Carbon MCS-352 Service Manual

Dual system for gasoline (petrol) and diesel engines

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SERVICE MANUAL

MCS-352

DUAL SYSTEM

FOR

Gasoline (Petrol) and

Diesel Engines

MOTORVAC TECHNOLOGIES INC.

Table of Contents

Summary of Contents for Carbon MCS-352

Page 1: Diesel Engines
SERVICE MANUAL MCS-352 DUAL SYSTEM Gasoline (Petrol) and Diesel Engines MOTORVAC TECHNOLOGIES INC.
Page 2: Table Of Contents
Table of Contents Introduction............................iii Overview..............................v System Features and Functions ...................... 1-1 Unit Features..........................1-1 Control Panel Functions........................ 1-3 Features and Functions ........................ 1-5 Safety Information ..........................2-1 GASOLINE (Petrol) SYSTEMS: Before You Begin ........................3-1 First Time Operation......................3-1 Mixing Ratios........................
Page 3: Introduction
Introduction Congratulations on your selection of the By choosing this CARBONCLEAN DUAL SYSTEM. product, you are acquiring the most technologically advanced method available for cleaning harmful fuel system contaminants from gasoline engines. is a self-contained cleaning system, designed to connect to any gasoline or MCS 352 diesel engine (up to 7.3L).
Page 4: Overview
Overview This manual contains all the information you need to use the . Please make sure all MCS 352 technicians have read this manual and have it within easy reach whenever the unit is being used. The following is a quick reference to the information in this manual: System Features and Functions This chapter describes the gauges, control switches, and connections.
Page 5: System Features And Functions
System Features and Functions MCS 352 The front of the cabinet contains the control panel, control switches and status indicators. The fuel reservoirs and filters are mounted on the sides of the cabinet. GASOLINE (PETROL) DIESEL OUTPUT HOSE-RED OUTPUT HOSE-RED 200-0400 200-0400 RETURN HOSE-...
Page 6 MCS 352 – BACK VIEW POWER CORD GASOLINE DIESEL TANK TANK...
Page 7: Mcs-352 Control Panel Functions
MCS-352 Control Panel Functions CONTROL PANEL ASSEMBLY START/RUN SWITCH AMBER ON/OFF GASOLINE DIESEL PRESSURE LAMP SWITCH (PETROL) GAUGE PRESSURE GREEN SERVICE LAMP SELECTOR TIMER GASOLINE 020- (PETROL) PRESSURE...
Page 8: Features And Functions
MCS 352 Features and Functions Descriptions of the gauges, control switches, and status indicators making up the control panel are listed below. Please become familiar with these features and functions before using the unit Adjust Time Knob Sets or re-sets the system run time in one-minute increments, from 1 to 60 minutes.
Page 9: Safety Information
Safety Information and Precautions /!\ DANGER Vehicle exhaust gases contain Carbon Monoxide, which is a colorless and odorless lethal gas. Only run engines in well-ventilated areas and avoid breathing exhaust gases. Extended breathing of exhaust gases will cause serious injury or death.
Page 10 Chemicals can cause harmful byproducts. Use only approved chemicals (refer to operator’s manual). Do not swallow or ingest any chemicals. Use with adequate ventilation. Avoid breathing vapors. Do not store chemicals on or in the machine. Improper use of chemicals can cause injury. Over exposure can have harmful effect on eyes, skin, respiratory system and possible unconsciousness and asphyxiation.
Page 11 Batteries produce explosive gases and can explode. Wear safety goggles when working on or near batteries. Use in a well-ventilated area. Keep sparks and flames away from the battery and never lay tools, equipment or other conductive objects on the battery. When tools or equipment is connected to the battery, make sure the equipment power switch is off.
Page 12: Before You Begin
Before You Begin First Time Operation NOTE The following process is used to flush factory- testing fluids out of your new machine, and is only necessary before the first time you use the unit. Verify that the fuel filter is connected and securely in place on the side of the cabinet Check the output/return hoses, battery connections, and all external components for damage Turn the Gasoline (Petrol) PRESSURE REGULATOR on the unit’s control panel counterclockwise until it is completely open.
Page 13: Mixing Ratios
• Set the TIMER knob for five minutes. • Direct the output (red) hose into an appropriate container. • Press the ON/OFF switch to the on position. NOTE: Alarm will sound continually until pump starts. • Press and hold the START/RUN switch until the fuel from the unit has been emptied into the container.
Page 14 Filling Reservoir Procedure-verify that regulator is open or use black hose when drawing fuel from vehicle. FIGURE THIS METHOD IS ALSO TYPICAL FOR RETURNLESS / SINGLE LINE FUEL CARBURETOR INJECTION SYTEMS FILLING 060-4500 FIGURE THIS METHOD TYPICAL FOR TWO LINE INJECTION SYSTEMS.
Page 15: Fuel System Cleaning Procedures
Fuel System Cleaning Procedures Determining the Vehicle's Fuel System Type It is very important to determine the fuel system type of the vehicle to be serviced before performing any setup or cleaning procedure on the vehicle. The unit can be used with any of the four different types of gasoline fuel systems listed below: Carburetion Carburetors come in a variety of sizes and shapes.
Page 16: Carburetor Setup Procedure
Carburetor Setup Procedure Follow the steps below to connect the unit to the vehicle's fuel system. Make sure the vehicle has at least 1/8 tank of fuel before beginning this process. Start the vehicle and allow the engine to reach normal operating temperature IMPORTANT Do not perform the setup or cleaning process if the vehicle’s engine oil or coolant level is low.
Page 17 SEE NEXT PAGE /!\ WARNING Flammable Liquid can squirt out of pressurized lines when connecting or disconnecting. Wear Safety goggles. Obtain ZERO pressure before connecting or disconnecting any fuel lines or adaptors. Wear chemical resistant gloves when connecting or disconnecting fittings and adaptors.
Page 18: Carburetor Cleaning Procedure
Carburetor Cleaning Procedure Follow the steps below to circulate the fuel/detergent mixture through the vehicle's carburetor. Verify that above have been completed. Carburetor Setup Steps 1- 8 Refer to the vehicle's service manual for the manufacturer's recommended pressure. Adjust knob for 30 minutes. (Run time may be adjusted TIMER depending on the condition of the vehicle’s fuel system.) Press the...
Page 19 Re-install the vehicle's gas cap. and verify that there are no leaks. Start the vehicle Test drive the vehicle for five kilometers (3 miles) immediately following the cleaning service to flush all detergent from the vehicle's fuel and exhaust systems.
Page 20: Throttle Body Injection (Tbi) Setup Procedure
Throttle Body Injection (TBI) Setup Procedure Follow the steps below to connect the unit to the vehicle's fuel system. Make sure the vehicle has at least 1/8 tank of fuel before beginning this process. Start the vehicle and allow the engine to reach normal operating temperature IMPORTANT Do not perform the setup or cleaning process if the vehicle’s engine oil or coolant level is low.
Page 21 /!\ WARNING Flammable Liquid can squirt out of pressurized lines when connecting or disconnecting. Wear Safety goggles. Obtain ZERO pressure before connecting or disconnecting any fuel lines or adaptors. Wear chemical resistant gloves when connecting or disconnecting fittings and adaptors. Wrap shop towel around pressure fittings and adaptors when disconnecting.
Page 22: Throttle Body Injection (Tbi) Cleaning Procedure
Throttle Body Injection (TBI) Cleaning Procedure WARNING: BEFORE BEGINNING THE RAIL-FLUSH PROCEDURE IT IS IMPORTANT TO TEST THE VEHICLE FOR INJECTOR LEAKDOWN. IF AN INJECTOR IS LEAKING IT IS POSSIBLE TO DAMAGE THE ENGINE DUE TO “HYDROLOCK’. (LIQUID FILLING THE CYLINDER). IF THE VEHICLE HAS INJECTOR LEAKAGE DO NOT DO THE RAIL FLUSH BUT PROCEDE DIRECTLY TO THE ENGINE CLEANING PROCESS.
Page 23 Turn the counterclockwise on the unit to open it Gasoline (Petrol) PRESSURE REGULATOR and release residual pressure. Disconnect the battery leads, hoses, and adaptors. Return the vehicle's fuel system to its normal operating condition by re-connecting the vehicle's fuel lines. Re-install the vehicle's gas cap.
Page 24: Port Fuel Injection (Pfi) Setup Procedure
Port Fuel Injection (PFI) Setup Procedure WARNING: BEFORE BEGINNING THE RAIL-FLUSH PROCEDURE IT IS IMPORTANT TO TEST THE VEHICLE FOR INJECTOR LEAKDOWN. IF AN INJECTOR IS LEAKING IT IS POSSIBLE TO DAMAGE THE ENGINE DUE TO “HYDROLOCK’. (LIQUID FILLING THE CYLINDER). IF THE VEHICLE HAS INJECTOR LEAKAGE DO NOT DO THE RAIL FLUSH BUT PROCEDE DIRECTLY TO THE ENGINE CLEANING PROCESS.
Page 25 /!\ WARNING Flammable Liquid can squirt out of pressurized lines when connecting or disconnecting. Wear Safety goggles. Obtain ZERO pressure before connecting or disconnecting any fuel lines or adaptors. Wear chemical resistant gloves when connecting or disconnecting fittings and adaptors. Wrap shop towel around pressure fittings and adaptors when disconnecting.
Page 26: Port Fuel Injection (Pfi) Cleaning Procedure
Port Fuel Injection (PFI) Cleaning Procedure WARNING: BEFORE BEGINNING THE RAIL-FLUSH PROCEDURE IT IS IMPORTANT TO TEST THE VEHICLE FOR INJECTOR LEAKDOWN. IF AN INJECTOR IS LEAKING IT IS POSSIBLE TO DAMAGE THE ENGINE DUE TO “HYDROLOCK’. (LIQUID FILLING THE CYLINDER). IF THE VEHICLE HAS INJECTOR LEAKAGE DO NOT DO THE RAIL FLUSH BUT PROCEDE DIRECTLY TO THE ENGINE CLEANING PROCESS.
Page 27 Turn the PRESSURE counterclockwise on the unit to release Gasoline (Petrol) REGULATOR any residual pressure. IMPORTANT Wrap a shop towel around pressure fittings before disconnection protect against residual fuel spray. Disconnect the battery leads, hoses, and adaptors. Return the vehicle's fuel system to its normal operating condition by re-connecting the vehicle's fuel lines.
Page 28: Continuous Injection System (Cis) Setup Procedure
Continuous Injection System (CIS) Setup Procedure WARNING: BEFORE BEGINNING THE RAIL-FLUSH PROCEDURE IT IS IMPORTANT TO TEST THE VEHICLE FOR INJECTOR LEAKDOWN. IF AN INJECTOR IS LEAKING IT IS POSSIBLE TO DAMAGE THE ENGINE DUE TO “HYDROLOCK’. (LIQUID FILLING THE CYLINDER). IF THE VEHICLE HAS INJECTOR LEAKAGE DO NOT DO THE RAIL FLUSH BUT PROCEDE DIRECTLY TO THE ENGINE CLEANING PROCESS.
Page 29 /!\ WARNING Flammable Liquid can squirt out of pressurized lines when connecting or disconnecting. Wear Safety goggles. Obtain ZERO pressure before connecting or disconnecting any fuel lines or adaptors. Wear chemical resistant gloves when connecting or disconnecting fittings and adaptors. Wrap shop towel around pressure fittings and adaptors when disconnecting.
Page 30: Continuous Injection System (Cis) Cleaning Procedure
Continuous Injection System (CIS) Cleaning Procedure Follow the steps below to circulate the cleaning mixture through the CIS fuel distributor to clean the Pressure regulator and the top portion of the fuel distributor. Verify that above have been completed before continuing. CIS Setup Steps 1-10 Refer to the vehicle's service manual for the manufacturer's recommended pressure.
Page 31 The unit will automatically shut off and the alarm will sound when the engine is stopped. Press off the switch. ON/OFF Turn the counterclockwise on the unit to release Gasoline (Petrol) PRESSURE REGULATOR residual pressure. IMPORTANT Wrap a shop towel around pressure fittings before disconnection protect...
Page 32: Before You Begin
Before You Begin First Time Operation The unit is tested at the factory with special test fluids then completely drained. These test fluids are compatible with diesel engine systems. Because the unit is dry during shipping, it will be necessary to prime the machine before it is put into service.
Page 33: Diesel Fuel System Cleaning Procedures
Diesel System Cleaning Procedures Filling and Mixture Setup Follow the steps below to obtain the proper fuel mixture for use during the cleaning procedure. Make sure the vehicle has at least 5 gallons (18.9L) of fuel before beginning this process. Start the vehicle.
Page 34 Filling Reservoir Procedure Figure A To pump diesel fuel into units tank, connect Red Hose to ball valve of 060-4500 tee adapter. Close ball valve. Start engine, check for leaks. Partially open ball valve enough to allow fuel to flow into...
Page 35: Priming
Purging Air from the System (Priming) It will be necessary to purge the air from the unit’s plumbing prior to connecting to the engine’s fuel system. Connect the hose and the hose together using OUTPUT (RED) RETURN (BLACK) adapters 060-1400 and 060-1100, as shown in below.
Page 36 Diesel Fuel System Setup Procedures Start the vehicle and allow the engine to reach normal operating temperature (if possible). IMPORTANT Do not perform the setup or cleaning process if the vehicle’s engine oil or coolant level is low. If necessary, add oil and/or coolant to the vehicle.
Page 37 NOTE Use an adaptor to plug off or loop back the fuel lines going to the tank to avoid any spills. NOTE Some fuel systems have two return lines: one from the injector pump and one from the injectors. When connecting to these types of systems, verify that both return lines have been captured.
Page 38 Diesel Cleaning Setup FIGURE C You are now ready to perform the Diesel cleaning procedure.
Page 39 Diesel Cleaning Procedures Verify that Mixture, Priming, and Diesel Setup Procedures above have been completed before continuing. Press and press the SERVICE SELECTOR SWITCH DIESEL FUEL SYSTEM ON/OFF switch on after turning past five minutes. NOTE: Alarm will sound until pump TIMER starts.
Page 40: Shut Down
Shut Down Just BEFORE the Run time expires, turn off the engine. During this time the pump will continue to run and supply fuel to the engine, when the expires, the pump shuts down. TIMER If the engine runs out of fuel, then it may be difficult to restart (especially if air is introduced into the fuel system).
Page 41 Diesel System Cleaning Procedures Filling and Mixture Setup Follow the steps below to obtain the proper fuel mixture for use during the cleaning procedure. Make sure the vehicle has at least 5 gallons (18.9L) of fuel before beginning this process. Start the vehicle.
Page 42 Filling Reservoir Procedure Figure A To pump diesel fuel into units tank, connect Red Hose to ball valve of 060-4500 tee adapter. Close ball valve. Start engine, check for leaks. Partially open ball valve enough to allow fuel to flow into...
Page 43 Purging Air from the System (Priming) It will be necessary to purge the air from the unit’s plumbing prior to connecting to the engine’s fuel system. Connect the hose and the hose together using OUTPUT (RED) RETURN (BLACK) adapters 060-1400 and 060-1100, as shown in below.
Page 44: Diesel Fuel System Setup Procedure
Diesel Fuel System Setup Procedures Start the vehicle and allow the engine to reach normal operating temperature (if possible). IMPORTANT Do not perform the setup or cleaning process if the vehicle’s engine oil or coolant level is low. If necessary, add oil and/or coolant to the vehicle.
Page 45 NOTE Use an adaptor to plug off or loop back the fuel lines going to the tank to avoid any spills. NOTE Some fuel systems have two return lines: one from the injector pump and one from the injectors. When connecting to these types of systems, verify that both return lines have been captured.
Page 46 Diesel Cleaning Setup FIGURE C You are now ready to perform the Diesel cleaning procedure.
Page 47: Diesel Cleaning Procedure
Diesel Cleaning Procedures Verify that Mixture, Priming, and Diesel Setup Procedures above have been completed before continuing. Press and press the SERVICE SELECTOR SWITCH DIESEL FUEL SYSTEM ON/OFF switch on after turning past five minutes. NOTE: Alarm will sound until pump TIMER starts.
Page 48 Shut Down Just BEFORE the Run time expires, turn off the engine. During this time the pump will continue to run and supply fuel to the engine, when the expires, the pump shuts down. TIMER If the engine runs out of fuel, then it may be difficult to restart (especially if air is introduced into the fuel system).
Page 49: Troubleshooting And Additional Help
Troubleshooting and Additional Help MCS 352. Refer to the list below in the unlikely event that you have problems with your Problem: Solution: 1. The MCS 352 is not operational or Polarity is reversed on vehicle battery connection. Check connections for correct polarity. Check trips breaker immediately.
Page 50 CHECKOUT PROCEDURE 1. Before diagnosing a problem, attempt to have the end user describe all symptoms. Most issues can be resolved by referring to the Troubleshooting (T/B) section on page 7-1. A ‘Baseline’ test can be performed to identify a component failure or unit problem. Once a repair has been made, perform a ‘real’...
Page 51 ELECTRICAL SCHEMATIC MCS 352 & ECS 350...
Page 52 – FLOW CHART MCS 352 GAS SYSTEM & ECS 350...
Page 53 – FLOW CHART MCS 352 DIESEL SYSTEM & ECS 350...
Page 54: Gas System
COMPONENT IDENTIFIER MCS 352 GAS SYSTEM Nylon Tube 5/16 0-160psi Pressure Gauge 070 0085 (GAS) Internal Harness 020- 8062 (Includes Alarm Pressure Regulator Assembly Power Harness –External 200-8049 020-0030 (Regulator Valve-Needle 050- Smooth-Hot Ribbed-Ground 15 Amp Circuit Breaker 020-0038 Internal 5-Way Block Assembly Harness 020- 200-8096...
Page 55 COMPONENT IDENTIFIER MCS 352 DIESEL SYSTEM 0-30 psi Pressure Gauge 200- 8090 (DIESEL) El 5/16 x ¼ fpt 030- 0011 Relief Valve (13psi) 050- 5-Way Block Assembly 5/16 Nylon Tube 070- 200-8096 0085 (Block 5-Way 030-0105) (Sold by the Foot) (El 5-16 x ¼...
Page 56 COMPONENT IDENTIFIER MCS 352 0-160psi Pressure Gauge (GAS) 200-8089 0-30 psi Pressure Gauge Ground (DIESEL) ON/OFF Rocker Switch (Blue, Black, 200-8090 (NOT SHOWN) Brown) (Red/Brown-Red) 020-1205 AMBER LAMP (Brown/Blue wires) GREEN LAMP (Blue/Blue wires) START/RUN Momentary Rocker Switch (Green/Black-White) 020- SERVICE/SELECT Rocker Switch-3way (Red/Red-Blue/Red) RELAY, Ear Mount 020-0090...
Page 57 COMPONENT IDENTIFIER TANK & FILTER ASSEMBLY MCS 352 (All Parts Below) 200-8648 010-6060 030-0017 Return Fitting 5/16-x ¼ MPT (Not 010-0012 TANK 040-0618 BOLT ¼-20 x ½” (2) 040-0619 STAR WASHER ¼” NOT SHOWN 030-3089 010-0023 BRACKET/with 3 030-0018 040-0607 EL 5/16-x ¼...
Page 58: Appendix A - Maintenance
Appendix A - Maintenance Maintenance Procedures The following maintenance procedures should be performed on a routine basis: Drain the unit’s fuel reservoirs and replace the fuel filters after every 30 cleaning services for Gasoline (Petrol), or every 10 cleaning services for the unit’s diesel fuel reservoir for maximum performance as described in the next section.
Page 59: Replacing The Fuel Filter
Replace the Fuel Filter Remove the old fuel filter from the mounting station on the side of the unit’s cabinet and install the new filter. Verify the filter is tightened securely Add the mixture back into the reservoir. Check the filter for leaks. Enter your initials, the date, and a check mark in the appropriate boxes of the Maintenance Record in the Operators Manual.