Operating Manual. Model Coolant Exchanger

Transcription

1 Operating Manua Mode Cooant Exchanger

2 Mode Cooant Exchanger SAFETY DEFINITIONS: Foow a WARNING, CAUTION, IMPORTANT, and NOTE messages in this manua. These messages are defined as foows: WARNING means you may risk death or serious persona injury; CAUTION means you may risk persona injury, property damage, or serious unit damage; IMPORTANT means you may risk unit damage; and NOTEs provide carity and hepfu tips. These safety messages cover situations ROBINAIR is aware of. ROBINAIR cannot know, evauate, and advise you regarding a possibe hazards. You must make sure a conditions and procedures do not jeopardize your persona safety. DISCLAIMER: A information, iustrations, and specifications contained in this manua are based on the atest information avaiabe at the time of pubication. The right is reserved to make changes at any time without obigation to notify any person or organization of such revisions or changes. Further, ROBINAIR sha not be iabe for errors contained herein or for incidenta or consequentia damages (incuding ost profits) in connection with the furnishing, performance, or use of this materia. If necessary, obtain additiona heath and safety information from the appropriate government agencies, and the vehice and cooant manufacturers. Warning Before using the cooant exchanger, read, understand, and foow the safety precautions and operating instructions outined in this manua. This equipment must be operated by quaified personne the operator must be famiiar with vehice cooing systems, cooants, and the dangers they present. If the operator cannot read Engish, operating instructions and safety precautions must be read and discussed in the operator's native anguage. Si e operador no puede eer ingés, as instrucciones de operación y as precauciones de seguridad deberán eerse y comentarse en e idioma nativo de operador. Si 'utiisateur ne peut ire 'angais, es instructions et es consignes de sécurité doivent ui être expiquées dans sa angue maternee. Do not drink antifreeze or soution. Avoid inhaing mist or hot vapors. (Ethyene gyco base.) If swaowed, drink two gasses of water; induce vomiting; and ca a physician. If inhaed, move to fresh air and ca a physician. Use the unit in ocations with mechanica ventiation that provides at east four air changes per hour. If accidenta system discharge occurs, ventiate the work area before resuming work. Do not store ethyene gyco based soutions in open or unabeed containers. Ethyene gyco causes birth defects in aboratory animas; soution may taste peasant to animas, but is poisonous to them. Contact with antifreeze/cooant may cause injury. Hot antifreeze/cooant can burn skin and injure eyes. Wear protective equipment, incuding safety gogges and goves, when operating this equipment. If contact with eyes occurs, ca a physician immediatey, and fush eyes with cod water for 30 minutes. If contact with skin occurs, thoroughy wash area with soap and water. Vehice cooing systems which are hot, are under pressure opening a hot system, except as described in this manua, can cause an uncontroed reease of engine cooant. Do not open the radiator cap, and do not remove hoses from a hot system except as directed in this manua. Do not pressurize the vehice cooing system above its pressure rating. Doing so may resut in cooing system faiure and the reease of engine cooant. Never run a vehice engine without adequate ventiation. Breathing vehice emissions can cause sickness, injury, or death. Working in the vicinity of a ead-acid or other automotive battery is dangerous. Wear eye protection. NEVER smoke, or aow a spark or fame in the vicinity of a battery. Batteries generate exposive gases during norma battery operation. This equipment is not designed for any other purposes than testing cooing systems and exchanging used antifreeze/ cooant with new or recyced product. The operator is responsibe for compying with any and a appicabe aws and reguations governing the use of this type of equipment, as we as disposa of used antifreeze/cooant and used equipment and components.

3 Tabe of Contents Introduction Technica Specifications Gossary Setup Attach Hoses Assembe Suppy Tanks Reieve Cooing System Pressure System Inspection Reieve Pressure on a Hot System that has a Radiator Cap Lower the Cooant Leve Vehice Connections Pressure Test Exchange Process Compete the Exchange Process Maintenance Changing Suppy Tanks Emptying the Waste Tank Ceaning the Fiter Troubeshooting Fow Chart Accessories Repacement Parts List Safety Precautions Inside Front Cover Warranty Statement Inside Back Cover Coo Tech CooXchange 1

4 Introduction The COOLXCHANGE offers everything you need to quicky remove and repace cooant in a vehice: drain and fi, and pressure test for eaks. Two externa, new cooant suppy tanks aow on-board storage of two different cooant types. No eectricity is needed shop air powers the unit. No hoses to cut. No additiona ventiation is required the service procedure is performed with the engine off. The cooant transfer process is hands off simpy make the correct connections and watch it happen. A typica exchange procedure may take ony 10 minutes! Vave 1 Vave 2 Pressure Gauge Pressure Reguator IMPORTANT : For correct operation of the unit, adjust Vave 1 and Vave 2 in the sequence specified in these instructions. Hoses may be stored on unit. Impact-resistant Poypropyene Cabinet Sight Gauge for Waste Tank Technica Specifications Power Suppy : psi shop air Interna Tank : 15-gaon capacity waste tank Externa Tanks : Two 5-gaon capacity suppy tanks Dimensions : 47" H x 26" W x 33" D (119 cm x 66 cm x 84 cm) Gossary Antifreeze : Substance used to ower the freezing point of another iquid; has not yet been mixed with water. Cooant : A mixture of antifreeze and water. System : The cooing system of the vehice being serviced. Unit : The COOLXCHANGE SPX Corporation

5 Setup Attach Hoses 1. Attach the back hose (new cooant) to the top couper on the upper eft side of the unit s rear pane. The deca next to the couper is marked Cooant Outet to Car. See Figure Attach the cear hose (waste cooant) to the bottom couper marked Cooant Inet from Car. Back Hose (new cooant) Suppy Hose 3. Verify Vave 1 and Vave 2 on the unit are in the OFF position. 4. Connect an air couper fitting (user-suppied) to the air suppy inet. Attach a shop air ine to the fitting that is reguated to suppy psi of cean compressed air. Assembe Suppy Tanks The is shipped with two empty suppy tanks, which wi be fied with new cooant and strapped to the back of the unit. Cear Hose (waste cooant) Figure 1 Attach air couper fitting (not suppied). 1. Fi one suppy tank with new cooant. Insta the dip tube cap on the tank, and open any vent on the suppy tank. See Figure 2. Note: You may fi the second suppy tank with a different type of cooant, or you may eave it empty at this time. Vent Dip Tube Cap for Suppy Tank 2. Insta the soid cap on the second tank, and position it on the back of the unit. 3. Stack the suppy tank with the dip tube cap on top of the second tank, and attach the Vecro strap. 4. Attach the suppy hose couper to the dip tube cap as shown in Figure 1. Suppy Tank Figure 2 Soid Cap for Suppy Tank Coo Tech CooXchange 3

6 Reieve Cooing System Pressure WARNING: Cooing systems that are hot, are under pressure. Working on a hot cooing system without first reieving the pressure wi resut in serious persona injury. Back Hose (new cooant) Vave in OPEN position. On some systems it is necessary to aow the cooing system to coo before servicing the vehice. On vehices that have a radiator cap, it is possibe to reieve pressure by drawing a vacuum on the overfow port. System Inspection Before starting the service procedure, verify : the unit is connected to a suppy tank hoding the correct amount and type of new cooant for the vehice being serviced. the waste cooant tank has enough capacity to exchange the desired amount of cooant. Note: Running the unit with a fu waste tank wi degrade the performance of the unit. the vehice ignition is in the OFF position. any vents on the suppy tank are OPEN. vaves 1 and 2 on the unit are OFF. the vave on the back hose is open. See Figure 3. the fiter screen on the cear hose is cean. Reieve Pressure on a Hot System that has a Radiator Cap : 1. Remove the vehice s overfow tank hose from the cooant overfow barb on the radiator neck. 2. Two sizes of siphon tubes have been incuded with the unit. See Fig. 4. Seect the siphon tube which most cosey matches the size of the cooant overfow barb on the vehice s radiator neck. 3. Side the siphon tube onto the cooant overfow barb on the radiator neck. 4. Connect the couper end of the siphon tube to the cear hose from the unit. See Figure Turn both vaves on the unit to VACUUM. As the vave in the radiator cap reeases pressure, cooant may be seen in the siphon tube. 6. After pressure is reieved, turn both vaves OFF. Siphon tube assembed between cear hose and overfow barb on radiator. Figure 3 Siphon Tubes Figure 4 Figure SPX Corporation

7 Lower the Cooant Leve 1. After the cooing system has been depressurized or cooed down, CAREFULLY remove the cooant reservoir cap and the radiator cap. 2. With the couper end of the siphon tube connected to the cear hose (waste cooant) from the unit, insert the other end of the siphon tube into the cooant reservoir. 3. Turn both vaves on the unit to VACUUM to empty the cooant reservoir. 4. Insert the siphon tube into the radiator, and ower the cooant eve in the radiator to a eve beow the upper radiator hose. 5. Turn both vaves on the unit OFF. 6. Remove the siphon tube from the radiator, and disconnect it from the cear hose. 7. Reinsta any disconnected hoses on the vehice. 8. Reinsta the radiator cap and cooant reservoir cap. Siphon Tube Use siphon tube to ower cooant eve in radiator. Figure 6 Coo Tech CooXchange 5

8 Vehice Connections The upper radiator hose may be disconnected either where it connects to the radiator or where it connects to the engine, whichever is most convenient on the vehice being serviced. 1. Disconnect the upper radiator hose from the radiator or the engine. 2. Insert a step adapter into the radiator hose. See Figure Seect an adapter hose that has the same inner diameter as the radiator hose. Camp a step adapter to the hose, and then camp the assemby to the hose barb where the upper radiator hose was connected. 4. Connect the cear hose (waste cooant) to the step adapter eading into the radiator. 5. Connect the back hose (new cooant) to the step adapter eading into the engine. The vave on the back hose shoud be OPEN. See Figure Pinch off the cooant overfow hose and any other hoses connected to the cooant reservoir. See Figure 9. Hose / Step Adapter Assemby Radiator Back Hose (new cooant) Figure 7 Step Adapter Vave in OPEN position. Figure 8 Cooant overfow hose pinched off. Figure SPX Corporation

9 Pressure Test This procedure checks the cooant system for eaks. A drop in pressure indicates a eak in the system that must be repaired before refiing the system with cooant. Pressure Gauge Reguator IMPORTANT: For correct operation of the unit, adjust Vave 1 and Vave 2 in the sequence specified in these instructions. Vave 1 Vave 2 1. Turn the reguator on the contro pane countercockwise (CCW) to ower the test pressure. See Figure 10. Note: Adjusting the reguator requires puing up on the reguator knob, and then turning the knob. 2. Turn Vave 1 to PRESSURE TEST. 3. Turn Vave 2 to PRESSURIZE. 4. Adjust the reguator cockwise to the correct test pressure. Figure 10 CAUTION: To prevent damage to the vehice, test pressure must range BELOW the pressure indicated on the radiator cap, overfow cap, or vehice specifications. 5. Turn Vave 2 to HOLD. 6. Observe the pressure gauge on the contro pane: a constant pressure reading indicates no eaks in the system; a drop in pressure indicates a eak in the system which must be repaired. Note: The cooing system may need to be pressurized more than once to equaize test pressure throughout the system. 7. If a eak must be repaired, turn both vaves to VACUUM to reieve pressure. Perform repairs, and repeat the Pressure Test. If no repairs are needed, proceed to the Exchange Procedure. Coo Tech CooXchange 7

10 Exchange Process IMPORTANT: For correct operation of the unit, adjust Vave 1 and Vave 2 in the sequence specified in these instructions. 1. Note the eve of cooant in either the sight gauge for the waste cooant tank or the new cooant tank on the back of the unit. 2. Turn Vave 1 to EXCHANGE. 3. Turn Vave 2 to EXCHANGE. 4. Watch the fuid eve indicator. After exchanging the correct amount of cooant (based on the vehice s cooing system capacity), turn Vave 1 OFF. Turn Vave 2 OFF. Note: The cooant running through the waste hose at this time shoud be cean. If not, continue the exchange process unti the cooant running through the waste hose is cean. Compete the Exchange Process This procedure wi top off the cooant in the radiator and fi the cooant overfow reservoir. 1. Remove the step adapters and hoses. Reassembe the upper radiator hose to the vehice. 2. Reease any pinched-off hoses. 3. Connect the siphon tube to the back hose (new cooant). 4. Remove the radiator cap and/or cooant reservoir cap. 5. Cose the vave on the end of the back hose (new cooant). See Figure Turn both vaves on the to EXCHANGE. 7. Insert the siphon hose into the radiator and/or cooant overfow reservoir, and open the vave on the end of the back hose. Top off the cooant in the radiator, and fi the cooant overfow reservoir to the FULL indicator. 8. Repace the radiator cap and cooant reservoir cap. 9. Start the engine to purge any air in the system. Repeat procedure to top off the cooant system as needed. Back Hose (new cooant) Back Hose (new cooant) Figure 11 Tech Tip Vave in CLOSED position. Vave in OPEN position. Some vehices require a different vehice hookup due to the way the cooant fows through the system. If, during the exchange process, you can t hear the pump running, and the fow rate is sower than usua, it may be necessary to change the way the hoses are connected to the vehice. 1. Connect the cear hose (waste cooant) to the step adapter eading into the engine. 2. Connect the back hose (new cooant) hose to the step adapter eading into the radiator. The vave on the back hose shoud be OPEN. 3. Leave the cooant overfow hose and any other hoses connected to the cooant reservoir pinched off. 4. Repeat the Exchange Process SPX Corporation

11 Maintenance Changing Suppy Tanks This procedure outines how to switch suppy tanks so the wi exchange the correct type of cooant for the vehice being serviced. 1. Disconnect the suppy hose from the dip tube cap. See Figure 12. Remove the dip tube cap. 2. Connect the siphon tube to the back hose (new cooant). 3. Insert the other end of the siphon tube into the suppy tank. 4. Turn the vaves on the to EXCHANGE unti cooant stops fowing in the siphon tube. 5. Turn the vaves on the OFF. 6. Connect the dip tube cap to a suppy tank containing the type of cooant that is correct for the vehice being serviced. 7. Stack the tanks on the back of the with the correct tank on the top. Attach the Vecro strap around the top tank. 8. Connect the suppy hose to the dip tube cap. 9. Open any vents on the suppy tank. Suppy Hose Dip Tube Cap Suppy Tank Figure 12 Emptying the Waste Tank Running the unit with a fu waste tank wi degrade the performance of the unit. 1. Connect the siphon tube to the back hose (new cooant). 2. Insert the other end of the siphon tube into a waste barre. 3. Turn both vaves on the to EMPTY WASTE. 4. Watch the sight gass for the waste tank. See Figure 13. Empty the tank competey. IMPORTANT: Do not eave any waste cooant in the back hose because it functions as the new cooant hose when servicing a vehice. Figure 13 Waste Tank Sight Gass Coo Tech CooXchange 9

12 Maintenance Ceaning the Fiter Sediment wi coect in the fiter that is instaed on the waste hose. See Figure 14. Routiney cean the fiter to keep the unit operating correcty. 1. Unthread the cap from the fiter body. 2. Rinse the screen and the inside of the cap under running water. 3. Reassembe the fiter. Cear Hose (waste cooant) Fiter Figure SPX Corporation

13 Troubeshooting Symptom Cause Soution Cooant exchanger does not operate. Unit does not reieve pressure in vehice cooing system. OR Unit does not ower cooant eve in radiator or cooant reservoir. Unit does not hod pressure during pressure test. No, or sow, exchange. 1. Air suppy is not connected to unit. 1. Fiter screen on waste cooant hose is pugged. 2. Waste cooant tank is fu. 3. Air suppy pressure is too ow. 4. Unit hoses are assembed incorrecty. 1. Hoses connected to cooant reservoir not pinched cosed. 2. Test pressure is too high. 3. Leak in cooing system. 1. Vehice requires a different hookup. 2. Vave on new cooant hose not competey OPEN. 3. Vent on new cooant suppy tank is not OPEN. 4. Fiter screen on waste cooant hose is pugged. 1. Attach shop air ine to unit that is reguated to suppy psi of cean compressed air. Refer to Setup in this manua. 1. Unthread cap from fiter; rinse screen and inside of cap under running water. See Maintenance. 2. Connect siphon tube to back hose; insert tube into waste barre; turn vaves to EMPTY WASTE. See Maintenance. 3. Reguate shop air ine to psi of cean compressed air. See Setup. 4. Attach back hose to top couper; attach cear hose to bottom couper. See Setup. 1. Use piers to pinch off cooant overfow hose and other hoses connected to cooant reservoir. Refer to Vehice Connections. 2. Test pressure must be beow pressure indicated on radiator cap, overfow cap, or vehice specs. See Pressure Test. 3. Repair eak and repeat Pressure Test. 1. Connect cear hose to engine; connect back hose to radiator. See Tech Tip in Exchange Process. 2. Open vave. See Exchange Process. 3. Open vent. See Setup. 4. Unthread cap from fiter; rinse screen and inside of cap under running water. See Maintenance. Coo Tech CooXchange 11

14 Troubeshooting Symptom Cause Soution No, or sow, exchange contd. 5. Waste cooant tank is fu. 6. Air suppy pressure to unit is too ow. 7. Hoses are incorrecty assembed to unit. 5. Connect siphon tube to back hose; insert tube into waste barre; turn vaves to EMPTY WASTE. See Maintenance. 6. Reguate shop air ine to psi of cean compressed air. See Setup. 7. Attach back hose to top couper; attach cear hose to bottom couper. See Setup. Cooant eve in cooant reservoir rising or overfowing during exchange procedure. Fuid eve in new cooant tank does not decrease during exchange. 1. Hoses connected to cooant reservoir not pinched cosed. 1. Cooant suppy hose not connected to new tank. 2. Vave on new cooant hose not competey OPEN. 1. Use piers to pinch off cooant overfow hose and other hoses connected to cooant reservoir. Refer to Vehice Connections. 1. Attach cooant suppy hose to dip tube cap on suppy tank. See Setup. 2. Open vave. See Exchange Process SPX Corporation

15 Fow Chart Air In Fiter / Reg Exhaust Air Reguator Vave 1 Bottom Pump Venturi Waste Tank New Tank Vave 1 Top Vave 2 Top Reguator Vave 2 Bottom P Vave 1 Fow Paths Bottom Top OFF / Pressure Test Vacuum Exchange Empty Waste Vave 2 Fow Paths Top Bottom OFF Exchange / Vacuum Pressurize Hod Coo Tech CooXchange 13

16 Accessories Here are some optiona accessories, avaiabe from SPX Robinair, to hep you take the guesswork out of servicing cooing systems. Radiator Cooant Dye Pinpoint eaks in radiators, water pumps, head gaskets, and hoses and fittings. Extended-ife dye is formuated for use in extended-ife cooants, which eimates the coor distortion probem found with existing radiator cooant dyes. Extended-ife dye is for use with red, orange, or yeow extended-ife cooants. Each botte services one vehice. No Extended-ife radiator cooant dye. Six (1 oz. / 30 m) bottes. No Standard radiator cooant dye. Six (.25 oz. / 7.5 m) bottes. Cordess / Rechargeabe True UV Light 12 LEDs produce high-intensity true UV ight. (100,000 hour LED bubs.) Nicke meta hydride battery (does not deveop a memory). Battery ife is 3 hours (continuousy ON). Incudes battery charger and UV-enhancing gasses. 1-year warranty. No Cordess & rechargeabe true UV ight. Wt., 9 oz. Cooant and Battery Refractometer Measures the freezing point of either propyene or ethyene-gyco based cooing systems. Checks eectroyte soution strength in batteries. Features high-quaity optics with utra-smooth focus. No Cooant and battery refractometer. Cooant scae range: 32 F to -60 F. No Cooant and battery refractometer. Cooant scae range: 0 C to -50 C SPX Corporation

17 Accessories Econo-Cean Cooant Service Accessories These toos hep adjust the cooant to the manufacturer s specifications. No Pocket ph pen. (Quicky shows the ph eve of the cooant, whether used or recyced.) No Cooant test strips. (Botte of 50 strips; just dip a strip in cooant, and it shows freezing point and ph.) Hose Pinch-off Piers Shuts off fow through vacuum ines, fue ines, cooant ines, etc. Ratchet mechanism hods pivoting jaws tighty in pace. Heavy-duty swive jaws pivot to ensure parae pinching. Three different sizes of piers are avaiabe. No in. too for sma hoses & tight areas. No in. too for radiator & vacuum ines. No in. too for radiator & vacuum ines Coo Tech CooXchange 15

18 Repacement Parts List No Repacement Suppy Tank w/ Cap (5 ga.) No Quick Couper Set No Step Adapter (2.25 { 2 { 1.75) No Dip Tube Assemby (1) Cear hose (waste cooant) (1) Back hose (new cooant) No Repacement Hose Set No Step Adapter (1.5 { { 1.25) No Repacement Pressure Gauge No Siphon Hose (5/16") No Repacement Pressure Reguator No Siphon Hose (3/8") No Repacement Pump Assemby SPX Corporation

19 This product is warranted to be free from defects in workmanship, materias, and components for a period of one year from date of purchase. A parts and abor required to repair defective products covered under the warranty wi be at no charge. Limited Warranty The foowing restrictions appy: 1. The imited warranty appies to the origina purchaser ony. 2. The warranty appies to the product in norma usage situations ony, as described in the Operating Manua. The product must aso be serviced and maintained as specified. 3. If the product fais, it wi be repaired or repaced at the option of the manufacturer. 4. Transportation charges for warranty service wi be reimbursed by the factory upon verification of the warranty caim and submission of a freight bi for norma ground service. Approva from the manufacturer must be obtained prior to shipping to an authorized service center. 5. Warranty service caims are subject to authorized inspection for product defect(s). 6. The manufacturer sha not be responsibe for any additiona costs associated with a product faiure incuding, but not imited to, oss of work time, oss of cooant, and unauthorized shipping and/or abor charges. 7. A warranty service caims must be made within the specified warranty period. Proof-of-purchase date must be suppied to the manufacturer. This Limited Warranty does NOT appy if: The product, or product part, is broken by accident. The product is misused, tampered with, or modified. The product has been used for any purpose other than exchanging and testing engine cooant.

20 Visit our web site at or Ca to-free in the continenta U.S. and Canada. In a other ocations, contact your oca distributor. To hep us serve you better, be prepared to provide the mode number, seria number, and date of purchase of your unit. To vaidate your warranty, compete the warranty card attached to your unit, and return it within ten days from date of purchase. If your unit needs repairs or repacement parts, pease contact a service center in your area. For hep ocating a service center, visit our web site at Due to ongoing product improvements, we reserve the right to change design, specifications, and materias without notice. SPX Corporation 655 Eisenhower Drive Owatonna MN Customer Service: Fax : Technica Service : Fax : Website : (Rev. A, ) Cooant Exchanger 2003 SPX Corporation