10.7.5 Servicing the cooling system

10.7.5 Servicing the cooling system

CAUTiON

danger of injury from hot and moving parts! ► Never open the driver‘s platform when the engine is running! danger of scalding from hot coolant! ► Never open the cooling system when the engine is hot or the cooling system is under pressure. ► Let the engine cool off or use protective gloves.

NOTE

danger of technical damage! ► Service the cooling system according to the inspection intervals specified in this operating manual. ► Turn off the engine immediately if the temperature indicator in the instrument panel is illuminated item 5 (Fig. 14). If the temperature indicator is illuminated, either the engine or the hydraulic oil or both have become too hot.

The hydraulic fluid cooler is located in the front carriage of the loader (Fig. 99). The engine radiator is installed behind the diesel engine. To access it, tilt up the rear plate. To do this, unscrew the two eye nuts of the towing equipment item 1 (Fig. 99).

1

Fig. 99 Radiator

Hydraulic fluid cooler

Engine radiator

The temperature indicator light item 5 (Fig. 14) is connected to two temperature sensors; one is located on the engine (Fig. 100), the other on the hydraulic oil tank (Fig. 101). To ascertain whether the engine or hydraulic oil (or both) have become too hot, disconnect the cable on one of the two temperature sensors.

Fig. 100 Engine temperature sensor

Fig. 101 Hydraulic oil temperature sensor

Should the loader get too hot during long drives on the road or at high outside temperatures, check the following:

• Is there enough coolant in the radiator and is it the correct coolant mix? • Is the fan‘s v- belt taut and in good condition? • Are the radiators continuously clean at all points? • are all seals fitted near the radiator? (hot air must not flow around the radiators and be drawn back in again!) • does the electrical fan of the hydraulic fluid cooler work?

Checking V-belt tension / Tensioning the V-belt

CAUTiON

risk of injury due to moving parts. ► Never open the engine hood while the engine is running. risk of scalding due to hot coolant. ► Never open the cooling system while the engine is hot. Never open the cooling system while it is pressurized. ► Allow the engine to cool off, or wear protective gloves.

NOTE

risk of technical damage. cracked or stretched v-belts will lead to engine damage. ► The v-belts must be maintained at the inspection intervals stated in this operator's manual. ► Observe the operating instructions for the engine! ► The v-belt must only be replaced by an authorized specialist workshop.

Preparations

1. Park the loader on a horizontal surface and apply the parking brake. 2. Lower the lift frame all the way to the bottom. 3. Switch off the engine. 4. Wait one minute. 5. Open the engine hood.

Checking the V-belt tension

using your thumb, check that the v-belt cannot be depressed by more than approximately 10 mm between the belt pulleys (Fig. 102).

G 1

Fig. 102 V-belt

2

1

ca. 10 mm

Tensioning the V-belt

1. loosen the fixing bolts item 2 and adjusting screw (item 1) of the generator item g (Fig. 102). 2. using a suitable tool, apply pressure to the generator until the correct V-belt tension is obtained (Fig. 103). 3. Hold the generator in this position and re-tighten the adjusting screw item 1 (Fig. 102). Next, re-tighten the fixing bolts item 2 (Fig. 102).

G

Fig. 103 Tensioning the V-belt

Checking the coolant level / refilling the coolant

CAUTiON

danger of scalding from hot coolant! ► Never open the cooling system when the engine is hot or the cooling system is under pressure.

ENViRONMENT NOTE

danger of environmental damage! ► Avoid environmental damage! do not allow antifreeze and coolant to be released uncontrollably into the environment. ► collect antifreeze and coolant and dispose of it in an ecologically sound manner.

NOTE

danger of technical damage! ► The coolant must consist of equal parts of water and antifreeze. This mix guarantees an optimal ratio of cooling performance and corrosion protection. ► do not pour in the coolant too quickly if the full amount is to be poured in, e.g. when changing the coolant. Pour in at a maximum of 5 l/ min. if the cooling system fills up too quickly, air pockets in the cooling system could form, causing the engine to overheat.

Fig. 104 Radiator opening Fig. 105 Checking the antifreeze mix

check the coolant level at regular intervals. If you look into the radiator opening (Fig. 104) from above, the radiator fins should be covered with coolant.

make sure that enough antifreeze is always present in the coolant, even in summer, as antifreeze also prevents internal corrosion of the radiator and the engine.

Checking the antifreeze mix

Antifreeze prevents the coolant from freezing at temperatures below zero and protects the engine block and the radiator from internal corrosion. under normal conditions, the antifreeze concentration is sufficient for protection down to between –20° and –30° c. You can determine the antifreeze concentration by using a conventional antifreeze tester (Fig. 105).

Changing the coolant

NOTE

danger of technical damage! ► Put in new coolant every 2 years. ► The coolant must consist of equal parts of water and antifreeze. This mix guarantees an optimal ratio of cooling performance and corrosion protection. ► do not pour in the coolant too quickly! Pour in at a maximum of 5 l/min. if the cooling system fills up too quickly, air pockets in the cooling system could form, causing the engine to overheat. 1. Stop the loader on a horizontal surface and set the parking brake. 2. Lower the lift frame as far as it will go. 3. Turn off the engine. 4. Place a sufficiently dimensioned receptacle under the lower radiator hose (see the chapter „Specifications and filling quantities“). 5. Open the radiator opening. 6. remove the lower radiator hose (remove the hose clamp and pull off the hose).

If the coolant has run out:

1. correctly reattach the lower radiator hose. 2. mix new coolant using equal parts of clean tap water and new antifreeze. 3. Add new coolant into the radiator opening until the radiator fins are covered with coolant. Pour in at a maximum of 5 l/min. 4. close the radiator opening. 5. check the coolant level once again after half an hour of operation.

Cleaning the cooling system

ENViRONMENT NOTE

danger of environmental damage! ► Avoid environmental damage! clean the loader only in a suitable place where the waste water can be collected in an ecologically sound manner. ► collect contaminated waste water and dispose of it in an ecologically sound manner.

NOTE

danger of technical damage! ► The greater the amount of dust in the air, the more frequently the radiator has to be checked and cleaned. ► Always cover up the suction connection of the air filter before cleaning the radiator. ► do not damage the radiator fins when cleaning the radiator. Straighten any twisted radiator fins carefully.

Fig. 106 Cleaning the cooling system

clean the dirty radiator with compressed air (Fig. 106). You can also clean heavily contaminated radiators with water under high pressure.

clean

• The engine‘s radiator • The hydraulic fluid cooler • The dynamo (with compressed air only!)