Bosch TRANSFLOW j-45096 User manual

TRANSFLOW Transmission Cooling System Service Tool J-45096 1
Operation Manual
Transmission Cooling System
J-45096

2 TRANSFLOW Transmission Cooling System Service Tool J-45096
Safety Precautions
WARNING: TO PREVENT PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT:
• ALLOW ONLY QUALIFIED PERSONNEL TO OPERATE THE UNIT. Before oper-
ating the unit, read and follow the instructions and warnings in this manual.
If the operator cannot read English, operating instructions and safety pre-
cautions must be read and discussed in the operator’s native language.
• Do not use this equipment in a manner not specified by the manufacturer.
• Wear eye protection that meets OSHA standards.
• Correctly connect power supply cord to the vehicle 12V DC battery and
chassis ground.
• Use only GM Approved Dexron VI®Automatic Transmission Fluid.
• Do not overfill the supply vessel with automatic transmission fluid (ATF).
• A minimum of 90 psi of shop air is required to operate this machine.
• Operate and store this machine in an upright position.
• Disconnect the machine from the shop air supply at the conclusion of each
day to ensure correct operation of the water separator.
• Dispose of waste ATF in accordance with all applicable federal, state and
local requirements.

TRANSFLOW Transmission Cooling System Service Tool J-45096 1
Table of Contents
Introduction
Glossary of Terms .............................................................................................................. 2
Equipment Specifications................................................................................................... 2
Component Location Overview
Front View .......................................................................................................................... 3
Rear View........................................................................................................................... 3
Control Panel ..................................................................................................................... 4
Set-Up Instructions
Initial Set-Up Instructions................................................................................................... 5
Waste Vessel Drain Set Up ................................................................................................ 6
Power Up ........................................................................................................................... 8
TransFlow Self-Test............................................................................................................ 9
Operating Instructions
Machine Set-Up ............................................................................................................... 11
Flow Test/Flush Operation ............................................................................................... 12
Waste Oil Removal .............................................................................................................. 15
Maintenance Instructions
Service Parts ................................................................................................................... 16
Accessories ..................................................................................................................... 16
Transmission Oil Cooler (T.O.C.) Adapters....................................................................... 17
Useful Information/Hepful Hints ....................................................................................... 18
Troubleshooting ................................................................................................................... 19
Warranty Information/Technical Support .................................................... Inside Back Cover

2 TRANSFLOW Transmission Cooling System Service Tool J-45096
Introduction
The TransFlow machine is a product designed to measure the transmission oil cooler (T.O.C.) oil
ow capability and to remove contaminated oil from the T.O.C. system after a transmission repair.
Measuring the transmission cooler system oil ow rate determines if the cooler meets the current
GM ow rate specication.
Glossary of Terms
ATF Automatic Transmission Fluid, Dexron VI®ATF or equivalent
GPM Gallons per Minute
T.O.C. Transmission Oil Cooler
Equipment Specifications
Component Specification
TransFlow Part Number J-45096
Power Supply Operating Voltage 11 Volts DC–16 Volts DC
Air Pressure 90 PSI (Minimum)
Minimum ATF Temperature 65° F
Supply Vessel Capacity 32 Quarts US
Waste Vessel Capacity 34 Quarts US
Flow Rate 0.5-2.5 gpm

TRANSFLOW Transmission Cooling System Service Tool J-45096 3
Control Panel
ATF Fill
Port
Polypropylene
Cabinet for
Durability
Locking Casters
Operation
Instructions
Convenient Handle
for Cord and
Hose Storage
Waste Oil
Vessel
Large Wheels for
Mobility across
Air Lines, Power
Cords, and Grates
Component Location Overview
Front View
Shop Air
Supply
Supply Oil
Outlet
Waste Oil
Inlet
Rear View

4 TRANSFLOW Transmission Cooling System Service Tool J-45096
Control Panel
Main Function Switch
The following table provides a quick reference for the main function switch positions:
Switch Position
Flush
Idle
Flow
Code
Description
Allows pressurized automatic transmission uid with a high pressure pulse
of air to ush the contaminated oil from the T.O.C. If any debris exists in
the T.O.C., it will also be ushed when the machine is in this mode.
Standby mode; zero pressure applied to the T.O.C. and cooler lines.
Tests the ow rate of the T.O.C. and cooler lines.
Provides a seven-character, encrypted warranty code following a success-
ful ow test. Note: The ow test must run for a minimum of 8–10 seconds
and be above 0.5 gpm for a code to be generated.
Red light indicates when
machine is pressurized
LCD Display
Window
ATF Fill
Port
Main Function
Switch
Operating
Instructions
Main Power
Switch

TRANSFLOW Transmission Cooling System Service Tool J-45096 5
8. Tighten the tting.
9. Apply Loctite®565 thread sealant to the
threads of an air line quick-disconnect tting
(customer supplied).
10. Thread the quick-disconnect tting clock-
wise onto the TransFlow tting, located on
the rear panel of the TransFlow unit, marked
Supply AIR.
11. Tighten the quick-disconnect tting.
12. Open the door on the unit by using a screw-
driver to turn the fasteners counterclockwise
about a quarter-turn. Snap one hose storage
bracket over the top of the door as shown
in Figure 4, and position the other hose
storage bracket 8"–10" away from the rst.
Set-Up Instructions
Initial Set-Up
1. Remove the TransFlow unit from the packag-
ing.
2. Locate the accessory package and remove
the black supply hose and the clear waste
hose. See Figure 1. Also locate and remove
the two hose storage brackets.
3. Apply Loctite®565 sealant (supplied) to the
threaded male end of the black supply hose.
4. Thread the supply hose clockwise onto the
TransFlow tting, located on the rear panel
of the TransFlow unit, marked SUPPLY. See
Figure 2.
5. Tighten the tting.
6. Apply Loctite®565 thread sealant to the
threaded male end of the clear waste hose.
7. Thread the waste hose clockwise onto the
TransFlow tting, located on the rear panel
of the TransFlow unit, marked WASTE. See
Figure 3.
Figure 1
Figure 2
Figure 3
Figure 4

6 TRANSFLOW Transmission Cooling System Service Tool J-45096
IMPORTANT: Dispose of the waste ATF in
accordance with all applicable federal, state
and local requirements.
1. If draining from the bottom of the waste
vessel, rst remove the drain tting cap plug
by turning the cap plug counterclockwise
while supporting the hexagonal drain tting.
Note: Be sure to support the hexagonal drain
tting while removing the cap plug to prevent
potential damage to equipment. See Figure
1.
2. Locate the drain support bracket and screws
from the accessory kit. Place the drain sup-
port bracket underneath the plastic lip of the
left side base of the TransFlow machine (or
towards front of TransFlow). The drain sup-
port bracket should be at against the inside
plastic lip and the hole in the drain support
bracket should be clearly below the plastic.
Set-up Instructions contd.
Figure 5
Waste Vessel Drain Set Up
Before TransFlow is used, it is recommended to
consider a draining strategy for the waste ATF
that will be stored in the waste vessel on the
side of TransFlow. The waste vessel may be
drained through a tting at the bottom or by
removing the waste vessel cap at the top of the
vessel to use an oil transfer pump to evacuate the
oil. This section describes a procedure to outt
the drain tting at the bottom of the waste vessel
with a standard 1/2" pipe to make it more
convenient for you to adapt to. It is your respon-
sibility to either cap this 1/2" pipe once installed,
or to adapt a tting or hose to it to allow you to
drain the waste vessel.
Figure 1
The waste and supply hoses can be stored on
these brackets when not in use. See Figure 5.
Waste Vessel Cap Plug
Hexagonal
Drain Fitting

TRANSFLOW Transmission Cooling System Service Tool J-45096 7
3. Use a pencil to trace the drain support brack-
et’s position at the three indicated locations.
You should have two horizontal lines drawn
on the bracket and one vertical line drawn on
the plastic base to indicate the vertical and
horizontal location of the bracket. See Fig-
ure 2.
4. Bring the drain support bracket out from un-
derneath the plastic lip of the plastic Trans-
Flow base. Place the drain support bracket on
the outside of the plastic base so the horizon-
tal lines drawn on the bracket are in line with
the bottom of the plastic TransFlow base.
The right edge of the drain support bracket
should line up with the vertical line that was
drawn on the plastic base.
5. Mark the two points on the plastic base
where the holes for the fasteners will be
drilled so the drain support bracket can be
secured to the plastic TransFlow base. See
Figure 3.
Figure 2
Figure 3
Figure 4
6. Drill the two holes (approximately 3/16"
diameter) in the plastic base. The hole shall
be drilled completely through the plastic lip
of the plastic base. See Figure 4.
7. Place the drain support bracket behind the
plastic lip of the base and line up the holes
in the bracket with the holes in the base. See
Figure 5.
Set-up Instructions contd.
Figure 5
With pencil, draw
horizontal
lines on brack-
et. (Lines are for
lining up purposes as
shown in Figure 3.)
Vertical Line

8 TRANSFLOW Transmission Cooling System Service Tool J-45096
Power Up
1. Connect the red battery clip to the positive
(+) battery post on the vehicle, and connect
the negative lead to a known good chassis
ground. See Figure 1.
Figure 1
Figure 7
Figure 8
8. Secure the drain support bracket with the two
screws included in the accessory package.
See Figure 6.
9. Rotate the drain tting so it is facing the gen-
eral direction of the drain support bracket.
10. Locate the drain pipe. Apply any remaining
Loctite 565 thread sealant to one end of the
1/2" drain pipe. Slide the drain pipe through
the drain support bracket so the end of the
drain pipe with thread sealant can be thread-
ed into the hexagonal drain tting.
11. Turn the drain pipe clockwise so it threads
into the drain tting. Tighten the drain pipe
while supporting the hexagonal drain tting.
See Figure 7.
Figure 6
12. To complete the waste vessel drain set up,
connect the tting of your choice to the male
1/2" pipe that is now installed. See Figure 8.