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INSTRUCTIONS FOR THERMAL CAP-CHECK
CAP.CHECK GENERAL DESCRIPTION -Model 1003 is a unique refrigeration capillary lube
cleaner that allows a serviceman to remove restrictions from cap tubes without messy and time
consuming removal and replacement.
The CAP-CHECK is a portable self-contained hydraulic power unit with auxiliary equipment. It
is designed to pump a high rate of oil into the cap tube to build up pressures needed to open any
plugged cap tube and will clean partially plugged cap tubes when used with the Thermal Chaser
Kit.
The CAP-CHECK unit contains the following items:
1. Pump and reservoir assembly with ¼” male flare outlet.
2. Hydraulic pressure gauge mounted in above assembly with trigger-operated gauge
shut-off valve.
3. An adapter to connect a cap tube to the CAP-CHECK without using a flare nut. A flare
plug is mounted on the unit to store the adapter when – not in use.
4. A 30” flexible high pressure hydraulic hose.
5. Pump handle with plastic grip.
TO PLACE UNIT IN OPERATION- Make sure reservoir contains oil. Open by-pass valve by
turning valve screw counter-clockwise. Remove sealing cap from CAP-CHECK outlet and attach
flexible hose. Close valve and pump till oil comes out end of hose. Put sealing cap on hose outlet.
TO FILL CAP-CHECK -When reservoir empties leave by-pass valve closed. Remove filler
fitting and fill reservoir with refrigerant oil. Replace filler fitting. Open by-pass valve and pump
10 or 12 strokes. Close by-pass valve and pump again to see if pressure builds up. If it doesn't,
open by-pass valve again and repeat the above procedure. PUMP WILL NOT WORK IF IT HAS
AIR IN IT.
TESTING REFRIGERATION CAPILLARY TUBES -Remove sealing cap from hose outlet.
Loosen cap on filler fitting so air can enter to replace oil pumped out. Close by-pass valve by
turning clockwise and pump till oil comes out of hose fitting. Close refrigerant supply to cap tube.
Disconnect cap tube from system and connect it to hose outlet either directly or with the adapter.
If using adapter be sure to push cap tube thru the neoprene sealer at least 1 inch and tighten
adapter nut until cap tube cannot be pulled out. Pump at an even rate of approximately 30 strokes
per minute (1 second down, 1 second up). The amount of pressure build-up in clean cap tubes
will depend on the size of the cap tube. Large capacity tubes will show practically none while
long tubes of small bore and lower capacity will show as high as 2000 PSI or more instantaneous
pressure but will rapidly return to zero. If pressure builds up and holds or drops very slowly cap
tube is restricted.
THERMAL ENGINEERING COMPANY
A Division of Airserco Manufacturing Company LLC
7555 Tyler Boulevard; Mentor, OH 44060 800-473-1754 Fax: 440 946-8188
www.thermalengineeringcompany.com
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TO REMOVE RESTRICTIONS -With CAP-CHECK connected as above pump at a rate which
will build up a pressure of not more than 4000 PSI. If this pressure does not remove the
restriction drop the pressure by opening the by-pass valve then close the valve and start pumping
again. When the pressure reaches about 1500 PSI, close the trigger valve gauge shutoff by
holding the trigger down while continuing to pump. As soon as the pressure stops rising on the
gauge indicating it is shut off, pumping can be continued as fast and to as high a pressure as
needed. When the restriction is removed the pressure will drop and as soon as it gets below the
pressure held in the gauge the gauge will start to drop. The trigger valve will open automatically
when the pressure drops so if pumping is started again the valve will be open and the gauge will
again indicate pressure. As long as pressure is held on the valve piston in the closed position the
valve cannot be opened and the trigger will have no effect on it. The Extended Base, which can
be purchased as an additional accessory, makes pumping the higher pressures which can be
reached with the gauge shutoff much easier.
Use of a CAP-CHECK CHASER KIT will insure that the cap tube is really clean and fully open.
It is especially valuable for larger cap tubes which are partially restricted since the rate of flow
required for such cap tubes is beyond the capacity of any hand operated hydraulic pump. In using
the CHASER KIT a piece of lead alloy wire about 3/8” long and a few thousandths of an inch
smaller than the ID of the cap tube is pushed through by hydraulic pressure. If a restriction stops
the wire, high velocity oil will flow between the wire and the cap tube wall and be directed
against the restriction washing it away. The wire will then move on until it falls harmlessly into
the evaporator where it will remain.
TO USE CAP-CHECK AS A HYDRAULIC POWER UNIT -To operate hydraulic cylinders
connect the power side of the cylinder to the outlet and the return side of the cylinder to the filler
opening of the CAP-CHECK. Since the volumetric capacity of the pump is low fill the cylinder
with oil before connecting the CAP-CHECK to it. For high pressure testing fill the article to be
tested with oil before connecting the CAP-CHECK.
Pump until the desired pressure is reached. BE SURE THE ARTICLE YOU ARE TESTING
WILL STAND THE PRESSURE YOU INTEND TO APPLY.
MAINTENANCE- Do not bend the hydraulic hose to a radius of less than 3 in. To do so will
kink it and cause it to fail.
The pump nut (1034) should only be finger tight. Over-tightening may cause the unit to leak
around the piston or may bind the piston and prevent the unit from pumping.
Dip neoprene adapter sealer in oil when replacing to prevent binding.
The valve assembly is made up of 3 balls which cover 3 different sized ports. The smallest ball
closes the port from the reservoir to the pump, the middle ball closes the port from the pump to
the outlet and the large ball closes the by-pass port from the outlet to the reservoir. If pump will
not raise any pres- sure the small ball is not sealing. If pressure can be raised but pump handle
raises from the bottom of the stroke by itself, middle ball is not holding and if pressure can be
THERMAL ENGINEERING COMPANY
A Division of Airserco Manufacturing Company LLC
7555 Tyler Boulevard; Mentor, OH 44060 800-473-1754 Fax: 440 946-8188
www.thermalengineeringcompany.com
Page 3
raised but will not hold against a sealed outlet and pump handle does not move by-pass valve is
not holding. Foreign matter in the ports is probably the trouble in all cases. Flush out by removing
valve screw, balls and filler plug and letting oil flow out valve screw hole. Replace balls and
valve screw and refill with oil.
Gauge and fittings on CAP-CHECK are sealed with Teflon pipe tape.
MODEL 5101 CAP-CHECK OUTFIT provides both the CAP-CHECK and CHASER KIT in one
compact case along with an extended base that holds the CAP-CHECK. In this way the CAPCHECK can be operated with one hand allowing high pressures to be easily pumped. Carrying
case has clips to hold CAP-CHECK, CHASER KIT, hose, handle, and extended base.
IMPORTANT NOTICE -Before returning a CAP-CHECK for failure to pump MAKE SURE it
has a full charge of oil and is not air bound. Follow instructions for filling and purging air from
the pump. Over 80% of all units returned have nothing wrong with them.
THERMAL ENGINEERING COMPANY
A Division of Airserco Manufacturing Company LLC
7555 Tyler Boulevard; Mentor, OH 44060 800-473-1754 Fax: 440 946-8188
www.thermalengineeringcompany.com
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Parts & Accessories
1003RK Repair Kit
1011 0-6000 PSI Gauge
1012 30" Hydraulic Hose
1014 Handle
1015* Trigger Poppet Spring
1016 Trigger Valve Poppet
1017* Poppet "O" Ring
1018* Trigger Valve "O" Ring
1020A Trigger Complete
1021 Gouge Post
1032 Pump Body
1033* Pump Wiper
1034 Pump Nut
1039 Pump Piston
1043 Bypass Valve Screw
1043A Roll Pin, Bypass Screw
1044* "O" Ring Bypass Valve, Piston
1045* Valve Ball Set
1048 Handle Socket Link Pin
*Contained in 100JRK Repair Kit
Limited Warranty
All products sold are warranted against defects in workmanship or materials under normal use for
one year. Manufacturer assumes no liability on the actual use of this equipment. Safety
responsibility lies with the user. Liability in all events is limited to the purchase price paid and
liability under aforesaid warrantee is limited to replacing or repairing any parts which are
defective in materials or workmanship and are returned to our warehouse with a detailed
description of the problem. Airserco reserves the right to repair or replace unit at our discretion.
1049 Handle Socket
10S3 Male Adopter
10S4 Female Adopter
105S Adapter Complete
1056 Adapter Seals (1 doz.)
105B Base Casting
1059 Cylinder
1060 Top Cap
1061 Top TP Base Nipple
1062* Cylinder "0" Ring
1063* Gauge Post "0" Ring
1064 Filler Fitting
1069 Adapter Holder Fitting
1071 Adapter Holder Screw
1072* Fiber Washer
1073* Teflon Back Up Ring
1101 Chaser Kit
1201 Metal Case for 5101
1301 Extended Base
THERMAL ENGINEERING COMPANY
A Division of Airserco Manufacturing Company LLC
7555 Tyler Boulevard; Mentor, OH 44060 800-473-1754 Fax: 440 946-8188
www.thermalengineeringcompany.com
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