MAHLE RTI VCX-1 User Manual

OPERATION MANUAL

VCX-1

Vacuum Coolant Exchanger

RTI Technologies, Inc

4075 East Market St.

York, PA 17402

800-468-2321

www.rtitech.com

Manual P/N 035-80923-00 (Rev A)

Table of Contents

Component Description ........................2

Safety Precautions ...........................3

Home Position ...............................4

Fill New Tank ................................ 5

Empty Radiator .............................. 6

Special Hookups ............................. 8

Fill Radiator ................................. 9

Top Off.................................... 10

Flush Radiator .............................. 10

Empty Waste Tank .......................... 11

Empty New Tank ............................ 12

Troubleshooting ............................. 13

Parts Identification ........................... 14

Flow...................................... 15

Page 1

Component Description

Unpack all components and verify quantities per this illustration.
Contact RTI if any items are missing.

WASTE COOLANT

TANK

PANEL VALVE

SYSTEM

VACUUM GAUGE

ADAPTER HOSE

NEW COOLANT

TANK

SHOP AIR COUPLER

CONE PLUG

ADAPTER

QTY=2

CONE ADAPTER

VALVE

CLEAR REINFORCED

HOSE 12FT

Page 2

Safety Precautions

WARNING: Failure to follow these precautions can result in serious

injury or death.

• Read and understand the Operation Manual completely before operating this unit.

• Always wear proper eye and skin protection when operating and maintaining this equipment.

• Automotive cooling systems can be under pressure and extremely hot. Use extreme caution
when removing caps. Place a rag over the radiator cap during removal.

• Coolants are poisonous to people and animals and are also corrosive. Clean up any spills
immediately.

• Do not allow waste coolant tank to overflow. Immediately clean up any coolant spills. Damage
to the vehicle and equipment can result from the corrosiveness of coolant.

• Continuous monitoring of the coolant exchange process is required.

• If cracks appear in the cylinders, hoses, or adapters these parts must be replaced.

• If leaks occur at the bottom or top of the cylinders the center nut located under the top cover plate
will need to be tightened. (see page 13 for instructions)

• The cylinders, hoses and adapters are plastic and rubber products and are in contact with oil and
chemicals which may lessen their durability. Therefore, when soiled, they should be cleaned with
water and a mild detergent. Caution: Do not clean with thinners, solvents or any other
chemical cleaners.

• Only disassemble or reassemble unit parts when directed by an RTI representative.

• Take precautions to keep clothing, hair, hands, hoses, etc. away from all moving parts of the
vehicle.

• Comply with local, state and federal regulations for fluid disposal.

• Material Safety Data Sheets (MSDS) must be obtained on all chemicals and placed in a shop
file for reference. These are available for down load and printing on the RTI web-site
(www.rtitech.com). Go to TECHNICAL HELP and look under Technical Bulletins.

CAUTION: Failure to follow the precautions as outlined in the operation manual can

result in damage to the engine, vehicle or equipment which will not be
supported or covered under warranty.

Page 3

Home Position

NEW COOLANTWASTE COOLANT

(PRESSURE)

EMPTY WASTE TANK

EMPTY NEW TANK

EMPTY WASTE TANK

EMPTY RADIATOR

TOP OFF

HOME

HOME

(VACUUM)

FILL NEW TANK
EMPTY RADIATOR

FILL NEW TANK
FILL RADIATOR
EMPTY NEW TANK
TOP OFF

VCX-1

HOME

The above valve configuration is set before the VCX is connected to the shop air supply. This is
also the position that the valves are returned to after each procedure. To select a procedure turn
all of the valves to the colored triangle that corresponds with the desired procedure.

This illustration demonstrates the open and closed position on the Cone Adapter Valve. The

Cone Adapter Valve

Valve Open Valve Closed

closed position is 90 degrees clockwise from center.

Page 4

C

Fill New Tank

1. Turn all panel valves to the Home position.

2. Connect shop air to VCX Shop Air Coupler.

3. Turn all panel valves to the Fill New Tank position as shown in the illustration below. This
orientation can also be obtained by positioning the panel valves toward the green highlights
closest to each valve.

4. Place the Cone Adapter, with the Adapter Hose attached, into the container of new coolant.
Open the Cone Adapter Valve to draw coolant into the New Coolant Tank.

5. Raise the hose out of the container of new coolant when the desired fluid level is reached in
the New Coolant Tank.

6. Close the Cone Adapter Valve.

7. Turn all valves to the Home position when done.

Note: DO NOT OVERFILL.

Tank

oolant

New Coolant

Tank

Waste

Clear Hose

WASTE COOLANT NEW COOLANT

(PRESSURE)

EMPTY WASTE TANK

EMPTY NEW TANK

TOP OFF

HOME

EMPTY WASTE TANK

EMPTY RADIATOR

HOME

VCX-1

HOME

(VACUUM)

FILL NEW TANK
EMPTY RADIATOR

FILL NEW TANK
FILL RADIATOR
EMPTY NEW TANK
TOP OFF

Cone Adapter

Valve

Adapter Hose

50/50 Mix Water/Coolant

Page 5

Empty Radiator

1. Run the vehicle with the heater turned on to bring the engine to operating temperature. Turn
the engine off.

2. Turn all panel valves to the Home Position as shown on page 4.

3. Connect shop air to VCX Shop Air Coupler.

4. Turn all panel valves to the Empty Radiator position as shown in the illustration below. This
orientation can also be obtained by positioning the panel valves toward the black highlights
closest to each valve.

5. Insert the Adapter Hose into the Cone Adapter. Insert end of Adapter hose into overflow tank.
Turn the Adapter Hose Valve to the open position to withdraw the coolant.

Waste Coolant

Tank

New Coolant

Tank

Cone Adapter

Valve

WASTE COOLANT

VCX-1

(PRESSURE)

EMPTY WASTE TANK

EMPTY NEW TANK

TOP OFF

EMPTY WASTE TANK

EMPTY RADIATOR

NEW COOLANT

FILL NEW TANK
EMPTY RADIATOR

HOME

FILL NEW TANK
FILL RADIATOR
EMPTY NEW TANK
TOP OFF

HOME

HOME

(VACUUM)

Clear Hose

Adapter Hose

Radiator

Overflow

Water
Pump

Engine

Block

Heater

Core

Page 6

Waste Coolant

Empty Radiator (Continued)

6. Carefully remove radiator cap. Use a
shop rag over the cap when removing to
avoid injury in case there is still pressure.

Waste Coolant

Tank

New Coolant

Tank

7. Place VCX Cone Adapter snugly into the
radiator spout. Do not force the Cone
Adapter into the spout, the suction
pressure from the VCX should secure it
adequately. Verify that the Cone Adapter
Valve is in the open position.

8. Start the engine once fluid starts to move
through the clear hose and into the VCX
Waste Coolant Tank. Verify that the
System Vacuum gauge reads at least 22
InHg.

9. Once the waste coolant from the vehicle
stops flowing through the clear hose, turn
all of the panel valves to Home Position
and turn the engine off.

DO NOT REMOVE CONE ADAPTER FROM
THE RADIATOR!

WARNING Do not overfill the Waste Tank.

Tank

New Coolant

Tank

Clear Hose

Cone Adapter

Valve

Hose Adapter

Radiator

Clear Hose

Overflow

Radiator

Hose

Water
Pump

Cone
Adapter Valve

Overflow

Engine

Block

Water
Pump

Engine

Block

Heater

Core

PINCH
HOSE

It may be necessary to pinch off the hose going

to

Sealing

Point

Radiator Neck

from the radiator neck to the overflow
container. This is only necessary when the
overflow line is below the sealing point created

Line

Overflow

by the Cone Adapter (see illustration). The hose
should be opened only after the Fill Radiator
procedure.

FAILURE TO RECOGNIZE THIS MAY RESULT IN
A POOR EXCHANGE RATE.

Page 7

C

Special Hookups

Seal Tight Radiator

1. Insert the Adapter Hose into the end of the Cone Plug Adapter.

2. Place the Cone Adapter snugly into the radiator, coiling the excess length of Adapter Hose
at the bottom.

3. Follow the Empty Radiator procedure steps 1-9.

More Effective Setup for Empty Radiator

During the Empty Radiator procedure clamp off the upper
radiator hose and follow steps 1-9 of the Empty Radiator
section.

PINCH
HOSE

Radiator

Hose

Overflow

PINCH

Adapter Seal

1. In some cases it may be necessary to cut up to 0.75" off of the Cone Plug Adapter. This is
only necessary when a tight seal can not be created due to bottoming out against the inside
of a shallow radiator neck.

2. Take care to cut a clean edge free of loose debris.

HOSE

ut back

0.750

Page 8

Fill Radiator

Fill Radiator

MAKE SURE ENGINE IS OFF

1. Turn all panel valves to the Home position.

2. Turn all panel valves to the Fill Radiator position shown in the illustration below, this orientation
can also be obtained by positioning the panel valves toward the magenta highlights closest to
each valve. Verify that the Cone Adapter Valve is open.

3. New coolant is automatically pulled out of the VCX New Coolant Tank and into the vehicle
radiator through the clear hose.

NOTE: IF THE CONE ADAPTER BECOMES DISLODGED BEFORE YOU CAN BEGIN THIS

PROCESS YOU MUST RERUN THE EMPTY RADIATOR FUNCTION, WITHOUT
STARTING THE VEHICLE, TO REGAIN THE VACUUM NEEDED TO FILL THE
VEHICLE COOLANT SYSTEM.

4. Once the coolant stops moving through the clear hose turn all of the panel valves back to the
Home position and remove the Cone Adapter from the radiator.

5. Turn all valves to the Home position.

6. Close the Cone Adapter Valve.

Waste Coolant

Tank

New Coolant

Tank

WASTE COOLANT

VCX-1

(PRESSURE)

EMPTY WASTE TANK

EMPTY NEW TANK

TOP OFF

EMPTY WASTE TANK

EMPTY RADIATOR

NEW COOLANT

FILL NEW TANK
EMPTY RADIATOR

HOME

FILL NEW TANK
FILL RADIATOR
EMPTY NEW TANK
TOP OFF

HOME

HOME

(VACUUM)

Clear Hose

PINCH
HOSE

Radiator

Hose

Cone
Adapter Valve

Overflow

Engine

Block

Water
Pump

Page 9

Top Off

1. Turn all panel valves to the Home position.

2. Turn the Cone Adapter Valve to the closed
position.

3. Turn all panel valves to the Top Off position as
shown in the illustration. This orientation can
also be obtained by positioning the panel
valves toward the blue highlights closest to
each valve.

4. Open the Cone Adapter Valve to fill the radiator
and overflow to the proper levels.

5. Turn all valves to the Home position.

6. Close the Cone Adapter valve when done.

7. Replace radiator and overflow caps.

WASTE COOLANT

VCX-1

(PRESSURE)

EMPTY WASTE TANK

EMPTY NEW TANK

TOP OFF

EMPTY WASTE TANK

EMPTY RADIATOR

NEW COOLANT

FILL NEW TANK
EMPTY RADIATOR

HOME

FILL NEW TANK
FILL RADIATOR
EMPTY NEW TANK
TOP OFF

HOME

HOME

(VACUUM)

Flush Radiator

1. The New Coolant Tank needs to be filled with water. See Empty Waste Tank and Fill New
Tank procedures.

2. The Empty Radiator function must be run to completion.

3. Run the Fill Radiator procedure.

4. The Empty Radiator function must be run again to extract all of the water inside the cooling
system.

5. Repeat steps 3 and 4 until the desired results are achieved. Once completed new coolant
needs to be added to the vehicle system.

Page 10

Empty Waste Tank

1. Turn all panel valves to the Home position.

2. Connect shop air to VCX Shop Air Coupler.

3. Close Cone Adapter Valve.

4. Turn all panel valves to the Empty Waste Tank position shown in the illustration below. This
orientation can also be obtained by positioning the panel valves toward the red highlights
closest to each valve.

5. Place the end of the clear hose into a bulk waste container and open the Cone Adapter Valve.

6. Waste coolant will begin leaving the VCX from the Waste Coolant Tank through the clear hose.
Be cautious not to spill waste coolant onto the floor as the hose may “jump” when the Waste
Coolant Tank is nearing empty. Clean up any spills that may occur immediately.

7. Once the Waste Coolant Tank is empty, close the Cone Adapter Valve and turn all valves to
the Home position.

Waste Coolant

Tank

New Coolant

Tank

Clear Hose

WASTE COOLANT

VCX-1

Cone Adapter

Valve

(PRESSURE)

EMPTY WASTE TANK

EMPTY NEW TANK

TOP OFF

EMPTY WASTE TANK

EMPTY RADIATOR

NEW COOLANT

FILL NEW TANK
EMPTY RADIATOR

HOME

FILL NEW TANK
FILL RADIATOR
EMPTY NEW TANK
TOP OFF

HOME

HOME

(VACUUM)

Bulk Waste Container

Page 11

Empty New Tank

1. Turn all panel valves to the Home position.

2. Connect shop air to VCX Shop Air Coupler.

3. Close Cone Adapter Valve.

4. Turn all panel valves to the Empty New Tank position shown in the illustration below. This
orientation can also be obtained by positioning the panel valves toward the blue highlights
closest to each valve.

5. Place the end of the clear hose into a bulk storage container and open the Cone Adapter
Valve.

6. Coolant will begin leaving the VCX from the New Coolant Tank through the clear hose. Be
cautious not to spill coolant onto the floor as the hose may “jump” when the New Coolant Tank
is nearing emptiness. Clean up any spills that may occur immediately.

7. Once the Waste Coolant Tank is empty, close the Cone Adapter Valve and turn all valves to
the Home position.

Waste Coolant

Tank

New Coolant

Tank

Clear Hose

WASTE COOLANT

VCX-1

(PRESSURE)

EMPTY WASTE TANK

EMPTY NEW TANK

TOP OFF

EMPTY WASTE TANK

EMPTY RADIATOR

NEW COOLANT

FILL NEW TANK
EMPTY RADIATOR

HOME

FILL NEW TANK
FILL RADIATOR
EMPTY NEW TANK
TOP OFF

HOME

HOME

(VACUUM)

Cone Adapter

Valve

Bulk Storage Container

Page 12

Troubleshooting

Problem Solution

Vacuum becomes weak Inside of the VCX, there is a venturi vacuum generator that

may have collected debris during the operation of the unit.
If this occurs, the vacuum will become weak resulting in a
lower vacuum reading on the System Vacuum gauge and
poor performance. Remove the venturi from the line and
blow shop air through it. Use the Parts Identification (page

12) to locate the venturi. Reconnect to correct lines when
done.

There may be a vacuum leak at either the top or bottom
sealing point on the tanks. Fill the tank to the top with water
and turn all valves to the Home position. Close the Cone
Adapter Valve and turn all valves to the Empty (leaking
tank) position. Check for leaks and tighten, replace or repair
as necessary.

Leakage The hex nut at the top of the tank may be loose. Tighten no

more than 1/4 turn past the factory setting. Caution, over

tightening the hex nut can lessen the integrity of the
tank, cause the tension spring to fail or damage the o­rings (see illustration).

Debris may have collected at the bottom of the tank.
Disassemble tank and clean the base of tank. Take care
when reassembling not to over tighten the hex nut. Turn nut

ONLY three revolutions past finger tight. Check for leaks
and turn in 1/4 turns as necessary.

TANK TOP PLATE

SMALL O-RING

1/4-20 1/2" BOLTS (QTY 4)

5/16 NUT

5/16 ID WASHER

COMPRESSION SPRING

Over time, the o-ring at the bottom or top of the cylinder may
become worn. Inspect and replace if needed.

Tank Overflow If fluid is ever filled to the top of the tank while using the unit

there is a device that will release excess to the inside of the
cabinet.

External Clear Hose Using the VCX to remove coolant from a vehicle creates

high temperatures throughout the unit particularly where the
clear hose connects to the Cone Adapter.
Repeated exposure to these temperatures may cause
deterioration of the hose. If possible cut affect area off and
reconnect Cone Adapter. If replacement of the hose is
required call RTI for a new one.

Page 13

1

Parts Identification

2

4

6

11

3

1 022-80115-00 Valve Relief

20

5

18

7

8

9

2 060-81209-00

3 040-80196-00 Compression Spring
4 370-80085-00 Acrylic Tube with Decal
5 035-80880-00 Tank Level Decal (VCX-1)
6 026-80238-00 Vacuum Gauge

7 022-80028-00 Ball Valve 3-Way

8 060-81215-00 Cone Plug Adapter
9 370-80109-00 Cone Adapter Valve Assy

P/N Description

1/4 MPT X 1/4 FPT

Top Cylinder Plate
028-80229-00
028-80228-00

Large O-Ring

Small O-Ring

30"-0 PSIG

1/4 FPT (BHD)

10

10 370-80110-00 Clear Hose Assy
11 060-81208-00

028-80229-00

Bottom Cylinder Plate

Large O-Ring

12 13 14

INSIDE OF UNIT

12 026-80197-00 Vacuum Pump (Venturi)
13 022-80116-00 Pressure Regulator

1/4 FPT X 1/4 FPT (BHD)

14 370-80095-00 Adapter Hose

Page 14

Flow

Page 15