HF345 S9 Operators Manual 511 Bailey Ave PO Box 324 New Hampton, IA 50659 Fax: 1-641-394-6224 Email: hotflush@iowatelecom.net Visit us @ www.hotflusher.com
FLUSHING PRINCIPLE OIL COOLER INPUT HF FLUID OUTPUT-ATTACH TO RETURN LINE OF THE OIL COOLER. RETURN HF FLUID RETURN ATTACH TO INPUT LINE OF OIL COOLER. PLEASE REMOVE OR BYPASS CHECKVALVE BEFORE FLUSHING! SECURE RED & BLUE HOSE TO VEHICLE FRAME BEFOR FLUSHING THE PRINCIPLE TO FLUSHING OIL COOLERS IS TO BACK FLUSH THEM. THE ILLUSTRATION ABOVE SHOWS HOW THIS PROCESS IS ACHIEVED. THE BLUE HOSE (PRESSURE LINE) IS HOOKED TO THE RETURN LINE OF THE COOLER. THE RED HOSE (RETURN) IS HOOKED TO THE INPUT OF THE COOLER LINE. SELECT A TIMER SETTING AND THE HOT FLUSH MACHINE WILL BACK FLUSH YOUR COOLER USING ITS PATENED REVERSE FLUSH TECHNOLOGY. THIS ACTION REVERSES FLOW FROM THE BLUE LINE TO THE RED LINE EVERY 3 SECONDS FOR A 1/4 SECOND TO JOG CONTAMINATION LOOSE. A SHORT BURST OF AIR IS ALSO INJECTED EVERY 3 MIN TO HELP INSURE YOUR COOLER GETS CLEAN. WHEN YOUR 28 MICRON SCREEN OR THE 10 MICRON PREFILTER IS CLEAN, SELECT THE ONE WAY MODE TO CHECK COOLER FLOW. IN THIS MODE THE HOTFLUSH MACHINE SWITCHES THE FLOW OUTPUT FROM THE BLUE LINE TO THE RED AND SIMULATES NORMAL COOLER FLOW AS IF THE COOLER WERE HOOKED UP TO THE TRANSMISSION. IF YOU HAVE ANY QUESTIONS PLEASE CALL HOTFUSH @ 1-800-852-5713
Table of Contents Safety Precautions.....4-5 Control Panel....6 Getting Started..7-8 Maintenance....9 Anti Theft feature...10 Optional Industrial Kits 11-12
SAFETY PRECAUTIONS WARNING: 200 DEGREE HOT OIL TO PREVENT PERSONAL INJURY AND/OR DAMAGE TO MACHINE, PLEASE OBSERVE THE FOLLOWING. READ AND UNDERSTAND ALL INSTRUCTIONS, CAUTIONS AND WARNINGS BEFORE OPERATING THE HOT FLUSH MACHINE. DO NOT USE THE HOT FLUSH MACHINE FOR ANY OTHER PURPOSE THAN THAT FOR WHICH IT WAS DESIGNED. ALWAYS MAKE SURE THE HOT FLUSH MACHINE IS ON A LEVEL SURFACE. ALWAYS CONNECT THE POWER CORD DIRECTLY INTO A GROUNDED 220 VOLT OUTLET. ALWAYS WEAR PROTECTIVE CLOTHING AND GEAR, INCLUDING FACE SHIELD AND GLOVES THAT MEET OSHA STANDARDS. ALWAYS USE AUTOMATIC TRANSMISSION FLUID AS THE FLUSHING AGENT IN THE HOT FLUSH MACHINE. NEVER USE SOLVENT, GASOLINE, KEROSINE, OR ANY OTHER HIGHLY FLAMMABLE LIQUID IN THE HOT FLUSH MACHINE. NEVER USE AN AIR SUPPLY OF OVER 120 PSI, TO OPERATE THE HOT FLUSH MACHINE. NEVER OPEN THE MAIN CABINET DOOR OF THE HOT FLUSH MACHINE WITHOUT UNPLUGGING THE POWER CORD FIRST. CONTINUED ON NEXT PAGE 4
SAFETY PRECAUTIONS CONTINUED WARNING: 200 DEGREE HOT OIL TO PREVENT PERSONAL INJURY AND/OR DAMAGE TO MACHINE, PLEASE OBSERVE THE FOLLOWING. NEVER ALTER THE HOT FLUSH MACHINE IN ANY WAY. NEVER ALLOW THE HOT FLUSH MACHINE TO GET WET. NOTE : NEW OPERATORS MUST BE TRAINED OR HAVE READ AND UNDERSTOOD OPERATORS MANUAL BEFORE USING THE HOT FLUSH MACHINE. NOTE : AIR HOSE IS PROVIDED AS A CONVENIENCE ONLY, IT IS NOT REQUIRED AS PART OF THE FLUSHING PROCESS. NOTE : CLEANLINESS OF THE COOLER IS TO BE DETERMINED BY QUALIFIED PERSONNEL. NOTE : MACHINE OPERATES AT 90 P.S.I., QUALIFIED PERSONNEL MUST DETERMINE THE COOLERS ABILITY TO FUNCTION PROPERLY AT THIS PRESSURE. NOTE : A THOROUGH MONTHLY VISUAL INSPECTION OF THE HOSES WILL YIELD ANY EVIDENCE OF COVER DAMAGE, WEAR, ABRASION, BLISTERING, CRACKING, REINFORCEMENT EXPOSURE, OR OTHER TELLTALE EVIDENCE THE HOSE SHOULD BE REMOVED FROM SERVICE. NOTE : REPLACE HOSES IF THEY GET CUT OR IF THEY GET BENT BELOW A 3 INCH RADIUS. 5
13 2 11 1 14 12 3 10 8 9 6 5 4 7 FIGURE 1 1 2 3 4 5 6 7 Main Power Switch Power Supply Cord (220v) Manual Air Injection/Clean Out Button Air Gun Shut Off Timer Switch/One Way Switch (use one way setting with pre-heat attachment) Pressure Gauge Primary Fluid Return Line (Important Note: When the ONE WAY is selected on the shut off timer this line becomes the primary output line) 8 Reverse Indicator Light 9 Primary Fluid Output Line (Hook to return line of the cooler) 10 Heat Indicator Light 11 Flow Meter 12 Temperature Gauge 13 Pre heater hook up 14 Hour Meter 6
GETTING STARTED 1. REMOVE THE HOT FLUSH MACHINE FROM THE BOX. 2. REMOVE HOSE PACKAGE.FROM INSIDE CABINET 3. OPEN TOP LID & REMOVE COVER ON RIGHT. 4. GRAB T-HANDLE & LAY BOTTOM COVER TO SIDE & POUR IN 12-16 QUARTS OF ATF. 5. REPLACE BOTTOM COVER OVER RESERVOIR. 6. REPLACE TOP COVER. 7. ATTACH HOSES TO MACHINE, RED HOSE TO THE TURRET WITH THE RED DOT, BLUE HOSE TO THE OTHER TURRET. ( SEE FIGURE 2 ) 8. NOTE: IF THERE IS A CHECK BALL IN THE COOLER LINE, IT MUST BE BYPASSED ATTACH BLUE HOSE FIGURE 2 (THIS IS THE PRIMARY OUTPUT LINE) TO THE RETURN LINE FROM THE COOLER. IMPORTANT: IF THERE IS A CHECK BALL IN THE COOLER LINE, IT MUST BE BYPASSED!!! 9. ATTACH THE RED HOSE TO THE OTHER LINE. 10. HOOKING UP SHOP AIR SUPPLY: ATTACH MALE FITTING THAT MATCHES YOUR QUICK COUPLER AIR HOSE TO 1/4 COUPLER ON RIGHT SIDE OF MACHINE, ( SEE FIGURE 3 ) THEN ATTACH AIR HOSE. ALWAYS: USE AN AIR SUPPLY OF A120 PSI MAXIUM TO OPERATE THE MACHINE. (NOTE: PRESSURE GUAGE READS OIL PRESSURE LEAVING MACHINE WHICH WILL BE LESS THEN AIR SUPPLY PRESSURE) NOTE: MACHINE FIGURE 3 MUST HAVE AIR SUPPLIED TO IT AT ALL TIMES WHILE IN USE! 11. MAKE SURE MAIN POWER SWITCH ( #1 ) ( SEE FIGURE 1 ) IS IN THE OFF POSITION. 12. PLUG POWER CORD DIRECTLY INTO 220 VOLT ( 40 AMP ) GROUNDED OUTLET. 13. REMOVE T-NUT ON 28 MICRON SCREEN HOUSING ( SEE FIGURE 4 ) AND REMOVE THE CAP. FIGURE 4 7
GETTING STARTED 14. MAKE SURE 28 MICRON SCREEN IS CLEAN BY LOOKING AT IT AGAINST A BACKGROUND OF LIGHT AND TILTING BACK AND FORTH. WHERE YOU CAN SEE LIGHT THRU THE SCREEN, IT IS CLEAN. THE DARK AREA S, ARE THE ACCUMULATION OF MINUTE PARTICLES. TO CLEAN, AGITATE BACK AND FORTH IN A SOLUTION OF DISH SOAP & WATER. THEN BLOW OUT THE 28 MICRON SCREEN WITH AN AIR NOZZLE TILL DRY FROM THE BACK SIDE. (THE BACK SIDE IS THE SIDE THAT DOES NOT HAVE NUMBER S ON THE CENTER RUBBER GASKET) REPLACE THE 28 MICRON SCREEN IN HOUSING SO THAT THE NUMBERS ON THE CENTER RUBBER GASEKET ARE FACING UP. REPLACE THE CAP AND TIGHTEN T-NUT, SO OIL DOES NOT LEAK FROM HOUSING, WHILE RUNNING! 15. REPLACE COVER AND CLOSE LID. 16. OPTIONAL: TO PRE-HEAT THE OIL CONNECT THE ENDS OF THE TWO 8 HOSES TO THE PREHEAT ATTACHMENT. (SEE FIGURE 5) TURN SELECTOR KNOB (#5) TO ONE WAY POSITION, TURN THE PUMP SWITCH ON AND RUN THE MACHINE TILL IT REACHES DESIRED TEMPERATURE. TURN PUMP SWITCH OFF. PRESS & HOLD CLEAN OUT SWITCH (#3) ( FIGURE 1) FOR 5 TO 10 SECONDS. DISCONNECT HOSE FROM THE PRE HEAT ATTACHMENT AND CONTINUE. 17. SELECT THE PROPER FITTING FOR THE VEHICLE AND CONNECT THE BLUE HOSE TO THE RETURN LINE FROM THE COOLER AND THE RED HOSE TO THE INPUT LINE OF THE COOLER. ATTENTION: MAKE SURE LINES ARE SECURED TO VEHICLE AND SEPARATE FROM EACH OTHER, AS THERE IS A VIOLENT JOLTING ACTION THAT OCCURS DURING THE FLUSHING ACTION. 18. SELECT 15 MINUTE TIMER OPERATION. ( SWITCH #5 ) ( SEE FIGURE 1 ) 19. TURN PUMP ON & MAKE NOTE OF FLOW RATE ON THE FLOWMETER (#11) ( SEE FIGURE 1) SO YOU CAN MONITOR PROGRESS OF FLOW RATE, STOP FLUSHING AFTER 15 MINUTES BECAUSE SCREEN MAY FILL UP QUICKLY! 20. NOTE THE FOLLOWING STATEMENTS THEN CONTINUE WITH STEP 23 UNDER NORMAL OPERATING CONDITIONS. 21. ATTENTION! PUMP MAY SHUT OFF IF SCREEN BECOMES FILLED WITH EXCESSIVE DEBRIS. THOUGH THIS IS DESIGNED TO PROTECT THE SCREEN, IT SHOULD NOT BE RELIED UPON AS AN AUTO SHUT OFF. IF SCREEN BECOMES DAMAGED THEY COST $80 TO REPLACE! 22. NOTE: IF PUMP DOES SHUT OFF BECAUSE OF EXCESSIVE DEBRIS, TURN OFF MAIN POWER SWITCH (#1), TAP THE CLEAN OUT BUTTON (#3) (FIGURE 1) 6 TIMES TO PURGE OIL FROM FILTER HOUSING. DO NOT HOLD DOWN, CONTINUE WITH STEP #24 23. PRESS & HOLD CLEAN OUT SWITCH ( #3 ) ( FIGURE 1 ) FOR ABOUT 5 TO 10 SECONDS. 24. REMOVE T-NUT FROM 28 MICRON SCREEN HOUSING AND REMOVE CAP. 25. REMOVE 28 MICRON SCREEN. 26. EXAMINE SCREEN FOR DEBRIS, IF DEBRIS IS PRESENT, CLEAN PER INSTRUCTIONS IN STEP 14. REPLACE & CONTINUE TO FLUSH. 27. INSPECT AND CLEAN THE SCREEN EVERY 15 TO 30 MINUTES, YOU MUST BE ABLE TO FLUSH FOR AT LEAST 15 MINUTES AND HAVE THE SCREEN REMAIN CLEAN IN ORDER TO BE ASSURED THAT THE COOLER IS CLEAN! 28. ALSO REMEMBER TO REPLACE THE SECONDARY TANK FILTER IN YOUR HOT FLUSH AFTER 30 FLUSHES OR 20 HOURS. THIS RESERVOIR FILTER IS A TOP QUALITY OEM SPEC FILTER THAT CLEANS THE OIL TO 10 MICRONS, REDUCING WEAR TO THE REVERSING VALVE & PUMP. THE OIL REMAINS CLEANER AND LAST TWICE AS LONG. TO ORDER MORE CALL 1-800-852-5713. ATTENTION! THE MACHINE IS DESIGNED TO SHUT OFF IF THE RESERVOIR FILTER PLUGS DUE TO NO PRESSURE IN THE SYSTEM. PRE-HEAT HOOK UP FIGURE 5 8
MAINTENANCE Sonically clean 28 micron screen every 100 flushes Replace 28 micron screen at least once a year Change the reservoir tank filter before 30 flushes or 20 hours of operation maximum. 10 micron reservoir filter may become plugged before this time due to excessive cooler contamination. Before replacing filter, lubricate the oring inside the filter, then gently twist back & forth while pushing down with steady pressure over inlet pipe in bottom of reservoir. DO NOT FORCE! CALL 1-800-852-5713, TO ORDER MORE RESERVOIR FILTERS Change the ATF in the reservoir after 50 to 60 flushes or 35 to 40 hours of operation maximum. TO CHANGE OIL Splice the ends of the blue and the red 8 hoses together either at the preheat attachment (with quick connect kit) or leave both lines hooked up to a cooler. Locate drain hose and open the valve at the end. Drain oil into your waste oil container. Turn on the pump switch while holding the drain hose in the waste oil container When fluid stops, turn off the pump switch and close the valve on the drain hose Refill with 16 quarts of ATF 9
511 BAILEY AVE PO BOX 324 NEW HAMPTON, IA 50659 1-800-852-5713 ANTI-THEFT FEATURE GREEN LIGHT Your Hot Flush machine is equipped with a special anti-theft feature. At a specific interval, the Hot Flush will go into a shutdown mode & the green light on the control panel will stay lit. You must then call (800) 852-5713 to verify your shop information & serial #. You will then receive a special code to enter for your specific serial #. Each time the Hot Flush goes into shutdown mode you will receive a new code. 10
INDUSTRIAL QUICK CONNECT KIT Can be ordered at 1-800-852-5713 IFQC101 3/4 FEMALE FLARE SWIVEL TO QC IFQC107 1/2 FLARE TO QC IFQC102 FLATE FACE TO QC IFQC108 5/8 FLARE TO QC IFQC103 3/4 MALE FLARE TO QC IFQC110 FEMALE RECIEVER IFQC104 3/4 JIC TO QC IFQC111 ALLISON 1000 SERIES TO QC IFQC105 1/2 FPT SWIVEL TO QC IFQC112 ALLISON 4000 SERIES TO QC IFQC106 1/2 FEMALE FLARE TO QC 11
Industrial Fittings Kit Can be ordered at 1-800-852-5713 IF101 1/2 MPT X 3/4 FEMALE FLARE SWIVEL IF102 1/2 MPT X FLATE FACE IF103 1/2 MPT X 3/4 FLARE IF104 IF105 1/2 MPT X 3/4 JIC 1/2 FPT X 1/2 FPT SWIVEL IF106 1/2 MPT X 1/2 FEMALE IF107 1/2 MPT X 1/2 FLARE IF108 1/2 MPT X 5/8 FLARE IF109 1/2 COUPLING 12