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FST PRO FUEL SYSTEM TESTER
MODEL MV5545E
USER'S MANUAL
Have a technical question?
Americas:
If you have questions, or require technical
service, please contact our trained service
technicians at:
1-314-679-4200 ext. 4782
Monday – Friday 7:30 am to 4:15 pm CST
Visit our website at www.mityvac.com for
new products, catalogs, and instructions
for product use.
Need service parts?
To order replacement or service parts, visit us
online at www.mityvacparts.com or call toll free
1-800-992-9898.
Europe/Africa:
Heinrich-Hertz-Str 2-8
D-69183 Walldorf
Germany
Phone +49.6227.33.0
Fax +49.6227.33.259
www.lincolnindustrial.de
Asia/Pacific:
25 Int'l Business Park
#01-65 German Centre
Singapore 609916
Phone +65.562.7960
Fax +65.562.9967
For a French or Spanish version of this
manual go to www.MityvacFST.com.
MV92-1
APRIL - 2009
Form 824262
Section -
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Summary of Contents for Mityvac MV5545E
- Page 1 1-314-679-4200 ext. 4782 Monday – Friday 7:30 am to 4:15 pm CST Visit our website at www.mityvac.com for new products, catalogs, and instructions for product use. Need service parts? To order replacement or service parts, visit us online at www.mityvacparts.com or call toll free...
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Page 2: Table Of Contents
Contents Safety Precautions ........3 Specifications . -
Page 3: Safety Precautions
3.8 liters/min. (1 gal./minute) gasoline/petrol (.73 specific gravity) 225 liters/hour (60 gal./hour) gasoline/petrol (.73 specific gravity) MV5545E must be operated by qualified service technicians. 3.5 liters/min. (0.9 gal./minute) diesel (.85 specific gravity) 205 liters/hour (55 gal./hour) diesel (.85 specific gravity) - Page 4 Kit Components and Accessories Part Number Description 824266 High Pressure Gauge (0 to 8 bar scale) 824265 Low Pressure Gauge (-1 to 3 bar scale) 824149 Pressure Relief Hose (3mm ID x 1.8 m long) 824266/824265 824149 824148 824148 Bypass Hose (6.5 mm ID x 1.8 m long) 824144 Scissor Hose Clamps (Qty 2) 824147...
- Page 5 Flowmeter Parts Part Number Description 824182 Flow Tube Shield 824177 Male Quick-Connect Fitting 824176 Bypass Port 824175 Flow Control Valve Knob 824174 Flowmeter Inlet/Outlet Connector (Qty 2) 824146 Flow Control Valve 824145 Flowmeter Seal Kit 824181 Flowmeter Boot 824182 824181 824177 824176 824175...
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Page 6: Fuel System Test Adapters
Fuel System Test Adapters Reference Description Applications Order No. ⁄ " Quick-change Adapter GM, Chrysler, Jeep/Eagle MVA512 Vehicles with ⁄ ", ⁄ " ⁄ " - ⁄ " Barbed ⁄ " rubber to steel Flex Hose Adapter hose connection Vehicles with ⁄... -
Page 7: Fuel System Test Adapters
Fuel System Test Adapters Reference Description Applications Order No. M16 x 1.5 Adapter GM Vortec MVA520 M14 x 1.5 Adapter GM Vortec MVA521 Carbureted & early ⁄ " Flare Nut Adapter MVA522 fuel injected systems Carbureted & early ⁄ " Flare Nut Adapter MVA523 fuel injected systems ⁄... - Page 8 Fig. 1 Fig. 2 Fig. 4 Fig. 3 Page Number - 8 Form 824262...
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Page 9: Setup And Installation
Setup and Installation Determining Where to Install the FST Inline Connection Regardless of the type of fuel delivery system, the FST Pro is most ef- fective at diagnosing malfunctions when connected inline with the flow of fuel. The initial installation should be made at an access point along the fuel supply line, as close as possible to the fuel rail (Figs. -
Page 10: Installation
Installation Once the installation point has been determined, follow the instructions below to setup the tester prior to disconnecting the fuel line. 1. Place the vehicle transmission in park or neutral, apply the parking brake, and turn the key off. 2. - Page 11 12. Connect the hose extending from the flowmeter connection labeled “IN", to the other end of the adapter (Fig. 13). 13. Install the second FST connection adapter to the fuel line run- ning to the fuel rail. If the fuel line connection used by the vehicle manufacturer is a 3/8"...
- Page 12 Fig. 16 Fig. 17 Read top of float Fig. 18 Page Number - 12 Form 824262...
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Page 13: Testing And Diagnostics
Testing and Diagnostics Testing and diagnostic procedures vary depending on the type of fuel delivery system. Prior to testing, the fuel delivery system must be identified as Return, Returnless (mechanically regulated) or Returnless (electronically regulated). For detailed information on fuel delivery systems and how to identify them, refer to the section entitled Types of Fuel Delivery Systems, earlier in this manual. - Page 14 6. Noting the values for pressure and volume, if either is out of range, these are indications of a problem with one or more components of the fuel system. However, performing the Pressure and Flow De- mand Tests below, is required to reach a more accurate diagnosis, and to pinpoint the cause of a malfunction.
- Page 15 procedures for the inspection and repair of these components. If the FST test results indicate a fuel delivery system malfunction, and the diagnostic chart clearly pinpoints the cause, follow the vehicle manufacturer’s repair procedures to correct the malfunction. After per- forming the repairs, re-test the fuel delivery system with the FST to ensure it is operating normally.
- Page 16 Assembly Faulty Fuel Pressure Regulator (Low Pressure) A pressure regulator that does not sufficiently restrict fuel flow will For flexibility and ease of storage, the FST Pro features a modular cause the idle pressure in Zones 1 and 2 to drop below spec, and the design that is quick to assemble and breakdown.
- Page 17 Returnless Fuel Delivery Systems (Mechanically Regulated) At this point, it is assumed that the FST has been properly installed inline with the fuel delivery system as recommended, and that it has been primed to ensure no leaks are present (See FST Pro Setup and Installation).
- Page 18 6. After noting the peak flow, return the flow control valve to the OPEN position. Peak Demand Test 7. Note the vehicle’s engine size and maximum engine speed (RPM). Refer to the Maximum Engine Fuel Volume Requirements table (Appendix A), and use the size and speed values to determine the maximum fuel volume requirement of the engine.
- Page 19 A clogged inlet strainer can cause the fuel pump to cavitate because it is starved for fuel. Cavitation will create rapid changes in fuel density, causing the float in the FST flowmeter to bounce up and down during the peak flow and/or peak demand test. It can also cause the needle on the pressure gauge to bounce.
- Page 20 After connecting the FST, it is normal to have air trapped in the fuel lines and flowmeter. Cycling the ignition switch (or cranking the engine briefly) with the flow control valve in the BYPASS position can help purge air from the system. Once fuel fills the flowmeter and flows through the bypass hose, return the valve to the OPEN position.
- Page 21 CLOSED position towards BYPASS (Fig. 31). Adjust the valve until the flowmeter indicates an amount of fuel flow equivalent to the value for the maximum engine fuel volume taken from the table (Fig. 32). 10. Note the pressure reading on the gauge. 11.
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Page 22: Return Fuel Systems
These indications of a clogged inlet strainer may or may not be evident during testing. If the results are inconclusive, and the fuel system has an accessible inline filter, follow the procedure above to rule out a clogged filter. If it is determined that the inline filter is not the problem, replace the strainer or the pump module, and retest. -
Page 23: Disconnecting The Fst
no leaks are evident, replace the fuel pump module due to a faulty pump check valve or leaking regulator. 4. Remove the clamp from the fuel line, and restart the engine to build pressure. 5. Turn off the engine and immediately clamp off the FST inlet hose running to the tester from the fuel supply line. -
Page 24: Appendix A
Appendix A Maximum Engine Fuel Volume Requirements (Gallons/Minute) Engine Size Engine Speed (RPM) liters 3000 4000 5000 6000 7000 8000 0.05 0.06 0.07 0.09 0.10 0.12 0.06 0.07 0.09 0.11 0.12 0.14 0.06 0.08 0.10 0.12 0.15 0.17 0.07 0.10 0.12 0.14 0.17... - Page 25 Appendix A Maximum Engine Fuel Volume Requirements (Liters/Minute) Engine Size Engine Speed (RPM) liters 3000 4000 5000 6000 7000 8000 0.19 0.23 0.26 0.34 0.38 0.45 0.23 0.26 0.34 0.42 0.45 0.53 0.23 0.30 0.38 0.45 0.57 0.64 0.26 0.38 0.45 0.53 0.64...
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Page 26: Appendix B
Appendix B – Return Fuel System Diagnostic Guide Results Idle Peak Pressure Peak Flow Idle Flow Potential Causes Pressure (CLOSED) (BYPASS) Scenario Greater than 50% to 100% 2.5 to 4.0 LPM Fuel system is maximum fuel Normal Normal Normal higher than Normal (.7 to 1.0 GPM) operating normally... - Page 27 Appendix B Return Fuel System Diagnostic Guide Scenario 2 Diagnosis: A restriction to the supply of fuel to the engine such as a clogged inlet strainer, inline filter, or pinched fuel supply line will reduce the flow of fuel. However, pressure will remain normal or drop only .05 or .15 bar (1 or 2 psi) (5 or 15 kpa) below spec.
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Page 28: Appendix C
Appendix C – Returnless (mechanically regulated) Fuel System Diagnostic Guide Results Idle Peak Flow Peak Demand Pressure Potential Causes Pressure (BYPASS) Scenario Less than 2.5 to 4.0 LPM Fuel system is operating Normal Normal Normal 10% below (.7 to 1.0 GPM) normally idle pressure Greater than... - Page 29 Appendix C Returnless (Mechanically Regulated) Fuel System Diagnostic Guide Scenario 2 Diagnosis: A restriction to the supply of fuel to the engine such as a clogged inlet strainer, inline filter, or pinched fuel supply line will reduce the flow of fuel. This will be evident by the reduction in peak flow.
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Page 30: Appendix D
Appendix D – Returnless (Electronically Regulated) Fuel System Diagnostic Guide Results Idle Peak Pressure Peak Flow Peak Demand Pressure Potential Causes Pressure (CLOSED) (BYPASS) Scenario Less than 50% to 100% 2.5 to 4.0 LPM Fuel system is Normal Normal Normal higher than Normal 10% below... - Page 31 Appendix D Returnless (Electronically Regulated) Fuel System Diagnostic Guide Scenario 2 Diagnosis: A restriction to the supply of fuel to the engine such as a clogged inlet strainer, inline filter, or pinched fuel supply line will reduce the flow of fuel. However, idle and peak pressure will remain normal or drop only .05 or .15 bar (1 or 2 psi) (5 or 15 kpa) below manufacturer’s specification.
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Page 32: Warranty
Lincoln Industrial Standard Warranty LIMITED WARRANTY Lincoln warrants the equipment manufactured and supplied by Lincoln to be free from defects in material and workmanship for a period of one (1) year following the date of purchase, excluding therefrom any special, extended, or limited warranty published by Lincoln. If equipment is determined to be defective during this warranty period, it will be repaired or replaced, within Lincoln’s sole discretion, without charge.
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