MotorVac DieselTune 4000 User Manual

INDUSTRIAL DIESEL TUNE

SYSTEM

200-8241 REV. 2

OPERATORS

FOR SERIAL NUMBERS 110000 AND ON

MANUAL

DieselTune 4000 Operators Manual

Table of Contents

System Features and Functions......................................................................................................... 3

System Features............................................................................................................................. 4

Control Panel Features and Functions ........................................................................................... 5

Features and Functions .................................................................................................................. 6

Theory of Operations ...................................................................................................................... 8

Safety Information............................................................................................................................. 12

Before You Begin .............................................................................................................................. 14

First Time Operation ..................................................................................................................... 14

Fuel System Cleaning Procedures .................................................................................................. 16

Filling and Mixture Setup .............................................................................................................. 16

Purging the System ...................................................................................................................... 17

Diesel System Setup Procedures................................................................................................. 19

Diesel Cleaning Procedures ......................................................................................................... 22

Soak Mode Procedures ................................................................................................................ 22

Shut Down Procedures................................................................................................................. 23

Glossary and Troubleshooting ........................................................................................................ 24

Glossary of Error Indicators .......................................................................................................... 24

Troubleshooting ............................................................................................................................ 24

Appendix A - System Accessories ................................................................................................... 26

Basic Adaptor Kit ........................................................................................................................... 26

Optional Adapters …………………………………………………………………………………………29

Appendix B - Parts ............................................................................................................................. 31

External Parts ................................................................................................................................ 31

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DieselTune 4000 Operators Manual

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. With the pressure control valve fully open (counter-clockwise) the pressure is internally regulated below 15 psi for typical services. Some diesel injection systems such as HEUI and some common rail engines require higher pressure from the lift pump to function. The pressure can be increased to match the pressure specified by the manufacturer by turning the pressure control valve clockwise.

A built-in self-test at power up verifies electronic functions, while continuous monitoring during operation verifies that parameters are within tolerance.

The noise level of this equipment was tested and a maximum level of 63 dB (A) was measured.

A fill adapter allows the system mixture tank to be filled from the vehicle's fuel tank or another fuel source. Fuel level is continuously monitored. Fuel siphoning adaptor MV p/n 061-0001 comes with a 3/8" (10mm) in-line fuel filter. Any inline filter with minimum flow capacity of 3 to 5 gallons per minute (11 to 19 LPM) is acceptable as a replacement, or it can be purchased directly under MV p/n 050-0071.

A 4.6 U.S. gallon (17.4 liter) solution tank provides for multiple cleaning cycles without the need for refilling.

All parts in the fuel path, including the tank, hoses, fittings, and seals, are made from non-corrosive materials.

A spin-on canister fuel filter provides quick filter changes.

A two-stage electronic programmable timer monitors the elapsed time, and sounds both a soak alarm shut-down alarm. A mixture level monitor sounds an alarm for an impending fuel shortage or out-of- fuel condition.

and

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DieselTune 4000 Operators Manual

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

Output & Return Hoses

Control Panel

Battery Cables

Fuel

Filter

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DieselTune 4000 Operators Manual

Control Panel:

Fuel Pressure Display

System Warning LED

Up Arrow LED

Down Arrow LED

Fill Button

Stop Button

Reverse Polarity

LED

Fuel Level Display

Time Display

Pressure Regulator

Soak Button

Start Button

Decrease Time Button

Increase Time Button

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DieselTune 4000 Operators Manual

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.

Return Hose (black) Connects to the return side of the vehicle's engine fuel system. Control Panel Contains displays, control buttons, and status indicators. Battery Cables Positive (red) and negative (black) battery connections (8.0-30

Volts DC, 8 Amperes at 12VDC)

Fuel Filter Filters out contaminants that have been removed during the cleaning

process. See Appendix A for replacement information 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.

Fuel Level LED A circle of LEDs displaying the amount of fuel/detergent mixture

remaining in the unit’s reservoir. Time LED A circle of LEDs displaying the remaining run cycle time in five-

minute increments.

Fuel Pressure Gauge Displays output pressure of the unit’s output hose. Pressure Control Valve Turn clockwise to increase output pressure and counter-clockwise to

reduce output pressure. Fill Button Transfers fuel from the fuel tank of the vehicle being serviced to the

unit’s reservoir. See Theory of Operation section for more details.

Stop Button Stops all run and fill conditions. Reverse Polarity LED Illuminates when:

•

Polarity is reversed on the connection between the vehicle battery and the unit.

Increase Time Button Decrease Time Button

( - )

Allows the increasing of time set on the timer.

(+)

Allows the decreasing of time set on the timer.

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Start Button Starts the run cycle. See Theory of Operation section for more

details. Soak Button Starts the soak cycle.

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Theory of Operations

Detailed descriptions of the various operations, control buttons, and LED indicators that make up the control panel are listed below.

IMPORTANT

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. The FILL button does not need to be held.

• The pump will also stop while filling at the instant the fuel dial reads full. If the FILL button

is pressed and held, when the fuel level reads full, the pump will run. The pump will run in the fill direction until the FILL button is released.

• The voltage to the pump motor is approximately 12 VDC whether the unit is operating from a 12

VDC battery or a 24 VDC battery.

• Whenever the pump is operating in the Fill direction, the DOWN ARROW LED (away from

the truck) is illuminated.

• If the pump is operating in the Cleaning (Run) direction the FILL button is ignored.

Cleaning (Run) Operation:

• When the START button is pressed and released, and the FUEL LEVEL shows at least 1/8 tank,

the motor will start the pump in the Clean (Run) direction. The timer dial will show the total Clean run time. The default total Clean time is 45 minutes. Refer to the Timer Operation section for operation of the timer buttons.

• The FUEL PRESSURE can be monitored by observing the fuel pressure gauge on the top of the

cabinet. Do NOT exceed 100 psi.!

• Whenever the pump is operating in the clean direction the UP ARROW LED (towards the

truck) is illuminated.

• If the pump is operating in the Cleaning direction and the FUEL LEVEL dial shows empty (the

empty “E” LED is illuminated) for at least 5 consecutive seconds, the total cleaning cycle time will be completed and the CYCLE COMPLETE LED on the timer dial will be illuminated. The pump will continue to operate. The SYSTEM WARNING LED will flash and the alarm will sound continuously until the STOP button is pressed. If the STOP button is not pressed the pump and alarms will automatically shut off after 5 minutes.

• The voltage to the pump motor is approximately 12 VDC whether the unit is running from a 12

VDC battery or a 24 VDC battery.

NOTE:

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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.

• If the total cleaning time is only 5 minutes, there is no Initial Cleaning time, and the cleaning

time will be 5 minutes with no automatic Soak run.

• The total clean time can be adjusted while the Initial Cleaning Cycle is running. Whenever the

total clean time is changed, the Initial Clean time is recalculated. Refer to the Timer Operation section for operation of the timer buttons.

Soak Cleaning Cycle:

• The Soak Cleaning Cycle is an optional procedure that enhances the cleaning process.

• When the Initial Clean time (see Initial Cleaning Cycle section for explanation) runs out, the timer

dial will display the remaining cleaning time, and the SOAK LED will flash. A unique audible alarm will sound for 3 seconds.

• If the SOAK button is pressed and released at this time the timer dial will display the Soak time,

and the SOAK LED will stay on to indicate the unit is in Soak Cleaning Cycle.

• The default Soak time is 15 minutes. The Soak time can be changed during the Soak time

run. Refer to the Timer Operation section for operation of the timer buttons.

• If the SOAK Button is pressed and released while the system is running the Initial Clean time,

the system will automatically go into the Soak Cleaning Cycle.

• If the Initial Clean time runs out and the SOAK Button is not pressed to enter the unit into Soak

mode, a second alarm will sound for 3 seconds after two minutes has passed to warn that the Soak is about to be aborted. If the SOAK Button is not pressed within 30 seconds of the second Soak alarm the Final Cleaning timer countdown will begin.

Final Cleaning Cycle:

• When the Soak time runs out, the timer dial will display only the CYCLE COMPLETE LED

and the SOAK LED will flash. A unique alarm will sound for 3 seconds, and will sound again for 3 seconds every minute afterwards, until the Final Cleaning Cycle is started.

• The Final Cleaning Cycle is started by pressing and releasing the START button. If the Start

button is pressed at any time during the Soak Cleaning Cycle, the Final Cleaning Cycle will start.

• If the SOAK Button is pressed while the system is running the Final Cleaning Cycle, the Soak

Cycle timer will start again, even if a Soak Cycle has already been completed. This gives the user the ability to perform another Soak Cleaning Cycle if necessary.

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• 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 until the STOP button is pressed. If the STOP button is not pressed the pump and alarms will automatically shut off after 5 minutes.

• If the tank is less than 1/8 full and the START button is pressed and held for approximately 3

seconds the pump will operate in the Cleaning direction until the button is released. This feature is used to completely empty the tank of fuel.

empty the

SYSTEM WARNING LED will flash and the alarm will sound continuously

Fuel Pressure Gauge:

• The FUEL PRESSURE displays the pressure being output by the unit. Do NOT exceed 100 psi!

Stop Operation:

• When ever the STOP button is pressed, the pump 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 illuminate and the end

of cycle alarm will sound.

Cycle Time Operation:

• The TIME +

Cleaning, or Soak Cycle 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 Soak Cycle set times.

• If the

occur and the CYCLE COMPLETE LED will illuminated.

(Increase) and the

button is continuously pressed until the time reaches zero the end of cycle alarm will

(Decrease) buttons are used to adjust the cycle time, while the

Fuel Level Operation:

• The FUEL LEVEL display shows the amount of fuel in the tank.

• The FUEL LEVEL LEDs that are illuminated indicate the level at or below the actual level in the

tank. For example, the FUEL LEVEL display will not read 1/8 until the tank is at least 1/8 full, or if the tank is 9/16 full the FUEL LEVEL LEDs will display 1/2 full.

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