MPS 7100 STEERCLEAN-II

Manual P/N 100-7100 Rev. A, 2006

MOTORVAC TECHNOLOGIES INC.

SteerClean-II Power Steering Service System

Operator Manual MODEL #500-7100

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Table of Contents

Introduction........................................................................................................................................... v Overview................................................................................................................................................ 7 System Features and Functions ......................................................................................................1-1

Control Panel Features and Functions .........................................................................................1-2 Left View .......................................................................................................................................1-3 Right View…………………………………………………………………………………………………1-4 Training (S.T.O.P.) Mode …………………………………………...................................................1-5 In Case of Emergency …………………………………………........................................................1-6

Safety Information .............................................................................................................................2-1 Before You Begin...............................................................................................................................3-1

First Time Operation .....................................................................................................................3-1 Service Procedure .............................................................................................................................4-1 Selling the SteerClean-II Service......................................................................................................5-1 Troubleshooting and Additional Help .............................................................................................6-1 Appendix A - Maintenance............................................................................................................... A-1

Maintenance Procedures ..............................................................................................................A-1 Cleaning the Unit’s Filter Screen ………………………………………………………………………A-1 Maintenance Record.....................................................................................................................A-3

Appendix B - System Accessories ................................................................................................. B-1 Adapter Kits ………………………………………………………………………………………..……..B-1

Appendix C - Parts ........................................................................................................................... C-1 Service Parts ............................................................................................................................... C-1 Ordering Parts……………………………………………………………………………………………C-1

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Notes:

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Introduction

Congratulations on your selection of the MotorVac STEERCLEAN-II Service System. By choosing this product, you are acquiring the most technologically advanced method available for power steering service and fluid exchange. The STEERCLEAN-II System is a self-contained system; designed to service virtually all power steering systems. Once the unit is connected, it can be used to exchange all the old power steering fluid with new, while flushing and conditioning the fluid at the same time. With the engine idling, simply push the Start button and follow the verbal commands. The STEERCLEAN-II Service System is designed to be fast, easy, and highly profitable. How profitable is up to you! Every car or truck that comes into your shop with over 30,000 miles is a potential customer. This service is also recommended every two years. But the key to profit is to sell the service, so we have included a detailed sales procedure at the end of this manual. It is recommended that a vehicle’s power steering system be serviced every 30,000 miles or every two years (Or according to the vehicle owner’s manual) to obtain the highest lubricant protection, to reduce friction and wear from internal components, and thus increase the efficiency and life span of the power steering system to it’s maximum. Please study this Operators Manual to become thoroughly familiar with the STEERCLEAN-II Power Steering Service System.

IMPORTANT

The STEERCLEAN-II Service System is designed to work EXCLUSIVELY

with MotorVac Products.

Use of other chemicals during this process may cause operational failure of the STEERCLEAN-II System and voids the manufacturer’s warranty.

See warranty card for details.

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Notes:

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Overview This manual contains all the information you need to use the STEERCLEAN-II System. Please make sure all technicians using the unit read this manual and have it within easy reach whenever the unit is being used. The following is a quick reference to the information in this manual: System Features and Functions

This chapter describes the STEERCLEAN-II Service System’s Switches, Lights and Connections.

Safety Information

Adhere to the safety guidelines in this chapter at all times!

Before You Begin

Follow the instructions in this chapter before using the unit for the first time. Service Procedure

This chapter contains step-by-step setup and service procedure for using the unit to flush the vehicle’s power steering system fluid completely.

Frequently Asked Questions Helpful information to common questions. Troubleshooting and Additional Help

Turn to this chapter in the unlikely event you have problems with your STEERCLEAN-II System or need additional help.

Appendices - Maintenance, Accessories, and Parts

The appendices contain routine maintenance procedures for the STEERCLEAN-II System, such as cleaning the filter screen, lists of available accessories, replacement parts.

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System Features and Functions The front of the MotorVac SteerClean-II cabinet showing the control panel, waste hose, service hoses and sink.

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Control Panel Features and Functions

A. Start Button Press the Start button to begin the service, (or continue the service if paused.) B. STOP Button To momentarily STOP the service, press the STOP button. The “Running” light will blink indicating “pause”. Use the STOP button to access the Training (S.T.O.P.) mode. (Hold the STOP button down and then connect to the vehicle battery.) C. Drain Button When pushed, will empty the on-board waste fluid tank. NOTE: Tank must be emptied after each service. The waste fluid tank must be emptied before a new service can be started. Flashing DRAIN TANK Light will indicate need to empty tank. D. System Lights Illuminate during service indicating each procedure running at the time. E. Low Battery Light Illuminates below 12.0 volts. F. Circuit Breaker The 10 amp circuit breaker protects the electronics. G. Fluid Tanks Cleaner and Power Steering fluid tanks.

A

B

C

D

E

F

G

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Left View

A. Battery Cables Positive (red) and negative (black) battery connections. B. check valve Disposal hose check valve to minimize fluid spill. C. Waste fluid hose Allows flow from Waste tank to oil disposal container.

A

B

C

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Right View

A. Sink Stores the “wand” and acts as waste tank overflow. B. Service Hoses New and used fluid delivery hoses C. Wand Inserts into the vehicles power steering reservoir.

A

B

C

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Training (S.T.O.P.) Mode The MotorVac Power Steering Fluid Exchange machine has been designed with its own training mode, to allow technicians to learn the operating procedure without having to connect it to a car, or actually exchange fluid. This allows the technician to become comfortable with the procedure, before servicing a customers car. To enter the S.T.O.P. mode (for Supplemental Training On Premises);

continued next page

Now you can watch and listen, as the SteerClean-II goes through its paces. You can actually hear the voice prompts, and watch the indicator lights just as you would during a real fluid exchange. The only difference is that no fluid is transferred during the STOP procedure. Go through the STOP procedure as often as you like, until you are comfortable with the entire procedure. When done, reset the battery connections.

Press and hold the STOP button while connecting power cord to battery.

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In Case of Emergency…...

Suppose the wand falls out of the reservoir… Or the engine stalls…Or the phone rings… If you cannot continue performing the service or something happens that requires you to stop the service momentarily, press the STOP button.

After pushing the STOP button, the Running light will begin to blink, telling you the machine has been ‘paused’, and go solid when the Start button is pushed.

Once you are ready to restart the service, press the Start button and the service will continue from where it left off.

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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. This list is by no means complete. Always pay close attention to the job at hand and obey all safety procedures. Read and understand the operator’s manual before using the STEERCLEAN-II 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 STEERCLEAN-II Service System can cause injury. Spilled service 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. Explosion or flame or exposure to flammable liquid and vapors can cause injury. Flammable liquid (service fluid) can splash out of reservoir when filling. Steering Fluid temperatures can reach in excess of 350°F, which can cause serious injury to the human body. Always keep Reservoir Cap secure except when filling reservoir. Explosion or flame can cause injury. Power steering systems may maintain residual pressure in connection lines to and from pump even after the engine has been turned off. Wear safety goggles. Wear chemical resistant gloves when connecting or disconnecting fitting and adapters. Do not swallow or ingest any chemicals.

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Use with adequate ventilation. Avoid breathing vapors. Improper use of service 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.

Moving engine parts. 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 is connecting 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. Always use a fender cover when working under the hood, to protect vehicles finish. Rinse any spills with water immediately.

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Before You Begin

First Time Operation

NOTE This unit has been tested using MotorVac SC8 Superior Universal Power Steering Fluid, and is ready for service after receiving inspection of the unit. Operate in above 50 degrees Fahrenheit area. Remember to send in your warranty card.

NOTE Check the output/return hoses, battery connections, and all external components for damage. See page 1-5 to enter the Training Mode. This allows the technician to become comfortable with the procedure before actually performing a service on a car

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Beginning the Service……

Performing a Standard Fluid Exchange:

The MotorVac SteerClean-II Power Steering Fluid Exchange machine is designed to flush all of the old fluid along with any contaminates out of the entire power steering system, and replace with the MotorVac SC 8 Superior Universal Power Steering Fluid. For most vehicles, this is as simple as one, two, three. 1 – Connect unit to the vehicles battery 2 – Install the unit’s wand into the vehicles power steering reservoir 3 – Push the start button

Here is the step-by-step procedure for a complete fluid exchange using the MotorVac SteerClean-II system.

STEP ONE. Remove cap from “Flush Fluid” tank and pour flush fluid into tank. (MotorVac SC7) 16 ounces. Replace cap.

STEP TWO. Remove cap from P/S fluid tank and pour Power Steering fluid into tank. (MotorVac SC8) 64 ounces. Replace cap.

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Standard Fluid Exchange (Continued): Standard Fluid

STEP FOUR: Connect the unit’s Battery Cables to the vehicles battery. Red to positive, black to negative. The Ready light will now be flashing.

STEP FIVE: Press the Start button. The Ready light will now go solid. Follow the audio prompt. Start the engine. When the Cleaning light is flashing, turn the steering wheel lock to lock at least twice.

STEP THREE: Remove the cap from the vehicles Power Steering reservoir and place the fluid Wand inside. The position of the ‘short’(suction) hose on the wand will control the fluid level during the service.

STEP SIX: Follow the audio prompt. When the Protecting light is flashing, turn the steering wheel lock to lock at least twice.

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STEP SEVEN: After the Protecting cycle is complete, the Completed light will come on solid and the audio prompt will announce that the service is complete. Stop the engine. Remove the wand and place back in the units sink. Follow the manufactures instruction for checking the level in the power steering reservoir.

STEP EIGHT: Once the service is complete, the DRAIN TANK light will be flashing. Place the waste hose in the shops waste oil container and push the DRAIN button. The DRAIN TANK light will go solid. Allow pump to run until pump stops. If DRAIN TANK light goes from solid to blinking, the STOP button may then be pushed to reset unit.

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Notes;

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Selling The Steer Clean –II Service The Sale: Since the MotorVac SteerClean-II Power Steering Fluid Exchange Service System is new, virtually every car or truck with at least 30,000 miles is a potential candidate for this service. You can sell the service based on fluid condition or mileage. To sell based on fluid condition, place a drop of the customer’s power steering fluid on a clean rag or piece of paper, and then place a drop of new fluid next to it. Show this to the customer. Explain that the old fluid is burnt, dirty, and contaminated. It is no longer able to provide the lubrication and protection needed. Over time, the fluid will damage power steering components, leading to failure. To sell based on mileage, you’re on solid ground by recommending the service as regular maintenance. Some auto manufactures are recommending the power steering fluid be replaced every 30,000 miles. Just as automatic transmissions require regular fluid replacement, so do power steering fluids. The Six Most Common Objections: 1 – “I’ve never heard of servicing the power steering system.” Your reply: Until recently, there was never a practical cost effective way to replace power steering fluid. With the MotorVac SteerClean-II System, you actually introduce a cleaning agent first (SC7 Flush Detergent), and then flush the system completely with MotorVac’s SC8 Superior Universal Power Steering Fluid. In under ten minutes, your power steering system protected with the necessary conditioners and lubricants. 2 – “I can’t afford it.” Your reply: With the high cost of labor and parts especially for a power steering rack or power steering pump, how can you not afford it? We can offer you a special price today to close the deal. 3 – “The cars not worth it.” 4 – “It’s a lease car, why spend the money?” Your reply: (Treat both 3 & 4 the same) Servicing your car’s power steering system isn’t about the car; it’s about your safety, and the safety of your family. Consider how a power steering failure could impact your life. 5 – “ I’m getting rid of the car soon.” Your reply: To get the most out of your sale, show the buyer that you have done everything possible to keep the car in good running condition, including servicing the power steering system. 6 – “ Why doesn’t my owners manual say anything about it?” Your reply: Some major auto manufacturers are recommending servicing the power steering. Others will probably follow soon. We recommend the MotorVac SteerClean-II Service to keep your cars power steering system like new!

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Follow up: Always answer any questions as truthfully as possible, and then always come back to the sales question: Can we take care of that for you now? Once his objectives have been satisfied, you have good chance of selling the service.

Notes:

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Troubleshooting and Additional Help Refer to the list below in the unlikely event that you have problems with your SteerClean-II Power Steering Service System.

Problem: Solution: 1. Unit does not power-up, no LEDs

are lighted

-Inspect power cord for breaks -Reset Circuit Breaker -Verify 12 volts available from battery.

2. Vehicle reservoir is overflowing

Check the ‘cleanable’ screen filter inside the back cover for blockage. “Wand” suction hose may be blocked with debris.

3. The Waste Tank pump is running, but nothing is coming out of the waste hose.

-The waste tank has a filter in-line between the pump and the waste tank. To access, remove the front “lower” metal cover. The filter and pump are located in the space below the waste capture tank. Clamp the hose closed between filter and tank. Push together and twist the two halves of the filter in opposite directions and separate. Remove screen with sharp pointed probe to clean. Reassemble. Align slots and push and twist filter closed. Be careful not to pinch the o’ring. Remove clamp and check for leaks.

ADDITIONAL HELP

Please verify that items above have been reviewed before calling for additional assistance. In the unlikely event that problems persist with the unit call Technical Support, have your model and serial numbers available before you call. Remember to send in your warranty card. In the U.S. Canada: (800) 841-8810 Contact your local

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(714) 558-4822 MotorVac distirbutor

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ELECTRICAL CONNECTIONS TO CONTROL BOARD.

Pump# WIRE COLORS GOES TO A Green/black ‘flush’ fluid pump B Brown/black “large” vacuum pump C Blue/black Waste tank pump D Yellow/black Power steering fluid pump White/black Low level switch in waste tank Red/black Power & ground leads

LOW LEVEL SWITCH

PUMP D POWERPUMP APUMP C

PUMP B

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Appendix A - Maintenance

Maintenance Procedures

The following maintenance procedures should be performed on a routine basis:

1. Carefully clean the exterior with a soft cloth to keep the cabinet

looking new. Check the cabinet for dents or impact markings, if found, inspect for damaged components.

2. Check all hoses and wires for cuts or frays.

3. Clean the unit’s waste filter screen after every 100 services or 6 months, which ever comes first. See the next section for procedure.

Cleaning The Unit’s Filter

1. Disconnect power harness from any power source.

2. Place unit on suitable catch tray.

3. Remove the lower front ‘metal” cover to expose the filter on bottom

‘waste fluid tank. Remove the back cover to access the Suction line filter.

4. Hold the bottom (black) half of the filters while rotating the other (clear) half of the filters counter-clockwise. Then separate the two pieces by pulling apart.

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5. Use a fine pick or bent pin to pull screen away from the filter housing.

Clean screen. 6. Assemble in reverse order. NOTE: Use caution not to pinch o’ring

on reassembly 7. Enter initials, date, and a check mark in the appropriate boxes of the

Maintenance Record at the end of the chapter.

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Clean fluid tanks - filter cleaning procedure.

1. remove the back panel cover. 2. disconnect hose connections that lead to the external hose

fittings. 3. disconnect wiring connectors to pumps. 4. remove sub-assembly from cabinet. 5. disconnect hose from bottom tank fitting. 6. remove bottom tank fitting. 7. use a pick to pull the internal filter out of the tank for cleaning. 8. re-assemble in reverse order.

Bottom hose fitting

Internal tank filter

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Maintenance Record Use the following table to keep a record of maintenance performed on the unit. Initial/Date

DRAIN WASTE TANK

CLEANED FILTER

CLEAN EXT. CABINET

CHECK HOSES AND WIRES

OTHER

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

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Standard Adapters

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Appendix C –External Parts

Service Parts for the SteerClean Power Steering Service System. Please refer to the part numbers below when ordering parts for this unit.

Part # Description 010-0027 Wheel (8 x 1.75) 010-0026 Hub cap (Black Plastic) 040-0604 Cap Nut (½” ID – Push 0n) 040-0507 Axle Bushing (Black Nylon) 010-5500 Axle, Rear Wheels (½” x 20.875 lg.) 010-5004 Hose bracket 200-7111 Control panel assembly with Printed Circuit Board 020-5341-VERSION-2 PROM. Printed Circuit Board 020-8043 Harness, External Power 050-1000 Screen filters- inline, ½ MPT. Pp. 050-3013 Check valve (1psi), (disposal hose) 200-7057 Output/Return Service hose assembly / Clear Braided 080-6009 Hose Clamp, 3/8”( Crimp Style, Steel ) 080-6016 Hose Clamp, 1/4”( Crimp Style, Steel ) 200-4064 Disposal hose assembly 100-7100 Operators Manual 010-6060 Fluid tank cap

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Internal parts – MPS-7100

SUB-ASSEMBLY #1 PUMPS & TANKS

CUE PART NUMBER DESCRIPTION Q’TY A 010-7100 Fluid Tanks 2 B 070-0090 ½” Hose (sold by the foot) C 030-4013 ½” female “T” fitting 1 D 050-3009 1 lb. check valve 2 E 050-2406 Pump 2 F 030-4410 Elbow fitting ½”TB x 3/8”MCT for Suction pump. 2 G 050-2400 Vacuum pump 1 H 040-0618 Screw ¼-20 X ½”php 8 I 030-4402 Elbow fitting J 050-1000 Filter 1 K 030-4007 Elbow fitting 1

A A

B

C

D

E F G D E

H

I

J

K

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200-7110 WASTE TANK ASSEMBLY

CUE PART NUMBER DESCRIPTION Q’TY A 070-0090 ½” CLEAR NYLON HOSE B 050-2406 PUMP 1 C 060-0440 SCREW CLAMP (NOT ON PHOTO) 1 D 030-4010 ½”MPT BY 3/8”BARB FITTING 1 E 050-1000 FILTER 1 F 030-4007 90 DEGREE ELBOW WING NUT TO BARB 1 G 070-0090 HOSE ‘CLEAR BRAIDED’ H 010-7101 TANK 1 I 050-2700 LOW LEVEL SWITCH 1 J 030-4410 ELBOW ½” NY TO 3/8” MPT 2

ORDERING PARTS Parts for the unit may be ordered by calling Customer Service, have your model and serial numbers available: inside U.S.A. Canada: (800) 841-8810 Contact your local (714) 558-4822 MotorVac distributor

A

B C D E

F

G

H

I

J

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