Diagnostic Cleaning Service Training Manual

Model: CC4300

Fuel System Service Center

Diagnostic

and Cleaning Service

Training Manual

White Industries 309 Exchange Ave. Conway, AR 72032

USA Phone: (800) 633-2827 Fax: (800) 683-9907

www.whiteac.com

White Industries CC4300

INTRODUCTION

THE QUESTION ? • Diagnosing and eliminating driveability and emission problems caused by “soft

carbon deposits” and “fuel system deposits” has been a problem to technicians everywhere. What can today’s auto and truck technicians do ?

THE ANSWER ! • The CC4300 Fuel System Service Center and Carbon-X Fuel System Cleaner will

clean away those deposits....and the headaches that go with them....quickly, easily and most of all PROFITABLY !!

THE QUALITY !! • The “user friendly” design of the White Industries CC4300 allows all

technicians....regardless of skill levels....to use the CC4300 with complete confidence AND with great results!

• Our “one touch” control valve....a STAINLESS STEEL BALL valve riding in a TEFLON seat....is not only an easy to use pressure adjustment control, BUT it allows quick and accurate diagnostic tests AND acts as a safety purge valve as well.

• [No “electronic interference” or complicated flow patterns means accurate diagnostics]

• The state of the art “MICRO-GLASS” FILTRATION SYSTEM will remove impurities from the fuel system that are less than 3 MICRONS in size…the industry leader.

• The CC4300 can be used on it’s own HEAVY DUTY 16 gauge steel stand in the shop - OR - can be used as a completely PORTABLE unit in the field. All the working components are housed INSIDE the rugged steel top cabinet....out of harm’s way !!

• And ALL ADAPTERS needed for today’s OEM vehicles, whether foreign or domestic are STANDARD EQUIPMENT…GUARANTEED !!

Take a few minutes and read this manual before performing your first Carbon-X cleaning. We hope you find it profitable as well as educational. Thank you from all of us at White Industries !!

White Industries – CC4300

SAFETY INFORMATION

THESE PRECAUTIONS MUST BE FOLLOWED EACH TIME THE WHITE INDUSTRIES CC4300 AND/OR CLEANER IS USED: 1) USE only on 4 stroke gasoline powered vehicles. 2) USE only in a well vented area. Make sure an exhaust vent is used if cleaning is to be done indoors. 3) MAKE sure an approved fire extinguisher is available. 4) DO NOT perform the cleaning procedure near sparks or open flames. 5) WEAR appropriate eye protection. 6) REMOVE the gas cap before breaking into the vehicle fuel lines. This will help to relieve some of the pressure build up in the tank. 7) CHECK all fuel lines and connections prior to performing the service. If fuel lines are deteriorated or the connectors are missing safety clips, etc....repair before continuing with the cleaning. 8) KEEP all wires, hoses and adapters clear of moving engine parts at all times. 9) NEVER operate the White Industries CC4300 without first participating in a

training session with your sales rep....or....without first reading this instruction manual thoroughly.

10) IF you have any questions about your White Industries CC4300 or need any information....call (800) 633-2827 during normal business hours....Eastern Time. 11) For cleaner safety information....refer to the Material Safety Data Sheet (MSDS).

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EVEC-DR White Industries Injector Flush Concentrate

Section 1: Chemical Product and Company Identification Manufacturer or Supplier Name: White Industries SL. Inc. Address: 308 Exchange Ave. Conway, AR 72032 Date of MSDS Preparation: 06/24/1999 Revision: 0 Product Use: Combustion chamber cleaner. Chemical Family: Complex mixture

Section 2: Composition/Information on Ingredients Hazardous Ingredients % LD50 and LC50 ACGIH TWA Ecotoxicity - Aquatic

Toxicity PETROLEUM SOLVENT

(C8-C10) 64742-95-6

40-50 Not Available Not Available Not Available

OLEIC ACID 112-80-1


4-METHYLPENTAN-2-OL 108-11-2

5-10 Oral LD50 Rat : 2590 mg/kgDermal LD50 Rabbit

: 3560 uL/kg

25 ppm TWA LC50 (24 hr) goldfish: 360 mg/L.; LC50 (96 hr) water flea: 143.17 mg/L. Cond: QSAR calculated.

2-BUTOXYETHANOL 111-76-2

5-10 Inhalation LC50 Rat : 450 ppm/4HInhalation

LC50 Mouse : 700 ppm/7HOral LD50 Rat :

470 mg/kgOral LD50 Mouse : 1230 mg/kgDermal LD50

Rabbit : 220 mg/kg

20 ppm TWA LC50 (96 hr) bluegill: 1490 mg/L. Cond: Static, 23 degrees C.; LC50 (24 hr) goldfish: 1650-1700

mg/L.; LC50 (24 hr) water flea: 1720 mg/L.

DISTILLATES (PETROLEUM), HYDROTREATED

HEAVY NAPHTHENIC 64742-52-5


AMMONIA SOLUTION 1336-21-6

1-5 Oral LD50 Rat : 350 mg/kg

Not Available LC50 (24 hr) rainbow trout: 0.008 mg/L.; LC50 (96 hr) fathead minnow: 8.2 mg/L.; LC50 (48 hr) bluegill: 0.024-0.093 mg/L. ; EC50 (48 hr)

water flea: 0.66 mg/L. Cond: 22 degrees C.

Section 3: Hazards Identification Ingestion: Ingestion of small amounts during normal handling are not

likely to cause injury. Larger amounts may cause effects similar to those described under inhalation. Ingestion of large amounts may cause stomach irritation. Aspiration into the lungs during swallowing or subsequent vomiting may cause chemical pneumonitis, which can be fatal.

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Skin Contact:

No hazard under normal conditions of use. 2-Butoxyethanol may be absorbed through the skin. Methyl Isobutyl Carbinol may be absorbed through the skin. Frequent or prolonged contact may dry and irritate the skin and cause a rash.

Inhalation: High concentrations may cause respiratory irritation and

central nervous system depression with results ranging from dizziness and headache to unconsciousness.

Eye Contact:

Direct contact causes eye irritation. Vapors will irritate the eyes. Symptoms will include pain, redness and tearing.

Chronic Effects:

Chronic overexposure to 2-Butoxyethanol may cause liver, kidney and blood damage. Reports have associated repeated and prolonged occupational overexposure to various organic solvents with internal organ, brain and nervous system damage.

Section 4: First Aid Measures Ingestion: Do not induce vomiting. If conscious, immediately drink one

half to one glass of water to dilute. Call physician. Skin Contact:

Wash with soap and water. Remove contaminated clothing and launder before reuse. Get medical attention if irritation persists.

Inhalation: Not a hazard under normal use conditions. If inhaled, remove

from area to fresh air. Get medical attention if respiratory irritation develops or if breathing becomes difficult.

Eye Contact:

In case of contact, immediately flush eyes with plenty of water for at least 15 minutes and get medical attention if irritation persists.

Additional Information

The main hazard following ingestion is aspiration of the liquid into the lungs during subsequent vomiting. Only if more than 2.0-ml/kg body weight has been ingested, vomiting should be induced with supervision. If symptoms such as convulsions or unconsciousness occur before vomiting, gastric lavage should be considered. Exposure may increase myocardial irritability. Cardiac arrhythmia has been reported. Use sympathomimetic drugs with caution.

Section 5: Fire Fighting Measures Flash Point (ºC): 44 TCC Flame Projection: Not Applicable. NFPA Classification: Combustible Liquid, Class II

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Autoignition Temperature (ºC): Not Available Lower Explosive Limit: Not Available Upper Explosive Limit: Not Available Conditions of Flammability: Flammable when heated to temperatures above the flash point and on contact with an ignition source. Vapors are heavier than air and may travel or be moved along the ground to an ignition source at locations distant from material handling. Sensitivity to Mechanical Impact: Not Available Sensitivity to Static Discharge: Take precautionary measures against static discharges. All 20L pails and larger metal containers including tank cars and tank trucks should be grounded and/or bonded when material is transferred. Extinguishing Media: Alcohol foam or water fog for large fires. Carbon dioxide or dry chemical for small fires. Use water spray to cool fire exposed containers and prevent bursting. Do not use a direct stream of water. Hazardous Combustion: Carbon dioxide, carbon monoxide and other unidentified organic compounds.

Section 6: Accidental Release Measures Leak or Spill Procedures: Contain spilled material. Avoid contamination of natural waterways. Wear suitable protective clothing. Follow applicable explosion and fire precautions during the response. Stop the spill at the source when safe to do so. For large spills, dike the area to prevent spreading. Pump excess to a salvage container. Absorb residues and small spills with a non-flammable absorbent material and collect adsorbate for disposal. For large quantities, refer to the environmental ministry.

Section 7: Handling and Storage Handling Procedures: Containers of this material may contain hazardous residues when emptied. Do not cut, weld, drill or grind on or near this container. Use with adequate ventilation. Avoid breathing vapors. Use good personal hygiene. Avoid smoking, eating and drinking during use. Wash with soap and water after handling. Storage Requirements: Combustible liquid. Keep away from heat, flame and oxidizers. Store in a cool area, away from all sources of heat, ignition and incompatibles. Storage temperatures should not exceed 40°C. Store at ambient temperatures above 5°C. Keep away from children. Keep containers tightly closed when not in use.

Page 4 Of 6

Section 8: Exposure Controls/Personal Protection Respiratory: Not normally required. If the TLV is exceeded, a NIOSH-

approved respirator is advised. Gloves: Use Viton or 4H gloves. Nitrile gloves. Eyewear: Chemical splash goggles. Contact lenses should not be

worn. They may contribute to the severity of the injury. Clothing: Sufficient clothing to prevent skin contact. Ventilation: Sufficient mechanical ventilation to maintain exposures

below the TLV. General mechanical ventilation is not recommended as the sole means of controlling exposure. Make-up air should always be supplied to balance air exhausted.

Other protective equipment

Emergency showers and eyewash facilities should be nearby. The selection of personal protective equipment will vary depending on the conditions of use.

Section 9: Physical and Chemical Properties Physical State: Liquid Odor: Ammonia. Hydrocarbon odor. Appearance: Amber. Odor Threshold: Not Available Evaporation Rate: Not Available Vapor Pressure (mmHg): Not available. Vapor Density (Air=1): > 1 VOC %: 55 Boiling Point: Not Available pH: 9.0 to 10.5 at 5% volume Coefficient of water: Not Available Solubility in Water: Partial Specific Gravity (H2O=1): 0.89 to 0.92 at 15°C Viscosity: Not available.

Section 10: Stability and Reactivity Conditions of Instability: Stable at ambient temperatures and pressures. Hazardous Polymerization: Hazardous polymerization will not occur. Hazardous Decomposition: See hazardous combustion products.

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Incompatible Materials: Avoid strong acid, strong oxidizers, corrosive to aluminum. Conditions of Reactivity: Avoid excessive heat, sparks and open flame.

Section 11: Toxicological Information Irritancy of Product: None. Not expected to be an eye irritant or a primary skin irritant. Sensitization to product: In rare cases, may sensitize the heart muscles causing heart arrhythmia. Carcinogenicity: No components are listed as carcinogens by ACGIH, IARC, OSHA, or NTP. Reproductive Effects: 2-Butoxyethanol is an experimental reproductive toxin. Teratogenicity: 2-Butoxyethanol is an experimental teratogen. In laboratory animal teratology studies on 2-Butoxyethanol, no embryotoxicity or lethality was observed without maternal effects (concentrations 100-300 ppm). These studies do not establish a risk of birth defects in humans. Mutagenicity: The results of in-vitro mutagenicity tests have been inconclusive. In-vitro mutagenicity tests for 2-Butoxyethanol have been negative. Synergystic Products: Not Available

Section 12: Ecological Information Environmental: Toxic to aquatic life. Aromatic hydrocarbons may be

bioaccumulative but they have no food chain concentration potential. See composition/information on ingredients.

Biodegradability:

Not available.

Section 13: Disposal Considerations Waste Disposal:

Reuse or recycling should be given priority over disposal under any circumstances. Do not dump unused contents into sewers, on the ground or into any body of water. Dispose of in accordance with municipal, provincial and federal regulations.

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Section 14: Transportation Information Road shipment: Petroleum products, n.o.s., Class 3, UN1268, PG III. Marine shipment:

Petroleum products, n.o.s., Class 3.3, UN1268, PG III, EmS #3-07, MFAG 311.

Air Shipment: Petroleum distillates, n.o.s. (Aromatic Naphtha), Class 3,

UN1268, PG III, Packing Instructions 309. Exemption: Not regulated for rail or road shipment if packaged in

containers of less than bulk size.

Section 15: Regulatory Information WHMIS: B3, D1A CEPA: All components are listed on the Domestic Substances List

(DSL). CPR Compliance:

This product has been classified in accordance with the hazard criteria of the CPR and the MSDS contains all of the information required by the CPR.

Section 16: Other Information HMIS Rating: 220B Information Tel #: 1-514-489-8870 Information Fax #: 1-514-489-8845

CANUTEC EMERGENCY (613) 996-6666


Warranty Information

White Industries warrants the model CC4300 Fuel System Service Center....and all it’s internal parts (external hoses and adapters not included) to operate correctly for a period of one year from the date of initial retail purchase.

White Industries makes no other warranty claims....expressed or implied....for the above equipment.

If any malfunction occurs within the one year warranty period (from date of purchase), White Industries or one of our authorized service centers will repair or replace (in accordance with the terms outlined in the Warranty Card) the defective equipment at no charge to the purchaser. Repair or replacement is the only warranty obligation of White Industries. White Industries shall not be held responsible for any damage incidental or consequential to the sale of or the use of the above equipment. The White Industries CC4300 is furnished with a complete training manual and all adapters needed to work on most vehicles. Carefully read then follow all instructions for best results. Failure to do so may cause damage to the equipment and/or the vehicle.

WARNING: Only White Industries 04810 brand cleaner has been tested with the various stainless steel parts, nylon tubing and special hoses that make up the White Industries CC4300 and it’s parts. These parts may be harmed if any other products are utilized in the White Industries CC4300, thereby voiding the warranty. Also, engine damage or other damage to the vehicle being serviced may occur if any other chemicals or cleaners are used with the CC4300. White Industries shall not be held responsible for these or any claims as a result of the use of unauthorized chemicals or cleaners.


Assembly Instructions - Cart (Illustration – next page)

1. Check to make sure you have the following parts:

• Shelves 3 • Front Legs (longer) 2 • Rear Legs (shorter) 2 • Handles 2 • Hose Brackets 2 • Axle 1 • Wheels 2 • Washers 4 • Cotter Pins 2 • 3/8” 8-32 Screws 40 • Shelf Mats 2

2. Begin by attaching the longer 2 front legs to the three shelves (Note that the bottom

two shelves are used as “trays” and the top shelf is inverted so that the CC4300 can be placed flush on top). The front edges of the shelves and legs do not have holes for screws.

3. Next, attach the shorter 2 rear legs (Note that when attaching the rear legs to the top

shelf, the screws used for the back side are OMITTED….so that the handle will fit flush to the legs). Attach the 2 handles to the rear legs with the 4 larger screws provided.

4. Once you have attached all 4 legs and the handle to the shelves, tighten all the screws. 5. Install a cotter pin into the hole on one end of the axle. Next slide a washer onto the

axle, followed by a wheel and then another washer. Slide the other end of the axle through the holes located on the bottom of the rear legs and finish this step by sliding on a washer, a wheel and another washer, then install the other cotter pin.

6. Install the 2 hose brackets onto the upper portion of the front legs with the screws

provided. 7. Lay the rubber shelf mats into the bottom and middle shelves. 8. Double-check all screws to make sure they are tight.


Assembly & Start-Up Instructions - Machine (Illustration – next page)

1. Check to make sure you have the following parts:

• Machine 1 • Spin on Micro Filter 1 • Red Pressure Hose 1 • Black Return Hose 1 • Hose Brackets 2 • 3/8” 8-32 Screws 4

2. Set the CC4300 on the cart (if applicable)….making sure that the “feet” on the

bottom are placed snugly into the holes in the top shelf. 3. Attach the red “pressure hose” and the black “return hose” to the respectively labeled

fittings on the face of the machine. Be sure to wrap the male threads on the ends of the hoses with Teflon tape before inserting them. Use two wrenches….one for the hose fitting and one for the bulkhead fitting on the face of the machine….and secure the hoses firmly. DO NOT OVERTIGHTEN !

4. Next, attach the two (2) hose brackets….one to each side of the cabinet….with the

four (4) screws provided. 5. Using a knife or wire cutters, cut off any wire ties from the hoses, power cord and

vacuum hose. 6. Connect the red “pressure hose” to the black “return hose” with adapter # UMM

(male quick disconnect X hose X male quick disconnect). 7. Using a fuel can, fill the filter with fuel and then install onto the back of the

unit…being careful not to overtighten. Fill the fuel reservoir to the 6 cylinder level (for level indicator, see rear of tank) and add one full bottle (8 oz.) of White Industries 04810 Gasoline Fuel System Cleaner.

8. Connect the unit to any 12 volt power source, turn the “on/off switch” to the “on”

position and turn the “control valve” to the “maximum pressure / hold” position. 9. Allow the fuel mix to circulate for a few minutes.

***NOTE*** The fuel mix may take 30 - 45 seconds to “prime” the pump…this is normal…before flow is started. Also, at this time, check your hose connections at the machine for leaks….tighten if necessary

10. Turn the “control valve” to the “pressure off / purge” position, turn the “on/off switch” to the “off” position and remove adapter # UMM from both external hoses.

11. You are ready to go !!

Please read the rest of this manual before proceeding.


DIAGNOSTIC & CLEANING PROCEDURES for most PORT FUEL &TBI vehicles

1) Make sure vehicle is at normal operating temperature. Utilize all safety precautions (safety glasses, exhaust hose, available fire extinguisher, etc.). Remove the vehicle’s gas cap to relieve any pressure in the tank.

2) Hook up to vehicle battery (Red to + / Black to - ). Make sure the “control valve” is in the “pressure off / purge” (counter-clockwise) position. 3) Connect the CC4300 vacuum hose to the vehicle in a convenient spot (the fuel pressure regulator connection is a good place - do not just connect to the factory hose and eliminate the connection to the regulator - use a “T” so that vacuum to the regulator will be maintained). 4) Break into the vehicle’s fuel lines (factory fittings) and hook up the proper

CC4300 adapters (4) to both sides of pressure and return lines. FIG. A 5) Extend the return line by hooking the CC4300 “loop” adapter between the two

return line adapters. FIG. A 6) Hook the “T” adapter between the two inlet line adapters (make sure the hose end of the “T” is on the side feeding fuel from the vehicle’s fuel tank). FIG. A 7) Connect the CC4300 red output hose to the male “T” connector. FIG. A 8) Turn the “control valve” to the “maximum pressure / hold” position. 9) Start the vehicle and note actual fuel pressure (this is a good time to check your connections for leaks). Also make a note of the vacuum reading at this time. 10) Quickly squeeze and release the “loop” and note pump dead-head pressure. 11) Slowly rotate the “control valve” back (gradually) toward the “pressure off / purge” position, allowing fuel to flow from the vehicle into the CC4300 tank (turning the valve too far too quickly may cause the vehicle to stall....if it does, turn the “control valve” back to the “maximum pressure / hold” position, restart the vehicle and repeat this step). Fuel flow should be sufficient to fill the CC4300 tank to the 4 cylinder level in approximately 30 seconds. 12) After checking the fuel volume in step 9, fill the CC4300 tank to the desired level,

as shown on the back of the fuel tank. Turn the “control valve” all the way to the

“maximum pressure / hold” position to stop the flow of fuel into the FS 2000 fuel tank....and shut off the vehicle.

13) Watch the pressure gauge. With most vehicles shut off, the pressure should

stabilize and then hold. This insures that there are no leaks in the fuel system and the vehicle’s pressure regulator is doing it’s job. If the pressure does not hold....first squeeze the “loop” adapter hooked into the return line. If the pressure holds, the problem will generally be in the regulator itself. Remove the vacuum hose to the regulator and check for the presence of fuel. If no fuel is present in the hose, the CC4300 cleaning should eliminate the problem. If the pressure continues to drop....squeeze the hose section of the “T” adapter to block any flow back through the pressure line to the vehicle’s fuel tank. If the pressure holds, the problem is likely either a bad check ball/valve in the fuel pump or a leak in the pressure line from the tank. If both the pressure and the return lines are squeezed off and the pressure continues to drop, one (or more) of the injectors is leaking. Again, the CC4300 cleaning will most likely take care of the problem.

***NOTE*** Some TBI vehicles do not maintain pressure after shutting off the engine. If that is the case....skip this step and go to step 14 14) The diagnostic part of the procedure is now complete. Return the “control valve” to the “pressure off / purge” position. This will purge the fuel line of any pressure build-up. 15) Leave the “T” attached to the inlet of the fuel rail and keep the red “output” hose

hooked to the “T” (as in step 7). Remove the hose end of the “T” from the tank side of the pressure line and hook up the “plenum cleaning valve” (making sure the valve is closed) to the hose end of the “T”. Connect the 1/4” open end hose adapter to the female connector of the “plenum cleaning valve” and attach the open end to a vacuum port near the throttle body of the vehicle, but downstream of the mass airflow sensor (the PCV port will be fine). This will allow the AutoCare cleaner / fuel mixture to be introduced into the intake plenum during the cleaning process.

***NOTE **On TBI vehicles, you do not need to use the “plenum cleaning valve”….hook the red “output” hose directly to the adapter going into the TBI)

Unhook the “loop” from the outlet of the rail or pressure regulator and attach the black “return” hose to the outlet adapter. Connect the two remaining adapters together (to and from the vehicle’s tank) with the “loop” to allow a continuous flow of fuel from the tank and right back to the tank. This will eliminate the need to disable the vehicle’s fuel pump. FIG. B

16) Pour the proper amount (see bottle) of White Industries 04810 cleaner into the

CC4300 tank. 17) Turn the “power switch” on and turn the “control valve” all the way to the “maximum pressure / hold” position.

18) With the “control valve” in the “maximum pressure / hold” position, note the maximum pressure on the gauge. This is an indication of rest pressure....where the regulator is opening without vacuum assist. Quickly turn the “control valve” back to the “pressure off / purge” position....wait several seconds....and then quickly turn it back to “maximum pressure / hold”. Again....wait a few seconds and repeat this step 8 to 10 times. This rhythmic pulsing action is what cleans the fuel rail, the injector screens and the pressure regulator. After pulsing, turn the “control valve” to the “maximum pressure / hold” position and let the Carbon-X cleaner and gasoline solution circulate through the rail for several minutes.

***NOTE*** On TBI vehicles, the rail cleaning may be eliminated 19) Start the vehicle. ***NOTE*** If at any time you feel that something might be wrong (leaks, hoses disconnected, etc.), you can easily initiate the safety purge feature by simply turning the “control valve” back to the “pressure off / purge” position. This will activate the safety purge from any point in the cleaning process. 20) The cleaning procedure will take about 25 to 35 minutes, depending on the engine

size and the amount of fuel in the FS-2000 tank. It is a good idea to turn off the vehicle after approximately half the cleaner and fuel mix has been used (turn off the vehicle’s ignition, turn the “power switch” off and let the vehicle “soak” for about 10 minutes before restarting....then repeat steps 17, 18 and 19).

21) After the “soak” period (or at any time during the cleaning process if you are not

utilizing the “soak” method), increase the engine speed to around 2000 RPM (use a throttle tool to maintain the proper speed) and VERY SLIGHTLY begin to open the “plenum cleaning valve”. Keep opening the valve a little bit at a time until you hear the engine start to bog down and run a bit rough (If the engine stalls, shut the “plenum cleaning valve” immediately and re-start the vehicle). Let the engine run rough for a few seconds and then shut the “plenum cleaning valve” tightly. Allow the engine to build back up to 2000 RPM and repeat the process 4 or 5 more times. White smoke may be visible from the exhaust system of the vehicle during this process....this is normal and is proof of the cleaner getting down through the combustion area and into the exhaust (including cleaning the O2 sensor and the catalytic converter). After completing this process, close the “plenum cleaning valve” completely and return the engine speed to idle.

22) When the FS-2000 tank runs out of fuel....the vehicle will stop running, but the

pump will continue to run. Turn off the vehicle’s ignition, turn the “power switch” off and turn the “control valve” to the “pressure off / purge” position to purge any remaining pressure from the fuel lines.

23) Unhook the clips from the battery terminals, carefully unhook all the adapters and re-connect the vehicle’s fuel lines and hoses used during the cleaning process.

24) Start the vehicle and check your connections for leaks. Make a note of the vacuum reading on the ``Fuel System Diagnostic Report`` to show to the vehicle owner....then remove the CC4300 vacuum hose and reconnect the original hose that was removed for testing. Re-install the gas cap.

25) Take the vehicle for a short test drive to eliminate any cleaner left in the fuel system. That’s all there is to it !

***NOTE*** Before beginning the initial cleaning process....it is a good idea to put some Carbon-X cleaner into a spray bottle and spray the throttle body of the intake plenum liberally with cleaner.

DO NOT SPRAY ON OR THROUGH THE VEHICLE’S MASS AIR-FLOW SENSOR

Pay attention to the throttle plate (front and back- you may want to use a soft - bristled brush) as well as the idle air control bypass. Re-install air hose before beginning the cleaning process. A second application during the cleaning process (while “soaking” - step 20) will help make sure that this area is well cleaned.


DIAGNOSTIC & CLEANING PROCEDURES for “Single Line” PORT FUEL vehicles

1) Make sure vehicle is at normal operating temperature. Utilize all safety

precautions (safety glasses, exhaust hose, available fire extinguisher, etc.). Remove the vehicle’s gas cap to relieve any pressure in the tank.

***NOTE*** On OBD-II vehicles, replace the cap before starting the vehicle 2) Hook up to vehicle battery (Red to + / Black to - ). Make sure the “control valve” is in the “pressure off / purge” (counter-clockwise) position. 3) Connect the CC4300 vacuum hose to the vehicle in a convenient spot. Do not just

connect to the vacuum port and eliminate the factory connection - use a “T” so that normal vacuum operations will be maintained).

4) Break into the vehicle’s single fuel line (factory fittings) and hook up the corresponding CC4300 adapters (2) to both sides of the pressure line. FIG. A 5) Hook the “T” adapter between the two inlet line adapters (make sure the hose end of the “T” is on the side delivering fuel from the vehicle’s fuel tank). FIG. A 6) Connect the CC4300 red “output hose” to the male “T” connector. FIG. A 7) Turn the “control valve” to the “maximum pressure / hold” position. 8) Start the vehicle and note actual fuel pressure (this is a good time to check your

connections for leaks). Also make a note of the vacuum reading at this time.

***NOTE*** Keep a record of running fuel pressure…you will need to dial in the proper pressure to run the vehicle during the cleaning procedure (step 16)

9) Slowly rotate the “control valve” back (gradually) toward the “pressure off /

purge” position, allowing fuel to flow from the vehicle into the CC4300 tank (turning the valve too far too quickly may cause the vehicle to stall….if it does, turn the “control valve” back to the “maximum pressure / hold” position, restart the vehicle and repeat this step). Fuel flow should be sufficient to fill the CC4300 tank to the 4 cylinder level in approximately 30 seconds.

10) After checking the fuel volume in step 9, fill the CC4300 tank to the desired level,

as shown on the back of the fuel tank. Turn the “control valve” all the way to the “maximum pressure / hold” position to stop the flow of fuel into the CC4300 fuel tank....and shut off the vehicle.

11) Watch the pressure gauge. With most vehicles shut off, the pressure should stabilize and then hold. This insures that there are no leaks in the fuel system and the vehicle’s pressure regulator is doing it’s job.

12) The diagnostic part of the procedure is now complete. Return the “control valve”

to the “pressure off / purge” position. This will purge the fuel line of any pressure build-up.

13) Leave the “T” attached to the inlet of the fuel rail and keep the red “output” hose

hooked to the “T” (as in step 6). Remove the hose end of the “T” from the tank side of the pressure line and hook up the “plenum cleaning valve” (making sure the valve is closed) to the hose end of the “T”. Connect an appropriate open end hose adapter to the female connector of the “plenum cleaning valve” and attach the open end to a vacuum port near the throttle body of the vehicle, but downstream of the mass airflow sensor (the power brake or PCV port will be fine). This will allow the Carbon-X 04810 cleaner / fuel mixture to be introduced into the intake plenum during the cleaning process. FIG. B

14) Attach one end of the “loop” to the adapter on the pressure line delivering fuel

from the vehicle’s fuel tank (only one end of the “loop” is connected…the quick disconnect on the other end acts as a cap or “dead-end”…stopping the flow of fuel). The pressure regulator and return line are in the vehicle’s fuel tank…the vehicle’s pump will continue to flow normally and will not dead-head. FIG. B

15) Pour the proper amount (see bottle) of Carbon-X cleaner into the CC4300 tank. 16) Turn the “power switch” on and SLOWLY turn the “control valve” clockwise

JUST ENOUGH TO ATTAIN PROPER RUNNING PRESSURE (step 8)

***NOTE*** On “Single Line” Port Fuel vehicles, the normal EFI rail cleaning step is eliminated

17) Start the vehicle. ***NOTE*** If at any time you feel that something might be wrong (leaks, hoses disconnected, etc.), you can easily initiate the safety purge feature by simply turning the “control valve” back to the “pressure off / purge” position. This will activate the safety purge from any point in the cleaning process. 18) The cleaning procedure will take about 25 to 35 minutes, depending on the engine

size and the amount of fuel in the CC4300 tank. It is a good idea to turn off the vehicle after approximately half the cleaner and fuel mix has been used (turn off the vehicle’s ignition, turn the “power switch” off and let the vehicle “soak” for about 10 minutes before restarting....then repeat steps 16 and 17).


utilizing the “soak” method), increase the engine speed to around 2000 RPM (use

a throttle tool to maintain the proper speed) and VERY SLIGHTLY begin to open the “plenum cleaning valve”. Keep opening the valve a little bit at a time until you hear the engine start to bog down and run a bit rough (If the engine stalls, shut the “plenum cleaning valve” immediately and re-start the vehicle). Let the engine run rough for a few seconds and then shut the “plenum cleaning valve” tightly. Allow the engine to build back up to 2000 RPM and repeat the process 4 or 5 more times. White smoke may be visible from the exhaust system of the vehicle during this process....this is normal and is proof of the cleaner getting down through the combustion area and into the exhaust (including cleaning the O2 sensor and the catalytic converter). After completing this process, close the “plenum cleaning valve” completely and return the engine speed to idle.

20) When the cleaning is finished and the CC4300 tank runs out of fuel....the vehicle

will stop running, but the CC4300 pump will continue to run. Turn off the vehicle’s ignition, then quickly turn off the CC4300 “power switch” and turn the “control valve” to the “pressure off / purge” position to purge any remaining pressure from the fuel lines

***NOTE*** Leaving the CC4300 pump run for long periods of time while “empty” may cause damage to the pump.

21) Unhook the clips from the battery terminals, carefully unhook all the adapters and re-connect the vehicle’s fuel lines and hoses used during the cleaning process. 22) Start the vehicle and check your connections for leaks. Make a note of the

vacuum reading on the ``Fuel System Diagnostic Report`` to show to the vehicle owner....then remove the CC4300 vacuum hose and reconnect the original hose that was removed for testing.


***NOTE*** Before beginning the initial cleaning process…it is a good idea to spray the throttle body of the intake plenum liberally with cleaner.

DO NOT SPRAY ON OR THROUGH THE VEHICLE’S MASS AIR-FLOW SENSOR

Pay attention to the throttle plate (front and back- you may want to use a soft - bristled brush) as well as the idle air control bypass. Re-install air hose before beginning the cleaning process. A second application after the rest of the cleaning process is complete will help make sure that this area is well cleaned.


DIAGNOSTIC & CLEANING PROCEDURES

FOR MOST VEHICLES WITH CARBURETORS

1) Make sure vehicle is at normal operating temperature. Remove air cleaner. Utilize all safety precautions (safety glasses, exhaust hose, fire extinguisher, etc.). Remove the vehicle’s gas cap to relieve any pressure in the tank.

2) Hook up to vehicle battery (Red to + / Black to - ). Make sure the “control valve” is in the “pressure off / purge” (counter-clockwise) position.

3) Connect the CC4300 vacuum hose to the vehicle in a convenient spot (Any manifold vacuum port will do). 4) Break into the vehicle’s fuel line at the carburetor (although it is not absolutely necessary to remove the fuel filter....removing it and installing a new one after the cleaning is highly recommended and hook up corresponding CC4300 adapters (2) to both sides of the fuel line. (If the vehicle has a return line (rare)....break into it, install the corresponding adapters and clean similar to a TBI vehicle) FIG. A 5) Hook the “T” adapter between the two fuel line adapters (make sure the hose end of the “T” is on the carburetor side). FIG. A 6) Connect the CC4300 red output hose to the male “T” connector. FIG. A 7) Turn the “control valve” to the “maximum pressure / hold” position. 8) Start the vehicle and note actual fuel pressure (this is a good time to check your connections for leaks). Also make a note of the vacuum reading at this time on the ``Fuel System Diagnostic Report.`` 9) Slowly rotate the “control valve” back toward the “pressure off / purge” position, allowing fuel to flow from the vehicle into the FS-2000 fuel tank. Fuel flow should be sufficient to fill the CC4300 tank to the 4 cylinder level in approximately 30 seconds. 10) After checking the fuel volume in step 9, fill the CC4300 tank to the desired level, as shown on the back of the fuel tank. Turn the “control valve” all the way to the “maximum pressure / hold” position to stop the flow of fuel into the CC4300 fuel tank....and shut off the vehicle.

11) Return the “control valve” to the “pressure off / purge” position. This will purge the fuel line of any pressure build-up. 12) Remove the hose end of the “T” from the adapter leading into the carburetor and

remove the red output hose from the male “T” connector. Hook the red output hose to the carburetor adapter and hook the hose end of the “T” to the male “T” connector. This will form a kind of dead end or “P” and effectively disable the vehicle’s mechanical fuel pump (for vehicle’s with return lines and/or electric fuel pumps....the cleaning should be performed similar to a TBI vehicle). FIG. B

13) Pour the proper amount (see bottle) of AutoCare cleaner into the CC4300 tank. 14) Turn the “power switch” on and turn the “control valve” very slightly to the right (clockwise) until pressure begins showing on the gauge. 15) Adjust the “control valve” so that the pressure gauge indicates between 5 and 10 pounds.

***NOTE***Be careful not to over-pressurize....damage to the carburetor may occur

16) Start the vehicle. 17) The cleaning procedure will take about 25 to 35 minutes, depending on the engine

size and the amount of fuel in the CC4300 tank. It is a good idea to turn off the vehicle after approximately half the cleaner and fuel mix has been used (turn off the vehicle’s ignition, turn the “power switch” off and let the vehicle “soak” for about 10 minutes before restarting....then repeat steps 14, 15 and 16). After restarting the vehicle, snap the throttle to wide open 5 or 6 times while holding the choke plate closed (or at least partially closed). Along with helping to clean the hard-to-get-to idle circuits of the carburetor, this will assist in flushing out the heavier build up of deposits on the manifold floor as well as on the valves and in the combustion chamber.

18) When the CC4300 tank runs out of fuel....the vehicle will stop running, but the


19) Unhook the clips from the battery terminals, carefully unhook all the adapters and reconnect the vehicle’s fuel line (don’t forget to install the fuel filter). 20) Start the vehicle and check your connections for leaks. Make a note of the

vacuum reading on the ``Fuel System Diagnostic Report`` to show to the vehicle owner....then remove the CC4300 vacuum hose and reconnect the original hose that was removed for testing. Re-install the air cleaner and the gas cap.



DIAGNOSTIC & CLEANING PROCEDURES for most CIS (K-Jetronic) vehicles

1) Make sure vehicle is at normal operating temperature. Utilize all safety

precautions (safety glasses, exhaust hose, available fire extinguisher, etc.). Remove the vehicle’s gas cap to relieve any pressure in the tank.

2) Hook up to vehicle battery (Red to + / Black to - ). Make sure the “control valve” is in the “pressure off / purge” (counter-clockwise) position. 3) Connect the CC4300 vacuum hose to the vehicle in a convenient spot. 4) Break into the vehicle’s fuel lines (generally at the fuel distributor) and hook up

the corresponding CC4300 adapters (4) to both sides of pressure and return lines. FIG. A

5) Extend the return line by hooking the CC4300 “loop” adapter between the two

return line adapters. FIG. A 6) Connect the “T” adapter between the two inlet line adapters (make sure the hose end of the “T” is on the side feeding fuel from the vehicle’s fuel tank). FIG. A 7) Connect the CC4300 red output hose to the male “T” connector. FIG. A 8) Turn the “control valve” to the “maximum pressure / hold” position. 9) Start the vehicle and note actual fuel pressure (this is a good time to check your connections for leaks). Also make a note of the vacuum reading at this time. 10) Quickly squeeze and release the “loop” and note pump dead-head pressure. 11) Slowly rotate the “control valve” back (gradually) toward the “pressure off / purge” position, allowing fuel to flow from the vehicle into the CC4300 tank (turning the valve too far too quickly may cause the vehicle to stall....if it does, turn the “control valve” back to the “maximum pressure / hold” position, restart the vehicle and repeat this step). Fuel flow should be sufficient to fill the CC4300 tank to the 4 cylinder level in approximately 30 seconds. 12) After checking the fuel volume in step 9, fill the CC4300 tank to the desired level,

as shown on the back of the fuel tank. Turn the “control valve” all the way to the “maximum pressure / hold” position to stop the flow of fuel into the CC4300 fuel tank....and shut off the vehicle.

13) Watch the pressure gauge. Generally, the pressure will drop somewhat, stabilize

and then hold at the regulator’s set pressure. This insures that there are no leaks in the fuel system and the vehicle’s pressure regulator is doing it’s job. If the pressure does not hold....first squeeze the “loop” adapter hooked into the return line. If the pressure holds, the problem will generally be in the regulator itself. Remove the vacuum hose to the regulator and check for the presence of fuel. If no fuel is present in the hose, the CC4300 cleaning should eliminate the problem. If the pressure continues to drop....squeeze the hose section of the “T” adapter to block any flow back through the pressure line to the vehicle’s fuel tank. If the pressure holds, the problem is likely either a bad check ball/valve in the fuel pump or a leak in the pressure line from the tank. If both the pressure and the return lines are squeezed off and the pressure continues to drop, the fuel distributor is probably leaking fuel to one or more injectors. Again, the CC4300 cleaning will most likely take care of the problem.

14) The diagnostic part of the procedure is now complete. Return the “control valve” to the “pressure off / purge” position. This will purge the fuel line of any pressure build-up. 15) Leave the “T” attached to the inlet of the fuel distributor and keep the red

“output” hose hooked to the “T” (as in step 7). Remove the hose end of the “T” from the tank side of the pressure line and hook up the “plenum cleaning valve” (making sure the valve is closed) to the hose end of the “T”. Connect the 1/4” open end hose adapter to the female connector of the “plenum cleaning valve” and attach the open end to a vacuum port near the throttle body of the vehicle (the PCV port will be fine). This will allow the White Industries cleaner / fuel mixture to be introduced into the intake plenum during the cleaning process.

***NOTE **On vehicles equipped with a cold-start injector….you can use any brand of injector “pulse/tester” to power the cold-start injector during the cleaning process (Step 20)sending the Carbon-X 04810 cleaner / fuel mixture through the plenum. This will eliminate the need for the “plenum cleaning valve” step above. )

Unhook the “loop” from the outlet of the rail or pressure regulator and attach the black “return” hose to the outlet adapter. Connect the two remaining adapters together (to and from the vehicle’s tank) with the “loop” to allow a continuous flow of fuel from the tank and right back to the tank. This will eliminate the need to disable the vehicle’s fuel pump. FIG. B

16) Pour the proper amount (see bottle) of Carbon-X cleaner into the CC4300 tank. 17) Turn the “power switch” on and turn the “control valve” all the way to the “maximum pressure / hold” position.

18) With the “control valve” in the “maximum pressure / hold” position, note the maximum pressure on the gauge. This is an indication of rest pressure....where the regulator is opening without vacuum assist. Quickly turn the “control valve” back to the “pressure off / purge” position....wait several seconds....and then quickly turn it back to “maximum pressure / hold”. Again....wait a few seconds and repeat this step 8 to 10 times. This rhythmic pulsing action is what cleans the fuel distributor and the pressure regulator. After pulsing, turn the “control valve” to the “maximum pressure / hold” position and let the White Industries cleaner and gasoline solution circulate through the system for several minutes.

19) Start the vehicle. ***NOTE*** If at any time you feel that something might be wrong (leaks, hoses disconnected, etc.), you can easily initiate the safety purge feature by simply turning the “control valve” back to the “pressure off / purge” position. This will activate the safety purge from any point in the cleaning process. 20) The cleaning procedure will take about 25 to 35 minutes, depending on the engine

size and the amount of fuel in the CC4300 tank. It is a good idea to turn off the vehicle after approximately half the cleaner and fuel mix has been used (turn off the vehicle’s ignition, turn the “power switch” off and let the vehicle “soak” for about 10 minutes before restarting....then repeat steps 17, 18 and 19).


utilizing the “soak” method), increase the engine speed to around 2000 RPM (use a throttle tool to maintain the proper speed) and VERY SLIGHTLY begin to open the “plenum cleaning valve”. Keep opening the valve a little bit at a time until you hear the engine start to bog down and run a bit rough (If the engine stalls, shut the “plenum cleaning valve” immediately and re-start the vehicle). Let the engine run rough for a few seconds and then shut the “plenum cleaning valve” tightly. Allow the engine to build back up to 2000 RPM and repeat the process 4 or 5 more times. White smoke may be visible from the exhaust system of the vehicle during this process....this is normal and is proof of the cleaner getting down through the combustion area and into the exhaust (including cleaning the catalytic converter). After completing this process, close the “plenum cleaning valve” completely and return the engine speed to idle.

***NOTE **Again, n vehicles equipped with a cold-start injector….use any brand injector “pulse/tester” to power the cold-start injector sending the White Industries cleaner / fuel mixture through the plenum. This will eliminate the need for the “plenum cleaning valve” step above. )

22) When the CC4300 tank runs out of fuel....the vehicle will stop running, but the


23) Unhook the clips from the battery terminals, carefully unhook all the adapters and re-connect the vehicle’s fuel lines and hoses used during the cleaning process.

24) Start the vehicle and check your connections for leaks. Make a note of the vacuum reading on the ``Fuel System Diagnostic Report`` to show to the vehicle owner....then remove the CC4300 vacuum hose and reconnect the original hose that was removed for testing. Re-install the gas cap


***NOTE*** Before beginning the initial cleaning process....it is a good idea to put some Carbon-X cleaner into a spray bottle and spray the throttle body of the intake plenum liberally with cleaner.

Pay attention to the throttle plate (front and back- you may want to use a soft - bristled brush) as well as the idle air control bypass. Re-install air hose before beginning the cleaning process. A second application during the cleaning process (while “soaking” - step 20) will help make sure that this area is well cleaned.

CC4300

CARBON-X TROUBLE SHOOTING GUIDE

Page 1 of 4

PROBLEM CAUSE REPAIR ACTION 1. NO POWER Faulty connection

on battery

Make sure that there is a good connection on battery (+) and ground to car.

2. NO POWER No power on the

battery

Use a new battery.

3. NO POWER Burnt or broken

fuse

Replace with a new 15 amp glass fuse.

4. NO POWER Faulty connection

on internal wiring

Using the wiring diagram and a volt meter, check the internal wiring starting at battery and work your way down.

5. CAR WILL NOT

START (during diagnostic procedure)

Control valve is in open purge position (Horizontal). This may overfill gas tank on machine.

Put control valve on maximum pressure hold position. (Vertical)

6. CAR WILL NOT

START (during diagnostic procedure)

Pressure and return lines are inverted and this may overfill the gas tank on the machine.

Make sure that the pressure line (red) and the :T” loop is on the pressure side of the car.

7. PRESSURE GOES

RIGHT UP TO 160 PSI OR MORE

Hooked up to a single line type fuel system and the technician has put the control valve to maximum pressure (vertical)

In the case of single-line system there is no pressure regulator between the machine and the fuel rail. It is in the vehicle’s tank. Technician must adjust the pressure manually with the control valve. If they put it to maximum pressure hold as in the case of a two-line system, it will over pressurize the system automatically and might cause damage to the vehicle. Please follow instructions for single line systems in the owners manual very carefully.

CC4300


Page 2 of 4

PROBLEM CAUSE REPAIR ACTION 8. PRESSURE GOES

RIGHT UP TO 160 PSI OR MORE

If the pressure (red) or return (black) hose quick connects are not hooked up properly it will prevent fluid from leaving the hose and will build internal pressure. This may cause safety magnetic clutch on pump to de-couple. Refer to #8 for repair action.

Push in Quick-Connect to make sure that it is well connected.

9. CAR WILL NOT

START (during cleaning procedure)

Machine pump is not running and does not build pressure.

Start pump.

10. CAR WILL NOT


Control valve is in the pressure “off” purge position (Horizontal)

Put control valve on maximum pressure hold for two line system or adjust pressure manually with control valve for single line system.

11. CAR WILL NOT


Pressure and return lines are inversed. This may over pressurize the system and de-couple the safety clutch on the machine pump. If so refer to #8 for repair action.

Make sure that red is on the pressure side and black is on the return side.

CC4300


Page 3 of 4

PROBLEM CAUSE REPAIR ACTION 12. NO PRESSURE

(during cleaning procedure) New machine or filter needs to be primed

Remove filter, fill with gas, re-install loop red and black hose with UMM adapter. Fill the gas reservoir with gas, hook up the machine to battery red to(+) black to car ground, start the machine. Put the control valve to maximum pressure hold, watch for fluid to return to tank. Once you have flow, stop machine and hook up to car to perform service.

13. NO PRESSURE

(or low pressure) (during cleaning procedure)

Loss of prime after doing a service and letting the machine run dry. Usually occurs when service is unattended by technician.

Follow priming instruction #12

14. NO PRESSURE

(during cleaning procedure) Inversed battery leads, makes pump turn backwards, builds no pressure

Install leads, red to (+) black to car ground.

15. NO PRESSURE

(after very high pressure)

Magnetic clutch on pump is de-coupled

After 160 PSI or higher, clutch decouples. To reset, stop pump (power off) for more than 10 secs and restart.

16. NO PRESSURE

(during cleaning procedure) Control valve is in purge position

Put control valve in correct position. (maximum pressure hold) “Vertical”

17. NO PRESSURE

(during cleaning procedure) Filter is not tight enough or air gets in at adapter or fittings are loose

Check and tighten filter and all fittings on the suction side of the pressure plumbing system to stop air intake to the pump.

CC4300


Page 4 of 4

PROBLEM CAUSE REPAIR ACTION 18. NO PRESSURE

(or very low pressure) (during cleaning procedure)

Sticky check valves on pressure or return line. Common on machines that are rarely used.

If filter is more than 3 months old or more than 50-60 services, change. Empty tank and machine completely. Use an open end adapter on (red) pressure line

and drain all fluid into waste container. Refill filter with fresh gas and re-install. Refill machine completely with fresh gasoline

only. Loop red (pressure) and black (return) hose

together using UMM adapter and the decarb valve in open position. Start machine with control valve in purge

position (horizontal), let it run 5 min. Turn control valve to maximum pressure

position (vertical) and let it run 5 min. Slowly close the decarb valve until you have 40-

60 psi in system. Let machine run for 30-40 min. This will

dissolve any accumulation of cleaner in machine. This is more likely to occur on a machine that is

not used frequently. SUGESTION: This should be done on a monthly basis as a preventive maintenance.

19. PRESSURE

GAUGE IS CAVITATING

Low fluid in machine tank, this creates a whirlpool effect at the bottom of the tank and lets air in the system which makes gauge needle oscillate erratically

Add more gas cleaner mixture to the machine tank.

20. PRESSURE

GAUGE IS CAVITATING

Air is entering the system between tank and pump if tank is more than half full

Refer to #17 of the trouble shooting guide to stop air in the system.

Documents

Diagnostic Cleaning Service Training Manual