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Cooling System
Do not perform this maintenance until you read and understand the material in the Safety and Cooling System Specifications sections of this publication.This procedure is to be used for normal maintenance of cooling system surfaces to return to "like new" condition. For heavy build-up of scale and deposits, a severe acid-type commercial cleaner or mechanical cleaning will be required.
Refer to the Cooling System Specifications for additional information regarding appropriate Flush/Fill for your application.Clean/Flush Coolant
If changing thermostats prior to this interval, go to step 5, Replace Thermostat, Gaskets and Seal.1. Stop the engine and allow to cool. Loosen the radiator filler cap slowly to relieve any pressure and remove the cap.2. Remove the cooling system drain plug(s) or open the drain valve and allow the coolant to drain. Open the cab heater valve to flush coolant from the cab heater. 3. Remove the drain plug (1) on bottom of water pump housing and/or radiator. Remove the cylinder head drain plug from the engine. Allow coolant to drain.Water Pump Seal
Over concentration of coolant additive (Conditioner), mineral deposits from hard water or cooling system contamination can accelerate the wear on the water pump coolant seal. The cooling system maintenance interval provides an opportunity to inspect and replace the water pump seal if necessary to reduce coolant leakage.Dispose of used engine coolant 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.Contact Caterpillar Service Technology Group:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Refer to Service Magazine article dated November 13, 1989 and/or Engine News article dated November 1989 for information regarding disposal and recycling of used coolant.4. Clean and install all drain plugs and/or close drain valve. All tools shown or mentioned in the following Disassembly and Assembly procedure are available at any Caterpillar dealer.Replace Thermostat, Gaskets and Seal
If replacing thermostats ONLY, drain the coolant from the cooling system to a level below the thermostat housing. 5. Loosen the hose clamps and remove the radiator hose from the thermostat housing.6. Remove the thermostat and gasket from the thermostat housing. The thermostats can be reused if they are tested and meet the test specifications below and are not damaged or have excessive buildup of deposits. Thermostats should begin to open and be fully open as indicated in the following chart. Install Thermostat
Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a thermostat installed.
Inspect gaskets before assembly and replace if worn or damaged. 7. Install a new thermostat in the thermostat housing. 8. Install a new gasket and the water outlet pipe on the thermostat housing.9. Install the radiator hose and tighten the hose clamps.
Use of commercially available cooling system cleaners may cause damage to aluminum cooling system components. Use only cooling system cleaners that are approved for engines that have aluminum cooling system and engine components.DO NOT use a cooling system cleaner that contains tri-sodium phosphate; it will damage the aluminum components in the engine.
10. Refill the cooling system with clean water mixed with a 6 to 10 percent concentration of Caterpillar Cooling System Cleaner. Install radiator filler cap. A 9-12 gallon (33-47 L) cooling system capacity requires one gallon (3.8 L) of Caterpillar Cooling System Cleaner to accommodate the 6-10 percent concentration.Caterpillar Cooling System Cleaner is available through your Caterpillar dealer.11. Start and run the engine to circulate fluid in the cooling system for 90 minutes. Stop the engine, remove radiator filler cap and cooling system drain plugs.12. Drain the cleaning solution. Flush the cooling system with clean water until draining water is clear. Clean and install all drain plugs and/or close the drain valve.
Fill the cooling system with the coolant solution at 5 U.S. gal (20 L) per minute or less to avoid air locks.
See Refill Capacities chart in this publication for the capacity of your engine's system.13. Add coolant to the system to bring it to the proper level by mixing a solution of acceptable water, Caterpillar Antifreeze (which contains coolant additive) or equivalent. If NOT using Caterpillar Antifreeze, add supplemental coolant additive, or if equipped with a coolant additive element, install the appropriate element.When NOT using Caterpillar Antifreeze, add 1 U.S. quart (1 L) of Caterpillar Coolant Additive (Conditioner) for every 8 U.S. gal (30 L) of cooling system capacity OR change maintenance element only (if equipped).Refer to the Cooling System Specifications in this publication for all information regarding acceptable water, antifreeze and supplemental coolant additive requirements or contact your Caterpillar dealer for assistance.14. Start and run the engine with the filler cap removed. Allow the coolant to warm, the thermostat to open and the coolant level to stabilize.15. Add coolant mixture if necessary to bring the coolant to within 1/2inch (13 mm) below the bottom of the fill tube or the correct level on the sight glass, if equipped.
In cold weather, frequently check the specific gravity of the coolant solution to ensure adequate protection.If the engine is to be stored in, or shipped to an area with freezing temperatures, the cooling system must be either protected to the lowest expected outside temperature or drained completely to prevent damage.Always check your cooling system before operating your engine.
16. Check the condition of the filler cap gasket. If the gasket is damaged, discard the old filler cap and install a new filler cap. If the gasket is not damaged, use a 9S8140 Service Tool (available from your Caterpillar dealer) to pressure test the filler cap. The correct filler cap pressure is stamped on the face of the filler cap. If the filler cap does not hold the correct pressure, install a new filler cap.17. Start the engine and inspect for coolant leaks and proper operating temperature. Check for coolant leaks at the oil cooler connections.18. Stop the engine.Air-to-Air Aftercooler
* Check the front of the air-to-air aftercooler on a daily basis for insects, dirt and other debris.* Clean the front of the aftercooler with a