Electronic Carburettor / Injector Balancing Tool 1. WARNING THIS PRODUCT IS A PROFESSIONAL TOOL WHICH SHOULD ONLY BE OPERATED BY A COMPETENT TRAINED TECHNICIAN AND ONLY FOR THE PURPOSE WHICH IT WAS DESIGNED FOR. READ THE INSTRUCTIONS FULLY BEFORE ATTEMPTING TO USE THIS TOOL. IF YOU HAVE ANY DOUBT ABOUT YOUR COMPETENCE TO USE THIS PRODUCT SAFELY WITHOUT ANY RISK, DON T! WHERE FLAMMABLE LIQUIDS AND VAPOURS ARE PRESENT, EXERCISE EXTREME CAUTION ENSURE THAT NO SMOKING OR ANY OTHER SOURCE OF IGNITION IS PRESENT. Page 1 of 14
1. Description The Prop-Tech Digital Vacuum Analyzer is a PC based interface with 4 highly sensitive transducers which connect to the engine's induction tracts via rubber tubes in the usual manner. 5mm & 6mm threaded adapters and a T-Piece are provided for connection to engines, which require them. The Digital Interface connects to the PC via a single USB connection. The Prop-Tech software provides all the display, storage and printing facilities. The use of a computer to do this means that Instead of just measuring the average amount of negative pressure in the way a vacuum gauge does, the is able to precisely analyse all the characteristics of the vacuum depression waves in the inlet tracts. With a dial gauge or mercury stick gauge you will see a heavily damped average of the rising and falling vacuum whereas with a computerized tool using accurate fast acting transducers can display the whole story, millisecond by millisecond. The advantages are that synchronization is far more accurate and the graphical display gives the user an insight into the whole induction process and the state of the valves and combustion chamber. Defective inlet & exhaust valves & camshafts, induction leaks and even incorrect valve clearances can be pinpointed, saving hours of wasted workshop labour time. 2. Software Installation Prerequisites To install the software you need: A PC with one available USB port. A laptop or notebook PC is highly recommended for practical reasons. A color printer is recommended. Windows95 OSR2, Windows 98, Me, Windows 2000, XP, WIN 8 One available CD-ROM drive, our download from Prop-tech.hu and adopt by USB stick To install Boot up the computer and start Windows. Page 2 of 14
Make sure you are logged on as an administrator. If the computer is set up with a multi-user environment (especially in the case of XP Home) it is best to be logged in on the same administrative user account you will use the software in. Insert the software CD into your CD-ROM drive the software should automatically start the installation. If not, use File Explorer (My Computer) and right click on the CD drive icon and select either autoplay or alternately explore and double click on the autorun file. The installation screen gives you a choice of programs to install. Click on the Vacuum Analyzer button. Follow the on-screen instructions click Next when prompted; it is required that you read and agree to the End User License Agreement in order to use the software; we recommend that you accept the default location suggested, but you can change it if you like; click Next and the program will complete the installation for you. After the Vacuum Analyzer program has installed, you can also choose to install other Prop-Tech programs for evaluation purposes if you wish, subject to the terms of the license. You will be able to see how the programs operate. You may open the included sample files, load or play them & print them where applicable. To run the software, double-click on the icon on your desktop. The first time it runs, you will be prompted to enter your company name, which will be used on printouts. Page 3 of 14
3. Connection Connect up to 4 rubber hoses from the Prop-Tech Interface to the vacuum take-of points on the inlets of the cylinders you wish to synchronize, following instructions given by the vehicle constructor. Depending on the configuration, it may be necessary to prepare the vehicle to provide access to the vacuum take-of points or to the adjustment screws. For example to remove or lift the fuel tank, to install an alternative fuel supply, etc. It is assumed that the user is a professionally trained mechanic who has sufficient training and qualification to carry out these tasks. Use of the 5mm or 6mm threaded adapters may be required and/or the T-Piece. Follow the vehicle manufacturer s instructions to make the connections. Connect the USB cable form the interface to the PC and secure the interface box, the rubber hoses and the connection cable safely away from any moving parts or hot components like exhaust pipes. Use common sense! If necessary one USB extension lead can also be used but it is generally easier to have the PC close to the engine you are working on, hence a laptop is ideal. NB WiFi aerials (e.g. in WiFi enabled laptops) will cause interference if too close to transducers. Keep away more than 20cm (8 ) when using a WiFi enabled laptop or turn of computer's WiFi radio. Page 4 of 14
4. Operation It is assumed that the operator is a trained technician who knows how to synchronize carburettors and injectors, so we will not cover the detail here. Start the engine and start the program on the computer. The USB symbol in the bottom right of the screen should confirm connection to the interface box. To start synchronizing, click on Enable test. At the end of the task, click on Disable Test. To save the test, click on Save As and choose a name for the test to identify it. We recommend recording a test of the engine as it is before you start work. That way you can print a record of the state of the engine balance prior to your work. It is always useful to be able to show the customer a before and after report and this can be a good sales aid for your business. Normally you tell your customer that the work has been done, but with a printout they can actually see the results. Page 5 of 14
5. Software Use The software is designed to be very clear and simple to use. The features and controls are described below. Individual vacuum curves for each cylinder Average pressure figure. Measurement unit selection Language selection Large comparison of vacuum Curves. On a good, balanced engine these will all be the same shape Tachometer Replay test from beginning Playback control Pause / Resume File Open / Close Send current details to printer Minimum and maximum pressure by cylinders Slider toggle for test replay Column display for average vacuum measurement Exit from application Page 6 of 14
The above screen-shot taken from Replay Mode. When the program turns to Test Mode these controls are changing slightly as shown below. Enable Test start Disable: Test stop Save test to file Page 7 of 14
Synchronizing Firstly, balance the carburettors or injectors as closely as possible using the column and digital average vacuum displays. The RPM will be displayed while you synchronize the channels to give you an idea of the target idle speed. During the balancing phase, the curves may seem to change shape somewhat this is not important at this time. As the cylinders become more closely synchronized, the column colors change through red to yellow to green. When they are all green, you can concentrate on the digital displays for additional fine adjustment. Diagnostics When you have the best idle balance you can start to check the engine condition. It is worth remembering that with a multi-cylinder engine, any fault with valves or inlets is most likely to be unique to one cylinder and on that basis, it is best to look for any cylinder which difers from the others. In some cases even if the engine single cylinder, you can use the tool to check engine condition! Page 8 of 14
First, look at the minimum and maximum figures of each cylinder and compare them with the other cylinders. Normally any problem is more likely to be with the minimum. You can quickly blip the throttle to see if the min & max are roughly similar the curves will go a bit strange while they are rapidly changing do not worry this is normal. With the engine running at idle with the channels balanced as best as possible, check the curves in each cylinder for consistency. If any one cylinder s curve is diferent in shape to the others, then check the figures on the following page. Page 9 of 14
Fault diagnosis A Normal curve This is an example of a normal vacuum curve with no faults present. At idle, with all cylinders balanced, this is what you should expect to see. The curve may be slightly diferent depending on the compression ratio and the camshafts used, but remember that all cylinders should be the same. Any one cylinder which is diferent from the others should be investigated. Page 10 of 14
B Induction Leak (eg. leak on carburettor or manifold) Page 11 of 14
C Exhaust Valve Leak (eg. valve clearance too tight or faulty valve/seat) Page 12 of 14
D Inlet Valve Leak (eg. valve clearance too tight or faulty valve/seat) Note that positive pressure is recorded via the leaking valve. SMALL PRINT This tool should only be operated by a technically competent person. After balancing throttle body, adjust fuel individually! The tool and connection cable are covered by a 12-month warranty against manufacturing defects only. In the event of a defect within 12 months from purchase, please return to the point of purchase together with a copy of your invoice/receipt and a written description of the fault. No liability is accepted for any consequential losses whatsoever. Page 13 of 14