GDI-605A User Manual
GDI-605A User Manual
GDI-605A User Manual
GDI-605S
Injector Cleaner & Tester
i
GDI-605S Injector Cleaner & Tester
General Notice
Other product names used herein are for identification purposes only and may be trademarks of their
respective owners. We disclaims any and all rights in those marks.
Disclaimer
To take full advantage of the unit, you should be familiar with the engine.
All information, illustrations, and specifications contained in this manual are based on the latest information
available at the time of publication. The manufacturer resume the right of modify this manual and the machine
itself with no prior notice.
This unit is made for the purpose of persons who have special techniques and certifications.
Safety Precautions
Read all service procedures and precautions, installation instructions and equipment operating manuals
thoroughly. Failure to observe these precautions, or the improper use of equipment, could result in property
damage, serious injury or death. Never allow improperly trained personnel to perform these procedures or
operate the equipment.
a) Read the operating instructions before attempting to operate the unit. Keep this manual with the unit at all
times.
b) Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged until it
has been examined by qualified service personnel.
c) Do not hang cords over the edge of the table, bench or counter, or come in contact with hot manifolds or
moving fan blades.
d) If an extension cord is needed, a cord with a rated current equal to or greater than that of the equipment
should be used. Cords rated for lower current than that of the equipment may overheat.
e) Always unplug equipment from electrical outlet when the machine is not in use. Never pull the cord when
unplugging from the outlet.
f) To protect against risk of fire, do not operate the equipment in the vicinity of open container containing
flammable liquid (gasoline).
g) Make sure that the unit is in the well-ventilation area when operating the fuel engine.
h) Keep lighted cigarettes, sparks, flames or other ignition sources away from fuel systems at all times.
i) In order to avoid electric shock, keep away from the damp part of a working unit and avoid exposing it to
the rain.
j) Please operate the unit according to the operation procedures in the manual. Only use the accessories
recommended by the manufacturer.
k) Do not switch on the ultrasonic system when there is no ultrasonic detergent in the ultrasonic cleaning
chamber. Otherwise, damage to the ultrasonic cleaner can be resulted.
l) Keep the unit well grounded.
m) ALWAYS WEAR SAFETY GOGGLES. Common used glasses are NOT safety glasses.
n) When disconnecting any connector of the pressurized fuel hose, wrap the connector with towel to prevent
the fuel from spurting out. Spurted fuel may cause personal injury or fire.
o) Test liquid is used by the main unit. Detergent is used for on-vehicle cleaning. The ultrasonic cleaning
uses specified ultrasonic detergent (It can be replaced by detergent provided together with the unit).
Note: Specifying operations that require attention when operating the equipment.
Warning: Specifying a possible hazard that could result in damage to the machine or personal injury.
CONTENTS
Introduction ....................................................................................................................................................... 2
Functions .......................................................................................................................................................... 2
Features ...........................................................................................................................................................1
Specifications...................................................................................................................................................1
Structure ..........................................................................................................................................................2
Overview ..........................................................................................................................................................2
Control Panel ...................................................................................................................................................4
Installation & Connection .................................................................................................................................4
First Use (Or reuse after long time storage)....................................................................................................4
Operating Procedures .....................................................................................................................................4
Preparation ......................................................................................................................................................4
Cleaning & testing sequences .........................................................................................................................5
Working with Air ...............................................................................................................................................5
Tidy up after operating .....................................................................................................................................6
Operation .........................................................................................................................................................6
Select Injector Type .........................................................................................................................................6
Ultrasonic Cleaning .........................................................................................................................................7
Uniformity/Sprayability Test .............................................................................................................................7
Leakage Test ...................................................................................................................................................8
Injecting Volume Test .......................................................................................................................................8
Auto. Test .........................................................................................................................................................9
On-vehicle Cleaning ........................................................................................................................................9
Transporting and Storing ............................................................................................................................. 10
Troubleshooting & Precautions ................................................................................................................... 11
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.
iii
GDI-605S Injector Cleaner & Tester
iv
GDI-605S Injector Cleaner & Tester
Introduction
Thank you for purchasing the Injector Cleaner & Tester with the technology of ultrasonic cleaning and fuel
pressure control, this equipment is an advanced electromechanical product, which can clean and test injectors
by simulating engine working conditions. It can also perform cleaning on the injectors and fuel supply system
on vehicle.
Functions
Ultrasonic cleaning:
To clean injectors to remove the carbon deposition on them completely.
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 backlight.
Leakage test:
To test the sealing and dribbling conditions of injectors under system pressure.
Injecting Volume test:
To check the injecting amount of the injector in 15 seconds of constant injection.
Auto. test:
To test injectors by preset program conditions.
On-vehicle cleaning:
On-vehicle cleaning to remove the carbon deposition on vehicle.
Setting:
To set the system language.
Inquire:
To check the equipment usage information.
Information:
To check the hardware and software version.
Features
Adopting the powerful ultrasonic cleaning technology, the equipment offers complete cleaning to the
injectors/pump.
It offers stable testing pressure and large adjustable range controlled through microcomputer.
With the help of microcomputer control and LCD display, the equipment makes possible automatic
cleaning, testing injectors and real-time monitoring of the dynamic values.
Automatic fuel draining through preset programs for some test items.
Adopting humanization design can make the system pressure fast restored to the default values.
LCD display to show the operation details.
Touch button.
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~50/60Hz □ AC110V~60Hz
Ultrasonic cleaner power: 60W
Fuel pressure: 0.1-10bar
Air inlet: 5-8bar
1
GDI-605S Injector Cleaner & Tester
Structure
Overview
2
GDI-605S Injector Cleaner & Tester
3
GDI-605S Injector Cleaner & Tester
Control Panel
Function icon
Function description
For the new machine, or reusing after long-time storage, the pipeline of the machine is empty and the fuel
pump is not with lubrication. When it starts to work, the fuel pressure may be difficult to establish. Now, you
should do as following:
1) Fill enough test liquid into the tank of the machine.
2) Connect the test adaptor to the outlet pipe and insert it into the Fill Port.
3) Power on, select the System Function, and then select the First Use function.
4) Run it.
5) When there have liquid out from the test adaptor, stop it. If not stop, it’ll stop automatically after 30s.
6) Now it can use normally.
Note: if there have no liquid out, you can run it again.
Operating Procedures
Preparation
1) Remove the injector from the engine to check the O-rings inside for damage. If it is be damaged need to
replace it. Put the outside of injector in gasoline or detergent, and wipe them with soft cloth after cleaning
the outside oil sludge carefully.
2) Check the test liquid level to be 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.
4
GDI-605S Injector Cleaner & Tester
Ultrasonic cleaning
Uniformity/Sprayability test
Leakage test
Auto. test
2) Select system function, and then select parameter setting. Change the parameter value of WORK WITH
AIR to Y and save it.
5
GDI-605S Injector Cleaner & Tester
3) When you do the test, please connect the compressed air. The air pressure into the machine should be
adjust to 4~6bar (EFI) or 6~8bar (GDI). If the air pressure is lower than 3bar, this mode will not work
4) If you do test with air, please set the test fuel pressure slightly higher than the air pressure. About
higher 0.5bar.
Warning: Don’t set the fuel pressure lower than the air pressure!
Operation
First power on
The fuel tank is empty and fill enough test fluid into it.
1) The test function can be entered after selecting the type of fuel injection nozzle.
2) Different test joints are required for testing different types of fuel injection nozzles. This equipment only
provides basic configuration, more configuration of the connector need to be purchased separately.
3) Due to the difference of internal structure, some types of GDI nozzle cannot be tested temporarily.
6
GDI-605S Injector Cleaner & Tester
4) In addition to cleaning the fuel injection nozzle, ultrasonic device can also clean fuel pump, spark plug,
and other small size parts, but pay attention to the selection of appropriate cleaning agent.
Ultrasonic Cleaning
Injector Cleaner takes advantage of the penetrability and cavitation impact wave caused by ultrasonic wave
traveling through the medium to provide powerful cleaning on objects with complex shapes, cavities and pores,
so that the stubborn carbon deposits can be removed from the injectors.
Procedures
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 about 20mm above 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 ENTER key to run.
6) When the time is up, it will stop automatically as the beeper rings.
7) Take the injector / pump out of the launder and wipe them with a dry soft cloth. Get ready for next
operation.
Note:
Do not let the ultrasonic cleaning running as ultrasonic basin without injector cleaning detergent.
Otherwise damage may be incurred.
Do not let the pulse signal cables or plug dip in the injector’s body into the detergent.
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 by electrical nature, bore variation and clogging.
Spray ability test is to inspect the spraying performance by observing the injectors.
closed state. Uniformity test can be done at this state. When DRAIN icon is pressed, solenoid
valve will drain oil.
b) The system pressure can be adjusted by pressing ◄or ►key at testing.
c) During operating, the user can select parameter, such as RPM or PW, and then press ◄ or ► key
to achieve the status of the simulation.
d) Good injectors may have identical injecting angle, uniform spraying but no jet. Otherwise, replace
the injector.
e) In the sprayability test, a special electrical parameter--the minimum injection pulse width of
injector--can be 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 (observed with the help of backlight). The value set at this moment is
the minimum injection pulse width, so the difference of minimum injection pulse width among
these injectors could be observed.
Leakage Test
Leakage test is to inspect the sealing conditions of the injector needle valve under system pressure and to find
out if the injector is dribbling.
Injecting volume 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.
8
GDI-605S Injector Cleaner & Tester
Auto. Test
Auto. test contains all above-mentioned tests (15-second injecting test, idle speed, middle speed, high speed,
varying acceleration, varying deceleration, changing pulse width test). This function can test more
comprehensive performance of injectors by simulating the various engine working conditions.
On-vehicle Cleaning
After the engine has been in operation for a period of time, its fuel flow may be blocked or become un-smooth
owing to buildup of dust and impurities in fuel channel. In addition, the carbon deposits and gum made by
combustion can easily adhere to the injectors, inlet and outlet ports, inlet and outlet hoses, throttle and
combustion chamber. So the fuel supply system, combustion chamber and injector of the engine must be
cleaned on a timely basis. Combustion Chamber cleaning is a solution that can save your time and labor.
Procedures:
1) Please check if there is test liquid or detergent inside the fuel tank before On-vehicle cleaning. If test liquid
is in the tank, replace it with detergent.
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 been shown in “Connecting” below.
4) Select On-vehicle cleaning function, and set the cleaning time.
5) Press ENTER key to start the function, adjust the fuel pressure by pressing ◄or ► keys.
6) Start the engine to begin cleaning.
Connecting
a) Disconnect the fuel supply hoses (E, F) of engine fuel system (wrap the connector when disconnecting the
connector), and then choose a proper connector and connect it to the E end.
b) Stop the other end of the disconnected end (F) with a proper stopper, (use when the fuel pump has the
fuel return function only) or remove the fuse of fuel pump or disconnect the power cable of fuel pump.
9
GDI-605S Injector Cleaner & Tester
Storing
A. Store only in dry area and keep away from water before the unit is unpacked.
B. Store the machine in well-ventilated area and do not expose it to direct sun shine or rain.
Installation Environment
A. Keep a distance of no less than 200mm between the unit and any wall or other substance. The unit should
be put in well-ventilated area. Make sure the temperature is within -10℃+40℃.
B. The unit has been well grounded for safety operation. Please confirm that the power socket is also well
grounded.
Warning!
If an extension cord is used, the rated current should be equal to or greater than that of the equipment.
10
GDI-605S Injector Cleaner & Tester
Connect the test adaptor to the outlet pipe Insert it into the Fill Port
Precautions
1) Do not place anything on the control panel to prevent from breaking the measuring cup because it is made
from vulnerable.
2) Do not disconnect hose before the system pressure reaches “0”.
3) Always ensure that the provided power supply is well contacted with ground safely.
4) The unit is designed with warning function. When the level switch checks the liquid inside the tank less
than the lowest line, the unit will utter the warning sound and meanwhile stop the fuel pump and injectors
automatically, and then the unit returns to the stop state. The unit will stop warning until the liquid is
supplied enough, at this time pressing the ENTER key will run the unit again.
5) Clean the control panel in time and Keep the pulse signal cable away from the liquid.
11
GDI-605S Injector Cleaner & Tester
Warning!
Unauthorized repair may cause the extension of faulty area of the unit, which will bring trouble to
general repair. Under the state of turning on the power, the electrical system inside the unit contains
the factor causing danger. Failure to comply with these instructions could result in death or serious
injury.
12