VACUTEC Leakfinder 625-WV609 User manual

INSTRUCTION MANUAL
Leakfinder®
Model No. 625-WV609
BMW Smoke Tester
Diagnostic Smoke®Vapor
with UltraTraceUV®Dye Solution
Leak Detection System for the Professional Technician
USA | Canada Patents ●6,392,227 •6,439,031 • 6,526,808 | 2,279,147 •2,394,911 | Int’l Patents Pending

Caution and Usage Tips
NOTE: A common question asked is if one can use a very basic generic mineral oil, such as ‘baby oil’, in the
Leakfinder®to create the smoke vapor.
Your Leakfinder®will create smoke vapor with baby oil, but we do not recommend it. The patented
UltraTraceUV® smoke solution supplied with your Leakfinder®; will perform hundreds of tests (is very
economical to use); is the only solution in the world containing dye that is approved by the OEMs; and will
not void any vehicle factory warranties. Plus you have the added benefit of the trace dye that marks the
exact location of a leak, increasing diagnostic accuracy. UltraTraceUV® solution is not a “generic” mineral oil.
In fact, generic mineral oils are not intended for this type industrial use. The generic mineral oils break
down, evidenced by its foul odor and they could damage vehicle components or systems, such as EVAP
system’s activated charcoal, and void factory warranty.
DISCONNECT the smoke tester from the vehicle prior to starting the engine or prior
to running any on-board monitor, including the DMTL or LDP. Damage caused by not
following proper operating procedures will not be covered by the vehicle warranty or
the smoke tester warranty.
Refer to SI B16 01 07 for additional information.
ALWAYS use smoke tester with vehicle engine turned <OFF>.
Use this equipment in the manner specified by the manufacturer.
Follow common sense safety precautions.
Connect to grounded extension cord supplied and grounded 120-volt AC 60 Hz wall
outlet.
Use UltraTraceUV® Smoke Solution No. 625-WV0712UV in Tester. Using a non-
approved solution; may cause damage to vehicles being tested; may cause personal
injury and may void vehicle warranties.
Do not leave Tester’s hose connected to the vehicle if tests are not being performed.
Do not perform test near source of spark or ignition.
Wear appropriate eye protection.
Wear yellow glasses supplied when using ultraviolet light.
Air or gas pressure supplied to Tester can be between 3.4 to 12 bar (50 ~ 175 PSI).
Connect Tester to inert gas, such as nitrogen or CO2, when testing fuel vapor (EVAP)
system. Note: DO NOT use workshop air for EVAP testing. Adding oxygen to the fuel
vapor space can create a flammable mixture in the fuel tank.
Connect Tester to workshop compressed air for general purpose leak detection
applications.
When using alternate source of UV light, use light that includes 405 nanometer (nm)
UV light range.
When operating the Tester in near freezing temperatures, cycle the operation of the
Tester 15 seconds <ON> and 15 seconds <OFF> for approximately the first minute or
two of operation. This will allow the Tester to reach optimum operating
temperature.
When testing an engine's intake or exhaust system for leaks, it is best if the engine is
cold. Small leaks may be sealed due to thermal expansion.
!

Contents
Accessories Included
Product Overview & Technical Specifications
Initial Setup
Quick Start Guide
Other Leak Samples
Control Valve Overview
Flow Meter Overview
EVAP Tech Tips
Troubleshooting Guide
Warranty
1
2
3
4 –7
8 –9
10
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12
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Thank You and Congratulations! Your Leakfinder® 625-WV609 smoke tester is approved for
Evaporative Emissions System (EVAP) leak-testing, as well as other systems, on all BMW
vehicles.
Your tester incorporates STAR Diagnostic Smoke® Technology, inside. It is the simplest and
quickest way to find many vehicle system leaks. Smoke vapor-generating leak detectors
containing STAR Technology inside are the only leak detectors in the world approved by BMW.
The patented technology inside your Leakfinder®, including the vapor-producing solution
(UltraTraceUV®), was designed in collaboration with major OEMs, in order to establish a standard
for leak detection. It is designed to be safe for vehicle systems and will not void factory
warranties.
It is also the only smoke technology in the world that meets SAE INTERNATIONAL Published
Papers’ safety standards recommendation to use a smoke tester designed to function with an
inert gas (such as Nitrogen, Argon or CO2) when testing a vehicle’s fuel evaporative (EVAP)
system [SAE: 2007-01-1235 & 2008-01-0554].

Accessories Included
UltraTraceUV®: (625-WV0712UV) this patented solution is the only Automaker-approved
smoke-producing solution in the world. The solution’s chemistry is specially formulated to
withstand vaporization temperatures, is designed not to damage vehicle components and
contains a special dye that deposits at the exact location of a leak. Each bottle will
perform approximately 300 tests. (12 oz. / 355 ml).
(Part No. is for one bottle. Two bottles included with smoke tester).
Combination Light: (625-WVA-074) white light, for easier smoke location and ultraviolet
(UV) light to highlight the fluorescent dye deposited at the exact location of a leak.
Note: For eye safety and UV enhancement; always use yellow glasses with UV light.
Smoke Diffuser: (625-WVA-03) locates leaks around doors, windows, sunroofs and trunk
compartment seals.
Adapter Cone (standard): (625-WVA-01) for introducing smoke into the exhaust system
or the induction system. Cone is 1” x 3.5” and 6” long (25.4 mm x 89 mm x 152 mm).
Power Converter (625-WVA-080) connects to smoke tester and grounded wall power
outlet, to avoid using the vehicle battery as a power source.
AC input: 100-240V AC/5A 50/60Hz | DC output:12V 25A
Inert Gas Pack Kit: (625-WVA-060E) includes preset pressure regulator, pressure gauge,
quick-connect fitting and 20 oz. liquid CO2 cylinder. (Cylinder arrives empty)
Cylinders can be locally filled or exchanged with liquid CO2at larger paintball or welding
supplies stores.
Handle Pad (625-WVA-087)
Air fitting: Two are supplied. The automotive style fitting is installed on the smoke tester.
The spare fitting is an industrial fitting but also popular in auto facilities.
See website for additional accessories and information: www.vacutec.com

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Product Overview & Technical Specifications
Technical Specifications
Height
Length
Width
Weight
Shipping weight
Power supply
13.5 in. (34 cm)
13 in. (33 cm)
9 in. (23 cm)
10.5 lb. (4.8 kg)
13.5 lb. (6.1 kg)
12 volts DC
Solution Max. Volume
Supply pressure
Supply volume
Smoke supply line
Power supply line
Power consumption
12 oz. (355 ml)
14.0 in. H2O (0.035 bar | 3.5 kPa)
10 liters per minute
8 feet (2.4m)
8 feet (2.4m)
15 amps.
Water Separator / Filter (inside tester) with drain port at underside of
tester; keeps tester and vehicle clean by automatically draining water
and contaminants from workshop air compressor. It is normal to
occasionally see drainage of fluid from this port. Excessive drainage
indicates your air compressor requires draining and/or a filter system.
Air/Gas Inlet
Dipstick
To maintain solution level.
Top off regularly
Flow Meter
With leak-size indicators
Scratch-Resistant Housing
Supply Hose
Indicator Lights
<ON> <OFF> Switch
On 5-minute timer
Control Valve
Power Cables
Back of tester
Filter Drain Port
Underside of tester

3
Initial Setup
1.
2.
NOTE: Your Leakfinder®is now ready for operation.
Read this Instruction Manual in its entirety before operating this tester.
Low
Full
> Pour entire contents of one 12 oz. UltraTraceUV® solution bottle into the smoke chamber.
.
NOTE: Use second bottle supplied to regularly maintain at or near FULL mark.
> If not supplied; install correct air fitting onto the Leakfinder®.

4
Quick Start Guide
Do One of the Following:
1.
Or
1.
Or
1.
Connect to workshop air for general
purpose (non EVAP) leak testing.
Connect to Nitrogen, or other inert gas, when
testing fuel evaporative (EVAP) system.
Regulate nitrogen from 50 to 175 PSI
(3.4 bar - 12 bar | 345 kPa –1,206 kPa)
Inert Gas Pack
Inert Gas Pack Kit (625-WVA-060). When filled
with liquid CO2 will perform approximately 50
EVAP tests.
(Cylinder arrives empty)

5
2.
> Green light will turn <ON>.
> A blinking green light
indicates a lack of power
from the converter, which
means it could be set too
low).
> Connect power converter to smoke tester and grounded extension
cord supplied to grounded 120-Volt AC 50/60 Hz wall outlet and turn
power converter <ON>.
Push in toward tester to lock,
pull out to unlock.
To remove plug:
First, unlock. Then push tab downward
while pulling plug at the same time.
The tester can also be powered by 12V DC
harness (625-WVA-072), not included
<ON> / <OFF> switch

6
3.
4.
> Press START button.
> Green and red lights are <ON>.
> 5-minute timer.
> Position to SMOKE (full flow).
> Use cone to access intake system and connect smoke supply hose to cone.
>Refer to SI B 16 01 07 for additional information.

7
5.
> Use white light to find the smoke. > Use UV light and yellow glasses to find the dye.

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Other Leak Samples
Leakfinder® can be used in virtually any vehicle low pressure system suspected of having a leak, such as;
intake / induction, intercooler and turbocharger, vacuum, exhaust, EVAP and even wind/water leaks. Can
also be used to verify air solenoid functions and test components prior to assembly.
Exhaust
Fluorescent Dye Deposit
The UltraTraceUV® smoke solution contains a special
ultraviolet-activated fluorescent dye that deposits at
the exact location of a leak. Use the UV light provided
to highlight the dye.
> The longer the smoke is allowed to exit a leak, the
more dye will be deposited.
> This technology has been designed so that the dye
deposits only if there is pressure-differential. So for
instance; the dye will deposit when exiting a leak but
will not deposit during a wind and water leak test.

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Wind and Water Leaks
1
1. . S Se et t v ve eh hi ic cl le e’ ’s s c cl li im ma at te e c co on nt tr ro ol l t to o ‘ ‘F Fr re es sh h A Ai ir r’ ’ ( (n no ot t t to o r re e- -c ci ir rc cu ul la at te e) ). . S Se et t b bl lo ow we er r o on n f fu ul ll l s sp pe ee ed d. .
>
> T Th hi is s c cr re ea at te es s p po os si it ti iv ve e c ca ab bi in n p pr re es ss su ur re e. .
2
2. . C Co on nn ne ec ct t s su up pp pl ly y h ho os se e n no oz zz zl le e t to o S Sm mo ok ke e D Di if ff fu us se er r. .
3
3. . L La ay y s sm mo ok ke e p pa at th h a al lo on ng g s se ea al ls s. .
4
4. . L Lo oo ok k f fo or r s sm mo ok ke e d di is st tu ur rb ba an nc ce e i in nd di ic ca at ti in ng g a a l le ea ak k. .
No smoke distrurbance means ‘No Leak’ >
<Smoke distrubance pinpoints the leak

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Control Valve Overview
TEST: Delivers non-smoke air and a very
accurate flow meter reading. This setting is
for determining if a leak exists and how
large it is.
SMOKE: Delivers maximum smoke volume.
FLOW CONTROL: Controls smoke volume.
> Locating the leak source is sometimes
easier with less smoke volume. First, fill
system with smoke then reduce volume.
Note: Flow Control does not affect delivery
pressure; it only affects flow volume.

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Flow Meter Overview
A flow meter ball indicating flow means there is flow going into (or through) the system being leak-
tested. This is normal while the system is being filled. If flow meter indicates flow after the system is
filled, this indicates a leak. The higher the ball is in the flow meter, the larger the leak size. No flow
indicates no flow through the system, or no leak.
Leak Size Reference Points:
The flow meter has leak size reference points which quantifies
the leak size in the system being leak tested.
When using workshop air (or nitrogen); read the left side of
the flow meter.
When using CO2; read the right side of the flow meter.
The .010” (0.25 mm), .020” (0.5 mm) and .040” (1.0 mm)
reference points are equivalent to leaks of those sizes in the
EVAP system being tested.
Once the system is filled (either in TEST or SMOKE setting) and
the flow meter ball stops descending, compare the level of the
ball with the reference points in order to determine a leak size
or pass/fail.
>Above reference point = FAIL.
>Below reference point = PASS.
NOTE: The flow meter measurements are most accurate when
the tester’s Control Valve is in TEST setting.

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EVAP Tech Tip
Do One of the Following:
1. The flow meter is active in the SMOKE and TEST positions of the Flow Control Valve. However, for the
most precise quantifying of a leak size use the TEST position in either of these two methods.
A. Fill system in TEST (no smoke) setting until flow meter ball stops descending. Position the flow meter’s
red flag so that it aligns with the flow meter ball position. Compare flow meter ball position with flow
meter’s Leak Size Reference Points.
NOTE: If the leak size is unacceptable and leak testing is required; first alleviate all pressure from the
EVAP system so that smoke can be introduced.
Then set control valve to SMOKE (full flow) setting, introduce smoke and look for smoke or dye to find
the leak(s).
Or
B. To save time; fill system in SMOKE (full flow) setting until flow meter ball stops descending. Be sure
the Leakfinder® is still <ON> and immediately position control valve to TEST, for a more accurate flow
meter reading. Be sure ball has stopped descending and compare flow meter ball position with flow
meter’s Leak Size Reference Points.
>Above reference point = FAIL.
>Below reference point = PASS.
If the leak size is unacceptable and leak testing is required, then time will have been saved because
you will have already filled the EVAP system with smoke. Immediately position the control valve again
to SMOKE and continue to introduce smoke while looking for smoke or dye at leak points.
NOTE: When testing a closed system, such as the EVAP system, it is best to purge the ‘non-smoke’ air out
of the system by leaving an opening in the system being filled (e.g. EVAP vent). Close the system once
smoke exits that opening and continue to fill with smoke. This quickly fills the system with smoke.
!
ALL TESTS WITH THIS TESTER ARE PERFORMED WITH THE VEHICLE’S ENGINE TURNED OFF!

13
Troubleshooting Guide
Two lights on the control panel double as diagnostic lights.
Green
Red
Interval
Cause

Blinks: 1 per second
Indicates a lack of power from the power
converter, which means it could be set too
low.


Blink simultaneously: 1 per second
Bad ground or power connection at smoke
canister or short in circuit


Blink simultaneously: 4 times per second
Bad ground at smoke canister or open
heating circuit


Blink alternately: 1 per second
(System shuts down)
Bad ground or circuit board failure *
Symptom
Likely Cause
Solution
The green power
indicator lamp on the
Tester does not turn ON.
1. Poor power-supply cable
connection.
1. Secure power connection at the machine
and wall outlet.
There is no air or smoke
coming out of the supply
hose.
1. Flow Control valve is closed.
2. Air/gas supply to tester is
insufficient.
3. Bad power-supply cable
connection, or power converter
is set too low.
1. Open flow control.
2. Check for sufficient air/gas supply.
3. Secure power converter connections
and/or increase power converter setting.
Very little smoke coming
out of the smoke hose or
oil dripping from the
smoke hose.
1. There is too much smoke
condensation inside the smoke
supply hose.
> This usually does not indicate a
failure.
1. Position the hose lower than the Tester.
Set control valve to TEST and turn Tester
<ON> for one cycle, or until oil has drained
from hose.
*If circuit board failure occurs, first disconnect power to your Tester for 10 seconds and
reconnect. If failure code occurs a second time, disconnect Tester and contact Authorized Dealer.

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Warranty | Technical Support
Your Product Warranty has already been activated,
no need for you to send us any information.
LIMITED TWO (2) YEAR WARRANTY
Leakfinder®Model 625-WV609
Worldwide Vapor, Inc. Warrants To the Original Purchaser; under normal use, care and service, Tester shall be
free from defects in material and workmanship for TWO YEARS from the date of original invoice.
Seller's obligations under this warranty are limited solely to the repair or, at Seller's option, replacement of or
refund of the original purchase price for, Equipment or parts which to Seller's satisfaction are determined to be
defective and which are necessary, in Seller's judgment, to return the equipment to good operating condition.
Repairs or replacements qualifying under this Warranty will be performed or made on regular business days
during Seller's normal working hours within a reasonable time following Buyer's request. All requests for
warranty service must be made during the stated warranty period.
© Worldwide Vapor, Inc. | Rev. 01Jan2013
This product contains
STAR licensed technology, inside.
www.StarEnviroTech.com

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