Evaporative Emission System Tester Setup: Assembly

WARNING:

Use the nitrogen gas. If other kind of gas is used for the nitrogen gas, the gasoline may ignite and explode.
If the proper procedure is not taken to treat the compressed gas, it may result in death or serious injury accidents. For the correct operation procedures and precautions, contact your local supplier of compressed gases.

CAUTION:

DO NOT remove the valve cover cap of the nitrogen gas tank until the nitrogen gas tank is securely attached to the EVAP cart.
Pressure regulator has been regulated to indicate the correct pressure. Therefore, DO NOT detach the black vinyl cover of the pressure regulator and regulate it by turning the valve. It may cause the malfunction of tester. When you need to regulate the pressure, refer to Output pressure calibration in these Instructions and regulate the pressure on the tester side.

NOTE:

Nitrogen gas tank is not attached to this tester. Procure the nitrogen gas tank from your local supplier of compressed gases. We recommend the tank with 125 cubic feet capacity for the nitrogen gas tank.
If the nitrogen gas tank pressure indicates lower than 100 psi, it is required to ask your local supplier of compressed gases to replenish the nitrogen gas to the tank.

Unpack the tester from its shipping carton.
NOTE: We recommend that you enlist the assistance of another person to help assemble the tester to the EVAP cart.
Bring the tester (1) up through the EVAP cart's handlebar, and place it on the two tabs (2) located on the bracket on the EVAP cart.
NOTE: Slightly rotate the tester to one side so the remote cable clears the handlebar.

Fig 1: Bringing Tester Up Through EVAP Cart's Handlebar
Courtesy of SUZUKI OF AMERICA CORP.
Install right and left side handlebar brackets (1) and the remote switch cord wrap (2) to the tester (3) by using the hexagon screws (4).

Fig 2: Installing Handlebar Brackets On Right & Left Side
Courtesy of SUZUKI OF AMERICA CORP.
Securely attach the nitrogen tank (3) to the EVAP cart (1) by using the tank fixing bands (2) that are attached to the EVAP cart (1).

Fig 3: Attaching Nitrogen Tank
Courtesy of SUZUKI OF AMERICA CORP.
Remove valve cover cap from the nitrogen tank.
Install the pressure regulator (1) to the nitrogen tank.

Fig 4: Installing Pressure Regulator
Courtesy of SUZUKI OF AMERICA CORP.
Tighten the nut (2) with wrench.
NOTE: No sealant is required.
Install the 90° adapter (1) onto the nitrogen inlet (2) on the side of the tester.

Fig 5: Installing 90° Adapter Onto Nitrogen Inlet
Courtesy of SUZUKI OF AMERICA CORP.
Connect regulator to tester hose (1) to pressure regulator (2) and 90° adapter (3).
NOTE: Connection should be finger tight.

Fig 6: Connecting Regulator To Tester Hose
Courtesy of SUZUKI OF AMERICA CORP.
Fill the tester with two bottles of smoke producing fluid according to the following procedures.
WARNING: To prevent personal injury and equipment damage, use only manufacturer-approved smoke producing fluid in the tester.
1. Remove the refill plug (1) located on the side of the tester.
  
  Fig 7: Removing Refill Plug
  Courtesy of SUZUKI OF AMERICA CORP.
2. Cut the end off the plastic tip on top of each smoke producing fluid bottle.
3. With the tester in an upright position, empty the contents of two smoke producing fluid bottles into the refill port.
  1. Filling amount of smoke producing fluid: 0.95 liters (32/33 US/lmp.oz)
4. Secure the plug back into the refill port.
5. Record your name and the date of the fluid change.
Upon completion of all jobs, calibrate evaporative emissions system tester referring to the following.