TP-5964 7/0114 Section 3 Scheduled Maintenance
3.7.3 Procedure to Drain the Cooling
System
For optimum protection, drain, flush, and refill the
cooling system at the intervals listed in the service
schedule.
Note: Dispose of all waste materials (oil, fuel, coolant,
filters, and gaskets) in an environmentally safe
manner.
1. Deenergize the block heater, if equipped.
2. Remove the radiator’s pressure cap and the surge
tank’s pressure cap to allow the entire system to
drain and prevent air pockets from restricting
coolant flow through the engine block.
3. Open the radiator and/or engine block coolant
drain valve(s) and allow the system to drain.
4. If the inside of the radiator has mineral deposits or
the used coolant contains dirt or grease, refer to
Section 3.7.4, Procedure to Flush and Clean the
Cooling System. If the cooling system does not
have mineral deposits, go to Section 3.7.5,
Procedure to Refill the Cooling System.
3.7.4 Procedure to Flush and Clean the
Cooling System
Use the instructions in the engine operation manual
when available to flush and clean the cooling system.
Otherwise, use the following procedure and the cooling
system cleaner manufacturer’s instructions.
1. Flush the cooling system with clean water.
2. If the inside of the radiator still has mineral
deposits, use a radiator cleaner to remove the
remaining deposits following the manufacturer’s
instructions.
3. Drain, clean, and flush the coolant recovery tank.
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3.7.5 Procedure to Refill the Cooling
System
See Figure 3-8 for coolant capacity.
Note: Do not add coolant to a hot engine. Adding
coolant to a hot engine can cause the cylinder
block or cylinder head to crack. Wait until the
engine has cooled.
Note: Pay special attention to the coolant level. After
the coolant drains, allow time for complete refill of
the water jacket.
1. Remove the pressure caps.
2. Close the radiator and/or engine block coolant
drain valve(s) and tighten the cooling system hose
clamps.
3. Add coolant additives or water pump lubricants
according to the engine manufacturer’s
recommendations in the engine operation manual.
4. Fill the c ooling system with the recommended
coolant/antifreeze mixture of 50% ethylene glycol
and 50% clean, softened water to inhibit
rust/corrosion and prevent freezing.
Note: A coolant solution of 50% ethylene glycol
provides freezing protection to -- 37°C
(--34°F) and overheating protection to
129°C (265°F). A coolant solution
containing less than 50% ethylene glycol
may not provide adequate freezing and
overheating protection. A coolant solution
containing more than 50% ethylene glycol
can cause engine or component damage.
Do not use alcohol or methanol antifreeze or
mix them with the specified coolant. Refer to
the engine operation manual for
recommendations regarding the coolant
mixture to use in extreme temperatures.
5. Replace the radiator’s pressure cap and the surge
tank’s pressure tank.
6. Fill the coolant recovery tank to the low mark or
approximately 1/4 full for tanks without marks.
7. Operate the generator set until the thermostat
opens when the upper cooling system hose
warms.
8. Stop the engine and allow it to cool.
9. Remove the radiator’s pressure cap.
10. If the radiator’s and the surge tank’s pressure caps
are mounted at the same level, proceed to step 11.
If not, proceed to step 12.
11. Open the valve at the top of the surge tank.
12. Add coolant to bring the coolant level to just below
the overflow tube opening of the filler neck.
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