4000 Hours Service

Maintenance to be performed every 4000th hour of operation.

1.Cooling system

If necessary, the cooling system should be cleaned more often.

1.1.External cleaning, at least every 4th year 5*

1.Clean externally the radiator fins and hoses. 2.Check that the radiator is not blocked on the air side and that the fins are not damaged. 3.Carefully scrape the deposit away from the radiator fins. If necessary, a paraffin-based engine cleaner may be used. 4.Check the fins, rubber hoses, clamps and pipes for corrosion, damage and leakages. 5.Bent fins can be carefully straightened, e.g. using a steel wire brush.

CAUTION

The cooling system must not be cleaned using caustic soda. It can damage aluminium parts.

1.2 Internal cleaning, at least every 4th year 5*

Removing deposits

1.If possible, run the engine until it is warm and then drain the cooling system, see changing coolant, item 1.4 2.Remove the thermostats.

3.Fill the system with clean, hot water mixed with one of the commercially available radiator cleaners based on sulphamin acid and containing dispersing agents. Follow the manufacturer's instructions (on the packaging) for mix ratios and cleaning times. 4.Run the engine for the specified time. 5.Drain the cooling system by removing a low hose or pipe.

Do not use the drain cocks, the loosened deposits can clog them!

6.Refit the hose which was used as drain hose.

7Fill the system again with hot water and run the engine for about 20 -30 minutes.

8.Drain the water from the cooling system in the usual way, use the drain cocks.

9.Refit the thermostats.

10.Fill the system with coolant as described in the specifications in item 1.3 at 2000 hours service.

WARNING

When handling cleaners for the cooling system: Study the warning on the packaging.

1. Inlet manifold, lower part 2. Gasket 3. Radiator element 4. Gasket 5. Inlet manifold, upper part 6. V-ring seal Maintenance to be performed every 4000th hour of operation.

1.3.Charge air cooler 5*

1.Drain the coolant from the engine, see changing coolant, item 1.4.

2.Detach the upper part of the inlet manifold. 3.Detach the charge air cooler hose and pipe connections. 4.Disassemble the charge air cooler as illustrated.

Take care not to damage the element's water connections.

5.Clean the outside of the element. Use a paraffin-based engine cleaner. 6.Reassemble the charge air cooler. Change all seals and gaskets. 7.Refit hose and pipe connections. 8.Fill coolant as described in the specifications in item 1.3 at 2000 hours service.

9.Connect the inlet manifold from the turbo.

Filler cap Maintenance to be performed every 4000th hour of operation.

1.4 Change coolant, at least every 4th year 5*

1.Remove the filler cap from the expansion tank. 2.Drain the coolant in two places: • drain cock on the engine. • drain cock underneath the oil coolers.

3.Close the cocks.

4.Fill with correct mixture, pre-mixed coolant through the expansion tank filler hole. See item 1.3 at 2000 hours service.

2.Continue with all items in 2000 Hours Service.