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Carbon Zapp ES Series Operation Manual

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RiD90121
ES Series

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Summary of Contents for Carbon Zapp ES Series

  • Page 1 CZ Operation Manuals RiD90121 ES Series...
  • Page 2 Operation Manual Operation Manual ES Series [ES.3] ver. 2016.3...
  • Page 3 This document may not, in whole or part, be copied, photocopied, reproduced, translated or reduced to any electronic medium of machine-readable form without prior consent in writing from Carbon Zapp. The information in this document is subject to change without notice. Company Information CARBON ZAPP 364 Varis-Koropiou Ave.
  • Page 4 Carbon Zapp warrants that the equipment it manufactures will be free of defects in materials and workmanship. The warranty terms are 2 years, beginning on the date of the Carbon Zapp invoice in accordance with the following described:...

  • Page 5: Table Of Contents

    CONTENTS Chapter 1 "Introduction" ............... 1-1 Components List .................... 1-2 Technical Specifications ................1-3 ES.3 Main parts ................................1-4 Adapters & Fittings ..................1-8 Chapter 2 "Operation" ..............2-12 SAFETY PRECAUTIONS ................. 2-12 Setup Machine ..................... 2-13 Change the language ................... 2-13 Switching Tanks (Internal / External) ............
  • Page 6 Operation Manual Figures Figure 1, ES.3 Front View ___________________________________________________________ 1-4 Fig. 2, ES.3 Control Panel ___________________________________________________________ 1-5 Figure 3, Gasoline Fuel Injection Systems, (Left Figure) Using Automobile's Fuel, (Right Figure) Typical Connection. ______________________________________________________________ 3-24 Figure 4, Typical Fuel Injection System _______________________________________________ 3-25 Figure 5, Gasoline Fuel Injection System (Return-less Type), Typical Connection.

  • Page 8: Chapter 1 "Introduction

    Carbon Zapp, a leading manufacturer in Automotive Engine Diagnosing, Testing & Cleaning Equipment, offers the ES Series units for the treatment of all types of fuel systems presently used (Carburetor, Diesel, MPFI, TBI, CIS, G-DI, Common-Rail Diesel), and provides upgradeability of the machine for Future Engine Types yet to come.

  • Page 9: Components List

    Components List • ES.3 Machine. • Standard Adapters & Fittings • Carbon Zapp’s Engine Detergent • DPF.01 (Diesel Particulate Filter Cleaning Adapter Kit) • IMC.01 (Intake Manifold Cleaning Adapter Kit)

  • Page 10: Technical Specifications

    Operation Manual Technical Specifications Mains Voltage (VDC) 12 VDC Power Consumption Idle (W) Power Consumption max (W) Fuel pressure gauge (bar) 0-10 Power Supply Cord 12V Dc, 2.5m Fuel Hoses Feed / Return lines (m) Pump High Pressure (bar) 0-50 Pump Blow-off valve (bar) Max.

  • Page 11: Es.3 Main Parts

    ES.3 Main parts Figure 1, ES.3 Front View Control Panel Fuel Tank Caps Fuel Tank Levels E-Tank (External Tank) Port Feed and Return Line and 12V Power Cord Fuel Filters...

  • Page 12: Fig. 2, Es.3 Control Panel

    Operation Manual a) Control Panel (Fig. 2), is the main interface between the user and the machine. Through the “Function Display” the user can find useful information, such as directions on how to proceed and select different operations by using the control buttons. Fig.
  • Page 13 • Pump/Leak Test Button: used to activate / deactivate the Machine Pump, or do a leak test. • (+) More/Increase Pressure Button: used to increase the Machine Pump pressure. • (-) Less/Decrease Pressure Button: used to decrease the Machine Pump pressure. viii.
  • Page 14 Operation Manual provided with the machine. One is used explicitly for Gasoline type engines and the other explicitly for Diesel type engines.

  • Page 15: Adapters & Fittings

    Adapters & Fittings Table 1, ES.3 Adapters ADAPTER FIGURE DESCRIPTION Hose Crimping Pliers “CPL-001” Female Thread Connector “FTC-14.1” Female Thread Connector “FTC-16.15” Hose Fuel Line “HFL-6” Hose Fuel Line “HFL-75” Hose Fuel Line “HFL-95” Banjo Fitting “BF-10” Banjo Fitting “BF-12”...
  • Page 16 Operation Manual Male-to-Male Fitting “MTM-14” Male Thread Connector “MTC-14.15” Male Thread Connector “MTC-16.1” Quick Connector “QC-8A” Quick Connector “QC-8B” Quick Connector “QC-95B” Special Adapter for all Banjo Fittings (+2 seals) “ADAPT-BF” T-Piece Quick Connector “ADAPT-T” Hose “H-75”...
  • Page 17 Fuel / Detergent Funnel Filter MANN FLEETGUARDFF5074 AEAK.1 Automobile exclusive adapters kit. Quick connectors-USA models (Optional Kit) DPF.01 / DPF.2L DPF adapter (optional) DPF Specific Detergend (optional) 1-10...
  • Page 18 Operation Manual IMC.01 IMC adapter (optional) CE285 Engine Detergent (Sold in Box of 24 items) E-TANK Hose Hose for connecting E-Tank Port to External Tank (1/8” male / 75cm) 1-11...

  • Page 19: Chapter 2 "Operation

    Chapter 2 "Operation" SAFETY PRECAUTIONS ALWAYS • Check fuel system for leaks. • Consult the automobile’s manufacturer manual for connection instructions. • Check automobile for correct level of engine oil and water coolant. • Check automobile for other problems that may cause overheating while operating.

  • Page 20: Setup Machine

    Operation Manual CAUTION: An EFI Fuel Pump is capable of delivering at least 2 liters (1/2 gallon) of fuel flow per minute at a pressure greater than 10bar (150psi) IMPORTANT: Always observe the automobile for fuel leaks or evidence for potential fuel leaks. “To avoid disaster and personal injury, take care when working on fuel systems”...

  • Page 21: Switching Tanks (Internal / External)

    Switching Tanks (Internal / External) Use the Manual Switch on the Control Panel to Switch Tanks. Always take care for correct connections and Tank Contents. 2-14...

  • Page 22: Instructions And Tips

    Operation Manual Instructions and Tips Before the Cleaning Cycle begins • Assure engine is at normal operating temperature. • Check oil level to be within the manufacturer’s specs. • Check water coolant level to be within the manufacturer’s specs. • Assure that engine coolant system is working properly. •...

  • Page 23: After The Cleaning Cycle Ends

    After the Cleaning Cycle ends 1. Turn off the automobile ignition. 2. Allow 3 minutes for system to cool down and release pressure. 3. Carefully disconnect the machine fuel lines from automobile. 4. Re-connect automobile fuel lines as shown at automobile manual.
  • Page 24 Operation Manual IMPORTANT NOTES: • The machine tank should always have fuel left up to ¼ of the tank level for maintenance of the fuel pump. Pour clear fuel (gasoline / diesel) inside tank and close tank cover. • Do not run the ES.3 ’s pump without fuel in the tank. The fuel cools the pump.
  • Page 25 Table 3, Fuel System Operating Characteristics 2-18...
  • Page 26 Operation Manual Table 4, DPF / IMC Parameters IMPORTANT NOTE ES.3 machine Operation Characteristics: • Pressure: 6 bar • Time: 75 min • Engine Speed: 1500-2000 RPM First heat-up Engine to maximum operating temperature in order to heat up the DPF, or make a re-generation of DPF if possible, using a scan-tool.
  • Page 27 2-20...

  • Page 28: Main Operation

    Operation Manual Main Operation Configure a Simulation The ES.3 unit is completely Automatic and provides step-by-step instructions on how to proceed. Once the unit is powered-up by 12 VDC power source, the user will be asked to select PUMP MODE; Here you can select the regular Engine Cleaning Cycle, or the DPF-IMC Cycle for Cleaning the DPF or Intake- Manifold.
  • Page 29 IMPORTANT: When selecting MANUAL mode, the ES.3 machine activates its fuel pump for a specific amount of time (no instructions are provided). The user is also responsible to set / fine tune the pressure, using the pressure more/less buttons in the control panel. INFORMATION: For DPF and IMC Mode, you can adjust the parameters like time, as per the DPF/IMC Table.

  • Page 30: Chapter 3 "Connections

    Operation Manual Chapter 3 "Connections" Below are different connection diagrams for the following systems: 1. MPFI, TBI, CIS Gasoline Engines 2. Return-less Gasoline Engines 3. G-DI / FSI Gasoline Direct Injection Engines 4. COMMON-RAIL and Conventional Diesel Engines 5. Carburetor Gasoline Engines 3-23...

  • Page 31: Mpfi, Tbi, Cis Gasoline Engines

    MPFI, TBI, CIS Gasoline Engines Figure 3, Gasoline Fuel Injection Systems, (Left Figure) Using Automobile's Fuel, (Right Figure) Typical Connection. 3-24...

  • Page 32: Figure 4, Typical Fuel Injection System

    Operation Manual Figure 4, Typical Fuel Injection System LEGEND a. Automobile Tank b. Electrical Pump with retention valve c. Fuel Filter d. Pressure Regulator IMPORTANT: Always bypass (loop) automobiles fuel lines using the adapters provided, if applicable, OR disconnect electrical power to the pump (Remove Pump RELAY or FUSE) 3-25...

  • Page 33: Return-Less Gasoline Engines

    Return-Less Gasoline Engines Figure 5, Gasoline Fuel Injection System (Return-less Type), Typical Connection. 3-26...

  • Page 34: Figure 6, Typical Gasoline Fuel Injection System

    Operation Manual Figure 6, Typical Gasoline Fuel Injection System (Return-less Type) LEGEND a. Automobile Tank b. Electrical Pump with retention valve c. Pressure Regulator d. Fuel Filter IMPORTANT: Always bypass (loop) automobiles fuel lines using the adapters provided, if applicable, OR disconnect electrical power to the pump (Remove Pump RELAY or FUSE) 3-27...

  • Page 35: G-Di / Fsi Gasoline Direct Injection Engines

    G-DI / FSI Gasoline Direct Injection Engines Figure 7, Gasoline Direct Injection System (G-DI), Typical Connection. 3-28...

  • Page 36: Figure 8, Gasoline Direct Injection System (G-Di)

    Operation Manual Figure 8, Gasoline Direct Injection System (G-DI) LEGEND a. Automobile Tank b. Electrical Pump with retention valve c. Fuel Filter d. High Pressure Mechanically Driven Pump IMPORTANT: Always bypass (loop) automobiles fuel lines using the adapters provided, if applicable, OR disconnect electrical power to the pump (Remove Pump RELAY or FUSE) 3-29...

  • Page 37: Common-Rail And Conventional Diesel Engines

    COMMON-RAIL and Conventional Diesel Engines Figure 9, Diesel Injection System {CRDI}, Typical Connection. 3-30...

  • Page 38: Figure 10, Diesel Injection System

    Operation Manual Figure 10, Diesel Injection System LEGEND a. Automobile Tank b. Electrical Pump with retention valve c. Fuel Filter a. High Pressure Mechanically Driven Pump IMPORTANT: Always bypass (loop) automobiles fuel lines using the adapters provided, if applicable, OR disconnect electrical power to the pump (Remove Pump RELAY or FUSE) 3-31...

  • Page 39: Carburetor Gasoline Engines

    Carburetor Gasoline Engines Figure 11, Carburetor System, (Left Figure) Return Type, (Right Figure) Return-less Type. 3-32...
  • Page 40 Operation Manual Figure 12, Carburetor System, (Left Figure) Return Type, (Right Figure) Return-less Type. LEGEND a. Automobile Tank b. Electrical Pump c. Retention valve d. Fuel Filter e. Low Pressure Mechanically Driven Pump IMPORTANT: Always bypass (loop) automobiles fuel lines using the adapters provided, if applicable, OR disconnect electrical power to the pump (Remove Pump RELAY or FUSE) 3-33...
  • Page 42 NOTES:...
  • Page 44 Main Offices & Production Plant 364 Varis-Koropiou Ave. Koropi 194 42 Athens, Greece Headquarters A.I.S. GmbH 75438 Knittlingen, Germany email contact@carbonzapp.com tel +30 210 9856110 fax +30 210 9928655 Support / Sales Telephone +30 210 98 56110 Support email support@carbonzapp.com TeamViewer email tv@carbonzapp.com Sales email...

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Es.3

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