Motorvac CARBONCLEAN MCS 245 User manual

Fuel System Service &
Diagnostic Equipment
OPERATOR’S MANUAL
MCS 245

Table of Contents
Introduction ...........................................................................................................................................3
Overview ................................................................................................................................................4
System Features and Functions ......................................................................................................... 5
System Features and Functions ........................................................................................................
Hose and Battery Connections ..........................................................................................................
Fuel Filter ...........................................................................................................................................
Theory of Operation………………………………………………………………………………………
Safety Information ..............................................................................................................................13
Before You Begin................................................................................................................................17
First Time Operation...........................................................................................................................
Mixing Ratio........................................................................................................................................
Fuel System Cleaning Procedures....................................................................................................19
Determining the Vehicle's Fuel System Type ....................................................................................
Carburetor Setup Procedure ..............................................................................................................
Carburetor Cleaning Procedure .........................................................................................................
Throttle Body Injection (TBI) Setup Procedure ..................................................................................
Throttle Body Injection (TBI) Cleaning Procedure .............................................................................
Port Fuel Injection (PFI) Setup Procedure .........................................................................................
Port Fuel Injection (PFI) Cleaning Procedure ....................................................................................
Continuous Injection System (CIS) Setup Procedure........................................................................
Continuous Injection System (CIS) Cleaning Procedure ...................................................................
Returnless System Setup Procedure.................................................................................................
Returnless System Cleaning Procedure ............................................................................................
Vehicle Diagnostics............................................................................................................................49
Fuel System Pressure Test................................................................................................................
Fuel Volume Test ...............................................................................................................................
Deadhead Test...................................................................................................................................
Leakdown Test ...................................................................................................................................
Vacuum Pressure Test.......................................................................................................................
Intake System Cleaning Procedures..................................................................................................56
Troubleshooting and Additional Help ..............................................................................................62
Appendix A - Maintenance.................................................................................................................65
Maintenance Procedures ...................................................................................................................
Replacing the Fuel Filter ....................................................................................................................
Maintenance Record ..........................................................................................................................
Appendix B - System Accessories ...................................................................................................69
Standard Adaptor Kit..........................................................................................................................
Deluxe Adaptor Kit .............................................................................................................................
Optional Adaptors Available ..............................................................................................................
Appendix C - Parts..............................................................................................................................78
Service Parts .....................................................................................................................................
Appendix D - MATERIAL SAFETY DATA SHEET ............................................................................ 80
Material Safety Data Sheet.......................................................................................................................

Introduction
Congratulations on your selection of the MotorVac CarbonClean Fuel System Cleaner. By choosing this
product, you are acquiring the most technologically advanced method available for cleaning harmful fuel system
contaminants from gasoline engines.
The MotorVac CarbonClean System 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 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 fuel loop, it loosens and dissolves accumulated deposits, which then pass harmlessly out through the
exhaust system or are removed by the unit’s fuel filter. Removing contaminants from the combustion chamber creates a
more even burn of fuel, which improves horsepower, increases fuel economy, and reduces exhaust emissions.
It is recommended that you perform the fuel system cleaning procedure on a vehicle every 12,000 miles to obtain the
highest fuel system efficiency.
Please study this Operators Manual to become thoroughly familiar with the MotorVac CarbonClean System before
using it.
IMPORTANT
The MotorVac CarbonClean System is designed to work
EXCLUSIVELY
with the MotorVac CarbonClean Detergent and Top Engine Cleaner.
Use of any other chemical during this process may cause operational failure of the
MotorVac CarbonClean System and voids the manufacturer’s warranty.
See warranty card for details.

Overview
This manual contains all the information you need to use the MotorVac CarbonClean System. 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 MotorVac CarbonClean System gauges, control buttons, LED’s, and
connections.
Safety Information
Adhere to the safety guidelines in this chapter at all times!
Before You Begin
Follow the instructions in this chapter before using the unit for the first time.
Fuel System Cleaning Procedures
This chapter contains step-by-step setup and cleaning procedures for using the unit with each of the four fuel
system types: Carburetor, Throttle Body Injection (TBI), Port Fuel Injection (PFI), Continuous Injection
System (CIS), and Returnless Injection System.
Vehicle Diagnostics
This chapter describes how to use the unit to perform system tests on the vehicle in order to rule out other fuel
system-related problems.
Troubleshooting and Additional Help
Turn to this chapter in the unlikely event you have problems with your MotorVac CarbonClean System or
need additional help.
Appendices - Maintenance, Accessories, and Parts
The appendices contain routine maintenance procedures for the MotorVac CarbonClean System, such as
changing the fuel filter, lists of available accessories and replacement parts, and the Material Safety Data
Sheets.

System Features and Functions
The front of the MotorVac CarbonClean System cabinet contains a software-driven control panel, the
opening for the fuel reservoir, and storage drawers for adaptors and other system accessories.
TIME DISPLAY, CYCLE COMPLETE
LED & TIMER BUTTONS
START BUTTON
FUEL
PRESSURE
GAUGE
REVERSE POLARITY LED
PRESSURE
REGULATOR
LEAK TEST
BUTTON
SYSTEM WARNING
STOP BUTTON
UP / DOWN
ARROWS
ENGINE
VACUUM
GAUGE
FILL / PURGE
BUTTON
FUEL LEVEL
WINDOW

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.
Stop Button Stops all run conditions.
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.
Engine Vacuum Gauge Displays vacuum pressure on the vehicle being serviced.
Reverse Polarity LED Illuminates when:
•Polarity is reversed on the connection between the vehicle battery and
the unit.
Down Arrow LED Illuminates when the filling process is under way.
Up Arrow LED Illuminates when the run cycle is under way.
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.
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.
Fuel Pressure Gauge Displays output pressure of the unit’s output hose, or system pressure of
the vehicle being serviced.
Start Button Starts the run cycle.
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).
Leak Test Button Starts the Leak Test.
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 five-minute
increments.

Hose and Battery Connections
As you face the system, the left side of the unit’s cabinet holds the fuel return and output hoses, while the
right side of the unit’s cabinet holds the battery cables and vacuum pressure hose.
Serial ID Plate
Output Hose
(Red) Return Hose
(Black)
Support Hanger
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.

Battery Cables
Red (pos) Black (neg)
Vacuum Hose
Support Hanger
Support Hanger
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 (8-16
VOLTS DC and 8 AMPERES)

Fuel Filter
The back of the unit’s cabinet contains an easy access area for the fuel filter, along with storage slots for
shop towels, detergent bottles, etc. Please see Appendix A for information on replacing the unit’s fuel filter.
A
ir Vents
A
ir Vents
System Filter
W heels

Theory of Operations
Detailed descriptions of the various operations, control buttons, and LED indicators are listed below.
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. Releasing the button stops the motor and closes the solenoid.
•Whenever the motor is pumping in the Fill/Purge direction, the DOWN ARROW LED (away from the
car) is on.
Cleaning (Run) Operation:
•When the START button is pressed and held the motor will start the pump in the clean (run) direction
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 TIME LED display will show the run time.
•When the run time is complete, the motor stops and an end of cycle beep 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 at least 4 PSI, the motor will stop for 1 second, then run in the purge direction for 5
seconds with the solenoid open. 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 (towards the car) is on.
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:
•While in a run cycle, the LEAK TEST button is pressed and released, the solenoid will close and the
timer will show the leak test time.
•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 on.

Pressure Switch Operation:
•The pressure switch is opened when the pressure is less than 4 PSI and is closed when the pressure is 4
PSI or greater.
Solenoid Operation:
•The solenoid is only opened when the motor is running in either fill or cleaning (run) directions.
Stop Operation:
•When ever the STOP button is pressed, the motor will stop and timer display is turned off.
Timer Operation:
•The highest time value LED will blink. For example, if 12 minutes are left in the run cycle, the 15
minute LED will flash until the timer reaches 10 minutes.
•When the timer reaches 0 minutes left, the CYCLE COMPETE LED will go on and the end of cycle
alarm will sound.
Cycle Time Operation:
•The TIME ✚and the ▀▀ buttons are used to adjust the cycle time, while the cleaning, or leak test is in
progress.
•The maximum settable time is 60 minutes, the minimum settable time is 5 minutes. The time is adjusted
in increments of 5 minutes. There is a 10 minute increment between 50 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 time will be stored as the cycle time
for the next run. This applies to cleaning, and leak test set times.
•If the ▀▀ button is continuously pressed until the time reaches zero the end of cycle alarm will occur
and the CYCLE COMPLETE LED will turn on.
•When the unit is powered on, the CYCLE COMPLETE LED is displayed.
Fuel Level Window Operation:
•The FUEL LEVEL WINDOW shows the amount of fuel in the tank.
•The FUEL LEVEL WINDOW indicates the fuel level in 1/8 tank increments.
•When the FUEL LEVEL WINDOW is at the empty (“E”) level there is approximately one and a half
quarts of fuel as a reserve below the empty level.

Notes:

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.
When using chemicals always refer to the MSDS sheets and manufacturer’s instructions for the
proper procedure to handle emergency medical treatment, cleanup, handling, and storage
requirements.
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.
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.
Cleanup any fuel or chemical spills immediately.
Dispose of contaminated cleanup material according to governing environmental laws.
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.
Keep Cleaner and Detergent container closed except when filling reservoir.
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.
Always keep Reservoir Cap secure except when filling reservoir.
Explosion or flame can cause injury.
Many fuel systems maintain residual pressure in fuel lines even after the engine has been turned off.
Wear safety goggles.
Wear chemical resistant gloves when connecting or disconnecting fitting and adaptors.
Obtain ZERO psi before connecting or disconnecting any fuel lines or adaptors.
Explosion or flame or exposure to flammable liquid and vapors can cause injury.

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.
Moving engine parts.
The engine cooling fan will cycle on and off depending on the coolant temperature and could operate without
the engine running.
Wear safety goggles.
Always keep objects, clothing, and hands away from the cooling fans and engine parts.
Moving engine parts can cause injury.
Hot surfaces are present during and after running the engine.
Do not contact hot surfaces such as, manifolds, pipes, mufflers, catalytic converters, or radiators
and hoses.
Hot surfaces can cause injury.
Catalytic converters become extremely hot.
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.
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.
Catalytic converters can cause burns.
Cracked fan blade can become airborne.
Examine fan blades for cracks. If found, do not service the vehicle.
Flying objects can cause injury.
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.
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.

Notes:

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.
Remember to send in your warranty card to properly
register your machine.
1. Verify that the unit’s fuel filter is connected and securely in place on the filter base assembly at the
rear of the cabinet.
2. Check the output/return hoses, battery connections, and all external components for damage.
3. Turn the Pressure Adjust regulator on the unit control panel counterclockwise until it is
completely open.
4. 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.
5. Fill the unit’s reservoir with clean gasoline until the Fuel Level Window indicates 1/4 tank.
6. Connect the unit’s output (red) hose and return (black) hose together by using the
#060-1100 and #060-1400 adaptors and securing them with a clamp. Follow the procedures below
to flush fuel through the system:
• Press and hold the Start button for five minutes. This will thoroughly flush the system with
clean gasoline.
• Release the Start button.
7. Disconnect the output and return lines.

8. Connect the #060-1100 adaptor to the output hose, then drain the gasoline from the unit’s 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.
• Release the Start button.
• Dispose of the fuel in an environmentally approved method.
9. The unit’s reservoir is now completely drained of fuel. Follow the steps below before performing
the first cleaning service:
• Repeat Steps 3-4 from the previous page.
• Add 20 oz. of detergent to the unit’s reservoir.
• Add clean gasoline to the unit’s fuel reservoir until the mixture of fuel and detergent reaches 1/4
tank according to the Fuel Level Window.
•The unit is now ready to perform a cleaning service.
NOTE: When adding detergent to reservoir, pour in the 8oz. bottle of detergent first. For each 8oz. bottle, bring fuel
level to ¼ level. When tank is at zero, add four 8oz bottles of detergent first, then fill reservoir to top with fuel.
NOTE:
The proper ratio is 1 oz. (30 ml.) per cylinder to 3 oz. (90 ml.) gasoline.
DETERGENT / GASOLINE (PETROL) RATIO
3 cylinders = 3 oz. (90 ml.) detergent to 9 oz. (270 ml.) gasoline, (360 TOTAL)
4 cylinders = 4 oz. (120 ml.) detergent to 12 oz. (360 ml.) gasoline, (480 TOTAL)
5 cylinders = 5 oz. (150 ml.) detergent to 15 oz. (450 ml.) gasoline, (600 TOTAL)
6 cylinders = 6 oz. (180 ml.) detergent to 18 oz. (540 ml.) gasoline, (720 TOTAL)
8 cylinders = 8 oz. (240 ml.) detergent to 24 oz. (720 ml.) gasoline, (960
TOTAL)
10 cylinders = 10 oz. (300 ml.) detergent to 30 oz. (900 ml.) gasoline, (1200
TOTAL)
12 cylinders = 12 oz. (360 ml.) detergent to 36 oz. (1080 ml.) gasoline, (1440
TOTAL)

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.
Throttle Body Injection (TBI)
Throttle bodies are centrally mounted, as are carburetors, and use one or two electronic
injectors.
Port Fuel Injection (PFI)
This system uses a single electronic injector per cylinder, mounted so that fuel spray is
directed into the intake port.
Continuous Injection System (CIS)
A Continuous Injection System is easily identified by noting the fuel distributor and the
solid steel or flex steel lines running from the fuel distributor to each individual injector.
The fuel distributor controls the amount of fuel sprayed into the intake port while the
injectors control the opening and closing pressure.
Returnless Injection System
Returnless fuel systems are similiar to Port Fuel Injection systems with a few exceptions.
Returnless systems do not have a pressure regulator on the fuel rail & do not use a fuel
return line leading back to the fuel tank. Because these systems do not control pressure at
the rail assembly (Pressure is regulated inside the fuel tank) and do not have a provision for
a return line connection, the rail flush procedure is not performed. Refer to the Returnless
fuel section for specific procedures.
NOTE
Once you have determined the fuel system type, turn
to the appropriate section in this chapter for
instructions on how to perform the fuel line setup
and cleaning procedure for that system.

Notes: