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Diesel Generator Operation Manual GENERAL MAINTENANCE Part 4
6.4 Cooling System
WARNING: CONTACT WITH HOT COOLANT CAN RESULT IN SERIOUS SCOLDING. ALLOW COOLING SYSTEM TO COOL BEFORE RELEASING PRESSURE AND REMOVING WATER JACKET RADIATOR CAP OR LTA EXPANSION TANK CAP.
Caution:Loss of coolant can allow engine to overheat without protection of shutdown device, and cause severe damage to the engine. Maintain coolant level for proper operation of high engine temperature shutdown system.
6.4.1 Coolant Level - Check
WARNING: DO NOT REMOVE THE RADIATOR CAP FROM A HOT ENGINE; WAIT UNTIL THE TEMPERATURE IS BELOW 50oC (122oF) BEFORE REMOVING PRESSURE CAP. FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY FROM HEATED COOLANT SPRAY OR STEAM. REMOVE FILLER CAP SLOWLY TO RELEASE COOLANT SYSTEM PRESSURE.
Caution:Avoid prolonged or repeated skin contact with antifreeze. Refer to the Health and Safety Manual 0908-0110-00 for handling and disposal of antifreeze.
Note: Never use a sealing additive to stop leaks in the coolant system. This can result in a blocked coolant system and inadequate coolant flow causing the engine to overheat.
Coolant level must be checked daily. The standard coolant concentration is either 25% or 50% Ethylene Glycol and water, this concentration must be maintained. Warranty claims for damage will be rejected if the incorrect mix of anti-freeze has been used. Consult your authorised distributor for the correct anti-freeze specifications and concentration for your operating conditions. The recommended antifreeze is Fleetguard® Compleat ES which is a low-silicate antifreeze, or its equivalent.
Caution:Do not add cold coolant to a hot engine. Engine castings can be damaged. Allow the engine to cool to below 50°C (122°F) before adding coolant.
Note: On applications that use a coolant recovery system, check to ensure the coolant is at the appropriate level on the coolant recovery tank dependent on engine temperature.
Fill the cooling system with coolant to the bottom of the fill neck in the radiator or expansion tank, with the coolant temperature at 50°C (122°F) or lower.
Note: Some radiators have two fill necks, both of which must be filled. Refer to the generator set specific drawings supplied with the set.
6.4.2 Cooling Fan - Inspect
WARNING: PERSONAL INJURY CAN RESULT FROM A FAN BLADE FAILURE. NEVER PULL OR PRY ON THE FAN, THIS CAN DAMAGE THE FAN BLADE(S) AND CAUSE FAN FAILURE
Note: Manually rotate the crankshaft by using a wrench on the accessory drive pulley nut.
A visual inspection of the cooling fan is required daily. Check for cracks, loose rivets, and bent or loose blades. Check the fan to make sure it is securely mounted.
Contact your authorised distributor if the fan is damaged.
6.4.3 Drive Belt - Inspect
Visually inspect the belt through the guarding, checking for intersecting cracks. Small transverse (across the belt width) cracks are acceptable. Longitudinal (direction of belt length) cracks that intersect with transverse cracks are NOT acceptable. Contact your authorised distributor if the belt is frayed or has pieces of material missing.
6.4.4 Radiator - Check
Inspect the exterior of the radiator (through the guarding) for obstructions. During the service life of a radiator a build up of foreign matter can obstruct the flow of air through the radiator cores, reducing the cooling capability. To ensure the continued efficiency of the radiator, the core will require cleaning.Check for damaged hoses, and loose and damaged hose clamps.
Refer to the Radiator Information Manual 0908-0107-00 for further details on cleaning the radiator.