Wilson Electronics 9836 Troubleshooting guide

8
SM-158
SPECIFICATIONS
Air Supply Pressure 90 psi
Air Consumption 22 CFM
Air Inlet 3/8” NPT
Vacuum Range 19-25 inches of Mercury
Thomas C. Wilson, Inc.
21-11 44th Avenue, Long Island City, New York 11101
Tel: [phone] Fax: [phone] http://www.tcwilson.com
E-mail: [e-mail]
SM-158
Thomas C. Wilson, Inc.
21-11 44th Avenue, Long Island City, New York 11101
Tel: [phone] Fax: [phone] http://www.tcwilson.com
E-mail: [email protected]
TO REDUCE THE RISK OF INJURY AND EQUIPMENT DAMAGE
USER MUST READ AND UNDERSTAND OPERATOR’S MANUAL.
Rev: A, 2/22/2007
OPERATING INSTRUCTIONS
&
SERVICE MANUAL
VACUUM LEAK DETECTOR
 9836

2
SM-158
SAFETY INSTRUCTIONS
1. Do not allow corrosive gases or foreign material to enter the unit. Moisture,
oil-based contaminants, or other liquids must be filtered out.
2. Eye protection is always required when running motor.
3. Hearing protection is recommended when in close proximity to all operating
air motors.
4. Dust mask, non-skid safety shoes, hard hat, gloves and other personal safety
equipment must be used.
5. Stay alert, watch what you are doing, and use common sense when operating
a power tool.
6. Dress properly. Do not wear loose clothing or jewelry.
7. Keep your work area clean and well lit.
8. Do not operate power tools in explosive atmospheres, such as in the presence
of flammable liquids, gases, or dust.
9. Disconnect the tool from the air supply before installing, making any adjust-
ment, changing accessories, servicing or storing tool.
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below, may result
in accident, fire and/or personal injury.
SAVE THESE INSTRUCTIONS
WARNING!
!
7
SM-158
TROUBLE-SHOOTING
PROBLEM CAUSE & SOLUTION
VLD pull no vacuum or
low vacuum 1. Clogged muffler
—see pg. 5 for disassembly instructions.
2. Clogged Venturi chamber
—see pg. 5 for disassembly instructions.
3. Clogged gage inlet
—see pg. 5 for disassembly instructions.
4. Inadequate air supply
—make sure air supply provides 22 SCFM
@90psi
VLD does not hold the
vacuum; falling pointer at
vacuum gage
1. Clogged Check Valve Disc
—see pg. 5 for disassembly instructions.
2. Leak in vacuum system
—check all connections and apply Teflon tape to
seal.
3. Worn Nozzle
—replace if necessary
VLD maintenance is performed as necessary and should be done more frequently
due to dirty compressed air and/or dirty tubes under test. Cleaning should be
done periodically on internal parts such as Muffler, Jet Needle, Jet Sleeve, Check
Valve, Check Valve Disc, Vacuum Gage Inlet.
MAINTENANCE

6
SM-158
PARTS LIST
Key Description Part No. Qty.
1 Nozzle 41460-100X 1
2 Pipe Fitting 9540 2
3 Filter 41608-0001 1
4 Check Valve 42827 1
5 O-Ring 28171 1
6 O-Ring 51856 1
8 Check Valve Disc 41464 1
9 Retainer 41465 1
10 Jet Needle 42828 1
11 Insert 42830 1
12 Lever 42832 1
13 Valve 7018 1
14 Body 42824 1
7 O-Ring 50824 1
15 Jet Sleeve 42829 1
16 Muffler 41362 1
17 Vacuum Gage 41332 1
7
4
3
1
2
8
17
10
11
15
16 14 12
9
6
5
13
3
SM-158
OPERATION
RECOMMENDED OPERATING AIR PRESSURE 90 PSI
MAY BE OPERATED AT 80 TO 125 PSI
1. Compressed Air Supply — Use 90 PSI clean, dry shop air. Do not use moist
or oil-laden air, Connect the Vacuum Leak Detector (VLD) (#42823) to the
air supply by means of the operating hose assembly (#24360-0012).
2. Tube Nozzle — Select the correct tube nozzle for the tube to be tested. (See
specifications above.) Thread the selected tube nozzle into the nozzle exten-
sion nipple (Key 4).
3. Tube Condition - Tubes to be tested should be free of visible liquids or other
residues. If necessary, blow the tube inner diameter clean using clean, dry
compressed air.
4. Tube Plugs — Plug far end of each tube to be tested with snap type tube plugs
or T-handle tube plug (#42834-100X).

4
SM-158
OPERATION(CONT’)
5. Seal the tube to be tested by pressing the rubber coated nozzle of the VLD
into the near end of the tube.
6. Release compressed air to the VLD by depressing the VLD lever trigger.
The tube under test will evacuate rapidly for a few seconds, as registered
by the vacuum gage (Key 17) and at a slower rate as the vacuum continues
to build up.
7. At some convenient gage reading, seal the evacuated tube by releasing the
VLD trigger.
8. Observe the gage for a few seconds. A steady gage indicates a satisfactory
tube. A falling vacuum indicates a leaky tube.
9. Test each tube in turn, repeating steps 5 through 8 above. NOTE: Before
replacing a tube indicated faulty, it is a good idea to repeat the test, first
checking the seals at the tube plug seat and at the VLD nozzle.
5
SM-158
DISASSEMBLY
MUFFLER - A clogged muffler (Key 116) will limit the VLD vacuum to less than
the 19 to 25 inches of mercury. To check the muffler, compare the VLD vacuums
produced with and without the muffler. If the difference between the vacuums ex-
ceeds 3 inches of mercury, a clogged muffler is indicated, Unthread the muffler
from the VLD. Flush and blow dry with clean, dry compressed air. Rethread the
muffler to the VLD assembly. Frequent necessity to clean the muffler usually indi-
cates unclean compressed air and/or unclean tubes under test. In these cases an air
line filter is recommended for the compressed air line. As necessary, this filtered air
should be used to blow tubes under test clean of liquids or other debris.
VENTURI - A clogged venturi chamber will limit the VLD vacuum. To inspect the
venturi chamber, unthread Muffler and Jet Sleeve (Key 16 & 15). Unthread check
valve (Key 4). Reach into the Insert (Key 11) from the muffler side and carefully
press jet needle (Key 10) out of the assembly. Inspect jet needle; rinse clean as nec-
essary. Wipe jet needle seat with a clean rag and blow out with clean, dry com-
pressed air. Reassemble. (The jet needle is essential in formation of the vacuum and
is manufactured to exacting requirements. Handle with care.)
VACUUM GAGE INLET - Unsatisfactory vacuum gage (Key 17) readings may be
due to a clogged gage inlet. Unthread Check Valve (Key 4). This will reveal a
small gage inlet port in the Check Valve. Be sure this port is clear. Reassemble.
CHECK VALVE DISC - When compressed air is shut off, the VLD check valve
(Key 4) automatically closes, sealing the evacuated tube. Had the Check Valve
Disc (Key 8) become clogged with debris prior to shut off, it will not seal and the
tube under test will fill with air incorrectly indicating a leaky tube. To correct this
condition, unthread the VLD check valve. Remove retainer (Key 9). Remove and
wipe the check valve disc clean. Flush and air dry the disc valve seat. Reassemble.

4
SM-158
OPERATION(CONT’)
5. Seal the tube to be tested by pressing the rubber coated nozzle of the VLD
into the near end of the tube.
6. Release compressed air to the VLD by depressing the VLD lever trigger.
The tube under test will evacuate rapidly for a few seconds, as registered
by the vacuum gage (Key 17) and at a slower rate as the vacuum continues
to build up.
7. At some convenient gage reading, seal the evacuated tube by releasing the
VLD trigger.
8. Observe the gage for a few seconds. A steady gage indicates a satisfactory
tube. A falling vacuum indicates a leaky tube.
9. Test each tube in turn, repeating steps 5 through 8 above. NOTE: Before
replacing a tube indicated faulty, it is a good idea to repeat the test, first
checking the seals at the tube plug seat and at the VLD nozzle.
5
SM-158
DISASSEMBLY
MUFFLER - A clogged muffler (Key 116) will limit the VLD vacuum to less than
the 19 to 25 inches of mercury. To check the muffler, compare the VLD vacuums
produced with and without the muffler. If the difference between the vacuums ex-
ceeds 3 inches of mercury, a clogged muffler is indicated, Unthread the muffler
from the VLD. Flush and blow dry with clean, dry compressed air. Rethread the
muffler to the VLD assembly. Frequent necessity to clean the muffler usually indi-
cates unclean compressed air and/or unclean tubes under test. In these cases an air
line filter is recommended for the compressed air line. As necessary, this filtered air
should be used to blow tubes under test clean of liquids or other debris.
VENTURI - A clogged venturi chamber will limit the VLD vacuum. To inspect the
venturi chamber, unthread Muffler and Jet Sleeve (Key 16 & 15). Unthread check
valve (Key 4). Reach into the Insert (Key 11) from the muffler side and carefully
press jet needle (Key 10) out of the assembly. Inspect jet needle; rinse clean as nec-
essary. Wipe jet needle seat with a clean rag and blow out with clean, dry com-
pressed air. Reassemble. (The jet needle is essential in formation of the vacuum and
is manufactured to exacting requirements. Handle with care.)
VACUUM GAGE INLET - Unsatisfactory vacuum gage (Key 17) readings may be
due to a clogged gage inlet. Unthread Check Valve (Key 4). This will reveal a
small gage inlet port in the Check Valve. Be sure this port is clear. Reassemble.
CHECK VALVE DISC - When compressed air is shut off, the VLD check valve
(Key 4) automatically closes, sealing the evacuated tube. Had the Check Valve
Disc (Key 8) become clogged with debris prior to shut off, it will not seal and the
tube under test will fill with air incorrectly indicating a leaky tube. To correct this
condition, unthread the VLD check valve. Remove retainer (Key 9). Remove and
wipe the check valve disc clean. Flush and air dry the disc valve seat. Reassemble.

6
SM-158
PARTS LIST
Key Description Part No. Qty.
1 Nozzle 41460-100X 1
2 Pipe Fitting 9540 2
3 Filter 41608-0001 1
4 Check Valve 42827 1
5 O-Ring 28171 1
6 O-Ring 51856 1
8 Check Valve Disc 41464 1
9 Retainer 41465 1
10 Jet Needle 42828 1
11 Insert 42830 1
12 Lever 42832 1
13 Valve 7018 1
14 Body 42824 1
7 O-Ring 50824 1
15 Jet Sleeve 42829 1
16 Muffler 41362 1
17 Vacuum Gage 41332 1
7
4
3
1
2
8
17
10
11
15
16 14 12
9
6
5
13
3
SM-158
OPERATION
RECOMMENDED OPERATING AIR PRESSURE 90 PSI
MAY BE OPERATED AT 80 TO 125 PSI
1. Compressed Air Supply — Use 90 PSI clean, dry shop air. Do not use moist
or oil-laden air, Connect the Vacuum Leak Detector (VLD) (#42823) to the
air supply by means of the operating hose assembly (#24360-0012).
2. Tube Nozzle — Select the correct tube nozzle for the tube to be tested. (See
specifications above.) Thread the selected tube nozzle into the nozzle exten-
sion nipple (Key 4).
3. Tube Condition - Tubes to be tested should be free of visible liquids or other
residues. If necessary, blow the tube inner diameter clean using clean, dry
compressed air.
4. Tube Plugs — Plug far end of each tube to be tested with snap type tube plugs
or T-handle tube plug (#42834-100X).

2
SM-158
SAFETY INSTRUCTIONS
1. Do not allow corrosive gases or foreign material to enter the unit. Moisture,
oil-based contaminants, or other liquids must be filtered out.
2. Eye protection is always required when running motor.
3. Hearing protection is recommended when in close proximity to all operating
air motors.
4. Dust mask, non-skid safety shoes, hard hat, gloves and other personal safety
equipment must be used.
5. Stay alert, watch what you are doing, and use common sense when operating
a power tool.
6. Dress properly. Do not wear loose clothing or jewelry.
7. Keep your work area clean and well lit.
8. Do not operate power tools in explosive atmospheres, such as in the presence
of flammable liquids, gases, or dust.
9. Disconnect the tool from the air supply before installing, making any adjust-
ment, changing accessories, servicing or storing tool.
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions listed below, may result
in accident, fire and/or personal injury.
SAVE THESE INSTRUCTIONS
WARNING!
!
7
SM-158
TROUBLE-SHOOTING
PROBLEM CAUSE & SOLUTION
VLD pull no vacuum or
low vacuum 1. Clogged muffler
—see pg. 5 for disassembly instructions.
2. Clogged Venturi chamber
—see pg. 5 for disassembly instructions.
3. Clogged gage inlet
—see pg. 5 for disassembly instructions.
4. Inadequate air supply
—make sure air supply provides 22 SCFM
@90psi
VLD does not hold the
vacuum; falling pointer at
vacuum gage
1. Clogged Check Valve Disc
—see pg. 5 for disassembly instructions.
2. Leak in vacuum system
—check all connections and apply Teflon tape to
seal.
3. Worn Nozzle
—replace if necessary
VLD maintenance is performed as necessary and should be done more frequently
due to dirty compressed air and/or dirty tubes under test. Cleaning should be
done periodically on internal parts such as Muffler, Jet Needle, Jet Sleeve, Check
Valve, Check Valve Disc, Vacuum Gage Inlet.
MAINTENANCE

8
SM-158
SPECIFICATIONS
Air Supply Pressure 90 psi
Air Consumption 22 CFM
Air Inlet 3/8” NPT
Vacuum Range 19-25 inches of Mercury
Thomas C. Wilson, Inc.
21-11 44th Avenue, Long Island City, New York 11101
Tel: [phone] Fax: [phone] http://www.tcwilson.com
E-mail: [email protected]
SM-158
Thomas C. Wilson, Inc.
21-11 44th Avenue, Long Island City, New York 11101
Tel: [phone] Fax: [phone] http://www.tcwilson.com
E-mail: [e-mail]
TO REDUCE THE RISK OF INJURY AND EQUIPMENT DAMAGE
USER MUST READ AND UNDERSTAND OPERATOR’S MANUAL.
Rev: A, 2/22/2007
OPERATING INSTRUCTIONS
&
SERVICE MANUAL
VACUUM LEAK DETECTOR
 9836