CHAPTER 12 COOLING GROUP REPAIR INSTRUCTIONS

TM-5-6115-545-34 Generator Set Diesel Engine Driven Tactical Skid Mtd. 30 Kw 3 Phase 4 Wire 120/208 and 240/416 Volts Manual
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CHAPTER 12 COOLING GROUP REPAIR INSTRUCTIONS 12-1. General. a. The cooling group consists of the radiator grille, shutter assembly and the shutter thermostat. b. The radiator is mounted at the front end of the engine generator set just behind the grille and shutter assembly. It is equipped with inlet and outlet hose connections, a filler cap and an overflow tube. A drain valve is located on the lower right side of the radiator. A shroud and fan guard are mounted on each side behind the radiator, enclosing the fan. c. The radiator shutter is mounted on the front of the radiator. The shutter control is mounted on the lower right side of the radiator and operates by thermal expansion. A plunger inside the thermostat, which is affected by temperature in the radiator, actuates the linkage system to the shutter. The shutter will remain closed until the engine warms up, at which time it will open upon action of the shutter control. A control lever is provided for manual operation of the shutter control in case of thermostat failure. d. The fan is located behind the radiator on the front of the engine. Driven by belts when the engine is running the fan draws cooling air through the doors at the rear of the unit and exhausts it through the radiator core, shutter and grille. 12-2. Radiator Assembly Removal. A malfunction of the radiator, shutter assembly or thermostat is usually indicated by an abnormally high reading on the coolant temperature gauge located on the engine control panel. To isolate the cause pro- ceed as follows: a. If the shutter assembly is closed, operate the manual control and open it. If the temperature begins to drop toward normal, the probable cause is a faulty shutter thermostat. (Refer to the Operator and Organizational Maintenance Manual). b. Open the radiator fill cap and check for a suff- cient amount of coolant. Add coolant if necessary and observe temperature gauge for a drop in temperature. C. Shut the engine down. Examine the pulley belts for tension. If they are tight examine the fan for bent or broken blades and freedom of motion. d. When it is determined that there has been a failure of the radiator, fan, or shutter assembly, remove the radiator, grille, shutter assembly, shroud and fan guard. (Refer to the Operator and Organizational Maintainance Manual). 12-3. Radiator and Shutter Repair and Test. a. Clean all parts with cleaning solvent Federal specification P-D-680 and dry thoroughly with compressed air at 10 to 15 pounds pressure. b. Inspect all hardware and threaded areas for damaged or crossed threads. c. Inspect shutter control body for damage and proper operation. d. Repair control assembly and shutter assembly by Emplacement of defective parts. (See figures 12-1 and 12-2). e. Using compressed air, remove all dirt and foreign material from the radiator core. (1) Solder or braze any radiator core leaks. (2) Straighten bent cooling fins. f. Replace all worn, damaged, or defective parts. g. Test the radiator for leaks by placing the radiator with outlet connection sealed in a tank of water. Apply compressed air of 10 to 15 psi at filler opening and observe for leakage indicated by air bubbles in the water. 12-4. Radiator Assembly Installation. Install the fan guard, shroud, radiator, shutter as- sembly, grille and shutter thermostat. (Refer to the Operator and Organizational Maintenance Manual. ) 12-1

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