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Cooling System Maintenance - Volvo Penta Engine

by Starlight Generator dieselgeneratortech

Cooling System

Volvo Penta engine's internal cooling system makes sure the engine works at the right temperature. It is a closed system that must always be filled with a mixture of concentrated coolant and water in order to protect the engine against internal corrosion, cavitation and bursting due to freezing. Coolant of a suitable chemical composition must be used all year round. This also applies in areas where there is never any risk of freezing, to provide the engine with full corrosion protection. The use of anti-corrosion agents alone is not permitted in Volvo Penta engines. Never use water alone as a substitute for coolant. The corrosion protection additives become less effective over time, which means that the coolant must be changed at regular intervals; refer to Maintenance Schedule. The cooling system must be flushed whenever the coolant is changed; refer to the Cooling System, Cleaning page 61section.

Volvo Penta coolants have been prepared to work best with Volvo Penta engines and offer excellent protection against corrosion, cavitation damage, and bursts due to freezing. Only coolants of this quality are adapted to, and approved by, Volvo Penta.

IMPORTANT!

Volvo Penta engines are delivered with either Volvo Penta Coolant (green) or Volvo Penta Coolant VCS (yellow); both are available as concentrates and Ready Mixed. We recommend that the coolant supplied with the engine on delivery be used. Future warranty claims related to engine and accessories may be denied if an unsuitable coolant has been used, or if the instructions for coolant mixture have not been followed. Engines using yellow Volvo Penta Coolant VCS must have a yellow decal with the text VOLVO COOLANT VCS on the expansion tank.

• The two types of Volvo Penta coolant may never be mixed with each other as this will affect the anti-corrosion properties.

• Coolant filters may not be used together with Volvo Penta Coolant VCS.

Ready Mixed

The ready-mixed coolant protects the Volvo engine from corrosion damage, cavitation damage and bursts due to freezing down to

-28 °C (-18 °F) Volvo Penta Coolant (green).

-24 °C (-11 °F) for Volvo Penta Coolant VCS (yellow).

Coolant, Mixing

WARNING!

All coolant is hazardous and harmful to the environment. Do not consume. Coolant is flammable.

IMPORTANT:

Different types of coolant must not be mixed with each other.

The concentrated coolant must be mixed with pure water (distilled or de-ionized water) according to specifications; refer to Water Quality page 72.

Mix: 40% concentrated coolant and 60% water

This mixture prevents against internal corrosion, cavitation and bursts due to freezing down to

-28°C (-18°F) Volvo Penta Coolant (green).

-24°C (-11°F) Volvo Penta Coolant VCS (yellow).

At 60% glycol concentration, the freezing point is lowered to

-54°C (-65°F) Volvo Penta Coolant (green).

-46°C (-51°F) Volvo Penta Coolant VCS (yellow).

Never mix in more than 60% of the concentrated coolant. A greater volume of concentrate entails a reduced cooling effect with the risk for overheating and reduced anti-freeze protection.

It is extremely important that the system be filled with the correct coolant concentration. Mix in a separate clean vessel before filling the cooling system. Make sure that the liquids mix.

Coolant Level, Checking and

Topping Up

Coolant filling must be performed with the engine stopped. Check the coolant level daily before starting.

IMPORTANT!

Only use the coolant recommended by Volvo Penta. Top up with the same type of coolant as already used in the system. Different types of coolant must not be mixed.

WARNING!

Do not open the coolant filler cap when the engine is hot, except in emergencies, this could cause serious personal injury. Steam or hot fluid could spray out.

1 Only open the filler cap (1). Do not open the pressure cap (2).

2 Check that the coolant level is above the MIN mark on the expansion tank.

3 Top up with coolant as required, so that the level is between the MIN and MAX marks. Fill slowly, to allow air to flow out.

Filling a completely empty system

NOTICE! Mix the correct amount of coolant in advance, to ensure that the cooling system is completely filled. Refer to Technical Data, Cooling System, for the correct coolant volume.

Do not open the pressure cap (2).

1 Check that all drain points are closed.

2 Open filler cap (1).

3 Fill with coolant, so that the level is between the MIN and MAX marks. Fill slowly, to allow air to flow out.

NOTICE! Do not start the engine until the system is completely filled and bled.

4 Start the engine when the cooling system has been completely filled and bled. Open any bleeding nipples a short while after starting, to allow trapped air to escape.

If a heating unit is connected to the engine cooling system, the heat control valve must be opened and the installation vented during filling.

5 Stop the engine after about an hour and check the coolant level. Top up as necessary.

Coolant, Draining

WARNING!

Do not open the coolant filler cap when the engine is hot, except in emergencies, this could cause serious personal injury. Steam or hot fluid could spray out.

IMPORTANT!

On engines which are to be put in storage, the engine cooling system must not be drained. The coolant contains corrosion-inhibiting additives.

1 Stop the engine.

2 Remove the filler cap (1). Do not open the pressure cap (2).

3 Open all drain points. Drain the coolant from the radiator and engine block, using the drain hose. The drain nipples are situated under the radiator on the right side of the engine block.

4 Check that all coolant drains out. Deposits may be found inside the drain plug/tap, and need to be cleared away. There is otherwise a risk that coolant could remain and cause damage due to freezing. Check whether the installation has any further taps or plugs at the lowest points of the cooling water pipes.

5 Shut any taps and check that the spring-loaded covers on the nipples close completely. Install the rubber plugs.

Charge Air Cooler, External

Cleaning

Remove guards as necessary, to access the radiator. Clean with water and a mild detergent. Use a soft brush. Be careful not to damage the radiator vanes. Reinstall removed parts.

IMPORTANT!

Do not use a pressure washer.

Coolant Filter, Change

NOTICE! Only applies to engines using Volvo Penta Coolant (green). Engines using Volvo Penta Coolant VCS are not fitted with coolant filters.

1 Turn the tap (1) 90° to stop the flow through the coolant filter.

2 Remove the coolant filter with a suitable extractor. Make sure that no residue from the old seal remains in the housing.

3 Put a thin layer of engine oil on the new coolant filter seal. Screw the coolant filter on by hand until the seal comes into contact with the mating surface of the filter bracket. Then tighten the coolant filter a further 1/2 turn.

4 Turn the tap (1) 90° to release the flow through the coolant filter again.

5 Start the engine and carry out a leakage check.

6 Switch the engine off and check the coolant level. Refer to Coolant Level, Checking and Topping Up page 58.

Cooling System, Cleaning

Cooling performance is reduced by deposits in the radiator and cooling galleries. The cooling system should be cleaned out when the coolant is changed.

IMPORTANT!

Cleaning must not be done if there is any risk of the cooling system freezing, since the cleaning solution does not have any antifreeze properties.

IMPORTANT!

It is extremely important that the correct concentration and volume of coolant is added to the system. Mix in a separate clean vessel before filling the cooling system.

Make sure that the liquids mix.

1 Empty the cooling system. Refer to Coolant, Draining page 59.

2 Put a hose into the expansion tank filling hole and flush with clean water, as specified by Volvo Penta– refer to section Water quality in Technical Data page 72 until the water draining out is completely clear.

3 If there should still be some contamination left after flushing for a long time, cleaning can be done with coolant. Otherwise, continue as in item 8 below.

4 Fill the cooling system with 15-20 % mixture of concentrated coolant. Use only Volvo Penta recommended concentrated coolant mixed with clean water.

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