Astro 78585 User Manual

This kit is designed to test for leakage in vehicle cooling systems, including radiator caps, and for quick change of coolant only. Use as intended only.

• Normal use of this product is likely to expose the user to dust and/or microscopic particles containing chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Always wear appropriate safety equipment and clothing when using this product. Study, understand and follow all instructions provided with this product. Failure to read and follow all warnings and operating instructions may result in damages and serious injury or death.

• Always wear ANSI approved goggles when using this product. (Users and Bystanders).

• Never use this tool for any application other than for

which it was designed.

• Only use accessories designed for this tool.

• Never alter or modify this tool in any way.

• Improper operation and/or maintenance of the tool, modification of the tool, or use of the tool with accessories not designed for it could result in serious injury or death.

• Always select the correct accessories of the correct size and design for the job that you are attempting to perform.

• Always work in a clean, safe, well-lit, organized and adequately equipped area.

• Do not begin repairs without assurance that vehicle is in secure position, and will not move during repair.

• Allows easy testing for leakage in radiator system and quick change of coolant

• Unit is suitable for domestic and import vehicles

• Color coded radiator test caps make it easy to choose the suitable test cap for the job

• Special design of vacuum purge & refill tool connection fits nearly all type of radiator opening

• Set includes:

- Pressure Testing Pump with Hose, Quick Coupler with Pressure Release, and Gauge: Test Range 0 – 35 psi (0 – 2.5 bar)

- 1pc. Blue and 1pc. Black Radiator Cap Test Adapters to test for original radiator cap leakage

- 17pcs. Test Caps for testing cooling systems on most domestic and import vehicles

- Vacuum Type Cooling System Purge and Refill Tool Kit for quick change of coolant

- Universal Adapter

- Temperature Gauge

- Blow Molded Case

• Applications: Mercedes Benz, GM, Jeep, Peugeot, Subaru, Chr ysler, Acura, Mitsubishi, Nissan,

Mazda, Toyota, Infiniti, Geo, Suzuki, Isuzu, Honda, Lexus, Volvo, Saab, Citroen, Renault, Fiat, Alfa, Mini Cooper, VW, BMW, Ford, Opel, Porsche, Audi, etc.

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INSTRUCTIONS FOR PRESSURE TESTING COOLING SYSTEM

INSTRUCTIONS FOR PURGING AND REFILLING COOLING SYSTEM

Test For Leaks In Cooling System

· Step 1: Remove the original radiator cap after assuring that the cooling

system is depressurized and cool.

· Step 2: Choose the correct radiator cap for the vehicle being tested from the test kit and install on cooling system opening.

· Step 3: Remove the hand pump assembly from the test kit and fasten the quick coupler at the end of the hose to the radiator cap securely. Operate the hand pump until reaching the pressure recommended by the vehicle manufacturer. (See fig. 1 & 2) DO NOT exceed vehicle manufacturer’s recommended pressure or maximum gauge range pressure of 35psi (2.5bar).

· Step 4: Check the pressure reading on the gauge immediately after reaching the vehicle manufacturer’s recommended pressure. If the pressure reading drops, there is a leak in the cooling system. After pressure testing is completed, press the release button on the quick coupler until the reading on the gauge reads 0. Remove quick coupler from radiator cap and then remove radiator cap from the cooling system opening. Locate the leak and repair as necessary.

Test For Leaks In Original Radiator Cap

· Step 1: Choose the correct radiator cap connector (02A or 02B) and correct steel radiator cap (03, 04, or 05) for the correct vehicle being tested from the test kit. Fasten the original radiator cap to the radiator cap connector and then fasten the steel radiator cap from the test kit to the other end of the radiator cap connector.

· Step 2: Remove the hand pump assembly from the test kit and fasten the quick coupler at the end of the hose to the radiator cap securely. Operate the hand pump until reaching the pressure recommended by the vehicle manufacturer. (See fig. 3) Do not exceed vehicle manufacturer’s recommended pressure or maximum gauge range pressure of 35psi (2.5bar).

Purge Cooling System

· Step 1: Drain coolant from radiator as well as possible.

· Step 2: Remove the purge and refill tool from the test kit and hang the tool

in a convenient location under the hood with the hook provided.

· Step 3: Choose the correct radiator cap for the vehicle being tested, or the

universal rubber radiator adapter from the test kit and install the one of your choice on the cooling system opening. Fasten the quick coupler at the end of the hose on the purge and refill tool to the radiator cap securely. (See fig. 4 & 5)

· Step 4: Turn valve No. 3 to the open position and valve No. 6 to the closed

position. (See fig. 6)

· Step 5: Connect air supply to the purge and refill tool and press operating

button until the pressure reaches 20-25 Hg (50-60cmHg). Turn valve No. 3 to the closed position and release the operating button. (See fig. 7 & 8)

· Step 3: Check the pressure reading on the gauge immediately after reaching the vehicle manufacturer’s recommended pressure. If the pressure drops, there is a leak in the radiator cap. After pressure testing is completed, press the release button on the quick coupler until the reading on the gauge reads 0. Remove quick coupler from radiator cap and then remove the original radiator cap from the radiator cap connector. Discard original radiator cap and replace with new cap if leaking or if it does not meet vehicle manufacturer’s recommendations.

Refill Cooling System

· Step 1: Connect the coolant hose to the purge and refill tool and submerge

in coolant.

· Step 2: Assure that valve No. 3 is in the closed position and that there is

coolant in the coolant hose.

· Step 3: Turn valve No. 6 to the open position to allow the coolant to refill the

cooling system.

· Step 4: The refill is complete when the gauge reads 0.

Note: Please check the coolant level and add coolant as necessary to the proper level.

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