SMOKE MACHINE 
The following list is designed to familiarize you with the location and function of the operational components of the machine. The list also includes the supplied accessories and how to use them.  

A Flow Control Valve
• Location: The Flow Control Valve is located on the front of the machine directly under the cycle Start/Stop button. It is a round knurled knob.
• Function: In many cases excessive smoke exiting a leak may make it difficult to determine exactly where the leak is. The purpose of this patent pending control valve is to decrease the amount of smoke exiting a leak so that its position may be pinpointed without the masking effect of excessive smoke. Turn clockwise to decrease flow, counterclockwise to increase flow. This valve is also used to lock out the system under test and observe any pressure decay on the pressure gauge.

B Start/Stop Button
• Location: The Start/Stop Button is located in the front of the machine directly under the Output Pressure Gauge.
• Function: Depressing the Start/Stop Button will start a 5 minute smoke producing cycle. To interrupt this cycle, press the Start/Stop Button again and the smoke production will stop. If the cycle is not interrupted, the smoke production will terminate automatically in 5 minutes. Once the leak has been located, it is recommended to stop the smoke production using this button rather than turning the Flow Control Valve to the fully closed position.

C Flowmeter (Total-Tech™ only)
• Location: The Flowmeter is located on the right side of the machine.
• Function: The purpose of the flowmeter is to provide a quick and simple visual method of measuring the amount of air passing through the system being tested. If the smoke supply nozzle is in a closed system, and there are no leaks in that system, the flowmeter will read zero (ball at bottom of scale). As a system is filled with air or smoke, the ball in the flowmeter will slowly fall to the bottom of the scale as the pressure in the system equalizes to the output pressure of the Smoke Pro™. As the flow decreases, the output pressure will increase. If the flowmeter ball never falls to the bottom of the scale there is leakage or air passing through the system. It is not necessary to use smoke when using the flowmeter to determine if a leak exists.

D Output Pressure Gauge (Total-Tech™ Only)
• Location: The Output Pressure Gauge is located directly on top of the machine.
• Function: The Output Pressure Gauge displays the output pressure of the machine. When the machine is coupled to a system to be tested, the pressure within that system becomes equal to the internal pressure of the machine. Placing your thumb over the Smoke Supply Nozzle, (deadheading) while air is passing through the machine will display on the Output Pressure Gauge the maximum output pressure of the machine. This gauge can also be used to confirm a leak by simply closing the Flow Control Valve while the system is under pressure. This method is called pressure decay. If the gauge holds the displayed pressure, there is no leakage. If the displayed pressure starts dropping when the Flow Control Valve is closed there is leakage in the system. Note: Pressure decay testing can be performed without smoke, just open the Flow Control Valve and use air only.

E Dip Stick (Checking oil level)
• Location: The Dip Stick is located on the top of the Smoke Pro™.
• Function: To check and confirm proper oil level.

F Cap Plugs
• Description: An assortment of yellow Cap Plugs ranging from 1.25’ to 3.9” is provided with your Smoke Pro™.
• Function: Cap Plugs are used to seal openings in the system under test. Your set has been designed to seal automotive intake tubes. (See Vacuum Leak Testing below for other methods of sealing the air intake).

G Exhaust Cone Adaptor
• Description: The Exhaust cone adapter is a black rubber cone that tapers from 3 1/2 inches in diameter to 1 inch in diameter and is 5 inches in length with a short length of 3/8 hose at its center to direct the smoke through.
• Function: The Exhaust Cone Adaptor is a very useful tool. The adaptor is designed to help find exhaust leaks by inserting it into the tail pipe and filling the cold exhaust system with smoke. By inserting the supplied 3/8” Cap Plug into the hose leading from the Exhaust Cone it also serves as a plug to seal the exhaust while testing for vacuum leaks under the hood. The Exhaust Cone Adaptor also works well to seal the intake tube at the air filter box and allow smoke to enter the engine without disconnecting anything else.

H OBD-II Service Port Adaptor
• Description: The Service Port Adaptor is a female brass fitting with a 2” length of black 3/8” diameter hose attached.
• Function: The Service Port Adaptor is designed to connect the Smoke Supply Nozzle to the OBD-II Service Port. The port is located under the hood of 1996 and newer vehicles. This port provides access to the Fuel Vapor Recovery System (EVAP) for inspection and test. Connecting the Smoke Pro™ to this port allows the technician to determine if a if a leak exists and to quickly locate the leak with smoke. Note: The schrader valve must be removed from the service port before installing the Service Port Adaptor. This valve has left hand threads.

I Schrader Valve Removal Tool
• Description: The Schrader Valve Removal Tool looks like a small screw driver with a slot in the end of it.
• Function: The Schrader Valve Removal Tool is used to remove the schrader valve from the OBD-II service port before connecting the Service Port Adaptor. Note: The service port is normally under the hood and is usually green in color.
J Hook
• Your new Smoke Pro™ comes with a handy stainless steel hook for conveniently hanging the machine under the hood or chassis. Check this occasionally and re-tighten as necessary.
Operation
All testing is performed with the engine off!

1 Setting up the Smoke Pro™
• Connect air supply. (110 P.S.I. Max) The Smoke Pro’s™ pressure inlet fitting will mate with an Amflo C2B and C1B or equivalent, (¼”automotive standard plug).
• Connect the Red & Black power leads to a car battery. (Red to Positive, Black to Negative). A green lamp indicates proper battery connection.
• Push Start/Stop Button to generate smoke. (A red lamp indicates smoke is being produced). For best results, allow dense smoke to develop before connecting nozzle to the system under test (approximately 30 seconds). Important: The Smoke Pro™ is designed to run a 5 minute smoke producing cycle and then shut off automatically. Pushing the Start/Stop Button during the cycle will stop smoke production. Pushing it again will start a new 5 minute cycle.
• Open Flow Control Valve located at the front of the Smoke Pro™. Place thumb over the tip of the Supply Nozzle to deadhead the output and read the output pressure. Pressure should read 11– 14 inches of Water.
• Insert Supply Nozzle into system to be tested or push Start/Stop Button again to stop smoke producing cycle.

2 Vacuum Leak Testing.
• Select an appropriate vacuum line to access the vacuum system. The brake booster supply line before the check valve is a good choice.
• Seal system openings such as the air intake. If the brake booster line or any other line leading to the intake manifold is selected for the test connection, the air intake must be sealed to prevent smoke from leaking back through the intake. If the vehicle has a round inlet tube from the air filter, the Exhaust Cone adaptor will seal this opening without disturbing other connections and may serve as the access point for smoke. Otherwise, to seal the intake, use the supplied Cap Plugs, a latex glove or cellophane wrap with a rubber band. If none of these methods are possible, pack the venturis with cellophane using a soft stick or the end of a pencil. Seal the exhaust pipe using the supplied Exhaust Cone, a latex glove or rag. Note: To use the Exhaust Cone as a plug you must seal the 3/8” diameter inlet on the Exhaust Cone with the yellow cap plug provided.
• Set-up the machine for operation per Item 1 above.
• This procedure will not only locate leaks in vacuum lines but in many others components such as; EGR valves, oil seals and gaskets, idle motors & solenoids, intercoolers & turbochargers, injector o-rings, ducting, throttle shafts, base gaskets, diaphragms, canisters and fittings to name a few. Important!! It is always best to test in a draft free area. Always use a bright halogen lamp to enhance the visibility of the smoke exiting the leak.

3 Exhaust Leak Testing.
• Insert the Exhaust Cone Adaptor into the end of the tailpipe. If the automobile has dual exhaust with a cross over pipe, simply plug the other pipe with a rag, tape, or latex glove with a rubber band.
• Set-up the machine for operation per Item 1 above.
• This test is most effective when the exhaust system is cold. Small leaks are sometimes sealed as the exhaust system heats up due to thermal expansion. A hot catalytic converter may consume some of the smoke in front of the converter. Remember, all testing is performed with the engine off!

4 Under Dash Leaks
• Most vehicles have a common vacuum line leading from the dashboard, through the firewall, to a vacuum source under the hood. This line supply’s vacuum to climate control functions and other vacuum operated systems. The flowmeter will quickly determine if a leak exists in this system. Locate this line under the hood and disconnect it at its source. We will use this line to check under the dashboard for leaks.
• Set-up the machine for operation per Item 1 above.
• While the pressure or smoke is being fed into the vacuum supply line observe the Flowmeter or Output Pressure Gauge. Change the climate control selector lever or button from heat to vent, to defrost, etc. As the lever is moved, a change in the flowmeter or pressure gauge reading will determine which system is leaking. Set the lever in the position that registered a reading on the flowmeter while looking for the leak under the dashboard using a bright halogen lamp. This method will thoroughly inspect this system for leakage.
• Inspection of central locking systems is performed in the same manor. Access the control solenoids and activate them while introducing smoke into the system.

5 Fuel Vapor Recovery System (EVAP)
• According to the Environmental Protection Agency, the EVAP system is the most neglected of all the emission systems in an automobile. A leak as small as 0.020” diameter can allow over 30 times the allowable hydrocarbons into the atmosphere then is currently acceptable through the exhaust. Additionally, EVAP system leaks can be a major cause of check engine lights occurring. In the past EVAP related problems have been difficult to locate and repair. These can now be quickly diagnosed and repaired, becoming a profitable ticket for service facilities.
• There are several acceptable methods of inspecting the EVAP system. Basically we need to close any vent solenoids, fill the system with smoke, and look for the smoke escaping at the leak. Since these systems vary in different vehicles and have evolved over the years, we will attempt to describe operating guidelines that should be helpful in inspecting these EVAP systems.
• Beginning with the 1996 model year, U.S. Vehicles have been produced with an EVAP Service Port to access this system. The port is usually located under the hood but may be located else were on the vehicle. To access this port for testing, remove the cap, then remove the Schrader Valve from inside the Service Port, using the supplied Schrader Valve Removal Tool. Important Note: The Schrader valve has left hand threads, turn clockwise to remove! Connect the Service Port Adaptor to the Service Port.
• The Onboard Diagnostics on vehicles 1996 and beyond will determine if a leak exists, the following trouble codes may appear to report the leak:
PO442 for a .040 leak standard
PO456 for a .020 leak standard.
• Using a scan tool, close the vent solenoids so that the EVAP system is closed to the atmosphere.
• Set-up the machine for operation per Item 1 above.
• Remove the fuel cap and begin to fill the system through the Service Port Adaptor until dense smoke is seen exiting the fuel neck. This procedure assures that the system is full of smoke. Replace the fuel cap and continue pumping smoke into the system.
• Inspect under the hood for leaks using a bright halogen lamp. Raise the vehicle on a hoist and inspect the underside of the vehicle, tracing the route of the EVAP system. Note: It may be necessary to hang the Smoke Pro™ under the car so that it is visible to the operator.
• As the system fills with smoke, and the pressure in the system equalizes, keep an eye on the Flowmeter and the Pressure Gauge. If there is no leakage in the system the Pressure Gauge will go to its maximum pressure and the Flowmeter will drop to zero.
For trouble code PO456 the meter should stabilize at .05 LPM or less with the Smoke Pro™ connected to 100PSI.
For trouble code PO442 the meter should stabilize at .5 LPM or less with the Smoke Pro™ connected to 100PSI.
If the reading exceeds these values there is an unacceptable leak present in the system.
• Once the leak has been located and repaired, it is a good idea to repeat the above procedure using air only. It is not necessary to turn on the smoke to test for leakage using the Flowmeter.
• Replace Schrader Valve and cover. (Note: Valve is Left-hand thread.)

Maintenance

Oil Level:
Check the oil level regularly, approximately every 50 or so tests. Always be sure the gasket is in place and tighten the dip Stick firmly when replacing. The oil level should be maintained between the high and low hash marks on the dipstick. When filling a new machine, add 8 oz of Mineral Oil. If the machine has been previously filled and drained, only 6 oz of oil is required to fill it. Oil can be purchased direct from Redline or from any retail store. To add oil to the Smoke Pro, simply pour oil into the dipstick hole. Note: It takes approximately 2 oz to raise the level from the low to high mark. Due to the high purity of the mineral oil supplied, it may sometimes be difficult to read the dipstick. An alternate method for determining fluid level is to drain the oil from the machine and refill with 6 oz of mineral oil.