Motorvac Cool Smoke HP 500-0150 User manual

1324 Blundell Rd. Mississauga ON Tel. [phone] Fax. [phone] www.motorvac.com
Cool Smoke® HP
High Pressure Leak Diagnostics System
Part No. 500-0150 & 500-0150NA
USER MANUAL
LEAK DETECTION
SERVICE

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Introduction
Congratulations! You are in possession of the most advanced and powerful (yet simple to operate) high
pressure diagnostic leak test machine available. Our patented Cool Smoke “no heat” technology creates a
high volume, smoke-like vapor eliminating the need for high temperature glow plugs or resistance coils. The
MotorVac Cool Smoke HP was specically developed to OEM specications for diagnosing leaks in high
pressure air systems such as turbo chargers and charge air coolers. The Cool Smoke HP can be used to not
only determine if there is a leak in a system and pinpoint its location, it can also determine the actual size of
the leak allowing the technician to decide whether a repair is necessary.
The Cool Smoke HP uses advanced dynamically controlled pneumatics and microprocessor technology to
determine the actual leak size throughout the entire operational pressure range. The Cool Smoke uid will
deposit ultraviolet (UV) dye at the location of small leaks where it would be dicult to see smoke.
The Cool Smoke HP comes with both a powerful UV light to easily locate the UV dye deposits at leak points,
as well as a powerful white light to locate the smoke at visible leak points.
The Cool Smoke Fluid is a unique solution that allows for highly visible vapor (smoke) to carry UV dye to leak
points. The UV dye will be deposited at small leak locations where the smoke is forced out during a test. Your
MotorVac Cool Smoke HP can perform smoke or leak tests between 3-60 psi (0.2-4.1 bar). The MotorVac
Cool Smoke HP comes prelled with a charge of Cool Smoke Fluid and is rellable by the end-user when the
smoke-producing solution is depleted. The smoke it produces, as well as the UV dye, is non-toxic, solvent
free and noncorrosive. The MotorVac Cool Smoke HP needs no assembly and requires no maintenance.
Please review the User Guide to become familiar with the Cool Smoke HP and all of its features.
Thank you for choosing MotorVac.

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Table of Contents
Page
Safety Information and Precautions .………….……………………...........................………………........
System Features and Functions …...………………………………………………………....................…..
Technical Specications ….………………………………...………….………….......................................
Modes of Operation …..……………………………………….………………………………......................
First Time Operations …..……………………………….…………...………..………….....................….....
Test Procedure …..……………………………………….…………...…………………………...........….....
Initial Set-up …..……………………………………….…………...……………….............…….....
Smoke Test …..……………………………………….…………...……………………....……….....
Leak Test …..……………………………………….………….……………........................…….....
Leak Size Test …..………………………………………....……...….............……...….....
Pressure Decay Test …..……………………………………….………...……………........
System Accessories …..……………………………………….………...…..........................…………........
Appendix A: Troubleshooting and Additional Help …..……………………………………….………...……
Appendix B: Service Parts …..……………………………………….…………...................................……
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Safety Information and Precautions
To prevent personal injury and / or damage to vehicle or equipment:
• Use this equipment in the manner specied by the manufacturer.
• Understand operating procedures / Follow all safety precautions.
• Correctly connect power supply to battery and chassis ground.
• Use only Cool Smoke Fluid in the Cool Smoke HP. Altering the uid, hoses, cables or any other
replacement parts will void the warranty; may cause machine malfunction; may cause damage to the
vehicle, to property or may cause personal injury.
• To view the dye deposit, use the included UV Phazer Black light and UV enhancing safety glasses.
• Do not use when vehicle engine is running.
• The 12-24V DC battery source you use to power the machine must be in good condition and fully
charged.
• Machine input pressure must be 90-150 psi. Operate the machine in an upright position.
TIP: Whenever possible allow the system to vent as far away from where the smoke is being
introduced. This will purge the air and quickly ll the system with smoke. Once the system is lled
with smoke, close the vent and allow the system to be pressurized.
WARNING: Do not overll unit.
WARNING: This is a high pressure leak detection tool NOT suitable for
EVAP/fuel tank system testing. Use of this machine to test for leaks in EVAP
systems may cause serious personal injury and/or vehicle damage.
CAUTION: Wear gloves and safety goggles (user and bystanders) when
performing this service

1. COOL SMOKE FLUID DIPSTICK: To check
the uid level insert dipstick until threads
touch then remove and read.
CAUTION: DO NOT OVERFILL THE UNIT.
2. COLOR SCREEN: The advanced color
LCD display is used to navigate through all
modes and gives feedback on pressure in the
system.
3. BUTTONS: The 4 buttons on the front of the
unit are used to navigate through onscreen
menus and select service modes.
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System Features and Functions
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Maximum
Minimum
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System Features and Functions
Technical Specications
4. COMPRESSED AIR INLET: Connect
appropriate ¼” NPT male quick coupler
to supply the Cool Smoke HP with
compressed air supply.
5. POWER CABLE: The power harness
with battery clips is intended to be
connected to either a 12 VDC or 24
VDC battery. The unit will automatically
adjust for the voltage that it is supplied.
6. SERIAL LABEL
7. SMOKE OUTPUT HOSE: The smoke
output hose is used to connect the Cool
Smoke to the system being tested in
either smoke or leak mode through the
use of the appropriate adapters. This
hose swivels at the connection to the
Cool Smoke HP to allow for easier use.
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Dimensions
Length x Width x
Height
18” x 11” x13”
46 cm x 28 cm x 33 cm
Current Usage 1.2 A
Weight (Equipment) 9.8 lbs (4.5 Kg) Input pressure required 90-150 psi (6.0-10 bar)
Weight
Turbo Adapter Kit
15.8 lbs (7.15 Kg) Output pressure 3-60 psi (0.2- 4.1 bar)
Voltage Requirement 12-24 VDC Output Volume 0-42 CFH (0-20 LPM)
Power Cord Length 10’ (3 m) Output hose Length 8’ (2.4 m)

First Time Operation
The Cool Smoke HP comes factory lled with Cool Smoke Fluid and is ready to use right out of
the box. The air inlet is supplied with a female ¼” NPT port. Connect an appropriate coupler that
mates with your compressed air supply hose.
Your Cool Smoke HP is now ready for its rst use!
Install ¼” NPT coupler
for compressed
air supply
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Modes of Operations
The Motorvac Cool Smoke has two modes of testing:
Smoke mode: The Cool Smoke HP will produce high density smoke-like vapor at set pressures
between 3-60 psi to quickly pinpoint the location of a leak using both visible vapor and UV dye
deposits.
Leak mode: The Cool Smoke HP utilizes two methods to determine if the system under test is
leaking beyond OEM specications. The machine can use either a Pressure Decay or Leak Size/
Flow Rate Test that can determine the actual leak size.

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Test Procedure
Initial Setup:
1. ALL tests with the MotorVac Cool Smoke HP are performed with the engine o.
2. Connect the Motorvac Cool Smoke HP red (+) battery clip to vehicle’s positive battery terminal;
connect the black (-) battery clip to a solid ground point as far from the battery as possible.
3. Connect shop air to the MotorVac Cool Smoke HP inlet located on the side of the machine. Be
sure supply pressure to the machine is between 90-150 psi.
4. Connect supplied adapters to the vehicle’s turbo induction system. To test the turbo charger
and intercooler (or charge air cooler) attach the adapters to the inlet of the turbo and the outlet
of the cooler.
5. Ensure you are connecting to pressurized parts of the system only. Do not connect to the air
lter box that is not intended for pressure.
6. Use leak test to determine if there is a leak in the system. See page 9 for description.
7. If there is a leak, use smoke test to pinpoint the leak location.
Cooler Outlet
Turbo Inlet

2. Set the test pressure by using the
scroll buttons ( ) to
adjust pressure. The test pressure
should be the same or less than the
operating pressure of the system
being tested.
1. Select smoke test by pressing
“select” ( ) button while
smoke test icon is highlighted in red.
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Smoke Test:
The purpose of a smoke test is to ll a system with pressurized smoke until the set pressure is
reached. Use the high intensity Phazer White light to detect the smoke exiting any leak points. The
Phazer White light has a focusing feature to zoom in on the leak points and improve visibility.
3. Follow on screen instructions and
press the ( ) button to start
pressurizing the system.
4. The screen displays the set pressure
as well as the current output pressure.
The test will automatically stop after
10 minutes.

1. Select leak test by pressing “select”
( ) button while leak test icon is
highlighted in red.
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Leak Test:
The purpose of a leak test is to verify if a system is leaking and after repairing the vehicle, conrm
that the leak has been xed. The Cool Smoke HP has two dierent leak tests: Leak Size and
Pressure Decay.
1. Leak Size Test
The Cool Smoke HP has advanced electronics that are capable of determining the size of a
leak that is greater than 0.015” ( 0.4mm).
2. Set the test pressure by using the scroll
buttons ( ) to adjust pressure.
The test pressure should be the same or
less than the operating pressure of the
system being tested.
3. Follow on screen instructions and press
the ( ) button to start pressurizing
the system.
4. The machine will ll the system with
pressurized smoke until the set pressure
is reached.
5. Results - When the output
pressure stabilizes at the
set pressure, the leak size
results page will display
the leak size and resulting
ow rate from the test.

1. To perform a pressure decay test,
begin a leak test. When the pressure
has reached the set pressure. Press
the “DECAY TEST” ( )button
2. Pressure Decay Test
A pressure decay test can be used for any size leak. This specification is used by many OEM
vehicle manufacturers to determine if the amount of leakage in the turbo system is acceptable
or requires repair.
Smoke Test
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2. The decay test will start the decay
timer and show a live update on
the screen of the output pressure.
The time for the decay test can be
changed in the options menu.
3. Results: When the pressure decay
test is complete the results will be
displayed. These results can be
compared with the manufacturer’s
specications.

System Accessories
Part # 500-0150 - Cool Smoke HP with Turbo adapter set.
Turbo Kit Part # 200-0150
Part # 500-0150NA - Cool Smoke HP without Turbo adapter set.
Break down of included lights. Part # 200-0175
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ITEM NO. PART NO. DESCRIPTION QTY
1 98821846 Phazer White 5 W Light AAA 1
2 98006475 Black UV LED Light AAA S/A 1
3 068-0100 Turbo Adapter Plug 2.25”to 2.5”Assembly 2
4 068-0120 Turbo Adapter Plug 2.75”to 3”Assembly 2
5 068-0140 Turbo Adapter Plug 1.75”to 2”Assembly 2
6 068-0250 Turbo Adapter Plug Assembly 1
7 98821847 Hose Silicone 1.75”I.D. X 3.7” 2
8 98821849 Hose Silicone 2.25”I.D. X 3.7” 2
ITEM NO. PART NO. DESCRIPTION QTY
9 98821852 Hose Silicone 2.75”I.D. X 3.7” 2
10 98821854 Hose Clamp Turn Key 64-89mm 2
11 98820992 Hose Clamp Turn Key 46-70 mm 2
12 471112 UV Enhancing Safety Glasses 1
13 98821848 Hose Silicone 2”I.D. X 3.7” 2
14 98821851 Hose Silicone 2.5”I.D. X 3.7” 2
15 98821853 Hose Silicone 3”I.D. X 3.7” 2
16 98027050 Battery AAA 12
ITEM NO. PART NO. DESCRIPTION QTY
1 98821846 Phazer White 5 W Light AAA 1
2 98006475 Black UV LED Light AAA S/A 1
3 471112 UV Enhancing Safety Glasses 2
4 98027050 Battery AAA 12

Appendix A: Troubleshooting and Additional Help
Refer to the list below in the unlikely event that you have any operating issues with your Cool
Smoke® HP Diagnostic System.
For additional help you can contact our Technical support team at 1-877-776-8486 or outside
of North America [phone] or e-mail [email protected].
Issue Solution
Excess uid exits output hose The unit may have been overlled with Cool Smoke
uid. Check uid level with dipstick. If overlled,
remove the dipstick and allow uid to pour out of the
dipstick port into an appropriate container. Remove
the smoke output hose and use compressed air to
expel any uid that is in the hose. Rell the tank.
Use the dipstick to ensure proper uid level. (From
empty the tank capacity is 180ml)
Screen does not power on Check connection with battery and check voltage
(12-24 VDC)
No smoke output Check uid level with dipstick. Check compressed
air supply.
Ouput pressure does not reach set pressure If there is a large leak the unit may not be able to
reach the set output pressure. Repair leak and
retest.
Machine Error If the machine declares an internal error, call our
technical support team.
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Appendix B: Service Parts
Please refer to the part number below when ordering replacement parts for the Cool Smoke® HP.
For Turbo kit accessories page 11.
ITEM NO. PART NO. DESCRIPTION QTY
1 200-1801 Smoke Output Hose Cool Smoke HP 1
2 200-1802 Dipstick Cool Smoke HP 1
3 200-1803 Smoke Solenoid Cool Smoke HP 1
4 200-1804 Pressure Solenoid Cool Smoke HP 1
5 200-1805 PCB Cool Smoke HP 1
6 200-1836 Power Harness Cool Smoke HP 1
N/A 200-0175 MotorVac® Cool Smoke® HP Light Kit 1
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1324 Blundell Rd. Mississauga ON Tel. [phone] Fax. [phone] www.motorvac.com
ZIM16-01729 Rev3