MAHLE RTI DCS-1 User Manual

DCS-1

Diesel Cleaning System

SAFETY INSTRUCTIONS

• Wear safety glasses or goggles

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• Have fire extinguisher available

• Do not smoke or use near ignition source

• Use in well ventilated area

Injector

Pump

Red

Hose

Supply

Return

Fuel

Filter

Black
Hose

Loop
Hose

Supply

Return

Fuel Tank

OPERATION INSTRUCTIONS

1 Verify that the batteries are good. With Timer at zero, turn the Power Switch

on. The buzzer should be heard - if not, change the batteries.

2 Start the engine and bring to full operating temperature. Then

turn engine off.

3 Make sure the valve on the bottom of the DCS-1 is closed as

shown to the right.

4 Remove Fill Cap and fill Tank with desired amount of cleaning fluid.

5 Replace Fill Cap - being careful that O-ring is in place.

6 Hang the DCS-1 at a location higher than the engine fuel filter. Position so

both control panels are accessible.

• Clean up any spills immediately

• Keep service hose away from hot or moving
engine parts

• Read the MSDS for any fluids used

BATTERY

The DCS-1 requires two AA batteries. An
access panel is located on the rear and is
secured with two screws. Always insert
batteries with polarity as shown in battery
compartment.

7 Connect hoses as shown in the illustrations using appropriate adapters and

adapter hoses.

! Red hose from engine supply line to port with red marking on bottom

of the DCS-1.

! Black hose from engine return line to port with black marking on

bottom of the DCS-1.

! Loop Hose between return and supply line of the fuel tank.

8 Open the Air Pressure Release Valve by turning counter-clockwise.

9 Open valve on the bottom of the DCS-1. Wait 30 seconds for cleaner to fill the

hose. Then start the engine. If the engine does not start it will be necessary
to pressurize the tank of the DCS-1 with shop air. If so, proceed with the
following steps:

! Close valve on bottom of DCS-1.

! Close Air Pressure Relief Valve by turning clockwise.

! Turn Air Pressure Regulator off by pulling knob away from cabinet

and turning all the way counter-clockwise.

! Connect shop air to port on the bottom of the DCS-1.

! Pull knob on Air Pressure Regulator away from cabinet and slowly

turn clockwise until Pressure Gauge indicates 10 to 15 PSI.

! Disconnect shop air.

! Open valve on bottom of DCS-1.

Page 1 of 2 RTI Technologies, Inc., 10 Innovation Drive, York, PA 17402 Ph.717-840-0678 035-81337-00

10 Start the engine. Immediately open the Air Pressure Release Valve to release any

remaining pressure and allow gravity flow to continue.

11 Turn Power Switch on and turn Timer knob clockwise to set time.

12 Run engine at 1200 RPM.

13 The Timer will go to zero and a buzzer will sound, indicating the service is complete.

If the level of cleaner in the Tank goes low enough, the buzzer will sound to alert that
the process should be stopped soon or the engine will be starved for fuel.

14 Shut engine off when the desired amount of cleaner has been consumed.

15 Close the valve on the bottom of the DCS-1. Do not close this valve with the engine

running as this could cause a vacuum in the engine fuel supply line.

16 Disconnect red and black hoses and remove the DCS-1.

17 Remove adapters and the Loop Hose and reconnect the fuel tank to the engine.

18 Replace engine fuel filter.

19 Start engine and check for any leaks.

Follow manufacturer’s procedure for purging after a filter change if engine will not start.

1998 and Newer Ford Power Stroke Engines

These engines have individual pumps on each injector rather than one central injector. These individual
injectors are fed with a conventional fuel pump. This pump is typically mounted along the frame rail
located under the front edge of the driver-side door.

Connect the DCS-1 as follows:

! Red hose from inlet of the fuel pump to port with red marking on the bottom of the DCS-1.

! Black hose from junction of the engine return line (by firewall) to the port with black marking on the

bottom of the DCS-1.

! The loop hose does not need to be connected.

The DCS-1 does not need to be pressurized as the cleaner will gravity feed.

MAINTENANCE

! The DCS-1 should be wiped clean after every use. Only a mild detergent soap should be used.

! Do not allow hoses to contact moving parts or hot surfaces during use.

! Periodically inspect and clean the two filters under the Fill Cap on the top of the DCS-1. These are

screen filters which can be lifted from the recessed holes as shown below.

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