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DIESEL FUEL TOOL

ON VEHICLE DIESEL FUEL SYSTEM SERVICE

MODEL Rx HD• 888 INSIDE FILTER

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DIESEL FUEL SYSTEM SERVICE

FUEL SYSTEM CONTAMINANTS

During normal diesel engine operations combustion contaminants build upon internal engine surfaces.

This new diesel fuel system service removes carbon, gum, varnish and other contaminants from the diesel engine's fuel system and combustion surfaces.

This service impoves diesel throttle response, reduces smoke, and restores fuel efficiency.

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SAFETY INFORMATION

HAND & EYE PROTECTION Wear safety glasses when operating. Wrap a shop rag around connectors before hook-up

and disconnect to prevent fuel from spraying. Immediately repair any leaks in the machine or

adapters. Keep all hoses and adapters away from moving

parts -- and hot objects. Read and understand the material safety data sheet.

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MORE SAFETY INFORMATION

MORE SAFETY INFORMATION Perform service in a well ventilated area Immediately clean up any spills. Keep a fire extinguisher available. Do not inhale or breathe the fumes from

the machine, the solutoin, or exhaust fumes from the engine.

Do not exceed the maximum canister air pressure of 40 PSI.

Always make sure that the Diesel Fuel Tool is hooked to a secure fixture or set on a firm foundation.

DIESEL FUEL TOOL Connects to the engine being

cleaned with adapters to the fuel system inlet and return lines.

The engines fuel tank is replaced with the fuel and cleaning solution in the canister.

While the engine is running at 1200 RPM the cleaning solution is circulated through the engines fuel system.

Carbon and other contaminants are removed from the engine through the exhaust system and the 1-5 micron filter on the machine.

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1-5 MICRON FILTRATION

5” 1-5 Micron Filter Element

Housed Inside Tool

Twist top cap with wrench to

fully closed (metal to metal)

Always double check for

leaks

Replace filter after every

service

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MINIMUM SOLUTION LEVEL

The minimum (base) solution level is 32 oz. Engine Clean Solution and diesel fuel.

Do not allow the Diesel Fuel Tool to run out of fluid during the cleaning operation.

If the canister becomes empty, the engine may suck air into the fuel system and will be difficult to start.

In addition, the reserve solution helps cool the injectors and high pressure pump.

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FILLING THE DIESEL FUEL TOOL

Unscrew the Filler Cap Close the Shop Air Inlet

Valve Add 1 bottle Engine Clean

Cleaning Solution To prevent spills, fill the

Diesel Tool with the solution very slowly and use a funnel.

Do not overfill Re-install Filler Cap Wrench

Tight Install new 1-5 micron filter

with each service

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CONNECTING TO THE ENGINE

The diesel engine was patented in 1892 by Rudolph Diesel. A key difference between early designs and modern engines is the fuel injection system.

In modern diesel engines, fuel is delivered to the diesel injection pump from the fuel tank by a mechanical lift pump.

A high pressure injection pump (up to 26,000 PSI) stores a reservoir of fuel at in a “common rail”. Computer controlled injectors directly inject fuel into the cylinders. Volkswagen, Dodge, Ford, and GM use a common rail direct injection system as diagramed.

Excess fuel is used to lubricate and cool the mechanical portion of the injection pump before returning to the fuel tank.

Note: For detailed instructions regarding 1997 and newer Ford Power Stroke, see page 14.

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SELECT FUEL LINE ADAPTERS

& FUEL LINE DISCONECT TOOLS

NORTH AMERICAN DIESEL KIT

VW/UNIVERSAL (6)

FORD (7)

DODGE (6)

CHEVY (5)

LOOP HOSE (1)

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DISCONNECT THE FUEL LINES Disconnect the fuel system feed supply

line. Preferably disconnect after the primary filter. If you connect prior to the primary filter, install a clean filter before cleaning the fuel system.

Attach the appropriate adapter to the engine side of the disconnected fuel line.

Disconnect the return fuel line at a convenient location. Install the appropriate adapter to the engine side of the fuel return line. Fuel lines often accessible under

the vehicle near the drivers door or at the under hood filter.

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INSTALL FUEL TANK BY-PASS LOOP

A loop hose is included in the adapter kit to re-route the fuel tank supply and return lines.

Install the by-pass loop to the tank side fuel inlet and return lines when performing any and all services.

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CONNECT DIESEL FUEL TOOL

Using the quick disconnects attach the

adapters to their respective hoses on the

Diesel Fuel Tool. The red hose is the fuel

supply line and the black hose is the fuel

return line. Install air line to the Fuel Tool.

Increase the canister pressure to 7-15 PSI.

(Never exceed 40 PSI).

Slowly open fuel inlet valve.

Check for leaks & repair as necessary.

Clean up any spills.

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EXCEPTON - FORD POWER STROKE

Ford diesel engines built before

1997 are conventional diesel

engines and have a single pump.

On Ford diesel engines built after

1997, each injector is a pump.

The injectors are supplied with

diesel fuel from an electric fuel

pump that is rated at 80-90 PSI.

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CONNECTING TO 1997 & NEWER FORD POWER STROKE ENGINES

Hook the Diesel Fuel Tool supply hose (red) to the inlet on the electric fuel pump.

Connect the return line from the Diesel Fuel Tool (black) to the engine fuel return line at the firewall.

Continue by isolating the fuel tank with the fuel by-pass loop.

Always hook the tool to the fuel pump. If you do not connect to the electric fuel pump the engine may or may not run. If the engine runs you will have no circulation through the Diesel Fuel Tool and no fuel cooling or injector cooling.

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START THE ENGINE

Let the engine idle until the air has been worked out of the fuel system.

The engine should now run smoothly. If it does not, check for loose connections.

Note: Once the engine is running smoothly, the air pressure can be turned off. Remove air hose press the pressure relief valve and then slightly loosen tool filler cap. The engine will draw the solution from the tool canister.

Run the engine at 1200 RMP for the duration of the service.

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WHILE THE ENGINE IS RUNNING

Set a timer for 15 minutes When the time has expired, check the fluid

level in the tool. Turn off the engine when the fluid level reaches the base level, then turn off the tool inlet valve.

Do not shut of the solution flow prior to turning off the engine. If you shut of the solution flow first, the engine may be difficult to start.

Disconnect the Fuel Tool, reconnect fuel inlet and return lines.

Start engine and check for leaks.

Simple Diagnostics After 5 minutes of engine

operation write down the temperature of each injector.

After 30 minutes write down the temperature of each injector.

Compare the temperature differences by Cylinder.

If the numbers are comparable, finish the cleaning operation

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AFTER SERVICE FUEL TREATMENT

After service, add Engine Clean Diesel Fuel Conditioner and fuel catalyst to the diesel fuel tank. (treats 20-30 gallons)

Cleans entire fuel system. Contains anti-gel and Cetane

improvement agents. Removes sludge caused by

bacteria. Disperses moisture. Improves fuel storage stability

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TOOL MAINTENANCE

The DIESEL FUEL TOOL requires

minimial maintenance.

Clean out the mixture tank after

50 services.

Periodically check connections &

fittings for tightness.

Inspect adapters for leaks &

replace if necessary.