EELD105A USER MANUAL - Snap
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1. un EELD105A USER MANUAL LEAKCHECK SYSTEM For Use By Qualified Automotive Technicians LEAKCHECK MANUAL P N 200 8228 REV N C 1999 NOTICE Please note that the matters set out in this operating manual are intended only to provide information to the user This manual is not an exhaustive discussion and does not constitute professional advice on the matters in question Please consult the manufacturer for further details and specific instructions or advice Although this operating manual has been prepared with the greatest care and attention to detail the manufacturer shall not be liable for damages or losses incurred due to any errors or omissions in this operating manual TABLE OF CONTENTS 1 8 9 PRODUCT OVERVIEW A Driveability Concerns B Present Detection Methods C Safety D Disclaimer INSTRUCTIONS FOR USE TEST METHODS Air Vacuum Leaks Oil Leaks Canister Purge System Leaks Visual Engine Performance stability Test Exhaust System EGR Test Under Dash Leak Test Cooling System Leak Test Brake Booster Test TAMMOAWS TROUBLE SHOOTING WARRANTY LEAKCHECK COMPONENTS FLOWCHART DIAGNOSIS FOR OPERATORS TOXICOLOGY REPORT AUTHORIZED SERVICE CENTER 10 FREQUENTLY ASKED QUESTIONS 11 PARTS LIST PAGE BBR WW y Nn 0 00 00 UU 10 11 13 13 14 15 1 PRODUCT OVERVIEW Traditionally in the automotive industry engine oil leaks transmission fluid leaks manifold2. PFI and TBI Injected Engine Throttle shafts throttle body shafts X Throttle body gaskets X Injector O rings Positive crank case vent hoses Air valves Exhaust gas recycle valves Hoses and hose connection Air cleaner assy Air cleaner duct hose assy LL P lt PS PS S OX T S DX Intake manifold gaskets Vacuum advance modules Charcoal canisters gt Switches one way valves PIPAS Choke pull off Air flow meters mass air flow sensors x x MAP sensors B Oil Leaks This test inspects the engine transmission and drive train components independently Engine 1 Block off air from crankcase ventilation areas example PCV hose etc 2 Attach the LEAKCHECK SYSTEM hose to the oil level dip stick tube 3 Remove oil filler cap 4 Push the pendant button until dense Visible Vapor appears from the oil filler opening 5 Securely replace the oil filler cap to pressurize the crankcase 6 Push the handheld pendant button to activate Visible vapor flow into the crankcase see Section 2 Instructions For Use 7 Use a bright light source to visually locate Vapor traces leaking from the engine 8 Please note that an engine crankcase drained of oil could give better test results if the Vapor is not detected for a known oil leak Oil bubbles may appear during this test indicating a leak Manual Transmission Differential This
3. Visible Vapor leak detecting machine at the University of Alberta Mechanical Engineering Lab Testing of the exposure of technician to vapor was performed during actual testing of the engine and a direct sample of FOG was taken for comprehensive analysis Ambient conditions were recorded immediately prior to LEAKCHECK testing of the engine Personal sample results were less than ten percent of the lowest OEL and components of the FOG would be several one hundredths of the appropriate OELs The conclusion reached from these tests is that occupational hygiene requirements will be met when the LEAKCHECK equipment is used as designed and under normal conditions 9 AUTHORIZED SERVICE CENTER For further information on the LEAKCHECK SYSTEM contact your SUN Representative 13
4. locate Vapor under the dash 4 Check for Vapor leaks when operating the vacuum motors G Cooling System Leak Test This test detects hose leaks leaks in the pump connections leaks in the water pump seal gasket installation leaks and coolant leaks into the combustion chamber This test requires the purchase of an exhaust cone Note This test will only be effective if there is no coolant present in the system Drain coolant from the radiator Insert the exhaust cone into the cooling system fill point Push the handheld pendant button to activate the Visible Vapor see Section 2 Instruction For Use Fill the system with Vapor Remove the exhaust cone Utilize conventional cooling system pressure testing to pressure the system to radiator cap rated pressure Use a bright light to visually locate Vapor traces indicating leaks AA Ge Qn Water Pump Installation Test ensures accurate pump installation before complete assembly 1 Secure the water pump to the engine 2 Insert the exhaust cone into one opening of the water pump while blocking off the other 3 Push the handheld pendant button to activate the Visible Vapor see Section 2 Instructions For Use 4 Fill the system with Vapor 5 Use a bright light to visually locate Vapor traces indicating leaks H Brake Booster Test 1 Remove one way check valve 2 Insert the LEAKCHECK SYSTEM hose into the booster 3 Push the handheld pendant button to activate the Vi
5. test is to be performed on standard manual transmissions and differential housings 1 Remove the oil fill plug Attach the LEAKCHECK SYSTEM hose to the fill hole 3 Push the handheld pendant button to activate Visible Vapor flow into the transmission or differential housing see Section 2 Instruction For Use 4 Use a bright light source to visually locate Vapor traces indicating oil leaks Note You should see Vapor from the transmission differential housing vent Lack of housing ventilation is the primary cause of oil leakage past seals Automatic Transmissions Remove transmission fluid level dip stick Attach the LEAKCHECK SYSTEM hose to the dip stick tube opening 3 Push the handheld pendant button to activate Visible Vapor flow into the transmission see Section 2 Instructions For use 4 Use a bright light source to visually locate traces 5 Verify that the Vapor does not leak from the transmission Ne Note Vapor will be present at transmission vents C Canister Purge System Leaks A charcoal canister is connected to the engine via a purge line The fuel tank is also connected via a vent line to the charcoals vapor recovery canister 1 Disconnect the vehicle s battery lead from the vehicle s battery before performing this test eliminating the chance of spark during testing 2 Remove one end of the vent line from the charcoal canister and install a tee fitting Attach one end of the t
6. anty The manufacturer shall at its option repair or replace the equipment or parts of it due to defective material or workmanship within ONE YEAR from the date of purchase upon proof of purchase and delivery of the equipment to the manufacturer This warranty is null and void for damage caused due to accidents tampering misuse corrosion or failure to follow operating instructions See Warranty Card for specific information 7 LEAKCHECK SYSTEM AND COMPONENTS Plugs Miscellaneous Ts and Plugs oT LED Exhauss Cone Diagnostic Indicators TT Wapor Hose 7 Pendant Quick Connector para Switch 12 Wolt Battery Cable Connector Vapor Hose See Page 15 For Detailed Parts List Of External Components 10 7 0 FLOWCHART DIAGNOSTICS FOR LEAKCHECK SYSTEM OPERATORS Below is a flowchart describing troubleshooting procedures Page 12 gives an explanation in detail of the flowchart observations you may make and the conditions you may encounter Al Depress pendant does the pump run IF YES A2 IF NO A2 A2 With the pendant depressed does the RED LED flash on and off IF YES A3 IF NO B2 A3 After 60 seconds is there Visible Vapor coming from tip of hose IF YES A4 IF NO B5 A4 System operation normal IF YES Al AA With the battery cable Clamps connected is the GREEN LED on IF NO B1 B2 Unit will require service Call 1 800 225 5786 b5 With pendant depressed am
7. d by a computer that will compensate for leaks and establish a virtually correct idle speed that causes hesitation and defies electronic diagnosis c The computer in a modern engine does not compensate for unfiltered air that is leaking into the intake without passing through the mass air flow sensor d Vehicles with carburetors will idle poorly because of an excessively lean mixture due to vacuum leaks e Leaking vacuum hoses raise manifold pressure causing the emissions devices to malfunction thus giving the MAP sensor and fuel pressure regulator false readings this leaves the transaxle modulator PVC system brake booster and other vacuum powered items with insufficient vacuum to function properly The LEAKCHECK SYSTEM is the visual solution for identifying these difficult to detect problems B Present Detection Methods Automotive system leaks are detected through the time consuming process of elimination Present detection methods include a Manual inspection of the condition of all vacuum hoses Vacuum leaks may make a hissing noise when the engine is running The noise may be altered by manipulating the hose with the leak This does not account for computer compensation and is not a reliable method b Inspection of the engine s mechanical condition A stethoscope may be used to inspect the engine s mechanical condition The sound drum and probe are removed then the stethoscope is inserted into the open end of the hose to de
8. e adequate ventilation Keep lighted cigarettes flames and other ignition sources away from the battery Do not start the vehicle with the LEAKCHECK SYSTEM attached to the car battery 2 INSTRUCTION FOR USE A Connect the two cable clamps to a 12 volt automotive battery red to positive black to negative The Green light will glow indicating that the battery polarity is correct B Connect the hose to the quick connect on the LEAKCHECK SYSTEM C Push the handheld pendant control button to produce Vapor D Use a bright light source to locate Visible Vapor 3 TEST METHODS All tests are performed with the engine turned off Battery clamps from the LEAKCHECK SYSTEM must be attached to a 12 volt battery A Air Vacuum Leaks This test encompasses intake manifold unfiltered air unmetered air leaks 1 Attach the LEAKCHECK SYSTEM hose to any large intake manifold vacuum hose i e brake booster of PVC line 2 Push the handheld pendant button to produce the Visible Vapor see Section 2 Instructions For Use 3 Use a bright light source to visibly locate the Vapor 4 Leaking EGR valves can be detected during this procedure Note that positive pressure EGR valves will leak Be sure not to condemn the EGR valve before checking to see if it is a positive or negative pressure EGR valve 5 Vapor sources indicating the need for a repair may be detected in the following areas Vapor Test Procedure Carbureted Engine
9. ee to the vent line and the opposite side of the tee to the canister Attach the LEAKCHECK SYSTEM hose to the tee fitting Push the handheld pendant button to activate the Visible Vapor flow see Section 2 Instructions For Use This allows you to test the charcoal canister the fuel tank ventilation system and the fuel filler cap seal Remove the fuel filler cap Wait until the Vapor is Visible Replace the fuel filler cap to pressurize the system Use a bright light source to visually locate the Vapor Verify that the Vapor is not originating from the gas cap and continuing to the canister purge system Se SOOO TONTA N WARNING During the test the technician is pressurizing the fuel tank vent fill system Any leakage will be accompanied by gas fumes This test should be performed in a well ventilated area that is void of any spark ignition source or heating device Smoking is prohibited during test D Visual Engine Performance Stability Test The LEAKCHECK SYSTEM may be used as a visual inspection tool prior to checking the condition of the pistons valves and rings It may also be used prior to a compression test or a cylinder down test 1 Close both valves in the cylinder by bumping the engine or manually rotating the crankshaft or camshaft Remove the spark plugs and place the grommet supplied with your kit onto the tip of the LEAKCHECK SYSTEM hose Insert the LEAKCHECK SYSTEM hose into the cyli
10. nder to be inspected Push the handheld pendant button to initiate Visual Vapor see Section 2 Instructions For Use Observe the Vapor a If there is a leak in the intake valve you will see Vapor originating from the intake manifold throttle body or carburetor If the head gasket is leaking you will see Vapor in an adjoining cylinder look at spark plug opening If the piston or ring is leaking Vapor will appear in the valve cover oil fill hole d Ifthe exhaust valve is leaking vapor will appear at the tailpipe Dr oS E Exhaust System EGR Test The EGR system may be back tested for operation and flow by attaching the exhaust plug to the end of the exhaust system 1 Push the handheld pendant button to initiate Visible vapor see Section 2 Instructions For Use 2 Fill the system with the Vapor 3 Observe the exit points of the vapor Please note that a small amount of Vapor will exit from the intake area during this operation Note If a large amount of Vapor is found to be leaking from the intake throttle area an incorrectly seated EGR pintle may be the cause This test is valid for both positive and negative pressure EGR valves F Under Dash Leak Test 1 Attach the LEAKCHECK SYSTEM hose to the vacuum supply line which is located near the fire wall under the hood 2 Push the handheld pendant button to activate Visible Vapor see Section 2 Instructions For Use 3 Use a bright Light source to visually
11. p pump Running does the pitch of the pump Increase and decrease IF YES A2 IF NO B2 Bl Are the battery cable clamps clean amp clamped RED to positive BLACK to negative IF YES Al IF NO B3 B3 Change cables to correct connection RED to battery positive BLACK to battery negative YES B4 B4 With pendant depressed and pump running does the battery maintain Voltage above 10 volts IF YES B5 IF NO B6 b6 Replace battery and retest IF YES B5 IF NO B2 CELL CONDITION OBSERVATION AA Green LED ON Indicates proper polarity Battery voltage is over 10 volts Green LED OFF Battery cable clamps reversed Battery voltage is below 10 volts dead battery Al Pendant depressed Pulls in relay that powers the compressor and timer for Vapor Generator Compressor with Green light should run on Red LED should flash on off A2 Red LED Pulsing Indicates relay circuit timer circuit pendant LED and load are ok with Green light on Pendant Pendant running Timer module not operating Red LED OFF Depressed Relay circuit OK No load from Vapor Generator with Green Light Pendant OK Defective Red LED on Compressor OK Pump NOT running Battery voltage too LOW Pendant open circuit Relay circuit defective Polly fuses open Compressor or wiring problems A3 Vapor visible Compressor pressure flow within range Relay timing correct Vapor generator functioning Bl Battery Conn System is polari
12. sible Vapor see Section 2 Instructions For Use 4 Fill the system with Vapor 5 Slowly depress the brake pedal several times 6 Use a bright light source to visually locate Vapor traces indicating vacuum leaks at the rear of the booster or under the dash past the brake pedal to the master cylinder rod 4 TROUBLE SHOOTING If the LEAHCHECK SYSTEM fails to operate do the following Check the battery Ensure that the battery you are using is fully charged If the battery is not fully charged it may cause slow operation of the compressor and lack of Vapor Check the Connection The LEAKCHECK SYSTEM operates on 12 volt DC power only Ensure that the 2 connector clamps are attached correctly and securely to positive red and negative black terminals respectively Check the temperature If the LEAKCHECK SYSTEM operates best at room temperature If it is cold Vapor may not be produced wait until the machine reaches room temperature See Flowchart Diagnostics on Page 11 for trouble shooting guide 5 WARRANTY Limited Warranty The manufacturer is not liable for any loss or damage whatsoever to person or property however caused including consequential loss except to the extent of the Limited Warranty The manufacturer does not warrant the merchantability of the equipment or its fitness for any other purpose In lieu of all other warranties whatsoever the manufacturer hereby limits its liability to the following Limited Warr
13. tect the leak False noises occurring while the engine is running make it difficult to detect vacuum leaks c Inspection of vacuum and air induction system connections Accessible connections are inspected by spraying soapy water over the suspected leak origin The intent is to temporarily seal the leak and cause an increase in engine speed Again this method is not considered accurate d Use of a fluorescent dye to locate oil leaks This test method may be effective for this type of leak However it is time consuming and expensive e Use of sonic testers Sonic testers were considered to be a potentially effective method for audibly testing for vacuum leaks However extraneous noises may interfere with the detection process Vacuum leaks located directly across from each other may also cause inaccurate diagnosis C Safety The LEAKCHECK SYSTEM is designed to operate using a 12 volt battery Do not start the vehicle s engine when the LEAKCHECK SYSTEM is connected D Disclaimer The LEAKCHECK SYSTEM must be operated by qualified automotive technicians Improper use of the LEAKCHECK SYSTEM may result in injury to yourself or someone else It may also result in damage to property The instructions in this manual are illustrations of how the apparatus may be used These illustrations are examples only and are not a substitute for training by a qualified representative N WARNING Some batteries may produce flammable gases Provid
14. ty insensitive however for diagnostic purposes it is preferred to be as described Red clamp battery Positive Black clamp battery Negative Indicator LED s are to aid in diagnostics ONLY When Directed To This Screen You Should Have Completed All Necessary Diagnostics And Be Ready To Answer Questions 1 800 225 5786 Incorrect polarity on battery hookup cables as described in B1 so that Diagnostic LED lights are visible B4 Battery Condition Using a volt meter test to ensure battery voltage Of over 10 volts DC is maintained during operation of the LEAKCHECK SYSTEM If a volt meter is not available turn on the front headlights and observe the brightness When the LEAKCHECK SYSTEM is operated if the head lights dim dramatically charge or replace the battery before continuing testing B5 Pump Running Red LED is pulsing Is pitch of pump increasing and decreasing in volume surging B6 Replace Bad If testing indicates bad battery it must be replaced before further testing continues Battery Tf all conditions test OK and still no Vapor is produced the unit will require canister replacement by the three steps below 1 Green LED 2 Compressor running varying pitch surging sound from compressor 3 But no Vapor coming from end of nozzle Red LED pulsating 12 8 TOXICOLOGY REPORT Occutech Services HSE was contacted to undertake an Industrial Hygiene Survey of the LEAKCHECK FOG
15. vacuum leaks and front and rear axle leaks have been detected using dyes with special lights and sound devices even flammable sprays Technicians have spent countless hours detecting and locating leaks using these methods with less than desirable results In some industries leak diagnosis has involved the use of Visible Vapor This technology is effective but expensive The LEAKCHECK utilizes an affordable technology that uses Visible Vapor at specific pressure It is now cost effective for the professional automotive technician to use this reliable and efficient visual leak detection technology Another key advantage to the LEAKCHECK visual diagnostic tool is that tests are performed with the engine off Automotive technicians are aware that while the vehicle s engine is running the computer is in control of the engine masking the Driveability problem By testing with the engine off the computer is taken out of the loop Therefore with the LEAKCHECK the computer is not compensating for and hiding potential problems Leaks that previously went undetected are found literally in seconds LEAKCHECK SYSTEMS are engineered and manufactured to exceed accepted quality standards ensuring long lasting durability for years to come A Driveability Concerns Driveability problems are difficult to detect Reasons for this are include a airevacuation leaks which are not visible to the naked eye b modern fuel injected engines are controlle
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