pump-Injectors 1-by-1 and also use RSP and BIP
adapters. This unit uses a Dynamic Mass Metering system and can do Coding on select
injectors.
Front View
Figure: CRU.2R
1. Diesel Injector (Not included)
2. Injector Harness Cables
3. Injector Clamp / Discharge Height Adjuster (iPSC mounted) with LED
4. Protective Hood
5. Control Panel / PC
6. USB Port
7. On/Off Switch for PC
8. Cushioned / Adjustable support pads
9. Air Vents
10. Carrying Handles
11. MACC level Indicator
12. Test Oil level Indicator
13. Emergency Stop Switch
14. MACC Fill Port
15. Test Oil Fill Port

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GDU.4R
Intended Use
This unit can automatically and fully Test up to 4 HP Gasoline Direct Injectors
simultaneously. It has the capability to fit SPR and RSP adapters on Common Rail
injectors. This unit uses a Dynamic Mass Metering system.
Front View
Figure: GDU.4R
1. Gasoline Injector (Not included)
2. Injector Harness Cables
3. Injector Clamp / Discharge Height Adjuster (iPSC mounted) with LED
4. Protective Hood
5. Control Panel / PC
6. USB Port
7. On/Off Switch for PC
8. Cushioned / Adjustable support pads
9. Air Vents
10. Carrying Handles
11. Test Oil level Indicator
12. Emergency Stop Switch
13. Test Oil Fill Port

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GDU.2R
Intended Use
This unit can automatically and fully Test and Clean up to 1 HP Gasoline Direct Injector.
It has the capability to fit SPR and RSP adapters on Common Rail injectors. This unit
uses a Dynamic Mass Metering system.
Front View
Figure: GDU.2R
1. Gasoline Injector (Not included)
2. Injector Harness Cables
3. Injector Clamp / Discharge Height Adjuster (iPSC mounted) with LED
4. Protective Hood
5. Control Panel / PC
6. USB Port
7. On/Off Switch for PC
8. Cushioned / Adjustable support pads
9. Air Vents
10. Carrying Handles
11. MACC level Indicator
12. Test Oil level Indicator
13. Emergency Stop Switch
14. MACC Fill Port
15. Test Oil Fill Port

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DS-R
Intended Use
This unit can fully Test and Clean up to 1 Common Rail Injector. It has the capability to
fit SPR and RSP adapters on Common Rail injector. In addition, it supports EUI (UIPR-A)
and HEUI (HUIR-A) Attachment units, that can perform testing of these Pump-Injectors
1-by-1 and also use RSP and BIP adapters. This unit comes in an automatic (D) & semi-
automatic (A) version and uses an Electronic Volumetric Measuring Unit or Volumetric
Tubes for measuring the injected volume. User intervention is needed in the (A) units
to complete the test for adjusting the Test Pressure and Entering the Volumetric Data.
Front View
Figure: DS-R
1. Injector Harness Cables
2. Diesel Injector (Not included)
3. Injector Clamp / Discharge Height Adjuster (iPSC mounted) with LED
4. Protective Hood
5. HP Knob for controlling the Pressure (Manual HP Machines only)
6. Control Panel / PC
7. On/Off Switch for PC
8. USB Port
9. Adjustable support pads
10. Air Vents
11. MACC level Indicator
12. Test Oil level Indicator
13. MACC Fill Port
14. Test Oil Fill Port
15. Volumetric Tubes (Non-Electronic Measuring unit machines only)

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DSF-R
Intended Use
This unit can Clean and Flush up to 4 Common Rail Injectors simultaneously. In
addition, it supports EUI (UIPR-A) and HEUI (HUIR-A) Attachment units, that can
clean/flush these Pump-Injectors 1-by-1. The Unit comes with 2 tanks for cleaning and
flushing.
Front View
Figure: DSF-R
1. Injector Harness Cables
2. Diesel Injector (Not included)
3. Injector Clamp (D-Adapt mounted)
4. Protective Hood
5. HP Knob for controlling the Pressure (Manual HP Machines only)
6. Control Panel / PC
7. On/Off Switch for PC
8. USB Port
9. Adjustable support pads
10. Air Vents
11. MACC level Indicator
12. Test Oil level Indicator
13. MACC Fill Port
14. Test Oil Fill Port

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GD-R
Intended Use
This unit can fully Test and Clean up to 1 HP Gasoline Direct Injector. This unit comes in
an automatic (D) & semi-automatic (A) version and uses an Electronic Volumetric
Measuring Unit or Volumetric Tube for measuring the injected volume. User
intervention is needed in the (A) units to complete the test for adjusting the Test
Pressure and Entering the Volumetric Data
Front View
Figure: GD-R
1. Injector Harness Cables
2. Gasoline Injector (Not included)
3. Injector Clamp / Discharge Height Adjuster (iPSC mounted) with LED
4. Protective Hood
5. HP Knob for controlling the Pressure (Manual HP Machines only)
6. Control Panel / PC
7. On/Off Switch for PC
8. USB Port
9. Adjustable support pads
10. Air Vents
11. MACC level Indicator
12. Test Oil level Indicator
13. MACC Fill Port
14. Test Oil Fill Port
15. Volumetric Tube (Non-Electronic Measuring unit machines only)

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UIP-R
Intended Use
As an attachment to the main units CRU / DS, or as a standalone unit, it will provide the
capability to Test and/or Clean EUI Injectors and Pumps.
Front View
Figure: UIP-R
1. CAM securing lock
2. Protective Hood
3. Adapter Connections
4. Adjustable support pads
5. (LP) Low Pressure gauge
6. Test Oil level Indicator
7. MACC level Indicator
8. Injection Connections
9. Injector Clamp / Discharge Height Adjuster (iPSC mounted) with LED
10. EUI Injector (Not included)
11. Plunge ROD
12. CAM Adjuster (always use the headless screw to secure)

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HUI-R
Intended Use
As an attachment to the main units CRU / DS, or as a standalone unit, it will provide the
capability to Test and/or Clean HEUI Injectors.
Front View
Figure: HUI-R
1. Protective Hood
2. Adapter Connections
3. Hydraulic Oil Gauge
4. Hydraulic Oil Adjusting Knob (Adjust on each TP)
5. Hydraulic Oil level Indicator
6. (LP) Low Pressure gauge
7. Test Oil level Indicator
8. MACC level Indicator
9. Adjustable support pads
10. Injection Connections
11. Injector Clamp / Discharge Height Adjuster (iPSC mounted) with LED
12. HEUI Injector (Not included)