MODEL MCS 245

Service Manual

TABLE OF CONTENTS INTRODUCTION GENERAL................................................................................................................................................................. I SAFETY INFORMATION AND PRECAUTIONS...................................................................................................... I OVERVIEW ............................................................................................................................................................. III SYSTEM FEATURES AND FUNCTIONS................................................................................................. iv CONTROL PANEL FEATURES AND FUNCTIONS: ................................................................................ v HOSE AND BATTERY CONNECTIONS: side views............................................................................... vi FUEL FILTER: rear view …………………………………………………………………………………….......................................... viii

CHAPTER 1 THEORY OF OPERATION START-UP DIAGNOSTICS..................................................................................................................................1-1 NORMAL OPERATIONS......................................................................................................................................1-1 FILL OPERATION ...................................................................................................................................1-1 CLEANING OPERATION ........................................................................................................................1-1 LEAK TEST OPERATION .......................................................................................................................1-2 COMPONENTS ....................................................................................................................................................1-2 CONTROL PANEL PCB..........................................................................................................................1-2 FUEL LEVEL WINDOW ..........................................................................................................................1-2 GAUGES .................................................................................................................................................1-2 PRESSURE ADJUST REGULATOR ......................................................................................................1-2 PRESSURE RELIEF VALVE...................................................................................................................1-2 PRESSURE SWITCH..............................................................................................................................1-3 PUMP ......................................................................................................................................................1-3 SOLENOID ..............................................................................................................................................1-3 CONTROL PANEL FUNCTIONS .........................................................................................................................1-3 ADJUSTING CYCLE TIME......................................................................................................................1-3 POWER-ON CONDITIONS.....................................................................................................................1-4 SOUNDER (WARNING ALARM) ............................................................................................................1-4 STOPPING THE SYSTEM ......................................................................................................................1-4 SYSTEM WARNING ...............................................................................................................................1-4 TIMER OPERATION ...............................................................................................................................1-4 DIAGNOSTIC FUNCTIONS .................................................................................................................................1-4

CHAPTER 2 CALIBRATION AND INSTALLATION SYSTEM CHECK OUT PROCEDURE.................................................................................................................2-1 SERVICE FUNCTION CHECKOUT PROCEDURES ..........................................................................................2-1 REMOVING FLUID AFTER CHECKOUT.............................................................................................................2-3 PRESSURE RELIEF VALVE CALIBRATION PROCEDURES ............................................................................2-4 CONTROL PANEL PCB DIAGN0STIC PROCEDURES......................................................................................2-4 PUMP CHECKOUT PROCEDURES....................................................................................................................2-5 CONTROL PANEL REAR VIEW: schematic.......................................................................................................2-6 CONTROL PANEL REPLACEMENT PROCEDURE ...........................................................................................2-7 POWER HARNESS REPLACEMENT PROCEDURE .........................................................................................2-8 PRESSURE REGULATOR REPLACEMENT PROCEDURE ..............................................................................2-8 PRESSURE / VACUUM GAUGE REPLACEMENT PROCEDURE.....................................................................2-8 FUEL TANK REPLACEMENT PROCEDURE......................................................................................................2-9 PUMP & TANK BRACKET ASSEMBLY REPLACEMENT PROCEDURE ..........................................................2-9 PUMP REPLACEMENT PROCEDURE .............................................................................................................2-10 SOLENOID REPLACEMENT PROCEDURE.....................................................................................................2-10 PRESSURE SWITCH REPLACEMENT PROCEDURE ....................................................................................2-11 MANIFOLD BLOCK ASSEMBLY REPLACEMENT PROCEDURE ...................................................................2-12 RELIEF VALVE REPLACEMENT PROCEDURE ..............................................................................................2-12 DRAWER REPLACEMENT PROCEDURE .......................................................................................................2-12

CHAPTER 3 TROUBLESHOOTING TROUBLESHOOTING..........................................................................................................................................3-1 ELECTRICAL RELATED PROBLEMS....................................................................................................3-1

PRESSURE RELATED PROBLEMS ......................................................................................................3-1 FLUID RELATED PROBLEMS................................................................................................................3-3 MISCELLANEOUS PROBLEMS .............................................................................................................3-3 ICS RELATED PROBLEMS ....................................................................................................................3-3

CHAPTER 4 PARTS AND DIAGRAMS FRONT VIEW .......................................................................................................................................................4-1 REAR VIEW..........................................................................................................................................................4-2 SIDE VIEWS.........................................................................................................................................................4-3 MANIFOLD BLOCK ASSEMBLIES AND FITTINGS..............................................................................................4-4 COMPLETE REPLACEMENT PARTS LISTING..................................................................................................4-5 DIAGRAMS AND SCHEMATICS .........................................................................................................................4-9 CONTROL PANEL REAR VIEW .............................................................................................................4-9 ELECTRICAL SCHEMATIC ..................................................................................................................4-10 HYDRAULIC SCHEMATIC: FLOW DIAGRAM ....................................................................................4-11

APPENDICES APPENDIX A: FILTER AND MAINTENANCE PROCEDURES ......................................................................... A-1 APPENDIX B: STANDARD AND DELUXE ADAPTOR KITS .............................................................................. B-1

INTRODUCTION GENERAL The MotorVac CarbonClean System is a very reliable product designed to perform many years of service. Because of the environment in which the unit operates, safety dictates that all system problems be repaired quickly and correctly. This service manual describes how to operate, maintain and repair the MotorVac CarbonClean System. Please study the Operator, Service and Maintenance Procedures to become thoroughly familiar with the unit before attempting any repairs.

SAFETY INFORMATION AND PRECAUTIONS 1.

2.

3.

4.

Vehicle exhaust gases contain Carbon Monoxide, which is a colorless and odorless lethal gas. a)

Only run engines in well-ventilated areas and avoid breathing exhaust gases.

b)

Extended breathing of exhaust gases will cause serious injury or death.

Exhaust gases, moving parts, hot surfaces, and potent chemicals are present during the use of the fuel system cleaner. a)

Read and understand the operator's manual before using the fuel system cleaner.

b)

When using chemicals always refer to the MSDS sheets and manufacturers’ instructions for the proper procedure to handle emergency medical treatment, cleanup, handling, and storage requirements.

c)

Improper use of the fuel system cleaner or exposure to exhaust gases or cleaning chemicals can cause injury.

Flammable fuel chemical and vapors can ignite. a)

Avoid exposure to flames, sparks, hot engine parts, and other ignition sources. Always keep fully charge fire extinguisher nearby. The extinguisher should have a class B rating and be suitable for gasoline, chemical, and electrical fires.

b)

Cleanup any fuel or chemical spills immediately.

c)

Dispose of contaminated cleanup material according to governing environmental laws.

d)

Never look directly into the air induction plenum or carburetor throat when the engine is operating. Always plug or cap any open fuel lines during service.

e)

Keep Cleaner and Detergent container closed except when filling reservoir.

f)

Explosion or flame or exposure to flammable liquid and vapors can cause injury.

Flammable liquid can splash out of reservoir when pump is on and/or unit is being moved. a)

Always keep Reservoir Cap secure except when filling reservoir.

b)

Explosion or flame can cause injury.

SAFETY INFORMATION AND PRECAUTIONS continued... 5.

6.

7.

8.

9.

10.

11.

Many fuel systems maintain residual pressure in fuel lines even after the engine has been turned off. a)

Wear safety goggles.

b)

Wear chemical resistant gloves when connecting or disconnecting fitting and adapters.

c)

Obtain ZERO PSI before connecting or disconnecting any fuel lines or adapters.

d)

Explosion or flame or exposure to flammable liquid and vapors can cause injury.

Chemicals can cause harmful byproducts. a)

Use only approved chemicals (refer to operator's manual).

b)

Do not swallow or ingest any chemicals.

c)

Use with adequate ventilation. Avoid breathing vapors.

d)

Do not store chemicals on the machine.

e)

Improper use of chemicals can cause injury.

f)

Over exposure can have harmful effect on eyes, skin, respiratory system and possible unconsciousness and asphyxiation.

Improperly blocked vehicles can move. a)

Set the parking brake and chock the wheels.

b)

Moving vehicles can cause injury.

Moving engine parts. a)

The engine-cooling fan will cycle on and off depending on the coolant temperature and could operate without the engine running.

b)

Wear safety goggles.

c)

Always keep objects, clothing, and hands away from the cooling fans and engine parts.

d)

Moving engine parts can cause injury.

Hot surfaces are present during and after running the engine. a)

Do not contact hot surfaces such as, manifolds, pipes, mufflers, catalytic converters, or radiators and hoses.

b)

Hot surfaces can cause injury.

Catalytic converters become extremely hot. a)

Do not park a converter-equipped vehicle over dry grass, leaves, paper, or any other flammable material. Do not touch a catalytic converter until the engine has been off for at least 45 minutes.

b)

For tests allowing unburned hydrocarbons or service involving operation of an overly rich condition, minimize the time of rich operation, monitor the catalytic converter temperature, and allow at least two minutes of operation at normal mixture subsequent to testing or service for converter cooling.

c)

Catalytic converters can cause burns.

Cracked fan blade can become airborne. a)

Examine fan blades for cracks. If found, do not service the vehicle.

b)

Flying objects can cause injury.

SAFETY INFORMATION AND PRECAUTIONS continued... 12.

Batteries produce explosive gases and can explode. a)

Wear safety goggles when working on or near batteries.

b)

Use in a well-ventilated area.

c)

Keep sparks and flames away from the battery and never lay tools, equipment, or other conductive objects on the battery.

d)

When tools or equipment is connected to the battery, make sure the equipment power switch is off. Connect the positive lead of the equipment to the positive lead battery first; connect the negative lead of the equipment to a solid ground point as far from the battery as possible.

e)

Keep battery acid away from skin or eyes. In case of eye contact, flush with clean water for 15 minutes and get medical attention.

f)

Battery explosion and ignited gases can cause injury.

IMPORTANT: In high static conditions, ensure that the negative battery cable is properly connected to a suitable chassis ground.

OVERVIEW The MotorVac CarbonClean System is a self-contained microprocessor-based cleaning system designed to connect to any gasoline engine. Once the unit is connected, it temporarily replaces the regular fuel supply with a mixture of gasoline and the specially formulated MotorVac CarbonClean Detergent and Top Engine Cleaner. With the engine idling, the unit pumps the gasoline/detergent mixture through the engine's fuel system. As the mixture passes through the vehicle fuel system, it loosens and dissolves accumulated deposits, which then pass harmlessly out through the exhaust system or are removed by the unit fuel filter. Removing contaminants from the combustion chamber creates a more even burn of fuel, that improves horsepower, increases fuel economy, and reduces exhaust emissions.

SYSTEM FEATURES AND FUNCTIONS The front of the MotorVac CarbonClean System cabinet contains a firmware-driven control panel, the opening for the fuel reservoir, and storage drawers for adapters and other system accessories. See figure 01.

REVERSE POLARITY

SYSTEM STOP BUTTON

TIME DISPLAY, CYCLE COMPLETE LED & TIMER

UP & DOWN

START BUTTON

FILL/PURGE BUTTON

LEAK TEST

ENGINE VACUUM

FUEL PRESSURE PRESSURE REGULAT

FUEL LEVEL

System Features and Functions Descriptions of the gauges, control buttons, and LED indicators that make up the control panel are listed below. Please become familiar with these control panel features and functions before using the unit. Engine Vacuum Gauge

Displays vacuum pressure on the vehicle being serviced.

Up Arrow LED

Illuminates when the run cycle is under way.

Down Arrow LED

Illuminates when the filling process is under way.

Fill/Purge Button

Fill: Transfers fuel from the fuel tank of the vehicle being serviced to the unit’s reservoir. Purge: Relieves fuel lines of remaining pressure by transferring fuel back into the unit’s reservoir.

Stop Button

Stops all run conditions.

System Warning LED

Illuminates when: • The fuel/detergent mixture runs out before run time expires. • Vehicle or unit pressure loss is detected.

Warning Alarm

Beeps when the run cycle is complete, and when the vehicle or unit pressure loss is detected.

Reverse Polarity LED

Illuminates when: Polarity is reversed on the connection between the vehicle battery and the unit.

•

Fuel Level Window

A window to see the amount of fuel/detergent mixture remaining in the unit’s reservoir.

Cycle Complete LED

Illuminates when the run cycle ends.

Timer Buttons

Allows the increasing or decreasing of time set on the timer. The  button increases the time, and the , button decreases the time.

Time LED

A circle of LEDs displaying the remaining run cycle time in fiveminute increments.

Start Button

Starts the run cycle.

Leak Test Button

Starts the Leak Test.

Fuel Pressure Gauge

Displays output pressure of the unit’s output hose, or system pressure of the vehicle being serviced.

Pressure Adjust Regulator

Used to adjust the system pressure during the cleaning process. Turn clockwise to close (increase the pressure); counterclockwise to open (decrease the pressure).

Hose and Battery Connections As you face the system, the left side of the unit’s cabinet holds the fuel return and output hoses (See Figure 0-2), while the right side of the unit’s cabinet holds the battery cables and vacuum pressure hose (See Figure 0-3).

Figure 0-2

Serial ID Plate

Output Hose (Red)

Support Hanger

Return Hose (Black)

Quick Couplers

Output Hose (red)

Connects to the input side of the vehicle's engine fuel system.

Return Hose (black)

Connects to the return side of the vehicle's engine fuel system.

Quick Couplers

Secures the unit’s return/output hose connections to the vehicle's engine fuel system.

Figure 0-3

Support Hanger

Support Hanger Vacuum Hose

Battery Cables Red (pos) Black (neg)

Vacuum Hose

Forms a connection between the vacuum pressure from the vehicle engine and the vacuum pressure gauge on the unit.

Battery Cables

Positive (red) and negative (black) battery connections (11-15 VOLTS DC)

Fuel Filter The back of the unit’s cabinet (See Figure 0-4) contains an easy access area for the fuel filter. Please see Appendix A for information on replacing the unit’s fuel filter.

Figure 0-4

Air Vents

System Filter

Air Vents

Wheels

CHAPTER 1 THEORY OF OPERATIONS START-UP DIAGNOSTICS The MotorVac CarbonClean System has automatic start-up diagnostics that allow for safe electrical connection to any vehicle. If the battery polarity is reversed, the unit will not start and the REVERSE POLARITY LED will illuminate. All of the start up functions are controlled by the Microprocessor.

NORMAL OPERATIONS FILL OPERATION: •

When the FILL/PURGE button is pressed and held the solenoid opens and the motor starts the pump in the fill/purge direction, the pump is running in reverse at this time. Releasing the button stops the motor and closes the solenoid.

•

If the motor is pumping in the CLEAN direction the FILL/PURGE button is ignored.

•

Whenever the motor is pumping in the fill/purge direction, the DOWN ARROW LED (away from car) is on.

CLEANING (RUN) OPERATION: •

When the START button is pressed and held the motor will pump in the clean (run) direction (the pump is running forward at this time) and the solenoid opens.

•

When the START button is released after the pressure gauge reads at least 4 PSI the pump will continue to run and the TIME LED display will show the clean run time. The default clean time is 30 minutes. Refer to the Adjusting Cycle Time section for operation of the timer buttons.

•

When the run time is complete, the motor stops and the end of cycle alarm will sound for 6 seconds. When the motor stops, the solenoid stays open and 1 second later the motor will run in the purge direction for 5 seconds. When the purge is complete, the motor stops and the solenoid closes.

•

If the pressure drops below 4 PSI while the motor is running, or the START button is released before the pressure reaches 4 PSI, the motor will stop for 1 second, then run in the purge direction for 5 seconds with the solenoid open. While the purge is in progress the alarm and SYSTEM WARNING LED will be illuminated for 6 seconds. When the purge is complete, the motor stops and the solenoid closes.

•

Whenever the motor is pumping in the clean direction the UP ARROW LED (toward the car) is illuminated. This LED will blink while the pressure switch is open (less than 4 PSI) and stays on solid when the pressure switch is closed (greater than 4 PSI).

LEAK TEST OPERATION: •

The LEAK TEST button can only be pressed while the motor is pumping in the clean direction during a cleaning cycle. All other times the LEAK TEST button is ignored.

•

When the LEAK TEST button is pressed and released, the solenoid will close and 150ms later the motor will stop pumping. The TIME LED display will show the leak test time. The default leak test time is 5 minutes. Refer to the Adjusting Cycle Time section for operation of the timer buttons.

•

When the leak test run time is complete, the solenoid remains closed and the end of cycle alarm will sound for 6 seconds. If the STOP button is pressed, during a leak test, the unit will open the solenoid and perform a purge. Pressing and holding the START button will cause the motor to pump in the clean direction and the solenoid opens.

•

During the leak test, only the TIME LED display will be illuminated.

COMPONENTS CONTROL PANEL PCB: •

The control panel PCB is a microprocessor base unit driven by a firmware EPROM.

• •

The EPROM version can be displayed when the control panel PCB is placed into it's diagnostic mode. The only readily serviceable item on this PCB is the 8-ampere fast-acting (5mm x 20mm) fuse.

FUEL LEVEL WINDOW: • •

The fuel level window show the amount of fuel in the fuel tank. The fuel level window has markings indicating ¼ tank increments.

GAUGES • •

The pressure gauge is a custom component for the MotorVac CarbonClean System. The fuel pressure is a 0 to 160 PSI (0 to 11 Bar) gauge with a 2% of full-scale accuracy. Vacuum gauge is a custom component for the MotorVac CarbonClean System. Primarily used for immediate verification of a job well done. Vacuum pressure is a 0 to 30 in. Hg. (0 to –1.0 Bar) gauge.

PRESSURE ADJUST REGULATOR: •

The pressure regulator is a stainless steel needle valve type regulator that is set up for unidirectional flow regulation.

PRESSURE RELIEF VALVE: • • •

The pressure relief valve is an adjustable unidirectional valve. This valve controls the units maximum pressure range. The range is 105 to 125 PSI. The nominal setting is 115 PSI. This valve can be adjusted from the outside of the unit, see the appropriate procedures in the calibration chapter.

PRESSURE SWITCH: • • • •

The pressure switch is opened when the pressure is less than 4 PSI and is closed when the pressure is 4 PSI or greater. The pressure switched is used to determine if the system should continue to pump in the clean direction or if a 5 second purge is required. While the pump is running in the clean direction, the UP ARROW LED (toward the car) will blink while the pressure switch is open and stays solid while the switch is closed. The pressure switch receives between +3 to +5 VDC from the control panel PCB.

PUMP: • • • •

The fuel pump is driven by a 12VDC electric motor. The pump and motor are magnetically coupled. If the pump de-couples, the motor will continue to operate but the pump will stop. To Re-couple, simply stop the unit completely and restart. The pump may de-couple if the pressure exceeds 150 PSI. Do not use Teflon tape on the plastic fittings in the pump, only use Teflon paste sealants. A typical pump draw at 40 PSI is 3 amperes at 11 volts.

SOLENOID: • • •

The solenoid is only opened when the motor is running and during the 1-second delay before an auto purge. The solenoid needs to be energized to be opened, so the solenoid will be closed when the unit is powered off. The solenoid is powered by the control panel PCB with approximately 1V less than the supply voltage to the unit.

CONTROL PANEL FUNCTIONS ADJUSTING CYCLE TIME: •

The Time Up () and Time Down (,) buttons are used to adjust the cycle time while a cleaning, or leak test is in progress.

•

The maximum settable time is 60 minutes, the minimum settable time is 5 minutes. The time can be adjusted in increments of 5 minutes: 5, 10, 15, etc. There is a 10-minute increment between 50 minutes and 60 minutes, so a time of 55 minutes cannot be set.

•

When the timer starts, the time can be adjusted. After the first minute from when the timer started the unit will check to see if the set time was changed. If it was, this new set time will be stored as the cycle time for the next run. This applies to the cleaning, and leak test times. The minimum time that can be stored is 5 minutes

•

If the Time Down (,) button is continuously pressed until the time reaches zero the end of cycle beeping/alarm will occur and the CYCLE COMPLETE LED will turn on.

POWER-ON CONDITIONS: •

When the unit is first powered, the CYCLE COMPLETE LED will turn on. The alarm will also turn on briefly, and the SYSTEM WARNING LED will flash once.

SOUNDER (WARNING ALARM): •

Whenever a button is pressed, the sounder will output a short tick.

•

When an alarm condition occurs, the sounder will go on and off at a rate of 10Hz and the SYSTEM WARNING LED will blink every 1/2-second.

•

At the end of a cleaning or leak test the sounder will make a long beep every second and the CYCLE COMPLETE LED will stay illuminated.

STOPPING THE SYSTEM: •

Whenever the STOP button is pressed, the motor will stop, Auto Purge for 5 seconds, and the TIME LED display turned off. The STOP button will also turn the warning alarm or end of cycle alarm off.

•

The solenoid closes when the STOP button is pressed.

SYSTEM WARNING: • The system warning will occur if the START button was released before the pressure switch was activated or if the pressure switch deactivates during a cleaning. TIMER OPERATION: •

While the timer is running, all the LEDs for the time remaining will be illuminated. The highest value LED will blink. For example, if a cycle starts to run for 20 minutes, the 5, 10, and 15 minute LEDs will be illuminated and the 20-minute LED will blink.

•

The TIME LEDs that are illuminated indicate that the cycle time is the time showing or up to 4 minutes less. For example, if 12 minutes are left in the cycle run, the 15-minute LED will flash until the timer reaches 10 minutes.

•

As the timer ticks down, the LEDs are updated. When the timer reaches 0, the CYCLE COMPLETE LED will illuminated and the end of cycle alarm will sound. After 6 seconds the alarm stops and the CYCLE COMPLETE LED turns off.

DIAGNOSTIC FUNCTIONS Diagnostics: •

The unit enters the Diagnostics mode by pressing the STOP button while powering up the unit. The SYSTEM WARNING LED will be illuminated to indicate the unit is in Diagnostics mode.

•

The timer dial will display the software version number as follows: The TIME LED display LED that is illuminated indicates the version integer (whole number) number, with the CYCLE COMPLETE LED meaning zero and increasing in increments of 1 going clockwise. For example, a version of 1.0 will have the 5-minute TIME LED illuminated.

•

If the START button is pressed at this time, the unit will continuously turn on and off each LED (except the Reverse Polarity) in an orderly manner to test that all the LEDs are working. Pressing the STOP button will end this test and the unit enters normal operation mode.

•

If both the Time Up () and Time Down (,) buttons are pressed at the time the system first entered diagnostics mode, a memory test will be performed. Both the UP and DOWN ARROW LEDs will be illuminated during the memory test. If the memory test passes, the UP and DOWN ARROW LEDs will turn off and the SYSTEM WARNING LED will stay illuminated. If the test fails every LED on the timer dial will turn on. The memory test will return all timer values to default settings regardless of the outcome of the test.

CHAPTER 2 CALIBRATION & INSTALLATION PROCEDURE - READ PROCEDURES THROUGHLY BEFORE SERVICING UNIT.

SYSTEM CHECK OUT PROCEDURE 1. Check external connections and clean exterior of cabinet. 2. With a Phillips head screwdriver, remove rear panel. 3. With the rear panel removed, visually check inside the unit for obvious problems such as leaks, or wires and fittings that are loose, broken, or disconnected. Repair as necessary. 4. Check the sides and bottom of the unit's interior for fluid, dust, or dirt. Carefully wipe liquid or debris from all connections and surfaces with a clean shop cloth to easily detect less obvious leaks. Repair leaks as necessary. 5. Hand check all fittings, hydraulic connections, regulators, solenoids, and connections for tightness. Tighten as necessary.

Service function checkout procedures 1. Connect the OUTPUT (Red) hose to "T" adaptor (060-4500) valve end (male quick disconnect) and connect the RETURN (Black) hose, using adaptors (060-1100) and (060-1400) hose clamp together. Connect to the "T" adaptor forming a complete loop. This will simulate a vehicle's fuel rail and regulator assembly. There will be one unused end of the “T” adaptor. See figure below. 2. Connect battery leads to a suitable 12 volt battery, RED = Positive, BLACK = Negative. Check that the unit powers up and that the TIME display is on, CYCLE COMPLETE LED.

Figure 2- 1

a)

If unit doesn’t power up then check battery connections, and supply voltage. Verify that power is present at the control PCB and fuse, with a multimeter. To test for power at the control PCB, probe the test points next to the power cord connector on the PCB. See Control Panel figure in this chapter. i)

If power is not present at the control PCB, then test the power harness and fuse for continuity with a multimeter. Replace any faulty parts.

ii)

If power is present at the control PCB and no lights or functions are operational, then perform the Control Panel PCB Diagnostic Procedures (in this chapter). If the procedures do not remedy the problem, then the control panel PCB may need to be replaced.

3. Reverse the polarity of the battery leads. Check that the "REVERSE POLARITY" light is on. Reconnect battery leads correctly. 4. Add at least 1/4 tank of fuel. Check that FUEL LEVEL Window.

5. Close "T" adaptor valve. 6. Turn pressure adjust regulator in completely (closed, clockwise), then back out a half turn. 7. Press and hold the START button while watching the pump and manifold assembly for any leaks. Once pressure has increased to approximately 4 PSI the UP ARROW LED should stay illuminated, release the START button. a) The UP ARROW will flash until the 4-PSI is attained, and then stay on solid after that. If this doesn’t occur check connections to the pressure switch and its operation. See Pressure Switch section in the Theory of Operation chapter. b) If the pump doesn’t start, check connections, voltage and amperage at the pump. See Pump Check Out Procedures in this chapter. 8. Continue to inspect internal components, while increasing pressure to 80 PSI (all fluid points: filter, hoses, gauge, tank, etc.). 9. Turn PRESSURE ADJUST regulator until closed. Note pressure. Pressure should be between 105-120 PSI. Check for leaks. a) If pressure doesn’t reach specifications. Verify that there is fuel returning into the tank, by observing the fuel flow through the filler neck of the tank. The return/bypass fuel should be flowing into the top of the tank, just to the right of the filler neck. i)

If there is still a substantial fuel flow, the pressure relief valve may be opening too soon. See Pressure Relief Valve Calibration Procedure for adjusting this valve, in this chapter.

ii)

If there is very little or no flow, check for any line restrictions, the filter, and the pump output (see Pump Check Out Procedures in this chapter).

10. Set pressure to 75 PSI with the PRESSURE ADJUST regulator, open "T" valve briefly (5 seconds) then close (this relieves any air in the hoses). Readjust pressure to 75 PSI if necessary. 11. Press the LEAK TEST button (pump will run for a ½ second, then shut off). This is a normal function for the LEAK TEST button. If this doesn’t happen check connections. 12. Check that pressure doesn't drop more than 5 PSI in 2 minutes. a) If pressure drops: During the leak test the solenoid will close (de-energize) and capture the pressure. When the solenoid is energized the solenoid is open. To verify if the solenoid is energized or not, place a small steel screw near the coil. When energized the screw will be held by the magnetic forces, and released when not energized. * NOTE: There should not be any leaks in the Female Quick Disconnects or any other adaptors used in the testing of this equipment, otherwise false readings will occur. i)

If the solenoid doesn’t energize and de-energize at the proper times, check connections and voltages applied. The solenoid should receive approximately 1 volt less than battery supply voltage.

ii)

If the solenoid is working electrically, and the pressure still drops. Disassemble (this can be done without removing from unit) and inspect solenoid for debris, damage, or sticking. If the solenoid plunger is damaged or swollen (possible improper fuels or chemicals), replace plunger assembly. See Solenoid Procedures in this chapter.

13. Press STOP. Repeat steps 10 through 12, and restart unit and build pressure back up to 50 and then again with 25 PSI instead. 14. Restart unit and build pressure back up to 50 PSI and reset timer to 5 minutes. Let unit run until time expires. When the cycle is complete check that unit runs in purge mode for at least 5 seconds, and stops. Press STOP button. Repeat this step one more time. a) This will verify that the timer, Cycle Complete and Auto Purge modes are operating correctly. 15. Restart unit and build pressure back up to 50 PSI and reset timer for 15 minutes. 16. Close PRESSURE ADJUST regulator completely while opening valve on the "T" adaptor until 50 PSI is maintained. Let unit run until time expires. While unit runs, check for any leaks. 17. When unit times out, check if the Auto Purge reverses the pump, fuel pressure drops and CYCLE COMPLETE LED illuminates. A continual alarm will sound for 6 seconds. 18. Press STOP to turn off alarm before the 6 seconds is complete. a) This will verify that STOP will shut off the Cycle Complete alarm.

19. Press and hold FILL/PURGE for at least 10 seconds. Check that pump goes into manual purge mode, and the solenoid is energized. a) This can be verified by watching the fuel in the clear lines at the pump output side, and following its direction of flow. The pump head is marked, on the end, “IN” and “OUT”. The solenoid is checked the same as in step 12.a. 20. Close valve on the "T" adaptor. Disconnect RETURN (BLACK) hose, OUTPUT (RED) hose from "T" adaptor, and separate adaptors (060-1100) and (060-1400). 21. Connect adaptor (060-1400) onto the OUTPUT hose. Securely restrict the open end of the adaptor by crimping the hose in half or using smooth jaw vise grips. 22. Back PRESSURE ADJUST regulator out 1/2 turn from closed position. Restart unit and build pressure back up to 50 PSI. 23. Using a suitable fuel container or the reservoir on the unit, open vise grips or crimped hose completely and quickly. Unit's pressure should immediately drop below 4 PSI and the Auto Purge function should reverse the pump for approximately 5 seconds while activating the SYSTEM WARNING ALARM and LED. a) If the alarm doesn’t turn on and the UP ARROW turn off, then either the pressure didn’t drop or the pressure switch is not working properly. i)

Verify that there is not a restriction when the crimped adaptor is released, and that this is being done in rapid manner. Also, check that there are no other crimped or pinched hoses or lines in the system.

ii)

If there are no restrictions, then retest several times to verify the problem is consistent. The Pressure Switch may not be opening the circuit when the pressure drops below 4 PSI. While testing the switch, try disconnecting the switch from the control PCB to simulate an open circuit; the unit should perform an Auto Purge. If it does, then replace the Pressure Switch. If it doesn’t then the control PCB may be at fault.

24. Press the STOP button to shut off alarm. 25. Remove adaptor. Disconnect battery leads. Roll up hoses on bracket. Check internal connections and clean interior. Replace rear panel.

REMOVING fluid after checkout 1. To remove any fluid that may have been used during the service checkout, use the following procedures. 2. Close the PRESSURE ADJUST regulator completely. Connect adaptor (060-1400) onto the OUTPUT hose. Place the open end of the adaptor into a container. 3. Press and hold the START button until fluid stops coming out of the adaptor, release button. Open regulator completely. Discard fluid according to local, state, and federal regulations. Remove adaptor.

PRESSURE RELIEF VALVE CALIBRATION PROCEDURES 1. Disconnect any power to unit. 2. Remove RETURN (BLACK) hose from elbow fitting, then remove elbow fitting from nipple leading into the unit. Be sure to support the elbow fitting, with the appropriate wrench, when removing the hose, and the nipple when removing the elbow. 3. Insert a 5/32” hex tool (at least 5 inch long) into the nipple, through the manifold block, and into the pressure relief valve. See the figure below. Loosen the locking nut counterclockwise then push the hex tool into the adjusting nut, turn both nuts clockwise to increase the maximum output pressure (approx. 1/4 turn for a 15 PSI modification). Tighten the locking nut securely. 4. Reinstall fitting (use Teflon sealer or Teflon tape on threads only) and RETURN hose assembly (no sealant should be used for hose connections). a) A temporary cap (1/4”FNPT) could be used to cap-off the nipple while testing the unit for proper pressure setting (there may be approx. 2-10 PSI. of fuel pressure, at the nipple).

5. Verify that no adaptors are connected to the OUTPUT hose. Turn the PRESSURE ADJUST REGULATOR clockwise to the end of its travel, then back it off a 1/2 turn. 6. Reconnect a power supply. Start unit and slowly build up the pressure by closing the PRESSURE ADJUST REGULATOR to the end of its travel, this should be maximum system pressure.

7. Pressure should be between 105 and 120 PSI (115 PSI Nominal). Repeat adjustment procedure if necessary. Figure 2- 2 Relief Valve: Adjustable M. V. part no.: 050-0088

Adjustment Nut Locking Nut

Hex 5/32 inch. Tension Spring Relief Valve body

If adjustment nut haves a bevel varify that it is facing the lock nut

Control panel PCB diagnostic Procedures 1. The unit enters the Diagnostics mode by pressing the STOP button while powering up the unit. The SYSTEM WARNING LED will be illuminated to indicate the unit is in Diagnostics mode. a) The timer dial will display the firmware version number as follows: The TIME LED display LED that is on indicates the version integer number, with the CYCLE COMPLETE LED meaning zero and increasing in increments of 1 going clockwise. For example, a version of 1.0 will have the 5-minute TIME LED on and a version of 2.0 will have the 10-minute TIME LED on. 2. If the START button is pressed at this time, the unit will continuously turn on and off each LED (except Reverse Polarity) in an orderly manner to test that all the LED’s are working. Pressing the STOP button will end this test and the unit enters normal operation mode. 3. If both the Time Up () and Time Down (,) buttons are pressed at the time the system first entered the diagnostics mode, a memory test will be performed. Both the UP and DOWN ARROW LED’s will be on during the memory test. If the memory test passes, the UP and DOWN ARROW LED’s will turn off and the SYSTEM WARNING LED will stay on. If the test fails every LED on the timer dial will turn on. The memory test will return all timer values to default settings regardless of the outcome of the test.

Pump Checkout Procedures 1. If the pump de-couples, the motor will continue to operate but the pump will stop. To Re-couple, simply stop the unit completely and restart. The pump may de-couple if the pressure exceeds 150 PSI. 2. Do not use Teflon tape on the plastic fittings in the pump, only use Teflon paste sealant. 3. A typical pump draw at 40 PSI is 3"1 amperes at 11 volts. Higher draws than this may indicated a restricted (Input or Output) flow or possibly a worn or defective pump. 4. A sufficient flow for the unit would fill a 1-quart container in 1 minute. a) To determine this, close the PRESSURE ADJUST REGULATOR completely and attach an adaptor to the OUTPUT hose. Insert the adaptor's open end into the container, and press and hold the START button. Monitor the fuel flow and the time it takes to fill the container.

CONTROL PANEL REPLACEMENT PROCEDURE 1. Remove any power source connected to battery leads, and rear panel of unit. 2. Remove all wire connectors from Printed Circuit Board (PCB). 3. Remove hose to pressure gauge and hose to vacuum gauge. 4. Remove ten nuts holding the control panel from inside the unit. Suggested tools: 5/16” deep socket with swivel, and an 8" to 10" extension. a) The two left most nuts on the upper portion of the panel can be removed through the vent slot, above the filter. 5. Remove pressure regulator knob (3/32” hex key) and then regulator (3/4” wrench) from control panel, do not remove hoses from regulator. See Pressure Regulator Replacement Procedure if necessary. 6. Pull control panel off unit. If the circuit board needs to be replaced follow next steps: a) Remove 5 6-32 Kep nuts holding PCB, disconnect the ribbon connector from membrane switch (keypad) overlay. b) Remove PCB from control panel. c) Verify that spacers are in place, install PCB with LED’s towards control panel. Line up LED’s with holes in control panel. d) Fasten board with 5 6-32 Kep nuts, and tighten. Connect ribbon connector from membrane switch overlay. The leftmost connection connects to pin #1 on the PCB (see control panel figure 2-3 in this chapter). 7. Install control panel. Verify that PCB doesn't become hung up on the edge of the unit. 8. Install control panel fastener nuts (10). Install the two top left nuts FIRST. See step 4.a if needed. NOTE: If a nut falls into the PCB, it needs to be removed before proceeding with installation (it will damage the PCB electronics). 9. Connect electrical connectors and hoses to pressure gauge and vacuum gauge. See Control Panel Rear View (figure 2-3) in this chapter for connection locations on the PCB. 10. Reinstall pressure regulator. 11. Connect to 12 VDC power source. Verify that unit powers-up. 12. Perform Service Checkout Procedures to verify proper operation of unit.

POWER HARNESS REPLACEMENT PROCEDURE 1. Remove any power source connected to battery leads, and rear panel of unit. 2. Disconnect power harness from PCB, and carefully cut off any wire ties holding harness. 3. From the exterior of the cabinet, use Heyco pliers # 29 or compatible tool, grip strain relief bushing and pull bushing and harness all the way out of the cabinet. 4. Measure the distance of between the strain relief bushing and the end of the harness at the PCB connector. 5. Using the measured distance position the strain relief bushing on replacement harness. Using the pliers close the bushing until it will fit into the cabinet. 6. Install harness into cabinet and seat bushing. Harness should not come out when pulled by hand. 7. Connect electrical connector to control PCB. 8. Use wire ties where necessary to support the harness. Verify that wires do not rub against any sharp edges. 9. Test unit to verify proper operation. See Service Check out procedure if necessary.

Pressure REGULATOR REPLACEMENT PROCEDURE 1. Remove any power source connected to battery leads, and rear panel of unit. 2. Loosen screw on the pressure regulator knob located on the lower side of the knob using a hex head driver (7/64” Hex). Remove knob. 3. Remove nut securing the regulator (3/4” wrench). Push regulator inward. Pull the regulator assembly out of cabinet with hoses still attached. 4. Loosen nuts from fittings on both sides of pressure regulator, detach hoses. 5. Install hoses onto replacement regulator, tighten securely (finger tight, then 1~1 1/2 turns with a wrench). NOTE: Verify flow direction of regulator, see arrow stamped in regulator body. Also see Hydraulic Flow Schematic for additional information if needed. 6. Install regulator into control panel and fasten with nut. (The ridge on the nut towards control panel). 7. Install regulator knob, and tighten (the flat side of the shaft is were the screw of knob seats). 8. Test unit to verify proper operation, and no leakage. See Service Check out procedure.

PRESSURE / VACUUM GAUGE REPLACEMENT PROCEDURE: 1. Remove any power source connected to battery leads, and rear panel of unit. 2. Remove hose: a) Pressure Gauge: Loosen compression nut from hose, remove hose from gauge b) Vacuum Gauge: Pull hose off barb fitting. 3. Remove fastening nuts (3/8" hex) at both sides of gauge and remove mounting bracket. 4. Carefully pull gauge out of control panel.

5. Install replacement gauge in reverse order as removed. 6. Pressure test unit. a) Pressure Gauge: Check for leaks, repair as necessary. See Service Check Out Procedure if needed. b) Vacuum Gauge: Use a vacuum pump to test unit.

Fuel tank REPLACEMENT PROCEDURE 1. Drain all fuel from the unit. (Refer to the Removing Fluid section of this chapter for further information regarding tank draining). 2. Disconnect the unit from all power sources and remove the rear panel. NOTE: It is recommended to remove the control panel and complete tank and pump assemblies in order to replace the tank. This is done to ensure that no damage occurs to the other components in the machine. 3. Remove the control panel assembly as described in the Control Panel Replacement Procedure in this chapter. 4. Remove the pump and tank assembly as described in the Pump & Tank Bracket Replacement Procedure in this chapter. 5. Disconnect the hoses at the top and bottom of the tank assembly. 6. Remove the Pan Head Phillips screws securing the tank to the bracket from underneath the tank. 7. The tank can now be removed by maneuvering the tank upwards. 8. Reinstall tank by reversing the removal steps. Use Teflon paste or Teflon tap sealer on any piper thread fittings. 9. Pressure test and check unit for any leaks. See Service Check Out Procedure in this chapter.

PUMP & TANK Bracket ASSEMBLY REPLACEMENT PROCEDURE 1. Drain all fuel from the unit. (Refer to the Removing Fluid section of this chapter for further information regarding tank draining). 2. Disconnect the unit from all power sources and remove the rear panel. 3. Remove control panel. See Control Panel Replacement Procedure. 4. Remove OUTPUT (RED) and RETURN (BLACK) hoses; remove elbows and nipples between the hoses and the machine. 5. Remove the two screws that connect the left support bracket to the tank & pump bracket. These can be found between the left inside cabinet wall (viewed from the back) and the filter support bracket. Loosen the two screws that connect the right support bracket to the tank & pump bracket. These can be found between the right inside cabinet wall (viewed from the back) and the tank. 6. Remove the six (6) Phillips screws that hold the mounting bracket in place. Locations: 2 - above the cabinet openings for OUTPUT and RETURN hoses, 2 - above the fuel filter bracket, 2 – below the vacuum hose and power harness. 7. Remove the left support bracket from the cabinet. Carefully pull the pump and tank bracket assembly out of the cabinet. 8. Install assembly in reverse order as removed. Use Teflon paste or Teflon tape sealer on the pipe thread fittings, but not on the compression fittings. Do not over tighten screws into the cabinet.

9. Pressure test and check unit for any leaks. See Service Check Out Procedure in this chapter.

PUMP REPLACEMENT PROCEDURE 1. Remove rear panel of unit, and connect unit to a suitable power source. 2. With regulator open (counterclockwise), press "FILL/PURGE" button until the hose leading into fuel pump is empty. 3. Disconnect power supply to unit's battery leads. 4. Loosen fuel filter to avoid siphoning fuel from unit's fuel tank through pump's hose. 5. Cut off any wire ties holding wires between fuel pump and control panel. Disconnect pump wires at control panel PCB, carefully. 6. Disconnect hoses at pump (cap hoses as necessary) and remove fuel pump from bracket, by loosening large clamp. a) Remove fittings from defective fuel pump and install onto replacement pump, if needed. Apply Teflon paste sealer on fittings before reinstallation; do not use Teflon tape here. Use only the proper plastic fittings for pump (NO METAL FITTINGS). b) Install replacement fuel pump onto bracket, and tighten into position with large clamp. c) Connect hoses and tighten fittings. NOTE: The end of the pump head is marked IN & OUT. See Hydraulic Schematic for system flow if necessary. 7. Connect pump wires to control PCB, and secure with wire ties. 8. Fill fuel filter and tighten securely before operating replacement pump. 9. Pressure test and check unit for any leaks. See Service Check Out Procedure in this chapter.

SOLENOID REPLACEMENT PROCEDURE 1. Remove rear panel of unit, and connect unit to a suitable power source. 2. With an open adaptor (060-1400) connected to the OUTPUT hose, press "FILL/PURGE" button until the hose leading into solenoid is empty. The solenoid is part of the Manifold Block Assembly #1 that the OUTPUT hose assembly is attached to, and it has two ports and two black wires. 3. Disconnect power supply to unit's battery leads. 4. Follow the next steps for disassembly and inspection of solenoid (try this before replacing). a) Hold the solenoid stem firmly with a slot screwdriver and remove the hex nut (9/16”) on top of solenoid, then slide the coil off the solenoid stem. b) Unscrew the stem counterclockwise, with the screwdriver. NOTE: Do not grip the stem from the center, or the cylinder that the plunger travels in may be crushed. c) Inspect the plunger seal for nicks or deterioration, inspect the solenoid base at plunger sealing area for damage around the edge of the orifice, and inspect for debris obstructing the plunger areas. There should be an indented area on the plunger seal, but if seal is damaged then replace plunger. d) Reassemble in reverse order, and verify proper operation.

i)

If solenoid still does not operate properly, try flushing by briefly running unit without solenoid plunger. Reinstall plunger, and then test again.

5. Continue with the next steps if the solenoid needs to be replaced. 6. Cut off any wire ties holding wires between solenoid and control panel. Disconnect solenoid wires at control panel PCB, carefully. 7. Disconnect hose (cap if necessary) to solenoid and remove solenoid from manifold assembly (support manifold block with 1-1/4” wrench). Remove fittings from solenoid and install into replacement solenoid. NOTE: Install fittings so that the solenoid port marked "IN" will be towards the manifold block and OUTPUT (RED) hose. Use Teflon paste sealer on pipe threads before reinstallation. 8. Reinstall solenoid into manifold block assembly. Connect hose. 9. Connect solenoid wires to control PCB, and secure with wire ties. 10. Pressure test and check unit for any leaks. See Service Check Out Procedure in this chapter, especially the leak test section.

PRESSURE SWITCH REPLACEMENT PROCEDURE 1. Remove rear panel of unit, and connect unit to a suitable power source. 2. With an open adaptor (060-1400) connected to the OUTPUT hose, press "FILL/PURGE" button until the hose leading into solenoid is empty. The pressure switch is part of the Manifold Block Assembly #1 that the OUTPUT hose assembly is attached to, and it has one port, and a green and a white wire. 3. Disconnect power supply to unit's battery leads. 4. Cut off any wire ties holding wires between pressure switch and control panel. Disconnect pressure switch wires at control panel PCB, carefully 5. Use a large wrench (1-1/4”) to hold the manifold block as the pressure switch is being unthreaded from block. NOTE: The solenoid may need to be removed for better access to the manifold block. See Solenoid Replacement Procedure if necessary. 6. Install replacement pressure switch in reverse order as removed. Use Teflon paste sealer. 7. Connect pressure switch wires to control PCB, and secure with wire ties. 8. Pressure test and check unit for any leaks. See Service Check Out Procedure in this chapter, especially the pressure switch testing section.

MANIFOLD BLOCK Assembly REPLACEMENT PROCEDURE 1. Remove control panel. See Control Panel Replacement Procedure. 2. Remove the pump & tank bracket assembly. See Pump & Tank Bracket Assembly Procedure 3. Remove any hoses attached to fittings, or wires fastened with wire ties on manifold block assemblies. 4. Remove manifold block: a) Manifold Block #1: Remove the four (4) Phillips screws, at one end of block, and the one in the middle, then remove block. b) Manifold Block #2: Remove the four (4) Phillips screws, at one end of block then remove block.

5. Install replacement assembly in reverse order as removed, and all previously removed assemblies. 6. Pressure test and check unit for any leaks. See Service Check Out Procedure in this chapter.

RELIEF VALVE REPLACEMENT PROCEDURE: 1. Remove control panel. See Control Panel Replacement Procedure. 2. Remove the pump & tank bracket assembly. See Pump & Tank Bracket Assembly Procedure 3. Remove Manifold Block Assembly #1. See Manifold Block Assembly Replacement Procedure. 4. Remove relief valve between the two manifold blocks. Note the direction of the flow arrow on the valve. 5. Install replacement relief valve. Verify that valve is installed with arrow pointing towards the block that attaches to the RETURN hose assembly. 6. Install all previously removed assemblies. 7. Pressure test and check unit for any leaks. See Service Check Out Procedure in this chapter. Note: Maximum pressure should be between 105 - 120 PSI. If not, then see Pressure Relief Valve Calibration Procedure.

DRAWER REPLACEMENT PROCEDURE 1. Verify that replacement drawer (if used), should include the following parts: 1 pc. 1 pc. 2 pcs. 2 pcs.

MotorVac P/N 010-5002 MotorVac P/N 040-6024 MotorVac P/N 040-6051 MotorVac P/N 040-6049

Black Plastic Drawer Magnet, with 3/16" mount (riveted to drawer) Tinnerman Nut, 10-32 Nylon Thumbscrew 1-1/2" x 10-32

2. Remove thumbscrews from replacement drawer (if applicable). 3. Verify that Tinnerman nut is aligned with the mounting hole on the drawer, adjust as necessary. 4. Remove any power source connected to battery leads, and rear panel of unit. 5. From the rear of the cabinet, remove the two thumbscrews from the sides of the drawer case that secure the drawer in it's slide rail. Pull the drawer out from the front of the cabinet. 6. Install replacement drawer half way into the cabinet drawer case. 7. Thread the thumbscrews into Tinnerman nuts though the slots of the unit's drawer case until the heads of the screws are flush with the outer edges of the slide rail. Note: On the bottom drawer. If the screws are not flush with the drawer case slide rails, they may be obstructed by the wheel cover (inside cabinet) and the drawer will not close completely. 8. Check for proper drawer operation and reinstall rear panel.

CHAPTER 3 TROUBLESHOOTING - MOST COMPLAINTS ARE ASSUMED TO OCCUR DURING CLEANING SERVICE

TROUBLESHOOTING COMPLAINT

CORRECTIVE ACTION

Electrical Related Problems I.

REVERSE POLARITY LED is ON and the unit is not operational

Polarity is reversed on vehicle battery connection. Check connections for correct polarity.

II.

PCB fuse is blown

Replace PCB fuse, perform the Service Check Out Procedure, Control Panel PCB Diagnostics.

III.

Alarm inaudible

Use the Service Check Out Procedure to determine if alarm sounds when it is supposed to; if not, replace PCB.

IV.

Front panel LEDs inoperable

Use the Control Panel Diagnostic Procedures to determine if all LEDs light when they should; if not, replace PCB.

V.

Timer adjust inoperative

Verify correct operation from operations manual. See Control Panel Functions (see Theory of Operation section) to determine if the timer operates correctly; if not, replace PCB.

VI.

Unit shuts down during high pressure operations

Possible low power source. Low voltage will require more amperage to perform same operations. Unit may shut down if amperage is excessive. Ensure proper voltage is available to unit.

VII.

Unit shuts down while trying to start engine (during cranking)

Possible low power source. Low voltage will require more amperage to perform same operations. Unit may shut down if amperage is excessive. Ensure proper voltage is available to unit, while cranking.

VIII.

Unit does not respond to any of the buttons

Keypad connector may have come disconnected from control PCB, check connection.

IX.

Unit does not respond to some of the buttons

The keypad may have a worn or defective button. Check continuity using a multimeter, and the electrical schematic.

Pressure Related Problems I.

Pressure gauge on the unit displays maximum pressure upon start-up

OUTPUT and RETURN hoses may be reversed on the vehicle connections. Press STOP on the unit and check hoses for correct connection. OUTPUT to pressure side, and RETURN to return fuel side.

II.

START is pressed but operation does not commence

Start with regulator open then close slowly to build pressure. •

If pump runs, then check vehicle connections and perform Service Check Out Procedures.

•

If pump does not run, then see Pump Check Out Procedures.

COMPLAINT

CORRECTIVE ACTION

III.

The unit performs poorly

Check all hoses and wires for cuts or frays. Check cabinet for dents or impact markings. Verify that the fuel filter has recently been replaced. (Refer to the maintenance log in Appendix A in the Operator Manual to view dates of services performed. Replace filter every 30 cleanings, if not sooner for dirty vehicle fuel systems.)

IV.

System pressure is low

Verify hose connections. • • • • •

Pressure adjust regulator may be miss-adjusted. Vehicle's regulator may be inoperable. Run system checkout procedure to identify specific problem. Change dirty fuel filter or filter with 30 or more cleanings. During high pressure (75 PSI or greater) operations, check pressure relief valve calibration.

V.

Pump runs, pressure gauge does not read

Verify correct hose connections. Use checkout procedure to verify if gauge is faulty, or if pressure is even reaching gauge at all (you may need an auxiliary pressure gauge).

VI.

Fill/Purge fails to operate

Verify "T" adaptor valve is open and hose connections are correct. •

Use the Service Check Out Procedure to verify the solenoid functions correctly, pump runs in reverse when necessary and PCB functions correctly.

VII.

Auto purge fails to operate

Use the Service Check Out Procedure to verify that pressure switch operates correctly, and how to test Auto Purge function.

VIII.

Abnormal pump noise

Use the Pump Check Out Procedure to verify output capabilities, pump may be OK.

IX.

Unit will not hold pressure on it's own, during leak down testing

Verify the vehicles fuel system is not the problem. Use the Service Check Out Procedure to determine if the leak down is internal to the unit. Look closely at the solenoid valve operations.

X.

Pressure adjust valve fails to turn

Stuck or binding replace Pressure Adjust Regulator valve.

XI.

Unit unable to obtain maximum pressures

Check calibration of pressure relief valve, and adjust as necessary.

XII.

Unit does not shut down while fuel is leaking

Perform Service Check Out Procedures to test pressure switch operations, also see Theory of Operations section. Fuel leak must be a substantial leak to cause a significant pressure drop to activate warning alarm and Auto Purge functions.

Fluid Related Problems I.

Rapid loss of fuel from the unit’s reservoir

RETURN hose and adaptor connection may be incorrect, allowing fuel/detergent to return to the vehicle's fuel tank.

II.

Fuel mixture turns to thick milky substance similar to some hand cleaners

The user has contaminated their unit with gasoline saturated with water, during vehicle servicing. User must remove as much contaminated fuel and the filter from the unit. Replace filter, and run a 50/50 mix of alcohol (Isopropyl) and uncontaminated gasoline in the unit to flush out contaminated substance. Discard all contaminants in a proper manner according to local regulations.

COMPLAINT

CORRECTIVE ACTION

III.

Tank level reads inaccurately

NOTE: approximately 32oz. of fuel will remain below the Empty (“E”) mark.

IV.

Leak in RETURN or OUTPUT hose, or Female Quick Disconnects

Repair or replace as necessary.

V.

Fuel is leaking at Pressure Adjust Regulator shaft

Tighten regulator shaft seal packing nut (7/16” Hex nut), while holding body. Over tightening will cause shaft to bind.

VI.

Fuel leak at fittings into tank

Use sufficient Teflon tape sealer on pipe threads, to obtain a proper seal.

Miscellaneous Problems I.

Vacuum gauge fails to operate

Check connections inside and out. A vacuum pump may be needed.

II.

User scratches or damages gauge lenses

Replace gauge lens, by twisting counter-clockwise and removing damaged lens, and then installing replacement lens.

III.

Drawer(s) pulls completely out of cabinet

Retaining thumbscrews have come off, and may be in the bottom of the cabinet, reinstall drawer(s) and screws.

ICS Related Problems I.

ICS bottle will not hold air pressure

Replace air filler valve core. This is a special Viton valve core. Tire valve and A/C valve cores will not last in this application. This is a consumable part and will require regular maintenance.

II.

ICS bottle is pressurized but will not spray or solution only trickles out

The valve mechanism or pickup tube is clogged. Replace ICS valve assembly, with ICS service kit. This is a consumable part and will require regular maintenance

CHAPTER 4 PARTS & DIAGRAMS FRONT VIEW 2 3 61

5 4

ITE M 1 1a 2 2a 3

DESCRIPTION Gauge, Vacuum Asmb. Lens, Vacuum Gauge Gauge, Fuel Press. Lens, Fuel Press. Gauge Regulator Assembly

3a Regulator Knob 4 Wheel

PART NUMBER 2008010 0501910 2008012 0500007 2007006 0500056 0100027

ITE M 5 5a 6 6a NS

DESCRIPTION

Drawer, Plastic Thumb Screw, 1.5”, Pls Cap, Reservoir Cap gasket Intake Cleaning Sys.(ICS) NS Hose, 30” (used in ICS)

PART NUMBER 0105002 0406049 0106060 0501914 2006000 1005001

REAR VIEW

2 1

4

5

3

ITE DESCRIPTION M 1 Filter, Orange (BT83910) 1a Filter Nipple 2

Tank Asmb. Reservoir

PART NUMBER 0500095 0303095 2008602

ITE DESCRIPTION M 3 Pump, Assembly 4a Adapter, 90° Bulkhead 4b Adapter, Hex Nipple 5 Manifold Assemblies

PART NUMBER 2008031 0300131 0303092 See Page 4-4

SIDE VIEWS 5

4

1 3 ITEM

6

2 DESCRIPTION

1

Hose, Black Return

PART NUMBER 2000300

ITE M 4

DESCRIPTION Cables, Battery

PART NUMBER 0208043

2

Hose, Red Out

2000400

5

Hanger, Black Metal

0105004

3a

Connector, Quick Disconnect

0800230

6

Hose, Vacuum (Requires 12 feet)

0700100 (Per foot)

3b

Fitting, 3/8”Cmp x ¼”MPT Nut, Compression

0300020 0300193

MANIFOLD BLOCK ASSEMBLIES and FITTINGS

1

6

7

2

8

11 9

3

10 4 5

ITE DESCRIPTION M 1 Valve, Relief

PART NUMBER 0500088

ITE DESCRIPTION M 7 Elbow, 5/16”Nt x 1/8”MPT (pump) 8 Elbow, 5/16”Tb x 1/8”FPT (pressure gauge) 9 Elbow, 5/16”Nt x ¼”FPT (regulator)

2

Block, Manifold

0300110

3

Valve, Solenoid (NC) Plunger (Alone)

0500018 1008138

4

Nipple, ¼”MPT x ¼”MPT

0300014

10

5

Switch, Pressure

0500016

11

6

Elbow, 5/16”Nt x ¼”MPT (block)

0300018

Union, 1/4”MPT x ¼”MPT, Zp Union, 5/16”Nt x ¼”MPT

PART NUMBER 0300015 0300033 0300011 0303092 0300017

CHAPTER 4 CONTINUED COMPLETE REPLACEMENT PARTS LISTING: ITEM LEVEL

MotorVac

Descriptions

Qty

S ASMB

Part Number SUB ASMB

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

N/A 010-0026 010-0027 011-0014 010-6008 010-5600 010-5403 040-0603 040-0604 040-0607 040-0610 040-6014 040-6015 040-6016 040-6049 200-8036 010-5002 040-6024 040-6025 040-6051

Cabinet Assembly Hub Cap Wheel, 8" x 1.75", rubber Hanger Bracket, Stl, painted black Axle, 0.5" Dia., Zinc Plate Cabinet, Red Plastic Drawer Magnet Contact Plate, Stl (2 studs) Snap Bushing, for Vacuum Hose Cap Nut, 1/2" Nut, Nylock 1/4"-20, Zp, for hanger Screw, PHP 1/4"-20 x 5/8", Zp, for hanger Spacer 1/16", Zp Tinnerman Nut, #8, to secure back panel Kep Nut, 6-32, Zp, for drawer magnet contact plate Thumbscrew, 10-32 x 1-1/2", Ny, for drawer retention Drawer Assemblies (4) Drawer, Black plastic Magnet, 30lbf pull, 3/16" mount Pop Rivet, Blind Head, 3/16", Al, for magnet Tinnerman Nut, 10-32, for drawers

2 2 2 2 2 2 2

200-0300 030-0020 070-0020 080-0230 030-0193 200-0400 030-0020 070-0010 080-0230 030-0193 200-8601 010-5400 010-5401 010-5402 010-5404 020-5320 040-0019 040-0200

2

040-0400

Return Hose Assembly, Black Un, 3/8"Cmp x 1/4"MPT, Ni NAB Hose, 3/8"OD, Blk, Ny Female Quick Disconnect, 1/4" x 1/4"FPT, Ni Compression Nut Output Hose Assembly, Red Un, 3/8"Cmp x 1/4"MPT, Ni NAB Hose, 3/8"OD, Red, Ny Female Quick Disconnect, 1/4" x 1/4"FPT, Ni Compression Nut Pump, Tank, Manifold Block, & Filter Assembly Mounting Bracket for pump, tank, manifold block Mounting Bracket for filter asmb. Mounting Bracket Support, left side Mounting Bracket Support, right side Ferrite Bead, for solenoid wires Screw, PHP 10-32 x 3/8", Zp, for filter bracket Starwasher, Internal, #6, Zp, for manifold block mounting Starwasher, Internal, #10, Zp, for filter bracket

1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 1 2 2 2 2 1 2 2 2 2 1

1 2 2 3 1 1 1 1 2 6 6 4 9 2 8 1 4 4 4 8 1 1 10ft 1 1 1 10ft 1 1 1 1 1 1 1 2 15 2

A A A A A

41 42 43 44 45 46 47

2 2 2 2 2 2 2

040-0603 040-0605 040-0612 040-0618 040-0619 040-0622 040-1203

Snap Bushing, for filter tubing into bracket Nut, Nylock 8-32, Zp, for pump mounting Allen Head Screw, 1/4"-20 x 5/8", Ss, for filter mount Screw, PHP 1/4"-20 x 1/2", Zp, for tank mounting Starwasher, Internal 1/4", Zp, for tank mounting Nylon Cable ties 4", for securing wire Screw, PHP 6-32 x 3/8", Zp, for manifold block mounting

2 4 3 2 2 3 15

48 49 50 51 52

2 2 2

040-6032 040-6037 070-0085 200-7002 020-0061

Nylon Cable ties 8", for securing tubing

1 3 9 1 2

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89

1 2 2 2 2 2 2 2 1 2 2 1 2 2 2 2 1 2 2 2 1 2 2 1 2 2 2 2 2 1 2 2 1 2 2 1 2 2

Cable Tie Mount, 0.75", 4-way, Ny Tubing, 5/16"OD, Nylon Manifold Sub-Assembly #2, towards rear of cabinet Molex Connector Housing, Male, 3 pin, for solnd & prs sw 030-0014 Un, 1/4"MPT x 1/4"MPT, Ny, between solnd and block 030-0017 Un, 5/16"Nt x 1/4"MPT, Ny, at solenoid 030-0018 90°, 5/16"Nt x 1/4"MPT, Ny, at block to prs. Gauge 030-0110 Manifold Block, 1/4"FPT ports, Al 050-0016 Pressure Switch, 1/4"MPT mount, Stl, N.O. till 4 PSI 050-0018 Solenoid, 2-way, 12 VDC, Ss, normally closed 200-7009 Filter Mount Assembly 030-0018 90°, 5/16"Nt x 1/4"MPT, Ny, at top of filter mount 050-1918 Filter Mount, 1/4"FPT ports, Al 200-8029 Manifold Sub-Assembly #1, towards front of cabinet 030-0017 Un, 5/16"Nt x 1/4"MPT, Ny, at block 030-0018 90°, 5/16"Nt x 1/4"MPT, Ny, at block 030-0110 Manifold Block, 1/4"FPT ports, Al 050-0088 Pressure Relief Valve, 1/4"MPT, 115 PSI (Nominal), Ss 200-8031 Fuel Pump Assembly 020-5320 Ferrite Bead, for pump wires 030-0015 90°, 5/16"Nt x 1/8"MPT, Ny, at pump 050-0043 Fuel Pump and Mounting bracket, 1/8"FPT ports, 12 VDC 200-8602 Fuel Tank Assembly 010-6002N Fuel Tank, Natural plastic 030-0018 90°, 5/16"Nt x 1/4"MPT, Ny, top and bottom fittings 200-8603 010-5005 010-5100 020-5330 040-0433 040-6035 200-7006 030-0011 050-0052 200-8010 030-0026 050-0006 200-8012 030-0033 050-0005

Control Panel Assembly complete, with PCB Control Panel steel backing plate, for ICC PCB Control Panel Overlay with integrated Keypad Control Circuit Board (PCB) assembly Round Spacer, #6 x 0.5", Al, for PCB Kep Nut, 4-40, Zp, for PCB Pressure Regulator Valve Assembly, needle valve 90°, 5/16"Nt x 1/4"FPT, Ny, regulator fittings Regulator Valve, needle valve, 1/4"MPT ports, Ss Vacuum Gauge Assembly, 2.5" dial Un, 0.170"Barb x 1/4"FPT, Br, for vacuum gauge Vacuum Gauge, 0-30 in. hg. 2.5" dial, "MOTORVAC" Pressure Gauge Assembly, 0-160 PSI, 3.5" dial 90°, 5/16"Nt x 1/8"FPT, Ny, pressure gauge fitting Pressure Gauge, 0-160 PSI, 3.5" dial, MotorVac

1 1 1 1 1 1 1 2 1 1 1 4 2 1 1 1 2 1 1 1 2 1 1 1 1 5 5 1 2 1 1 1 1 1 1 1

B B

90 91 92 93 94

1 2 2 2

N/A 010-5601 010-6060 020-0375

95

2

020-5316

96 97 98 99

2 2 2

020-5315 020-8043 030-0131 030-3092

100

2

040-6016

101

2

040-6023

102

2

040-6039

103

2

050-0095

104

2

070-0085

Un, 1/4"MPT x 1/4"MPT, Stl, fitting connects to mnfld block Kep Nut, 6-32, Zp, for control panel mounting to cabinet Screw, PHP #8 x 3/4", SMS, Zp, for rear panel mounting Screw, Truss Head 6-32 x 1/2", Zp, for filter mount. Plate Fuel Filter, spin-on, 10 micron rating, Baldwin BT83910 Tubing, 5/16"OD, Nylon

105 106 107 108

2 2

070-0100 100-8403

Vacuum Hose 5/32"ID, rubber Caution Label, for top of cabinet application

3

110 111 112 113 1 1

116 117 118

90°, 3/8"Comp x 1/4"FPT, Ni, fitting connects to hose asmb

N/A 1 1 1 1

C

1 1 2 2

C

10 8 6 1 7.42f t 12ft 1

Notes: A > for only one drawer order 1 of each and 2 nuts and screws B, C> these parts only sold together, not separate

109

114 115

Final Pull Assembly, for machine assembly Rear Panel, Black plastic, for cabinet Fuel Tank Cap, black plastic Strain Relief, for external power harness mount into cabinet Internal Grounding Cable, between cntrl pnl and tank brkt Internal Grounding Plate, connects to pressure regulator External Power Harness, 11Ft, with battery clips

2 2 1

119 120 121

1

122 123 124 125 126

1 1 1 1

Additional Parts 200-3025 Standard Adaptor Kit, fuel system connecting adaptors 200-8400 Packet including Operator manual & Quick Reference Cards 200-8200 Operator's Manual 200-8300 Quick Reference Cards: Carb, TBI, PFI, & CIS fuel systems 200-6000 Intake Cleaning System (ICS) kit, w/ nozzles & spray tubes Replacement Parts 020-5329 Fuse, 8 Amperes, 5mm x 20mm, fast-acting, for cntrl PCB 050-0056 Pressure Adjust Regulator Knob, Black plastic 050-0007 Pressure Gauge Replacement Lens, for 3.5" gauge 050-1910 Vacuum Gauge Replacement Lens, for 2.5" gauge 100-5009

ICS, Air Filler Assembly, includes viton valve core &

1 1 1 1set 1

1ea 1ea 1ea 1ea 1ea

127 128 129 130 131

1 1 1

100-5010 100-5034 100-5035 100-5043 100-5044

132

1

200-5046

1 1

100-8138 200-3026

133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168

Abbreviatio ns AL ASMB BLK BRKT BTTM CNTRL DIA FPT ID LBF MNFLD MPT N/A NAB Ni N.O. NY OD PCB PHP PNL PRS PSI SMS SOLND Ss STL SW UN VDC W/ W/O ZP 90°

gasket ICS, Viton Valve Core, for air filler assembly ICS, Bottle Neck, Black plastic, w/o air filler asmb ICS Base O-Ring ICS, 6” Spray Tube, With Nozzle ICS, 30" Spray Tube, with Spray Nozzle-multi spray pattern ICS Service Kit, includes pickup tube w/valve, nozzle, 6" tube Solenoid Replacement Plunger, viton, Blue Deluxe Adaptor Kit, Sun/Snap-On P/N EEFS-102A

Aluminum Assembly Black Bracket Bottom Control Diameter Female National Pipe Thread Inside Diameter Pound of Force Manifold Male National Pipe Thread Not Applicable or Not Available Nylon Air Brake Nickel Normally Open Nylon Outside Diameter Printed Circuit Board Pan Head Phillips Panel Pressure Pound per Square Inch Sheet Metal Screw Solenoid Stainless Steel Steel Switch Union fitting Voltage, Direct Current With With Out Zinc Plate Ninety degree angled fitting

1ea 1ea 1ea 1ea 1ea 1ea 1ea 1ea

Appendix A - Maintenance Maintenance Procedures The following maintenance procedures should be performed on a routine basis: 1.

Drain the unit’s fuel reservoir and replace the fuel filter after every 30 cleaning services, as described in the next section.

2.

Clean the exterior with a plastics cleaning agent or similar product to keep the cabinet looking new. Check the cabinet for dents or impact markings.

3.

Check all hoses and wires for cuts or frays.

Replacing the unit Fuel Filter The unit’s fuel reservoir should be drained and the fuel filter replaced after every 30 cleanings to ensure maximum system performance and pump life. Drain the Fuel Reservoir 1. 2.

3.

Turn the Pressure Adjust regulator on the control panel clockwise until it is completely closed. Attach the unit to a motor vehicle battery by connecting the red battery clip to the positive (+) battery terminal and connect the black battery clip to a solid ground point as far from the battery as possible.

Connect the #060-1000 adaptor to the output (red) hose, then drain the gasoline from the unit’s fuel reservoir using the following procedure: • • • •

Direct the adaptor and output (red) hose into an appropriate container. Press and hold the Start button until the fuel from the unit has been emptied into the container. Release the Start button and allow the run time to expire. Dispose of the fuel in an environmentally approved method.

Replace the Fuel Filter 1.

Unscrew the old fuel filter from the mounting station on the back of the unit’s cabinet.

2.

Lightly grease the seal of the new filter and hand-tighten it onto the mounting head.

3.

Add 16 oz. of MotorVac CarbonClean Detergent and Top Engine Cleaner to the fuel reservoir and then fill the unit’s fuel reservoir with clean gasoline until the Fuel Level Window shows 1/4 tank.

4.

Check the filter for leaks.

The unit is now ready for the next cleaning service.

DIAGRAMS and SCHEMATICS:

Notes:

Appendix A - Maintenance Maintenance Procedures The following maintenance procedures should be performed on a routine basis: 1.

Drain the unit’s fuel reservoir and replace the fuel filter after every 30 cleaning services, as described in the next section.

2.

Clean the exterior with a plastics cleaning agent or similar product to keep the cabinet looking new. Check the cabinet for dents or impact markings.

3.

Check all hoses and wires for cuts or frays.

Replacing the unit Fuel Filter The unit’s fuel reservoir should be drained and the fuel filter replaced after every 30 cleanings to ensure maximum system performance and pump life. Drain the Fuel Reservoir 1. 2.

3.

Turn the Pressure Adjust regulator on the control panel clockwise until it is completely closed. Attach the unit to a motor vehicle battery by connecting the red battery clip to the positive (+) battery terminal and connect the black battery clip to a solid ground point as far from the battery as possible.

Connect the #060-1000 adaptor to the output (red) hose, then drain the gasoline from the unit’s fuel reservoir using the following procedure: • • • •

Direct the adaptor and output (red) hose into an appropriate container. Press and hold the Start button until the fuel from the unit has been emptied into the container. Release the Start button and allow the run time to expire. Dispose of the fuel in an environmentally approved method.

Replace the Fuel Filter 1.

Unscrew the old fuel filter from the mounting station on the back of the unit’s cabinet.

2.

Lightly grease the seal of the new filter and hand-tighten it onto the mounting head.

3.

Add 16 oz. of MotorVac CarbonClean Detergent and Top Engine Cleaner to the fuel reservoir and then fill the unit’s fuel reservoir with clean gasoline until the Fuel Level Window shows 1/4 tank.

4.

Check the filter for leaks.

The unit is now ready for the next cleaning service.

Appendix B - System Accessories Standard Adaptor Kit (200-3025A) The standard adaptor kit is included with your system. The most commonly used application is listed however, other applications may apply.

PART & NO.

QT

2 060-1000 2 060-1100 2

APPLICATION GENERAL APPLICATIONS UTILIZING 1/4" FUEL LINE - MALE. (USE WITH SUITABLE HOSE CLAMPS.) GENERAL APPLICATIONS UTILIZING 5/16" FUEL LINE- MALE. (USE WITH SUITABLE HOSE CLAMPS.) GENERAL APPLICATIONS UTILIZING 3/8" FUEL LINE - MALE. (USE WITH SUITABLE HOSE CLAMPS.)

060-1200 2 060-1300 2 060-1400

060-1500

060-1700

060-1800 PART & NO.

2

1

1 QTY

GENERAL APPLICATIONS UTILIZING 1/4" FUEL LINE FEMALE. (USE WITH SUITABLE HOSE CLAMPS.) GENERAL APPLICATIONS UTILIZING 5/16" FUEL LINE FEMALE. (USE WITH SUITABLE HOSE CLAMPS.) GENERAL APPLICATIONS UTILIZING 3/8" FUEL LINE FEMALE. (USE WITH SUITABLE HOSE CLAMPS.) CARBURETED VEHICLES WITH 5/16" FLARE FUEL INLETS. USE WITH 060-3304 FOR SOME FUEL INJECTED VEHICLES RETURN LINE. CARBURETED AND EARLY FUEL INJECTED VEHICLES WITH 3/8" FLARE FUEL INLETS.

APPLICATION

1

060-2501

FORMS "TANK TO TANK" LOOP ON ALL VEHICLES. USED TO EXTEND VEHICLE'S RETURN LINE DURING DIAGNOSTICS. 1/4" MALE.

1 060-2800 1 060-3100

080-3402 (O-Ring)

060-3105

1 080-3302

060-3305

1 080-3402 (O-Ring) 080-3501 (Clip)

1 060-3505

TBI AND/OR PORT FUEL PRESSURE LINE - FEMALE. G.M. VORTEC M16 x 1.5

TBI AND/OR PORT FUEL RETURN LINE - MALE. G.M. VORTEC M14 x 1.5

(O-Ring)

1

060-3500

TBI AND/OR PORT FUEL PRESSURE LINE - MALE. G.M. VORTEC M16 x 1.5

1

060-3300

LATE MODEL VEHICLES TBI AND/OR PORT FUEL. (GM-CHRYSLER-JEEP/EAGLE).

TBI AND/OR PORT FUEL RETURN LINE - FEMALE. G.M. VORTEC M14 x 1.5

3/8" MALE SPRING LOCK WITH CLIP (GREY). PORT FUEL-RETURN LINE. (USE AS PRESSURE LINE ON SOME RANGERS AND BRONCOS)

3/8" FEMALE SPRING LOCK. PORT FUEL - RETURN LINE. (USE AS PRESSURE LINE ON SOME RANGERS AND BRONCOS)

PART & NO.

QTY

1

060-3600

APPLICATION

1/2" MALE SPRING LOCK WITH CLIP (BLACK). PORT FUEL - PRESSURE LINE. FORD

080-3602 (O-Ring) 080-3601 (Clip)

1/2" FEMALE SPRING LOCK 1 PORT FUEL - PRESSURE LINE. FORD

060-3605

3/8" QUICK DISCONNECT 1 PORT FUEL AND TBI 060-3901

080-3904 (Clip)

1

5/16" MALE TBI AND/OR PORT FUEL (GM-CHRYSLER-JEEP/EAGLE).

060-4200 1 060-4300 1

3/8" TBI AND/OR PORT FUEL (GM-CHRYSLER-JEEP/EAGLEFORD). 1/4" FEMALE TBI AND/OR PORT FUEL (GM-CHRYSLER-JEEP/EAGLEFORD).

060-3902

Tee Adaptor For Single Line Fuel Injection Systems

060-4501

2 2 060-0440

060-0450

HOSE CLAMPS. USE WITH 0601000 THROUGH 060-1500.

Deluxe Adaptor Kit

(200-3026A)

The Deluxe adaptor kit is included with your system.

The most commonly used application is listed however, other applications may apply.

PART & NO.

QTY

1

060-1600

1 060-1602

2

APPLICATION 12MM BANJO FITTING CIS OR EFI SYSTEMS. IN CONJUNCTION WITH 060-1900, 060-1901, 060-1902. 12MM 90° BANJO FITTING CIS OR EFI SYSTEMS. IN CONJUNCTION WITH 060-1900, 060-1901, 060-1902 14MM BANJO FITTING BMW AND LATE MODEL VW PRESSURE LINE.

060-2402

060-3304

080-3302 (O-Ring)

1

USED WITH MV0601700 TBI AND/OR PORT FUEL RETURN LINE - MALE M14 x 1.5

1 060-3400

080-3402 (O-Ring)

1 060-3508

060-3700

080-3701 (Viton Seal)

1

USED WITH 060-1800 TBI AND/OR PORT FUEL RETURN LINE - MALE M16 x 1.5

"TEST PORT/SCHRADER VALVE" CONNECTION - FORD. NOTE: THE SCHRADER VALVE CORE MUST BE REMOVED. "TEST PORT/SCHRADER VALVE" CONNECTION - GM.

5/16" QUICK DISCONNECT

2 060-3900

080-3903 (Clip)

PORT FUEL AND TBI FORD 5 LITER

3/8" QUICK DISCONNECT

060-3901

1

PORT FUEL AND TBI

1

3/8" TBI AND/OR PORT FUEL (GM-CHRYSLER-JEEP/EAGLE).

080-3904 (Clip)

060-4300 2 6 060-1900

060-1901

060-1902

(Bolt)

(Washer)

(Nut)

2 1 3

060-2740

060-2741

060-2742

(Bolt)

(Washer)

(Nut)

CONNECTS 12MM BANJO FITTINGS FOR DIAGNOSTICS AND/OR CREATING A LOOP.

1

CONNECTS 14MM BANJO FITTINGS FOR DIAGNOSTICS AND/OR CREATING A LOOP

New / Optional GAS Adapters offered by MotorVac The following GAS adapters have been added to the CarbonClean adaptor line-up. The adapters listed are not included with any configured adapter sets & may be purchased separately from MotorVac Technologies, Inc.

PART & NO.

APPLICATION Late Model Mitsubishi Products (Also includes Chrysler Imports, various Kia, Suzuki, & Hyundai Gas Powered Models)

060-4800 / Male Side

Late Model Mitsubishi Products (Also includes Chrysler Imports, various Kia, Suzuki, & Hyundai Gas Powered Models)

060-4805 / Female Side

“Bubble Flare” Type Adapter / 14 mm x 1.5 Common Applications Include: Mercedes-Benz, Volkswagen, Audi,

060-2310 / Female Side

“Bubble Flare” Type Adapter / 14 mm x 1.5 Common Applications Include: Mercedes-Benz, Volkswagen, Audi,

060-2315 / Male Side

Japanese / Toyota 14 mm x 1.5 Flare Type Adaptor (Pressure Side)

060-2320 / Female Side (O-Ring P/N: 080-2321)

Japanese / Toyota 14 mm x 1.5 Flare Type Adaptor (Pressure Side)

060-2325 / Male Side

060-3101 / Male Side

080-3402 O’Ring

2000 & Newer Nissan Products (Includes Nissan Quest & Maxima)

10-32 x ½” 080-0593

060-3102 / Female Side

2000 & Newer Nissan Products (Includes Nissan Quest & Maxima)

I.C.S. (Intake Cleaning System) Kit Chapter 2 Part Number – (200-8667, Red Bottle)

One Kit Includes All Components Shown Below: Air Filler Housing, 100-5009 (Includes Viton Valve Core, 100-5010) (Includes Nylon Washer / Seal) Black Plastic Bottle Neck 100-5034

Valve with 9’ Siphon Tube 100-5019

Spray Tube 6” 100-5043 (Included with Spray Nozzle)

Base O’Ring 100-5035

Spray Nozzle 100-5043 (Included with 6” Spray

Spray Tube 30” with Nozzle 100-5044

Note; Knurled Nut is not available separately.

I.C.S. Repair Kit available Separately Part Number – (200-5046) One Kit Includes Components Listed Below: •

Valve with 9’ Siphon Tube (100-5019)

• •

Base O’Ring (100-5035) Spray Tube 6” with Nozzle (100-5043)