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SERVICE MANUAL - Snap

1. Pressure line Red From outlet side of fuel rail Return line Black DIAGNOSTIC MODE ENGINE RUNNING NO KEYS PRESSED 1 LINE SERVICE Fuelkare series 1 14 FLOW DIAGRAM wo H Bypass Pressure 3 solenoid solenoid Return solenoid Pressure line Red From outlet side of fuel rail Return line Black DIAGNOSTIC FILL MODE ENGINE RUNNING FILL TANK PRESSED Fuelkare series 1 15 FLOW DIAGRAM Tank _ d IN Ext check valve Pressure 22 solenoid solenoi Return solenoid Pressure line Red From outlet side of fuel rail Return line Black DIAGNOSTIC MODE ENGINE RUNNING DEADHEAD KEY PRESSED Fuelkare series 1 16 FLOW DIAGRAM Tank To inlet side of fuel rail To vehicle s fuel pump Fuelkare series 1 Pressure solenoid E Bypass solenoid L Int 7 check valve
2. T IN Ext check valve Ju Pressure solenoid solenoi check valve U q Return solenoid Filter L VW E Pressure line Red From outside of fuel rail regulator Return line Black DIAGNOSTIC MODE ENGINE RUNNING DEADHEAD KEY PRESSED Fuelkare series 2 82 FLOW DIAGRAM Inline filter Tank JU Pressure al Bypass solenoid solenoid L L Int inlet side check of fuel rail valve gt U t Return e solenoid Filter H Pressure line Red From return of fuel rail regulator Return line Black To vehicles fuel pump DIAGNOSTIC MODE LEAKDOWN TEST Fuelkare series 2 83 FLOW DIAGRAM Inline filter Bypass Pressure i solenoid solenoid Return solenoid To inlet side of fuel rail Pressure line Red From outlet side of fuel rail regulator Return line Black 2 LINE SERVICE Fuelkare series 2 84 FLOW DIAGRAM Inline filter
3. PUMP ASSEMBLY FUELKARE SERIES 1 AND 1 5 2246 22 11 0 No PART NUMBER DESCRIPTION QTY 1 2247 22 10 0 PUMP EXTERNAL GEAR 1 8 FPT X 12VDC FUEL 1 2 2352 21 10 6 FITTING 1 8 MPT X 90 X 5 16 HOSE NYLON 2 Fuelkare series 1 PARTS amp COMPONENTS CHAPTER 2 DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY 3030 01 01 0 No PART NUMBER DESCRIPTION QTY I 5135 00 01 2 DISPLAY MOUNTING PANEL W OVERLAY FUELKARE 1 2 3030 01 00 0 CIRCUIT BOARD FUELKARE 1 3 1614 12 46 4 STAND OFF 250 OD X 172 ID X 461 LONG ALUMINUM 13 4 1011 99 00 8 NUT 6 32 HEX ZINC 13 Fuelkare series 1 PARTS amp COMPONENTS CHAPTER 2 TANK 1 GALLON ASSEMBLY FUELKARE 1 amp 1 5 2262 44 11 1 No PARTNUMBER DESCRIPTION QTY 1 2262 44 10 1 TANK 1 GALLON FUELKARE 1 2 3113 58 50 5 SENSOR LEVEL gt X 6 LEADS 1 3 2354 21 10 6 FITTING X 90 X 5 16 HOSE NYLON 1 4 2352 21 10 6 FITTING 1 8 X 90 X 5 16 HOSE NYLON 1 5 2293 00 90 1 TANK TUBE 38 X 9 700 LONG S S 1 6 2291 78 11 4 CAP 1 ID TANK FUEL 1 Fuelkare series 1 10 CHAPTER 2 PARTS amp COMPONENTS ALPHABETICAL PART LIST PART NUMBER 3160 68 12 1 5120 11 00 2 3030 00 00 0 3030 01 00 0 3075 12 22 7 1615 03 16 8 3030 01 01 0 2354 20 10 6 2352 21 10 6 0901 54 90 2 0901 54 90 1 0904
4. Bypass solenoid Pressure solenoid Return solenoid To fuel rail Pressure line Red Bi Return line Black 1 LINE SERVICE Fuelkare series 2 85 CHAPTER 2 PARTS amp COMPONENTS COMPONENT POWER CHART RETURN PRESSURE BY PASS PUMP SOLENOID SOLENOID SOLENOID ON OFF OFF OFF ON OFF OFF er OFF OFF ON ON ED ON OFF OFF ON Rees ON OFF OFF ON SERVICE OFF OFF ON ON Fuelkare series 2 86 3142 10 01 1 FUELKARE ve LLI ne lt c Lu O WIRE DIAGRAMS Fuelkare series 2 87 3d V r13f3 1 0 01 18 553 INdINO WIRE DIAGRAMS 88 2 Fuelkare series 34 V T13f3 1 0 01 1 Ef SSINYVH LAdNI 89 2 Fuelkare series CHAPTER 3 THROUBLE SHOOTING E E UNIT WILL NOT POWER UP Verify that power leads are securely connected to a 12VDC power source car battery Verify proper connection Black lead to ground and red lead to positive Make sure connections are clean Check for battery power at J1 connector pins 1 2 and 3 4 red and black wires If no battery power is detected at J1 connector check internal connection between power cord and J1 wire loom repair or replace as needed FAILS TO CALIBRATE AFTER POWER UP If hoses where c
5. No PART NUMBER DESCRIPTION QTY 1 5135 00 01 2 DISPLAY MOUNTING PANEL W OVERLA Y FUELKARE 1 2 3030 01 00 0 CIRCUIT BOARD FUELKARE 1 3 1614 12 46 4 STAND OFF 250 OD X 172 ID X 461 LONG ALUMINUM 13 4 1011 99 00 8 NUT 6 32 HEX ZINC 13 Fuelkare series 1 5 43 PARTS amp COMPONENTS CHAPTER 2 TANK 1 GALLON ASSEMBLY FUELKARE 1 amp 1 5 2262 44 11 1 No PARTNUMBER DESCRIPTION QTY 1 2262 44 10 1 TANK 1 GALLON FUELKARE 1 2 3113 58 50 5 SENSOR LEVEL MPT X 6 LEADS 1 3 2354 21 10 6 FITTING 4 MPT X 90 X 5 16 HOSE NYLON 1 4 2352 21 10 6 FITTING 1 8 X 90 X 5 16 HOSE NYLON 1 5 2293 00 90 1 TANK TUBE 38 X 9 700 LONG S S 1 6 2291 78 11 4 CAP 1 4 ID TANK FUEL 1 Fuelkare series 1 5 44 CHAPTER 2 PARTS amp COMPONENTS ALPHABETICAL PART LIST PART NUMBER 3160 68 12 1 5120 11 00 2 3030 00 00 0 3030 01 00 0 3075 12 22 7 1615 03 16 8 3030 01 01 0 2354 20 10 6 2352 21 10 6 0901 54 90 2 0901 54 90 1 0904 53 10 1 2227 36 32 3 3142 10 03 1 3113 58 50 5 1029 95 00 8 3142 10 02 1 3142 10 01 1 3109 54 31 2 2246 22 11 0 2023 12 10 2 2023 13 10 2 1029 04 58 3 1017 10 56 8 2291 78 11 4 2262 44 11 1 2122 39 40 8 2136 10 20 3 2144 94 10 0 2135 30 20 3 2136 30 20 3 1631 09 61 2 1635 44 40 4 Fuelkare series 1 5 DESCRIPTION AUDIO SIGNAL 3 28VDC AXLE FUELKARE ALL CHIP VER 7 58 FUEL
6. IN Bulkhead Inline filter Bulkhead Ext check valve U Pressure Bypass solenoid solenoid L LI Return solenoid Bulkhead Bulkhead Pressure Line Return Line DIAGNOSTIC MODE ENGINE RUNNING DEADHEAD KEY PRESSED Fuelkare series 1 5 49 FLOW DIAGRAM Fil Tank ee Bulkhead Inline filter Bulkhead solenoid m Pressure solenoid To inlet side of fuel rail valve E U Return solenoid Bulkhead Bulkhead Pressure Line DIAGNOSTIC MODE From LEAKDOWN TEST return side ine of fuel rail regulator To vehicles fuel pump DIAGNOSTIC MODE LEAKDOWN TEST Fuelkare series 1 5 50 FLOW DIAGRAM Bulkhead Inline filter Bulkhead E Bypass solenoid Pressure solenoid Return solenoid Bulkhead Bulkhead
7. If plunger does not move freely replace solenoid assembly Fuelkare series 1 5 57 2 1 2006 CHAPTER 3 THROUBLE SHOOTING Dr oie DO 10 11 12 13 14 15 16 17 18 19 20 LOOSES PRESSURE DURING LEAKDOWN MODE Remove Fuelkare red and black hoses from vehicle and press leak down test key pressure should ramp up to 100 p s i once archieved the pressure displayed will alternately show baseline and current pressure Normal acceptable decay is 10 amp 100 psi over 1 minute If holding pressure problem with vehicle If not holding pressure perform the following Press and release the STOP key to relieve pressure Install open end adapters to red hose Remove fuelkare tank cap and insert red hose with adapter in new fluid tank Remove spin on filter Using shop air and an appropriate blow gun blow air into center port of spin on filter housing until red hose is empty Using shop air apply short bursts of pressure to red hose to reseat internal check valve Remove adapter from red hose and reinstall spin on filter Loop black and red hoses using male loop p n 6016 02 01 1 press and release leak down key to restore cleaning solution to the now cleared pathway through the machine and hoses When pump stops remove loop from black and red hoses Re test leak down mode If not holding pressure Remove rear panel Press leak down key monitor clear tube between manifold and pump and mo
8. 3 CHAPTER 3 THROUBLE SHOOTING UNIT WILL NOT POWER UP FAILS TO CALIBRATE AFTER POWER UP DOES NOT FILL TANK LOOSES PRESSURE DURING LEAK DOWN MODE LOW PRESSURE DURING SERVICE MODE HIGH PRESSURE DURING SERVICE MODE 4 CHAPTER 4 SERVICE PROCEDURES REPLACING INTERNAL CHECK VALVE REPLACING CIRCUIT BOARD REPLACING PROCESSOR CHIP e FUELKARE SERIES 2 1 CHAPTER 1 COMPONENT DESCRIPTION DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY LEVEL SENSOR PUMP ASSEMBLY MANIFOLD BLOCK ASSEMBLY FILTRATION 2 CHAPTER 2 PARTS amp COMPONENTS MANIFOLD BLOCK ASSEMBLY PUMP ASSEMBLY DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY TANK ASSEMBLY PARTS LIST ALPHABETICAL PARTS LIST NUMERICAL FLOW DIAGRAMS COMPONENT POWER CHART WIRE DIAGRAMS 3 CHAPTER 3 THROUBLE SHOOTING UNIT WILL NOT POWER UP FAILS TO CALIBRATE AFTER POWER UP DOES NOT FILL TANK LOOSES PRESSURE DURING LEAK DOWN MODE LOW PRESSURE DURING SERVICE MODE HIGH PRESSURE DURING SERVICE MODE 4 CHAPTER 4 SERVICE PROCEDURES REPLACING CIRCUIT BOARD FROM TOP REPLACING CIRCUIT BOARD FROM REAR 46 47 52 53 54 56 57 57 57 58 59 59 60 63 64 66 67 70 71 71 71 72 73 74 75 76 77 78 79 80 85 86 87 89 90 90 90 91 92 92 93 94 95 96 IDENTIFY YOUR FUELKARE There are 3 versions of FUELKARE machines SERIES 1 Single spin on filter located under hose hanger SERIES 1 5 Has 2 filters the spin on filter loca
9. Pressure inlet side of fuel rail Return From Tine outlet side of fuel rail 2 LINE SERVICE Fuelkare series 1 5 51 FLOW DIAGRAM Filter Bulkhead Inline filter Bulkhead Bypass Pressure solenoid solenoid Return solenoid Bulkhead Bulkhead Pressure To fuel rail Line Return Line 1 LINE SERVICE Fuelkare series 1 5 52 CHAPTER 2 PARTS amp COMPONENTS COMPONENT POWER CHART RETURN PRESSURE BY PASS PUMP SOLENOID SOLENOID SOLENOID aa ON OFF OFF OFF ON OFF OFF vr OFF OFF ON ON Me ON OFF OFF ON SERVICE ON OFF OFF ON SERVICE OFF OFF ON ON Fuelkare series 1 5 53 WIRE DIAGRAMS 3142 10 01 1 FUELKARE ou ve LLI ne lt I Lu O Fuelkare series 1 5 54 WIRE DIAGRAMS 3YIVMIINI L 20 OL ZHLE SSANYVH INdINO 55 Fuelkare series 1 5 WIRE DIAGRAMS 34 V T3f3 1 0 01 1 Ef SSINYVH LAdNI 56 Fuelkare series 1 5 2 1 2006 CHAPTER 3 THROUBLE SHOOTING UNIT WILL NOT POWER UP Verify that power leads are securely connected to a 12VDC power source car battery Verify proper con
10. REPLACING CIRCUIT BOARD 5 Place board assembly on top of unit and remove screws or nuts to separate circuit board from display panel 6 Replace circuit board 7 Reassemble and test Fuelkare series 1 33 CHAPTER 4 SERVICE PROCEDURES REPLACING PROCESSOR CHIP 1 Remove rear center panel 9 Phillips screws 2 Remove 2 Allen head 4 20 screws using 5 32 Allen wrench Fuelkare series 1 34 CHAPTER 4 SERVICE PROCEDURES REPLACING PROCESSOR CHIP 3 Remove the 4 nyloc nuts securing the front control board assembly using long extension with 3 8 Socket Fuelkare series 1 35 CHAPTER 4 SERVICE PROCEDURES REPLACING PROCESSOR CHIP 5 Place board assembly on top of unit and remove screws or nuts to separate circuit board from display panel Fuelkare series 1 36 CHAPTER 4 SERVICE PROCEDURES REPLACING PROCESSOR CHIP 7 Pay close attention Find the flat corner of the new processor chip and flat corner of socket FLAT CORNER IN SOCKET LINE UP WITH FLAT CORNER OF CHIP 8 Insert new processor chip into socket 9 Reassemble board to display panel connect wires to board and test before closing up machine Fuelkare series 1 37 CHAPTER 1 COMPONENT DESCRIPTION 3030 01 01 0 DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY This assembly consists of 2 components 1 5135 00 01 2 Display mounting panel w overlay assy 2 3030 01 00 0 Circuit b
11. 4 MPT X 90 X 3 8 HOSE Fuelkare series 1 5 39 CHAPTER 1 COMPONENT DESCRIPTION FILTRATION A EEFS308A5 3 Micron spin on filter kit 2 pieces This filters all fluid returning from vehicle 0600 01 00 0 Inline fuel filter 3 8 barb x 3 8 barb This filters all fluid leaving the fuelkares tank Fuelkare series 1 5 40 CHAPTER 2 PARTS amp COMPONENTS MANIFOLD BLOCK ASSEMBLY FUELKARE 1 5 2141 98 13 4 No PARTNUMBER DESCRIPTION QTY A 2136 30 20 3 RETURN VALVE ASSY FUELKARE ALL 1 2140 00 20 1 CHECK VALVE INTERNAL 5 PSI FUELKARE 1 S S 1 3109 54 31 2 PRESSURE DRANSDUCER MPT ASSEMBLY 1 D 2136 10 20 3 BY PASS VALVE 1 32 ORIFICE FUELKARE 1 1 E 2354 21 10 6 FITTING 4 MPT X 90 X 5 16 HOSE NYLON 2 2135 30 20 3 PRESSURE VALVE ASSY FUELKARE ALL 1 2140 39 20 1 CHECK VALVE EXTERNAL X 4 FPT S S VITON 1 2354 31 14 1 FITTING POLY MPT X 90 X 3 8 HOSE 1 Fuelkare series 1 5 41 CHAPTER 2 PARTS amp COMPONENTS PUMP ASSEMBLY FUELKARE SERIES 1 AND 1 5 2246 22 11 0 No PART NUMBER DESCRIPTION 1 2247 22 10 0 PUMP EXTERNAL GEAR 1 8 X 12VDC FUEL 2 2352 21 10 6 FITTING 1 8 MPT X 90 X 5 16 HOSE NYLON Fuelkare series 1 5 42 CHAPTER 2 PARTS amp COMPONENTS DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY 3030 01 01 0
12. 5 16 HOSE NYLON 1 3 2352 41 14 8 FITTING 1 8 X 90 X 3 8 BARB NICKEL 1 Fuelkare series 2 75 CHAPTER 2 PARTS amp COMPONENTS dang ae jas 2 ANAL O GEER 5 ti DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY 3030 01 01 0 No PART NUMBER DESCRIPTION QTY 1 5135 00 01 2 DISPLAY MOUNTING PANEL W OVERLAY FUELKARE 1 2 3030 01 00 0 CIRCUIT BOARD FUELKARE 1 3 1614 12 46 4 STAND OFF 250 OD X 172 ID X 461 LONG ALUMINUM 13 4 1011 99 00 8 NUT 6 32 HEX ZINC 13 Fuelkare series 2 76 PARTS amp COMPONENTS CHAPTER 2 TANK 1 GALLON ASSEMBLY FUELKARE 2 2262 44 12 1 No PARTNUMBER DESCRIPTION QTY 1 2262 44 10 1 TANK 1 GALLON FUELKARE 1 2 3113 58 50 5 SENSOR LEVEL X 6 LEADS 1 3 2354 21 10 6 FITTING MPT X 90 X 5 16 HOSE NYLON 1 4 2352 41 14 8 FITTING 1 8 MPT X 90 X 3 8 BARB NICKEL 1 5 2293 00 90 1 TANK TUBE 38 X 9 700 LONG S S 1 6 2291 78 11 4 CAP 1 ID TANK FUEL 1 Fuelkare series 2 77 CHAPTER 2 PARTS amp COMPONENTS ALPHABETICAL PART LIST PART NUMBER 3160 68 12 1 5120 11 00 2 3030 00 01 0 3030 01 00 0 3075 12 22 7 1615 03 16 8 3030 01 01 0 2354 20 10 6 2352 41 14 8 0901 54 90 2 0901 54 90 1 0904 53 10 1 3142 10 03 1 3113 58 50 5 1029 95 00 8 3142 10 02 1 3142 10 01 1 3109 54 31 2 2246 22 12 0 20
13. PARKER 08 SERIES VALVE PRESSURE ASSEMBLY FUELKARE ALL VITON VALVE RETURN ASSEMBLY FUELKARE ALL VITON WHEEL 9 OD X 3 4 WD X 1 2 BORE WHEEL CASTER 4 OD X 1 1 4 WD WITH BRAKE 11 CHAPTER 2 PARTS amp COMPONENTS NUMERICAL PART LIST PART NUMBER DESCRIPTION 0901 54 90 1 HOSE 1 4 MPT X 90 X 10 RETURN ASSEMBLY BLACK HYTRON 0901 54 90 2 HOSE 1 4 MPT X 90 10 PRESSURE ASSEMBLY RED HYTRON 0904 53 10 1 HOSE 10 VACUUM BLACK RUBBER 1017 10 56 8 SCREW 10 32 X 3 8 PANHEAD PHILLIPS 1029 04 58 3 SCREW 1 4 20 X 3 8 BHCS ALLEN BLACK 1029 95 00 8 NUT 1 4 20 NYLOC HEX ZINC 1615 03 16 8 COTTERPIN 1 8 OD X 1 1 4 LONG 1631 09 61 2 WHEEL 9 OD X 3 4 WD X 1 2 BORE 1635 44 40 4 WHEEL CASTER 4 OD X 1 1 4 WD WITH BRAKE 2023 12 10 2 QUICK DISC BODY S 23 X 1 4 FPT VITON NICKEL 2023 13 10 2 QUICK DISC BODY S 23 X 1 4 MPT VITON NICKEL 2122 39 40 8 VALVE BALL 1 4 MPT X 1 4 FPT WITH T HANDLE NICKEL 2135 30 20 3 VALVE PRESSURE ASSEMBLY FUELKARE ALL VITON 2136 10 20 3 VALVE BY PASS 1 32 ORIFICE FUELKARE 1 1 5 2136 30 20 3 VALVE RETURN ASSEMBLY FUELKARE ALL VITON 2144 94 10 0 VALVE COIL 12VDC 14WATT FITS PARKER 08 SERIES 2227 36 32 3 HOUSING FILTER ASSEMBLY FUELKARE 1 1 5 2246 22 11 0 PUMP ASSEMBLY FUELKARE 1 1 5 12VDC 2262 44 11 1 TANK FUEL 1 GALLON ASSEMBLY FUELKARE 1 1 5 2291 78 11 4 TANK CAP 1 3 4 ID FUELKARE ALL 2352 21 10 6 FITTING 1 8 MPT X 90
14. board to display panel connect wires to board and test before closing up machine Fuelkare series 1 5 71 CHAPTER 1 COMPONENT DESCRIPTION 3030 01 01 0 DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY This assembly consists of 2 components 1 5135 00 01 2 Display mounting panel w overlay assy 2 3030 01 00 0 Circuit board receives 12 vdc through wire loom J1 upper 4 pins and powers pump through J1 lower 4 pins J2 wire loom channels output signals to solenoids and audio signal J3 wire loom receives input signals from pressure transducer and max level switch ACUUM RANSDUCER 77 3113 58 50 8 LEVEL SENSOR NPTM X 6 LEADS Normally open reed switch with magnetic float that closes the switch in presence of fluid located near the top of the tank and used to prevent tank overfill i Note Install with red dot at 2 o clock NE 2246 22 11 0 PUMP ASSEMBLY FUELKARE 1 1 5 12 vdc gear pump with 1 gpm flow rate 175 psi max pressure magnetic clutch Fuelkare series 2 71 CHAPTER 1 COMPONENT DESCRIPTION 2141 98 13 4 MANIFOLD BLOCK ASSEMBLY FUELKARE 2 RED A 2136 30 20 3 RETURN VALVE Normally closed cartridge valve open during 2 line service leakdown test and to fill tank B 2140 01 20 5 INTERNAL CHECK VALVE open during diagnostic mode to return fuel to vehicle gas tank C 3109 54 31 2 PRESSURE TRANSDUCER Measures and monitors pressure 0 175 psi D 2136 00 21 4 BY PASS V
15. closed 250 millisecond when pulsing leak down test and to fill tank B 2140 00 20 1 INTERNAL CHECK VALVE open during diagnostic mode to return fuel to vehicle gas tank C 3109 54 31 2 PRESSURE TRANSDUCER Measures pressure 0 175 psi D 2136 10 20 3 BY PASS VALVE 1 32 orifice opens during purge to remove unwanted air from internal lines and passages and to perform 1 line service allowing return of excess volume pressure of cleaning solution mixture back to fuelkare tank E 2354 21 10 6 FITTING 4 MPT X 90 X 5 16 TUBE F 2135 30 20 3 PRESSURE VALVE Normally open cartridge valve closes to perform dead head test G 2140 39 20 1 EXTERNAL CHECK VALVE Prevents fuel to return to pump 2 FILTRATION 3 Micron spin on filter Fuelkare series 1 6 CHAPTER 2 PARTS amp COMPONENTS adfici MANIFOLD BLOCK ASSEMBLY FUELKARE 1 2141 98 12 4 No PART NUMBER DESCRIPTION QTY A 2136 30 20 3 RETURN SOLENOID VALVE ASSY FUELKARE ALL 1 B 2140 00 20 1 CHECK VALVE INTERNAL 5 PSI FUELKARE 1 S S 1 C 3109 54 31 2 PRESSURE TRANSDUCER ASSEMBLY 1 D 2136 10 20 3 BY PASS VALVE 1 32 ORIFICE FUELKARE 1 1 E 2354 21 10 6 FITTING MPT X 90 X 5 16 HOSE NYLON 2 F 2135 30 20 3 PRESSURE SOLENOID VALVE ASSY FUELKARE ALL 1 G 2140 39 20 1 CHECK VALVE EXTERNAL X 4 MPT S SJVITON 1 Fuelkare series 1 CHAPTER 2 PARTS amp COMPONENTS
16. if needed HIGH PRESSURE DURING SERVICE Check for kinked hoses Check if red hose is properly connected to adapter Change ultra fine spin on filter Resume service nai Riva Fuelkare series 1 5 59 CHAPTER 4 SERVICE PROCEDURES REPLACING INTERNAL CHECK VALVE 1 Remove the Phillips Head pan screws from the center back panel 2 Remove the two 2 5 32 Allen Head screws in filter cavity a 4mm Allen Socket will also fit these 2 screw heads 3 Remove the nickel plated hex head bolt threaded into the top of the black anodized Manifold Block 7 8 across the flats Fuelkare series 1 5 60 CHAPTER 4 SERVICE PROCEDURES REPLACING INTERNAL CHECK VALVE Fuelkare series 1 5 61 CHAPTER 4 SERVICE PROCEDURES REPLACING INTERNAL CHECK VALVE 4 Take a pick tool and work the check valve from the manifold block it is held in with an O ring interference fit by inserting the tip of the tool alternately in the offsetting holes in the top of the check valve Fuelkare series 1 5 62 CHAPTER 4 SERVICE PROCEDURES REPLACING INTERNAL CHECK VALVE Insure there are no contaminants in the manifold block insert the new check valve in the manifold block The correct orientation is with the holes up as described in the removal process Firmly seat to bottom of block and replace the retainer bolt This process takes maybe ten minutes and can also be tested by powering
17. leak down mode If fluid flows from manifold to tank 18 Remove internal check valve inspect for debris and condition of O rings or replace if needed Fuelkare series 2 91 CHAPTER 3 THROUBLE SHOOTING LOW PRESSURE DURING SERVICE MODE Check inline filter replacement history 50 services per filter Remove hoses from vehicle Install open end adapters to red hose Insert red hose to new fluid tank Repower Fuelkare Once diagnostic fill cycle led is flashing Press and hold and keys until 2 line and 1 line service led start flashing Press 2 line key Press start soak key and monitor flow through red hose 9 If flow is low or stops with pump still running replace inline filter DN oe oos NOTE Whene replacing inline filter it is recommended to clean line from filter to tank Remove cap from tank and apply shop air to line check tank for debris and clean if needed HIGH PRESSURE DURING SERVICE Check for kinked hoses Check if red hose is properly connected to adapter Change ultra fine spin on filter Resume service dpa Fuelkare series 2 92 CHAPTER 4 SERVICE PROCEDURES REPLACING CIRCUIT BOARD FROM TOP 1 Remove top tray two 2 Phillips screws 2 Disconnect wire connectors from board if not marked J1 J2 J3 please mark before removal Fuelkare series 2 93 CHAPTER 4 SERVICE PROCEDURES REPLACING CIRCUIT BOARD FROM TOP 3 Remove the 4 nyloc nuts se
18. n o Return solenoid Pressure line Red From return side of fuel rail regulator Return line Black DIAGNOSTIC MODE LEAKDOWN TEST 17 FLOW DIAGRAM H Bypass Pressure solenoid solenoid Return solenoid To inlet side of fuel rail Pressure line Red From outlet side of fuel rail regulator Return line Black 2 LINE SERVICE Fuelkare series 1 18 FLOW DIAGRAM Pressure solenoid Bypass solenoid Return solenoid To fuel rail Pressure line Red N A Return line Black 1 LINE SERVICE Fuelkare series 1 19 CHAPTER 2 PARTS amp COMPONENTS COMPONENT POWER CHART RETURN PRESSURE BY PASS PUMP SOLENOID SOLENOID SOLENOID VALVE VALVE VALVE tee ON OFF OFF OFF Da SURE OFF ON OFF OFF or OFF OFF ON ON EE AA ON OFF OFF ON ON OFF OFF ON SERVICE OFF OFF ON ON Fuelkare series 1 20 WIRE DIAGRAMS 3142 10 01 1 FUELKARE ou ve LLI ne lt I oe Lu O Fuelkare series 1 21 WIRE
19. up the unit hooking the red and black hoses together with the 6016 02 01 1 extension double male adapter Press and buttons simultaneously Version 7 56 software only for three seconds to bypass diagnostics Press Two Line button press Start Soak button and watch the air disappear from the plastic hoses inside the machine Your pressure display will indicate 16 p s i or thereabout depending on battery voltage and the resulting pump speed which is enough pressure to continue the simulation without crimping hoses Press the Set Time button until you round the clock back to 0 minutes shortly after which the process will time out and stop Paying attention to the lines inside the machine you will note that no air reappears and the lines do not drain down Remove the extension adapter from the red and black hoses with a shop towel handy to catch the solution that escapes from the adapter Fuelkare series 1 5 63 Replace the back cover and retaining screws to complete the process CHAPTER 4 SERVICE PROCEDURES REPLACING CIRCUIT BOARD 1 Remove rear center panel 9 Phillips screws 2 Remove 2 Allen head 4 20 screws using 5 32 Allen wrench Fuelkare series 1 5 64 CHAPTER 4 SERVICE PROCEDURES REPLACING CIRCUIT BOARD 3 Remove the 4 nyloc nuts securing the front control board assembly using long extension with 3 8 Socket 4 Disconnect wire connectors from board if not ma
20. 22 39 40 8 2135 30 20 3 2136 10 20 3 2136 30 20 3 2144 94 10 0 2227 36 32 3 2246 22 11 0 2262 44 11 1 2291 78 11 4 2352 21 10 6 2354 20 10 6 3030 00 00 0 3030 01 00 0 3030 01 01 0 3075 12 22 7 3109 54 31 2 3113 58 50 5 3142 10 01 1 3142 10 02 1 3142 10 03 1 3160 68 12 1 5120 11 00 2 Fuelkare series 1 5 NUMERICAL PART LIST DESCRIPTION HOSE 1 4 MPT X 90 X 10 RETURN ASSEMBLY BLACK HYTRON HOSE 1 4 MPT X 90 X 10 PRESSURE ASSEMBLY RED HYTRON HOSE 10 VACUUM BLACK RUBBER SCREW 10 32 X 3 8 PANHEAD PHILLIPS SCREW 1 4 20 X 3 8 BHCS ALLEN BLACK NUT 1 4 20 NYLOC HEX ZINC COTTERPIN 1 8 OD X 1 1 4 LONG WHEEL 9 OD X 3 4 WD X 1 2 BORE WHEEL CASTER 4 OD X 1 1 4 WD WITH BRAKE QUICK DISC BODY S 23 X 1 4 FPT VITON NICKEL QUICK DISC BODY 5 23 X 1 4 MPT VITON NICKEL VALVE BALL 1 4 MPT X 1 4 FPT WITH T HANDLE NICKEL VALVE PRESSURE ASSEMBLY FUELKARE ALL VITON VALVE BY PASS 1 32 ORIFICE FUELKARE 1 1 5 VALVE RETURN ASSEMBLY FUELKARE ALL VITON VALVE COIL 12VDC 14WATT FITS PARKER 08 SERIES HOUSING FILTER ASSEMBLY FUELKARE 1 1 5 PUMP ASSEMBLY FUELKARE 1 1 5 12VDC TANK FUEL 1 GALLON ASSEMBLY FUELKARE 1 1 5 TANK CAP 1 3 4 ID FUELKARE ALL FITTING 1 8 MPT X 90 X 5 16 HOSE NYLON FITTING 1 4 MPT X 90 X 5 16 HOSE NYLON CHIP VER 7 58 FUELKARE 1 CIRCUIT BOARD FUELKARE ALL DISPLAY amp BOARD ASSEMBLY FUELKARE ALL CORD CLAMP ASSEMBLY 12VDC X 12 RED BLACK PRESSURE TRANSDUCER 1
21. 23 12 10 2 2023 13 10 2 1029 04 58 3 1017 10 56 8 2291 78 11 4 2262 44 12 1 2122 39 40 8 2136 00 21 4 2144 94 10 0 2135 30 20 3 2136 30 20 3 1631 09 61 2 1635 44 40 4 Fuelkare series 2 DESCRIPTION AUDIO SIGNAL 3 28VDC AXLE FUELKARE ALL CHIP VER 7 59 FUELKARE 2 CIRCUIT BOARD FUELKARE ALL CORD CLAMP ASSEMBLY 12VDC X 12 RED BLACK COTTERPIN 1 8 OD X 1 1 4 LONG DISPLAY amp BOARD ASSEMBLY FUELKARE ALL FITTING 1 4 MPT X 90 X 5 16 HOSE NYLON FITTING 1 8 MPT X 90 X 3 8 BARB NICKEL HOSE 1 4 MPT X 90 X 10 PRESSURE ASSEMBLY RED HYTRON HOSE 1 4 MPT X 90 X 10 RETURN ASSEMBLY BLACK HYTRON HOSE 10 VACUUM BLACK RUBBER INPUT HARNESS J3 FUELKARE ALL LEVEL SENSOR 1 2 MPT X 6 LEADS NUT 1 4 20 NYLOC HEX ZINC OUTPUT HARNESS J2 FUELKARE ALL POWER HARNESS J1 FUELKARE ALL PRESSURE TRANSDUCER 1 4 MPT ASSEMBLY NICKEL PUMP ASSEMBLY FUELKARE 2 12VDC QUICK DISC BODY S 23 X 1 4 FPT VITON NICKEL QUICK DISC BODY 5 23 X 1 4 MPT VITON NICKEL SCREW 1 4 20 X 3 8 BHCS ALLEN BLACK SCREW 10 32 X 3 8 PANHEAD PHILLIPS TANK 1 3 4 ID FUELKARE ALL TANK FUEL 1 GALLON ASSEMBLY FUELKARE 2 VALVE BALL 1 4 MPT X 1 4 FPT WITH T HANDLE NICKEL VALVE BY PASS 1 32 ORIFICE FUELKARE 2 VALVE COIL 12VDC 14WATT FITS PARKER 08 SERIES VALVE PRESSURE ASSEMBLY FUELKARE ALL VITON VALVE RETURN ASSEMBLY FUELKARE ALL VITON WHEEL 9 OD X 3 4 WD X 1 2 BORE WHEEL CASTER 4 OD X 1 1 4 WD WITH BRA
22. 4 MPT ASSEMBLY NICKEL LEVEL SENSOR 1 2 MPT X 6 LEADS POWER HARNESS J1 FUELKARE ALL OUTPUT HARNESS J2 FUELKARE ALL INPUT HARNESS J3 FUELKARE ALL AUDIO SIGNAL 3 28VDC AXLE FUELKARE ALL 46 FLOW DIAGRAM Tank Bulkhead Inline filter Bulkhead Ext check valve U Pressure 2 solenoid Return solenoid Bulkhead Bulkhead To Pressure return line Line of vehicle tank Return Line From out side of fuel rail regulator DIAGNOSTIC MODE ENGINE RUNNING NO KEYS PRESSED Fuelkare series 1 5 47 FLOW DIAGRAM Ed Bulkhead Inline filter Bulkhead Ext check valve up Pressure solenoid L Pressure Line DIAGNOSTIC FILL MODE From outlet side Bypass solenoid Return solenoid Bulkhead Bulkhead Return Line of fuel rail regulator ENGINE RUNNING FILL TANK PRESSED Fuelkare series 1 5 48 FLOW DIAGRAM Tank 2
23. 53 10 1 2227 36 32 3 3142 10 03 1 3113 58 50 5 1029 95 00 8 3142 10 02 1 3142 10 01 1 3109 54 31 2 2246 22 11 0 2023 12 10 2 2023 13 10 2 1029 04 58 3 1017 10 56 8 2291 78 11 4 2262 44 11 1 2122 39 40 8 2136 10 20 3 2144 94 10 0 2135 30 20 3 2136 30 20 3 1631 09 61 2 1635 44 40 4 Fuelkare series 1 DESCRIPTION AUDIO SIGNAL 3 28VDC AXLE FUELKARE ALL CHIP VER 7 58 FUELKARE 1 CIRCUIT BOARD FUELKARE ALL CORD CLAMP ASSEMBLY 12VDC X 12 RED BLACK COTTERPIN 1 8 OD X 1 1 4 LONG DISPLAY amp BOARD ASSEMBLY FUELKARE ALL FITTING 1 4 MPT X 90 X 5 16 HOSE NYLON FITTING 1 8 MPT X 90 X 5 16 HOSE NYLON HOSE 1 4 MPT X 90 10 PRESSURE ASSEMBLY RED HYTRON HOSE 1 4 MPT X 90 X 10 RETURN ASSEMBLY BLACK HYTRON HOSE 10 VACUUM BLACK RUBBER HOUSING FILTER ASSEMBLY FUELKARE 1 1 5 INPUT HARNESS J3 FUELKARE ALL LEVEL SENSOR 1 2 MPT X 6 LEADS NUT 1 4 20 NYLOC HEX ZINC OUTPUT HARNESS J2 FUELKARE ALL POWER HARNESS J1 FUELKARE ALL PRESSURE TRANSDUCER 1 4 MPT ASSEMBLY NICKEL PUMP ASSEMBLY FUELKARE 1 1 5 12VDC QUICK DISC BODY S 23 X 1 4 FPT VITON NICKEL QUICK DISC BODY 5 23 X 1 4 MPT VITON NICKEL SCREW 1 4 20 X 3 8 BHCS ALLEN BLACK SCREW 10 32 X 3 8 PANHEAD PHILLIPS TANK CAP 1 3 4 ID FUELKARE ALL TANK FUEL 1 GALLON ASSEMBLY FUELKARE 1 1 5 VALVE BALL 1 4 MPT X 1 4 FPT WITH T HANDLE NICKEL VALVE BY PASS 1 32 ORIFICE FUELKARE 1 1 5 VALVE COIL 12VDC 14WATT FITS
24. ALVE 1 32 orifice opens during purge and to perform 1 line service E 2354 21 10 6 FITTING 4 MPT X 90 X 5 16 TUBE F 2135 30 20 3 PRESSURE VALVE Normally open cartridge valve closes to perform dead head test G 2140 39 20 1 EXTERNAL CHECK VALVE Prevents fuel to return to pump Fuelkare series 2 72 CHAPTER 1 COMPONENT DESCRIPTION FILTRATION A EEFS308A5 3 Micron spin on filter kit 2 pieces This filters all fluid returning from vehicle 0600 01 00 0 Inline fuel filter 3 8 barb x 3 8 barb This filters all fluid leaving the fuelkares tank Fuelkare series 2 73 CHAPTER 2 PARTS amp COMPONENTS MANIFOLD BLOCK ASSEMBLY FUELKARE 2 2141 98 22 0 No PARTNUMBER DESCRIPTION QTY A 2136 30 20 3 RETURN VALVE ASSY FUELKARE ALL 1 B 2140 01 20 5 CHECK VALVE INTERNAL 5 PSI FUELKARE 1 S S 1 3109 54 31 2 PRESSURE DRANSDUCER MPT ASSEMBLY 1 D 2136 00 21 4 BY PASS VALVE 1 32 ORIFICE FUELKARE 1 1 E 2354 21 10 6 FITTING 4 MPT X 90 X 5 16 HOSE NYLON 2 2135 30 20 3 PRESSURE VALVE ASSY FUELKARE ALL 1 2140 39 20 1 CHECK VALVE EXTERNAL X FPT S S VITON 1 Fuelkare series 2 74 CHAPTER 2 PARTS amp COMPONENTS PUMP ASSEMBLY FUELKARE SERIES 2 2246 22 12 0 No PARTNUMBER DESCRIPTION QTY 1 2247 22 10 0 PUMP EXTERNAL GEAR 1 8 FPT X 12VDC FUEL 1 2 2352 21 10 6 FITTING 1 8 X 90 X
25. DIAGRAMS 3d V r13f3 L 20 OL ZHLE SSANYVH INdINO 22 Fuelkare series 1 WIRE DIAGRAMS 34 V T13f3 1 0 01 1 wef SSINYVH LAdNI 23 Fuelkare series 1 CHAPTER 3 THROUBLE SHOOTING p UNIT WILL NOT POWER UP Verify that power leads are securely connected to a 12VDC power source car battery Verify proper connection Black lead to ground and red lead to positive Make sure connections are clean Check for battery power at J1 connector pins 1 2 and 3 4 red and black wires If no battery power is detected at J1 connector check internal connection between power cord and wire loom repair or replace as needed FAILS TO CALIBRATE AFTER POWER UP If Fuelkare black and red hoses where connected before power up remove hoses from fuel system and connect 2 open end adapters to red and black hose If still no calibration using shop air apply short bursts of pressure to red hose this should reset transducer If still no calibration check connection to J3 wire loom If connection is correct replace pressure transducer DOES NOT FILL TANK First time use will take up to 60 seconds on a properly functioning vehicle s fuel supply system to prime filter and lines Verify that hoses and adapters are properly connected to vehicle fuel system If properly connected to fuel system check return solenoid assembly for 12vdc If 12VDC is not present c
26. KARE 1 CIRCUIT BOARD FUELKARE ALL CORD CLAMP ASSEMBLY 12VDC X 12 RED BLACK COTTERPIN 1 8 OD X 1 1 4 LONG DISPLAY amp BOARD ASSEMBLY FUELKARE ALL FITTING 1 4 MPT X 90 X 5 16 HOSE NYLON FITTING 1 8 MPT X 90 X 5 16 HOSE NYLON HOSE 1 4 MPT X 90 X 10 PRESSURE ASSEMBLY RED HYTRON HOSE 1 4 MPT X 90 X 10 RETURN ASSEMBLY BLACK HYTRON HOSE 10 VACUUM BLACK RUBBER HOUSING FILTER ASSEMBLY FUELKARE 1 1 5 INPUT HARNESS J3 FUELKARE ALL LEVEL SENSOR 1 2 MPT X 6 LEADS NUT 1 4 20 NYLOC HEX ZINC OUTPUT HARNESS J2 FUELKARE ALL POWER HARNESS J1 FUELKARE ALL PRESSURE TRANSDUCER 1 4 MPT ASSEMBLY NICKEL PUMP ASSEMBLY FUELKARE 1 1 5 12VDC QUICK DISC BODY S 23 X 1 4 FPT VITON NICKEL QUICK DISC BODY 5 23 X 1 4 MPT VITON NICKEL SCREW 1 4 20 X 3 8 BHCS ALLEN BLACK SCREW 10 32 X 3 8 PANHEAD PHILLIPS TANK CAP 1 3 4 ID FUELKARE ALL TANK FUEL 1 GALLON ASSEMBLY FUELKARE 1 1 5 VALVE BALL 1 4 MPT X 1 4 FPT WITH T HANDLE NICKEL VALVE BY PASS 1 32 ORIFICE FUELKARE 1 1 5 VALVE COIL 12VDC 14WATT FITS PARKER 08 SERIES VALVE PRESSURE ASSEMBLY FUELKARE ALL VITON VALVE RETURN ASSEMBLY FUELKARE ALL VITON WHEEL 9 OD X 3 4 WD X 1 2 BORE WHEEL CASTER 4 OD X 1 1 4 WD WITH BRAKE 45 CHAPTER 2 PARTS amp COMPONENTS PART NUMBER 0901 54 90 1 0901 54 90 2 0904 53 10 1 1017 10 56 8 1029 04 58 3 1029 95 00 8 1615 03 16 8 1631 09 61 2 1635 44 40 4 2023 12 10 2 2023 13 10 2 21
27. KE 78 CHAPTER 2 PARTS amp COMPONENTS PART NUMBER 0901 54 90 1 0901 54 90 2 0904 53 10 1 1017 10 56 8 1029 04 58 3 1029 95 00 8 1615 03 16 8 1631 09 61 2 1635 44 40 4 2023 12 10 2 2023 13 10 2 2122 39 40 8 2135 30 20 3 2136 00 21 4 2136 30 20 3 2144 94 10 0 2246 22 12 0 2262 44 12 1 2291 78 11 4 2352 41 14 8 2354 20 10 6 3030 00 01 0 3030 01 00 0 3030 01 01 0 3075 12 22 7 3109 54 31 2 3113 58 50 5 3142 10 01 1 3142 10 02 1 3142 10 03 1 3160 68 12 1 5120 11 00 2 Fuelkare series 2 NUMERICAL PART LIST DESCRIPTION HOSE 1 4 MPT X 90 X 10 RETURN ASSEMBLY BLACK HYTRON HOSE 1 4 MPT X 90 X 10 PRESSURE ASSEMBLY RED HYTRON HOSE 10 VACUUM BLACK RUBBER SCREW 10 32 X 3 8 PANHEAD PHILLIPS SCREW 1 4 20 X 3 8 BHCS ALLEN BLACK NUT 1 4 20 NYLOC HEX ZINC COTTERPIN 1 8 OD X 1 1 4 LONG WHEEL 9 OD X 3 4 WD X 1 2 BORE WHEEL CASTER 4 OD X 1 1 4 WD WITH BRAKE QUICK DISC BODY S 23 X 1 4 FPT VITON NICKEL QUICK DISC BODY 5 23 X 1 4 MPT VITON NICKEL VALVE BALL 1 4 MPT X 1 4 FPT WITH T HANDLE NICKEL VALVE PRESSURE ASSEMBLY FUELKARE ALL VITON VALVE BY PASS 1 32 ORIFICE FUELKARE 2 VALVE RETURN ASSEMBLY FUELKARE ALL VITON VALVE COIL 12VDC 14WATT FITS PARKER 08 SERIES PUMP ASSEMBLY FUELKARE 2 12VDC TANK FUEL 1 GALLON ASSEMBLY FUELKARE 2 TANK CAP 1 3 4 ID FUELKARE ALL FITTING 1 8 MPT X 90 X 3 8 BARB NICKEL FITTING 1 4 MPT X 90 X 5 16 HOSE NYLON CHIP VER 7 59 FUE
28. LKARE 2 CIRCUIT BOARD FUELKARE ALL DISPLAY amp BOARD ASSEMBLY FUELKARE ALL CORD CLAMP ASSEMBLY 12VDC X 12 RED BLACK PRESSURE TRANSDUCER 1 4 MPT ASSEMBLY NICKEL LEVEL SENSOR 1 2 MPT X 6 LEADS POWER HARNESS J1 FUELKARE ALL OUTPUT HARNESS J2 FUELKARE ALL INPUT HARNESS J3 FUELKARE ALL AUDIO SIGNAL 3 28VDC AXLE FUELKARE ALL 79 FLOW DIAGRAM nline filter Tank T Ext check valve solenoid L C Int check valve Return solenoid D L Pressure solenoid To return line of vehicle tank Pressure line Red From fuel rail outlet side regulator Return line Black DIAGNOSTIC MODE ENGINE RUNNING NO KEYS PRESSED Fuelkare series 2 80 FLOW DIAGRAM Inline filter ty pe 3 4 Bypass Pressure solenoid solenoid Return solenoid To return line of vehicle tank Pressure line Red From outlet side of fuel rail regulator Return line Black DIAGNOSTIC FILL MODE ENGINE RUNNING FILL TANK PRESSED Fuelkare series 2 81 FLOW DIAGRAM Inline filter Tank
29. SERVICE MANUAL FUELKARE EEFS305A SERIES 1 SERIES 1 5 SERIES 2 AEC GROUP 3600 WEST CARRIAGE DRIVE SANTA ANA CA 92704 PH 877 906 1395 FAX 714 444 1395 TABLE OF CONTENTS e IDENTIFY YOUR FUELKARE e FUELKARE SERIES 1 1 CHAPTER 1 COMPONENT DESCRIPTION DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY LEVEL SENSOR PUMP ASSEMBLY MANIFOLD BLOCK ASSEMBLY FILTRATION 2 CHAPTER 2 PARTS amp COMPONENTS MANIFOLD BLOCK ASSEMBLY PUMP ASSEMBLY DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY TANK ASSEMBLY PARTS LIST ALPHABETIC PARTS LIST NUMERICAL FLOW DIAGRAMS COMPONENT POWER CHART WIRE DIAGRAMS 3 CHAPTER 3 THROUBLE SHOOTING UNIT WILL NOT POWER UP FAILS TO CALIBRATE AFTER POWER UP DOES NOT FILL TANK LOOSES PRESSURE DURING LEAK DOWN MODE LOW PRESSURE DURING SERVICE MODE 4 CHAPTER 4 SERVICE PROCEDURES REPLACING INTERNAL CHECK VALVE REPLACING CIRCUIT BOARD REPLACING PROCESSOR CHIP e FUELKARE SERIES 1 5 1 CHAPTER 1 COMPONENT DESCRIPTION DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY LEVEL SENSOR PUMP ASSEMBLY MANIFOLD BLOCK ASSEMBLY FILTRATION 2 CHAPTER 2 PARTS amp COMPONENTS MANIFOLD BLOCK ASSEMBLY PUMP ASSEMBLY DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY TANK ASSEMBLY PARTS LIST ALPHABETIC QV NARA tA 21 23 24 24 24 25 26 27 30 31 33 35 37 38 38 38 39 40 41 42 43 44 45 TABLE OF CONTENTS PARTS LIST NUMERICAL FLOW DIAGRAMS COMPONENT POWER CHART WIRE DIAGRAMS
30. X 5 16 HOSE 2354 20 10 6 FITTING 1 4 MPT X 90 X 5 16 HOSE 3030 00 00 0 CHIP VER 7 58 FUELKARE 1 3030 01 00 0 CIRCUIT BOARD FUELKARE ALL 3030 01 01 0 DISPLAY amp BOARD ASSEMBLY FUELKARE ALL 3075 12 22 7 CORD CLAMP ASSEMBLY 12VDC X 12 RED BLACK 3109 54 31 2 PRESSURE TRANSDUCER 1 4 MPT ASSEMBLY NICKEL 3113 58 50 5 LEVEL SENSOR 1 2 MPT X 6 LEADS 3142 10 01 1 POWER HARNESS J1 FUELKARE ALL 3142 10 02 1 OUTPUT HARNESS J2 FUELKARE ALL 3142 10 03 1 INPUT HARNESS J3 FUELKARE ALL 3160 68 12 1 AUDIO SIGNAL 3 28VDC 5120 11 00 2 AXLE FUELKARE ALL NYLON NYLON Fuelkare series 1 12 FLOW DIAGRAM Tank Ext check valve S JU Pressure Bypass solenoid solenoid Return solenoid To return line of vehicle Pressure line Red From fuel rail outlet side regulator Return line Black DIAGNOSTIC MODE ENGINE RUNNING NO KEYS PRESSED 2 LINE SERVICE Fuelkare series 1 13 FLOW DIAGRAM Tank IN Ext check valve w Pressure solenoid L U Bypass solenoid L Return solenoid
31. ase leak down test key to restore cleaning solution to the now cleared pathway through the machine and hoses When pumps stops remove loop from black and red hoses 8 Retest leak down mode If not holding pressure 9 Remove rear panel 10 Press leak down key monitor clear tube between manifold and pump and monitor clear tube between manifold and tank for fluid flow If fluid flows from manifold to pump 11 Unscrew white nylon nut from clear tube on output side of pump 12 Install adapter on red hose and insert hose in new fluid tank 13 Using shop air blow into clear tube until red hose is empty 14 Take red hose with adapter and apply short bursts of air to reseat external check valve 15 Reattach clear tube to pump and press leak down test key fluid will circulate through red hose repeat if needed to remove air from system 16 Remove adapter from red hose 17 Retest leak down mode If fluid flows from manifold to tank 18 Remove internal check valve inspect for debris and condition of O rings or replace if needed Fuelkare series 1 25 CHAPTER 3 THROUBLE SHOOTING LOW PRESSURE DURING SERVICE MODE Check filter replacement history 50 services per filter Remove hoses from vehicle Install open end adapters to red and black hose Insert red hose to new fluid tank Using shop air pressurize black hose until red hose is empty Using shop air apply short bursts of pressure to red hose to reseat internal c
32. curing the control board assembly using 3 8 socket 4 Place board assembly on top of unit and remove screws or nuts to separate circuit board from display panel 5 Replace circuit board 6 Reassemble and test Fuelkare series 2 94 CHAPTER 4 SERVICE PROCEDURES REPLACING CIRCUIT BOARD FROM REAR 1 Remove rear center panel seven 7 Phillips screws 2 Remove the 4 nyloc nuts securing the front control board assembly using long extension with 3 8 Socket Fuelkare series 2 95 CHAPTER 4 SERVICE PROCEDURES REPLACING CIRCUIT BOARD FROM REAR 3 Disconnect wire connectors from board if not marked J1 J2 J3 please mark before removal 4 Place board assembly on top of unit and remove screws or nuts to separate circuit board from display panel 5 Replace circuit board 6 Reassemble and test Fuelkare series 2 96
33. h vehicle If not holding pressure perform the following 2 Install open end adapter to red hose 3 Remove Fuelkare tank cap and Insert red hose with adapter in new fluid tank 4 Remove spin on filter 5 Using shop air and appropriate blow gun blow air into center port of spin on filter housing until red hose is empty 6 Using shop air apply short bursts of pressure to red hose to reseat internal check valve 7 Remove adapter from red hose and re install spin on filter connect black and red hoses together with male loop adapter p n 6016 02 01 1 press and release leak down test key to restore cleaning solution to the now cleared pathway through the machine and hoses When pump stops remove loop from blck and red hoses 8 Re test leak down mode If not holding pressure 9 Remove rear panel 10 Press leak down key monitor clear tube between manifold and pump and monitor clear tube between manifold and tank for fluid flow If fluid flows from manifold to pump 11 Unscrew white nylon nut from clear tube on output side of pump 12 Install adapter on red hose and insert hose in new fluid tank 13 Using shop air blow into clear tube until red hose is empty 14 Take red hose with adapter and apply short bursts of air to reseat external check valve 15 Reattach clear tube to pump and press leak down fluid will circulate through red hose repeat if needed to remove air from system 16 Remove adapter from red hose 17 Retest
34. heck J2 wire loom repair or replace as needed If 12VDC is present remove return solenoid assembly and apply power to see if plunger retracts If not push center of plunger several times with Phillips screw driver and clean with compressed air re power solenoid valve assembly and check plunger movement If plunger moves freely reinstall and repeat fill tank mode If plunger does not move freely replace solenoid assembly Fuelkare series 1 24 CHAPTER 3 THROUBLE SHOOTING LOOSES PRESSURE DURING LEAKDOWN MODE 1 Remove Fuelkare red and black hoses from vehicle and press leak down test key pressure should ramp up to 100 p s i once achieved the pressure displayed will alternately show baseline and current pressure Normal acceptable decay is 10 100 p s i over one minute If holding pressure problem with vehicle If not holding pressure perform the following 2 Press and release the STOP key to relieve pressure 3 Install open end adapters to red and black hoses 4 Remove Fuelkare tank cap and insert red hose with adapter in new fluid tank 5 Using shop air and an appropriate blow gun blow air into adapter now attached to black hose Continue blowing until red hose is empty 6 Using shop air apply short bursts of pressure to red hose to reseat internal check valve 7 Remove adapters from black and red hoses connect black and red hoses together with male loop adapter p n 6016 02 01 1 press and rele
35. heck valve Reconnect red and black hoses to vehicle Resume service 9 Fuelkare series 1 26 CHAPTER 4 SERVICE PROCEDURES REPLACING INTERNAL CHECK VALVE 1 Remove the Phillips Head pan screws from the center back panel 2 Remove the two 2 5 32 Allen Head screws in filter cavity a 4mm Allen Socket will also fit these 2 screw heads 3 Remove the nickel plated hex head bolt threaded into the top of the black anodized Manifold Block 7 8 across the flats Fuelkare series 1 27 CHAPTER 4 SERVICE PROCEDURES REPLACING INTERNAL CHECK VALVE Fuelkare series 1 28 CHAPTER 4 SERVICE PROCEDURES REPLACING INTERNAL CHECK VALVE 4 Take a pick tool and work the check valve from the manifold block it is held in with an O ring interference fit by inserting the tip of the tool alternately in the offsetting holes in the top of the check valve Fuelkare series 1 29 CHAPTER 4 SERVICE PROCEDURES REPLACING INTERNAL CHECK VALVE Insure there are no contaminants in the manifold block insert the new check valve in the manifold block The correct orientation is with the holes up as described in the removal process Firmly seat to bottom of block and replace the retainer bolt This process takes maybe ten minutes and can also be tested by powering up the unit hooking the red and black hoses together with the 6016 02 01 1 extension double male adap
36. nection Black lead to ground and red lead to positive Make sure connections are clean Check for battery power at J1 connector pins 1 2 and 3 4 red and black wires If no battery power is detected at J1 connector check internal connection between power cord and J1 wire loom repair or replace as needed FAILS TO CALIBRATE AFTER POWER UP If Fuelkare black and red hoses where connected before power up remove hoses from fuel system and connect 2 open end adapters to red and black hose If still no calibration using shop air apply short bursts of pressure to red hose this should reset transducer If still no calibration check connection to J3 wire loom If connection is correct replace pressure transducer DOES NOT FILL TANK First time use will take up to 60 seconds a properly functioning vehicle s fuel supply system to prime filter and lines Verify that hoses and adapters are properly connected to vehicle fuel system If properly connected to fuel system check return solenoid assembly for 12vdc If 12VDC is not present check J2 wire loom repair or replace as needed If 12VDC is present remove return solenoid assembly and apply power to see if plunger retracts If not push center of plunger several times with Phillips screw driver and clean with compressed air re power solenoid assembly and check plunger movement If plunger moves freely reinstall and repeat fill tank mode
37. nitor clear tube between manifold and tank for fluid flow If fluid flows from manifold to pump Unscrew white nylon nut from clear tube on output side of pump Install adapter on red hose and insert hose in new fluid tank Using shop air blow into clear tube until red hose is empty Take red hose with adapter and apply short bursts of air to reseat external check valve Reattach clear tube to pump and press leak down fluid will circulate through red hose repeat if needed to remove air from system Remove adapter from red hose Retest leak down mode If fluid flows from manifold to tank Remove internal check valve inspect for debris and condition of O rings or replace if needed Fuelkare series 1 5 58 2 1 2006 CHAPTER 3 THROUBLE SHOOTING LOW PRESSURE DURING SERVICE MODE Check inline filter replacement history 50 services per filter Remove hoses from vehicle Install open end adapters to red hose Insert red hose to new fluid tank Repower Fuelkare Once diagnostic fill cycle led is flashing Press and hold and keys until 2 line and 1 line service led start flashing Press 2 line key Press start soak key and monitor flow through red hose 9 If flow is low or stops with pump still running replace inline filter Aide RD NOTE Whene replacing inline filter it is recommended to clean line from filter to tank Remove cap from tank and apply shop air to line check tank for debris and clean
38. oard receives 12 vdc through wire loom J1 upper 4 pins and powers pump through J1 lower 4 pins J2 wire loom channels output signals to solenoids and audio signal J3 wire loom receives input signals from pressure transducer and max level switch ACUUM RANSDUCER EF 3113 58 50 8 LEVEL SENSOR NPTM X 6 LEADS Normally open reed switch with magnetic float that closes the switch in presence of fluid located near the top of the tank and used to prevent tank overfill E INSTALL WITH RED gt Note Install with red dot at 2 o clock E ww 6211 0 PUMP ASSEMBLY FUELKARE 1 1 5 12 vdc gear pump with 1 gpm flow rate 175 psi max pressure magnetic clutch Fuelkare series 1 5 38 CHAPTER 1 COMPONENT DESCRIPTION 2141 98 13 4 MANIFOLD BLOCK ASSEMBLY FUELKARE 1 5 BLACK A 2136 30 20 3 RETURN VALVE Normally closed cartridge valve open during 2 line service leakdown test and to fill tank B 2140 00 20 1 INTERNAL CHECK VALVE open during diagnostic mode to return fuel to vehicle gas tank C 3109 54 31 2 PRESSURE TRANSDUCER Measures and monitors pressure 0 175 psi D 2136 10 20 3 BY PASS VALVE 1 32 orifice opens during purge and to perform 1 line service E 2354 21 10 6 FITTING 4 MPT X 90 X 5 16 TUBE F 2135 30 20 3 PRESSURE VALVE Normally open cartridge valve closes to perform dead head test G 2140 39 20 1 EXTERNAL CHECK VALVE Prevents fuel to return to pump 2354 31 14 1 FITTING POLY
39. onnected before power up remove hoses from fuel system and connect 2 open end adapters to red and black hose If still no calibration using shop air apply short bursts of pressure to red hose this should reset transducer If still no calibration check connection to J3 wire loom If connection is correct replace pressure transducer DOES NOT FILL TANK First time use will take up to 60 seconds to prime filter and lines Verify that hoses and adapters are properly connected to vehicle fuel system If properly connected to fuel system check return solenoid assembly for 12vdc If 12VDC is not present check 72 wire loom repair or replace as needed If 12VDC is present remove return solenoid assembly and apply power to see if plunger retracts If not push center of plunger several times with Phillips screw driver and clean with compressed air re power solenoid assembly and check plunger movement If plunger moves freely reinstall and repeat fill tank mode If plunger does not move freely replace solenoid assembly Fuelkare series 2 90 CHAPTER 3 THROUBLE SHOOTING LOOSES PRESSURE DURING LEAKDOWN MODE 1 Remove Fuelkare black and red hoses from vehicle and press leak down test key pressure should ramp up to 100 p s i once archieved the pressure displayed will alternately show baseline and current pressure Normal acceptable decay is 10 100 p s i over one minute if holding pressure problem wit
40. rked J1 J2 J3 please mark before removal Fuelkare series 1 5 65 CHAPTER 4 SERVICE PROCEDURES REPLACING CIRCUIT BOARD 5 Place board assembly on top of unit and remove screws or nuts to separate circuit board from display panel 6 Replace circuit board Fuelkare series 1 5 66 7 Reassemble and test CHAPTER 4 SERVICE PROCEDURES REPLACING PROCESSOR CHIP 1 Remove rear center panel 9 Phillips screws 2 Remove 2 Allen head 4 20 screws using 5 32 Allen wrench Fuelkare series 1 5 67 CHAPTER 4 SERVICE PROCEDURES REPLACING PROCESSOR CHIP 3 Remove the 4 nyloc nuts securing the front control board assembly using long extension with 3 8 Socket Fuelkare series 1 5 68 4 Disconnect wire connectors from board if not marked J1 J2 J3 please mark before removal CHAPTER 4 SERVICE PROCEDURES REPLACING PROCESSOR CHIP Fuelkare series 1 5 69 5 Place board assembly on top of unit and remove screws or nuts to separate circuit board from display panel 6 Remove processor chip from board using chip puller or tool that came with new chip 1 CHAPTER 4 SERVICE PROCEDURES REPLACING PROCESSOR CHIP 7 Pay close attention Find the flat corner of the new processor chip and flat corner of socket Fuelkare series 1 5 70 FLAT CORNER IN SOCKET LINE UP WITH FLAT CORNER OF CHIP 8 Insert new processor chip into socket 9 Reassemble
41. ted under hose hanger and the inline filter is located towards bottom SERIES 2 Also has 2 filters but spin on filter is located towards bottom and inline filter below hose hanger N At 2 VEG JA p i H i A FUELKARE 1 FUELKARE 1 5 FUELKARE 2 SERIES 1 SERIES 1 5 SERIES 2 CHAPTER 1 COMPONENT DESCRIPTION 3030 01 01 0 DISPLAY PANEL W CIRCUIT BOARD ASSEMBLY This assembly consists of 2 components 1 5135 00 01 2 Display mounting panel w overlay assy 2 3030 01 00 0 Circuit board receives 12 vdc through wire loom J1 upper 4 pins and powers pump through J1 lower 4 pins J2 wire loom channels output signals to solenoids and audio signal J3 wire loom receives input signals from pressure transducer and max level switch ACUUM RANSDUCER EF 3113 58 50 8 LEVEL SENSOR 7 NPTM X 6 LEADS Normally open reed switch with magnetic float that closes the switch in presence of fluid located near the top of the tank and used to prevent tank overfill E INSTALL WITH RED gt Note Install with red dot at 2 o clock E ww 6211 0 PUMP ASSEMBLY FUELKARE 1 1 5 12 vdc gear pump with 1 gpm flow rate 175 psi max pressure magnetic clutch Fuelkare series 1 5 COMPONENT DESCRIPTION 2141 98 12 4 MANIFOLD BLOCK ASSEMBLY FUELKARE 1 BLACK A 2136 30 20 3 RETURN VALVE Normally closed cartridge valve open during 2 line service Soak
42. ter Press and buttons simultaneously Version 7 56 software only for three seconds to bypass diagnostics Press Two Line button press Start Soak button and watch the air disappear from the plastic hoses inside the machine Your pressure display will indicate 16 p s i or thereabout depending on battery voltage and the resulting pump speed which is enough pressure to continue the simulation without crimping hoses Press the Set Time button until you round the clock back to 0 minutes shortly after which the process will time out and stop Paying attention to the lines inside the machine you will note that no air reappears and the lines do not drain down Remove the extension adapter from the red and black hoses with a shop towel handy to catch the solution that escapes from the adapter Replace the back cover and retaining screws to complete the process Fuelkare series 1 30 CHAPTER 4 SERVICE PROCEDURES REPLACING CIRCUIT BOARD 1 Remove rear center panel 9 Phillips screws 2 Remove 2 Allen head 4 20 screws using 5 32 Allen wrench Fuelkare series 1 31 CHAPTER 4 SERVICE PROCEDURES REPLACING CIRCUIT BOARD 3 Remove the 4 nyloc nuts securing the front control board assembly using long extension with 3 8 Socket 4 Disconnect wire connectors from board if not marked J1 J2 J3 please mark before removal Fuelkare series 1 32 CHAPTER 4 SERVICE PROCEDURES

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