Operation and maintenance manual

Section 210-0000
Cooling System - Cooling System (Series 60 Engine)
SM 2117 Rev 1 11-03
4
Every 4 000 Hours
Drain, flush and refill the cooling system. Inspect all
components that make up the cooling system and
make necessary repairs at this time.
Note: Mix coolant and water solution at the proper
concentration before adding to the cooling system.
This should prevent over or under coolant
concentration problems.
DRAINING AND FLUSHING
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.
1. With the engine cool, drain the coolant from the
engine and radiator assembly.
2. Refill the cooling system with clean, soft water and a
good radiator cleaning compound. If the engine is
warm, fill slowly to prevent the rapid cooling and
distortion of the metal castings.
3. Start the engine and operate the vehicle for fifteen
minutes to circulate the solution completely.
4. Stop the engine and allow to cool. With the engine
cool, drain the cooling system completely.
5. Refill the cooling system with clean, soft water and
operate it for fifteen minutes.
6. Stop the engine and allow to cool. With the engine
cool, drain the cooling system completely.
7. Refill the cooling system with the proper mix of
antifreeze and clean, soft water.
8. Entrapped air must be purged after filling the cooling
system. To do this, allow the engine to warm up with
the pressure cap on the remote header tank removed.
With the transmission in neutral, increase engine speed
above 1 000 rev/min and add coolant as required. Vent
the cock on the water return line at the water-jacketed
turbocharger until a steady stream of water (no air) is
seen. Close the cock.
9. Install the pressure cap on the remote header tank
after the coolant level has stabilized at the bottom of
the header tank filler neck.
Note: If the engine overheats and the coolant level is
satisfactory, the cooling system may require cleaning
with a descaling solvent and back-flushing.
Back-flushing Engine Jacket
Whenever the engine water jacket is rust clogged,
pressure back-flushing should be used after the
draining of the cleaning compound. Be certain to
remove both thermostats from thermostat housing
before beginning back-flushing operation.
1. Close shut-off cocks at coolant/conditioner filter.
2. Remove both thermostats from thermostat housing
and clamp flushing gun to front neck of the water
manifold.
3. Temporarily block engine water pump inlet opening
and fill engine jacket with clean, soft water.
4. Unblock water pump inlet opening and blow water
from the engine jacket with air from flushing gun
clamped to neck of water manifold. Use full air
pressure.
5. Repeat operation by alternately filling engine with
clean, soft water and blowing out with air until flushing
water runs out clean.
6. Open shut-off cocks at the water filter.
Back-flushing Radiator
1. Disconnect all coolant lines at the engine.
2. Clamp flushing gun to lower hose on the radiator and
fill the radiator with clean, soft water from the gun.
3. Apply air pressure gradually increasing to a pressure
of 0.7 bar (10 lbf/in²). DO NOT EXCEED THIS
PRESSURE.
4. Alternatively fill radiator with clean, soft water and
flush with air until water runs out clear.