This guide is written for maintenance supervisors and workshop technicians responsible for industrial equipment cooling systems. It covers daily checks through annual major services, and provides the practical procedures your team can follow without specialist radiator training.
Daily Operator Checks (5 Minutes)
Check Coolant Level (Cold Engine Only)
Inspect the coolant reservoir tank level. Never open the radiator cap on a hot engine — pressurised coolant will eject and cause serious burns. Reservoir should be between MIN and MAX marks.
Visual Leak Check
Walk around the equipment and check under it for puddles or staining from coolant. Green, blue, or orange liquid (depending on coolant type) under the equipment is a leak that needs immediate attention.
Temperature Gauge Behaviour During Warmup
Observe the temperature gauge for the first 10 minutes of operation. It should rise steadily from cold to the normal operating band and stabilise there. Gauge that never rises may indicate a stuck-open thermostat; gauge that rises past normal quickly may indicate a stuck-closed thermostat or coolant loss.
Weekly Checks
- Inspect radiator hoses (top and bottom) for softness, swelling, or cracking
- Check hose clamps for tightness
- Visual inspection of fin face — check for debris accumulation and bent fins
- Inspect fan belt tension (where applicable) — should deflect no more than 10–15mm under thumb pressure
Monthly Service Procedure
- Inspect coolant colour — should be clear, green, blue, or orange depending on type. Brown or milky appearance requires immediate investigation
- Test coolant specific gravity with a hydrometer if operating in cold climates
- Use a coolant test strip to check inhibitor/pH level (5 minutes, no specialist equipment needed)
- Check pressure cap seal condition — replace if seal is hard or cracked
- Inspect radiator mounting brackets and rubber isolators for deterioration
Annual Major Service
- Drain cooling system completely via the drain plug (capture and dispose of old coolant responsibly)
- Flush with radiator flush chemical mixed with water — run engine for 10–15 minutes at temperature
- Drain flush solution completely
- Flush again with clean water until drain runs clear
- Remove radiator and clean external fins with compressed air or gentle water spray
- Pressure test radiator to manufacturer specification (typically 1.0–1.5 kg/cm²)
- Inspect and replace thermostat if over 3 years old
- Replace pressure cap
- Replace all rubber hoses if over 5 years old or showing any deterioration
- Refill with fresh coolant mixture at correct concentration
- Bleed air from system via bleed screws or by running with cap off until no air bubbles
- Run to operating temperature, check for leaks, recheck coolant level after cool-down
We offer on-site radiator inspection, cleaning, pressure testing and repair services for fleets across Mumbai.