0323444 JOHNSON GASKET, Manifold

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Introduction
Use following procedures to check the cooling system.Required Tools
Table 1
Required Tools
Item Qty Part Number Part Name
T1 1 9S-8140 Pressurizing Pump
T1a 1 2P-2329 Adapter As
T1b 1 2P-2331 Release Valve
T1c 1 3R-3810 Hose As
T2 N/A Pressure Gp(1)
T2a 1 4C-7090 Valve
T2b 1 4C-7121 Nipple
T2c 1 4C-7158 Fitting
T2d 1 4C-8852 Regulator
T2e 1 4M-5317 Reducer Bushing
(1) Tooling (T5) consist of individual piece parts (T5a) through (T5e).Testing the Filler Cap
Illustration 1 g01084180
(1) Expansion tank
(2) Filler caps
Illustration 2 g06441451
Tooling T1 Pressurizing Pump
(T1a) Release valve
(T1b) Adapter assembly
(T1c) HoseTest Preparation
After the engine cools, carefully loosen the cap assembly to release the pressure from the cooling system. Remove the cap assembly.
Carefully inspect the cap assembly. Look for any damage to the seals and to the sealing surface.Remove any deposits that are found.If the cap assembly is damaged, obtain a new cap assembly.
Install the cap assembly on Tooling (T1) by using the Tooling (T1b).The opening pressure for the cap assembly's pressure relief valve is stamped on the cap assembly.Test Procedure
Apply pressure to the cap assembly.
Compare the gauge reading with the opening pressure that is listed on the cap assembly.If the cap assembly cannot sustain the correct pressure, obtain a new cap assembly.If the cap assembly's pressure relief valve does not open within approximately 7 kPa (1 psi) of the pressure that is stamped on the cap assembly, obtain a new cap assembly.Testing the Radiator and Cooling System for Leaks
Pressure Pump
Illustration 3 g06441451
Tooling T1 Pressurizing Pump
(T1a) Release valve
(T1b) Adapter assembly
(T1c) HoseTest Preparation
After the engine cools, carefully loosen the filler cap to release the pressure from the cooling system. Remove the filler cap.
Ensure that there is enough of coolant in the expansion tank.
Install Tooling (T1) onto the radiator filler tube.Test Procedure
Increase the pressure reading on the gauge to 20 kPa (3 psi) more than the pressure on the filler cap.
Inspect the radiator, all connection points, and the hoses for leaks.If no leaks are found and the gauge reading remains steady for a minimum of 5 minutes, the cooling system is not leaking.If leaking is observed and/or the gauge reading decreases, make repairs, as needed.Shop Air
Test Preparation
After the engine cools, carefully loosen the filler cap to release the pressure from the cooling system. Remove the filler cap.
Ensure that there is enough of coolant in the expansion tank.
Assembly Tooling (T2) using valve (T2a), nipple (T2b), fitting (T2c), regulator (T2d), and reducer bushing (T2e).
Attach hose (T1c) to reducer bushing (T2e).
Install adapter (T1a) onto the radiator filler tube.Test Procedure
Increase the pressure reading on the gauge to 20 kPa (3 psi) more than the pressure on the filler cap.
Shut off valve (T2a).
Inspect the radiator, all connection points, and the hoses for leaks.If no leaks are found and the gauge reading remains steady for a minimum of 5 min