1. Introduction
This manual provides instructions for the safe and effective use of the Orion Motor Tech 9-Piece Turbo Leak Tester. This kit is designed to assist in identifying leaks within the turbocharger, cooling, and emissions systems of various cars and light trucks. Proper use of this tool can help diagnose issues related to boost pressure loss and system integrity.
Figure 1.1: The Orion Motor Tech 9-Piece Turbo Leak Tester kit, including the blue storage case, pressure gauge assembly, and various stepped adapters. This kit is used for diagnosing leaks in turbo, cooling, and exhaust systems.
2. Safety Information
Always observe the following safety precautions when using the Turbo Leak Tester:
- Wear appropriate personal protective equipment, including safety glasses and gloves.
- Ensure the vehicle's engine is off and cooled down before beginning any testing.
- Do not exceed the recommended pressure for the system being tested. The kit's pressure gauge has a range of 0-86 psi. Keep the pressure below 30 psi to avoid activating the safety valve and potential damage to the system or tester.
- Use the tool only for its intended purpose as described in this manual.
- Keep children and unauthorized personnel away from the work area.
- Store the kit in its blow-molded case when not in use to prevent damage and ensure longevity.
3. Package Contents
The Orion Motor Tech 9-Piece Turbo Leak Tester kit includes the following components:
- 1 x Pressure Gauge Assembly (0-86 psi) with Pressure Regulator, Ball Valve, and Pressure Relief Valve
- 4 x Test Adapters (stepped design for various hose sizes)
- 4 x Blanking Adapters (stepped design for various hose sizes)
- 1 x DIN Adapter
- 1 x Pair of Gloves
- 1 x Blow-Molded Storage Case
4. Components Overview
Familiarize yourself with the key components of the turbo leak tester kit:
Figure 4.1: Detailed view of the pressure gauge assembly and the stepped adapters. The assembly includes a pressure regulator for precise control, a ball valve for air flow, a pressure gauge for monitoring, and a pressure relief valve for safety. Adapters are designed for both system inlet and outlet points.
Figure 4.2: The stepped design of the adapters ensures an airtight fit for various pipe and hose diameters. These adapters are constructed from durable, lightweight nylon for wear resistance.
Figure 4.3: Overview of the four pairs of stepped adapters included in the kit, detailing the various hose sizes they accommodate. Each adapter has multiple steps to fit a range of diameters, from 1-3/4" (45 mm) up to 3-1/2" (90 mm).
The adapters are designed to fit hoses of various sizes, ensuring a precise and airtight seal. Refer to Figure 4.3 for specific size ranges.
5. Setup
Before performing a leak test, ensure the following:
- Prepare the Vehicle: Ensure the engine is off and cool. Access the turbocharger, cooling, or emissions system components that require testing.
- Select Adapters: Identify the hoses or pipes to be tested. Select the appropriate sized test adapters and blanking adapters from the kit that provide a snug fit. The stepped design allows for versatility.
- Insert Adapters: Insert the selected adapters into the ends of the hoses or pipes to be sealed. One end will typically receive the pressure gauge assembly, while the other ends will be sealed with blanking adapters.
- Connect Air Supply: Connect your compressed air equipment to the pressure gauge assembly. The assembly supports both US Standard and EU Standard air inlets.
Note: Assembly of the pressure gauge unit to the air hose may be required.
6. Operating Instructions
Follow these steps to perform a turbo system leak test:
- Step 1: Select and Fit Adapters. Choose the correct stepped adapters for the hoses you intend to test. Ensure they fit securely onto the hose ends.
- Step 2: Set Pressure. Turn the ball valve to the closed position and adjust the pressure regulator knob to set your desired test pressure. Do not exceed 30 psi.
- Step 3: Connect Gauge. Connect the pressure gauge assembly to one of the test adapters, which is fitted to the system under test. Ensure all connections are secure.
- Step 4: Charge System and Listen for Leaks. Slowly open the ball valve to allow compressed air into the system. Observe the pressure gauge and listen carefully for any audible leaks. If no leaks are heard, apply soapy water to all joints and connections to visually identify bubbles, which indicate a leak.
Figure 6.1: Visual guide illustrating the four main steps for operating the turbo leak tester, from adapter selection to system charging and leak detection.
Figure 6.2: Instructions for adjusting the pressure regulator. Pull up the knob to rotate and adjust the pressure, then press down to lock the setting in place.
Important Tip: For hard-to-find leaks, a spray bottle with soapy water can be used on connections and hoses. Bubbles will form at the leak point.
7. Maintenance
To ensure the longevity and reliable performance of your Turbo Leak Tester, follow these maintenance guidelines:
- Cleaning: After each use, wipe down all components with a clean, dry cloth. If exposed to soapy water, rinse with clean water and dry thoroughly.
- Storage: Store the entire kit in its original blow-molded case in a clean, dry environment, away from direct sunlight and extreme temperatures.
- Inspection: Periodically inspect the adapters, hoses, and pressure gauge for any signs of wear, cracks, or damage. Replace any damaged components immediately.
- Pressure Gauge: Handle the pressure gauge assembly with care to prevent damage to the gauge mechanism.
8. Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Cannot build pressure in the system. |
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| Pressure drops quickly after charging. |
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| Adapters are difficult to fit or remove. |
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9. Specifications
- Model Number: CLT-B001-00
- Brand: Orion Motor Tech
- Pressure Gauge Range: 0-86 psi
- Adapter Material: Lightweight Nylon
- Kit Dimensions (L x W x H): 39.5 x 29.49 x 12.5 cm (approx.)
- Item Weight: 2.49 kg (approx.)
- Assembly Required: Yes (minor assembly for pressure gauge unit)
- Application: Turbocharger, cooling, and emissions systems leak detection for cars and light trucks.
10. Warranty and Support
For warranty information or technical support regarding your Orion Motor Tech 9-Piece Turbo Leak Tester, please refer to the contact information provided with your purchase or visit the official Orion Motor Tech website. Keep your purchase receipt as proof of purchase for any warranty claims.
