1. Make sure this service is performed in a well-ventilated area.
2. Keep all hoses and tools away from moving engine parts.
3. Check all lines, hoses, adaptors and points of connection for cracks and leaks before and after service.
4. WARNING! Use EXTREME CAUTION when removing radiator cap to prevent being burned by hot fluid escaping from the cooling system. Use EXTREME CAUTION when handling hoses and connectors on BG CT4 unit as they can reach the same temperature as coolant.
5. Dispose of cooling system fluids and filters in accordance with federal, state and local regulations.

Filling BG CT4 New Coolant (N) Container

1. Remove cap from BG CT4 new coolant (N) container.
2. Insert pressurized fluid supply dispenser into BG CT4 new coolant (N) container and fill.
3. When filling is complete, replace cap on BG CT4 new coolant (N) container.

1. Move the used coolant drain hose (not the clear drawer drain hose) from the BG CT4 used coolant (U) container to the new coolant (N) container.
2. Attach suction wand to service hose and insert into container of 50/50 coolant.
3. Turn V1 control valve to “Remove” (–). This will fill the BG CT4 new coolant (N) container.
4. Turn S1 pump switch to “On” (I).
5. When filling is complete, turn S1 pump switch to “Off” (O).
6. Return BG CT4 used coolant drain hose to used coolant (U) container.

BG Cooling System Service
Install Cleaner

1. Add 12 oz. (354 mL) of BG Universal Cooling System Cleaner, PN 540, to cooling system.
2. Start engine and bring to normal operating temperature. Keep engine at normal operating temperature for 10–30 minutes with heater controls at their highest position.

Drain Unpressurized Recovery Tank

1. Turn S1 and S2 pump switches to “Off” (O).
2. Turn V1 control valve to “Remove” (–).
3. Attach air supply to BG CT4.
4. Attach suction wand to service hose and open the ball valve on the wand.
5. Insert suction wand into recovery tank.
6. Turn S1 pump switch to “On” (I) to begin extracting used coolant.
7. Turn S1 pump switch to “Off” (O) when finished.
8. Remove the suction wand from the recovery tank.

Extract Used Coolant

CAUTION! To prevent being burned by hot fluid escaping from the cooling system, allow engine to cool before removing radiator cap!

1. Shut off engine and very carefully remove the cap from the radiator or from the remote tank.
2. Seat adjustable vacuum plug into the fill neck. Be sure nylon tube reaches as deep into the radiator or remote tank as possible. The nylon tubing must be in the coolant to work properly. If vacuum plug seals above the recovery tank port in the neck, pinch off the tube connecting port to tank.
3. Turn V1 control valve to “Remove” (–).
4. Start engine and turn S1 pump switch to “On” (I).
5. When radiator hoses collapse, use pinch off pliers to completely close the radiator hose opposite the thermostat hose. If the coolant extraction starts to slow, you should notice a burst of used coolant immediately after pinching off the hose.
   
   NOTE: To aid in the removal of fluid, it sometimes helps to break the vacuum connection at the vacuum plug, allowing air to enter the system and then immediately reseat the plug and let the vacuum pull down again. This will work only once per service. Do not allow engine to run longer than 3 (three) minutes once hoses have collapsed!

Helpful Hints for Extracting Coolant

BG Cooling System Service
Refill with New Coolant

1. When there is no more flow out of the cooling system, remove pinch off pliers from the radiator hose.
2. Leave the engine running and turn the V1 control valve to “Return” .
3. Turn S1 pump switch to “Off” (O). New 50/50 coolant will flow into the cooling system, filling the vacuum without leaving any air pockets.
4. When radiator hoses have inflated, the installation of new 50/50 coolant should be complete.
5. Remove vacuum plug from radiator or recovery tank and check coolant level.
6. Install BG Universal Super Cool,® PN 546, in cooling system.
7. Top off coolant as necessary.

Top Off Radiator or Fill Remote/Recovery Tank

1. Attach the suction wand to the service hose. Make sure the suction wand ball valve is closed.
2. Insert suction wand into the radiator or remote/recovery tank.
3. Turn V1 control valve to “Add” (+).
4. Turn S2 pump switch to “On” (I).
5. Slowly open ball valve on the suction wand to fill to the normal level with new coolant.
6. Turn S2 pump switch to “Off” (O).
7. Remove suction wand from radiator or remote/recovery tank.
8. Securely replace radiator cap or remote/recovery tank cap.

Removing Trapped Air

1. Remove cap from the radiator or remote/recovery tank. Fluid level should be at least 2–3 inches (5–7 cm) below fill neck.
2. Attach suction wand to the service hose.
3. Turn V1 control valve to “Remove” (–).
4. Turn S1 pump switch to “On” (I) to lower the fluid level as necessary.
5. Turn S1 pump switch to “Off” (O).
6. Install vacuum plug into radiator or remote/recovery tank fill neck.
7. Turn S1 pump switch to “On” (I) only a few seconds at a time. If the radiator hoses begin to collapse, the BG CT4 will extract coolant instead of the air pockets. Recheck coolant level every few seconds. When level ceases to go down, all the air pockets have been removed.
8. Turn S1 pump switch to “Off” (O).
9. Remove vacuum plug.
10. Turn V1 control valve to “Add” (+).
11. Turn S2 pump switch to “On” (I) to top off cooling system to normal level.
12. Replace radiator cap or remote/recovery tank cap.