WPG MRTALPCH611LDC Guía de referencia

TST-019 MRTALPCH CHANNEL –Rev. 2016-310

LEAK TEST

PROCEDURE

MRTALPCH611LDC –REMOTE READY LIFTERS W/ 3 BUTTON CONTROL

APPLICABLE TO LIFTERS WITH

SERIAL NUMBERS GREATER THAN # 20100742

TESTING AND MAINTENANCE MUST BE

DONE BY A QUALIFIED PERSON

KEEP FOR FUTURE REFERENCE

TST-019 MRTALPCH CHANNEL –Rev. 2016-310

TST-019 MRTALPCH CHANNEL –Rev. 2016-310 Page 1 of 20

SYMPTOMS OF VACUUM LEAK

Severe leakage is evidenced by a lifter’s inability to draw full vacuum while attached to a clean,

smooth, nonporous surface. In such cases, the vacuum pump will run continuously and the vacuum

level shown on the vacuum gauges will be less than 16" Hg [-54 kPa], the red zone of the vacuum

gauge.

Moderate leakage is indicated by intermittent cycling of the vacuum pump during a lift. If the

vacuum generating system turns on more than once every 10 minutes, leakage is serious enough to

warrant repairing the lifter’s vacuum system.

To determine if your lifter has a vacuum leak, perform the Vacuum Test as described in the

Maintenance section of your instruction manual.

When you perform the vacuum test, we recommend that you note the time and leakage rate, such

as “lost 5" Hg [-17 kPa] in 10 minutes”. Note that, if both the blue/green and red circuits of the lifter's

vacuum system are leaking, you should record this information for each circuit. This information can

assist in diagnosing the location of the leak because there may be more than one component

leaking vacuum. For example, when you are performing maintenance, if an isolated section tests

positive for a leak, but the leakage rate is less than that of the whole lifter, this indicates that there is

still one vacuum leak or more elsewhere in the system.

Note: The vacuum test, as described in the instruction manual, is performed with the power switch

in the off ( ) position. However, due to the unique design of this vacuum system, the situation

may arise where, with the power turned on (), the vacuum pump may cycle repeatedly but the

vacuum level, as shown on the vacuum gauges, does not drop, giving no indication of a vacuum

leak.

Due to this, it is recommended that an additional vacuum test be performed with the power switch

on ( ). In this test, if you do not see a drop in vacuum as indicated on either of the vacuum

gauges, but the vacuum pump does cycle more than once in 10 minutes, a specific section of the

vacuum generating system is indicated as being the problem. Review the remaining information in

this section and then proceed to the Vacuum Generating System Test, step 10.

If, when tested in the off ( )position, the vacuum level, as shown on the gauges, does begin and

continue to drop and the rate of leakage, as shown on the vacuum gauge(s), is sufficient to warrant

repair, proceed as follows:

To locate the cause of leakage, begin by inspecting the vacuum pads, fittings and hoses of the

entire vacuum system. Look for contamination, cuts or abrasions on pad faces and cracking at the

suction stem, cracks, abrasions or cuts in hoses, damaged fittings and loose hoses at connection

points. If leakage is severe, the cause is often a visibly damaged part.

Do not apply soapy water to fittings or vacuum hoses in an attempt to find leaks, since it will only be

drawn inside the vacuum system.

If the source of leakage is not immediately evident, the various sections of the entire vacuum system

must be systematically isolated and tested to determine the leakage point. The process to

accomplish this is described in the tests to follow.

TST-019 MRTALPCH CHANNEL –Rev. 2016-310 Page 2 of 20

Please note that the information gathered when performing a vacuum test is only valid if the tools

used to perform the test are accurate. Be sure that the tools you use are capable of completely

sealing the isolated parts of your system when tested. Recommended tools, in addition to an

appropriate test surface, are plugs for hoses and fittings, a ball valve with vacuum gauge attached,

push-in and barbed hose adapters and extra vacuum hose of the required sizes. This procedure is

written with the assumption that you have access to the appropriate tools.

If needed, test equipment is available from Wood’s Powr-Grip Co. To find out what is available,

contact a WPG Technical Sales Representative for additional information.

A set of screwdrivers may also be needed if the valve enclosure or pump cover needs to be

removed. Note: Always proceed with caution when removing the covers. Since wiring and hoses

may be connected to components in the cover, gentle removal is recommended so as not to

damage the attached components.

When removing a hose from a barbed fitting, take care to avoid damaging the barbs of the fitting to

which the hose is attached. Cuts or nicks in fitting barbs can create a leak that did not previously

exist. Additionally, if a hose is removed from a barbed fitting, cut approximately 1/8"-1/4" [3-6 mm]

off the end of the hose before reinstalling it on the fitting, in order to remove damaged hose ends.

For push-in fittings, the hose end must be cut square and straight to seal properly. To remove a

hose from a push-in fitting press the locking collar in towards the fitting and pull out on the hose. If a

hose is removed from a push-in fitting, cut approximately 1/8" [3 mm] off the end of the hose before

reinstalling it on the fitting, in order to remove damaged hose ends and to provide a fresh point of

contact for the locking collar. When installing a hose in a push-in fitting, push the hose in firmly and

then gently pull outward on the hose to ensure that it is fully secured (the hose should not pull out).

Additionally, when a hose is installed in a push-in fitting, it needs to run reasonably straight out from

the fitting, with minimal sideways pressure on the hose locking collar, to reduce the chance of a

vacuum leak.

Note: The vacuum system of this model lifter provides release using a “blow off” feature. This is

where the pressure side of the vacuum pump is plumbed to the control valve and pumps air into the

pad system when release mode is engaged, to help speed the release of the vacuum pads. When

testing the lifter for leaks, it is often necessary to seal off the system in some manner (cap off or plug

fittings and/or plug lines). Due to this, the use of the release function is not recommended during

the repair process, as it will cause pressure to build in the sealed-off section and may damage

components.

TST-019 MRTALPCH CHANNEL –Rev. 2016-310 Page 3 of 20

PRELIMINARY TEST

This test determines whether leakage is located in the vacuum generating system or the pad

system. This test should be performed if, during the overall test, the lifter’s vacuum gauges

indicated a leak sufficient to warrant repair. Note: The following assumes that you have access to

suitable plugs, a ball valve with vacuum gauge, and additional hose and adapter fittings for

connecting the ball valve to the lifter’s vacuum lines and fittings.

Note: Since the vacuum tanks are part of the pad system, any leakage will appear to be faster than

seen in the overall test, due to the reduced system volume.

1) Remove the 4 screws (1A) that attach the valve

cover (1B) to the channel. Note, there are no

components attached to this cover, so it can be

removed and set aside.

2) This will expose the 2 filters (2A) shown in FIGURE 2.

3) Since the vacuum gauges are connected to the pad system, it will be necessary to use a ball

valve with vacuum gauge, fitted with an adapter for the push-in hose, as shown below, to

perform the following test. Also, when using a single ball valve assembly, if, during the overall

test of the lifter, it was determined that both circuits (red and blue/green) leak, you will have to

test each circuit individually.

FIGURE 2

FIGURE 1

TST-019 MRTALPCH CHANNEL –Rev. 2016-310 Page 4 of 20

4) Remove the 1/4" o.d. hose (3A) from one of the filters (3B), that connects the filter to the pad

line. Using an additional piece of 1/4" o.d. hose, connect the end of the ball valve with the

vacuum gauge to the filter. Close the ball valve (turn handle perpendicular to valve body). See

FIGURE 3, where the red circuit is shown being tested.

5) Note, since only one of the two circuits (red or blue/green) is being tested, the lifter will need to

be attached to a smooth, clean, non-porous surface for the other circuit to seal.

6) Switch the power on ( ), and activate the vacuum generating system by pressing the apply

( ) push button.

7) Switch the power to off () and observe the vacuum gauge of the ball valve to determine the

area of the leak.

If the vacuum level on the ball valve’s vacuum gauge holds steady and does not drop, the

indication is that this circuit (red or blue/green) does not leak between the check valve and

the filter.

If, during the overall test of the lifter, a leak was indicated in both circuits (red and

blue/green), remove the ball valve from the circuit being tested and repeat the process for

the other circuit.

Once it has been verified that neither circuit (red or blue/green) of the vacuum generating

system leaks, proceed to Pad System Tests.

If the vacuum level on the ball valve’s vacuum gauge starts and continues to drop, the

indication is that this circuit of the vacuum generating system does leak.

If, during the overall test of the lifter, a leak was indicated in both circuits (red and

blue/green), remove the ball valve from the circuit being tested and repeat the process for

the other circuit. This is to determine if the leak in this circuit is also in the vacuum

generating system.

Once both circuits (red and blue/green) of the vacuum generating system have been

checked and the condition of each is known, proceed to Vacuum Generating System Test.

FIGURE 3

BALL VALVE SHOWN

IN CLOSED POSITION

TST-019 MRTALPCH CHANNEL –Rev. 2016-310 Page 5 of 20

VACUUM GENERATING SYSTEM TEST

Note: The following assumes that you have access to suitable plugs, a ball valve with vacuum

gauge, and additional hose and adapter fittings for connecting the ball valve to the lifter’s vacuum

lines and fittings.

Note: If you are testing only one of the two circuits, the lifter will need to be attached to a clean,

smooth surface for the remaining section to seal to during testing.

The most likely leak points in the vacuum generating system are the check valve, the hose

connections to the filters, the control valve or vacuum tank/check valve assembly. Leave the filter

disconnected and test these items as follows:

Isolate the filter from the control valve / check valve assembly:

1) Remove the ball valve from the filter.

Disconnect the 1/4" o.d. hose (4A) from

the port (4B) of the solenoid valve that

connects to the filter. Connect the end

of the ball valve with the vacuum gauge

to this port of the solenoid valve. See

FIGURE 4.

2) With the ball valve in the closed position

(handle turned perpendicular to the

valve), switch the power on ( ), and

activate the vacuum generating system by pressing the apply ( )push button.

3) Switch the power to off ( )and observe the vacuum gauge of the ball valve to determine the

area of the leak.

If the vacuum level on the ball valve’s vacuum gauge holds steady and does not drop, the

indication is that the filter is the source of the leak.

Verify that the O-ring seal of the filter cap is in good shape, that the cap is tight and that the

filter housing is clean. Check the filter and the ends of the hose attached to the filter. Cut

approximately 1/8" [3 mm] from the ends of the hoses, ensuring that the cuts are straight

and square. Reattach the hoses to the filter in the same manner as done in the Preliminary

Test and retest the lifter as shown in the Preliminary Test. If the lifter continues to leak,

replace the filter and or hoses.

Note: When the filter is installed in its holder, it is critical that the hoses be positioned so

that there is minimum sideways pressure on the filter hose.

If the vacuum level on the ball valve’s vacuum gauge starts and continues to drop, the

indication is that the leak is located in either the solenoid valve assembly or the check valve.

Proceed to next step.

FIGURE 4

TST-019 MRTALPCH CHANNEL –Rev. 2016-310 Page 6 of 20

4) Remove the ball valve from the solenoid. Using a piece of 1/4" O.D.

hose, cap off the end of the hose to create a fitting plug, as shown in the

picture at right. Use the capped hose to cap off the port of the solenoid

that connected the filter. See picture for how to create the fitting plug and

FIGURE 5 for how used.

Note, the yellow caps shown at right can be used to create a fitting plug

for any fitting using hose sizes 1/4" O.D. and smaller.

5) The capped port of the solenoid is item 5A.

This is the port that was connected to the filter.

Disconnect the 1/4" o.d. hose (5B) from the

solenoid of the affected circuit that connects to

the vacuum tank assembly. The red hose

shown (5B), loops around the battery and back

to the vacuum tank assembly on the left; the

blue/green circuit is more direct. Connect the

end of the ball valve without the vacuum gauge

to the hose from the vacuum tank. Using an

additional piece of hose, connect the end of

the ball valve with the vacuum gauge to the

port (5C) of the solenoid assembly.

See FIGURE 5.

6) With the ball valve in the open position (handle

in line with the valve), switch the power on ( ), and activate the vacuum generating system by

pressing the apply ( ) push button.

7) Close the ball valve (turn handle perpendicular to the valve), switch the power to off ( )and

observe the vacuum gauge of the ball valve to determine the area of the leak.

If the vacuum level on the ball valve’s vacuum gauge holds steady and does not drop, the

indication is that the check valve, located on the vacuum tank assembly, or the connecting

hose, is the cause of the leak.

Check the ends and overall condition of the hose connected to the tank assembly. If

needed, cut approximately 1/8" [3 mm] from each end, ensuring that the cuts are straight

and square.

If there are no visible problems with the hose, remove the tank assembly of the affected

circuit (blue/green or red) and check the fittings for any indications of damage. If neither the

hose nor fittings appear to be the cause, replace the check valve.

If the vacuum level on the ball valve’s vacuum gauge starts and continues to drop, this

indicates that the solenoid assembly is the cause of the leak. Remove the solenoid

assembly of the affected circuit (blue/green or red) and check the fittings for any indications

of damage. If the fittings do not appear to be the cause, replace the solenoid valve.

8) Once all leaks, for both the red and blue/green circuit, have been located and repaired,

reassemble the vacuum generating system. If needed, repeat the preliminary test, where the

ball valve was attach to each circuit’s filter, to confirm that the vacuum generating system no

longer leaks.

FIGURE 5

TST-019 MRTALPCH CHANNEL –Rev. 2016-310 Page 7 of 20

Once the vacuum generating system is confirmed to not leak, reattach the pad lines to the

filters and repeat the original vacuum test with all parts attached and the power in the off ( )

position.

If the vacuum level, as shown on the lifter’s vacuum gauge(s), starts and continues to drop,

this indicates that there is still a leak present in the pad system. Proceed to the Pad System

Tests.

If the vacuum level as shown on both of the lifter’s vacuum gauges holds steady and does

not drop, the indication is that there are no leaks in the vacuum system between the check

valves and the vacuum pads. Proceed to next step.

9) Repeat the vacuum test with all parts attached and the power switch left in the on ( ) position.

If the vacuum level, as shown on both of the lifter’s vacuum gauges, holds steady and does

not drop and the lifter does not cycle during the second test with the power switch on,

proceed to System Confirmation.

If, during the second test with the power switch on ( ), the lifter cycles, but there is no

indication of a leak, as shown on the lifter’s vacuum gauges, the indication is a special

circumstance unique to this lifter design. Proceed as follows.

10) The following deals with a specific issue, where, if during a vacuum test of the whole lifter, the

vacuum pump cycles regularly but the system’s vacuum level does not drop (no leak indicated

by either vacuum gauge), the indication is that a leak exists between the vacuum pump and the

check valve(s).

If either the solenoid valve that seals off the vacuum pump to the vacuum system, the vacuum

switch, or the connections from the pump to the vacuum switch or vacuum tank(s) were to

develop a leak, but the check valves sealing the main vacuum circuits still seal properly, the

result is that the pump will recycle regularly even though the vacuum level on the vacuum

gauges does not indicate a leak. This is caused by the fact that the area the vacuum switch is

located in is sealed via the pump valve and, if a leak were to exist in this section, the vacuum

switch would sense the leak and cycle the system to maintain its set vacuum level. However,

since the vacuum gauges are located in the individual vacuum circuits, which are sealed via

their respective check valves, there would be no loss of vacuum shown on either vacuum

gauge if the check valves continue to keep the pad system sealed. If this is the situation,

proceed as follows.

11) The vacuum tanks are connected to the pump by

the 3/8" O.D. hose connected to the 45° barbed

fitting (6A), of the pump solenoid. Note, the valve

shown is for lifters with serial numbers before

20161736. If your lifter has serial number

20161736 or greater, there will be a digital

vacuum switch attached to the valve. The test is

the same for either configuration.

Note, to provide easier access to the connected

hose, the hose cover (shown in FIGURE 13) was

removed from the channel and hose 6A pulled out

of the frame slot before performing the test shown

in FIGURE 7.

FIGURE 6

TST-019 MRTALPCH CHANNEL –Rev. 2016-310 Page 8 of 20

12) Begin by separating the tank line from the

pump/control box assembly. Disconnect the

hose (7A) from the 45° barbed fitting,

connected to the pump solenoid. Attach the

end of the ball valve assembly with the

vacuum gauge to this hose. Using an

additional piece of hose, attach the other end

of the ball valve to the 45° barbed fitting.

See FIGURE 7.

13) With the ball valve in the open position,

(handle in line with the valve), switch the

power on ( ), and activate the vacuum

generating system by pressing the apply ( ) push button.

14) Close the ball valve (turn handle perpendicular to the valve) but leave the power turned on

( ).

Note, it is possible for both the following conditions to exist. If so, then perform the tests in the

order listed.

If the vacuum pump cycles during the test, the indication is that the pump solenoid, the

vacuum switch or the hose connections between these parts, is the cause of the leak.

Switch the power off ( ) and proceed to next step.

If the vacuum level, as shown on the ball valve’s vacuum gauge, starts and continues to

drop, the indication is that the hose connection to the vacuum tanks is the cause of the leak.

Proceed to step 30.

15) Remove the ball valve from the tank

line and solenoid valve. Using a short

piece of hose (8A), connect the end of

the ball valve with the vacuum gauge

directly to the pump solenoid. With the

gauge end of the ball valve connected

to the 45° barbed fitting of the solenoid

valve, close the ball valve (turn handle

perpendicular to the valve), as shown in

FIGURE 8.

16) With the ball valve in the closed

position (handle perpendicular to the

valve), switch the power on ( ) and

activate the vacuum generating system by pressing the apply ( ) push button.

17) Switch the power to off (). If the vacuum level of the ball valve’s vacuum gauge starts and

continues to drop, a leak does exist in this section of the pump/vacuum switch assembly.

18) Note: Lifters with serial number 20161736 or greater, have been fitted with the digital vacuum

switch. Proceed to next step for these lifters.

Lifters with serial numbers before 20161736, will have an analog vacuum switch mounted

inside the control enclosure. Proceed to step 20 for these lifters.

FIGURE 8

FIGURE 7

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