Operation and maintenance manual

Section 210-0000
SM 2117 Rev 1 11-03
3
Cooling System - Cooling System (Series 60 Engine)
Every 50 Hours
Check all drive belts for wear and tension. Refer to
Section 110-0030, ENGINE AND MOUNTING for belt
tension specifications.
Every 500 Hours
Replace coolant/conditioner filter. Check and replenish
coolant inhibitor as required.
Note: Failure to use and maintain coolant and coolant
inhibitor mixture at sufficient concentration levels can
result in damage to the cooling system and its related
components. Conversely, over-concentration of coolant
and/or inhibitor can result in poor heat transfer, leading
to engine dropout, or both. Always maintain
concentrations at recommended levels.
Inspect water pump drain hole to make sure it is open.
Note: A small chemical build up or streaking at the
drain hole may occur. This is not an indication of a
defective water pump or seal. If coolant does not leak
from the drain hole under normal operating conditions,
do not replace the water pump.
Inspect the radiator and air-to-air charge cooler fins
and, if necessary, clean with a quality grease solvent
such as mineral spirits and dry with compressed air.
Note: Fuel oil, kerosene or gasoline should not be used
to clean fins.
Note: It may be necessary to clean radiator and
air-to-air charge cooler fins more frequently if the
vehicle is being operated in extremely dusty or dirty
areas.
WARNING
To prevent possible injury when using
compressed air, wear adequate eye protection
and do not exceed 2.75 bar (40 lbf/in²).
Every 2 000 Hours
Replace all drive belts. Refer to Section 110-0030,
ENGINE AND MOUNTING.
Note: Replace all belts in a set when one is worn.
Single belts of similar size should not be used as a
substitute for a matched belt set. Premature belt wear
can result because of belt length variation.
pulled into the turbocharger where it is compressed. It
then exits the turbocharger through outlet pipe (4) and
enters air-to-air charge cooler (2), mounted on the front
of radiator assembly (1), through inlet pipe (3). The hot
air travels through a series of tubes in
air-to-air charge cooler (2) core, where the air
temperature is lowered from approximately 149° C
(300° F) to below 38° C (100° F). From here the air
flows through outlet pipe (5) and into the engine intake
manifold through inlet pipe (6). From the engine intake
manifold the air travels into the cylinders where it
mixes with atomized fuel from the injectors. This cooler
air aids combustion, thereby increasing fuel economy.
PREVENTIVE MAINTENANCE
To ensure the continued efficient functioning of the
cooling system, certain checks and operations should
be performed at regular intervals.
WARNING
Do not remove the pressure control cap from
the radiator header tank or attempt to drain the
coolant until the engine has cooled. Once the
engine has cooled, use extreme caution when
removing the cap. Always release pressure
from the system by depressing the pressure
relief button on the cap. Remove cap slowly as
the sudden release of pressure from a heated
cooling system can result in a loss of coolant
and possible personal injury (scalding) from
the hot liquid.
Every 10 Hours (Daily)
Check coolant level and add if low. Fill the radiator
header tank with coolant until coolant reaches the
bottom of the filler neck and holds at that level.
Note: Any time a significant amount of coolant is
added, the coolant inhibitor MUST be checked. If the
concentration is low, engine damage will result.
Conversely, over-inhibiting antifreeze solutions can
result in silicate dropout. Refer to 'Test Kit Procedures'.
Check cooling fan for cracks, loose rivets and bent or
loose blades. Check fan mounting and tighten if
required. Replace cooling fan if damaged.
Check coolant lines, pipes and components for leaks
and wear.