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Contents
1. The unit is in the DRAIN RECOVERY TANK mode 1 5 Introduction Specifications Dimensions Height Width Depth 41 5 33 25 75 Weight 123 Ibs tanks empty Power Compressed shop air 90 PSI Operating Temperature 0 to 120 F 17 8 to 48 9 C Storage Temperature 4 to 150 F 20 to 65 5 C 1 6 Testing Tips Installation and Operation O When servicing coolant systems the coolant in the overflow bottle should also be removed Use the suction wand to remove the coolant O When performing a Pressure Test if coolant seeps into the overflow bottle before the system is at the pressure specified on the radiator cap the pressure relief valve is bad and the radiator cap needs to be replaced DO NOT OVER FILL THE SYSTEM O Normal expansion rate for coolant is 4 796 Fill overflow bottle after the engine reaches normal operating temperature to assure system will not be overfilled An overfilled system will expel any additional coolant during normal system expansion O When looking for coolant leaks Check all hose connections prior to in operation and after all tests are performed Check heater core water pump thermostat housing freeze plugs and radiator for any visible leaks Water pumps are sometimes located under timing belt covers f leaks are evident but no visible leaks are found check the internal engine The leak may be from a cracked head head gasket intak2. 3 Turn Valve A to the left pointing to the DRAIN position 4 Perform Drain and Fill if desired Radiator or Surge Cap Pressure Ranges 4 PSI Cap 3 5 Ibs 7 PSI Cap 6 8 Ibs 10 PSI Cap 9 11 Ibs 13 or 14 PSI Cap 12 16 Ibs 15 or 16 PSI Cap 14 18 Ibs 18 PSI Cap 16 20 Ibs 20 PSI Cap 18 22 lbs 30 PSI Cap 28 30 Ibs Subtract one Ib from Ibs reading for used caps e g 15 or 16 PSI Cap would be 13 18 Ibs Table 2 1 Cooling System Pressure Ranges Drain and Fill Conventional Thermostat Location Follow this procedure to drain and fill the cooling system 1 Verify recovery tank of the DF1000 unit is not full and there is enough room left to complete a Drain and Fill process 2 Verify supply tank level of the DF1000 unit is adequate enough to complete a Drain and Fill process 3 Pinch off overflow hose between radiator neck and overflow reservoir with supplied hose pinch pliers 4 On vehicles with a heater hose connected to the radiator pinch off heater hose also Use two or three hose pinch pliers to pinch off hoses connected to surge tank including the overflow hose connected to the surge tank neck if applicable 4 Make sure all hose valves are closed 5 Make sure adapters and hoses are connected to vehicle as described in Pressure Test in this chapter 2 7 Installation and Operation 6 Turn Valve A to the left pointing to the DRAIN position 7 Turn Valve B up pointing to the DRAIN a
3. gauge reads zero before removing supply tank cap Flying particles can cause eye injury SAVE THESE INSTRUCTIONS IV Table of Contents I eeaeee Eee eA Rr AEE A E E AE E A Aa AE e E Ae E E Ea l laldgoXo tt ea dlo i PEE A E E 1 1 Functional DescriptiOD acide nee tapete tnde otc see KERERE REAREA KRAE EUREKA REREN SEEE ERa 1 1 Front Panel zeriona a O ine an o sR I RNV MEUSE 1 1 Back Panel TEE 1 2 ericllcurlgee c H 1 3 hercle 1 4 Key TOMS Seite tentem iuge it ue paxeeian bin arts O 1 5 lepus 1 6 Installation and Operation iunsedskeusxansudsaaubnd aiu daa upux asa daa pana D RR OUR APR RON RI MU d QUA 2 1 Testing TIPS cimi eto E rndexaaiiabetke dc e UNI RID LO edetudus 2 1 Valve Position Chart Tc 2 2 Preparing Vehicle for Service ssssssssssssessssseseeneeenee nennen nenne tnn enne nnne nenne 2 4 Frossure TeSt 2 4 picante a E T ieee 2 7 Power Drain Recovery TanK sairsassanirarieeaiai aeoiee aiana OEE nennen nnn RAKERA EAER 2 10 Recycle Used Coolant from Recovery Tank ssssssssssssseseeeee mener nnns 2 11 Maintenance eese eesepranasunaakbaa aga nahbERaeuFRERREERAERFARARFERREREARRRFAREVENASRRFKERES FARE RFUNAREFEREEKUs 3 1 Cleaning Recovery Hose Strainer ssessssssssssssssssseeeeeeee nennen nennen nnn nnns 3 1
4. the manufacturer of the vehicle or equipment being tested Read All Instructions Read understand and follow all safety messages and instructions in this manual Safety messages in this section of the manual contain a signal word with a three part message and in some instances an icon Safety Information The signal word indicates the level of the hazard in a situation DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury to the operator or bystanders WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury to the operator or bystanders CAUTION indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury to the operator or bystanders IMPORTANT indicates a situation which if not avoided may result in damage to the equipment or vehicle Safety messages in this section contain three different type styles Normal type states the hazard Bold type states how to avoid the hazard Italic type states the possible consequences of not avoiding the hazard An icon when present gives a graphical description of the potential hazard IMPORTANT SAFETY INSTRUCTIONS General AWARNING AWARNING Risk of fire Wear safety goggles and protective gloves user and bystander Everyday eyeglasses only have impact resistant lenses they are NOT safe
5. 2 PSI Open drain hose valve and drain used coolant d Properly dispose or recycle used coolant Installation and Operation Recycle Used Coolant from Recovery Tank Used coolant in the recovery tank can be filtered using the optional Drain and Fill Add on Recycler kit part number EAK0239L01A see a White Industries dealer for details If the optional recycler kit is installed follow these steps to recycle coolant 1 2 8 Close all hose valves on the DF1000 unit Turn Valve A to the left pointing to the DRAIN position Turn Valve B down pointing to the DRAIN RECOVERY TANK position Remove supply tank fill cap if recycled coolant is to be directed to the supply tank Connect shop air to the DF1000 unit and adjust air regulator valve to achieve 8 12 PSI Turn manual valve on recycler kit to the RECYCLE position Position end of drain hose to direct filtered coolant into the supply tank or other coolant collection container Open drain hose valve and drain filtered coolant d Add proper additives to the filtered coolant 2 11 Installation and Operation Maintenance Use this chapter to maintain the DF1000 unit 4 Troubleshooting information and a list of parts and accessories are also included Cleaning Recovery Hose Strainer The recovery hose strainer needs to be cleaned after every Drain and Fill operation Follow this procedure to clean the strainer 1 U
6. Safety Information Safety Notice For your safety read this manual thoroughly before operating your DF1000 unit Your DF1000 unit is intended for use by properly trained skilled professional automotive technicians The safety messages presented below and throughout this user s manual are reminders to the operator to exercise care when using this unit There are many variations in procedures techniques tools and parts for servicing vehicles as well as in the skill of the individual doing the work Because of the vast number of test applications and variations in the products that can be serviced with this instrument White Industries cannot possibly anticipate or provide advice or safety messages to cover every situation It is the automotive technicians responsibility to be knowledgeable of the system that is to be tested It is essential to use proper service methods and test procedures and to perform tests in an appropriate and acceptable manner that does not endanger your safety the safety of others in the work area the vehicle or equipment being tested It is assumed that the operator has a thorough understanding of vehicle cooling systems before using the DF1000 unit This understanding of principles and operating theories is necessary for competent safe and accurate use of this instrument Before using your DF1000 unit always refer to and follow the safety messages and applicable test procedures provided by
7. TROUBIGSMOOLING rU 3 2 Replacement Parts E c 3 3 Optional Accessories pr HERREN RXRR UR D ER aden Ext ERA Rneerbx S E RISQM EEA 3 3 Table of Contents es Table of Illustrations Introduction Figure t 12 Front Panel 2 2 Las ete Heb eg A Lee pee nde ee od nd 1 1 Figure 1 25 Back Panel ar tit he GEM ee 1 2 Figure 1 3 Control Panel 2 eee ec pel n t tein tete c e Loved b Dre aor SER Bee 1 3 Figure 1 4 DF1000 Accessories seesssssssesssseeeseeen nennen enne nn nenne nnne 1 4 Installation and Operation Figure 2 1 Recovery Hose and Adapter Attached to Radiator seseseeseseesss 2 5 Figure 2 2 Supply Hose and Adapter Attached to Engine ccceceeeeeeeeeeeeeeeeeeeeeeenaees 2 5 Table 2 1 Cooling System Pressure Ranges ssssssssssesenene mener 2 7 Maintenance Figure 3 1 Strainer Assembly siir neto n lade e HERR ERR RR ERE C FRE Mexx een ges 3 1 iii Table of Illustrations Using this Manual This manual contains instructions for use and setup of your DF1000 unit A table of contents and table of illustrations are provided to make this manual easy to use Some of the information shown in text or illustrations is obtained using optional equipment Conventions This section contains a list of conventions used in text Check Note A check note provides additional information about the subject in the preceding paragraph Example 4 A pulsating re
8. Tank recovery tank and hose Recovery and supply hose Reverse recovery and connections reversed supply hose connections refer to Drain and Fill Recovery hose strainer is Clean strainer refer to blocked with debris Cleaning Recovery Hose Strainer Machine does not Supply tank level too low before Add coolant to supply completely fill cooling starting drain and fill process tank and repeat fill cycle system with new coolant 3 2 Maintenance Replacement Parts Part Number Description EAAO196L47AR sess Suction Wand Assembly EAAO0195L26AR ss Radiator Adapter Assembly 1 1 4 to 1 3 8 EAA0195L27AR ess Radiator Adapter Assembly 1 1 2 to 1 3 4 8 850 cons uod iut Hose Pinch Pliers Large 86 950 din tte tie re osten s Hose Pinch Pliers Medium 8 141504 hore cote end Hose Pinch Pliers Small 5 4835 030 Rubber Coolant Hose 1 1 4 I D 5 4935 030 Rubber Coolant Hose 1 3 8 I D 5 5035 030 Rubber Coolant Hose 1 1 2 I D 5 5135 030 Rubber Coolant Hose 1 3 4 I D Optional Accessories EAKO239LO1A eme Drain and Fill Add on Recycler Option Kit 3 3 Maintenance 3 4
9. covery hose red is a normal condition while draining Equipment Tips Equipment tips provide information that applies to specific equipment Each tip is introduced by this icon O for easy identification Example O When servicing coolant systems the coolant in the overflow bottle should also be removed Use the suction wand to remove the coolant Using this Manual Safety Messages Safety messages are provided to help prevent personal injury and equipment damage All safety messages are introduced by a signal word indicating the hazard level The types of safety messages are Indicates an imminently hazardous situation which if not avoided will result in death or serious injury to the operator or to bystanders Indicates a potentially hazardous situation which if not avoided could result in death or serious injury to the operator or to bystanders Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury to the operator or to bystanders Some safety messages also contain visual symbols with signal words Example pe Engine systems can malfunction expelling fuel oil vapors hot steam hot toxic exhaust gases acid refrigerant and other debris Wear safety goggles and protective gloves user and bystander Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses Engine systems that malfunction can cause injury vi Introd
10. e etc Installation and Operation Valve Position Chart Refer to this quick reference for correct valve positions during operations Valve A Valve B Supply Hose Recovery Hose Valve Valve SUCTION WAND apio CLOSED OPEN E PRESSURE APPLY TEST CLOSED l oe PRESSURE HOLD TEST IL CLOSED DRAIN EVACUATE oP Installation and Operation Valve A Valve B Supply Hose Recovery Hose Valve Valve HOLD E OPEN CLOSED FILL FLUSH DRAIN RECOVERY TANK CLOSED CLOSED l jel f i TOP OFF COOLING SYSTEM E GG OPEN CLOSED d 4 Drain Recovery Tank hose valve must be closed during all operations except Drain Recovery Tank 2 3 Installation and Operation Preparing Vehicle for Service Engine cooling systems run at high temperatures and pressures Allow coolant system to cool before attempting service Pressure Test 4 Pressurized engine coolant may be hot and cause 1 injury Remove radiator or surge tank cap after coolant system has cooled Perform a pressure test on vehicle cooling system before draining or refilling the system Follow this procedure to pressure test the cooling system Refer to Valve Position Chart in this chapter for proper valve positioning during operations 1 2 10 11 Follow the steps in Preparing Vehicle for Service Close all hose valves and air supply valve on the DF1000 unit Turn Valve A to the left pointing to t
11. he DRAIN position Turn Valve B up pointing to the DRAIN and FILL position Connect shop air to the DF1000 unit and turn air regulator knob counterclockwise until it stops Attach suction wand to the recovery hose red Open air supply valve and recovery hose red valve Use suction wand to extract coolant from radiator or surge tank until coolant level is below upper radiator hose port Close recovery hose red valve Close air supply valve if desired to reduce noise Disconnect upper radiator hose from radiator thermostat housing or intake manifold Connect recovery hose red and adapter to radiator side of disconnected radiator or hose refer to fig 2 1 2 4 Installation and Operation Figure 2 1 Recovery Hose and Adapter Attached to Radiator 12 Connect supply hose blue and adapter to engine side of disconnected radiator hose refer to fig 2 2 Figure 2 2 Supply Hose and Adapter Attached to Engine 13 Replace radiator or surge tank cap 14 Open air supply valve and supply hose blue valve Make sure recovery hose red valve remains closed 15 SLOWLY turn the air regulator knob clockwise until gauge pressure reaches the cooling system pressure rating Cooling system pressure rating can be found on radiator cap or verify rating in owner s manual or factory repair manual 16 Turn Valve A to HOLD position when gauge reads the specified pressure and inspect cooling system for
12. ing system contains a bleed screw or cap follow 27 manufacturer s instructions to ensure the system is properly purged of air Start vehicle engine and allow it to run until it reaches normal operating temperature and the thermostat has opened Verify vehicle s heat is operating properly while engine is running 2 9 Installation and Operation Alternate Thermostat Location On some vehicles the thermostat is located at the point where the lower radiator hose is connected to the engine 1 These applications may require connecting recovery hose red to the engine side and the supply hose blue to the radiator side of the upper radiator hose If insufficient coolant flow is observed in the recovery hose red during drain cycle Close air supply valve Wait for gauge to read zero Close hose valves and disconnect hoses from adapters Reverse connection of hoses on adapters and Continue Drain and Fill process Power Drain Recovery Tank The recovery tank needs to be drained when full Shop air is diverted to the recovery tank to assist the draining process Follow these steps to drain the recovery tank 1 2 5 Close all hose valves on the DF1000 unit Turn Valve A to the left pointing to the PRESSURE position Turn Valve B down pointing to the DRAIN RECOVERY TANK position Connect shop air to the DF1000 unit and adjust air regulator valve to achieve 8 1
13. leaks 2 5 Installation and Operation If Leak is Found 1 2 Close air supply valve Position Valve A to the left pointing to the PRESSURE position Close supply hose blue valve when gauge reads zero Drain coolant from vehicle cooling system using the DF1000 unit refer to Drain and Fill in this chapter without performing the Fill portion Disconnect the DF1000 unit from the vehicle and repair leak After leaks are repaired repeat Pressure Test If No Leaks are Found but Pressure Gauge Drops 1 2 Observe pressure gauge Pressure should not drop below pressure indicated in Table 2 1 after 1 minute No pressure drop proceed to Drain and Fill in this chapter If pressure drops check radiator or surge tank cap for inadequate holding capacity If air or coolant is venting into overflow reservoir or out of the surge tank at pressures below those specified in Table 2 1 replace the radiator or surge tank cap If pressure drops and radiator or surge tank cap is okay a leaky head gasket or other internal engine problem may exist Consult factory service and diagnosis procedures for vehicle cooling system Disconnect the DF1000 unit from the vehicle and repair leak After leaks are repaired repeat Pressure Test 2 6 Installation and Operation If No Leaks are Found and Pressure Gauge is Stable 1 Pressure test is complete 2 Close air supply valve
14. mount of coolant so radiator cap if applicable can be removed with minimal spillage 2 8 Installation and Operation 18 19 Close recovery red and supply hose blue valves Remove recovery red and supply hose blue quick couplers from adapters S If coolant is still present in the adapters 20 21 22 23 24 25 26 Reinstall quick couplers on adapters Open air supply valve Open recovery hose red valve long enough to allow a small amount of coolant to be removed from the system then close valve On vehicles with radiator caps remove cap to determine coolant level in radiator When coolant level is low enough adapters can be removed with minimal spillage On vehicles with surge tanks open recovery hose red valve for about 2 seconds to bring coolant level low enough to remove adapters with minimal spillage Close air supply valve Reinstall upper radiator hose Remove radiator or surge tank cap Remove all hose pinch pliers from hoses Fill overflow reservoir or surge tank with new coolant to proper level Top off radiator with new coolant if applicable The supply hose blue can be used with the suction wand to top off the cooling system To fill Connect suction wand to end of supply hose blue Turn Valve A to the FILL position Open air supply and supply hose blue valves Reinstall radiator or surge tank cap 4 If cool
15. nd FILL position 8 Open air supply valve 9 Adjust air regulator to 8 12 PSI 10 Open supply blue and recovery hose red valves and observe old coolant flowing through the recovery hose red into the recovery tank d A pulsating recovery hose red is a normal condition while draining 11 Turn Valve A clockwise to HOLD position when stream of old coolant is replaced by the flow of air A Cooling system hoses will collapse 12 When vacuum gauge reading reaches 13 17 in Hg close recovery hose red valve Gauge should not deviate from 13 17 in Hg If gauge reading drops check system for leaks n some instances the vacuum gauge reading will not reach 13 17 in Hg due to the upper or lower radiator hose collapsing If this occurs continue to step 13 13 Turn Valve A clockwise to FILL position A rush of new coolant will pass through the supply hose blue and into vehicle s cooling system 14 When gauge reads 8 12 PSI open recovery hose red valve to allow more old coolant to flow out of vehicle cooling system 15 Close recovery hose red valve when coolant flow through recovery hose red turns from old to new coolant S Wait for cooling system hoses to fully expand before continuing 16 Close supply hose blue and air supply valves 17 When gauge reads zero open recovery red and supply hose blue valves This will relieve pressure within cooling system and remove a small a
16. nscrew strainer bowl from housing Jf Be careful not to lose rubber bowl gasket 2 Remove strainer screen and clean with running water and or wipe clean with a shop towel 4 Be careful not to deform strainer screen 3 Clean rubber gasket if necessary 4 Re install strainer screen rubber gasket and strainer bowl Strainer bowl should be installed onto housing finger tight 4 Do not overtighten strainer bowl Figure 3 1 Strainer Assembly 3 1 Maintenance Troubleshooting Symptom Possible Cause Remedy Machine does not work Low or no shop air pressure Check shop air works very slow or gauge pressure pressure does not reach desired reading Shop air not connected to Connect shop air hose machine to air supply valve Leaky hose or connection Check shop air and the DF1000 hose connections and fittings e Supply tank fill cap off or not Install or tighten filler cap tight Gauge does not reach Low shop air pressure Check shop air desired vacuum during pressure evacuation cycle Hose s not pinched off on Check all hoses surge tank or overflow tank connected to surge tank and or overflow are pinched off Leaky hose or connection Check shop air hose connections and fittings Machine drains very little Recovery tank full Drain recovery tank or no coolant during drain Check valve on recovery tank refer to Power Drain cycle closed shutting off vacuum to Recovery
17. re and vacuum applied to cooling system B Air Regulator Valve Used to regulate air pressure applied to cooling system C Control Valve A Switches the DF1000 unit between PRESSURE HOLD and FILL FLUSH operations D Control Valve B Switches the DF1000 unit between DRAIN and FILL and DRAIN RECOVERY TANK operations 1 3 Introduction Accessories Figure 1 4 DF1000 Accessories A Suction Wand Used to extract coolant from radiator or surge tank to lower coolant level B Hose Pinch Pliers Small medium and large pliers Used to pinch off hoses C Multi size Hoses and Adapters Used to connect recovery red and supply blue hoses to the vehicle cooling system Adapters sizes are 1 1 4 1 3 8 1 1 2 and 1 3 4 1 4 Introduction Key Terms Vacuum Test l Fill Flush Drain Tank Recycle Use the following definitions for a description of control panel figures REGULATOR Changes the air pressure setting higher or lower HOLD The supply hose blue is closed to allow a vacuum to evacuate the remainder of the coolant in the cooling system PRESSURE Air pressure is applied to the supply hose blue to assist in cooling system draining and pressure testing FILL New coolant from the supply tank is directed through the supply hose blue to fill the cooling system DRAIN and FILL The unit is in the DRAIN and FILL mode DRAIN RECOVERY TANK
18. sk of unexpected vehicle movement Block drive wheels before performing a test with engine running Unless instructed otherwise set parking brake and put gear selector in neutral for standard transmissions or park for automatic transmissions If vehicle has an automatic parking brake release disconnect release mechanism for testing and reconnect when testing is completed Do not leave a running engine unattended A moving vehicle can cause injury Il Safety Information AWARNING Misdiagnosis may lead to incorrect or improper repair and or adjustment Do not rely on erratic questionable or obviously erroneous test information or results If test information or results are erratic questionable or obviously erroneous make sure that all connections and data entry information are correct and that the test procedure was performed correctly If test information or results are still suspicious do not use them for diagnosis Contact White Industries customer services Improper repair and or adjustment may cause vehicle or equipment damage or unsafe operation AWARNING Risk of flying particles Wear safety goggles user and bystander Rotating engine parts can cause flying particles Make sure gauge reads zero before connecting or disconnecting hose connections to adapters Make sure cooling system pressure has been relieved before connecting or disconnecting hose connections and adapters Make sure
19. ty glasses Do not position head directly over or in front of carburetor or throttle body Engine backfire can occur when air cleaner is out of normal position Keep a dry chemical Class B fire extinguisher rated for gasoline chemical electrical fires in the work area Fire can cause death or serious injury Il Safety Information wd Risk of entanglement Do not place test equipment or tools on fenders or other places in engine compartment Keep yourself clothing and tester leads clear of moving parts such as fan blades pulleys hood and doors Barriers are recommended to help identify danger zones in test area Prevent personnel from walking through immediate test area Contact with moving parts can cause injury Risk of expelling fuel oil vapors hot steam hot toxic exhaust gases and other debris Wear safety goggles and protective clothing user and bystander Engine systems can malfunction expelling fuel oil vapors hot steam hot toxic exhaust gases and other debris Fuel oil vapors hot steam hot toxic exhaust gases and other debris can cause serious injury Risk of burns Do not remove radiator cap unless engine is cold Pressurized engine coolant may be hot Burns can cause injury Risk of burns Do not touch hot exhaust systems manifolds engines radiators etc Wear gloves when handling hot engine components Hot components can cause injury Ri
20. uction The White DF1000 unit part number EESE504A is a device that removes and refills engine coolant and also pressure tests the cooling system Coolant is extracted and refilled through the upper radiator hose connection without the vehicle engine running Before coolant refill a vacuum is applied to the cooling system to eliminate any air in the system Functional Description Front Panel Figure 1 1 Front Panel A Supply Tank Fill Port Filler neck for supply tank reservoir B Supply Tank Sight Tube Sight tube used to determine level of fresh coolant in supply tank 1 1 Introduction C Recovery Tank Sight Tube Sight tube used to determine level of used coolant in recovery tank D Control Panel Houses air regulator valve pressure gauge and control valves A and B E Tray Use for tool and adapter storage Back Panel Figure 1 2 Back Panel A Supply Tank Hose blue and Valve B Recovery Tank Hose red and Valve C Recovery Hose Strainer Strainer used to filter large contaminants from recovered coolant D Power Drain Hose and Valve Used for draining of recovery tank E Air Inlet Valve Switches shop air supply ON or OFF Introduction Control Panel Vacuum Test Normal E a s WM NEN e Drain 3 FilV Flush D OE A B Drain Tank Recycle _ Figure 1 3 Control Panel A Air Pressure Vacuum Gauge Used to monitor pressu
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