INSTRUCTION MANUAL
INJECTOR CLEANER & TESTER MACHINE
(SEMI AUTOMATIC)
Manufactured By
Xtreme Engineering Equipment (P) Ltd.
Factory/Off.: Xtreme House, S.N 32/2, Ashtavinayak Indl.
Estate, Parvati Nagar, Next to Pari Robotics, Narhe, Pune –
41,
Tel.020-24690312,
INDEX
SR.N
DESCRIPTION PAGE NO.
O.
1 System Components 03
2 Photograph of System 04
3 Introduction 05
4 System Description 06
5 Power control panel Description 08
6 Clean and test of Injectors 09
7 Operations 11
8 Precautions 12
9 Trouble shooting guide 13
1.
2 INJECTOR CLEANER AND TESTER MACHINE (SEMI AUTOMATIC)
Xtreme Engineering Equipment (P) Ltd.
1. SETUP COMPONENTS
After unpacking the consignment, you will find the following items mounted on the
main structure.
Pressure gauge.
Tightening Screw.
Injector Rail.
Burettes.
Operation Display.
Clean Switch.
Pulse flow Test Switch.
RPM test.
Drain Switch.
Hold Switch.
Buzzer.
Power/Battery Switch.
Battery Terminals.
Fuse.
Kindly remove all the packing material & clean the components if required. Please
check the components as per list. If you have any difficulty, please feel free to
contact us.
2. PHOTOGRAPH OF SYSTEM
3 INJECTOR CLEANER AND TESTER MACHINE (SEMI AUTOMATIC)
Xtreme Engineering Equipment (P) Ltd.
3. INTRODUCTION
Multi Point fuel injection is much more efficient both in terms of fuel efficiency
as well as performance, but if the quality of fuel is not good, the injectors may
get clogged and replacing them is expensive.
In order to provide adequate after sales service the dealer is required to equip the
garage with facility for fuel Injector servicing. Machine has been developed
indigenously that not only cleans the clogged injector but also assesses other
conditions such as flow over, low flow and spray pattern.
The machine has been specially designed to clean and test fuel injectors of all
makes and models of MPFI cars on road in India. The machine can accept any
type of injector without changing detachable adapters on manifold as well as ‘O’
Ring or Washers. This is micro controller-based machine simple to operate and
4 INJECTOR CLEANER AND TESTER MACHINE (SEMI AUTOMATIC)
Xtreme Engineering Equipment (P) Ltd.
programmed to provide the functions as:
1. Power
2. Clean
3. Pulse Flow Test
4. RPM Test
5. Drain
6. Hold
The Injector Cleaning Machine has been designed to clean the Injector of the
Cielo/Matiz/Santro/Opel/ Maruti/Ford Ikon etc. Cars. The discharge of each
INJECTOR can also be measured as detailed later.
4. SYSTEM DESCRIPTION
1. Operation Display:
Operation Display indicates the time pending & current function during cleaning
and testing operations. The time shown in the display is in seconds.
2. Power Switch:
Power Switch is two make the machine ready for any function.
3. Clean Switch:
Clean switch is used to run the machine in cleaning mode to clean the Injectors.
4. Pulse Flow Test Switch:
This switch is used to test the Injectors by making them on and off. The valves
should be closed for this test. The user has to see the chemical level collected in
the glass burettes. The Chemical level in the burettes should be same if all
Injectors are working with same efficiency.
5. RPM Test (500 to 9000 RPM)
The practical Car running condition for Injectors is tested in this test. The
Injectors are pulsed to run at as High Speed as they run in Car when it is moving
on road.
6. Drain Switch:
The Drain Switch used to send the extra remaining chemical after the all cleaning
& testing Operations. For avoiding any type of leakage or wastage of chemical.
5 INJECTOR CLEANER AND TESTER MACHINE (SEMI AUTOMATIC)
Xtreme Engineering Equipment (P) Ltd.
7. Buzzer:
The BUZZER will sound up to ensure the completion of process.
8. Hold Switch:
Hold switch is to pause any of the operation any time. To resume the paused
operation again push the same switch.
9. Pressure gauge:
The Pressure gauge will indicate the pressure of chemical create by the pump
[Link] Screw:
The Injectors will be fitted with the rail by the help of these tightening screws.
[Link] Rail:
This part of the machine supplies the chemical to the Injectors. There is no need to
change any O-Rings or adaptor for any type of Injector.
[Link]:
through the Burettes the user can see or analyze the spray pattern comes from the
injectors & the total
chemical Level sprayed by the Injectors in certain tests.
5. POWER CONTROL PANEL
1. Power/Battery Switch:
The switch used to make change over the Power Supply from mains to Battery or
Vice versa. It means the machine can be operated on mains as well as on battery
by selecting the right position of switch. (Up or Down)
2. Battery Terminals:
In the case of Power Failure the machine could be operated on 12V D.C. @15
Amp. Battery supply. The positive terminal of the battery should be connected to
6 INJECTOR CLEANER AND TESTER MACHINE (SEMI AUTOMATIC)
Xtreme Engineering Equipment (P) Ltd.
the positive terminal (Red Terminal) and the Negative terminal should be
connected terminal (Black Terminal) of the Machine
3. Fuse:
The fuse unit is mounted on this panel to protect the circuitery or electrical
components of the machine from any type of electrical disturbances..
6. TO CLEAN AND TEST THE INJECTORS
1. Press the power push button on the system Control Panel. The display will show
“READY”.
2. Now press the CLEAN PUSH BUTTON. The PUMP and intermittent
ON/OFF circuit will start.
3. After the elapsing of set time for cleaning operation, the display will show
“READY” and buzzer will turn on the sound
4. Now press the Pulse Flow Test Push button to check the discharged chemical
from each Injectors. The closing valves should be closed for this test. The user
has to see the chemical level in each burette which should be the same.
5. After the Pulse Flow Test the user must perform the Open Flow Test for
analyzing the spray pattern and chemical sprayed by the Injectors. The closing
valve should be closed for this test also and the chemical level also remains same
in all the burettes if injectors don’t have any fault.
6. Now the user has to check the leakage from each Injector through the leak test
switch. There should not a single drop chemical leakage from any Injectors.
7. Up to this stage the user has done all the cleaning & testing operation of the
machine.
Before removing Injectors from Machine, the user has to Drain all the extra or
Balance Chemical of the Rail by pressing the Drain Push Button.
.
7 INJECTOR CLEANER AND TESTER MACHINE (SEMI AUTOMATIC)
Xtreme Engineering Equipment (P) Ltd.
TO REMOVE INJECTORS
1. Untighten the Tightening Screw on the Rail Support.
2. Gently remove the connectors from the INJECTORS.
3. Gently pull the INJECTORS from the RAIL sockets
FILLING THE TANK
1. Flush the tank by filling the TANK with at least ½ liter of chemical and then
draining it out from the drain hole.
2. Tighten the DRAIN NUT.
3. Fill the TANK with Butanol.
7. OPERATIONS
1. Untighten the Tightening Screw and insert the INJECTORS to be cleaned in the
sockets on the RAIL SYSTEM. Ensure the alignment of the Injectors.
2. Tighten the Tightening Screw the to anchor RAIL properly.
3. Fix the connectors on the INJECTORS.
4. Now the machine is ready to start the power Control Panel & System Control
Panel.
8 INJECTOR CLEANER AND TESTER MACHINE (SEMI AUTOMATIC)
Xtreme Engineering Equipment (P) Ltd.
5. If power supply is from battery (12 VDC@15 Amp) than keep the MAIN
BATTERY switch off and if power
supply is 220 V AC i.e. electricity then keep the MAIN/Battery switch ON.
6. Switch the power supply ON. The display will show nothing (remain blank.)
7. Now press the Power push button on the system control Panel & Display will
start showing “REDY”.
8. There are different type of operation can be conducted by the switches which are
on the system control panel. In the operation display first two letters display the
code of operation followed by pending time in seconds.
NOTE:
The user has to press the respective push button for each cleaning & testing
or Hold operation.
8. PRECAUTIONS
1. The cleaning chemical must be of reputed brand, no other chemical should be
used otherwise pump & wiring harness may be damage.
2. Check level of the CHEMICAL in the TANK with the help of Glass Chemical
Level Indicator.
3. Wipe any split BUTANOL on the Machine since this is inflammable, pungent
and Corrosive.
4. Use the fuse of correct rating. (10 Amp.)
5. Do not remove the RAIL or the INJECTORS prior to the completion of the
Drain Function.
6. Flush the tank at least once after every 200 hours of the operation.
7. Change the filter cartridge after every 200 hours of the operation.
8. Keep BUTANOL away from eyes, as it is pungent. In case of contact with the
eyes rinse thoroughtly
with water.
9 INJECTOR CLEANER AND TESTER MACHINE (SEMI AUTOMATIC)
Xtreme Engineering Equipment (P) Ltd.
9. Keep BUTANOL away from any naked flame since it is highly inflammable.
[Link] only APPROVED CHEMICAL for cleaning the INJECTORS since any
other liquid may damage parts like PUMP.
[Link] that the INJECTORS are properly aligned on the Panel before tightening
the RAIL as failure to ensure this may result in leakage of BUTANOL from top
of the INJECTORS.
9. TROUBLE SHOOTING GUIDE
TROUBLE SHOOTING GUIDE FOR THE INJECTOR CLEANING MACHINE
10 INJECTOR CLEANER AND TESTER MACHINE (SEMI AUTOMATIC)
Xtreme Engineering Equipment (P) Ltd.
11 INJECTOR CLEANER AND TESTER MACHINE (SEMI AUTOMATIC)
Xtreme Engineering Equipment (P) Ltd.
