Motorvac TRANSTECH IV User 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

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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).

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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.

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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

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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)

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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 Auto-
Prime 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.

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BASIC OPERATION
Control Panel Pressure Gauge
Automatic Fluid Exchange Operation.
1. Make sure the TransTech IV new fluid tank is filled with the correct type and
amount of Transmission Fluid.
2. Connect TransTech IV power leads to the vehicle’s battery.
3. With vehicle running, pressure should be present at the TransTech IV pressure
gauge and the START ENGINE light 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 COMPLETE light will come on and
TransTech will beep continuously until STOP button is pressed.
6. Once transmission service is complete, check ATF level with engine running.
Press and hold DRAIN or FILL to adjust ATF level. Stop the engine, the service
is complete.
7. Direct waste hose to a suitable container; open the ball valve on the end of the
waste hose and press EMPTY WASTE button to empty dirty fluid tank.

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BASIC OPERATION (CONT’D)
Optional Procedure - Drain Pan for Filter Change
Warning! Software V2.24. It is no longer 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!
1. Make sure the TransTech IV new fluid tank is filled with the correct type and
amount of transmission fluid.
2. Connect TransTech IV power leads to the vehicle’s battery.
3. With vehicle running, pressure should be present at the TransTech IV pressure
gauge and the START ENGINE light should be on solid. If pressure drops to
zero, and START ENGINE light is flashing, the hoses may be reversed.
4. With the 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. Immediately turn off the vehicle’s engine and press STOP to silence the alarm.
Perform drain pan service.
6. When the filter change is complete, press START/RESUME button and the
TransTech IV will refill the vehicle with the same amount of fluid removed.
7. The buzzer will sound and START ENGINE light will flash.
8. Start vehicle.
9. Press START/RESUME button to begin the exchange.
10.When fluid exchange is finished, the COMPLETE light will come on and
TransTech will beep continuously until STOP button is pressed.
11.Once transmission service is complete, check ATF level with engine running.
Press and hold DRAIN or FILL to adjust ATF level. Stop the engine, the service
is complete.
12.Direct waste hose to a suitable container; open the ball valve on the end of the
waste hose and press EMPTY WASTE button to empty dirty fluid tank.

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BASIC OPERATION (CONT’D)
Pause Feature
If service needs to be paused at any time press STOP. To resume, press
START/RESUME. The machine will pause indefinitely until the START/RESUME button
is pressed. While 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 begins. However, additional ATF can be added after a
service has started but ONLY when the service is paused. Any ATF added while the
unit is performing a service will not be properly measured and may result in an OVER
FILL of the vehicle’s transmission!

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BASIC OPERATION (CONT’D)
Dipstick Exchange
Warning! Software V2.24. It is no longer 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!
1. Fill the TransTech 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 will be
illuminated.
4. Check the transmission fluid level. The Transmission fluid level can be
adjusted at this time using the DRAIN or FILL buttons. This will ensure the
service completes with the correct amount of fluid in the transmission.
5. Measure the vehicle dipstick and set spacer on dipstick fill tube/drain tube on
TransTech IV to the correct length. Insert the TransTech IV tube into the
vehicles dipstick tube.

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BASIC OPERATION (CONT’D)
6. Press START/RESUME button to begin service.
7. The DRAIN light is on solid. Initial drain cycle begins.
8. Once fluid flow has stopped, service pauses, FILL light flashes. The operator
can continue with service or remove the drain pan if drain pan service is
required.
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 START ENGINE light will flash.
10.Start the engine.
11.Press the START/RESUME button to continue the service to completion.
12.The COMPLETE light will turn on when the service is complete and alarm will
sound. Press STOP button to silence alarm.
13.Remove the Dipstick fill adaptor and check the level of transmission fluid in
the vehicle.

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BASIC OPERATION (CONT’D)
14.If the transmission fluid 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 container; open the ball valve on the end of
the waste hose and press EMPTY WASTE to empty dirty fluid tank.

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BASIC OPERATION (CONT’D)
Changing Fluid Types
Follow these steps if it is necessary to completely empty the clean fluid tank in
order to change to another type of fluid.
1. Install an open adapter in the clean hose coupler. Install hose into a capture
container.
2. Connect power cord to a 12 volt DC source. Press the MODE button until
both the In-Line and Manual LED’s are on.
3. Press & hold the FILL button. The pump will operate until the FILL button is
released.
4. Tip the unit slightly backwards to let the fluid flow toward the back of the tank
for complete evacuation.
5. Pressing the STOP button for five seconds will reset the 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 ball valve on
the end of the waste hose.
3. If the EMPTY WASTE LED is on, press the EMPTY WASTE button. The unit
will automatically pump out the dirty fluid until the fluid level stops at the
switch in the bottom of the tank. The EMPTY WASTE LED will go off.
4. Press and hold the EMPTY WASTE button for 5 seconds to enter MANUAL
WASTE mode. Unit will beep. Release the button. The EMPTY WASTE LED
will flash.
5. Press and hold the EMPTY WASTE button. The pump will operate until the
EMPTY WASTE button is released.
6. Tip the unit slightly backwards to let the fluid flow toward the back of the tank
for complete evacuation.
7. Pressing the STOP button for five seconds will reset the unit.

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THEORY OF OPERATION
INLINE MANUAL MODE
DRAIN
INPUT - Press and hold the drain button
OUTPUT - Inline solenoid turns on.
Fill
INPUT - Press and hold the fill button
OUTPUT - Clean fluid pump turns on (80% voltage to clean pump)
DIPSTICK MANUAL MODE
DRAIN
INPUT - Press and hold the drain button
OUTPUT - Waste pump turns on (50% voltage to waste pump)
Fill
INPUT - Press and hold the fill button
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.
- Press the Empty Waste button
OUTPUT – Waste Pump, Dipstick Solenoid and Waste Solenoid are turned on
INLINE PAN DRAIN MODE
BEFORE BEGINNING SERVICE
INPUT – Inline Pressure Switch must be closed (greater than 5 psi on TransTech
gauge)
- Press Drain button
OUTPUT – Inline Solenoid turns on
DURING PAN DRAIN
INPUT – Pan drain complete when Inline Pressure Switch opens
OUTPUT – Inline Solenoid turns off, alarm sounds, Stop Engine LED flashes

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THEORY OF OPERATION (CONT’D)
REFILL TRANSMISSION PAN
INPUT – Press the fill button
OUTPUT – Clean Fluid Pump turns on, Inline Solenoid turns on. Unit beeps and Start
engine LED flashes after the pan is refilled.
AUTOMATIC PORTION OF EXCHANGE
INPUT – Inline Pressure Switch closes (vehicle turned on)
OUTPUT - Inline solenoid turns on.
- Clean fluid pump turns on.
- PCB maintains fluid level by monitoring clean and waste tank pressure
transducers
EXCHANGE COMPLETE
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 EXCHANGE
BEFORE BEGINNING SERVICE
INPUT – Inline Pressure Switch must be closed (greater than 5 psi on TransTech
gauge)
- Press Start button
OUTPUT – Inline Solenoid turns on
- Clean Fluid Pump turns on
- PCB controls pump and solenoid to maintain fluid level by monitoring
clean and waste tank pressure transducers
EXCHANGE COMPLETE
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.