Hickok WAEKON FPT2600 User manual

FPT2600-EX1
I/M Handheld Fuel Cap Test System
User Guide
© 2009 Hickok Inc.
All rights reserved.

© 2009 Hickok Inc. All rights reserved.
All rights reserved.
No part of this manual may be reproduced or transmitted in any form or
by any means, electronic or mechanical, without written permission from
Hickok.
Hickok assumes no responsibility for use of this equipment by untrained
or unauthorized persons.
Printed in the United States of America.
© 2009 Hickok Inc.
All rights reserved.

FPT2600-EX1 User Guide 3
Contents
Safety Information ................................................4
Features ............................................................... 6
Fuel Cap Tester ............................................................................... 6
Pass/Fail Standard ......................................................................... 8
Storage Case and Fuel Cap Adapters ....................................... 8
Connecting & Using the Tester ...........................10
Step 1—Check the Tester’s Flow Rate Calibration .............. 10
Step 2—Setup .............................................................................. 12
Step 3—Testing ............................................................................ 13
Warranty ............................................................ 14
Contact Information .......................................... 15
© 2009 Hickok Inc.
All rights reserved.

4 FPT2600-EX1 User Guide
Safety Information
Before using this equipment, carefully read, understand and follow
instructions and safety messages on equipment and in this guide.
The guide cannot anticipate or provide advice and cautions for all situations
encountered by technicians. With this in mind, always follow and refer to
the manuals provided by the manufacturer or the vehicle or equipment
being tested or used for all information and testing procedures whenever
diagnosing, repairing or operating such vehicle or equipment.
Failure to follow the instructions, cautions and warnings provided here as well
as those provided by the vehicle and equipment manufacturers can result in
fire, explosion, bodily injury and property damage.
In addition to the information listed below, additional warnings and cautions
are listed throughout the guide. Please read them carefully.
Fuel vapors are toxic and explosive, which can cause severe
injury or death.
• Use proper ventilation to avoid breathing fuel vapors.
• Minimize contact with the skin with the use of gloves (such as nitrile
gloves) when there is possibility of getting methanol fuel on your hands.
• If the skin is directly exposed, wash the area immediately and change any
clothes that have become wet with fuel.
• Always wear approved safety glasses when testing. Should fuel get into
eyes, flush eyes immediately with water and consult your physician.
Vehicles emit flammable vapors which can ignite.
• Keep flames, sparks, cigarettes and other ignition sources away from the
vehicle at all times.
• In case of fire, never use water to fight flames caused by methanol or
methanol blended gasoline. This will cause the flames to spread instead of
extinguishing them.
• Use a dry chemical extinguisher to fight flames (preferably one marked
ABC, though BC is acceptable). A foam extinguisher is acceptable only if it
is ARF grade, which is resistant to alcohol.
© 2009 Hickok Inc.
All rights reserved.

FPT2600-EX1 User Guide 5
Safety Information
Before beginning any tests, make sure the test environment
is safe and the vehicle meets these testing conditions:
• Test area should be well ventilated.
• Vehicle should be in park.
• Wheels should be blocked.
• Engine should be at normal operating temperature.
• Vehicle should have normal exhaust flow.
• Keep all tester cables clear of exhaust manifolds and radiator fan blades.
• Use caution when testing on a vehicle while the engine is running
(surfaces may become hot, electric cooling fans may turn on
unexpectedly, etc.)
© 2009 Hickok Inc.
All rights reserved.

6 FPT2600-EX1 User Guide
Features
Fuel Cap Tester Quick Disconnect Coupling
Pump Handle
PASS
MODEL FPT2600
FAIL
LOW
BATT
READY
PUT CAP ON
PUMP
TEST
BEGINS
STOP
PUMPING
CAP OFF
PRESS TO START
NO
LEAK
OVER
PRES
PUMP
T
E
S
T
R
E
S
U
L
T
S
FUEL CAP TESTER
NO LEAK / TEST BEGINS
(Green LED)
OVER PRES / LOW BATT
(Yellow LED)
PRESS TO START
(ON/OFF Button)
PASS
(Green LED)
FAIL / READY
(Red LED)
© 2009 Hickok Inc.
All rights reserved.

FPT2600-EX1 User Guide 7
Features
PRESS TO START (ON/OFF Button)—Pressing this button turns the power
on and off.
• Turning on the unit also initiates tester auto zero and the start of the test.
• The tester automatically turns off if the test is not started within 20
seconds after the unit is turned on.
• The tester also turns off automatically after the test result
LED flashes.
PASS (Green LED)—Flashes at the end of the test if the cap leak down
test passes (pressure loss is within acceptable specification).
• Steady light on after power up indicates auto zero is in progress.
• Steady light on during pumping indicates the pressure to the cap is
being built up.
FAIL / READY (Red LED)—Flashes at end of test if cap leak down test fails.
• Steady light on indicates auto zero is complete and the unit is ready
to start the test.
NO LEAK / TEST BEGINS (Green LED)—Flashes at end of test if cap leak
down test passes and no pressure loss is measured.
• Steady light on during pumping indicates pressure to cap is
sufficient to perform test—stop pumping.
OVER PRES / LOW BATT (Yellow LED)—Flashes after power on to
indicate battery voltage is low. Batteries must be replaced before testing
is performed.
• Steady light on during pumping indicates pressure to the cap is
excessive and pumping should be stopped.
Quick Disconnect Coupling—Allows quick changing of cap adapters
and provides a way to update the tester with new adapters as needed.
Pump Handle—Provides a quick and easy way to build up the necessary
pressure for testing.
© 2009 Hickok Inc.
All rights reserved.

8 FPT2600-EX1 User Guide
Pass/Fail Standard
PASS (Green)
Swing Valve
FAIL (Red)
Quick
Disconnect Fitting
Storage Case and Fuel Cap Adapters
Features
© 2009 Hickok Inc.
All rights reserved.

FPT2600-EX1 User Guide 9
Features
Pass Fail Standard—Allows you to verify that the tester is calibrated properly.
Storage Case and Fuel Cap Adapters—Color coded for easy identification,
the fuel cap adapters allow you to test most vehicle’s fuel caps.
• Black Cap Adapter—Standard threaded cap, used for most vehicles.
• Brown Cap Adapter—Dual threaded cap. Typically used for 1996 Ford
Explorer, 1999 or newer Chrysler vehicles, 2001 Mitsubishi and Nissan
vehicles. Also used for many newer GM, Ford, Lincoln Mecury, and
Toyota vehicles.
• Orange Cap Adapter—Three tab quick turn cap. Typically used for
1996 and newer Ford vehicles, 1997 and newer Mazda B-Series , and
2001 Mazda Tribute.
• Blue Cap Adapter—Two tab quick turn cap. Typically used for 1996
and newer GM vehicles.
• Red Cap Adapter—1½” shallow cam. Typically used for Acura, Audi,
BMW, 1970’s Fords, IHC, Jaguar, Mazda, Mercedes, and VW.
• Gray Cap Adapter—13/8” shallow cam. Typically used for AMC, Audi,
Chrysler, Isuzu, Jeep, Nissan, Renault, Subaru, Toyota, and VW.
• Yellow Cap Adapter—1½” deep cam. Typically used for mid 1970’s
Ford trucks, IHC, Winnebago, and Mercury Capri.
• Purple Cap Adapter—Typically used for late model VWs.
• Green Cap Adapter—1½” deep cam. Typically used for mid 1970’s
Ford trucks, IHC, Winnebago, and Mercury Capri.
© 2009 Hickok Inc.
All rights reserved.

10 FPT2600-EX1 User Guide
Connecting & Using the Tester
Before You Begin
• Please read the instructions carefully before using the tester. Failure
to follow the instructions may cause incorrect test results.
• Before using the tester for the first time, remove the battery
protector pull tab.
• Make sure the vehicle is turned off before removing the fuel cap.
• When removing the fuel cap, do so slowly and allow any pressure to
decay before fully removing the cap.
• Because residual pressure from a previous test will cause an
incorrect auto zero, never power up the tester with the fuel cap
connected to the adapter.
Step 1—Check the Tester’s Flow Rate Calibration
Always check the tester’s flow rate calibration before initial use for
certified vehicle testing and before testing begins each day. Failure to
check the tester’s calibration may cause inaccurate test results. There are
two parts to this test—one with the swing valve set to Pass, and the other
with the valve set to Fail.
• Do not attach the Pass/Fail Standard to the tester until after the
power is on.
• Install the Pass/Fail Standard and start the test as soon as possible
after auto zero.
If testing is not started within one minute after auto zero, the tester
will shut itself off. If this happens, repeat the instructions for the
calibration test from the beginning.
• Do not disturb (turn or press) the Pass/Fail Standard during pumping
and testing.
IMPORTANT! If the Flow Rate Calibration Check fails, do not use the
tester for certified testing. Contact Waekon Customer Service for
technical assistance.
© 2009 Hickok Inc.
All rights reserved.

FPT2600-EX1 User Guide 11
Connecting & Using the Tester
Procedure—Part 1
1. Set the Pass/Fail Standard swing valve to PASS (green).
2. Push the Press To Start button to turn the tester on. The LEDs will light
in the following order:
• All LEDs will light briefly.
• The green PASS LED will turn on
during the auto zero function
and then turn off.
• The red READY LED turns on
indicating the tester has auto
zeroed and is ready for testing.
3. Immediately install the Pass/Fail Standard to the tester’s quick
disconnect fitting to begin the test.
4. With the Pass/Fail Standard connected to the tester and the tester
powered on (red READY LED on), begin pumping the handle to build
up pressure and start the test.
Continue pumping as the PASS LED turns on, stopping after the NO
LEAK LED turns on. The 10 second test is automatically initiated.
Note: If the OVER PRES LED turns on, stop pumping immediately and
allow test to start.
At the end of the test, the results are displayed by the tester flashing
the appropriate LED:
Test Passed—Green PASS LED flashes
Test Failed—Red FAIL LED flashes, or the standard cannot be
pressurized (the No Leak LED will not turn on with
continued pumping)
Procedure—Part 2
1. Follow the same instructions for part 1 except set the swing valve to
Fail (Red).
© 2009 Hickok Inc.
All rights reserved.

12 FPT2600-EX1 User Guide
Chapter
Step 2—Setup
1. Remove the fuel cap from the vehicle and inspect for the following:
• Damage to the fuel cap—if damaged, replace with new cap
• Cracked or missing gasket—if damaged or missing, replace with a
new gasket.
• Dirty gasket—clean gasket or replace if necessary
IMPORTANT! Allow any fuel on the cap to evaporate before continuing.
2. Connect the appropriate
adapter to the tester’s
quick disconnect fitting.
Remember, do not attach the
fuel cap until after the tester
is turned on.
3. Push the PRESS TO START
button to turn the tester on.
The LEDs will light in the following order:
• All LEDs will light briefly.
• The green PASS LED will turn on to indicate the auto zero function is
running, and then turns off.
• The red READY LED turns on indicating the tester has auto zeroed
and the unit is ready for testing.
4. Immediately install the fuel
cap on to the adapter to
begin testing. Make sure the
cap is firmly seated
Note: If testing is not started
within 20 seconds after auto
zero, the tester will turn off. If this happens, remove the cap and return to
the beginning of the setup procedure and start again.
© 2009 Hickok Inc.
All rights reserved.

FPT2600-EX1 User Guide 13
Connecting & Using the Tester
Step 3—Testing
1. With the adapter and fuel cap connected to the tester, and with the
tester power on (red READY LED on) , begin pumping the handle to
build up pressure and to start the test.
While pumping the handle, the green PASS LED will turn on.
2. Continue pumping until the green NO LEAK LED turns on, then stop
pumping. The test is automatically initiated at this point.
Note: If the OVER PRES LED turns on, stop pumping immediately and
allow test to start.
At the end of the test, the results are displayed by the tester flashing
the appropriate LED:
Test Passed—Green PASS LED flashes (indicates a slight pressure drop,
but within pass specifications) or,
The green PASS LED and the green NO LEAK flashes
(indicates no pressure drop is measured)
Test Failed—Red FAIL LED flashes, or
The cap cannot be pressurized (the NO LEAK LED will not
turn on with continued pumping) or,
The cap is obviously damaged or it is not the correct cap
for the test vehicle.
3. Once the fuel cap has passed testing, inspect the vehicle’s fuel filler (fuel
cap retainer) for thread and seat damage. If necessary, repair or replace.
4. Testing is complete.
If the cap passed—Put the cap back on the vehicle.
If the cap failed—Remove the cap from the adapter and inspect
the gasket for cracks or debris build-up. Clean the
gasket if necessary and retest. If the cap still fails, it
should be replaced.
© 2009 Hickok Inc.
All rights reserved.

14 FPT2600-EX1 User Guide
Warranty
Subject to the conditions that follow and are noted below, this product is warranted
to be free from defects in material and workmanship, under proper use and in
accordance with the manufacturer’s written recommendation and specifications,
for a period designated below on all products:
• For all electronic parts and for the FPT series of evaporative equipment (both mechanical
and electronic parts), a one-year limited warranty is in effect from the time of the
purchase of the new product by the initial end user.
• For all hard parts (including mechanical and machined parts), other than listed in
the preceding paragraph, a lifetime limited warranty is in effect from the time of the
purchase of the new product by the initial end user.
The manufacturer’s obligation under this warranty is limited to unaltered products
returned to the manufacturer by the initial end user of the new products. Therefore,
this warranty does not cover any products resold by the end user to third parties,
nor any reconditioned products sold as such, by the manufacturer. The sole remedy
for any such defect shall be the repair, or replacement, of the product at the sole
discretion of the manufacturer. This warranty does not cover expendable parts, such
as batteries, nor does it cover shipping or handling. In addition, manufacturer is not
liable for any loss or damage to product during shipping.
In the event it is determined that the product has been tampered with, or altered in
any way, this warranty is void and all claims against the product will not be honored.
All warranty claims must be submitted as outlined by the manufacturer and shall
be processed in accordance with the manufacturer’s established warranty claim
procedures. These procedures include provisions that proof of purchase must be
established (by either warranty card from the seller or by point of purchase receipt)
and that the manufacturer will make every attempt to return ship the product within
one business day from receipt of the returned product, freight prepaid.
In addition, all maintenance procedures, as outlined by the product manuals, should
be followed for the warranty to be kept in force. Should the product not be used in
accordance with procedures as specified, or if the product otherwise fails outside of
the warranty, the manufacturer reserves the right to make such judgment and the
party returning the product will be notified that written notification will be necessary
to repair the product at a cost which the manufacturer deems as reasonable. The
product will then be shipped back to the customer, COD; or as the manufacturer
deems appropriate.
This is the only authorized manufacturer’s warranty and is in lieu of all other
expressed, or implied, warranties or representations, including but not limited to
any implied warranties of merchantability or fitness or any other obligations on the
part of the manufacturer. In no event will the manufacturer be liable for business
interruptions, loss of profit, personal injury, costs of delays, or any special, indirect,
incidental or consequential damages, costs or losses.
(See Contact information for telephone and fax numbers and shipping
information.)
© 2009 Hickok Inc.
All rights reserved.

FPT2600-EX1 User Guide 15
Contact Information
If you have any questions about our products including technical
assistance, call our customer care department during standard business
hours EST. If a customer care representative directs you to return any
equipment, be sure to include these items:
• a written description of the problem;
• the name and telephone number of your contact person;
• your shipping address, and
• our return authorization number (from customer care).
Customer care and tech support: 800/342-5080
Service and repair center: 662/453-6212
Fax: [phone]
E-mail: [email protected]
[e-mail]
Service address: Hickok Inc.
Automotive Group
1716 Carrollton Avenue Dock E
Greenwood, MS 38930
Don’t forget to check out other testers, equipment and parts at our websites.
Access our Quick-n-E-Z Parts and Service from any of these sites 24/7 for
ordering parts or service.
© 2009 Hickok Inc.
All rights reserved.

02490-974 Rev C
© 2009 Hickok Inc.
All rights reserved.