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ZIM12-00505 Rev. 1

TransTech IV Service Manual

5

SPECIFICATIONS

Power Cord: 10’ (3 m) 12 gauge
Power Supply: 12 volt DC
New Fluid Capacity: 26 Quart (24.6L)
Shipping Height: 41“(104 cm)
Shipping Width: 24” (61 cm)
Shipping Depth: 19” (48 cm)
Shipping Weight: 90lbs (40.8 kg)
Clean pump flow 20°C 1 GPM
Dipstick drain 20°C, 5/16 tube 1 Quart/min

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Summary of Contents for 500-1125

Page 1: ...TRANSTECH IV Transmission Service System P N 500 1125 Service Manual...

Page 2: ...f Contents 1 SAFETY INFORMATION 3 2 SPECIFICATIONS 5 3 FEATURES AND FUNCTIONS 6 4 MACHINE OVERVIEW 8 5 MACHINE SETUP 10 6 BASIC OPERATION 12 7 THEORY OF OPERATION 19 8 TROUBLESHOOTING 22 9 FLUID FLOW...

Page 3: ...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 th...

Page 4: ...mely 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 C...

Page 5: ...NS Power Cord 10 3 m 12 gauge Power Supply 12 volt DC New Fluid Capacity 26 Quart 24 6L Shipping Height 41 104 cm Shipping Width 24 61 cm Shipping Depth 19 48 cm Shipping Weight 90lbs 40 8 kg Clean pu...

Page 6: ...evel windows Front View Control Panel Features and Functions MODE Button Toggles from Inline to Dipstick and enters manual mode for both functions INLINE LED Unit set to Inline exchange when LED is on...

Page 7: ...luminates when the vehicle s engine is running in inline mode The Start Engine LED flashes when the vehicle s engine needs to be started STOP ENGINE LED LED illuminates when the vehicle s engine is OF...

Page 8: ...es fluid flow through the unit when in Inline mode Right Side Features Dipstick Adapter Manifold that is permanently attached to DIPSTICK RETURN hose The manifold allows the CLEAN FLUID hose to be att...

Page 9: ...from the vehicle through this hose The filter protects the unit from debris coming from the vehicle in Inline Mode Disposal Hose Ball Valve Open manually before EMPTY WASTE button is pushed Waste Disp...

Page 10: ...oint as far from the battery as possible 6 Check to ensure the unit is in Inline mode Inline LED is on Press and hold the START button for 5 seconds until the unit sounds the alarm The FILL and DRAIN...

Page 11: ...o will result in waste tank overflowing Connection to Vehicle using H Adapter 1 Connect appropriate adapters to vehicle transmission cooler lines Attach opposite ends to H adapter Ensure valve is part...

Page 12: ...ight should be on solid If pressure drops to zero and START ENGINE light is flashing the hoses may be reversed 4 Press START RESUME button to begin the exchange 5 When fluid exchange is finished the C...

Page 13: ...TransTech connected and engine running press DRAIN When the transmission pan is emptied ATF pressure in the machine drops a buzzer will sound The LOW VEHICLE FLUID and STOP ENGINE lights will flash 5...

Page 14: ...paused fluid will flow through the machine in a bypass loop Adding ATF to Clean Tank It is recommended that the desired amount of clean ATF to be exchanged is added to the Clean Tank before a service...

Page 15: ...IV new fluid tank with the correct type and amount of Transmission Fluid 2 Connect TransTech IV power leads to the vehicle s battery 3 Press MODE button to select Dipstick operation Dipstick indicator...

Page 16: ...red 9 Press FILL button to continue service The unit will refill the same amount of fluid that was drained from the transmission oil pan After the initial Fill sequence the unit will pause and the STA...

Page 17: ...level needs adjustment re insert the dipstick fill drain tube back into the vehicle and adjust the fluids as necessary by pressing the DRAIN or FILL buttons 15 Direct waste hose to a suitable contain...

Page 18: ...unit Follow these steps if it is necessary to completely empty the dirty fluid tank 1 Connect the power cord to a 12 volt DC source 2 Direct the waste hose to a suitable disposal container Open the ba...

Page 19: ...OUTPUT Clean fluid pump turns on 80 voltage to clean pump Inline Solenoid turns on EMPTY WASTE MODE INPUT When the unit powers on with fluid in the waste tank switch open the empty waste LED flashes P...

Page 20: ...LETE INPUT When the Clean Tank Level Switch closes the unit drains until the TransTech has drained the same amount of fluid as it filled OUTPUT Complete LED flashes alarm sounds INLINE AUTOMATIC EXCHA...

Page 21: ...pty PAN REFILL INPUT Press Fill button OUTPUT Clean fluid pump turns on Inline Solenoid turns on PCB stops pan refill based on clean and waste tank pressure transducer values Unit flashes Start Engine...

Page 22: ...reater than 12 VDC Is there continuity on wiring harness and pump wiring Is feedback wire connected to pump YES NO Replace clean pump check valve Replace Clean Fluid pump YES Replace PCB UNIT DOES NOT...

Page 23: ...mp NO NO UNIT WON T EMPTY WASTE UNIT PERFORMS DIPSTICK DRAIN SLOWLY OR NOT AT ALL Is voltage being supplied to the Waste Pump while attempting dipstick drain Note Voltage at pump 50 of supply voltage...

Page 24: ...k wiring Replace Inline Pressure Switch FLUID LEVEL IS CONSISTENLY OFF AT THE END OF THE SERVICE Is the waste tank at zero before the exchange begins YES NO Check waste tank level switch Is the vehicl...

Page 25: ...s while the TransTech is pumping Is the voltage greater than 12 VDC Refer to Unit won t pump clean fluid section of trouble shooting guide Does the unit pump clean fluid Nominal flow rate 20 C approx...

Page 26: ...k fluid level is around the zero mark at the front of the cabinet 2 Hook TransTech IV to 12 VDC power source 3 see picture for this step Set multimeter for voltage and put the probes on the top 2 pins...

Page 27: ...ff NC NO Filter To Waste Receptacle Dipstick Adapter Assembly Check valve on fill port Waste Fluid Off Sol 1 Off NC NO NC NO From Car Sol 2 On P TransTech IV Flow Diagram In Line Drain Mode Clean Flui...

Page 28: ...NO Filter To Waste Receptacle Dipstick Adapter Assembly Check valve on fill port Waste Fluid Off Sol 1 Off NC NO NC NO From Car Sol 2 On P TransTech IV Flow Diagram In Line Fluid Exchange Mode Clean F...

Page 29: ...Off NC NO Filter To Waste Receptacle Dipstick Adapter Assembly Check valve on fill port Waste Fluid On Sol 1 Off NC NO NC NO From Car Sol 2 On P TransTech IV Flow Diagram Dipstick Fill Mode Clean Flui...

Page 30: ...ar Clean Fluid Tank Filter External Dirty Hose 10 ft External Clean Hose 10 ft Dipstick Adapter Assembly Quick Disconnects TT IV Machine Exterior To Trans Cooler Line From Trans Cooler Line Filter Was...

Page 31: ...GE BLUE ORANGE GREEN Clean Fluid Pump 200 1104 P P WHITE WHITE Clean Tank Level Switch 050 2700 YELLOW W RED YELLOW W RED Waste Tank Level Switch 050 2700 Waste Fluid Pump 200 1105 Solenoid 1 Dipstick...

Page 32: ...Pump Clean 2 200 1105 Assembly Pump Waste 3 200 1107 Assembly Solenoid 2 Inline Bypass 4 200 1106 Assembly Solenoid 1 High Flow 5 200 1108 Assembly Solenoid 3 Waste Pump Outlet 6 200 1109 Assembly Fil...

Page 33: ...ick up tube assembly 9 011 0001 Dipstick hanger assembly 3 050 2700 Tank level switch 10 010 1052 Bottle for adaptor tray 4 010 6060 Reservoir cap 11 010 5500 Axle rear wheels 5 200 1604 Internal ligh...

Page 34: ...Nylon 040 2200 Threaded Standoff for adapter box 050 1000 Filter inline MPT 050 1928 Filter for Dirty hose assembly 200 0061 Assembly Dipstick Tube 1 4 x 42 PTFE 200 0085 Assembly Dipstick Tube 5 16...

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