HD TransTech Manual
Contents
1. NOTE Use hoses 064 4012 200 1033 In Standard Adaptor Kit Appendix C Parts Service Parts for the INDUSTRIAL TRANSTECH Please refer to the part numbers below when ordering parts for the unit Part Description 010 6106 Swivel caster 5 dia non locking 010 6107 Swivel caster 5 dia with wheel lock 011 0060 Hose bracket black texture 010 1030 Adapter Box 100 8702 1607 Bottle for Adaptor Box 010 6060 Reservoir cap 011 0062 Handle black texture 020 1019 Harness power 020 1601 Internal Light 040 0612 Screw Allen Head 14 20 x Handle 040 0613 Screw Phillips stainless steel 6 32 Rear panel 040 0623 screw Allen Head 8 32 x 5 8 Control Panel 040 1200 Screw 5 8 php x 6 for adapter box 040 2000 Flat washer 6 for adapter box 040 2200 Threaded Standoff for adapter box 050 3001 Check valve disposal hose 060 5810 Cap plug handle 080 0243 Female Quick Disconnect Couplers 3 4 Brass 200 8732 Output Return hose assembly 200 8612 Disposal hose assembly 200 8236 Operators Manual Industrial Transtech 200 3107 Adapter Kit standard See Appendix B of this manual for individual adapter part numbers In the U S 800 841 8810 714 558 4822 ORDERING PARTS Parts for the unit may be ordered by calling Customer Service have your model and serial numbers available Outside the U S Contact Your Local Distributor2. ELM ED an C 1 Waern axe nee cece ree ee eee C 1 System Features and Functions The front of the INDUSTRIAL TRANSTECH cabinet contains the control panel the fluid fill neck for adding new transmission fluid and the fluid level windows See page 1 4 for complete theory of operation Front View Control Panel Features and Functions Change Fluid button Drain button Low Vehicle Fluid warning light Complete light Engine Start On warning light Engine Stop Off warning light Fill button Low Clean Fluid warning light Fill Additional fluid count lights Stop button Empty Waste button INDUS TRIAL TRANSTECH TRANSIWISSIUN FLUID AUTOMATIC TRANSMISSION FLUID ONLY e Starts exchanging used fluid for new fluid Service in progress mode e Starts the unit during the Prime procedure e Drains fluid from vehicle s transmission when performing the drain pan procedure e Provides momentary drain function when the units Complete light is illuminated Illuminates when e Vehicle transmission fluid is two quarts low e When vehicles transmission is empty at end of drain pan procedure Illuminates when e The service procedure has been completed The stop button has been pressed amp unit s alarm is not sounding Flashes when the vehicle s engine needs to be started e lluminated constantly when vehicle s engine is running
3. ENGINE START ON light should be ON solid NOTE Transmission fluid will circulate through the unit and return to the vehicle s transmission when unit is off bypass mode If no flow is indicated 9 And the start up alarm does not sound when the engine 1s started or the unit does not commence service when the CHANGE FLUID button is pressed Check filter and transmission fluid cooler for blockage Filter Change If the vehicle s transmission is to be removed perform the following steps before removal of the transmission oil pan If not go to step 8 NOTE 10 NOTE 1 Follow steps 1 6 note fluid level the WASTE tank then press the Drain button allow 10 qts of fluid to drain if the vehicle is equipped with a shallow pan Drain 12 14 qts of fluid if the vehicle is equipped with a deep transmission pan It is possible to drain the transmission pan through the drain plug if so equipped If the pan is drained manually it is necessary to add new transmission fluid manually trough the normal channel usually the dipstick tube before proceeding with service CAUTION Letting the transmission run for an extended period of time without fluid can cause serious damage to internal components b Stop the vehicle s engine The machine will sound an alarm and flash the LOW VEHICLE FLUID and ENGINE STOP OFF lights Press STOP button once to turn alarm off d Replace or clean the ve
4. 1 9 must be performed BEFORE first time operation and or any time the unit s reservoir is completely drained of fluid Transmission service procedure Follow the steps below to connect the unit to the vehicle s transmission cooler lines Make sure the vehicle has at least 1 8 tank of fuel before beginning this process IMPORTANT Do not perform the transmission service if the vehicle s engine oil or coolant level is low lf necessary add motor oil and or coolant M WARNING AWARNING AWARNING AWARNING Flammable Liquid can squirt out of pressurized lines when connecting or disconnecting Verify that engine and machine are both off before connecting or disconnecting cooler lines or adapters Wear safety goggles Wear chemical resistant gloves when connecting or disconnecting fittings and adapters Wrap a shop towel around pressure fittings and adapters when disconnecting Avoid exposure to flames sparks hot engine parts and other ignition sources Explosion or flame or exposure to flammable liquid and vapors can cause injury 1 Add the correct amount of automatic transmission fluid into the INDUSTRIAL TRANSTECH S clean tank reservoir See vehicle s service manual for fluid quantity 2 Start engine let run until it reaches operating temperature turn engine OFF 3 Locate and disconnect the cooler line at the easiest connection point Atcooler line connection to radiator Atheat exchanger e At filter co
5. amp the unit senses fluid pressure Flashes when the vehicle s engine needs to be stopped e lluminated constantly when the vehicle s engine is OFF Adds a pre programmed amount of fluid to the transmission at beginning of service e Adds a pre programmed amount of fluid to the transmission after the Drain procedure e Provides momentary fill function when the units Complete light is illuminated Illuminates when the clean fluid tank in the machine is empty zero level Will illuminate according to the amount of pre programmed fluid that will be added Stops units pump amp completely resets unit f alarm is not sounding e Stops units alarm if alarm is sounding Empties used transmission fluid from the unit s waste tank Left View A Adaptor Tray Output Return Hose Disposal Hose Serial Number Plate Tank filler neck Not shown F Quick Coupler G Disposal Hose Check Valve e bj Used to store the unit s adaptors Connects to the Transmission s cooling system Inserts into the shop s fluid recycling receptacle or into a suitable container approved for storing used transmission fluid Identifies the unit s model amp specific manufacturer s production number Access port to add new transmission fluid to the unit s new fluid tank Secures the needed service adaptors to the unit s output return hose assemblies Prevents excessive drainage from waste hose opens automatically when EMP
6. lines to their original connection ports 13 Start the engine check cooler lines for leaks and re tighten as necessary 14 Step on the foot brake firmly then slowly shift the gear lever to Low Gear first gear then back to Park Check the transmission s fluid level adjust 1f necessary Service tip To minimize fluid mixture a Pan Drain procedure may be performed without removing the transmission pan A Follow steps 1 6 from this section Perform Filter change procedure steps a b c g h C Continue with steps 8 amp 9 Troubleshooting and Additional Help Refer to the list below in the unlikely event that you have problems with your INDUSTRIAL TRANSTECH Transmission Service System Problem 1 Unit does not power up no LEDs are lighted 2 Unit does not sound the start up alarm 3 The start up alarm sounds and an intermittent alarm sounds 30 40 seconds after pressing the Change Fluid button 4 Unit stops and alarm sounds 30 40 seconds after pressing the Drain button 5 An intermittent alarm sounds during the Transmission Service Procedure and the ENGINE STOP light is flashing 6 The level in the transmission is 2 qts low after service 7 New fluid is above the 2qt line but the LOW CLEAN FLUID light is ON 8 Theunit performs poorly Solution Polarity is reversed on vehicle battery connection Check connection to battery for a loose condition No fluid pressure 1s reaching t
7. E HEAT EXCHANGER FILTER BASE Filter Side Marked OUT 064 3100 12 JIC X 1 MALE PIPE HEAT EXCHANGER FILTER BASE Filter Side Marked OUT PART Qty Application 064 4100 rm 12 JIC X 1 FEMALE PIPE 4 HEAT EXCHANGER FILTER BASE Filter Side Marked OUT 064 4021 12 X 16 JIC REDUCING MALE UNION COOLER LINE 064 4022 NOTE TWO PARTS 16 nut swivels on 12 union 12 X 16 JIC FEMALE UNION COOLER LINE Optional HEAVY DUTY TRANS Adapters The following TRANS adapters have been added to the INDUSTRIAL TRANSTECH adaptor line up The adapters listed are not included with any configured adapter sets amp must be purchased separately from MotorVac Technologies Inc PART amp NO APPLICATION International Harvester Trucks Late Model Application Note These three pieces are sold as a kit 064 4111 064 4111 12 X 12 SAE MALE UNION 064 4112 COOLER LINE 064 4112 12 SAE FEMALE to MALE COOLER LINE 064 3020 20 JIC MALE NIPPLE Use with 064 4020 and 064 4012 064 4020 20 JIC FEMALE ADAPTOR NOTE TWO PARTS 20 nut swivels on 12 union Optional HEAVY DUTY TRANS Adapters Continued PART amp NO APPLICATION 064 4114 Plate 050 1931 Base 200 1033 080 1201 O Ring 1 1 8 x 16 THD 080 1202 O Ring 545 ALLISON TRANSMISSION WITH SPIN ON FILTER Baldwin BT230 Donaldson P55 5570 Fleetguard LF3342 PH3519A 064 4115 12 JIC x
8. MOTORVAC TECHNOLOGIES INC INDUSTRIAL TRANSTECH Transmission Service System Operator Manual PDF VERSION Table of Contents 1 eme EE RTT Error Bookmark defined eA AERE Error Bookmark not defined System Features and FUNCIONS 1 1 Control Panel Features FUNCUONS 1 1 We 1 3 sete tote ete te ace area Pe 1 4 THEON m 1 5 Safety Inrormalloh 3 eo ee 2 1 Before You BO 3 1 ODN 3 1 Transmission Service Procedure 12 4 1 Troubleshooting and Additional Help 5 1 Appendix Maintenance eco A 1 Maintenance Procedules iiec 1 Cleaning the Units Filter Screen Exe RU 1 MialiSnanmeEe p 218 0180 ht 3 Appendix B System Accessories ee B 1 RT Lc B 1 Appendbc C P afle Emr en Pa Oe ee ene ee eee DU LLL err eer fore errr re C 1 nn lr ui A M
9. TOP button TWICE The first press will stop the alarm and the second press will stop the pump Safety Information and Precautions DANGER Vehicle exhaust gases contain Carbon Monoxide which 1s a colorless and odorless lethal gas Only run engines in well ventilated areas and avoid breathing exhaust gases Extended breathing of exhaust gases will cause serious injury or death M WARNING Exhaust gases moving parts hot surfaces are present during and after the vehicle s engine is running Read and understand the operator s manual before using the TRANSTECH Service system When using petroleum products always refer to the MSDS sheets and manufacturer s instructions for the proper procedure to handle emergency medical treatment cleanup handling and storage requirements Improper use of the INDUSTRIAL TRANSTECH Transmission Service System or exposure to exhaust gases can cause Injury Spilled transmission fluid on an engine can ignite Avoid exposure to flames sparks hot engine parts and other ignition sources Always keep fully charge fire extinguisher nearby The extinguisher should have a class B rating and be suitable for gasoline chemical and electrical fires Cleanup any oil spills immediately Dispose of contaminated cleanup material according to governing environmental laws Never look directly into the air induction plenum or carburetor throat when the engine is operating Always verify hose connections to th
10. TY WASTE button is pushed Right View A Output Return Hose B External Power Harness w Battery Clamps C Quick Coupler D Adaptor Tray Connects to the Transmission s cooling system Positive Red battery connection Negative Black battery connection Secures the needed service adaptors to the unit s output return hose assemblies Used to store the unit s service adaptors Theory of Operations Detailed descriptions of the various operations control buttons and indicators that make up the control panel are listed below OFF MODE e When the unit is connected to power an alarm will sound indicating power up Fluid will be re circulated to the vehicle s transmission e When the vehicle is started the unit will sound an alarm indicting that fluid and pressure from the vehicle have reached the machine and it is ready for service CHANGE FLUID If pressed before draining the transmission pan at beginning of service the unit will automatically rout the used fluid from the vehicle s transmission into the unit s WASTE tank and supply an equal amount of new fluid from the unit s CLEAN fluid tank to the vehicle If pressed after the transmission fluid was drained using the DRAIN button the machine will add to transmission the equal amount of fluid collected during the drain mode plus the amount entered manually using the FILL button see FILL section once this amount is added to
11. atically etc See chart below FILL ADDITIONAL FLUID COUNT LIGHTS First light on 1 2 qt Second light on 1 qt First and second lights on 1 qts Third light on 2 qts Third and first lights on 212 qts Third and second lights on 3 qts All lights on 3 qts Maximum fluid added automatically Pressing the Fill button once more will turn all lights off LOW CLEAN FLUID The light will be on when the CLEAN FLUID tank is empty COMPLETE e The COMPLETE light will turn on when clean fluid tank is empty or the STOP button is pressed The unit will automatically revert to re circulating mode ENGINE START ON e The light will flash if the engine needs to be started to continue The light will be on constantly when the engine is running or if the machine s system 15 pressurized over 4 psi ENGINE STOP OFF e The light will flash if the engine needs to be stopped turned off e The light will be on constantly when the engine 1s not running EMPTY WASTE e The light will be on when the waste fluid is at or over 4 quarts in the WASTE tank The unit will not run unless the level in the waste tank is less than 1 4 full approximately 4 qts STOP e Will turn off an alarm without stopping the service when sounding Will stop the pump and revert the system to recirculating mode if no alarm 15 sounding NOTE Ifthe unit needs to be stopped completely while an alarm is sounding press the S
12. e transmission s oil cooler lines before starting the vehicle s engine Explosion or flame or exposure to flammable liquid and vapors can cause injury Flammable liquid transmission fluid can splash out of reservoir when filling or when unit is being moved Always keep Reservoir Cap secure except when filling reservoir Explosion or flame can cause injury Transmission cooling systems may maintain residual pressure in connection lines to and from transmission and cooler radiator even after the engine has been turned off Wear safety goggles Wear chemical resistant gloves when connecting or disconnecting fitting and adapters Chemicals can cause harmful byproducts do not add any chemicals to INDUSTRIAL TRANSTECH s reservoir tank Use only approved automatic transmission fluid Do not swallow or ingest any chemicals Use with adequate ventilation Avoid breathing vapors Do not store chemicals in or on the machine other than automatic transmission fluid Improper use of transmission fluid can cause injury Over exposure can have harmful effect on eyes skin respiratory system and possible unconsciousness and asphyxiation Improperly blocked vehicles can move Set the parking brake and chock the wheels Moving vehicles can cause injury Moving engine parts The engine cooling fan will cycle on and off depending on the coolant temperature and could operate without the engine running Wear safety goggles Always k
13. eck waste tank level switch wire connctions The low level switch on the new fluid tank has become disconnected Remove unit s back panel and check the clean tank level switch wire connections Check all hoses and wires for cuts or frays Check cabinet for dents or impact markings Verify that the filter screen has recently been cleaned Refer to the maintenance log in Appendix A to view dates of services performed ADDITIONAL HELP Please verify that items 1 6 above have been reviewed before calling for additional assistance In the unlikely event that problems persist with the unit call Technical Support have your model and serial numbers available before you call Remember to send in your warranty card In the U S Outside the U S 800 841 8810 Call your local distributor Standard Adapter Kit The most commonly used application are listed below however other applications may apply PART Application m DII Jit E 1 064 3008 8 X 12 NIPPLE COOLER LINE 064 3010 10X X 12 JIC NIPPLE COOLER LINE 064 3012 12 X 12 JIC NIPPLE COOLER LINE 064 4008 8 JIC FEMALE COOLER LINE 064 4010 10 JIC FEMALE COOLER LINE il LETT ZII 064 4012 12 JIC FEMALE COOLER LINE 064 3034 10 JIC X 4 MALE PIPE HEAT EXCHANGER FILTER BASE Filter Side Marked OUT 064 4034 12 JIC X 4 FEMALE PIP
14. eep objects clothing and hands away from the cooling fans and engine parts Moving engine parts can cause injury Hot surfaces are present during and after running the engine Do not contact hot surfaces such as manifolds pipes mufflers catalytic converters or radiators and hoses Hot surfaces can cause injury Catalytic converters become extremely hot Do not park a converter equipped vehicle over dry grass leaves paper or any other flammable material Do not touch a catalytic converter until the engine has been off for at least 45 minutes Catalytic converters can cause burns Cracked fan blade can become airborne Examine fan blades for cracks If found do not service the vehicle Flying objects can cause injury Batteries produce explosive gases and can explode Wear safety goggles when working on or near batteries Use in a well ventilated area Keep sparks and flames away from the battery and never lay tools equipment or other conductive objects on the battery When tools or equipment are connected to the battery make sure the equipment power switch is off Connect the positive lead of the equipment to the positive lead battery first connect the negative lead of the equipment to a solid ground point as far from the battery as possible Keep battery acid away from skin or eyes In case of eye contact flush with clean water for 15 minutes and get medical attention Battery explosion and ignited gases can cause
15. he machine See Transmission Service Procedure page 4 2 steps a b and c also see steps 3 and 4 of this page Fluid flow is extrmely slow but enough to pressure the system to 4 psi service ports are opened when Change Fluid is pressed then pressure drops completely this will trigger the alarm Verify flow See Transmission Service Procedure page 4 2 steps a b and c See steps 2 amp 4 of this page No fluid is being received in unit S WASTE tank Check hose connections to adapters Check adapters for a kinked condition Check vehicle s fluid flow See Transmission Service procedure page 4 2 steps a b and c See steps 2 and 3 of this page The transmission fluid level is low 2 qts press STOP button Once this will stop the alarm but not the unit s pump Check transmission fluid level stop engine if fluid is low enough that the dipstick does not reach to measure fluid The unit will sound an alarm when fluid has reached the proper level start engine and proceed with service Check hose conncetions to adapters for proper connection check adapters and hoses for a kinked condition The low level switch from the WASTE tank may have become disconnected previous to starting the service Insert unit s Drain Hose into a waste oil recycling container Press DRAIN WASTE button Verify that the pump stops automatically and that fluid level is still visible though the visual level window If not remove unit s back panel and ch
16. hicle s transmission fluid filter if applicable and reinstall the transmission s oil pan as per shops repair manual and manufacturer s recommendations Note approximate amount of fluid removed from transmission s fluid pan after it was removed from the transmission f Press the unit s FILL button according to approximate amount of fluid removed from the transmission s fluid pan step Press Once 2 qt Twice 1 qt Etc Press CHANGE FLUID button The unit will fill vehicle s transmission according to amount emptied into the unit s WASTE tank and the amount of fluid entered from step f h Start the vehicle s engine when the START ENGINE flashes and alarm sounds Continue with the service until all fluid has been exchanged and the unit stops automatically Press STOP to turn off alarm Quantity of fluid used per vehicle may vary depending on the condition of the fluid in the transmission of the vehicle being serviced Let engine run for one minute then check the transmission s fluid level If level is low a Press and hold the FILL button for 5 10 seconds b Re check fluid level repeat step if necessary If level is high Press and hold the DRAIN button for 5 10 seconds d Re check fluid level repeat step c if necessary Stop engine and let cool off if necessary 12 Disconnect hoses from the INDUSTRIAL TRANSTECH and connect the vehicle s cooler
17. injury Before You Begin First Time Operation Priming Procedure 10 NOTE This unit has been tested with Dextron Automatic Transmission Fluid and is ready for service after receiving inspection of the unit Remember to send in your warranty card to properly register your machine Check the output return hoses battery connections and all external components for damage Fill the unit s reservoir with a minimum of 20 quarts of new transmission fluid Connect two compatible adapters to each other secure tightly Attach the output return hoses together using the proper adapters Insert the Disposal hose into the unit filler neck or into a suitable container if the unit has been used to service a vehicle previously Attach unit s black negative battery clip to a solid ground point as far from the battery as possible do not connect the positive battery connector yet Press the and hold CHANGE FLUID button connect the positive power harness clamp to the vehicle s 12 volt battery allow the unit to run until the EMPTY WASTE light begins to flash then press STOP Press the EMPTY WASTE button let unit run until it stops automatically Press the DRAIN button to release pressure contained within the output return hoses Disconnect power to machine and check new transmission fluid level add if necessary The unit is now ready to perform a service See service instructions for procedure NOTE Steps
18. nnection Side marked OUT of filter base e At cooler line connecting to the transmission NOTE Adapters are connected to either cooler line from or to the radiator and or the transmission 4 Install the proper adapters onto the disconnected lines 5 Connect the FLOW DIRECTION INDICATOR LOOP H adapter to the previously attached cooler line adapters NOTE The ball valve must be in the closed position The valve handle 1s at a right angle to flow See photo Valve Closed Part 200 8100 Patent Pending 6 Attach the unit to the vehicle s battery by connecting the unit s red battery clip to the positive battery terminal and connecting the black battery clip to a solid ground point as far from the battery as possible The ENGINE START ON light will be flashing NOTE Connect to 24 volts whenever possible 7 Start the vehicle s engine Note the direction of flow dirty oil from the cooler lines right or left side of the adapter After determining direction of flow rotate the valve handle 90 counterclockwise Transmission 15 now ln closed loop or bypass operation 8 Attach the units hose marked Dirty Oil to the side of the H adapter that indicated flow from the vehicle dirty side Attach the hose marked Clean Oil to the side of the adapter that indicated flow to the vehicle Once unit s lines are connected to the H adapter close the H adapter valve handle The
19. sion s fluid level before beginning the service and the level in the transmission is gt of a quart low the FILL button should be pressed once The light above qt indicator will light This amount of fluid will automatically be added to the transmission during the service The alternative action would be for the technician to add the correct amount of fluid manually to the transmission before starting the service e If pressed after DRAIN mode the unit will add the amount of fluid entered according to the lights that are lighted under the FILL button see chart in this section EXAMPLE When the transmission fluid pan is to be removed the technician will press the DRAIN button the unit will empty fluid until the filter cannot pull any from the pan Once the pan is removed there will be some fluid left at the bottom of the pan this fluid is emptied manually into the shop s recycling container When this happens the machine will not account for the fluid that was removed manually The technician should calculate the amount of fluid removed manually then press the FILL button according to the amount calculated If pressed when the COMPLETE light is ON but the LOW CLEAN FLUID light is OFF First press the pump will run continuously Second press 2 qt light will turn on the unit will add half of a quart and stop automatically Press three times the 1 qt light will turn on and the unit will add one full quart and stop autom
20. the transmission an alarm will sound and the ENGINE START light will flash At this time the technician should start the engine Once started the machine will automatically rout the used fluid to the WASTE tank and supply new fluid into the vehicle s transmission Note Fluid level in the transmission may vary during service Level will be adjusted automatically at end of service e If pressed and held while power is connected to unit the unit s computer will commence the PRIME mode This procedure 15 used any time the waste tank is drained completely DRAIN e If pressed at beginning of service fluid will be drained from the vehicle s transmission into the machine s WASTE tank until no fluid 15 received from the vehicle s transmission An alarm and ENGINE STOP light will be activated when the transmission fluid pan 15 empty e The machine s computer will account for the amount of fluid collected in the WASTE tank during the DRAIN mode If pressed after service The COMPLETE light is lit fluid will drain only as long as the button is pressed flow will stop when the button is released FILL If pressed at beginning of service for every time pressed the unit count 5 of a quart a light will turn ON to indicate the amount entered see chart In this section The unit will automatically add the amount of fluid indicated to the overall fluid level of the transmission EXAMPLE When the technician checks the transmis
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