Mityvac MV4525 User Manual [en, de, es, fr]

OCTOBER - 2006 Form 822947 Section - MV42-1

USER’S MANUAL

Have a technical question?

If you have questions, or require technical
service, please contact our trained service
technicians at:

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Visit our website at www.mityvac.com for
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for product use.

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To order replacement or service parts, visit us
online at www.mityvacparts.com or call toll free
1-800-992-9898.

SPECIFICATIONS

Vacuum Air Pressure Requirements:

Min. Pressure: 90 psi

(6.2 bar) (600 kPa)

Max. Pressure: 120 psi

(8.3 bar) (830 kPa)

Vacuum threads for
air line connection: 1/4" NPT

COOLING SYSTEM TEST & REFILL KIT

MODEL MV4525

Page Number - 2 Form 822947

Table of Contents

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Applications and Basics of Testing . . . . . . . . . . . . . . . . . . . 6

Static Pressure Test (Engine Off). . . . . . . . . . . . . . . . . . . . . 7

Temperature Testing (Engine On) . . . . . . . . . . . . . . . . . . . 8-9

Dynamic Pressure Test (Engine On) . . . . . . . . . . . . . . . . . 10

Dynamic Pressure/Vacuum/Temperature Test

(Engine On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

Cap Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Vacuum Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

System Refill/Airlock Elimination . . . . . . . . . . . . . . . . . . . . 15

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Service Parts

Part Number Description

823032 Valve Coupler

823033 Valve Coupler Repair Kit

823034 Temperature Probe

823035 Extension Hose

823036 Pressure Pump

823038 Venturi Vacuum

823039 Refill Hose

823040 Compound Gauge

823042 Adapter Wrench

823043 Plug and Tether

823044 Hose Clip

823045 Drain Hose

823046 Deep Neck Adapter

MVA100 O-Ring and Washer, MVA101 O-Ring

823047 and Washer, MVA102 O-Ring and Washer,

MVA103 O-Ring and Washer

823050 Custom-molded case

Form 822947 Page Number - 3

823033

823032

823035823034

823038823036

823040823039

823044 823045

823046 823047

823050

823042 823043

Page Number - 4 Form 822947

Static Pressure Test (Engine Off)

Dynamic Pressure Test (Engine On)

Temperature Testing (Engine On)

Compound
Gauge

Coupler Plug

Extension Hose

(optional)

Drain Hose

Valve Coupler

Bayonet System Adapter

Radiator

Coolant Bottle

Threaded System Adapter

Compound
Gauge

Coupler Plug

Extension Hose

(optional)

Extension Hose

(optional)

Pressure

Pump

Valve Coupler

Bayonet System Adapter

Radiator

Coolant Bottle

Threaded System Adapter

Compound
Gauge

Temperature Probe

Extension Hose

(optional)

Drain Hose

Valve Coupler

Bayonet System Adapter

Radiator

Coolant Bottle

Threaded System Adapter

Temperature

Probe

Drain Hose

Valve Coupler

Bayonet System Adapter

Radiator

Coolant Bottle

Threaded System Adapter

Dynamic Pressure/Vacuum/Temperature Test
(Engine On)

Form 822947 Page Number - 5

Cap Pressure Test Vacuum Leak Test

System Refill/Airlock Elimination

Compound Gauge

Coupler Plug

Extension Hose

(optional)

Extension

Hose

(optional)

Refill Hose

Valve Coupler

Bayonet System Adapter

Radiator Coolant Bottle

Threaded System Adapter

Compound Gauge

Venturi

Vacuum

Coupler Plug

Extension Hose

(optional)

Extension

Hose

(optional)

Valve Coupler

Bayonet System

Adapter

Radiator Coolant Bottle

Threaded System

Adapter

Compound Gauge

Pressure

Pump

Coupler Plug

Extension Hose

(optional)

Extension Hose

(optional)

Valve Coupler

Bayonet Cap Adapter

Bayonet Cap

Threaded Cap

Threaded Cap Adapter

Venturi Vacuum

Applications & Basics of Testing

The MV4525 Cooling System Test & Refill Kit includes equip­ment to test and monitor pressure, temperature and vacuum
simultaneously to perform a complete cooling system analysis.
It is capable of performing diagnostic tests with either the
engine off or engine on. While engine off tests are quick and
reliable, testing with the engine on more accurately represents
the conditions under which cooling system failures occur, and
greatly expands the types of failures that can be diagnosed.

Engine “Off” Testing

Cooling system leaks are a common cause of overheating, and
can be quickly and easily diagnosed without running the engine.
With the MV4525, the user can choose to apply either pressure
or vacuum to the system, and then monitor it for a short period
of time to determine if a leak exists. Pressure is most commonly
used to perform this test because it will force fluid to seep from
any external leak, making it easy to identify.

For convenience, a vacuum leak test is usually performed in
conjunction with a vacuum refill. A vacuum refill is performed
with the engine off, and is a quick and effective way to refill the
cooling system without trapping air. A vacuum leak test and
refill is performed after the cooling system has been drained.
A compressed air operated vacuum is used to remove all air
from the empty system, and then the system is monitored to
determine if there are any leaks. If no leaks are present, the
vacuum is used to automatically draw in new fluid, and fill the
system without reintroducing air.

Testing proper function of the cooling system pressure cap is
another test that is performed with the engine off. All pressure
caps have a built-in vent designed to release pressure from the
cooling system when it exceeds a maximum value. The proper
function of this cap is critical to preventing failures caused by
under- or over-pressurization. This test is performed using the
pressure pump and gauge included in this kit, however it also
requires cap test adapters that are not included with this kit, and
must be purchased separately. Refer to the Adapter Selection
Guide included in the kit for more information on cap adapters.

Engine “On” Testing

Simultaneously monitoring pressure, vacuum, and temperature
when the engine is first started, and while it progresses towards,
or cools down from, normal operating temperature, provides
extensive information that is invaluable to diagnosing cooling
system related problems. Performing an engine-on test using
the MV4525 can quickly diagnose a blown head gasket or
cracked or damaged block or head. It can also indicate a faulty
thermostat, fan switch/relay, or coolant sensor. In addition, some
system leaks may only be evident during an engine’s normal
operational warm-up and cool-down cycle. The procedures in
this manual will illustrate how to perform engine-on tests as well
as diagnose the results.

Precautions

This equipment is designed for servicing a variety of vehicles
in a safe, convenient manner. However, differences in cooling
systems may make it impossible to perform some of the tests
indicated in these instructions on every vehicle. The procedures
documented in this manual are to serve as guidelines for the
use of this equipment. In addition to these guidelines, always

follow the manufacturer’s recommended procedures when
servicing each unique vehicle. Do not attempt to force a test
on a cooling system for which this equipment is not designed
to perform.

Performing cooling system tests using the MV4525 is simple
and straightforward if you follow the instructions. However,
always keep in mind that you are working with a system that
may be full of hot, pressurized fluid that is just waiting to be
expelled. The MV4525 has safety valves built-in at every possible
connection, but if you are testing an engine that is hot and/or
pressurized, always stop to think before disconnecting a hose
or other component, or shifting a valve.

Always read carefully and understand instructions prior to using
this equipment.

Always wear eye protection when removing the radiator or
coolant bottle cap, or when performing any cooling system test.

Never remove the radiator or coolant bottle cap, or attempt to
pressurize the cooling system of a vehicle that is overheated.

Always allow system to cool prior to attempting to perform any
cooling system related test procedure.

Basics of Testing

When deciding where to connect to the cooling system,
first look for the radiator and determine if it has a fill neck
and pressure cap. This is common on about half of U.S.
manufactured vehicles, and almost all Asian manufactured
vehicles, and would be the first choice for connecting. If the
radiator is closed and inaccessible, then the connection will
be made through a coolant bottle. Some automotive cooling
systems utilize a coolant overflow bottle that is not part of the
sealed system. Attempting to test the cooling system through
this bottle will not connect you into the sealed system, and will
simply vent the test pressure or vacuum to the atmosphere.
This type of overflow bottle is easily recognized because it
typically utilizes a snap-on style cap or a threaded cap that is
open to atmosphere. There are no adapters that are designed
to fit this type of coolant overflow bottle. A test connection
should be made through a radiator or coolant bottle with a
bayonet or threaded style of cap designed to maintain a
specific pressure in the cooling system.

Adapters

The MV4525 includes four cooling system adapters that fit
the radiators and coolant bottles on the vast majority of U.S.
and Asian manufactured vehicles, and even some European
vehicles. An adapter is required to connect the test equipment
to the specific make and model being tested. Once the correct
adapter is identified for the test vehicle, it can be used to
perform all of the tests outlined in this manual except for the
cap pressure test. To perform a test on a vehicle application not
covered by one the four included adapters, or to perform a cap
pressure test, additional adapters must be purchased. Adapters
are available for virtually every make and model of car, and can
be purchased individually or as part of an adapter kit from
Mityvac Tools. Refer to the Adapter Selection Guide included in
the kit for more information on adapters.

Page Number - 6 Form 822947

Static Pressure Test (Engine Off)

For diagnosing:

Cooling system leaks

Set-up & Procedure:

1. Ensure the cooling system is cool and not pressurized. Carefully
remove the radiator or coolant bottle pressure cap (Fig.1).

2. Check to see that the radiator or coolant bottle is filled to the
proper level, and check hoses for visual damage or leaks. Fill
and repair as necessary prior to testing.

3. Select the correct Cooling System Adapter for the application.
Refer to the Adapter Selection Guide included in the kit.

4. Apply water or coolant to the rubber gasket and/or o-ring
on the adapter, and install the adapter in place of the pressure
cap (Fig. 2).

5. Install the Valve Coupler onto the System Adapter using the
quick-connect. Make sure the quick-connect sleeve snaps
forward to lock the connection (Fig. 3).

6. Install the Coupler Plug into the top of the Valve Coupler and
tighten the threaded cap securely to form an airtight seal (Fig. 4).

7. Connect the Compound Gauge to the quick-connect labeled
“Gauge” extending from the Valve Coupler. Note: It may be more
convenient to install an Extension Hose between the Valve
Coupler and the Gauge (Fig. 5).

8. Connect the Pressure Pump to the quick-connect labeled
“Pressure/Vacuum” extending from the Valve Coupler. Note: It
may be more convenient to install an Extension Hose between
the Valve Coupler and the Pump (Fig. 6).

9. Ensure the Shuttle Valve on the Valve Coupler is shifted to the
“Closed” position.

10. Operate the Pressure Pump until the needle on the Compound
Gauge moves to the end of the colored band indicating the
appropriate pressure range (see Chart A) of the cap (Fig. 7).

11. Watch the gauge for a short period of time. If the pressure
reading drops, a leak is present.

12. With the system still pressurized, perform a visual inspection
of the entire cooling system. Check hoses and connections
for seepage, which would indicate a leak. Return to the gauge
and check the reading once more.

13. Most leaks are external, and visible seepage occurs. However,
a drop in pressure with no visible leakage can indicate a blown
head gasket or cracked block, where fluid leaks into the
combustion chamber. Visually inspect oil and transmission fluid
for signs of coolant. Proceed to the Dynamic Pressure Test for
better methods of diagnosing internal leaks.

14. When testing is complete, shift the Shuttle Valve to the “Open”
position to relieve system pressure (Fig. 8).

15. Disconnect components, clean and store them properly.

16. Refill the radiator or coolant bottle to the proper level, and replace
the cap.

Form 822947 Page Number - 7

Fig. 7

Fig. 2

Fig. 4

Fig. 6

Fig. 8

Fig. 1

Fig. 3

Fig. 5

Chart A: Cooling System Cap Pressure Test Ranges

Rated Pressure (PSI) Pressure Test Range (PSI)

43 - 5
76 - 8

10 9 - 11
13 or 14 12 - 16
15 or 16 14 - 18

18 16 - 20

20 18 - 22

30 28 - 30

Temperature Testing (Engine On)

For diagnosing:

Thermostat
Cooling fan and related components
Coolant sensor

Set-up & Procedure:

1. Ensure the cooling system is cool and not pressurized. Carefully
remove the radiator or coolant bottle pressure cap (Fig. 9).

2. Check to see that the radiator or coolant bottle is filled to the
proper level, and check hoses for visual damage or leaks. Fill
and repair as necessary prior to testing.

3. Select the correct Cooling System Adapter for the application.
Refer to the Adapter Selection Guide included in the kit.

4. Apply water or coolant to the rubber gasket and/or o-ring on
the adapter, and install the adapter in place of the pressure
cap (Fig. 10).

5. Install the Valve Coupler onto the system adapter using the
quick-connect. Make sure the quick-connect sleeve snaps
forward to lock the connection (Fig. 11).

6. Loosen the threaded cap on top of the Valve Coupler, and remove
the Plug if necessary. Insert the Temperature Probe through the
Valve Coupler, and adjust the depth of the probe to ensure it is in
contact with the coolant in the bottle or radiator (Fig. 12). Do not
force the probe down so hard that it damages the probe,
radiator, or coolant bottle.

7. Tighten the cap on the Valve Coupler to form a seal around the
Temperature Probe and hold it securely.

8. Ensure the Shuttle Valve on the Valve Coupler is shifted to the
“Closed” position. (Fig. 13).

9. Start the vehicle engine and monitor the probe reading as the
engine rises to operating temperature. Compare the results to
the diagnosis below to determine proper function of thermostat,
cooling fan sensor/relay, and coolant temperature sensor.

Thermostat

When the thermostat opens, the temperature will surge as hot
coolant from the engine flows into the radiator or bottle. Note
the peak temperature during this surge and compare it to the
manufacturer’s thermostat specification. If the reading is not
within a few degrees of the specification, the thermostat is
faulty and should be replaced.

If the temperature reading on the probe does not increase as the
engine warms, this may indicate the thermostat is stuck closed,
and should be replaced.

If the reading on the probe increases very slowly and will not
reach the thermostat opening temperature, the thermostat may
be stuck open, and should be replaced.

Cooling Fan(s)

If the vehicle has electric fan(s), note the temperature at which
they cycle on and off. Verify this reading against the manufacturer’s
specification. If it’s within a few degrees, the cooling fan sensor(s)
are functioning properly. If the fan(s) do not cycle on and off,
check the fuse(s), motor(s), switch(s), and relay(s) to determine
possible cause(s).

continued on next page

Page Number - 8 Form 822947

Fig. 13

Fig. 9

Fig. 10

Fig. 11

Fig. 12

Temperature Testing (Engine On) continued

Coolant Temperature Sensor

A faulty coolant temperature sensor can cause a multitude of
drivability issues, but can be extremely difficult to diagnose. With
the engine at normal operating temperature, and the thermostat
open, note the temperature reading on the probe. Use a scan tool
to retrieve the coolant temperature from the ECM and compare it
to the probe reading. If they are not within a few degrees, the
sensor should be replaced.

10. When testing is complete, connect the Drain Hose to the Shuttle
Valve using the quick-connect. Make sure the quick-connect
sleeve snaps forward to lock the connection (Fig. 14).

11. Place the opposite end of the Drain Hose into a container
appropriate to capture hot, pressurized coolant. Use the
Hose Clip to secure the Drain Hose in position (Fig. 15).

12. Shift the shuttle valve to the “Open” position, allowing the
hot fluid and pressure to be expelled (Fig. 16).

13. Once all pressure is relieved, cautiously disconnect components,
clean and store them properly.
Caution: Hot fluid being expelled through the test equipment will
cause quick-connects and other metal components to become
hot. Handle such components with care, using a rag if necessary.

14. Refill the radiator or coolant bottle to the proper level, and replace
the cap.

Form 822947 Page Number - 9

Fig. 16

Fig. 14

Fig. 15

Dynamic Pressure Test (Engine On)

For diagnosing:

Cooling system leaks

Set-up & Procedure:

1. Ensure the cooling system is cool and not pressurized. Carefully
remove the radiator or coolant bottle pressure cap (Fig. 17).

2. Check to see that the radiator or coolant bottle is filled to the
proper level, and check hoses for visual damage or leaks. Fill
and repair as necessary prior to testing.

3. Select the correct Cooling System Adapter for the application.
Refer to the Adapter Selection Guide included in the kit.

4. Apply water or coolant to the rubber gasket and/or o-ring on the
adapter, and install the adapter in place of the pressure cap (Fig.

18).

5. Install the Valve Coupler onto the System Adapter using the
quick-connect. Make sure the quick-connect sleeve snaps
forward to lock the connection (Fig. 19).

6. Install the Coupler Plug into the top of the Valve Coupler and
tighten the threaded cap securely to form an airtight seal (Fig. 20).

7. Connect the Compound Gauge to the quick-connect labeled
“Gauge” extending from the Valve Coupler. Note: It may be
more convenient to install an Extension Hose between the
Valve Coupler and the Gauge (Fig. 21)

8. Ensure the Shuttle Valve on the Valve Coupler is shifted to the
“Closed” position (Fig. 22).

9. Start the vehicle engine and allow it come to normal operating
temperature and pressure.

10. Turn off the engine and allow it to cool with pressure still applied.
Check for leaks as the engine cools. A leak caused by a slightly
loose hose clamp or a stuck hose clamp that gives a false sense
of tightness may only be noticeable during cool down.

11. When testing is complete, connect the Drain Hose to the Shuttle
Valve using the quick-connect. Make sure the quick-connect
sleeve snaps forward to lock the connection (Fig. 23).

12. Place the opposite end of the Drain Hose into a container
appropriate to capture hot, pressurized coolant. Use the
Hose Clip to secure the Drain Hose in position (Fig. 24).

13. Shift the shuttle valve to the “Open” position, allowing the hot
fluid and pressure to be expelled (Fig. 25).

14. Once all pressure is relieved, cautiously disconnect components,
clean and store them properly.
Caution: Hot fluid being expelled through the test equipment will
cause quick-connects and other metal components to become
hot. Handle such components with care, using a rag if necessary.

15. Refill the radiator or coolant bottle to the proper level, and replace
the cap.

Page Number - 10 Form 822947

Fig. 24

Fig. 18

Fig. 20

Fig. 22

Fig. 17

Fig. 19

Fig. 21

Fig. 23

Fig. 25

Dynamic Pressure/Vacuum/Temperature Test

(Engine On)

For diagnosing:

Cooling system leaks
Cylinder head damage
Blown head gasket
Cracked block

Set-up & Procedure:

1. Ensure the cooling system is cool and not pressurized. Carefully
remove the radiator or coolant bottle pressure cap (Fig. 26).

2. Check to see that the radiator or coolant bottle is filled to the
proper level, and check hoses for visual damage or leaks. Fill
and repair as necessary prior to testing.

3. Select the correct Cooling System Adapter for the application.
Refer to the Adapter Selection Guide included in the kit.

4. Apply water or coolant to the rubber gasket and/or o-ring on
the adapter, and install the adapter in place of the pressure
cap (Fig. 27).

5. Install the Valve Coupler onto the system adapter using the
quick-connect. Make sure the quick-connect sleeve snaps
forward to lock the connection (Fig. 28).

6. Loosen the threaded cap on top of the Valve Coupler, and remove
the Plug if necessary. Insert the Temperature Probe through the
Valve Coupler, and adjust the depth of the probe to ensure it is in
contact with the coolant in the bottle or radiator (Fig. 29). Do not
force the probe down so hard that it damages the probe,
radiator, or coolant bottle.

7. Tighten the cap on the Valve Coupler to form a seal around the
Temperature Probe and hold it securely.

8. Connect the Compound Gauge to the quick-connect labeled
“Gauge” extending from the Valve Coupler. Note: It may be
more convenient to install an Extension Hose between the
Valve Coupler and the Gauge (Fig. 30).

9. Ensure the shuttle valve on the Valve Coupler is shifted to the
“Closed” position (Fig. 31).

10. Start the engine, and monitor the readings on the compound and
temperature gauges. Pressure and temperature should increase
steadily as the engine warms to normal operating conditions.

A rapid pressure increase followed by a quicker then normal
increase in temperature, indicates significant cylinder compres­sion leakage into the coolant system, most likely caused by a
blown head gasket. Other indications of a blown head gasket
may be a faster than normal increase in temperature, steam
flowing from the exhaust, and deposits in the oil. If symptoms
indicate a blown head gasket, immediately shut the engine off to
prevent overheating and the possibility of additional damage.

Smaller internal leaks can be caused by a cracked block or
head(s). These leaks may not cause obvious rapid pressure
buildup, but can still be identified and diagnosed. If the pressure
builds to higher than normal readings and/or the pressure gauge
reading fluctuates rapidly, a compression or combustion leak is
present. A gauge reading indicating vacuum can be a cause by
a crack in the intake port or intake valve seat.

continued on next page

Form 822947 Page Number - 11

Fig. 27

Fig. 29

Fig. 31

Fig. 26

Fig. 28

Fig. 30

Dynamic Pressure/Vacuum/Temperature Test

(Engine On)

continued

11. When testing is complete, connect the Drain Hose to the Shuttle
Valve using the quick-connect. Make sure the quick-connect
sleeve snaps forward to lock the connection (Fig. 32).

12. Place the opposite end of the Drain Hose into a container
appropriate to capture hot, pressurized coolant. Use the
Hose Clip to secure the Drain Hose in position (Fig. 33).

13. Shift the shuttle valve to the the “Open” position, allowing the
hot fluid and pressure to be expelled (Fig. 34).

14. Once all pressure is relieved, cautiously disconnect components,
clean and store them properly.
Caution: Hot fluid being expelled through the test equipment will
cause quick-connects and other metal components to become
hot. Handle such components with care, using a rag if necessary.

15. Refill the radiator or coolant bottle to the proper level, and
replace the cap.

Page Number - 12 Form 822947

Fig. 34

Fig. 33

Fig. 32

Cap Pressure Test

For diagnosing:

Proper function of pressure cap

Set-up & Procedure:

1. Ensure the cooling system is cool and not pressurized. Carefully
remove the radiator or coolant bottle pressure cap.

2. Select the correct Cap Adapter for the application. Refer to the
Adapter Selection Guide included in the kit.

3. Apply water or coolant to the rubber gasket and/or o-ring on the
cap, and install the cap onto the adapter (Fig. 35).

4. Install the Valve Coupler onto the Cap Adapter using the
quick-connect. Make sure the quick-connect sleeve snaps
forward to lock the connection (Fig. 36).

5. Install the Coupler Plug into the top of the Valve Coupler and
tighten the threaded cap securely to form an airtight seal (Fig. 37).

6. Connect the Compound Gauge to the quick-connect labeled
“Gauge” extending from the Valve Coupler. Note: It may be more
convenient to install an Extension Hose between the Valve
Coupler and the Gauge (Fig. 38).

7. Connect the Pressure Pump to the quick-connect labeled
“Pressure/Vacuum” extending from the Valve Coupler. Note: It
may be more convenient to install an Extension Hose between the
Valve Coupler and the Pump (Fig. 39).

8. Ensure the Shuttle Valve on the Valve Coupler is shifted to the
“Closed” position (Fig. 40).

9. Determine the rated cap pressure. It will be printed on the cap or
in the vehicle manual. Compare this value to the chart (see chart
A) to determine the acceptable pressure test range.

10. Operate the Pressure Pump until the cap releases pressure. The
pressure should relieve when the arrow is in the colored band on
the gauge face corresponding to the test range of the cap.

11. When testing is complete, shift the Shuttle Valve to the “Open”
position to relieve the pressure (Fig. 41).

12. Disconnect the components, clean, and store them properly.

Form 822947 Page Number - 13

Fig. 36

Fig. 38

Fig. 40

Fig. 41

Fig. 35

Fig. 37

Fig. 39

Chart A: Cooling System Cap Pressure Test Ranges

Rated Pressure (PSI) Pressure Test Range (PSI)

43 - 5
76 - 8

10 9 - 11
13 or 14 12 - 16
15 or 16 14 - 18

18 16 - 20

20 18 - 22

30 28 - 30

Vacuum Leak Test

For diagnosing:

Cooling system leaks

Notes

This equipment uses a venturi vacuum to perform a vacuum leak test.
The venturi requires clean, dry, high pressure air between 90 and 120
psi (5.5–10 bar) (550–1000 kpa) to create the vacuum.

Prior to testing, install a male quick-change air nipple with 1/4" NPT
male thread to the venturi.

The altitude at which the vacuum test is performed can significantly
affect the ability of the venturi to produce a vacuum. As the altitude
increases, the maximum vacuum the venturi can create will decrease.
This is normal and should not be considered a malfunction.

It is recommended that the cooling system be drained of coolant prior
to performing a vacuum leak test and automatic refill.

When connecting components using quick-connects, make sure the
sleeve snaps forward to lock the connection.

Set-up & Procedure:

1. Properly position the vehicle for service access to the radiator
or coolant bottle. Turn on the heater and set it to its highest
temperature setting.

2. Ensure the cooling system is cool and not pressurized. Carefully
remove the radiator or coolant bottle pressure cap (Fig. 42).

3. Select the correct Cooling System Adapter for the application.
Refer to the Adapter Selection Guide included in the kit.

4. Apply water or coolant to the rubber gasket and/or o-ring on
the adapter, and install the adapter in place of the pressure
cap (Fig. 43).

5. Install the Valve Coupler onto the system adapter using the
quick-connect. Make sure the quick-connect sleeve snaps
forward to lock the connection (Fig. 44).

6. Install the Coupler Plug into the top of the Valve Coupler and
tighten the threaded cap securely to form an airtight seal (Fig. 45).

7. Connect the Compound Gauge to the male quick-connect
labeled “Gauge” extending from the Valve Coupler. Note: It may
be more convenient to install an Extension Hose between the
coupler and the gauge (Fig. 46).

8. Connect the Venturi Vacuum to the male quick-connect labeled
“Pressure/Vacuum” extending from the Valve Coupler. Note: It
may be more convenient to install an Extension Hose between
the coupler and the vacuum (Fig. 47).

9. Ensure the Shuttle Valve on the Valve Coupler is shifted to the
“Closed” position (Fig. 48).

10. Connect clean, dry, regulated compressed air between 90 and
120 psi (6.2 and 8.3 bar) (600 and 830 kPa) to the Venturi Vacuum
by means of the previously installed air nipple (Fig. 49).

11. Turn on the compressed air. The vacuum will make a hissing noise
as the high pressure air passes through it. If the cooling system is
not empty, it is normal that some fluid may be expelled from the
venturi exhaust.

continued on next page

Page Number - 14 Form 822947

Fig. 43

Fig. 45

Fig. 47

Fig. 49

Fig. 42

Fig. 44

Fig. 46

Fig. 48

Vacuum Leak Test continued

12. Allow the vacuum to pull air from the cooling system until the
gauge indicates 24 to 26 in Hg (1.6 to 1.8 bar) (81 to 88 kPa) or
the value stops increasing (Fig. 50). This should only take about 1
to 2 minutes during which time it is normal for the radiator hoses
to collapse.

13. Once the proper vacuum is achieved, disconnect the Venturi
Vacuum from the Valve Coupler before turning off the air or
disconnecting the air hose (Fig. 51). Turning off the air or
disconnecting the air hose prior to disconnecting the venturi
from the valve coupler, will allow air to reenter the system.

14. Watch the gauge for at least 30 seconds. The vacuum reading will
remain steady if the system does not have a leak. If the cooling
system has a leak, the vacuum will drop.

15. If the cooling system has a leak, it may be difficult to determine
the exact location because the vacuum will prevent fluid from
seeping. At this point it may be best to relieve the vacuum by
shifting the shuttle valve to the “Open” position, and run a
pressure test as outlined on page 7.

16. If no leak is detected and no further repairs are required, the
vacuum may be used to quickly refill the system without trapping
air. See the following section for the proper procedure to refill the
cooling system with new coolant. Otherwise, shift the Shuttle
Valve on the Valve Coupler to the “Open” position to relieve
the vacuum.

17. Disconnect components, clean and store them properly.

System Refill/Airlock Elimination

Set-up & Procedure:

1. Follow steps 1 through 15 of the procedures for the
Vacuum Leak Test.

2. If there are no leaks in the system, do not open the Shuttle Valve!

3. Connect the Refill Hose to the Shuttle Valve using the
quick-connect coupler (Fig. 52).

4. Place the opposite end of the Refill Hose into a supply of coolant
adequate enough to completely refill the cooling system (Fig. 53).

5. Place the coolant supply at a level even with the radiator or
coolant bottle, or higher.

6. Shift the Shuttle Valve to the “Open” position, allowing the
vacuum to pull the coolant into the system (Fig. 54).

7. If the system does not completely refill, reapply the vacuum
and repeat the refill procedure.

8. Once the refill is complete, disconnect the components, clean,
and store them properly.

9. Top off the radiator or coolant bottle if necessary, and replace
the cap.

Form 822947 Page Number - 15

Fig. 51

Fig. 50

Fig. 52

Fig. 53

Fig. 54

Page Number - 16 Form 822947

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.

This warranty is conditioned upon the determination of a Lincoln authorized representative that the equipment is defective. To obtain
repair or replacement, you must ship the equipment, transportation charges prepaid, with proof of purchase to a Lincoln Authorized
Warranty and Service Center within the warranty period.

This warranty is extended to the original retail purchaser only. This warranty does not apply to equipment damaged from accident,
overload, abuse, misuse, negligence, faulty installation or abrasive or corrosive material, equipment that has been altered, or equipment
repaired by anyone not authorized by Lincoln. This warranty applies only to equipment installed, operated and maintained in strict
accordance with the written specifications and recommendations provided by Lincoln or its authorized field personnel.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, BUT NOT
LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

In no event shall Lincoln be liable for incidental or consequential damages. Lincoln’s liability for any claim for loss or damages arising
out of the sale, resale or use of any Lincoln equipment shall in no event exceed the purchase price. Some jurisdictions do not allow
the exclusion or limitation of incidental or consequential damages, therefore the above limitation or exclusion may not apply to you.

This warranty gives you specific legal rights. You may also have other rights that vary by jurisdiction.

Customers not located in the Western Hemisphere or East Asia: Please contact Lincoln GmbH & Co. KG, Walldorf, Germany, for your
warranty rights.

Lincoln Industrial Contact Information:
To find Lincoln Industrial’s Nearest Service Center call the following numbers, or you may also use our website.
Customer Service 314-679-4200 Website: lincolnindustrial.com

Americas:
One Lincoln Way
St. Louis, MO 63120-1578
USA
Phone [phone]
Fax [phone]

Europe/Africa:
Heinrich-Hertz-Str 2-8
D-69183 Walldorf
Germany
Phone [phone]
Fax [phone]

Asia/Pacific:
25 Int’l Business Park
#01-65 German Centre
Singapore 609916
Phone [phone]
Fax [phone]

© Copyright 2006 www.lincolnindustrial.com Printed in Taiwan

NOVEMBRE - 2006 Formulaire 822947 Section - MV42-1

MANUEL D’UTILISATION

Avez-vous besoin d’un renseignement technique?

Pour toute question ou pour demande de service
technique, veuillez vous adresser à nos techniciens
spécialisés au numéro suivant:

1-314-679-4200 poste 4782
du lundi au vendredi, de 7 h 30 à 16 h 15, heure
normale du Centre des États-Unis

Visitez notre site web: www.mityvac.com pour les
nouveaux produits, les catalogues et les modes
d’emploi de produit.

Avez-vous besoin de pièces de service?

Pour commander des pièces de rechange ou de service,
utilisez notre site web : www.mityvacparts.com
ou téléphonez sans frais au numéro 1-800-992-9898.

SPÉCIFICATIONS

Exigences de vide/pression :

Pression min: 600 kPa (90 psi) (6,2 bar)

Pression max: 830 kPa (120 psi) (8,3 bar)
Filets de vide pour raccord
de conduite d’air: 1/4 po. NPT

LE KIT DE TEST DU SYSTÈME DE

REFROIDISSEMENT ET DE REMPLISSAGE

MV4525

Nombre de pages - 18 Formulaire 822947

Table des matières

Pièces de rechange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Schémas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Applications et essentiel des tests . . . . . . . . . . . . . . . . . . 22-23

Test de pression statique (moteur à l’arrêt) . . . . . . . . . . . . . . 24

Test de température (moteur en marche) . . . . . . . . . . . . 25-26

Test de pression dynamique (moteur en marche) . . . . . . . . . 27

Test dynamique de pression/vide/température

(moteur en marche) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29

Test de pression du bouchon . . . . . . . . . . . . . . . . . . . . . . . . 30

Test de fuite de vide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-32

Remplissage du système/Élimination du bouchon d’air. . . . 33

Garantie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Pièces de rechange

N° de catalogue Description

823032 Coupleur de vanne

823033 Kit de réparation de coupleur de vanne

823034 Sonde de température

823035 Tuyau de rallonge

823036 Pompe de pression

823038 Vide à tube de Venturi

823039 Tuyau de remplissage

823040 Manovacuomètre

823042 Clé d'adaptateur

823043 Bouchon et filin

823044 Agrafe de tuyau

823045 Tuyau de vidange

823046 Adaptateur long

MVA100 Joint torique et rondelle,

823047 MVA101 Joint torique et rondelle,

MVA102 Joint torique et rondelle,
MVA103 Joint torique et rondelle

823050 Mallette moulée sur mesure

Formulaire 822947 Nombre de pages - 19

823033

823032

823035823034

823038823036

823040823039

823044 823045

823046 823047

823050

823042 823043

Nombre de pages - 20 Formulaire 822947

Test de pression statique (moteur à l’arrêt)

Test de pression dynamique (moteur en marche)

Test de température (moteur en marche)

Manovacuomètre

Bouchon de coupleur

Tuyau de rallonge

(optionnel)

Tuyau de

vidange

Coupleur de vanne

Adaptateur de système

à baïonnette

Radiateur

Réservoir de liquide

de refroidissement

Adaptateur de système fileté

Manovacuomètre

Bouchon de coupleur

Tuyau de rallonge

(optionnel)

Tuyau de rallonge

(optionnel)

Pompe de

pression

Coupleur de vanne

Adaptateur de système

à baïonnette

Radiateur

Réservoir de liquide

de refroidissement

Adaptateur de système fileté

Manovacuomètre

Sonde de température

Tuyau de rallonge

(optionnel)

Tuyau de

vidange

Coupleur de vanne

Adaptateur de système

à baïonnette

Radiateur

Réservoir de liquide de

refroidissement

Adaptateur de système fileté

Sonde de

température

Tuyau de

vidange

Coupleur de vanne

Adaptateur de système

à baïonnette

Radiateur

Réservoir de liquide

de refroidissement

Adaptateur de système fileté

Test dynamique de pression/vide/
température (moteur en marche)

Formulaire 822947 Nombre de pages - 21

Test de pression du bouchon Test de fuite de vide

Remplissage du système /
Élimination du bouchon d’air

Manovacuomètre

Bouchon de coupleur

Tuyau de rallonge

(optionnel)

Tuyau de

rallonge

(optionnel)

Tuyau de

remplissage

Coupleur de vanne

Adaptateur de système

à baïonnette

Radiateur

Réservoir de liquide

de refroidissement

Adaptateur de système fileté

Manovacuomètre

Vide à tube

de Venturi

Bouchon de coupleur

Tuyau de rallonge

(optionnel)

Tuyau de

rallonge

(optionnel)

Coupleur de vanne

Adaptateur de système

à baïonnette

Radiateur

Réservoir de liquide

de refroidissement

Adaptateur de
système fileté

Manovacuomètre

Pompe de

pression

Bouchon de coupleur

Tuyau de rallonge

(optionnel)

Tuyau de rallonge

(optionnel)

Coupleur de vanne

Adaptateur de bouchon

à baïonnette

Bouchon à baïonnette

Bouchon fileté

Adaptateur de bouchon fileté

Vide à tube de Venturi