COOLING SYSTEM
Structure .................................................................................................... 2–1
Removal and Installation ...................................................................... 2–2
2
Inspection and Adjustment .................................................................. 2–5
Fan Belt Condition ..................................................................................... 2–5
Fan Belt Tension ........................................................................................ 2–5
Connecting Radiator Hoses ....................................................................... 2–5
Coolant ...................................................................................................... 2–6
Radiator Cap ............................................................................................. 2–6
COOLING SYSTEM
Structure
1
6
5
8
5
4
10
1
2
3
2 3
207009 208411
8 8
9
7
7
6 6
9
208412 208413
1 Engine 6 Upper hose
2 Universal joint 7 Lower hose
3 Gear pump 8 Radiator
4 Fan belt 9 Oil cooler hoses
5 Cooling fan 10 Tension pulley
2-1
COOLING SYSTEM
Removal and Installation
Fan Belt Removal
1
2
(Only loosen.)
208414
Sequence
1 Universal joint
2 Tension pulley assembly, Bolt
3 Fan belt
Start by:
Remove the radiator cover.
Suggestion for removal
Tension pulley assembly
(1) Using a ratcheting wrench inserted in the gap between
the weight and frame, loosen the tension pulley lock
bolt by three or four turns. If the bolt is loosened A
insufficiently, the tension pulley will not be moved.
NOTE A
Do not loosen the lock bolt to such an extent that the
tension pulley would be removed.
(2) Move the tension pulley fully toward the fan, then Tension pulley lock bolt
remove the belt.
Section A–A
208415
2-2
COOLING SYSTEM
Installation
Perform installation by following the removal sequence in
reverse. Also follow the instructions given below.
(1) Before installing the belt, turn the fan to check for
smooth rotation. Replace the bearing if it generates
abnormal sound.
(2) After installing the belt, push it at a point midway
between the driven and drive pulleys to make sure that
the tension pulley moves, then tighten the pulley lock
bolt firmly.
Fan Assembly Removal
3
2
208416
Sequence
1 Fan cover
2 Fan assembly
3 Tension pulley assembly
Start by:
Remove the radiator cover.
Suggestion for removal
Remove the fan support bolts, detach the belt from the
driven pulley, and then remove the fan assembly. Place the
fan assembly with the fan support facing down and turn the
fan to check for smooth rotation. Replace the bearing if it
generates abnormal sound.
2-3
COOLING SYSTEM
Installation
Perform installation by following the removal sequence in
reverse. Also follow the instruction given below.
(1) With the tension pulley lock bolt loosened, attach the
belt to the driven pulley (fan assembly pulley), then
screw in the bolt at the bottom of the fan support; do
not tighten the bolt yet. Holding the fan support by its
top, move the support until it reaches the boss (frame),
then tighten all the fan support bolts.
(2) Adjust the tension of the fan belt.
2-4
COOLING SYSTEM
Inspection and Adjustment
Fan Belt Condition
(1) Check the belt for contamination with oil, grease
and/or dust. If the contamination is slight, remove the
belt and clean with rag or wiping paper. Do not use
gasoline, oil or any other solvent to clean the belt.
(2) During engine overhaul or belt tension adjustment,
closely check the condition of the belt. Replace the
belt with a new one if it has any sort of damage.
Fan Belt Tension
Apply a force of 98 N (10 kgf) [22 lbf] perpendicularly to
the belt at a point midway between the fan pulley and
tension pulley. If necessary, adjust the tension by moving
the tension pulley assembly such that the belt deflects 16
mm (0.63 in) when pressed with the above force. After
adjustment, tighten the tension pulley assembly lock bolt
firmly.
Connecting Radiator Hoses
When connecting the hoses to the radiator, fit their ends
fully on the fittings and secure them with clamps. Tighten
the clamp bolts to the torques indicated below. Make sure
that each hose is correctly retained and prevented from
disconnection by the flare of the fitting.
Clamp bolt tightening torques
3.92 to 5.88 N·m
Upper and lower hoses (0.4 to 0.59 kgf·cm)
[2.9 to 4.3 lbf·ft]
2.94 to 4.9 N
Cooler hose (0.3 to 0.5 kgf)
[2.2 to 3.6 lbf]
2-5
COOLING SYSTEM
Coolant
Fill the radiator with coolant containing antifreeze. Start
and operate the engine to let it warm up while checking for
abnormal noise. Make sure that the quantity of coolant is
as specified by checking the level in the reserve tank.
Quantity of coolant
Unit: liter (U.S. gal.)
Truck Model GP40K, GP40KL, DP40K, DP40KL,
Item GP45K, GP50K DP45K, DP50K
Engine 11.2 (2.96) 7.1 (1.9)
Radiator 3.4 (0.9) 4.7 (1.2)
Reserve tank (FULL level) 0.65 (0.17) 0.65 (0.17)
Total quantity of coolant
15.3 (4.04) 14.7 (3.9)
(including coolant in hoses)
Oil cooler 0.62 (0.16) 0.31 (0.08)
Radiator Cap
90 ± 15 kPa
Opening pressure (0.92 ± 0.15 kgf/cm2)
[13.1 ± 2.2 psi]
0 to 5 kPa
Vacuum valve (0 to 0.05 kgf/cm2)
[0 to 0.73 psi]
2-6
