MAHLE RTI ELF-1 User Manual

Operation Manual

ELF-1

E

vap Leak Finder

RTI Technologies, Inc.

10 Innovation Drive
York, Pennsylvania 17402 USA
Phone: [phone]
Web-site: [e-mail]

035-81259-00

SAFETY PRECAUTIONS & HIGH PRESSURE WARNINGS

i Pay close attention to ALL warnings, as serious injury or

damage could result! Throughout the ELF-1 Operation
Manual, the symbol shown at right will designate where
particular attention should be paid and caution should be
exercised.

i Be aware that even at the relatively low pressures delivered

by the ELF-1, improper use can cause permanent damage to
some systems and components, and can be hazardous to the
operator and others in the vicinity.

i Under no circumstances should the Pressure Regulator be set fully open at 15

PSI when initially applying pressure from the ELF-1 to a system of any kind.
Always start with a very low pressure and gradually increase it. Always observe
the amount of component deflection taking place under pressure.

i Never leave any system or component under high pressure. Avoid leaving the

ELF-1 hoses and power cables connected to the vehicle under test when not
in use for extended periods of time.

i When conducting EVAP testing of the vehicle fuel vapor recovery system, it is

STRONGLY RECOMMENDED that a non-combustible inert gas – such as
nitrogen – be used instead of shop air. Use of shop air may create a HIGHLY
DANGEROUS situation which will support the combustion of the volatile fuel
vapors in the EVAP system, resulting in serious personal injury and damage.

i Always follow the vehicle manufacturer’s recommendations and any required

test procedures when testing the vehicle EVAP system.

i EVAP testing must comply with any applicable Federal and State regulations.

i Always wear safety goggles when applying pressure to a system or component.

i Do NOT tamper with or modify any of the ELF-1 components, including hoses,

cables or other replacement parts. This will void the warranty, and may cause
the unit to malfunction or to incur damage to the vehicle under test or other
property.

i Never use the ELF-1 on an engine that is running.

i The ELF-1 should ONLY be used with RTI Patented Fluid

Part Number: 438100 (4 oz bottle) or 438115 (6 Bottles)

i The ELF-1 should only be operated and stored in the upright position.

INDEX

Use Caution when Working with High Pressure ......................... 1

Leak Testing Techniques ........................................................... 1

Control Devices .......................................................................... 2

Initial Set up ............................................................................... 3

Calibration & Internal Leak Check .............................................. 3

Modes of Operation

1 PSI Mode .......................................................................... 3

3 PSI Mode .......................................................................... 4

4-15 PSI Mode .................................................................... 5

Flow Meter ................................................................................. 5

Air Flow Valves .......................................................................... 5

Leak Flow Confirmation ............................................................. 5

Pressure & Air Flow Charts ........................................................ 6

Fog Chemical - Low Level ......................................................... 7

The Many Uses for ELF-1

EGR Valves ......................................................................... 7

Fuel Injectors ....................................................................... 7

Base Gaskets ...................................................................... 7

Air Intake Mass Flow Sensor ............................................... 7

Vacuum Lines - Intake Manifold - Plenum ........................... 8

Engine Mechanical - Head Gasket - Cooling System .......... 8

Engine Mechanical - Head Gasket Between Cylinders ....... 8

Engine Mechanical - Head Gasket - Coolant to Oil ............. 9

Engine Mechanical - Cylinder Condition .............................. 9

Oil Leaks ............................................................................. 9

Evaporative Emissions Systems ......................................... 10

HVAC Controls ................................................................... 10

Hoses & Heater Cores ........................................................ 10

Air Conditioning Systems ................................................... 10

Parts List - With Part Numbers ........................................... 11

SAFETY PRECAUTIONS & HIGH PRESSURE WARNINGS

PLEASE!

Review the important information on the preceding page.

SAVE ORIGINAL PACKAGING IN CASE ELF-1 NEEDS TO BE RETURNED TO RTI FOR REPAIRS

USE CAUTION WHEN WORKING WITH HIGH PRESSURE

ELF-1 is capable of supplying over 15 PSI of pressure when the Pressure Regulator
is fully opened. While this may not seem to be a very high pressure reading when
compared to some pressure levels, it is very high when exposed to systems and
components that were not designed for high pressure.

Components such as a fuel tank will certainly be distorted at 15 PSI, and may even
rupture. Technically, 1 PSI, when fed into a 12 inch cube (tank) has a net force of 144
lbs on each side of the cube. Therefore, a 15 PSI feed into the same cube will have
(15 x 144) 2160 lbs of force applied to each side.

Consider the dimensions of a fuel tank. If the dimensions were say 9 inches high by 18 inches deep
by 30 inches long - the top and bottom (18 x 30) would each have a total force of 540 lbs (at 1 PSI) and
8100 lbs (at 15 PSI) pushing against them.

Consider raising a 4,500 lb car on a hydraulic lift, with a piston that is about 10 inches in diameter. The
piston area is (Pi R2) or 79 square inches. Multiply this by an air supply of 125 PSI (125 x 79) and the
potential force of 9,875 lbs forces the piston (and the car) into the air.

That’s the basic principle that causes a piston to lift many times its potential. The same principle may
be a destructive force when used incorrectly. USE PRESSURE CAREFULLY.

ELF-1 has been designed and built by automotive technicians, for automotive technicians. It is NOT
a tool for an amateur or do-it-yourselfer.

It is essential that the operator reads and understands the instructions provided here, as well as the
concepts of pressure and flow testing. Failure to read and understand ALL of the following information
will result in unsatisfactory performance from ELF-1. It may also lead to damaging systems and
components via excessive air pressure.

LEAK TESTING TECHNIQUES

ELF-1 uses a specially formulated fog liquid. The results are different than any previous smoke-based
leak detector.

ELF-1 is not a smoke machine. It generates a highly reflective fog that can be spotted easier when
exiting a leak. A white light is supplied that will reflect off the reflective fog to quickly home in on any
leaks.

The simple technique for using the white light most effectively is as follows:

Turn the light on when ready to begin locating a leak. Shine the light in the direction of the suspected
leak to spot any air movement in the light beam, then move the beam in the direction of the leak.

The smaller the leak, the faster the stream of fog will be, making it more difficult to see. Move a little
further away from the suspect area if air movement is not detected. As the fog movement slows down,
it will gather and be more visible.

Because of the formulation of the fog, it is quite likely that the leak may be located as the internal
pressure of the system/component being tested drops to near zero. At or near zero, the fog is not being
forced out of the leak, it therefore will drift out slowly and accumulate in the area of the leak. This is an
excellent opportunity to find the leak at this time.

Repeat the process if the fog dissipates before the leak is seen. This requires a quick (2-3 seconds)
shot of fog to set the process in motion again. This may be repeated as often as necessary.

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CONTROL DEVICES

Pressure Regulator: Regulates air pressure. Pull control knob away from cabinet and rotate in

desired direction. It locks in position when the control knob is released.

Timer: Power is turned on when the knob is turned clockwise to set a time period

up to ten minutes. It can be turned counterclockwise to turn off power.

Polarity Indicator: Illuminates when power cable is correctly connected to a 12 VDC battery.

Always ensure the red clamp is attached to the positive battery post and
the black clamp is attached to the negative battery post.

Flow Meter: A small floating ball indicates when air is flowing. The ball indicates a

positive air flow if there is a leak internally to ELF-1 during initial setup or
in the external system during a leak test.

Flow Indicator: Illuminates as the system under test is being pressurized when in the 1 or

3 PSI mode. Turns off when 1 or 3 PSI is attained. It will illuminate
continuously when in the 4-15 PSI mode.

Pressure Gauge: Indicates pressure of the air or fog.

Fill Port: Unscrew cap to fill ELF-1 with Fog Chemical.

Pressure Selector: Three selectors - 1, 3 or 4-15 PSI. Any one of the buttons can be pressed

to select the pressure of the fog during a leak test.

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