Motorvac TRANSTECH IV, 500-1125 Service Manual

TRANSTECH IV

Transmission Service System

P/N

500-1125

Service Manual

ZIM12-00505 Rev. 1 TransTech IV Service Manual

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Table of 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 DIAGRAMS..................................................................27

10. WIRING DIAGRAM..............................................................................31

11. SPARE PARTS LIST.............................................................................32

ZIM12-00505 Rev. 1 TransTech IV Service Manual

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SAFETY INFORMATION AND PRECAUTIONS

/!\ DANGER

Vehicle exhaust gases contain Carbon Monoxide, which is 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.

/!\ 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 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 the 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 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).

ZIM12-00505 Rev. 1 TransTech IV Service Manual

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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.

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 keep 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, resulting in injury.

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 machine is connected to the battery, make sure the unit’s power switch is
off. Connect the positive lead of the unit to the positive lead battery first; connect
the negative lead of the unit 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.

ZIM12-00505 Rev. 1 TransTech IV Service Manual

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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

ZIM12-00505 Rev. 1 TransTech IV Service Manual

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FEATURES AND FUNCTIONS

The front of the TRANSTECH IV cabinet contains the control panel, the fluid fill neck for
adding new transmission fluid, and the fluid level 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
(see below, Fig. 1)

DIPSTICK LED - Unit set to Dipstick exchange when LED is on
(see below, Fig. 2)

MANUAL LED – Indicates Manual Mode for either Inline or Dipstick Modes

(see below, Fig. 3 & Fig. 4)

Fig. 1 Fig. 2 Fig. 3 Fig. 4

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FEATURES AND FUNCTIONS (CONT’D)

START/RESUME Button - Begins & Resumes service

DRAIN Button - Drains fluid from vehicle’s transmission.
FILL Button – Adds fluid to the transmission.

LOW VEHICLE FLUID LED- Illuminates when fluid in the

vehicle in service is low or empty.

COMPLETE LED - Illuminates when service is complete.

START ENGINE LED – The LED illuminates 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 OFF in inline mode. The Stop Engine LED flashes
when the vehicle’s engine needs to be stopped.

LOW CLEAN FLUID LED – Illuminates when clean fluid in the
unit’s clean tank is low or empty.

STOP Button – Pauses service and stops alarms. Hold for 5 seconds to
reset unit.

EMPTY WASTE Button - Empties fluid from unit’s waste tank.

MODE Button – Toggles between four different modes

(Inline/Dipstick etc)

ZIM12-00505 Rev. 1 TransTech IV Service Manual

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MACHINE OVERVIEW

Front Features

Control Panel – All electronic operational functions
are initiated at this location. See Control panel features
section.

Filler Port & Cap – New ATF is poured into unit
before service.

Pressure Gauge – Indicates 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 attached to it as
well as connecting them to a common dipstick wand
for the drain and fill process

Clean Fluid Hose – Clean ATF is introduced to the
vehicle through this hose for both In-Line and Dipstick
modes.

Dipstick Return Hose – Draws dirty ATF from the
vehicles in Dipstick Mode.

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MACHINE OVERVIEW (CONT’D)

Left Side Features

In-Line Return Hose & Filter –

Used ATF is drawn in

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 Disposal Hose - Is inserted into the shop’s

fluid recycling container or into a suitable container
for proper disposal of used transmission fluid.

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MACHINE SETUP
AUTO-PRIME (FIRST USE ONLY)

1. Check the output/return hoses, battery connections, and all external components
for damage.

2. Fill the CLEAN FLUID tank with approximately 4 quarts (3.78 liters) of new ATF.

3. Connect two compatible adapters to each other, secure tightly. Attach the
CLEAN FLUID & INLINE RETURN hoses together using the connected adapters

4. Place the waste hose into the clean tank fill neck with the ball valve open.

5. Attach the units’ red (+) battery clip to vehicle’s positive battery terminal; connect
the black (-) battery clip to a solid ground point 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 LEDs will flash. Press and hold the START button again for 5 seconds
until the unit sounds the alarm. The DRAIN, FILL and COMPLETE LEDs will
cycle in a clockwise
direction while the unit is
performing the Auto­Prime procedure. The
unit will pump fluid from
the clean tank to the
waste tank. The unit will
then set the waste tank
zero level by pumping
fluid from the waste tank
into the clean tank.
When complete, the unit
will automatically reset.
Both tanks should have
fluid approximately at the
zero mark on the front of
the cabinet.

7. Return the hoses to their
original location.

8. The initial setup is
complete.

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MACHINE SETUP (CONT’D)

Inline Exchange

Warning! Software V2.24. It is not necessary to empty the waste tank before

beginning an exchange. If beginning an exchange with fluid in the waste tank ensure
that there is less fluid in the clean tank than the remaining capacity of the waste tank.
Failure to do so 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 partially open.

2. Start the vehicle.

3. Determine ATF flow direction then fully open H-adapter valve.

4. With the male to male couplers connected to the TransTech IV hoses, attach the

INLINE RETURN hose to the transmission output side of the H-adapter. Attach
CLEAN FLUID hose to the transmission return side of the H-adapter valve.

5. Close valve on H-Adapter.