Part No. PF General Information

Transcription

1 Reference Manual

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3 General Information Part No. PF The BG Big Dawg II Heavy Duty Power Flush and Fluid Exchange system is not just another piece of equipment, instead it is a complete transmission service. The system is designed to handle transmissions from those in small passenger cars to medium capacity heavy duty application, such as school buses, refuse trucks, some city buses, most dump trucks and other delivery vehicles. Modern automatic transmissions and their related parts suffer from overheating due to downsizing, higher operating temperatures and cramped quarters. Such applications as school buses, city delivery trucks, refuse trucks and city buses are especially tough on automatic transmission fluid because of their stop and go driving habits. Conventional drain and fill methods of changing the transmission fluid can only remove a portion of the transmission's actual capacity. The remaining large quantity of old oxidized fluid simply contaminates the new fluid and often the mixture causes more damage than if the old fluid had been left alone. Also, no efforts were made to chemically clean the inside of the transmission because the contaminants could not be removed. The BG Big Dawg II Heavy Duty Power Flush and Fluid Exchange System is the ultimate solution to effective transmission maintenance for all types of vehicles, regardless of age. BG Big Dawg II service begins with a thorough chemical flush with BG Quick Clean for Automatic Transmissions, Part No. 106, which cleans ALL internal transmission components. The service is specially designed to clean components such as the valve body (control center), the torque converter, oil galleys, clutch pack and filter screen. The service also cleans ALL externally connected components, including transmission lines and coolers. Cleaning lines and coolers is so important that the OEM's recommend this service and sell specialized tools for cleaning these components. Next, the BG Big Dawg II uses a simple and highly effective method of removing all the old fluid and flush while simultaneously installing new ATF of the exact specification required for each individual vehicle. The BG Big Dawg II does it cleaner, faster and more economically than conventional drain and fill methods. The final step in the BG Big Dawg II Heavy Duty Service is the installation of BG ATC Plus, Part No. 310, to restore pliability to seals and prolong the life of new ATF by protecting it from the ravaging effects of oxidation. The BG Big Dawg II Heavy Duty Service is not a repair service, it is a maintenance service. A thorough inspection of the transmission, including related components such as lines and coolers, should be performed and all repairs made before performing this service. Check the vent on top of the transmission to be sure it is open and functioning. Inspect seal areas and gaskets and replace any that are leaking or badly deteriorated. If the pan gasket needs replacing, it is recommended that the transmission filter be replaced as well. In fact, the filter should be changed anytime a repair service requires that the pan be removed. On heavy duty vehicles such as trucks and buses, always follow the manufacturers filter change and fluid change instructions. 1

4 Limited Warranty Part No. PF This product is warranted by BG Products, Inc. to be free of defects in workmanship and materials for a period of 1 year from the date of purchase by original purchaser. If the product fails within this period, it will be repaired or replaced at seller s option, provided (1) the product is submitted with proof of purchase date and (2) transportation charges are prepaid to the nearest Service Center. Liability under this warranty is expressly limited to repairing or replacing the product or parts thereof. This warranty does not apply to product or parts broken by accident, negligence, overload, abuse or if they have been tampered with or altered in any way. This warranty does not apply to service hoses and adaptors which may need replacing due to normal wear. If this warranty does not apply, then the purchaser shall pay all costs for labor, material and transportation. Note: The use of this apparatus for any purpose other than the services described will render this warranty null and void, as will the use of any chemicals other than the BG products described in this manual. No other warranties are expressed or implied. 2

5 Safety Requirements Part No. PF The following instructions must be read and understood before attempting to set up or use the BG Big Dawg II Heavy Duty Power Flush and Fluid Exchange System. 1. Carefully read the BG Big Dawg II Heavy Duty Power Flush and Fluid Exchange System Reference Manual before assembling and using any part of the system. 2. Before handling any chemical, read its Material Safety Data Sheets. 3. Wear safety goggles to protect your eyes. 4. Wear Nitrile, Neoprene or PVC gloves to protect your hands. 5. Wear a long-sleeved shirt. 6. A combination of mechanical and local ventilation should be used to prevent operator exposure to noxious fumes. 7. Keep all hoses and tools away from moving engine parts. 8. Check all lines and fittings for cracks and leaks before and after service. 9. Use EXTREME CAUTION when removing transmission lines and/or adaptors before and after the service. Transmission fluid could be under pressure and will likely be very hot. Be very careful in handling connections because they will also be very hot. 10. Dispose of used Automatic Transmission Fluid in accordance with Federal, State, and Local regulations. 11. The BG Big Dawg II Heavy Duty Power Flush and Fluid Exchange System is designed to be used only with BG products described in this manual. The use of any other chemicals or fluids other than conventional ATF, mineral- or synthetic-based, with this system will void all warranties and could create hazardous conditions. 12. Do not spray solvents on sight glass. Sight glass should be cleaned using mild detergents only. 3

6 Part No. PF Service Selector Control valve Sight glass Used ATF gauge New ATF gauge Manual fill valves & caps Service hoses Vent valve 4

7 Part No. PF Manual fill valves & caps New ATF gauge Service Selector Control valve Sight glass Used ATF gauge Service hoses Adaptor storage drawer 5

8 Part No. PF Initial Setup and Charging (Filling) 1. Unpack system and check for shipping damage and missing parts and components. Place adaptors in the drawer. 2. Connect service hoses to the ports on the side of the cabinet as shown in the drawing at right. Remove plug from drain valve and install barbed fitting. The drain valve is used to remove ATF from the transmission, when necessary, to make room for chemicals. 3. For initial charging (filling) of the apparatus: A. Turn Service valve to Heavy Duty. B. Turn the Control lever to Bypass/Recharge. Attach any open-end adaptor, to the end of either service hose. The adaptor opens the valve in the quick coupling to allow used fluid to flow out. Expect only a small amount of air during initial filling. C. Attach recharge adaptor to the Recharge port on the side of the unit. Be sure the vent valve on the side of the Big Dawg II is closed. Open valve on top of each tank (handle in parallel direction). Apply air pressure to the adaptor until the New ATF gauge reads approximately 50 PSI and the Used ATF gauge reads 0. Release air supply and turn the Control lever to Pressure Release until New ATF gauge reads 0. This procedure will move the rubber bladders into position for initial filling. Be sure the clear hose is connected to the vent valve on the side. Open the vent valve. Place the loose end of the hose into a clean container that can hold up to a quart of ATF. D. Remove Manual Fill valve cap from the Fill tube of one tank and install the included funnel. Slowly open the Manual Fill valve. There may be a small amount of air pressure or vacuum in the cylinder. Pour appropriate ATF into the funnel and keep filling until a full stream of fluid is visible at the vent valve on the side of the Big Dawg II. This procedure insures that the system is full and any trapped air has been removed. Allow fluid to drain from the vent valve until it is just below the Manual Fill valve on Manual Fill tube. Repeat for each tank. NOTE: All tanks must be filled initially, even if only one is to be used in service. E. Close the vent valve and all Manual Fill valves. Either cap the funnels or remove them and replace Manual Fill caps. This cap is not a pressure seal and should only be finger tight. F. Remove recharge adaptor. Remove the open-end adaptor from the sevice hose. The BG Big Dawg II Heavy Duty Power Flush and Fluid Exchange System is now ready for service. 6

9 Pre-service Checklist Part No. PF Be sure there is no pressure inside the unit. If a pressurized BG Big Dawg II is connected to a vehicle, fluid will be dispensed into the vehicle without removing any fluid and the transmission could be overfilled. Although the gauges may be indicating 0 pressure, that does not guarantee that there is not still enough pressure inside the system to dispense some fluid into the transmission. Always expect at least some pressure to be inside the unit. To remove pressure open the Drain and turn Control Lever to Pressure Release. Some fluid will be released so place a small container under the Drain. After pressure has been released, be sure to close the Drain! 2. At least one tank must be on line. Check the shut-off valves on top of each tank to be sure you have the correct number of tanks on line for the service capacity you wish to use. At least one tank must be on line that means the shut-off valve must be in the open position (parallel to the line). 3. Be sure Service Selector is in appropriate mode: Light Duty for cars and pick ups, Heavy Duty for larger vehicles. 4. The Control Lever must be in the Bypass/Recharge position when you start the engine. 5. If filling with pressurized ATF, the system must be filled through the Recharge port only. This is the only port that contains check valves and regulators necessary for filling the unit. 6. Do not attempt to use this system to exchange fluids from hydraulic systems. 7

10 Operating Instructions for Light and Heavy Duty Applications Part No. PF Open shut-off valves on the appropriate number of tanks (determined by the transmission s fluid capacity refer to model-specific transmission fluid capacities in the back of this manual). Tanks may be used in any combination. At least one tank must be on line! Be sure tanks are filled with the correct fluid. 2. Start vehicle s engine and run until normal operating temperature is reached. Turn engine off. If the internal transmission filter(s) is going to be changed, do it at this time. Drain the transmission pan into a clean container and save the fluid. Drop the pan and install new filter(s). Clean the pan and install new gasket. Reinstall pan and refill with the fluid just removed. 3. Check transmission fluid level adjust to normal. 4. Add the appropriate amount of BG Quick Clean for Automatic Transmissions, Part No. 106, through the transmission fill tube. Start engine and drive the vehicle for at least 10 minutes, but no longer than 30 minutes. If it is not feasible to drive the vehicle, allow vehicle to idle for minutes. With the engine idling, the parking brake firmly set and the brakes applied, shift the transmission through all gears so that the BG Quick Clean circulates through all areas of the transmission. CAUTION: Increasing engine RPM in this procedure will rapidly increase fluid temperature beyond acceptable limits and is not recommended. 5. Turn engine off. Locate a junction at the radiator, transmission or external transmission cooler that is easiest to access. Avoid connecting to transmission external filter lines. The pressure in these lines may exceed 300 PSI and could trip the pop-off valve in the BG Big Dawg II causing fluid to be expelled from the unit. Separate the line at the junction and attach adaptors to both ends of the line it does not matter which line the service hoses are attached to since the BG Big Dawg II will adjust itself for proper flow direction. Be certain that the Service Hoses are connected to transmission lines and NOT power steering or engine oil cooler lines. Many of these lines look similar. 6. Turn Service Selector to Light Duty for cars and pick ups, Heavy Duty for larger vehicles. 7. Turn Control Lever to Bypass/Recharge and start the engine. In the sight glass verify that there is flow. If there is no flow, turn engine off immediately and recheck all quick connectors to be sure they are fully engaged. 8. Turn Control Lever to Process/Purge. With the parking brake firmly set and the brakes applied, immediately shift the transmission through all gears to ensure that the valve body is thoroughly flushed before process is complete. Process time depends on the diameter of transmission lines, the pressure put out by the transmission pump and the number of tanks on line. The system is fully automatic from this point and will go into bypass mode when the fluid exchange is complete. 8

11 Part No. PF Note the pressure on the New Fluid Gauge and Used Fluid Gauge at the beginning of the exchange. Fluid exchange is complete when there is a pressure differential between the gauges of approximately 20 PSI or higher. Pressures are generally lower on Light Duty vehicles and there may be only a 10 PSI differential when the fluid exchange is complete. 10. When the exchange is complete, recheck fluid level. If it needs lowering to accomodate BG Automatic Transmission Conditioner (see Step 10), remove fluid through the Drain. Turn engine off and turn the Control Lever to Pressure Release to release pressure trapped inside the BG Big Dawg II. 11. Remove adaptors and reconnect transmission lines. Change external filters on the vehicle (if applicable). Install the appropriate amount of BG Automatic Transmission Conditioner (ATC), Part No Start engine, check fluid level and inspect for leaks at connections and filters. BG Big Dawg II Heavy Duty Power Flush and Fluid Exchange service is complete. 9

12 Recharging Part No. PF The tanks in the BG Big Dawg II Heavy Duty Power Flush and Fluid Exchange System must be recharged with new ATF before the next service. They can be recharged easily and quickly from any ATF source and with any factory specification ATF required by the next vehicle to be serviced. The process for recharging the apparatus will also discharge the captured used fluid from the last service. To recharge apparatus by either pressurized or manual filling, turn Control lever to Bypass/ Recharge. Attach any open-end adaptor to the end of either service hose and place end in the used oil receptacle. Be sure that the other service hose does NOT have an adaptor attached or fluid will come out of both hoses. Next, attach recharge adaptor to the Recharge port on the side of the cabinet. Do not attempt to apply air or fluid pressure to the service hoses because these are not regulated and the system will be damaged. Attach to shop air for manual filling or to the shop s pressurized ATF supply hose for pressure filling. Be sure all Manual Fill valves and vent valves are closed. Pressurized Recharging: IMPORTANT! Be sure valve(s) on top of tanks to be recharged are in the open position! 1. Turn Service Selector to Heavy Duty. 2. For pressurized recharging, turn Control lever to Bypass/Recharge and apply pressurized ATF to the recharge adaptor on the Recharge port and let chambers fill until Used ATF gauge reads 0 and pressure on the New ATF gauge starts to rise. This reading indicates all used fluid has been expelled and the tank is now filled with new fluid. 3. Turn Control lever to Pressure Release. Pressure is vented back into the service hoses and on the used oil storage tank through the hose that is opened. Always completely fill the BG Big Dawg II regardless of the capacity of transmission being serviced. Recharging is complete. The BG Big Dawg II Heavy Duty Power Flush and Fluid Exchange System is ready for the next vehicle service. 10

13 Part No. PF Manual Recharging: 1. Turn Service Selector to Heavy Duty. 2. For manual recharging, turn Control lever to Bypass/Recharge and attach the recharge adaptor to the Recharge port on the side of the cabinet. Make sure the vent valve on the side of the Big Dawg II is closed. Place the hose from the vent valve into a clean empty container. Attach any open-end adaptor to the end of one of the service hoses and place the end into the used oil receptacle. 3. Apply shop air into the recharge adaptor on the Recharge port, until the pressure reading on the Used ATF gauge reads 0. This indicates that all used ATF has been expelled and bladder is fully collapsed against the bottom of the tank. Remove the air supply and turn the Control lever to Pressure Release until the New ATF gauge reads Next, remove Manual Fill valve cap from one tank and slowly open the Manual Fill valve. Install included funnel for easier pouring. Open the vent valve on the side of the Big Dawg II. This will allow air to escape from the tank while pouring in the ATF and will also make it easy to tell when the system is properly filled. 5. Pour ATF into the funnel until a solid stream of fluid runs out of the vent valve. This signals that the system is completely full and there is no air in the lines. Allow ATF to drain out the vent valve until the level in the funnel is just below the Manual Fill valve. The ATF captured from the vent valve is new and can be used for top off or, it can be put back into the new ATF supply container. 6. Close the Manual Fill valve and replace Manual Fill cap or cap the funnel. 7. Repeat Steps 3, 4, 5 for each tank. Recharging is complete. The BG Big Dawg II Heavy Duty Power Flush and Fluid Exchange System is now ready for the next service. 11

14 Purging New ATF Part No. PF The following procedure applies to removing new ATF from a fully charged unit. This is necessary to charge the unit with a different transmission fluid or to empty the unit for maintenance. 1. Open shut-off valves on tanks to be purged. 2. Attach open-end adaptor to the end of either service hose and place end into appropriate receptacle. 3. Locate the Bladder Inverting port inside the unit and attach Recharge Adaptor. 4. Turn Control lever to Process/Purge. 5. Apply shop air into the Recharge Adaptor until only air is exhausted from the service line. (Too much air pressure will cause most of the air to bypass the tank resulting in a mixture of air and ATF to be exhausted.) 6. Turn Control lever to Pressure Release to complete purge process. The BG Big Dawg II Heavy Duty Power Flush and Fluid Exchange System is now empty and can be recharged with a different ATF. 12

15 Part No. PF Possible points to make connections on light/medium trucks (Note: It is only necessary to disconnect one line) CAUTION: Be sure the line you have is a transmission fluid line and not an engine oil line. Crossflow radiator with ATF cooler on side Transmission front wheel drive Crossflow radiator with ATF cooler on opposite side Transmission rear wheel drive Top tank with ATF cooler on bottom and opposite side External ATF cooler 13

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17 Part No. PF Connection may be made at any accessible point along the automatic transmission fluid (ATF) route. However, it is possible that the adaptors may not fit every connection encountered. Radiator Transmission External cooler 15

18 Parts Identification list Part No. PF New Fluid Pressure Gauge 200 PSI 2. Used Fluid Pressure Gauge 200 PSI 3. Sight Glass 4. Three-Way Ball Master Control 5. Service Selector Ball 6. Tank Bladder Inverting Port With Quick Coupler, Part No. SP Pressure Bypass 8. Pop Off 200 PSI 9. Flow Direction Rectifier Assembly 10. Recharge Pressure Regulator 11. External Service Hose (2) 12. Pressure Recharge Port with Male Quick Connect, Part No. SP Manual Recharge Ball (2), Part No. TF Individual Tank Cut Off (2), Part No. SP Manual Fill Tube Check (2) 16. Recharge Indicator (2), Part No. BD Upper Tank Half (2), Part No. BD0452D 18. Tank Bladder (2), Part No. BD Tank Clamp Ring (2), Part No. SP Tank Bottom (2), Part No. BD Vent 22. Strainer (3) 16

19 Part No. PF Parts Identification Diagram 17

20 Part No. TF832QC TF83242QC 90 quick connect TF83202QC 1/4 open hose, mate 01 TF83203QC 1/4 & 5 /16 barb, mate 04 TF83204QC 5/16 open hose, mate 03, 27 TF83206QC 3/8 open hose, mate 05, 25, 35 TF83207QC 3/8 & 1 /2 barb, mate 08 TF83208QC 1/2 open hose, mate 07, 26, 28, 33 TF83209QC 3/8 male flare SAE, mate 10, Volvo, Isuzu, Jeep TF83210QC 3/8 female flare SAE, mate 09, Volvo, Isuzu, Jeep TF83211QC 5/16 male inv. flare, mate 12, most GM products TF83212QC 5/16 female inv. flare, mate 11, most GM products TF83213QC 1/4 male pipe thread, mate 14, requires Ford tool P/N 7244 for some 85 & later TF83214QC 1/4 female pipe thread, mate 13, requires Ford tool P/N 7244 for some 85 & later TF83215QC 3/8 male inv. flare, mate 22, Jeep 79 & older, some GM TF83216QC 1/2 male inv. flare, mate 37, GM products TF83217QC 3/8 inverted flare, long, mate 32, Ford, Mercury TF83218QC 5/16 inverted flare, long, mate 31, Ford, Mercury TF83219QC Recharge adaptor (optional) TF83220QC 3/4 open hose, mate 43 TF83221QC 5/16 male SAE, mate 23, GM products TF83222QC 3/8 female inv. flare, mate 15, Jeep 79 & older, some GM TF83223QC 5/16 female flare, mate 21, GM products TF83224QC 7/16 inv. flare, mate 38 TF83225QC 3/8 spike quick connect, mate 72, late Chrysler TF83226QC 1/2 spike quick connect, mate 79, late Chrysler TF83227QC 5/16 spike quick connect, mate 80, Windstar, Villager TF83228QC GM male quick connect, mate 72, Blazer, Impala TF83229QC 5/8 18 male flare, mate 30, Contour/Mystique TF83230QC 5/8 18 female flare, mate 29, Contour/Mystique TF83231QC 5/16 long female, mate 18, Ford, Mercury TF83232QC 3/8 long female, mate 17, Ford, Mercury NOTE: Adaptor set contents subject to change. 18 continued on next page

21 Part No. TF832QC continued from previous page TF83233QC GM large male quick connect, mate 79, late GM only TF83234QC 3/8 male flare, 37 JIC, mate 39 TF83235QC Male banjo adaptor, mate 06, Ford Escort TF83236QC Female banjo adaptor, Ford Escort, use with factory banjo bolt TF83237QC 1/2 inverted female flare, mate 16, GM products TF83238QC 7/16 inverted female flare, mate 24 TF83239QC 3/8 female flare, 37 JIC, mate 34 TF83240QC 5/16 male flare, fine thread, mate 41, Chrysler truck TF83241QC 5/16 female flare, fine thread, mate 40, Chrysler truck TF83243QC Pick up w/allison quick connect, mate 73 TF83272QC 3/8 GM quick connect female, mate 28, 25 TF Replacement clip TF83273QC 5/8 GM Quick Connect Female, mate 43 TF Replacement clip TF83277QC 5/8-18F Jeep Liberty adaptor, mate 45 TF83278QC 3/8 male adaptor, Corvette & Ford trucks, mate 06 TF83279QC 1/2 female quick connect, mate 26, 33 TF Replacement clip TF83280QC 5/16 female quick connect, mate 27 TF Replacement clip TF83284QC 1/2 male inverted flare-long TF83285QC 1/2 female inverted flare-long TF83288QC 1/2 male adaptor, F350 Powerstroke G /8 MNPT x 1 /4 hose barb, straight, brass TF83245QC Jeep Liberty adaptor, mate 77 TF83248QC Male adaptor 11 /16 16 Jeep Cherokee mate 49 TF83249QC Female adaptor 11 /16 16 Jeep Cherokee mate 48 NOTE: Adaptor set contents subject to change. 19

22 Part No. BD0300 PF850A Light duty adaptor hoses (2) BD0228 HD adaptor hose female BD0201 3/4 O-ring face elbow (2) BD0227 HD adaptor hose male 5/8 O-ring face seal Optional adaptors BD0207 BD0208 5/8 JIC (37 flare) BD0209 BD0210 3/4 JIC BD0211 BD JIC BD0233 Allison New World Transmission adaptor kit BD0213 BD0214 BD0215 BD0216 3/4 SAE (45 flare) BD0231 Adaptor, 20 mm DIN male (Isuzu Cabover w/allison) 1/2 O-ring face seal BD0217 BD0218 1/2 JIC (37 flare) BD0232 Adaptor, 20 mm DIN female (Isuzu Cabover w/allison) BD0219 BD0220 NOTE: Adaptor set contents subject to change 20

23 NOTE: Entire system is pressurized during all operations even though ATF may not be flowing through all components. Process/Check Flow New ATF Used ATF NEW ATF Gauge Processing Route Service Selector Sight Glass USED ATF Gauge Process/Check Flow Automatic Bypass Engaged New ATF Used ATF NEW ATF Gauge HEAVY DUTY MODE Service Selector Sight Glass USED ATF Gauge Control Lever Control Lever Bypass s Pressure Regulator Bypass s Pressure Regulator Manual Fill Fill Tube Check Tank Shut-off Manual Fill Tank Shut-off Fill Tube Check Manual Fill Fill Tube Check Tank Shut-off Tank Shut-off Manual Fill Fill Tube Check Side Vent Recharge Indicator Recharge Indicator Side Vent Recharge Indicator Recharge Indicator Process Tank with Bladder Process Tank with Bladder Process Tank with Bladder Process Tank with Bladder Process/Check Flow Automatic Bypass Engaged New ATF Used ATF NEW ATF Gauge LIGHT DUTY MODE Service Selector Sight Glass USED ATF Gauge Process/Check Flow New ATF Used ATF Recharging Route NEW ATF Gauge Service Selector Sight Glass USED ATF Gauge Control Lever Control Lever Bypass s Pressure Regulator Bypass s Pressure Regulator Manual Fill Fill Tube Check Tank Shut-off Tank Shut-off Manual Fill Fill Tube Check Manual Fill Fill Tube Check Tank Shut-off Manual Fill Tank Shut-off Fill Tube Check Side Vent Recharge Indicator Recharge Indicator Side Vent Recharge Indicator Recharge Indicator Process Tank with Bladder Process Tank with Bladder Process Tank with Bladder Process Tank with Bladder 21

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26 Part No. PF X V 24 BG No. PF19-002