1. Caution: Heavy object. Consider mechanical aid or at least a two-person team lift when lifting machine.
2. Make sure this service is performed in a well-ventilated area.
3. Keep all hoses and tools away from moving engine parts.
4. Check all lines, hoses and points of connection for cracks and leaks before and after service.
5. This machine incorporates parts such as snap switches and receptacles that may produce arcs or sparks. Keep it in a designated room or enclosure for machines of this nature, or keep it 18 inches (46 cm) or more above the floor.
6. WARNING! Use EXTREME CAUTION when removing radiator cap to prevent being burned by hot fluid escaping the cooling system. Use EXTREME CAUTION when handling hoses and adaptors as they can reach the same temperature as coolant.
7. WARNING! Fluid ejection hazard. Do not run machine unless properly connected to a cooling system.
8. Ensure that the BG CT2 S1 pump switch is in the “Off” (O) position before connecting to a power source.
9. Dispose of cooling system fluids and filters in accordance with federal, state, and local regulations.
10. The BG CT2 Coolant Transfusion System is designed for use with BG products described in these instructions only. The use of any other chemicals or fluids with this system will void all warranties and could create hazardous conditions. DO NOT use the BG CT2 to pump or transfer any flammable or combustible liquids.
11. Caution: Operator can lose control of the machine while moving on uneven or inclined surfaces, risking the machine tipping over and causing injury to personnel or damage to property.

Preparing for Service

1. Place the two 6-gallon containers inside the BG CT2. Insert the hoses hanging down inside the machine into the corresponding container: left hose (used coolant) in the left container and the right hose (new coolant) in the right container.
2. Attach the suction wand to the end of the pump hose (P).
3. Roll BG CT2 to the new (or recycled) 50/50 coolant supply. Be sure S1 pump switch is set to “Off” (O).
4. Connect the power cables to a 12-volt battery or other 12-volt power source.
5. Insert the suction wand into the new coolant supply.
6. Turn V1 control valve to “N”.
7. Turn S1 pump switch to “Remove” (–). This will fill the BG CT2 new coolant (N) container.
8. Turn S1 pump switch to “Off” (O).

1. Attach the suction wand to the pump hose (P) and place the wand securely into a used coolant receptacle.
2. Turn V1 control valve to “U.”
3. Turn S1 pump switch to “Add” (+) until BG CT2 used coolant (U) container is empty.
4. Turn S1 pump switch to “Off” (O).

BG Upper Radiator Hose Adaptor Set
PN E100-4455
Installation

1. Radiator
2. Upper radiator hose
3. Radiator adaptor with hose
4. CT700 Bypass Adaptor
5. Ball valve on CT700
6. BG CT2 Used Fluid Hose (H1)
7. BG CT2 New Fluid Hose (H2)
8. Loose clamp
9. Quick connect
10. Adaptor for radiator base

1. Remove radiator cap and insert the suction wand end of the pump hose (P) as deep into the radiator as possible.
2. Turn V1 control valve to “U.”
3. Turn S1 pump switch to “Remove” (–). Remove enough used coolant to allow for a dry removal of the upper radiator hose, then turn S1 pump switch to “Off” (O).
4. Move the suction wand to the radiator overflow tank.
5. Turn S1 pump switch to “Remove” (–) to remove all the used coolant from the tank.
6. Turn S1 pump switch to “Off” (O).
7. Clamp off the upper radiator hose about 4–6 inches (10–15 cm) from the end that connects to the radiator. Remove the upper radiator hose from the radiator.
8. Determine the correct size adaptor and matching short hose/adaptor assembly needed for the upper radiator hose. Screw the adaptors into the CT700 Bypass Adaptor—it makes no difference which adaptor goes into which end. Put the loose clamp into place on the hose—do not tighten.
9. Install the Upper Radiator Hose Adaptor between the radiator and upper radiator hose and tighten all clamps. Be sure the ball valve on the connector hose is in the open position (handle parallel to the hose).

BG Cooling System Service
PROCEDURE

1. Install 12 oz. (354 mL) of BG Universal Cooling System Cleaner, PN 540, into the mouth of the radiator.
2. Insert the suction wand into the radiator.
3. Turn V1 control valve to the halfway position between “N” and “U”.
4. Turn S1 pump switch to “Add” (+).
5. Turn V1 control valve slowly to “U” to avoid splashing the coolant. Fill the radiator.
6. Turn S1 pump switch to “Off” (O). Remove suction wand from the radiator.
7. Replace the radiator cap securely.
8. Start the engine and run at idle for 10–15 minutes to circulate the BG Universal Cooling System Cleaner.
9. Stop engine and remove the suction wand from the end of the pump hose (P).

Coolant Transfusion: Engine Off

1. Attach the pump hose (P) to the engine side of the CT700.
2. Attach the return hose (R) to the radiator side of the CT700.
3. Close the ball valve on the CT700.
4. Turn V1 control valve to the halfway position between “N” and “U”.
5. Turn S1 pump switch to “Add” (+).
6. Slowly turn the V1 control valve to “N” until used fluid starts to flow out of the return hose (R). Once flow is established, leave the V1 control valve in that position.

1. Attach the pump hose (P) to the radiator side of the CT700.
2. Attach the return hose (R) to the engine side of the CT700.
3. Close the ball valve on the CT700.
4. Pinch off the small tube that connects the radiator fill neck to the recovery tank. (Failure to pinch off this hose may allow the cap to vent coolant under pressure to the recovery tank causing it to fill and overflow.)
5. Turn V1 control valve to the halfway position between “N” and “U”.
6. Turn S1 pump switch to “Add” (+).
7. Slowly turn the V1 control valve to “N” until used fluid starts to flow out of the return hose (R). Once flow is established, leave the V1 control valve in that position.

NOTE: If attempting to do service and the pump stops or flutters (turns off and on repeatedly),* check for flow through the service hoses. If there is flow, the service will proceed without a problem. The fluttering can be stopped by moving the control valve towards the center position (do not completely shut off flow). If there is no flow, check quick coupler connections and verify thermostat location for proper flow direction.

^*The BG CT2 contains a pressure switch that is set to prevent over-pressurizing of the cooling system. Motor will start again when pressure is released.

If flow cannot be achieved with the engine off, the service can be performed with the engine running.

Removing the Upper Radiator Hose Adaptor

1. When transfusion is complete, turn S1 pump switch to “Off” (O).
2. Turn vehicle engine off.
3. Open the ball valve on the CT700 Bypass Adaptor to release any trapped pressure from the engine.
4. Important! Allow the engine to cool before removing the radiator cap! Remove radiator cap.
5. Disconnect both service hoses (P and R) from the CT700 Bypass Adaptor.
6. Attach the suction wand to the pump hose (P) and insert the suction wand deep into the radiator.
7. Turn V1 control valve to “N”.
8. Turn S1 pump switch to “Remove” (–). This will transfer the new coolant in the upper radiator into the BG CT2 new coolant (N) container.
9. Turn S1 pump switch to “Off” (O). Remove suction wand from the radiator.
10. Remove the CT700 and reconnect the upper radiator hose securely.
11. Add BG Universal Super Cool®, PN 546, to radiator.
12. Place the suction wand back into the radiator.
13. Turn V1 control valve half way between “N” and “U”.
14. Turn S1 pump switch to “Add” (+).
15. Turn V1 control valve slowly to “N” to avoid splashing the coolant. Refill radiator with new coolant.
16. Turn S1 pump switch to “Off” (O). Remove suction wand from the radiator.
17. Replace radiator cap securely.
18. Move suction wand to overflow tank and fill to the normal level with new coolant.

BG Cooling System Service
Using BG Expansion Tank Cooling System Hose Set
PN E101-1244

1. Carefully remove the expansion tank cap and add BG Universal Cooling System Cleaner, PN 540.
2. Replace the expansion tank cap, start the engine, and allow the vehicle to run for 15 minutes.
3. Attach the suction wand to the pump hose (P).
4. Turn V1 control valve to “U”.
5. Turn off the engine.
   Important! Allow the engine to cool before removing the expansion tank cap!
6. Remove the expansion tank cap and insert the Suction Wand as deep into the expansion tank as possible.
7. Turn S1 pump switch to “Remove” (–), lower the coolant level in the expansion tank below the level of the hose coming off the side of the tank.
8. Replace the expansion tank cap and remove the hose coming off the side of the expansion tank.
9. Connect the appropriate size BG hose to the tank. Secure with supplied worm gear hose clamp.
10. Connect the appropriate size BG barbed adaptor to the vehicle hose. Secure with supplied worm gear hose clamp.
11. Connect the pump hose (P) and return hose (R) to the BG adaptors.
12. Turn V1 control valve to the halfway position between “N” and “U”.
13. Turn S1 pump switch to “Add” (+).
14. Slowly turn the V1 control valve to “N” until used fluid starts to flow out of the return hose (R). Once flow is established, leave the V1 control valve in that position.
    
    NOTE: If attempting to do service and the pump stops or flutters (turns off and on repeatedly),* check for flow through the service hoses. If there is flow, the service will proceed without a problem. The fluttering can be stopped by moving the control valve towards the center position (do not completely shut off flow). If there is no flow, check quick coupler connections and verify thermostat location for proper flow direction.

    If the vehicle has more than one hose off the side of the tank, use Pinch Pliers to pinch off the other hose during service.

15. When transfusion is complete, turn S1 pump switch to “Off” (O).
16. Carefully remove the expansion tank cap to relieve cooling system pressure.
17. Lower the coolant level in the expansion tank below the level of the hose coming off the side of the tank.
18. Remove BG adaptors, reinstall the hose onto the side of the expansion tank and clamp it securely.
19. Add BG Universal Super Cool®, PN 546, to the tank and top off the system with new coolant.
20. Replace the expansion tank cap, start the vehicle, and check for system leaks.