INDUSTRIAL DIESEL TUNE SYSTEM OPERATORS MANUAL FOR SERIAL NUMBERS 110000 AND ON 200-8241 REV.
Table of Contents System Features and Functions......................................................................................................... 3 System Features............................................................................................................................. 4 Control Panel Features and Functions ........................................................................................... 5 Features and Functions ............................................................
System Features and Functions System controls are all microprocessor-based. Solenoid valves, and electro-mechanical switches have been eliminated to increase reliability. A membrane switch operators panel and LED readouts provide an extremely simple operator interface. The system operates on any D.C. voltage between 8 and 30. Automatic electronic voltage control reduces stress on the pump motor. A manual pressure control valve and mechanical pressure gauge are located on the top of the cabinet.
System Features The front of the Industrial Diesel Tune cabinet contains a manually and automatically operated control panel and the opening for the fuel reservoir. Fuel Filler Control Panel Output & Return Hoses Battery Cables Fuel Filter 200-8241 REV.
Control Panel: Fuel Pressure Display Fuel Level Display System Warning LED Time Display Up Arrow LED Pressure Regulator Down Arrow LED Soak Button Fill Button Start Button Decrease Time Button Stop Button Increase Time Button Reverse Polarity LED 200-8241 REV.
Features and Functions Descriptions of the external components, displays, control buttons, and status indicators that make up the unit and control panel are listed below. Please become familiar with the control panel features and functions before using the unit. Fuel Filler & Cap Fill unit’s fuel tank with cleaning detergent, fuel, or mixture. Fuel cap for tank. Output Hose (red) Connects to the input side of the vehicle's engine fuel system, or fill the units fuel reservoir.
Start Button Starts the run cycle. See Theory of Operation section for more details. Soak Button Starts the soak cycle. 200-8241 REV.
Theory of Operations Detailed descriptions of the various operations, control buttons, and LED indicators that make up the control panel are listed below. IMPORTANT NOTE: THERE IS A 5 SECOND DELAY REQUIRED BETWEEN PRESSING THE START AND FILL BUTTONS, IF THEY ARE PREESED SOONER THERE WILL BE 3 SECOND DELAY BEFORE THE PUMP WILL OPERATE. Fill Operation: • When the FILL button is pressed and released and the fuel tank is not full, the motor starts the pump in the fill direction.
Initial Cleaning Cycle: • The Initial Cleaning period is half the time of the total cleaning period. If the total cleaning period is greater than or equal to 40 minutes, the Initial Cleaning Cycle is 20 minutes. • The Initial Cleaning Cycle is half the total time rounded down to the next 5 minute interval. For example, if the total cleaning time is 25 minutes, the Initial Cleaning Cycle will be 10 minutes.
• When the Final Clean time is complete, the end of cycle alarm will sound for 6 seconds. The Cycle Complete LED will be on, and the pump will continue to run. Every minute afterwards the end of cycle alarm will repeat for 6 seconds. This will continue until the STOP BUTTON is pressed and released, or until the FUEL LEVEL dial indicates empty. If the FUEL LEVEL dial indicates empty the SYSTEM WARNING LED will flash and the alarm will sound continuously until the STOP button is pressed.
• When the FUEL LEVEL displays “E” the tank is at the empty level or below (there is approximately a gallon of fuel as a reserve below the empty level). • When the unit is powered on, the FUEL LEVEL is displayed. If the tank is empty the “E” LED will be illuminated to indicate power is applied to the unit and it is ready for operation. • The FUEL LEVEL display can be calibrated to the Fuel Level Sensor, see APPENDIX A for the calibration procedures. 200-8241 REV.
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 Industrial Diesel Tune. Read and understand the operator’s manual before using the Industrial Diesel Tune.
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. Moving vehicles can cause injury.
Before You Begin First Time Operation The unit system 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, it will need to be primed before the machine is put into service. 1. Fill the unit’s fuel filter completely with diesel fuel, approximately 1 quart (32 ounces, 0.95L). Verify that the unit’s fuel filter is securely in place on the unit. 2.
NOTE Repeat the above procedures any time the unit’s reservoir and filter is completely drained of fuel. Unless filling from a container of premixed 1:1 ratio of detergent and diesel fuel. • The reservoir has a usable capacity of 3.0 gallons (11.3L). A reserve amount of mixture 1 gallon (3.8L) will remain below the last segment on the fuel level display. When filling an empty reservoir, extra cleaning solvent is required to maintain the correct ratio of cleaner and diesel fuel.
Diesel Fuel System Procedures Filling and Mixture Setup Follow the steps below to connect the unit to the vehicle's fuel system in order to obtain fuel from the vehicle for use during the cleaning procedure. Make sure the vehicle has at least 5 gallons (18.9L) of fuel before beginning this process. 1. Start the vehicle and allow the engine to reach as close as possible to normal operating temperature. NOTE The diesel engine cleaning system should be operated on a level surface.
6. If the REVERSE POLARITY LED illuminates then battery connections are incorrect, reconnect leads properly. The FUEL LEVEL Display LEDs should be illuminated and display the fuel level. NOTE If nothing appears on the display, check that the battery clips are attached to the proper terminals on the battery (BLACK clip to ground connection, RED clip to positive terminal). If the battery clips are connected correctly, check the condition of the vehicle’s battery. 7.
2. Press and release the START button. Operate the system in Priming mode for one minute, then press and release the STOP button. The unit’s filter and hoses should now be purged of air, that could possibly go in the engine’s fuel system, if this procedure was not performed. 3. Disconnect the PRIME adaptor. 200-8241 REV.
Diesel Fuel System Setup Procedures 1. Start the vehicle and allow the engine to reach as close as possible to 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. Stop the cleaning process if the engine is low on oil or overheats. 2. Turn the engine OFF when normal operating temperature has been reached. 3.
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. Usually they will join together at some point before going back to the tank. 7. As shown in FIGURE B on the next page, connect the appropriate adaptors at the points listed in Step 6.
You are now ready to perform the Diesel cleaning procedure. 200-8241 REV.
Diesel Cleaning Procedures 1. Verify that Mixture, Priming, and Diesel Setup Procedures above have been completed before continuing. 2. Turn the pressure regulator fully counter clockwise. Press and release the START button. The unit will start and the pressure will be indicated on the pressure gauge. The pressure can be increased if necessary by turning the pressure regulator clockwise. Do NOT exceed 100 psi. 3. Check for fuel leaks and correct as necessary. 4.
4. Press the START button to restart the unit and continue on with the RUN MODE. Verify that the RUN timer had gone back to the time last showed before the Soak Cycle began. Restart the engine. The RUN mode and the cleaning cycle will continue for the remaining RUN time. The Final Cleaning time can be adjusted either up or down, if necessary. Press and release the INCREASE ( +) or DECREASE (- ) TIME buttons to adjust the Run time either up of down.
Glossary and Troubleshooting Glossary of Error Indicators Refer to the list below in the unlikely event that you have problems with your unit. Error Indicator Mode: Description: 1. Reverse Polarity Any Polarity is incorrect at the battery lead connections. The correct connections are as follows: • Attach the unit to a vehicle’s battery by connecting the red battery clip to the positive (+) battery terminal and connect the black battery clip to a solid ground. 8 - 30 Volts DC, 8 Amperes at 12VDC.
4. Unit stops filling, pump is not running. Unit has become disconnected from power, or the STOP button was accidentally activated. 5. Unit stops supplying fuel, pump is running. There may be a blockage or air in the system. • The filter is clogged or dirty in either the unit or the Fill adaptor. • The unit is not primed, see Before You Begin chapter to prime unit. • There may be some debris in the tank, blocking the supply port. 6. Unit stops supplying fuel, pump is not running.
Appendix A - System Accessories Basic Adapter Kit 200-3021A The Standard adaptor kit is included with all new machines shipped. The most commonly used application is listed; however, other applications may apply. Image 200-8241 REV. 2 Part Number Description Quantity 060-0440 CLAMP-HOSE, MEDIUM 7/32"-5/8" 2 060-0450 CLAMP-HOSE, LARGE 7/16"-25/32 HC66 2 060-4700 PRIME ADAPTER 1 061-0001 FILL ADAPTER 1 060-2501 FORMS “TANK TO TANK” LOOP ON ALL VEHICLES.
200-8241 REV. 2 060-1100 GENERAL APPLICATIONS UTILIZING 5/16" FUEL LINEMALE. (USE WITH SUITABLE HOSE CLAMPS.) 2 060-1200 GENERAL APPLICATIONS UTILIZING 3/8" FUEL LINE MALE. (USE WITH SUITABLE HOSE CLAMPS.) 2 061-3510 GENERAL APPLICATIONS UTILIZING 3/16” FUEL LINE FEMALE. (USE WITH SUITABLE HOSE CLAMPS.) 2 060-1300 GENERAL APPLICATIONS UTILIZING 1/4" FUEL LINE FEMALE. (USE WITH SUITABLE HOSE CLAMPS.) 2 060-1400 GENERAL APPLICATIONS UTILIZING 5/16” FUEL LINE FEMALE.
200-8241 REV. 2 060-1900 060-1901 060-1902 CONNECTS 12MM BANJO FITTINGS FOR DIAGNOSTICS AND/OR CREATING A LOOP. 2 060-2300 17MM WRENCH SIZE WITH 14MM THREADS - EUROPEAN CARS INLET AND/OR RETURN. MAY BE USED WITH 060-2700. 2 060-2402 14MM BANJO FITTING 2 060-2600 19MM WRENCH SIZE WITH 16MM THREADS - EUROPEAN CARS INLET AND/OR RETURN. MAY BE USED WITH 060-2700. 2 060-2700 14MM X 16MM UNION. USE IN CONJUNCTION WITH 060-2300 AND 060-2600 FOR CIS APPLICATIONS.
060-3900 FQD-5/16 Ford 2 060-4300 MALE 3/8 FORD/GM 2 060-3901 FQD-3/8 Ford 2 060-3903 12mm male quick connect 2 060-3904 12mm female quick connect 2 Optional Adapters The following adapters are available individually as accessories. . The most commonly used application is listed; however, other applications may apply. Image 200-8241 REV.
200-8241 REV. 2 060-3200 1/4" MALE NPT.
Appendix B - Parts External Parts for the Industrial Diesel Tune Please refer to the part numbers below when ordering parts for the unit. MotorVac Part Number 040-0604 Wheel, hub cap 010-0027 Wheel 010-6060 Reservoir Cap (tank cap) 020-0028 Power Harness with battery clips 050-0073 Filter, spin-on, 10 microns (US & Canada) 050-0071 080-0230 Filter, inline for Fill adaptor (3/8” I.D.
ORDERING PARTS Contact your sales Rep or Distributer 200-8241 REV.
