CARBONCLEAN MODEL LE-1 CARBONCLEAN SYSTEM II OPERATORS MANUAL MOTORVAC TECHNOLOGIES MV P/N 100-8135 Rev C 1998
Table of Contents Introduction ...........................................................................................................................................ii Overview ...............................................................................................................................................iv System Features and Functions...................................................................................................... 1-1 Control Panel Features and Functions............
Introduction Congratulations on your selection of the CARBONCLEAN SYSTEM II. By choosing this product, you are acquiring the most technologically advanced method available for cleaning harmful fuel system contaminants from gasoline engines. The LE-1 is a self-contained 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 CarbonClean Cleaning Detergent for Gasoline.
Introduction Notes: 1998 MotorVac Technologies, iii
Overview This manual contains all the information you need to use the LE-1. Please make sure all technicians using the unit 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 LE-1 gauge, control switches, and connections.
Overview Notes: 1998 MotorVac Technologies, v
Overview System Features and Functions The front of the LE-1 cabinet contains the control panel, control switches and status indicators. The fuel reservior and filter are mounted on the rear of the cabinet.
Overview LE-1 Features and Functions Descriptions of the gauge, control switches, and status indicators that make up the control panel are listed below. Please become familiar with these control panel 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. Start/Run Switch Starts the cleaning cycle. Run Cycle Light Illuminates when the run cycle is under way.
Overview 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. /!\ WARNING Exhaust gases, moving parts, hot surfaces, and potent chemicals are present during the use of the fuel system cleaner. Read and understand the operator’s manual before using the fuel system cleaner.
Overview 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 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. Improperly blocked vehicles can move. Set the parking brake and chock the wheels.
Overview 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. Keep battery acid away from skin or eyes. In case of eye contact, flush with clean water for 15 minutes and get medical attention. Battery explosion and ignited gases can cause injury.
Overview 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. 1. Verify that the LE-1’s fuel filter is connected and securely in place in the rear of the cabinet. 2. Check the output/return hoses, battery connections, and all external components for damage. 3.
Overview • • 9. Release the Start/Run switch. Dispose of the fuel in an environmentally approved method. The LE-1’s reservoir is now completely drained of fuel. Follow the steps below before performing the first cleaning service: Mixing Ratios Using a separate container or the LE-1’s reservoir, follow the chart below to mix the proper amounts of CarbonClean Cleaning Detergent for Gasoline and fuel for the cleaning process. NOTE The proper ratio is 1 oz. (30 ml.) per cylinder to 3 oz. (90 ml.
Overview 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 fuel systems listed below: Carburetion Carburetors come in a variety of sizes and shapes. These can be easily identified by locating the choke plate in the air horn.
Overview Notes: 1998 MotorVac Technologies, xiv
Overview 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. 1. 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. If necessary, add oil and/or coolant to the vehicle. 2.
Overview /!\ 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. Avoid exposure to flames, sparks, hot engine parts, and other ignition sources.
Overview Carburetor Cleaning Procedure Follow the steps below to circulate the fuel/detergent mixture through the vehicle's carburetor. 1. Verify that Carburetor Setup Steps 1- 9 above have been completed. 2. Refer to the vehicle's service manual for the manufacturer's recommended PSI. 3. Adjust Timer knob for 30 minutes. (Run time may be adjusted depending on the condition of the vehicle’s fuel system.) 4. Press and hold the Start/Run switch. 5.
Overview 14. Test drive the vehicle for five kilometers immediately following the cleaning service to flush all detergent from the vehicle's fuel and exhaust systems.
Overview 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. 1. 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. If necessary, add oil and/or coolant to the vehicle. 2.
Overview /!\ 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. Avoid exposure to flames, sparks, hot engine parts, and other ignition sources.
Overview Throttle Body Injection (TBI) Cleaning Procedure Follow these steps to circulate the cleaning mixture through the TBI unit to clean the throttle body, injector screens, and pressure regulator. 1. Verify that TBI Setup Steps 1-11 above have been completed before continuing. 2. Refer to the vehicle's service manual for the manufacturer's recommended PSI. 3. Adjust Time for 10 minutes. 4. Press and hold the Start/Run switch. 5. Turn the Pressure Adjust regulator clockwise until closed.
Overview IMPORTANT Wrap a shop towel around pressure fittings before disconnection to protect against residual fuel spray. 13. 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. 14. Re-install the vehicle's gas cap. 15. Start the vehicle and verify that there are no leaks. 16.
Overview Port Fuel Injection (PFI) 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. 1. 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. If necessary, add oil and/or coolant to the vehicle. 2.
Overview 9. As shown in the figure below, connect one end of the loop adaptor (#060-2501) to the pressure line coming from the vehicle's fuel tank. Connect the other end of the loop adaptor (#060-2501) to the return line going back to the fuel tank. This forms a tank-to-tank loop, making it unnecessary to disconnect the fuel pump. 10. As shown in the figure above, connect the output (red) hose from the unit to the adaptor on the pressure line going into the fuel rail.
Overview Port Fuel Injection (PFI) Cleaning Procedure Follow these steps to circulate the cleaning mixture through the Port Fuel Injection unit to clean the fuel rail, injector screens, and pressure regulator. 1. Verify that PFI Setup Steps 1-11 above have been completed before continuing. 2. Refer to the vehicle's service manual for the manufacturer's recommended PSI. 3. Adjust Time until it displays 10 minutes. 4. Press and hold the Start/Run switch. 5.
Overview IMPORTANT Wrap a shop towel around pressure fittings before disconnection to protect against residual fuel spray. 13. 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. 14. Re-install the vehicle's gas cap. 15. Start the vehicle and verify that there are no leaks. 16.
Overview Continuous Injection System (CIS) 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. 1. 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. If necessary, add oil and/or coolant to the vehicle. 2.
Overview 9. As shown in the figure below, connect one end of the loop adaptor (#060-2501) to the pressure line coming from the vehicle's fuel tank. Connect the other end of the loop adaptor (#060-2501) to the return line going back to the fuel tank. This forms a tank-to-tank loop, making it unnecessary to disconnect the fuel pump. 10. As shown in the figure above, connect the output (red) hose from the unit to the adaptor on the pressure line going into the fuel distributor.
Overview 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. 1. Verify that CIS Setup Steps 1-11 above have been completed before continuing. 2. Refer to the vehicle's service manual for the manufacturer's recommended PSI. 3. Adjust Time knob for 10 minutes. 4. Press and hold the Start/Run switch. 5.
Overview 11. DO NOT ALLOW CIS VEHICLES TO RUN OUT OF FUEL. TURN OFF THE VEHICLE’S ENGINE BEFORE COMPLETION OF THE RUN CYCLE. 12. Turn the Pressure Adjust regulator counterclockwise on the unit to release residual pressure. IMPORTANT Wrap a shop towel around pressure fittings before disconnection to protect against residual fuel spray. 13. 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. 14.
Overview Vehicle Diagnostics Although vehicle diagnostic tests are not a mandatory part of the cleaning procedure, they can help determine if poor engine performance is caused by other conditions related to the fuel system.
Overview Fuel System Pressure Test 1. Verify that Setup Steps 1-12 from the previous chapter have been completed for the specific fuel system type to be tested. 2. Note the vehicle’s fuel system pressure reading from the Fuel Pressure gauge on the control panel of the unit after starting the cleaning process. • Check vehicle’s pressure regulator’s opening pressure. Check the manufacturers specifications for the correct specification. • Check the vehicle’s running pressure.
Overview Troubleshooting and Additional Help Refer to the list below in the unlikely event that you have problems with your LE-1. Problem: Solution: 1. Power Light is ON and the LE-1 is not Polarity is reversed on vehicle battery connection. Check connections for correct operational. polarity. Check FUSE on the front panel 2. Pressure Gauge on the LE-1 displays maximum pressure upon start up. Output and Return hoses may be reversed. Turn Timer to zero and check hoses for correct connection. 3.
Overview 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 non-abrasive 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.
Overview Replace the Fuel Filter 1. Remove the old fuel filter from the mounting station on the back of the unit’s cabinet and install the new filter. Verify correct direction of the arrow for fuel flow. 2. Tighten the clamps securely to prevent any spills. 3. Add the mixture back into the LE-1’s reservoir. 4. Check the filter for leaks. 5. Enter your initials, the date, and a check mark in the appropriate boxes of the Maintenance Record at the end of this chapter.
Overview Initial/Date DRAIN FUEL RESERVOIR REPLACE FUEL FILTER CLEAN EXT.
Overview Initial/Date DRAIN FUEL RESERVOIR REPLACE FUEL FILTER CLEAN EXT.
Overview Appendix B - System Accessories Standard Adaptor Kit (200-8058) The standard adaptor kit is included with your LE - 1 system. The most commonly used application is listed; however, other applications may apply. PART & NO. QTY 2 060-1400 060-1600 1 1 APPLICATION GENERAL APPLICATIONS UTILIZING 5/16" FUEL LINE FEMALE. (USE WITH SUITABLE HOSE CLAMPS ) 12MM BANJO FITTING CIS OR EFI SYSTEMS. IN CONJUNCTION WITH 0601900, 060-1901, 060-1902. HOSE MENDER TUBE 5/16" - MALE.
Overview PART & NO. QTY APPLICATION 2 14MM X 16MM UNION. USE IN CONJUNCTION WITH 060-2300 AND 060-2600 FOR CIS APPLICATIONS. 5 HOSE CLAMP. (MEDIUM) 1 HOSE MENDER STEM USE WITH 080-2300 AND 0600440 1 HOSE MENDER NUT USE WITH 080-2301 AND 0600440 060-2700 060-0440 080-2301 080-2300 060-2501 1 FORMS "TANK TO TANK" LOOP ON ALL VEHICLES. USED TO EXTEND VEHICLE'S RETURN LINE DURING DIAGNOSTICS.
Overview Deluxe Adaptor Kit (200-8059) Contact your LE - 1 sales representative for information on obtaining the deluxe adaptor kit. The most commonly used application is listed; however, other applications may apply. PART & NO. QTY 1 APPLICATION HOSE CLAMP (LARGE) 060-0450 2 060-1000 GENERAL APPLICATIONS UTILIZING 1/4" FUEL LINE MALE. (USE WITH SUITABLE HOSE CLAMPS.) 2 GENERAL APPLICATIONS UTILIZING 5/16" FUEL LINEMALE. (USE WITH SUITABLE HOSE CLAMPS.
Overview QTY PART & NO. 1 10MM BANJO FITTING EFI SYSTEMS OR COLD START INJECTOR. USE WITH 10MM DOUBLE BANJO BOLT (060-2720). 1 8MM DOUBLE BANJO BOLT. 060-2400 060-2710 060-2720 060-2711 060-2721 APPLICATION 3 USE WITH 060-2401. 1 10MM DOUBLE BANJO BOLT. 3 USE WITH 060-2400. 1 "TEST PORT/SCHRADER VALVE" CONNECTION - FORD. (SCHRADER VALVE CORE MUST BE REMOVED) 060-3508 1 "TEST PORT/SCHRADER VALVE" CONNECTION - GM.
Overview Appendix C - Parts External Parts for the LE-1 Please refer to the part numbers below when ordering parts for the LE-1. Part # Description 010-6060 Reservoir cap, Vented 020-8063 Harness, power 030-0020 Conn M.
