Page Number - 4
Form 801680
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 MV4510
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 cold
or hot fluid that is under pressure and just waiting
to be expelled. If you are testing an engine that is
hot and/or pressurized, always stop to think before
pressing the relief lever, removing a cap, or discon-
necting a hose or other component.
• Always read carefully and understand
instructions prior to using this equipment.
• Always wear eye protection when removing
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 attempt-
ing to perform any cooling system related test
procedure.
applications & Basics of testing
The MV4510 Cooling System Test Kit is designed
to diagnose and pinpoint the presence of cooling
system leaks. It contains equipment to manually
pressurize and monitor the pressure in a cooling
system. Leaks are indicated by a drop in pressure
over a few seconds or minutes. The location of an
external leak(s) is pinpointed by the visible seep-
age of fluid resulting from the pressure. Internal
leaks, which may not be visible, typically indicate
a blown head gasket or damaged block or head,
and can be diagnosed by monitoring the pressure
during a quick “engine on” test.
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. If the radiator is
closed and inaccessible, then the connection will
be made through a coolant bottle.
The MV4510 can also be used to test cooling
system pressure caps, which utilize a relief valve
for protection against over-pressurization. A
malfunctioning cap can cause over- or under-
pressurization of the cooling system, leading to
overheating and/or severe engine damage.
Cooling system caps are marked with the rated
pressure of the cooling systems for which they
are designed to be used. Chart A on page 5
indicates the range of pressure the cap must
maintain in the system based on its rated pres-
sure. The cap must not leak below the low limit
of the range, and must not open below the high
limit of the range.
On the face of the pressure gauge, colored ar-
rows are used to indicate the pressure rating of
the cooling system, while colored bands indicate
the range of the corresponding cap.
When testing a used cap, consider that the seal
may have retained an impression left by the
seat of the filler neck. Remove, re-assemble and
retest the cap several times if necessary before
rejecting the cap for a leak. When testing a
new cap, consider that the seal is new and has
never been softened by heat. Some breaking-in
of the seal may be necessary to prevent it from
leaking.
adapters
The MV4510 includes a cooling system test
adapter that fits the radiators and coolant bottles
on the vast majority of motorcycles and other
sport, recreation and utility vehicles. The adapter
is required to connect the test equipment to the
vehicle being tested. This adapter can be used to
perform all of the cooling system tests outlined in
this manual.
The MV4510 also contains an adapter for testing
the function of radiator or coolant bottle caps.
