SAFARI

1295 / 1525

ENGINE
128
SERVICE INSTRUCTION FOR ALUMINUM
Radiator : Heat Rejection - 87.5 Kw. With 2 electric
fans 300 mm dia. Mounted on fan shroud. Max fan
speed 2900 rpm.
1. Introduction
This manual explains the procedure for servicing of
Aluminum Radiators with plastic tanks. The following
aspects are covered.
Leakage spot detection Sealing Techniques
Confirmation of proper sealing.
2. Procedure for Servicing
2.1 Removal of Radiator from Vehicle
Allow the coolant in the radiator to reach to the room
temperature.Drain the coolant from radiator
completely. Take out the radiator from vehicle
carefully to avoid damage to any of it’s parts
CAUTION: Radiator core and plastic tanks are
susceptible to cracking due to impact and
deformation
2.2 Detection of Leakage Spot
Connect the inlet of the radiator to air supply at the
gauge pressure of 1.5 bar Seal all other outlet
points.
Dip the radiator completely in a clean water tank Tilt
the radiator and shake it vigorously to let the air
bubbles trapped at the clinching area to escape.
Observe carefully for one minute and locate the
source of air leakage on the radiator from the
direction of air bubbles that are coming out of
radiator. If the Leakage spot is at radiator core then
follow the procedure given at . 2.3 to seal the
leakage, else if the Leakage spot is found at Tank or
its accessories then follow the procedure given at
Sr.No.2.4 to seal the leakage
CAUTION : Do not use the water tank that is used
for copper radiator
2.3 Sealing the Leakage at Radiator Core
Different procedure of sealing shall be followed for
MINOR and MAJOR leaks in the radiator core.
MINOR LEAKS: Leak spots which are very minute
are to be sealed in following manner.
Install the radiator on vehicle as explained Sr.No.3
(Radiator Installation) Pour the contents of
ALUMASEAL in the radiator. Fill proper quantity of
coolant liquid. Run the engine in idling speed for 20
minutes.
MAJOR LEAKS
Procedure of sealing major leaks in the radiator is
as follows:
Wash the core with clean water and brush to
remove dirt, dust etc. To remove the greasy spot on
the core, apply thinner with cotton swab and take
off the grease. Dry the core using a dryer (Do not
use heating source).
Mix adequate quantity of ARALDITE RESIN (Araldite
rapid may be used in place of Araldite standard for
faster drying & curing of seal) and HARDENER in the
ratio of 1:1 and stir it thoroughly.
Apply the mixture immediately at the leakage spot
with the applicator. Allow the mixture to dry and
harden under the shade at room temperature for
10-12 hour. Silver color paint may be used for
touching up the araldite spots and impart the
aluminum type appearance.
CAUTION
Do not damage the fins during process. As the
Araldite is inflammable do not dry it by using any
heating source. Proper cleaning of leakage area is
must for proper setting of Araldite or else it will
come off.
2.4 Servicing of Tank and its accessories
If the source of leakage is tank, then replace the
tank. Take out the member support using correct
size spanner Remove the tabs of the header plate
using screw driver and monkey plier. After making
all clinching projections up, take out the tank from
its seat in header plate. In case it takes more effort,
pat the tank with rubber or plastic hammer lightly.
Take of the tank packing.
INSPECTION AND CLEANING RADIATOR AND CAP
Cleaning
Fit radiator cap. Close radiator drain cock firmly.
Refer Figure 60. Place radiator upside down on
ground. Connect water supply line to radiator
bottom tank at its outlet. Slowly increase water
supply to radiator. Maximum pressure in system
should not exceed 1.0 bar.
Continue water flow till outlet water is visually clean
and clear. Remove connection made for cleaning.
Remove radiator cap and suitably plug inlet and
outlet of radiator. Completely fill radiator with
measured quantity of water. If radiator capacity is
less than specified it reflects choked tube. e clean/
de-scale radiator using suitable cleaning compound
as per manufacturer’s instruction. Fit back radiator