REHS-8728

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SB-10054556-1435
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Special Instruction
CT11, CT13, and CT15 Cooling System Flush After Oil Cooler Failure{7000}
Media Number -REHS8728-00
Publication Date -27/09/2013
Date Updated -27/09/2013
i05453871
CT11, CT13, and CT15 Cooling System Flush After Oil Cooler
Failure{7000}
SMCS - 7000
On Highway Truck:
CT660 (S/N: TGA1-UP; TGD1-UP; TJD1-UP; TEJ1-UP; TRK1-UP; TKL1-UP; TEM1UP; TEP1-UP; TGR1-UP; TGS1-UP; TJS1-UP; TGT1-UP; TGW1-UP; TSW1-UP; TEY1
-UP; TSY1-UP; TEZ1-UP; TGZ1-UP)
Introduction
In the event of an oil cooler failure, engine oil may have entered the cooling system and mixed with
the engine coolant. This special instruction contains the procedure for flushing and cleaning the
contaminated cooling system.
Safety
Do not operate or work on this machine unless you have read and
understand the instructions and warnings in the Operation and
Maintenance Manuals. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact any Caterpillar dealer
for replacement manuals. Proper care is your responsibility.
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For machines equipped with quick coupler, improper attachment of
work tools could result in injury or death.
Do not operate this machine until you have positive indication that the
coupler pins are fully engaged. Follow recommended procedure in
Operation and Maintenance Manual.
Securely fasten radio (if equipped) and all loose items such as lunch
boxes or tools. Failure to do so could allow items to shift position during
rough machine operation or tip over and result in injury. Refer to the
Operation and Maintenance Manual for specific fastening and latching
requirements.
Sudden movement or accidental starting of the machine can cause
personal injury or death to persons on or near the machine.
To prevent personal injury or death, perform the following:
Park the machine on a smooth level surface.
Lower the blade and or attachments to the ground.
Stop the engine and engage the parking brake.
Block the wheels and install the steering frame lock.
Turn the battery disconnect switch to the OFF position and remove the
key.
Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the
battery disconnect switch location to inform personnel that the machine
is being worked on.
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact skin.
At operating temperature, the engine coolant is hot and under pressure.
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Steam can cause personal injury.
Check the coolant level only after the engine has been stopped and the
cooling system pressure cap is cool enough to touch with your bare
hand.
Remove the cooling system pressure cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid contact with the skin
and eyes to prevent personal injury.
Personal injury can result from improper handling of chemicals.
Make sure you use all the necessary protective equipment required to
do the job.
Make sure that you read and understand all directions and hazards
described on the labels and material safety data sheet of any product
used to clean the components.
Observe all safety precautions recommended by the chemical
manufacturer for handling, storage, and disposal of cleaning agents.
To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin and
nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
Engine Fluids (Oil, Fuel and Coolant) are a threat to the environment. Properly recycle or
dispose of engine fluids according to local regulations. Never put engine fluids in the trash, on
the ground, in sewers or bodies of water.
Wear gloves and other protective gear while working with hot engine fluids. Use caution when
draining hot engine fluids and avoid direct skin contact.
Required Parts
• 3.8 L (1 US gal) 269-1948 Soap (Non-Foaming)
• 3.8 L (1 US gal) 4C-4611 Cooling System Cleaner
• 238-8648 Extended Life Coolant
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Service Procedure
1. Remove the lower hose on the plastic surge tank. Drain all coolant and contaminants into the
pan.
Illustration 1
g03445916
Lower radiator hose drain valve
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Illustration 2
g03445918
Lower "Low Temperature Radiator" (LTR) drain valve
2. Drain the rest of the cooling system at the lower radiator hose drain valve and the lower "Low
Temperature Radiator" (LTR) drain valve. Refer to Illustrations 1 and 2.
Note: If the fluid is too thick to drain out of the drain valve, then remove the lower radiator
hose (if necessary).
3. Remove the surge tank. Clean the tank with detergent and hot water to remove the oil
contaminants. Continue until clean.
4. Reinstall surge tank and hoses temporarily during coolant flush.
5. Open all heater valves.
6. Close all drain valves. Refill the cooling system with 3.8 L (1.0 US gal) of 269-1948 Soap (Non
-Foaming), and the remaining amount with tap water.
7. Unplug the Coolant Control and Mixing valve. (Unplugging will cause the valves to default to
open, allowing proper cleaning of the Low Temperature Coolant circuit.)
8. Run the engine at operating temperature for 20 minutes at 1200 rpm, then drain the system.
9. Repeat Steps 5 and 6 until all contaminants are removed from the cooling system.
10. Fill the cooling system with an appropriate mixture of water and 4C-4611 Cooling System
Cleaner . Follow label instructions.
11. Run the engine at operating temperature for 20 minutes at 1200 rpm.
12. Drain the cooling system as described in Step 2.
13. Refill with water and run the engine for 5 minutes at 1200 rpm.
14. Drain the water.
15. Reconnect the Coolant Control and Mixing valve
16. Refer to Special Instruction, REHS5462, "Coolant Management Tool for the CT660 On
Highway Truck". Fill the system with 238-8648 Extended Life Coolant 50/50 premix.
Copyright 1993 - 2013 Caterpillar Inc.
Wed Oct 2 17:47:20 CDT 2013
All Rights Reserved.
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