Sealey VS2030.V2 User manual

TURBO SYSTEM LEAKAGE TESTER
MODEL NO: VS2030.V2
Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these instructions,
and properly maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE
THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR
PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY.
1. SAFETY
WARNING! Ensure Health & Safety, local authority and general workshop practice regulations are adhered to when using this
equipment.
999Read instructions thoroughly to ensure safe and effective use.
9IMPORTANT! Read instructions in conjunction with vehicle or equipment manufacturer’s workshop manual. 9
9Maintain the apparatus in good condition (use an authorised service agent). Before each use check condition of each component. If any
component is damaged, replace immediately. Use genuine parts only. Unauthorised parts may not function correctly and will invalidate
the warranty.
9Use in a suitable work area. Keep area free from unrelated materials and ensure that there is adequate lighting.
WARNING! Always wear approved eye, face and hand protection when pressure leakage testing.
9Keep children and unauthorised persons away from the working area.
8DO NOT operate the leakage tester when you are tired or under the influence of alcohol, drugs or intoxicating medication.
8DO NOT clean the equipment with solvents or other harsh chemicals.
8DO NOT use the leakage tester for any purpose other than that for which it is designed.
9When not in use return parts to the case, and store it in a safe, dry, childproof location.
2. INTRODUCTION
Designed to charge the turbo system with a low pressure of regulated workshop mains air supply; to indicate the presence of leaks within the
system. The kit includes a pressure gauge, a shut off ball valve, a pressure relief valve, a mains air male barbed quick coupler and four pairs of
system stepped adaptors for use on a wide range of hose sizes. The kit can also be used on cooling system hoses. All items supplied in a storage
case.
3. SPECIFICATION
Model no .............................................................. VS2030.V2
Adaptor size ............................................................ 35-90mm
Weight......................................................................... 2.52kg
4. CONTENTS
5. OPERATION
5.1. Follow the manufacturer’s instructions for the removal, if required, of the device or hose to be tested. Use cloth or gloves and arm
protection if the system is known to be hot.
5.2. Connect an air line with known air pressure to the regulator of the tester with the ball valve shut (operating lever at 90° to hose axis).
IMPORTANT! Regulate air pressure in tester to 25psi maximum. Refer to manufacturer’s manual relating to the maximum air
pressure of the turbo or other system being tested. Over pressurisation may damage system components.
Refer to
instruction
manual
Wear a face
shield
Wear protective
gloves
g.1 Item no. Part no. Diameter Description
1 VS2030.01 80/85/90mm Inlet adaptor c/w air coupling
2 VS2030.01A 80/85/90mm Adaptor blank end
3 VS2030.02 65/70/75mm Inlet adaptor c/w air coupling
4 VS2030.02A 65/70/75mm Adaptor blank end
5 VS2030.03 50/55/60mm Inlet adaptor c/w air coupling
6 VS2030.03A 50/55/60mm Adaptor blank end
7 VS2030.04 35/40/55mm Inlet adaptor c/w air coupling
8 VS2030.04A 35/40/45mm Adaptor blank end
9 VS2030.05 N/A Pressure gauge assembly
VS2030.V2 Issue:2 (H,F) 26/04/19
Original Language Version
© Jack Sealey Limited

Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 01284 703534 [e-mail] www.sealey.co.uk
ENVIRONMENT PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to
a recycling centre and disposed of in a manner which is compatible with the environment. When the product becomes completely
unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and dispose of the product and fluids
according to local regulations.
Note: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior
notice. Please note that other versions of this product are available. If you require documentation for alternative versions, please email or call
our technical team on [e-mail] or 01284 757505.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.
5.2.1. For example the maximum pressure in most vehicle turbo systems is
approximately 15psi (1bar) up to 25psi (1.7bar). A vehicle coolant system is
typically rated at 15psi.
5.2.2. A graduated approach to leakage testing is recommended.
5.3. TEST METHOD 1, (REFER TO FIG.2):
5.3.1. Select the correct air inlet adaptor and plug adaptor (fig.1) by first measuring
the hose diameter. Each adaptor has three diameters to fit different sizes of
hose.
5.3.2. Set regulator of tester to 5psi to check for large leaks with valve, open
(operating handle inline with the hose axis). and with the air coupling
disconnected.
5.3.3. Plug the outlet of the system with the appropriate blank end adaptor.
5.3.4. Connect the inlet adaptor, set at 5psi, to the system inlet.
5.3.5. Connect the air coupling to check for leaks at the pre-set (5psi). If a leak is
identified audibly or if the pressure gauge pointer falls, it indicates that the
system has a fault resulting in loss of pressure. Repair the leak and retest.
5.3.6. If no leaks are evident, regulate pressure to 10psi and repeat 5.3.5.
5.3.7. If no leaks are evident, regulate pressure to a maximum of 15psi or to the
manufacturer’s maximum pressure and retest as in 5.3.5.
5.3.8. If the gauge pointer remains stationary for one minute it will indicate that the
system is in good working order.
5.3.9. Release the pressure in the system by rotating the ball valve lever to align with hose axis.
5.3.10. Disconnect the quick coupler, clean and return all items to carry case.
5.4. TEST METHOD 2, (REFER TO FIG.2):
5.4.1. Set up as in test method 1: 5.3.1. to 5.3.5.
5.4.2. When the system is pressurized, close the ball valve. By closing the ball valve the system is isolated from the constant air supply. The
system can now be tested to ensure it is holding a constant pressure. By monitoring the pressure gauge over a period small leaks can
be detected, showing as a fall in pressure within the system.
6. MAINTENANCE
6.1. Always keep the plastic adaptors clean and free of oil and grease. Regularly clean with a solvent free cleaner. Ensure components are
dry before storage.
g.2
Example (left) shows the kit
testing a turbo system
intercooler for integrity.
Intercooler
Turbo
Engine
Typical turbocharger system
VS2030.V2 Issue:2 (H,F) 26/04/19
Original Language Version
© Jack Sealey Limited