AUTOOL CT400 GDI Fuel Injector Cleaner and Tester

1. Overview

1.1 Functions and Features

The AUTOOL CT400 GDI Fuel Injector 6-cylinder Cleaner and Tester represents a significant upgrade, incorporating the latest GDI design. It is capable of cleaning and testing standard injectors, as well as performing cleaning and testing for GDI injectors. The unit supports multiple voltages for GDI injectors, allowing adaptation for various injector testing types. It is an essential and preferred piece of equipment for automotive service and maintenance, research, and educational training departments.

Functions

• Ultrasonic cleaning: Performs simultaneous cleaning on one or several injectors to completely remove carbon deposits.
• Uniformity test: Tests the uniformity of the injecting amount for each injector.
• Sprayability test: Monitors the spraying status of each injector using a backlight.
• Leakage test: Tests the sealing and dribbling conditions of injectors under system pressure.
• Injecting flow test: Checks the injecting amount of the injector under specific working parameters (e.g., same time, same number of times).
• Automatic test: Tests injectors under specific working parameters by simulating different working conditions.
• Supports the latest unique GDI fuel injector driving software, capable of driving 12V, 70V, and 120V high-pressure fuel injectors.

Features

• Employs powerful ultrasonic cleaning technology for comprehensive injector cleaning.
• Microcomputer-controlled fuel pressure regulation provides stable pressure and a wide adjustable range.
• Features a high-definition digital control panel display for simple and intuitive operation.
• Test liquid level is visually displayed and the liquid can be recovered for recycling.
• A bright LED backlight aids in clearly observing the various working conditions of the injectors.
• Includes a patented, replaceable composite coupling suitable for many models.
• Test time, operating frequency, number of injections, and minimum switching pulse width are freely adjustable within the allowed range.

1.2 Working Environment and Technical Parameters

Working Environment

• Power supply: AC 110/220V ±10%
• Frequency: 50-60HZ ±0.5
• Relative humidity: <85%
• Ambient temperature: 0°C ~ +40°C
• External magnetic field strength: <400A/m
• No open flames are allowed in the vicinity.

Technical Parameters

• Fuel tank capacity: 1500 ml
• Test tube amount: 140 ml
• RPM range: 0~7500 r/min
• Time range: 0~9900 times
• PWM pulse width: 0~20.0 ms
• System pressure: 0~0.55Mpa (adjustable)
• Timing: 0~20 minutes adjustable
• Ultrasonic cleaning power: 60W (intermittent work)
• Ultrasonic cleaning frequency: 28 KHZ ±0.5 KHZ
• Dimensions: 390mm (length) x 410mm (width) x 430 mm (height)
• Weight: 16.6KG

2. Structure

2.1 Overview Structure

The AUTOOL CT400 Injector Cleaner & Tester features several key components: 1. Filling inlet, used for adding cleaning or test liquid. 2. Test tube, where injected fuel is measured. 3. Drain button, for controlling liquid drainage. 4. Control panel, housing the interface for operation. 5. Pulse signal cable, for connecting to injectors. 6. Ultrasonic cleaning bath, for the cleaning process. 7. Power switch, to turn the unit on/off. 8. Power socket, for connecting the power cord. 9. Pressure gauge, to monitor system pressure. 10. Test liquid drain valve, for emptying the tank.

2.2 Control Panel

The control panel provides access to all functions and settings. Key elements include:

• Pulse width display: Shows selected function options and allows pulse width adjustment.
• Display of working hours/injecting times: Indicates the operational duration and number of injections for the injectors.
• Start key: Initiates the selected work item.
• Function menu selection buttons: Used to navigate and select functions from the menu.
• Pause key: Temporarily halts the selected work item.
• Time and frequency adjustment button: Adjusts the working time and spray frequency of the fuel injector.
• Stop key: Terminates the selected work item and returns to the menu.
• Pressure decrease adjustment button: Reduces the system pressure.
• Pressure increase adjustment button: Increases the system pressure.
• Text description of function menu: Provides labels for the various test and cleaning functions available.

The control panel lists the following functions:

1. Ultrasonic Cleaning
2. Idling Test (0~20ms)
3. Medium Speed Test (0~7.5ms)
4. High Speed Test (0~4ms)
5. Accelerating Test
6. Shifting Speed Test
7. Leak Checking Test
8. Idling Spray Value Test
9. Medium Speed Spray Value Test
10. High Speed Spray Value Test
11. Reverse Flushing
12. No-disassembly Cleaning

How to use the drain button: When performing work items 8, 9, and 10, press the drain button to close the valve. This allows the injected oil from the fuel injectors to collect in the glass tube for comparison. After observation, open the oil drain valve to return the test liquid to the oil tank.

3. Operation Procedures

3.1 Ultrasonic Cleaning

The Injector Cleaner utilizes the penetrability and cavitation impact wave generated by ultrasonic waves to provide powerful cleaning for objects with complex shapes, cavities, and pores, effectively removing stubborn carbon deposits from injectors.

Preparation:

• Remove the injector from the vehicle engine and inspect the rubber seals for damage. Replace any damaged seals with identical ones to prevent leakage during testing. Clean the exterior of the injectors with gasoline or detergent and wipe them with a soft cloth to remove oil sludge.
• Turn on the power. Note: There may be a delay of several seconds when the device restarts after a prolonged power disconnection.
• Remove the cleaning bracket from the accessory box, place it into the ultrasonic bath, and then insert the clean fuel injector into the designated positioning hole within the bracket in the ultrasonic bath.

Operation Steps:

• Add an appropriate amount of injector cleaning liquid into the ultrasonic bath, ensuring it slightly immerses the cleaning bracket.
• Turn on the ultrasonic switch located on the right side of the main unit to begin ultrasonic cleaning.
• Pulse signals can be input to the fuel injector during the ultrasonic cleaning process.
• Steps:
• Connect the injector pulse signal wires to the injectors sequentially. (Special injectors may require adapter wires).
• Use the item selection up and down keys to select the "01 Ultrasonic Cleaning" item.
• Use the working time up and down keys to set the desired cleaning time. The system defaults to 10 minutes; this can be modified using the up and down keys.
• Press the run key to start the cleaning cycle. The system will begin inputting pulse signals.

After cleaning is complete, remove the injectors from the ultrasonic tank, wipe off any residual cleaning liquid with a soft cloth, and prepare for the next operation.

Notes:

• During the cleaning process, intermittent vibration can be heard when an injector is near your ear, indicating it is receiving a pulse signal.
• Do not turn on the ultrasonic cleaner before adding the injector detergent, as this may cause damage.
• Only the ultrasonic cleaning liquid specifically matched with the machine should be used in the ultrasonic tank. Using other cleaning liquids may cause the equipment's surface coating and mask to peel off, voiding the warranty.

3.2 Test Functions

This function is designed to detect the sprayability, dripping, blockage, fuel injecting angle, and the amount and uniformity of fuel injection for each fuel injector at various RPMs.

3.2.1 Preparation

• Add test liquid: Pour test liquid from the filling port. Approximately 1000ml should be added, ensuring the liquid level remains above 800ml for each test.
• Installation of fuel injectors:

A. Install the injector adapter and plug into the Fuel distributor assembly.

B. Install the fuel injector in the forward direction. Apply a small amount of grease to the "O" ring of the fuel injector.

C. Install the fuel distributor assembly and the fuel injectors onto the top assembly plate. Tighten and secure with a fixed screw nut and sleeve. The unit is now ready for testing.

D. Select the appropriate voltage (12V/70V/120V) based on the injector type.

3.2.2 Steps:

Item 02 Idle Speed Test:

• Connect the quick connector of the black outlet hose on the machine to the male end connector on the fuel distributor assembly. Insert the pulse line of the fuel injector.
• Press the item selection up and down keys to select the "02 Idle Speed Test" item.
• Press the working time up and down keys to set the test duration (normally set to 10 minutes).
• Press the "run" key to start the test.
• Rotate the pressure adjustment knob to set the pressure between 2-5 kg. (For electronic spraying systems, the oil pressure is typically 2-5 kg).
• Use the up and down keys to select the appropriate pulse width (the system defaults to 3MS, generally adjusted to 3MS).
• The working time will decrease gradually and the system will stop automatically when it reaches 0.

03 Middle-Speed Test:

• Press the item selection up and down keys to select the "03 Middle-speed test" item.
• Press the RUN button.
• The remaining operation steps are consistent with item 02.

04 High-Speed Tests:

• Press the item selection up and down keys to select the "04 High-speed test" item.
• Press the RUN button.
• The rest of the operation steps are consistent with item 02.

05 Accelerated Test:

• Press the project selection up and down keys to select the "05 Accelerated test" item.
• Press the RUN button.

Notes:

1. The fuel pressure, working time, and pulse width are automatically set by the system. The time system presets 10 seconds as a loop cycle, which can be adjusted by the user.
2. The system will automatically loop three times to simulate the working conditions and fuel spraying amount of the fuel injectors during uniform engine acceleration from 1,500 to 15,000 rpm.

06 Various Speed Test:

• Press the item selection up and down keys to select the "06 Various speed test" item.
• Press the RUN button.

Notes:

1. The fuel pressure, working time, and pulse width are automatically set by the system. The time system presets 10 seconds as a loop cycle, which saves the user the effort of manual setting.
2. The system will automatically loop three times to simulate the working conditions and fuel spraying amount of the fuel injectors at idling (1,500 rpm), middle-speed (9,000 rpm), and high-speed (15,000 rpm).

07 Leakage Test:

• Press the item selection up and down keys to select the "07 Leakage test" item.
• Press the working time selection keys to set the time (generally set to 1 minute).
• The remaining operation steps are consistent with item 02.

Notes:

1. The pulse width system is preset to 3ms and does not require further setting.
2. Simulates whether the fuel injectors drip and leak when the vehicle's oil pressure is 0.3Mpa.

Item 08 Idle Fuel Injecting Amount Test:

• Press the item selection up and down keys to select the "08 Idle fuel injecting amount test" item.
• Press the up and down keys to set the number of injection times (generally set to 2,000 times).
• The remaining operation steps are consistent with item 02.

Notes:

1. Simulates the working condition and injection amount of the engine at idle speed when the injectors operate a specified number of times.

09 Middle-Speed Fuel Injecting Amount Test:

• Press the item selection up and down keys to select the item "09 Middle-speed fuel injecting amount test".
• The rest of the operation steps are consistent with item 08.

10 High-Speed Fuel Injecting Amount Test:

• Press the item selection up and down keys to select the "10 High-speed fuel injecting amount test" item.
• The rest of the operation steps are consistent with item 08.

Notes:

1. Uniformity: This test checks uniformity across various RPMs. When the test liquid level reaches 2/3 of the test tube, pause or stop the machine to observe the uniformity of the injecting amount. The injecting difference between all injectors on one vehicle should be kept within 2%. Refer to the relevant technical manual of the fuel injector for specific uniformity determination.
2. Injector Shape: Observe the shape of the injectors and whether the injecting shapes and angles of all injectors on the same vehicle are identical at various speeds. The injection pulse width of the fuel injectors can be adjusted to compare if the minimum injection pulse width among them is consistent.
3. Leakage Test: This inspects the sealing conditions of the injector needle valve under system pressure. Observe the tightness of the fuel injectors; generally, there should be no leakage within one minute.

11 Reverse Flush Test:

• Press the item selection up and down keys to select "11 Reverse Flush". Install the injectors in the opposite direction for cleaning.

12 Fully Automatic Cleaning Items:

• Cleaning time can be set to a maximum of 20 minutes. Connect to various special parts designed to clean the combustion chamber or throttle.

4. Maintenance

1. Tidy up

• Turn off the power and unplug the power cord.
• Return all connectors to the accessory box for storage.
• Place the ultrasonic cleaner back into its original container, seal it, and wipe the equipment clean with a dry soft cloth.
• If the unit will not be used for an extended period, open the test liquid valve and drain the test liquid back into its original bottle for sealed preservation.

2. Maintenance

Replacement of test liquid

• Impurities can accumulate in the test liquid after a period of use. Do not use contaminated test liquid, as it can block injectors and fuel pumps. Drain the test liquid by removing the level indicator on the left of the main unit. It is recommended to clean the fuel tank with a small amount of test liquid before refilling with new liquid. After cleaning, close the test liquid valve and pour in the new test liquid.

Replacement of Fuse

• A square box marked with a fuse is located at the power socket on the left side of the equipment. If the fuse is blown, open the box and replace it with a new one (5A).

5. Precautions

• The test device is made of quartz glass and is fragile; avoid placing other objects around it to prevent accidental breakage.
• If there is no digital display after powering on (there might be a delay), check if the power supply is active. If there is a power failure, verify the plug connection and check the fuse. If the fuse is intact and the switch still does not respond after multiple presses, contact your local dealer. Do not attempt to disassemble the unit yourself, as this will void the warranty.
• Do not activate the ultrasonic system when there is no ultrasonic detergent in the cleaning chamber, as this can damage the ultrasonic cleaner.
• The unit must be completely emptied before adding 1000ml of test liquid for each liquid change.
• Using unqualified test liquid can cause corrosion of the pump and oil supply line, leading to pressure gauge failure.
• Only the ultrasonic cleaning liquid matched with the machine should be used in the ultrasonic bath. Other cleaning liquids may cause the equipment's surface coating and mask to peel off, voiding the warranty.
• Kerosene, gasoline, pure water, and other testing and cleaning solutions are strictly forbidden for use with this equipment. Doing so may damage the "O" rings and rubber parts within the pipeline, causing leaks.
• Do not mix cleaning liquid with testing liquid.
• Place the machine on a flat surface and ensure all four feet support its weight. Failure to do so may damage the ultrasonic cleaning bath, which is not covered by the warranty.

6. Warranty

Thank you for choosing AUTOOL products. We are committed to providing excellent services and promises.

• The warranty period for this product is 1 year.
• After the warranty period expires, repairs will incur charges for replacement parts.
• In case of failure, please contact the manufacturer for the most efficient service.

The following items are not covered by the warranty:

• Vulnerable parts, including glass tubes, signal wires, stickers, connectors, pressure gauges, and oil outlet pipes.
• Damage to the ultrasonic system caused by turning on the ultrasonic cleaning switch without cleaning agent in the tank.
• Blockage of the oil pump filter screen and burnout of the oil pump due to failure to replace the testing agent in time after long-term use.
• Burnout of the fuel pump caused by using fuel injector cleaning agent as fuel injector testing agent.
• Man-made faults.

Disclaimer: AUTOOL reserves the right to modify this manual and the machine itself without prior notice. Physical appearance and color may differ from those shown in the manual; please refer to the actual product. While every effort has been made to ensure accuracy, inaccuracies may still exist. If in doubt, please contact your dealer or the AUTOOL after-service center. AUTOOL is not responsible for any consequences arising from misunderstandings.

Contact Information

Shenzhen Oruan Technology Co., Ltd.

Guangdong Province, Shenzhen City, Baoan District, Beiba Road, Hangcheng Jinchao Industrial Park

Shenhua Innovation Park, Baoan, Shenzhen, China

Website: www.autooltech.com

Email: aftersale@autooltech.com

Phone: +86-400 032 0988 / +86-755-27807580

Certifications: FC, CE, ROHS (Made in China)