Thinkcar Tk-imt602 User manual

TK-IMT602 Fuel Injector Cleaner & Tester

User Manual

Thinkcar Tech Inc

@thinkcar.official @ObdThinkcar

THINKCAR

www.thinkcar.com

Content

1 Introduction.............................................................................................................1

2 Function & Specifications......................................................................................1

2.1 Main functions........................................................................................................................1

2.2 Main Features........................................................................................................................1

2.3 Working environment & Technical parameters ....................................................................2

3 Structural composition...........................................................................................2

3.1 Overview ...............................................................................................................................2

3.2 Control Panel ........................................................................................................................3

3.3 Tool drawer description..........................................................................................................4

4 Operating Procedures.............................................................................................4

4.1 Ultrasonic Cleaning................................................................................................................4

4.1.1 Preparation...................................................................................................................4

4.1.2 Method and Steps........................................................................................................5

4.2 Test Function..........................................................................................................................5

4.2.1 Preparation...................................................................................................................5

4.2.2 Method and Steps........................................................................................................6

4.3 Reverse Flushing...................................................................................................................9

4.3.1 Preparations.................................................................................................................9

4.3.2 Methods and steps......................................................................................................10

4.4 No disassembly cleaning......................................................................................................11

4.4.1 Preparations...............................................................................................................11

4.4.2 Methods and Steps....................................................................................................11

5 Maintenance...........................................................................................................12

5.1 Organization.........................................................................................................................12

5.2 Maintenance.........................................................................................................................13

6 General Notice........................................................................................................13

7 Warranty Service....................................................................................................13

8 Warranty Terms......................................................................................................14

9 Packing list of TK-IMT602 Injector Cleaner & Tester.......................................15

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1 Introduction

Thinkcar TK-IMT602 Injector Cleaner & Tester is an electronic mechanical product which

combining ultrasonic clean technology and microcomputer control simulation automobile fuel

injection technology. The product uses efficient ultrasonic and the solubility of the cleaning

liquid to clean the surface of injectors to recover its original characteristics. At the same time,

the product simulates various working conditions of the engine, and tests injectors of various

cars. The products is necessary for the automobile maintenance, repair shops, research and

teaching and training departments.

2 Function & Specifications

2.1 Main functions

· Ultrasonic Cleaning: To perform simultaneous cleaning on one or several injectors and to

remove the carbon deposits on the injector completely.

· Reverse Flushing: to remove the dirt inside the injector and attached to the filter.

· No disassembly cleaning: The unit is equipped with various adaptors and couplers that

facilitate cleaning on the injectors on vehicle (additional tools and special liquids).

· Atomization observation: to carefully observe the spray atomization of the fuel injectors

under background lamp.

· Sealing test: test the sealing and leakage of injectors under high pressure.

· Uniformity test: detect the uniformity of each injector.

· Automatic cleaning detection: real simulation of injectors test under various conditions.

· Injection Detection: the injection fuel amount of injectors under specific operating

parameters ( for example in the same time or the same times) can be detected.

2.2 Main Features

· Ultrasonic powerful cleaning technology has strong cleaning ability.

· Electronic pressure regulating control technology, stable oil pressure, wide adjustable range.

· BOSCH oil pump can ensure long-term and stable use.

· High-definition digital tube display makes the operation clear and easy to learn.

· Fuel tank level is visually displayed, and the test liquid can be recycled.

· Bright background light for a clear view of the injector operation.

· Applicability wide, It can work for different types of injector with compound adapters.

· Allow arbitrary adjustment the test time, operating frequency, oil injection times, minimum

switching cycle of the injectors within the allowable range.

2.3 Working environment & Technical parameters

Power supply AC 220 V/ 110 V ± 10%

Frequency 50 Hz / 60 Hz ± 0.5

Relative humidity < 90 %

Ambient temperature 0℃~ + 50℃

Notice No open fire is allowed around.

External magnetic field strength < 400 A/m

Oil tank volume 1500 ml

Measuring cylinder volume 125 ml

Speed 0 ~ 7500 r/ min

Injection times 0~7500, steps 100 ms

PWM width 0~20.0 ms, step 0.1 ms

System pressure 0~72 psi (adjustable)

Timiming 0~20 min (adjustable)

Input power 250 W

Ultrasonic cleaning power 70 W (intermittent operation)

Ultrasonic cleaning frequency 28 KHz ± 0.5 KHz

Dimensions (L x W x H) 380 mm × 485 mm × 470 mm

Net weight 16 Kg

3 Structural composition

3.1 Overview

1 2

Working panel

Glass measuring cylinder

(add test liquid)

Oil drain handle

Tool drawer

Power interface

Test wire interface

Oil inlet pipe

Lock nut

Ultrasonic tank

(add cleaning liquid)

Injector

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3.2 Control Panel

FUNCTIONS/PULSE WIDTH

Four - bit red tube displays selected functions. Select the function【FUNCITONS MENU】in

order by【+】and【-】.【01】means the top one,【13】means the last one. When the

machine is in startup, press【+】and【-】can change the pulse width ratio, affecting the

amount of oil injected.

WORKING/INJECTING TIMES

Four - bit red tube displays time, each function runs with the default time. When it needs to be

increased, it can change the working time by pressing【+】and 【-】before clicking

【START】.

PRESSURE REGULATING

The pressure gauge is used to display the working pressure ( 0 ~ 72psi ). The pressure of the

test fluid is increased or decreased by【+】and 【-】icons to simulate the pressure of

automobile fuel injection.

FUNCITONS MENU

The function list is detailed and needs to be selected by the【+】and 【-】buttons of

【FUNCTIONS / PULSE WIDTH】.

START

Press to execute the functions selected in【FUNCTIONS/PULSE WIDTH】.

PAUSE

Stop the selected function temporarily and press 【START】again to continue.

STOP

Stop the selected function immediately and return the selected function item.

3.3 Tool drawer description

(1) Adaptors for reverse cleaning

(2) 10-13.6 mm conical adaptor for spray testing

(3) 11mm Japanese Automotive Fittings for Jet Testing

(4) Round plug, need to be used when not testing all 6 cylinders

(5) Special oil nozzle gasket, some oil nozzles are small, used for fixing

(6) The oil rail, the joint is screwed on this groove, the nozzle is connected to the head,

and it is pressed tightly.

(7) Adapter cable, used to solve some special nozzle electronic interface

(8) The cleaning fluid drain valve is installed on the back of the machine after

disassembly. In order to prevent liquid leakage, it must be covered with sealant

(9) The fuel injector locks the screw nut for pressing the fuel rail and the nozzle.

4 Operating Procedures

4.1 Ultrasonic Cleaning

Ultrasonic cleaning is the penetration and cavitation shock wave generated by the ultrasonic

wave propagating in the medium. The object with complex shape, inner cavity and fine pores is

strongly cleaned to completely remove the stubborn carbon on the injector.

4.1.1 Preparation

1）Remove the injector from the vehicle and carefully check the rubber seal of the injector for

damage. If it is damaged, replace the same type of seal before the cleaning test, in order to

avoid leakage during the test. Put the nozzle into gasoline or detergent, carefully remove

the external oil and wipe it with a soft cloth.

2）Turn on the power. Plug the end of the power cord into the socket of the equipment and the

other end into the AC 220 V power outlet. Turn on the power switch at the side of the main

unit.

3）Take out the cleaning bracket from the accessory box, put it into the ultrasonic tank, and

place the outside cleaned injector on the positioning hole of the cleaning bracket in the

ultrasonic tank.

4.1.2 Method and Steps

【01】Ultrasonic Cleaning

1) Add an right amount of cleaning liquid to the ultrasonic tank. Generally, the cleaning liquid

can be immersed over the cleaning bracket.

2) Insert the injector pulse signal line into the injector separately. (Special injectors need to be

connected with an adapter cable)

3) Press the【+】and【-】keys of【FUNCTIONS/PULSE WIDTH】to select【01】,

corresponding to the【Ultrasonic Cleaning】option, then press the【+】and【-】keys of

【WORKING/INJECTING TIMES】to set the time. (The system defaults to 10 minutes.

Please use the up and down keys for modification if needed)

4) Press【START】. (Press【PAUSE】to suspend or press【STOP】to exit during working)

5) The working time is counting down. When it is 0, the system automatically stops.

6) Take the nozzle from the ultrasonic tank and clean the cleaning liquid with a soft cloth to

prepare for the next job.

! Note:

· During the cleaning process, you can hear the intermittent (approximately 5 seconds)

vibrating sound when you take the injector out and put it next to your ear, to judge whether

the injector is working properly.

· In the case that the ultrasonic tank is not filled with cleaning liquid, don’t perform ultrasonic

cleaning, otherwise the ultrasonic equipment will be damaged.

4.2 Test Function

This function is to detect the atomization, dripping, blockage, fuel injection angle status of the

injector, and the size and balance of the fuel injection volume of each injector at different

speeds.

4.2.1 Preparation

1）Add test liquid，as shown below.

Add test liquid

(Right amount is 1200 ML, and the liquid level should not be lower than 1000 ML normally)

1 2 3 4 5

25 125

150

psi

kg/cm2

100

8.8.8.8.

3 4

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4 Operating Procedures

4.1 Ultrasonic Cleaning

Ultrasonic cleaning is the penetration and cavitation shock wave generated by the ultrasonic

wave propagating in the medium. The object with complex shape, inner cavity and fine pores is

strongly cleaned to completely remove the stubborn carbon on the injector.

4.1.1 Preparation

1）Remove the injector from the vehicle and carefully check the rubber seal of the injector for

damage. If it is damaged, replace the same type of seal before the cleaning test, in order to

avoid leakage during the test. Put the nozzle into gasoline or detergent, carefully remove

the external oil and wipe it with a soft cloth.

2）Turn on the power. Plug the end of the power cord into the socket of the equipment and the

other end into the AC 220 V power outlet. Turn on the power switch at the side of the main

unit.

3）Take out the cleaning bracket from the accessory box, put it into the ultrasonic tank, and

place the outside cleaned injector on the positioning hole of the cleaning bracket in the

ultrasonic tank.

4.1.2 Method and Steps

【01】Ultrasonic Cleaning

1) Add an right amount of cleaning liquid to the ultrasonic tank. Generally, the cleaning liquid

can be immersed over the cleaning bracket.

2) Insert the injector pulse signal line into the injector separately. (Special injectors need to be

connected with an adapter cable)

3) Press the【+】and【-】keys of【FUNCTIONS/PULSE WIDTH】to select【01】,

corresponding to the【Ultrasonic Cleaning】option, then press the【+】and【-】keys of

【WORKING/INJECTING TIMES】to set the time. (The system defaults to 10 minutes.

Please use the up and down keys for modification if needed)

4) Press【START】. (Press【PAUSE】to suspend or press【STOP】to exit during working)

5) The working time is counting down. When it is 0, the system automatically stops.

6) Take the nozzle from the ultrasonic tank and clean the cleaning liquid with a soft cloth to

prepare for the next job.

! Note:

· During the cleaning process, you can hear the intermittent (approximately 5 seconds)

vibrating sound when you take the injector out and put it next to your ear, to judge whether

the injector is working properly.

· In the case that the ultrasonic tank is not filled with cleaning liquid, don’t perform ultrasonic

cleaning, otherwise the ultrasonic equipment will be damaged.

4.2 Test Function

This function is to detect the atomization, dripping, blockage, fuel injection angle status of the

injector, and the size and balance of the fuel injection volume of each injector at different

speeds.

4.2.1 Preparation

1）Add test liquid，as shown below.

2）Installation of injector

Installation of up-inlet injector

Installation diagram of up-inlet injector

a) Select the fuel injection assembly and oil separator plug from the accessory box, and install

them into the oil separator.

b) Install the injector in the forward direction (apply a small amount of grease on the “O” ring of

the injector).

c) Horizontally put the oil separator and the injector on the upper plate base, and tighten the

two ends with the locking rod, to prepare for the test. (Special injectors must use extension

rods, for example, micro-faces must also use extension pads or backing plates)

4.2.2 Method and Steps

【02】Idling Test (0-20 ms)

Add test liquid

(Right amount is 1200 ML, and the liquid level should not be lower than 1000 ML normally)

1）Connect the quick connector of the black oil outlet pipe on the machine with the male end

connector on the oil separator, and plug the fuel injector drive line.

2）Press the【+】and【-】buttons of 【FUNCTIONS/PULSE WIDTH】to select 【02】

Idling Test.

3）Press up and down keys of working time to set the time. (Generally set to 2 minutes)

4）Press【START】to start working.

5）Press【+】and【-】keys of 【PRESSURE PE GULATING】to adjust the pressure to

36-45 psi. (In the electronic injection system, the general oil pressure works at 36-45 psi)

6）Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select the

corresponding pulse width.(Default system set is 3MS, normal adjustment is 3MS). Press

the oil drain handle in order to observe the level of the oil.

7）The working time is counting down until 0, the system will automatically stop.

8）When the test completed, uplift the oil drain handle and put the test liquid back to the oil

tank.

【03】Medium Speed

1) Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select【03】

Medium Speed test mode.

2）Press 【START】key.

3）The following operation procedures is same with the 02 item.

【04】High speed Test（0-4 ms）

1）Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select【04】High

Speed Test mode.

2）Press START key

3）The following operation procedures is same with the 02 item.

【05】Accelerating Test

1）Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select 【05】

Accelerating Test mode.

2）Press 【START】key.

! Note:

· The system will set the fuel pressure, working time and pulse width systems automatically,

default time is 10s as one circulation period. User’s setting is unnecessary.

· The system will automatically simulate the working status and oil inject value of injector at

700-7500 rpm constant accelerate condition in three times.

【06】Shifting Speed Test

1）Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select 【06】

Shifting Speed Test mode.

Oil Separator

Up-inlet Composite

Assembly

Up-inlet Injector

5 6

【09】Medium Speed Spray Value Test

1）Press the【+】and【-】key of 【FUNCTIONS/PULSE WIDTH】to select the 09 Medium

Speed Spray Value Test mode.

2）The following operation procedures is same with the 08 item.

【10】High Speed Spray Value Test

1）Press the【+】and【-】key of 【FUNCTIONS/PULSE WIDTH】to select the 10 High

Speed Spray Value Test mode.

2）The following operation procedures is same with the 08 item.

! Note:

· Flow equilibrium: Test the flow equilibrium under different rmp, when the test liquid level

at 2/3 of the counting instrument, it will pause or stop work. The deviation of the inject

value should not exceed 2% for all the nozzle of one vehicle. Please refer to the relative

tech-manual of injector nozzle, in order to observe the flow equilibrium.

· Injector shape observation: Observe the injection shape, angle uniformity of all the

injector nozzle of one vehicle. And adjust the injector nozzle open pulse width

simultaneously, observe the uniformity of the minimum open pulse width.

· Leakage test: Detect the nozzle valve seal under system high pressure.(Observe the

nozzle seal, it should not has the leakage in one minute normally.

4.3 Reverse Flushing

Reverse Flushing, The test liquid from the outlet to the inlet, it can wash the dirt out from the

internal parts of the nozzle and filter mesh.

4.3.1 Preparations

1) Add test liquid, reference to 4.2.1.

(Approximately fill about 1800 ml. The liquid level should not be lower than 1000 ml normally)

2) Reverse flushing installation of the top-injection nozzle.

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2）Installation of injector

Installation of up-inlet injector

Installation diagram of up-inlet injector

a) Select the fuel injection assembly and oil separator plug from the accessory box, and install

them into the oil separator.

b) Install the injector in the forward direction (apply a small amount of grease on the “O” ring of

the injector).

c) Horizontally put the oil separator and the injector on the upper plate base, and tighten the

two ends with the locking rod, to prepare for the test. (Special injectors must use extension

rods, for example, micro-faces must also use extension pads or backing plates)

4.2.2 Method and Steps

【02】Idling Test (0-20 ms)

1）Connect the quick connector of the black oil outlet pipe on the machine with the male end

connector on the oil separator, and plug the fuel injector drive line.

2）Press the【+】and【-】buttons of 【FUNCTIONS/PULSE WIDTH】to select 【02】

Idling Test.

3）Press up and down keys of working time to set the time. (Generally set to 2 minutes)

4）Press【START】to start working.

5）Press【+】and【-】keys of 【PRESSURE PE GULATING】to adjust the pressure to

36-45 psi. (In the electronic injection system, the general oil pressure works at 36-45 psi)

6）Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select the

corresponding pulse width.(Default system set is 3MS, normal adjustment is 3MS). Press

the oil drain handle in order to observe the level of the oil.

7）The working time is counting down until 0, the system will automatically stop.

8）When the test completed, uplift the oil drain handle and put the test liquid back to the oil

tank.

【03】Medium Speed

1) Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select【03】

Medium Speed test mode.

2）Press 【START】key.

3）The following operation procedures is same with the 02 item.

【04】High speed Test（0-4 ms）

1）Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select【04】High

Speed Test mode.

2）Press START key

3）The following operation procedures is same with the 02 item.

【05】Accelerating Test

1）Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select 【05】

Accelerating Test mode.

2）Press 【START】key.

! Note:

· The system will set the fuel pressure, working time and pulse width systems automatically,

default time is 10s as one circulation period. User’s setting is unnecessary.

2）Press 【START】key.

! Note:

· The system will set the fuel pressure, working time and pulse width systems automatically,

default time is 10s as one circulation period. User’s setting is unnecessary.

· The system will automatically simulate the working status and oil inject value of injector at

Idle Speed (700rpm), Medium Speed(4,500rpm) and High Speed (7,500rpm) working

condition in three times.

【07】Leak checking Test

1）Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select【07】

Leakage checking Test mode.

2）Press the【+】and【-】key of the【WORKING TIMES】to set time. (General setting is

one minute)

3）The following operation procedures is same with the 02 item.

! Note:

· Default pulse width system is 3 ms.

· Simulate the system pressure under 45 psi and test whether the injector has dripping.

【08】Idling Spray Value Test

1）Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select【08】Idling

Spray Value Test mode.

2) Press the【+】and【-】key of the【WORKING/INJECTING TIMES】to set times.

(General time is 2,000)

3）The following operation procedures is same with the 02 item.

! Note:

Simulate the working status and inject value under the idle speed of engine in several times.

· The system will automatically simulate the working status and oil inject value of injector at

700-7500 rpm constant accelerate condition in three times.

【06】Shifting Speed Test

1）Press the【+】and【-】key of the【FUNCTIONS/PULSE WIDTH】to select 【06】

Shifting Speed Test mode.

7 8

3) The system default time is 1 minute. Press【START】to start working.

4) Adjust the pressure to 36 - 45 psi.

5) The remaining working time reduces gradually. When it goes to 0, the system automatically

stops.

6) After the test, raise the drain handle and put the test agent back into the fuel tank.

! Note:

· Reverse flushing is applicable to top-injection nozzles only.

· In reverse flushing, the pulse width parameter of the fuel injector has been automatically

set in the program, and users do not need to set it separately.

· Test liquid must be clean in the tank, to avoid clogging injector nozzle.

4.4 No disassembly cleaning

After the engine fuel supply system has been used for a period of time, the dust in the air and

the impurities in the gasoline will make the fuel path unsmooth or blocked. In addition, the

carbon deposits and gums produced during the combustion process will adhere to injector

nozzle, fuel inlet, exhaust valve, throttle valve and combustion chamber. Therefore, it is

necessary to clean the engine fuel supply system, combustion chamber and fuel injection

nozzles in time.

4.4.1 Preparations

1 ) Open the oil drain screw at the bottom of the main engine to release all the test liquid in the

oil tank.

2) Open the hood of the car to find the fuel inlet and return pipes of the fuel supply system of

the car.

4.4.2 Methods and Steps

【12】No disassembly cleaning (need to purchase additional accessories)

* This function requires Special cleaning fluid and tools, please use it with caution.

1) Connect the male end of the red non-dismantling pipe to the oil return pipe of the fuel

supply system (choose a suitable connector from the accessory box), and the other end to

the male end on the upper right side of the equipment.

2) Start the engine to extract 600ml-800ml gasoline from the car tank through the oil return

pipe (watching through the right window of the machine), and then turn off the engine.

3) Connect the male end of the blue non-dismantling pipe to the oil inlet pipe of the fuel supply

system, (choose the right connector from the accessory box), and the other end to the black

high-pressure oil pipe of the equipment.

4) Unplug the car oil pump fuse or oil pump relay in the condition of not affecting the work of

other systems, or find a suitable connector from the accessory box to connect the oil inlet