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.