0395894 JOHNSON EXTENSION, Gearcase

Drain the Cooling System
Stop the engine and allow the engine to cool. Ensure that the engine will not start when the cooling system is drained.
Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.
Illustration 1 g00130652
Location of the cooling system drain valves or drain plugs on the water pumps (1) Jacket water pump (2) Aftercooler and oil cooler pump
Illustration 2 g00475784
Location of the drain plug (jacket water) for 3606 and 3608 Engines
Illustration 3 g00475850
Location of the drain plugs (jacket water) for 3612 and 3616 Engines
Open the cooling system drain valves (if equipped). Remove the cooling system drain plugs. Allow the coolant to drain.
Dispose of used engine coolant properly or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant.
For information regarding the disposal and the recycling of used coolant, consult your Cat dealer or consult Cat Dealer Service Tools Group:Outside U.S.A.: (309) 675-6277Inside U.S.A.: 1-800-542-TOOLInside Illinois: 1-800-541-TOOLCanada: 1-800-523-TOOLCSTG COSA Geneva, Switzerland: 41-22-849 40 56Clean the Cooling System
After the cooling system has been drained, flush the cooling system with clean water in order to remove any debris.
Close the cooling system drain valves (if equipped). Clean the drain plugs and install the drain plugs.
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
Fill the cooling system with clean water. Install the cooling system filler cap. Install the vent plug (4). Operate the engine until the temperature reaches 49 °C (120 °F) to 66 °C (150 °F).
Stop the engine and allow the engine to cool. Ensure that the engine will not start when the cooling system is drained. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.
Open the cooling system drain valves (if equipped). Remove the drain plugs. See Illustration 1. Allow the coolant to drain. Flush the cooling system with clean water. Close the cooling system drain valves (if equipped). Install the drain plugs.
Repeat Steps 3, 4, and 5.Fill the Cooling System
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
Illustration 4 g00546449
Fill the cooling system with Extended Life Coolant (ELC). The water lines for the turbochargers must be vented when the cooling system is filled. Remove plug (1). Press a small screwdriver into the check valve in order to vent the line.After filling the cooling system, do not install the cooling system filler cap.
Start the engine. Operate the engine in order to purge the air from the cavities of the engine block. Allow the ELC to warm and allow the coolant level to stabilize. Stop the engine.
Check the coolant level. Maintain the coolant to the proper level on the sight gauge (if equipped). If a sight gauge is not equipped, maintain the coolant within 13 mm (.5 inch) below the bottom of the filler pipe.
Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets of the cooling system filler cap are damaged, discard the old filler cap and install a filler cap. If the gaskets of the cooling system filler cap are not damaged, use a 9S-8140 Pressurizing Pump to pressure test the filler cap. The correct pressure is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not maintain the correct pressure, install a new filler cap.
Start the engine. Inspect the cooling system for leaks and for proper operating temperature.