SmartSafe CNC-605A Injector Cleaner & Tester

General Notice

Other product names used herein are for identification purposes only and may be trademarks of their respective owners. SmartSafe 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 reserves the right to 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.

• Read the operating instructions before attempting to operate the unit. Keep this manual with the unit at all times.
• 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.
• Do not hang cords over the edge of the table, bench or counter, or come in contact with hot manifolds or moving fan blades.
• 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.
• Always unplug equipment from electrical outlet when the machine is not in use. Never pull the cord when unplugging from the outlet.
• To protect against risk of fire, do not operate the equipment in the vicinity of open containers containing flammable liquid (gasoline).
• Make sure that the unit is in a well-ventilated area when operating the fuel engine.
• Keep lighted cigarettes, sparks, flames or other ignition sources away from fuel systems at all times.
• In order to avoid electric shock, keep away from damp parts of a working unit and avoid exposing it to the rain.
• Please operate the unit according to the operation procedures in the manual. Only use the accessories recommended by the manufacturer.
• 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.
• Keep the unit well grounded.
• ALWAYS WEAR SAFETY GOGGLES. Common used glasses are NOT safety glasses.
• When disconnecting any connector of the pressurized fuel hose, wrap the connector with a towel to prevent the fuel from spurting out. Spurted fuel may cause personal injury or fire.
• 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.

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 that can clean and test injectors by simulating engine working conditions. It can also perform cleaning on the injectors and fuel supply system on the vehicle.

Functions

• Ultrasonic cleaning: To clean injectors to remove carbon deposition completely.
• Uniformity/Sprayability test: To test the uniformity of injecting amount of each injector and 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: For cleaning the injectors and fuel supply system on the vehicle.
• Setting: To set the system language.
• Inquire: To check the equipment usage information.
• Information: To check the hardware and software version.

Features

• Adopts powerful ultrasonic cleaning technology for complete cleaning of injectors/pump.
• Offers stable testing pressure and a large adjustable range controlled through a microcomputer.
• Features automatic cleaning, injector testing, and real-time monitoring of dynamic values via microcomputer control and LCD display.
• Automatic fuel draining through preset programs for some test items.
• Humanization design allows for fast system pressure restoration to default values.
• LCD display shows operation details.
• Touch button interface.

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 or AC110V~60Hz
• Ultrasonic cleaner power: 60W
• Fuel pressure: 0.1-10bar
• Air inlet: 5-8bar

Structure Overview

The following components are identified in the diagrams:

Diagram 1:

• 1-Fill Port Cap
• 2-Fill Port
• 3-LED Light Band
• 4-Liquid Level Pipe Cap
• 5-Liquid Level Pipe Connector
• 6-Lower Pressing Plate
• 7-Pressure Gauge
• 8-Ultrasonic Cleaner Protective Silicone
• 9-Ultrasonic Cleaner
• 10-Glass Panel
• 11-Monochrome Display Screen
• 12-Fixed Rod
• 13-Glass Tube
• 14-Adjusting Screw
• 15-Compression Screw
• 16-Fuel Distributor
• 17-Adjusting Nut
• 18-Door Mat
• 19-Power Supply Base
• 20-Control Board
• 21-Power Switch
• 22-Power Socket & Fuse
• 23-Copper Pillar
• 24-Screw
• 25-Screw
• 26-Upper Pressing Plate
• 27-Cabinet
• 28-Copper Plug

Diagram 2:

• 29-Pulse Signal Line Base
• 30-Manifold Block Connector
• 31-Pressure Switch
• 32-Pagoda-Shape Connector
• 33-Screw
• 34-Switch Power
• 35-Screw
• 36-Cool Fan
• 37-Fuel Tank
• 38-Fuel Pump
• 39-Screw
• 40-Draining Solenoid Valve
• 41-Four Way Aluminum Base
• 42-Pagoda-Shape Connector
• 43-Fuel Inlet Port

Note: The image in this manual may be different from the actual product!

Control Panel

The control panel features a display screen and several buttons for operation. Key elements include:

• Function icon: Displays the current function.
• Function description: Provides a text description of the selected function.
• Drain for Ultrasonic: Button/indicator for draining the ultrasonic basin.
• Drain for test tubes: Button/indicator for draining test tubes.
• Navigation buttons: Up, Down, Left, Right arrows.
• EXIT button: Used to exit current operations or menus.
• ENTER button: Used to confirm selections or start operations.

Installation & Connection

1. Move the machine onto the workbench after unpacking and loosen the strips on the outlet hoses.
2. Take the adjusting bolt from the kit and install it to the press plate on the top of the glass tube.
3. Take the fuel distributor from the kit, install it on the knurled nuts, and tighten them with the pressing nut.
4. Take the power cable from the kit and insert it into the input socket at the bottom of the unit.

First Use (Or reuse after long time storage)

FOR FIRST USE

Connect the test adaptor to the outlet pipe, and insert it into the oil filling port.

ENTER: Start | EXIT: Stop

For a new machine, or after long-time storage, the machine's pipeline may be empty and the fuel pump may not have lubrication. When it starts to work, the fuel pressure may be difficult to establish. Follow these steps:

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 the function.
5. When liquid flows out from the test adaptor, stop the function. If it does not stop automatically, it will stop after 30 seconds.
6. The unit can now be used normally.

Note: If there is no liquid output, you can run the function again.

Operating Procedures

Preparation

1. Remove the injector from the engine and check the O-rings for damage. Replace if damaged. Clean the outside of the injector with gasoline or detergent, then wipe with a soft cloth after removing oil sludge.
2. Check the test liquid level in the tank. Pour test liquid from the port at the top left side of the unit and observe the level in the fuel level viewer. Fill the liquid up to approximately 1/2 of the tank capacity.
3. Turn on the power switch on the right of the Cabinet.
4. Pour ultrasonic detergent into the ultrasonic cleaning basin, ensuring the needle valve of the injector is covered by the detergent.
5. Connect the injectors with the appropriate couplers.

Cleaning & testing sequences

A complete cleaning and testing sequence should be followed:

• Ultrasonic cleaning
• Uniformity/Sprayability test
• Leakage test
• Injecting Volume test
• Auto. test
• On-vehicle cleaning (for EFI system)

Select the corresponding parameter and set up according to the test requirements. Refer to the "Operation" section for detailed instructions.

Working with Air

Statement: The equipment can operate normally without compressed air. This function enhances the test and cleaning effect.

Note: This function is OFF by default.

The WORKING WITH AIR mode is designed to improve the spray ability and cleaning effect of injectors. For injectors with serious blockage, this mode can provide a more effective cleaning by pulsing with pressurized air. It also allows for a more intuitive observation of injector spray ability during testing.

1. Install the quick male connector to the air inlet on the top of the device.
2. Select system function, then select parameter setting. Change the parameter value of WORK WITH AIR to 'Y' and save it.

When performing tests, connect compressed air. The air pressure should be adjusted to 4-6bar (EFI) or 6-8bar (GDI). If the air pressure is lower than 3bar, this mode will not work.

If testing with air, set the test fuel pressure slightly higher (about 0.5bar) than the air pressure.

Warning: Do not set the fuel pressure lower than the air pressure!

Tidy up after operating

Tidy-up should be performed after cleaning and testing are completed:

1. Press the "Drain" icon to drain the test liquid into the fuel tank.
2. Switch off the power and unplug the unit from the socket.
3. Clean the Injector Cleaner & Tester control panel with a soft cloth.
4. Drain the test liquid from the tank into a container to avoid volatilization. Store the test liquid safely if it can be reused, or dispose of it in accordance with relevant regulations if it is too dirty.

Operation

First power on

LANGUAGE:

• ENGLISH
• 繁體中文
• 简体中文

Please set your language.

Warning: W01: the fluid is not enough.

The fuel tank is empty. Fill enough test fluid into it.

Select Injector Type

Injector type:

• EFI
• GDI

The test function can be accessed after selecting the type of fuel injection nozzle.

Different test joints are required for testing different types of fuel injection nozzles. This equipment provides basic configuration; additional connectors may need to be purchased separately.

Due to internal structure differences, some types of GDI nozzles cannot be tested temporarily.

Ultrasonic Cleaning

The CNC-605A Injector Cleaner & Tester utilizes ultrasonic waves to provide powerful cleaning for injectors, effectively removing stubborn carbon deposits from complex shapes, cavities, and pores.

Procedures:

1. Place the injector/pump, after surface cleaning, into the cleaning basin.
2. Add enough injector detergent so the liquid level is about 20mm above the needle valve of the injectors/whole pump.
3. Connect the pulse signal wire to the injector/pump respectively.
4. Select the ultrasonic cleaning function and set the time.
5. Press ENTER to run.
6. The unit will stop automatically when the time is up, indicated by a beeper.
7. Remove the injector/pump from the basin and wipe it with a dry soft cloth. Prepare for the next operation.

Note:

• Do not run the ultrasonic cleaning without injector cleaning detergent in the basin, as this may cause damage.
• Do not let the pulse signal cables or plugs dip into the detergent.

Uniformity/Sprayability Test

This test identifies differences in injector output under the same working conditions. It helps diagnose issues related to electrical nature, bore variation, and clogging. The sprayability test inspects the spraying performance by visual observation.

Installing and testing procedures for injectors:

1. Choose a proper adaptor for the injector type and mount it to the fuel distributor.
2. Install the injectors in the forward direction (apply a little lubricating grease on the O-ring).
3. Install the fuel distributor with injectors onto the test tube plate.
4. Connect the injector pulse signal wire.
5. Before this test, press the DRAIN icon to drain any residual test liquid from the measuring cup.
6. Select the Uniformity/Sprayability test function, set the corresponding parameters (consult the appendix for pressure setting, and vehicle manuals for other parameters), and press ENTER to start the test.
7. When the test is completed, the equipment will automatically stop with a buzzer sound.

Note:

• While testing, fuel can be drained by pressing the DRAIN icon. By default, the solenoid valve is in the closed state. Uniformity test can be performed in this state. When the DRAIN icon is pressed, the solenoid valve will drain oil.
• System pressure can be adjusted by pressing the ◄ or ► keys during testing.
• During operation, the user can select parameters like RPM or PW, and use the ◄ or ► keys to achieve the desired simulation status.
• Good injectors may exhibit identical injection angles and uniform spraying, but no jet. If not, replace the injector.
• In the sprayability test, the minimum injection pulse width of the injector can be tested to compare injectors on the same engine. Set the cylinder number, start the test from the minimum injection pulse width, and gradually increase the pulse width until the injector starts injecting. The value at this point is the minimum injection pulse width. This allows observation of differences among injectors.

Leakage Test

This test inspects the sealing conditions of the injector needle valve under system pressure to detect dribbling.

Procedures (Installation refer to Uniformity/Sprayability Test):

1. Before performing the leakage test, press the DRAIN icon to drain any residual test liquid from the measuring cup.
2. Select the Leakage Test function and press ENTER to run.
3. System pressure can be adjusted by pressing the ◄ or ► keys. Adjust the pressure preferably 10% higher than the manufacturer's specifications to observe dribbling from the injector.
4. When the test is over, the equipment will automatically stop with a buzzer sound.

Note: In general, the injector drip should be less than 1 drop within 1 minute (or as per specifications). The default test time is 1 minute.

Injecting Volume Test

This test verifies if the injecting flow in 15 seconds meets the specified injecting amount. Deviation indicates injector wear or clogging, not electrical parameter variation.

Procedures (Installation refer to Uniformity/Sprayability Test):

1. Before this test, press the DRAIN icon to drain any test liquid from the measuring cup.
2. Choose the Injecting Volume Test function and press ENTER to start the test.
3. Adjust the fuel pressure by pressing the ◄ or ► keys according to the injector specification.
4. When the test is over, the equipment will automatically stop with a buzzer sound.

Auto. Test

The Auto. test includes all the above-mentioned tests (15-second injecting test, idle speed, middle speed, high speed, varying acceleration, varying deceleration, changing pulse width test). This function comprehensively tests injector performance by simulating various engine working conditions.

Procedures (Installation refer to Uniformity/Sprayability Test):

1. Before the test, press DRAIN icon to drain all test liquid from the measuring cups if any is present.
2. Select the AUTO function and press ENTER to start the test.
3. Adjust the fuel pressure by pressing the ◄ or ► keys.
4. When the test is over, the equipment will automatically stop with a buzzer sound.

On-vehicle Cleaning

This function is used for cleaning the fuel supply system, combustion chamber, and injectors on the vehicle, addressing issues like blocked fuel flow, carbon deposits, and gum buildup.

Procedures:

1. Ensure there is test liquid or detergent in the fuel tank before starting on-vehicle cleaning. If test liquid is present, replace it with detergent.
2. Blend the detergent with fuel at a specified ratio and fill the mixture into the fuel tank.
3. Refer to the "Connecting" section for engine fuel pipe connections.
4. Select the On-vehicle cleaning function and set the cleaning time.
5. Press ENTER to start the function and adjust the fuel pressure using the ◄ or ► keys.
6. Start the engine to begin the cleaning process.

Connecting

• Disconnect the fuel supply hoses (E, F) of the engine fuel system. Wrap the connector when disconnecting. Choose a proper connector and connect it to the E end.
• Stop the other end of the disconnected hose (F) with a proper stopper (use only when the fuel pump has the fuel return function) or remove the fuel pump fuse or disconnect the fuel pump power cable.

Tidy up after cleaning

1. After cleaning is completed, turn off the ignition switches, reconnect the fuel hoses, and then start the engine. Check the fuel system for leaks.
2. Clean the fuel tank and hose lines with test liquid (if residual detergent is present in the fuel tank, please clean it).
3. Tidy up and prepare for the next cleaning session.

Note:

• When cleaning, be aware that the detergent is flammable. Prepare a fire extinguisher.
• Ensure all hose lines are well connected and there are no leaks before performing cleaning.

Transporting and Storing

Transporting

• Before packing, drain the liquid inside the fuel tank completely to prevent overflow during transport.
• Move the unit by hand or lift with a soft belt.
• Do not use package or lifting tools for long-distance transportation.
• To prevent the unit from shocking and knocking, ensure it is on its base seat and in the packing case during transportation. Pack the unit with cushioning material (like plastic strips, foam, or sponge) between the unit and the packing case to avoid scratching the surface when the unit shakes.
• Ensure the maximum incline angle does not exceed 45 degrees. Do not place the unit upside-down.

Storing

• Store the unit in a dry area, away from water, before it is unpacked.
• Store the machine in a well-ventilated area, protected from direct sunlight or rain.

Installation Environment

• Keep a distance of at least 200mm between the unit and any wall or other substance. Ensure the unit is placed in a well-ventilated area. The temperature should be within -10°C to +40°C.
• The unit must be well grounded for safety operation. Confirm that the power socket is also well grounded.

Warning! If an extension cord is used, its rated current must be equal to or greater than that of the equipment.

Troubleshooting & Precautions

Troubleshooting

1. Unit does not correspond when switched on: Check the fuse (5A) at the lower right side of the unit. Replace if damaged or broken.
2. Leakage in the fuel distributor coupler: Check the O-rings and replace if damaged or unfitted. Do not overtighten the two riffle screws, as this may cause leakage.
3. No working pressure when running: For a new machine or one unused for a long time, fuel pressure may be low. Select the First Using function in the System Function and operate as follows:
   • Connect the test connector on the fuel outlet pipe and insert it into the Fill Port.
   • Run the function.
   • When liquid flows out from the test adaptor, stop the function. If it does not stop automatically, it will stop after 30 seconds.
   • The unit can now be used normally.

   Note: If there is no liquid output, run the function again.

4. Buzzer rings continually when there is no fuel pressure: The machine has a fuel-lack warning function. It rings when the fuel tank is low, and automatically switches off the fuel pump and injectors, returning to the stop state. Supply detergent or test liquid to stop the ringing.
5. Draining test liquid in glass tube thoroughly: Press the DRAIN icon multiple times. The solenoid valves stop automatically after 15 seconds. Drain more times if there is more liquid.

Precautions

1. Do not place anything on the control panel, as the measuring cup is fragile and may break.
2. Do not disconnect hoses before the system pressure reaches "0".
3. Always ensure the provided power supply is well connected and grounded safely.
4. The unit has a warning function. When the liquid level in the tank is below the lowest line, the unit will sound a warning and automatically stop the fuel pump and injectors. The unit will stop warning once the liquid is replenished. Pressing ENTER will resume operation.
5. Clean the control panel promptly and keep the pulse signal cable away from liquids.