Flushing and Refilling Cooling System

TS281-UN-15APR13

High-Pressure Fluids

RG12833-UN-13FEB03

Radiator Cap

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

NOTE: When John Deere COOL-GARD is used, the drain interval is 3000 hours or 36 months. The drain interval may be extended to 5000 hours or 60 months of operation, provided that the coolant is tested annually AND additives are replenished, as needed, by adding a supplemental coolant additive (SCA).

If COOL-GARD is not used, the flushing interval is 2000 hours or 24 months of operation.

Drain old coolant, flush the entire cooling system, test thermostats, and fill with recommended clean coolant per the following procedure.

1. Pressure test entire cooling system and pressure cap if not previously done. (See PRESSURE TESTING COOLING SYSTEM, in the Lubrication and Maintenance 250 Hour (Jet Fuel Capable Engine) /500 Hour/12 Month Section.)

2. Slowly open the engine cooling system filler cap or radiator cap (A) to relieve pressure and allow coolant to drain faster.

3. NOTE: Oil cooler housing coolant drain plug (A) is normally preferred, as it is the lowest drain location. Engine block drain plug (B), located behind the fuel rail, is not easily accessible. Block heater ports (C) are another option for draining. These engines use several different oil filter adapters. Use either drain plug (A) or (B), or block heater ports (C), to drain coolant, whichever is more accessible for the oil filter adapter on your engine.

   
   RG13734-UN-18NOV04

   Oil Cooler Housing Coolant Drain Plug

   
   RG13800-UN-18NOV04

   Engine Block Coolant Drain Plug

   
   RG13801-UN-18NOV04

   Block Heater Ports

   A - Oil Cooler Housing Coolant Drain Plug

   B - Engine Block Drain Plug

   C - Block Heater Ports

   Open oil cooler housing coolant drain plug (A), engine block drain plug (B), or block heater ports (C). Drain all coolant from engine block.

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4. Open radiator drain valve. Drain all coolant from radiator.

5. Remove thermostats at this time, if not previously done. Install cover (without thermostats and seals) and tighten cap screws to specifications.

   Item	Measurement	Specification
   Thermostat Cover Cap Screw	Torque	66—80 N·m (49—59 lb-ft)

6. Test thermostat opening temperature. (See Inspecting Thermostats And Testing Opening Temperature in Service As Required Section.)

7. Close all drain valves after coolant has drained.

8. CAUTION: Do not run engine longer than 10 minutes. Doing so may cause engine to overheat which may cause burns when radiator water is draining.

   Fill the cooling system with clean water. Run the engine about 10 minutes to stir up possible rust or sediment.

9. Stop engine, pull off lower radiator hose and remove radiator cap. Immediately drain the water from system before rust and sediment settle.

10. After draining water, close drain valves. Reinstall radiator cap and radiator hose and clamp. Fill the cooling system with clean water and a heavy duty cooling system cleaner such as Fleetguard® RESTORE™ and RESTORE PLUS™. Follow manufacturer's directions on label.

11. After cleaning the cooling system, drain cleaner and fill with water to flush the system. Run the engine about 10 minutes, remove radiator cap and pull off lower radiator hose to drain out flushing water.

12. Close all drain valves on engine and radiator. Reinstall radiator hose and tighten clamps securely. Install thermostats using a new gasket. (See TESTING THERMOSTATS OPENING TEMPERATURE later in this section.)

    IMPORTANT: Air must be expelled from cooling system when system is refilled. Loosen plug on top of thermostat housing to allow air to escape when filling system. Retighten plug when all the air has been expelled. Cooling system must be free of air when operating engine or damage to EGR cooler may result..

13. Add coolant to radiator or surge tank (See specification for capacity, which can vary with application). Coolant level should be at bottom of surge tank filler neck or radiator filler neck. If equipped with a translucent surge tank, coolant level should be at cool fill line indicator on surge tank. Install radiator cap.

    Item	Measurement	Specification
    4.5 L Engine	Coolant Capacity	8.5 L (9 qt)
    6.8 L Engine	Coolant Capacity	11.8 L (12.5 qt)

14. Run engine until it reaches operating temperature. This mixes the solution uniformly and circulates it through the entire system. The normal engine coolant temperature range is 82°—94°C (180°—202°F).

15. After running engine, check coolant level and entire cooling system for leaks.

16. Inspect the fan belt for wear and check belt tension. (See Checking Belt Tensioner Spring Tension and Belt Wear in Lubrication and Maintenance 250 Hour (Jet Fuel Engine) or 500 Hour/12 Month section.