Procedure To Refill The Cooling System - Kohler 7.5EOR Service

5.2.5 Procedure to Refill the Cooling
System
See the generator set spec sheet 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.
1. Remove the pressure cap.
2. Close the radiator and/or engine block coolant
drain valve(s) and tighten the cooling system hose
clamps.
3. Open the air-bleed petcocks, if equipped. Close
the air-bleed petcocks when coolant begins to flow
from them.
4. Add coolant additives or water pump lubricants
according to the
recommendations in the engine operation manual.
5. Fill the cooling 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).
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
recommendations regarding the coolant
mixture to use in extreme temperatures.
TP-6073 4/06
engine manufacturer's
A coolant solution
operation manual for
6. Replace the pressure cap.
7. Fill the coolant recovery tank to the low mark or
approximately 1/4 full for tanks without marks.
8. Operate the generator set until the thermostat
opens when the upper cooling system hose
warms.
9. Stop the engine and allow it to cool.
10. Remove the pressure cap.
11. Add coolant to bring the coolant level to just below
the overflow tube opening of the filler neck.
12. Replace the pressure cap.
13. Maintain the coolant level in the coolant recovery
tank between the high and low marks or
approximately 1/4 full for tanks without marks.
Note: Air pockets often form in the engine water
jacket when the coolant system is refilled.
Check the coolant level in the coolant
recovery tank after each generator set
operation and add coolant as necessary
until the coolant level stabilizes. Then check
the coolant at the interval specified in the
service schedule.
14. Reenergize the block heater, if equipped.
x:sm:003:006
Section 5 Cooling System 29