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3.8 Cooling System
WARNING
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
Allow the engine to cool. Release pressure from the
cooling system before removing the pressure cap. To
release pressure, cover the pressure cap with a thick
cloth and then slowly turn the cap counterclockwise to
the first stop. Remove the cap after pressure has been
completely released and the engine has cooled. Check
the coolant level at the tank if the generator set has a
coolant recovery tank.
3.8.1
Checking and Filling Coolant
Maintain the coolant level in the coolant overflow bottle
between the High and Low markings. See Section 1,
Service Views, for the coolant overflow bottle location.
Note: Periodically check the coolant level by removing
the radiator's pressure cap. Do not rely solely on
the level in the coolant overflow bottle.
Add fresh coolant until the level is just below the
overflow tube opening. Use a coolant 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 with less than 50% ethylene
glycol may not provide adequate freezing and
overheating protection. A coolant solution with
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.
When checking the coolant level, also check the rubber
seal of the radiator's pressure cap and replace a
cracked or deteriorated cap. The pressure cap raises
the boiling point of the coolant, enabling higher
operating temperatures. If the cap leaks, replace it with
the same rating type of cap. Find the pressure cap rating
in Figure 3-7. Remove dirt and other debris from the
pressure cap and filler neck.
24
Section 3 Scheduled Maintenance
Item
Pressure cap
Thermostat
Figure 3-7 Pressure Cap and Thermostat Rating
To prevent generator shutdown or damage because of
overheating, keep the cooling air inlets clean and
unobstructed at all times. Inspect the radiator's exterior
for obstructions and remove dirt and foreign material
with a soft brush or cloth to avoid damaging the radiator
fins. Check the hoses and connections for leaks and
replace any cracked, frayed, or spongy hoses.
3.8.2
Draining Cooling System
The radiator contains a coolant drain valve to drain the
cooling system. When draining the coolant, remove the
radiator's pressure cap, which will allow the entire
system to drain and will prevent air pockets from forming
and restricting coolant passage to the block.
Note: Pay special attention to the coolant level. After
the coolant drains, allow time for complete refill of
the engine water jacket. Check the coolant level
as described earlier.
3.8.3
Filling Cooling System
1. Close the radiator's coolant drain valve and tighten
the hose clamps.
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 engine has cooled.
2. Fill the radiator with the recommended coolant
mixture of 50% ethylene glycol and 50% clean,
softened water to inhibit rust/corrosion and prevent
freezing.
The coolant capacity is shown in
Figure 3-8.
Model
15RES
30RES
Figure 3-8 Coolant Capacity
3. Operate the engine with the radiator cap removed
until the thermostat opens and the upper radiator
hose becomes hot.
4. Stop the engine and allow it to cool.
Rating
97 kPa (14 psi)
91_C (195_F)
Coolant Capacity, L (Qt.)
11.5 L (3.0 qt.)
11.5 L (3.0 qt.)
TP-6344 4/09
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Troubleshooting
