3A3-72537-0 Tohatsu LEAD WIRE, METER

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.
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, NENG2500, "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.
Illustration 1 g00654902
Location of the cooling system drain valves on the water pumps
(1) Jacket water pump
(2) Aftercooler and oil cooler pump
Illustration 2 g00654910
Location of the drain plug (jacket water)
Open the cooling system drain valves. Remove the cooling system drain plug. 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 Caterpillar dealer or consult Caterpillar Service Technology Group:Outside U.S.A. (309) 675-6277
Inside U.S.A. 1-800-542-TOOL
Inside Illinois 1-800-541-TOOL
Canada 1-800-523-TOOL
CSTG COSA Geneva, Switzerland 41-22-849 40 56
Clean 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. Clean the drain plug and install the drain plug.
Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks.
Illustration 3 g00748213
(1) Plug
Fill the cooling system with clean water. Install the cooling system filler cap. Operate the engine until the temperature reaches 49 °C (120 °F) to 66 °C (150 °F). 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 air from the line.
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. Remove the drain plug. Allow the coolant to drain. Flush the cooling system with clean water. Close the cooling system drain valves. Install the drain plug.
Repeat Steps 3, 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 g00748213
(1) Plug
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 air from 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 cooling system filler cap and install a new cooling system filler cap. If the gaskets of the cooling system filler cap are not damaged, use a 9S-8140 Pressurizing Pump in order to pressure test the cooling system 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 cooling system filler cap.
Start the engine. Inspect the cooling system for leaks and for proper operating temperature.