Bg CT6 Reference Manual

Download

Page 1

COOLANT TRANSFUSION SYSTEM

Reference Manual

Page 2

Page 3

BG Cooling System Service

PRODUCTS

BG Universal Cooling

System Cleaner

PN 540

BG Universal

Super Cool

PN 546

BG Universal Cooling

System Sealer

PN 511

Page 4

Specifications

Height: 48.1 inches/ 1.22 Meter

Width: 30.1 inches/.76 Meter

Depth: 17.5 inches/.44 Meter

Construction: Steel frame with heavy duty casters PVC plastic skin and console

Power Requirements: 12 Volt DC

Process Rate: Average transfusion time is 10–20 minutes, depending on condition and model of vehicle

Process Method: In loop with vehicle’s cooling system using pump to assist with delivery of new coolant while transferring used coolant to machine.

MADE IN U.S.A.

Limited Warranty

This product is warranted by BG Products, Inc. to be free of defects in workmanship and materials for a period of one (1) year from the date of purchase by original purchaser. If the product fails within this period, it will be repaired or replaced at seller’s option, provided (1) the product is submitted with proof of purchase date and (2) transportation charges are prepaid to the nearest Service Center. Liability under this warranty is expressly limited to repairing or replacing the product or parts thereof. This warranty does not apply to product or parts broken by accident, negligence, overload, abuse, or if they have been tampered with or altered in any way. This warranty does not apply to service hoses and adaptors which may need replacing due to normal wear. If this warranty does not apply, then the purchaser shall pay all costs for labor, material and transportation.

Note: The use of this apparatus for any purpose other than the services described will render this warranty null and void, as will the use of any chemicals other than the BG products described in this manual. No other warranties are expressed or implied.

Page 5

Page 6

Safety Requirements

Wear safety goggles to

protect your eyes.

Wear Nitrile,® Neoprene®

or PVC gloves to protect

your hands.

Wear a long-sleeved shirt

and rubber or other

protective apron.

The following instructions must be followed before servicing or attempting to place this system into operation and removing or adding fluid to any vehicle cooling system.

1. Carefully read the BG CT6 Reference Manual before beginning vehicle service.

2. Before handling any BG product, read its Safety Data Sheet.

3. A combination of mechanical and local ventilation should be used to prevent operator exposure to noxious fumes.

4. This machine incorporates parts such as snap switches and receptacles that may produce arcs or sparks and, therefore, when located in a garage, should be in a room or enclosure provided for the purpose, or should be 18 inches (46 cm) or more above the floor.

5. Keep all hoses and tools away from moving engine parts.

6. Check all lines and adaptors for cracks and leaks before and after service.

7. Use EXTREME CAUTION when removing radiator cap to prevent being burned by hot fluid escaping from the cooling system. Use EXTREME CAUTION when handling hoses and adaptors on BG CT6 as they can reach the same temperature as coolant.

8. Ensure that the BG CT6 S1 pump switch is in the “Off” (O) position before connecting to power source.

9. DO NOT dispose of any cooling system fluids or filters in a manner that is not in compliance with federal, state or local environmental regulations.

The BG CT6 Coolant Transfusion System is designed to be used only with a vehicle cooling system service. DO NOT use the BG CT6 to pump or transfer any flammable or combustible liquids.

Page 7

Storage drawer

Remote switch box assembly

Power cables

V1 control valve

S1 pump switch

Circuit breaker

Funnel

Service hoses (P and R)

N New coolant container

U Used coolant container

Page 8

Preparing for Service

1. Attach the suction wand to the end of the pump hose (P).

2. Roll BG CT6 to the new (or recycled) 50/50 coolant supply. Be sure S1 pump switch is set to “Off” (O).

3. Connect the power cables to a 12-volt battery or other 12-volt power source.

4. Insert the suction wand into the new coolant supply.

5. Turn V1 control valve to “N”.

6. Turn S1 pump switch to “Remove” (–). This will fill the BG CT6 new coolant (N) container.

7. Turn S1 pump switch to “Off” (O).

IMPORTANT! Do not run pump dry!

The BG CT6 can also be filled by pouring or pumping coolant (using an external pump) directly into the funnel on top of the machine.

To empty the BG CT6 Used Coolant (U) container:

1. Attach the CT6 Waste Fluid Drain Hose to the waste fluid (W) port place the end of the hose into a used coolant receptacle.

2. Attach an air line to the supply air (A) port.

3. Open the ball valve at the supply air (A) port.

4. When the used coolant (U) container is empty, close ball valve at the supply air (A) port

5. Disconnect air line from the the supply air (A) port.

NOTE: Filling the new coolant (N) container and emptying the used coolant (U) container can be done simultaneously.

Page 9

Installing BG Upper Radiator Hose Adaptor

CAUTION! To prevent being burned by hot fluid escaping from the cooling system, allow vehicle to

cool before removing radiator cap!

1. Remove radiator cap and insert the suction wand end of the pump hose (P) as deep into the radiator as possible.

2. Turn V1 control valve to “U.”

3. Turn S1 pump switch to “Remove” (–). Remove enough used coolant to allow for a dry removal of the upper radiator hose, then turn S1 pump switch to “Off” (O).

4. Move the suction wand to the radiator overflow tank.

5. Turn S1 pump switch to “Remove” (–) to remove all the used coolant from it.

6. Turn S1 pump switch to “Off” (O).

7. Clamp off the upper radiator hose about 4–6 inches (10–15 cm) from the end that connects to the radiator. Remove the upper radiator hose from the radiator.

8. Determine the correct size adaptor and matching short hose/adaptor assembly needed for the upper radiator hose. Screw the CT700 adaptors into the base unit—it makes no difference which adaptor goes into which end. Put the loose clamp into place on the hose—do not tighten.

9. Install the CT700 adaptor between the radiator and upper radiator hose and tighten all clamps. Be sure the ball valve on the connector hose is in the open position (handle parallel to the hose).

Note: The CT700 is non–directional.

BG CT6 return hose (R)

BG CT6 pump hose (P)

Radiator

BG Upper Radiator Hose Adaptor

Short hose/adaptor

assembly

Ball valve

Upper radiator hose

PN CT700

Page 10

BG Cooling System Service

PROCEDURE

1. Install one 12 oz. (355 mL) bottle of BG Universal Cooling System Cleaner, PN 540, into the mouth of the radiator.

2. Insert the suction wand into the radiator.

3. Turn V1 control valve half way between “N” and “U”.

4. Turn S1 pump switch to “Add” (+).

5. Turn V1 control valve slowly to “U” to avoid splashing the coolant. Fill the radiator.

6. Turn S1 pump switch to “Off” (O).

7. Replace the radiator cap securely.

8. Start the engine and run at idle 10–15 minutes to circulate the BG Universal Cooling System Cleaner.

9. Stop engine and remove the suction wand from the end of the pump hose (P).

Coolant Transfusion: Engine Off

Systems with thermostat connected to upper radiator hose:

1. Attach the pump hose (P) to the engine side of the CT700.

2. Attach the return hose (R) to the radiator side of the CT700.

3. Close the ball valve on the CT700.

4. Turn V1 control valve to “N”.

5. Turn S1 pump switch to “Add” (+).

Systems with thermostat connected to lower radiator hose

1. Attach the pump hose (P) to the radiator side of the CT700.

2. Attach the return hose (R) to the engine side of the CT700.

3. Close the ball valve on the CT700.

4. Pinch off the small tube that connects the radiator fill neck to the recovery tank. (Failure to

continued on next page

Page 11

Procedure continued from previous page

pinch off this hose may allow the cap to vent coolant under pressure to the recovery tank causing it to fill and overflow.)

5. Turn V1 control valve to “N”.

6. Turn S1 pump switch to “Add” (+).

NOTE: If attempting to do service and the pump stops or flutters (turns off and on repeatedly),* check for flow through the service hoses. If there is flow, the service will proceed without a problem. The fluttering can be stopped by moving the control valve towards the center position (do not completely shut off flow). If there is no flow, check quick coupler connections and verify thermostat location for proper flow direction.

*The BG CT6 system contains a pressure switch that is set to prevent over-pressurizing of the cool-

ing system. Motor will start again when pressure is released.

In the event that flow cannot be achieved with the engine off,

the service can be performed with the engine running.

Coolant Transfusion: Engine Running

1. Reverse the BG CT6 service hoses (P and R) at the BG CT700, so that the pump hose (P) is attached to the side opposite the thermostat. The return hose (R) should be attached to the thermostat side.

2. Open ball valve on BG CT700

3. Start engine and run until it reaches full operating temperature.

4. Close ball valve on BG CT700.

5. Turn V1 control valve to “N”.

6. Turn S1 pump switch to “Add” (+).

7. It will be necessary to pinch off the small hose to the recovery tank to prevent the radiator cap from releasing coolant as the thermostat closes and opens. The pump motor will also likely cycle on and off as pressure builds when the thermostat closes.

Page 12

Removing the CT700 Upper Radiator Hose Adaptor

NOTE: Do not allow the BG CT6 new coolant (N) container to run dry—save enough coolant to refill the overflow tank.

1. When transfusion is complete, turn S1 pump switch to “Off” (O).

2. Turn vehicle engine off.

3. Open the ball valve on the CT700 to release any trapped pressure from the engine.

4. Important! Allow the engine to cool before removing the radiator cap! Remove radiator cap.

5. Disconnect both service hoses (P and R) from the CT700.

6. Attach the suction wand to the pump hose (P) and insert the suction wand deep into the radiator.

7. Turn V1 control valve to “N”.

8. Turn S1 pump switch to “Remove” (–). This will transfer the new coolant in the upper radiator into the BG CT6 new coolant (N) container.

9. Remove the CT700 and reconnect the upper radiator hose securely.

10. Add BG Universal Super Cool,

PN 546, to radiator.

11. Place the suction wand back into the radiator.

12. Turn V1 control valve half way between “N” and “U”.

13. Turn S1 pump switch to “Add” (+).

14. Turn V1 control valve slowly to “U” to avoid splashing the coolant. Refill radiator with new coolant.

15. Turn S1 pump switch to “Off” (O).

16. Replace radiator cap securely.

17. Move suction wand to overflow tank and fill to the normal level with new coolant.

Page 13

BG Upper Radiator Hose Adaptor Set

PN CT700

Installation

Radiator

Upper radiator hose

CT700 Assembly

Note: The CT700 is non-directional.

Upper radiator hose

Short hose/adaptor

assembly

Loose clamp

Quick connect

Ball

valve

Quick connect

Adaptor

Short hose/

adaptor

assembly

Short hose/

adaptor

assembly

CT700

BG CT2 return hose (R)

BG CT2 pump hose (P)

Upper radiator hose

CT700

Page 14

H110-4

Garden hose seal

(#313 Buna O-ring)

CC718

Swivel adaptor

assembly

BG Upper Radiator Hose Adaptor Set

PN CT700

Parts List

H110-4

Garden hose seal

(#313 Buna O-ring)

BG27

Nipple,

/4˝ MNPT

/4˝ MNPT,

close length, brass

CC715

/4˝ male chrome

quick connect

Ball valve

x 3/8˝ FNPT, hex stock,

brass, chrome plated

BG25

/8˝ MNPT

CC719

Adaptor body

CT707

Hose

assembly

for CT728

CT728

CT700 female body assembly only for CT2

CC732

/4˝ adaptor

CC725

2˝ adaptor

CC724

/4˝ adaptor

CC723

/2˝ adaptor

CC722

/8˝ adaptor

CC721

/4˝ adaptor

CC720

1˝ adaptor

CC733

/4˝ x 4˝ radiator hose

CC704

2˝ x 4˝ radiator hose

CC727

/4˝ x 4˝ radiator hose

CC703

/2˝ x 4˝ radiator hose

CC726

/8˝ x 4˝ radiator hose

CC702

/4˝ x 4˝ radiator hose

CC701

1˝ x 4˝ radiator hose

Page 15

(2 each)

Optional Upper Radiator Hose Adaptors

991-017

Ford 6.4 radiator

adaptor, female

CC730

BMW & VW radiator adaptor

(mates w/CC735)

991-023

Mercedes radiator

adaptor, male

991-018

Ford 6.4 radiator

adaptor, male

CC731

/8˝ & 3/4˝ adaptor

CT2-017

/4˝ remote coolant

tank adaptor

991-020

Ford Focus radiator

adaptor, female

CC734

VW radiator

adaptor, female

991-025

Audi/Ford expansion

tank adaptor

991-021

Ford Focus radiator

adaptor, male

CC735

BMW & VW radiator

adaptor, female

991-029

Ford 6.7L coolant

adaptor, female

CC729

VW radiator adaptor

(mates w/CC734)

991-022

Mercedes radiator

adaptor, female

991-030

Ford 6.7L coolant

adaptor, male

Large Capacity Upper Radiator Hose Adaptor Set

PN CT6-100

CC738

/4˝ x 6˝ radiator hose

CC741

/2˝ x 6˝ radiator hose

2 1/2˝ x 6˝ radiator hose

CC737

CC740

3˝ x 6˝ radiator hose

CC736

/2˝, 2 3/4˝ radiator adaptor

(2 each)

CC739

3˝, 31/2˝ radiator adaptor

Page 16

Page 17

Scan this code or visit

http://bgfor.me/ct6ref

to access instructions in other languages and additional information.

This code can also be

found on the serial plate

on the back of the BG CT6.

•