Section 10 Chapter 15

Transcription

1 Section 10 Chapter Valve, 8.3 Liter Engine Note: All coding used in the 8.3 Liter and 9 Liter engine manuals are Cummins engine codes. These engine codes have no meaning to New Holland warranty codes and should only be used for procedure steps NH

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3 24 Valve, 8.3 Liter Engine Page a Contents Coolant Filter ( )... 5 Install ( )... 6 Remove ( )... 5 Coolant Filter Head ( )... 6 Clean ( )... 7 Install ( )... 7 Remove ( )... 6 Coolant Filter Valve ( )... 8 Install ( )... 9 Remove ( )... 8 Coolant Heater ( ) Clean ( ) Install ( ) Preparatory ( ) Remove ( ) Coolant Temperature Gauge ( )... 5 General Information... 5 Initial Check ( )... 5 Coolant Thermostat ( ) Clean ( ) General Information Inspect for Reuse ( ) Install ( ) Leak Test ( ) Remove ( ) ( ) General Information Drive Belt, Cooling Fan ( )... 4 Inspect for Reuse ( )... 4 Install ( )... 4 Remove ( )... 4 Fan Clutch, On-Off ( ) General Information Fan Shroud Assembly ( ) General Information Initial Check ( ) Fan Spacer and Pulley ( ) Remove ( ) NHSection 10 Chapter 15 Issued

4 Page b 24 Valve, 8.3 Liter Engine Fan, Cooling ( ) Inspect for Reuse ( ) Install ( ) Remove ( ) Flow Diagram,... 1 Radiator ( ) General Information Initial Check ( ) Radiator Hoses ( ) Inspect for Reuse ( ) Radiator Pressure Cap ( ) General Information Inspect for Reuse ( ) Specifications Water Pump ( ) General Information Inspect for Reuse ( ) Install ( ) Preparatory ( ) Remove ( ) NHSection 10 Chapter 15 Issued

5 24 Valve, 8.3 Liter Engine Flow Diagram, Page 1 Flow Diagram, The following illustration identifies the significant features of the cooling system. 1. Coolant is drawn from the radiator by the integrally mounted water pump. The output from the water pump empties into the oil cooler cavity of the cylinder block. 2. The coolant then circulates around each cylinder and crosses the block to the fuel pump side of the engine. 3. Coolant then flows up into the cylinder head, crosses over the valve bridges and down the exhaust manifold side of the engine to the integral thermostat housing. 4. As the coolant flows across the head toward the thermostat housing, it provides coolant for the injector. When the engine is below operating temperature, the thermostat is closed, and the coolant flow bypasses the radiator and goes to the water pump inlet through internal drillings in the block. When operating temperature is reached, the thermostat opens, blocking the bypass passage to the water pump and opening the outlet to the radiator., CAUTION, Never operate the engine without a thermostat. Without a thermostat, the coolant will not flow to the radiator and the engine will overheat.

6 Flow Diagram, 24 Valve, 8.3 Liter Engine Page 2 1. Coolant Inlet from Radiator 2. Water Pump Suction 3. Coolant Flow through Lubricating Oil Cooler 4. Block Lower Water Manifold (to cylinders) 5. Coolant Filter Inlet 6. Coolant Filter Outlet 7. Coolant Supply To Cylinder Head 8. Coolant Return from Cylinder Head 9. Block Upper Water Manifold 10. Thermostat Bypass 11. Coolant Return to Radiator

7 24 Valve, 8.3 Liter Engine Specifications Page 3 Specifications Coolant Capacity (Engine Only) liters [11.5 qt] Standard Modulating Thermostat- Range to 91 C [180 to 195 F] Maximum Allowable Operating Temperature C [212 F] Minimum Recommended Operating Temperature C [158 F ] Minimum Recommended Pressure Cap kpa [15 psi]

8 Drive Belt, Cooling Fan ( ) Page 4 24 Valve, 8.3 Liter Engine Drive Belt, Cooling Fan ( ) Remove ( ) 3/8-Inch Square Drive Lift the tensioner to remove the drive belt. NOTE: The belt tensioner is spring loaded and must be pivoted away from the drive belt. Pivoting in the wrong direction can result in damage to the belt tensioner. Inspect for Reuse ( ) Inspect the belt for: Cracks Glazing Tears or cuts Excessive wear. Inspect the drive belt pulleys and idlers for cracked or broken grooves. Refer to the following sections if a pulley or idler is damaged: Inspect fan pulley. Refer to Procedure Inspect crankshaft pulley. Refer to Procedure Inspect alternator drive belt. Refer to Procedure Inspect water pump idler. Refer to Procedure Belt tensioner idler. Refer to Procedure Install ( ) 3/8-Inch Square Drive Lift and hold the belt tensioner. Install the drive belt and release the tensioner. NOTE: The belt tensioner is spring loaded and must be pivoted away from the drive belt. Pivoting in the wrong direction can result in damage to the belt tensioner.

9 24 Valve, 8.3 Liter Engine Coolant Temperature Gauge ( ) Page 5 Coolant Temperature Gauge ( ) General Information Gauges and sensors are used in the system to measure the coolant temperature. These can malfunction and provide an incorrect temperature reading. The coolant temperature sensor used by the engine control system is discussed in Procedure of the 24 Valve, 8.3 Liter, Fuel System Troubleshooting and Repair Manual. Initial Check ( ) Check for a blown fuse. Check the wiring from the gauge to the sending unit for a broken connection. Refer to the vehicle service manual. Use a temperature gauge of known accuracy to check the existing gauge. Replace a faulty gauge or sending unit. Coolant Filter ( ) Remove ( ) Turn the shutoff valve to the OFF position. Remove and discard the coolant filter. Clean the gasket surface.

10 Coolant Filter Head ( ) Page 6 24 Valve, 8.3 Liter Engine Install ( ), CAUTION, Do not allow oil to get into the filter. Oil will damage the DCA., CAUTION, Mechanical overtightening can distort the threads or damage the filter head. Apply a thin film of lubricating oil to the gasket sealing surface before installing the new coolant filter. Install the coolant filter on the filter head. Tighten the filter until the gasket contacts the filter head surface. Tighten the coolant filter an additional 1/2 to 3/4 of a turn, or as specified by the filter manufacturer., CAUTION, The valve must be in the ON position to prevent engine damage. Open the shutoff valve and install the coolant system pressure cap. Operate the engine and check for coolant leaks. After the air has been purged from the system, check the coolant level again. Coolant Filter Head ( ) Remove ( ), WARNING, Some coolants are toxic. Keep away from children and pets. Dispose in a accordance with local environmental regulations. Drain at least three gallons of coolant from the cooling system. Refer to Procedure Remove the coolant filter. Refer to Procedure

11 24 Valve, 8.3 Liter Engine Coolant Filter Head ( ) Page 7 Loosen the four filter head capscrews. Remove the filter head and gasket. Clean ( ) Clean the mating surfaces. Install ( ) Install a new gasket and the filter head. Tighten the four capscrews. Install the coolant filter. Refer to Procedure Torque Value: 24 N m [18 ft-lb] Fill the cooling system with either a 50/50 mixture of good quality water and fully formulated antifreeze or fully formulated coolant. The fully formulated antifreeze or coolant must meet TMC RP329 or TMC RP330 specifications.

12 Coolant Filter Valve ( ) Page 8 24 Valve, 8.3 Liter Engine Operate the engine and check for leaks. Coolant Filter Valve ( ) Remove ( ) Remove the coolant filter head. Refer to Procedure Loosen the shutoff valve screw from the end of the valve. Remove the two pieces of the shutoff valve from both sides of the valve bore.

13 24 Valve, 8.3 Liter Engine Coolant Filter Valve ( ) Page 9 Install ( ) Replace the shutoff valve o-rings. Lubricate the o-rings before installing the valve pieces back into the bore. Tighten the shutoff valve screw to tighten the two pieces of the valve together. Install the coolant filter head on the engine. Refer to Procedure Install the coolant filter. Refer to Procedure Fill the cooling system with either a 50/50 mixture of good quality water and fully formulated antifreeze or fully formulated coolant. The fully formulated antifreeze or coolant must meet TMC RP329 or TMC RP330 specifications.

14 Coolant Heater ( ) Page Valve, 8.3 Liter Engine Operate the engine and check for leaks. Coolant Heater ( ) Preparatory ( ) Drain at least 19 liters [5 U.S. gal] of coolant. Refer to Procedure Disconnect the block heater electrical cord. Remove ( ) 1-1/8 Inch Loosen the block heater and remove it from the block. Clean ( ) Clean the heater threads thoroughly.

15 24 Valve, 8.3 Liter Engine Coolant Heater ( ) Page 11 Install ( ) Lubricate the new heater with clean engine oil. 1-1/8 Inch Install the heater. Torque Value: 43 N m [32 ft-lb] Attach the heater electrical cord. Operate the engine and check for leaks.

16 Coolant Thermostat ( ) Page Valve, 8.3 Liter Engine Coolant Thermostat ( ) General Information The thermostat controls the coolant temperature. When the coolant temperature is below operating temperature, coolant is bypassed to the inlet of the water pump. When the coolant temperature reaches the operating range, the thermostat opens, sealing off the bypass, forcing coolant to flow to the radiator. The thermostat begins opening at 82 C [180 F]., CAUTION, Never operate the engine without a thermostat. Without a thermostat, the path of least resistance for the coolant is through the bypass to the pump inlet. This will cause the engine to overheat. An incorrect or malfunctioning thermostat can cause the engine to run too hot or too cold. Remove ( ) 10 mm Remove the water outlet tube capscrews and water outlet tube. Refer to Procedure Remove the thermostat. Clean ( ) Clean all mating surfaces. NOTE: Do not let any debris fall into the thermostat cavity when cleaning the surfaces.

17 24 Valve, 8.3 Liter Engine Coolant Thermostat ( ) Page 13 Inspect for Reuse ( ) Inspect the thermostat for damage. NOTE: Do not allow the thermostat or thermometer to touch the container. Heat the water and check the thermostat as follows: Suspend the thermostat and a 100 C [212 F] thermometer in a container of water. The nominal operating temperature is stamped on the thermostat. The thermostat must meet the following criteria: The thermostat must begin to open within 1 C [2 F] of this nominal temperature. The thermostat must be fully open within 12 C [22 F] of this nominal temperature. The fully open distance between the thermostat flange and housing is 9.4 mm [0.370 in]. Leak Test ( ) The engine thermostat and thermostat seal must operate properly in order for the engine to operate in the most efficient heat range. Overheating or overcooling will shorten engine life.

18 Coolant Thermostat ( ) Page Valve, 8.3 Liter Engine, WARNING, Complete this test with the engine coolant temperature below 49 C [120 F]. Hot steam can cause serious personal injury. Remove the radiator hose from the thermostat housing. Use an electronic service tool to monitor the coolant temperature. Install a thermocouple or temperature gauge, which is known to be accurate, in the water heater plate on the engine side of the thermostat housing. Install a hose of the same size on the thermostat housing outlet long enough to reach a remote dry container used to collect coolant. Install and tighten a hose clamp on the housing outlet. Place the other end of the hose in a dry container. Operate the engine at rated speed for 1 minute. Shut off the engine and measure the amount of coolant collected in the container. The amount of coolant collected must not be more than 100 cc [3.3 fl. oz.].

19 24 Valve, 8.3 Liter Engine Coolant Thermostat ( ) Page 15 If more than 100 cc [3.3 fl. oz.] of coolant is collected, the thermostat is leaking and must be replaced. Complete the following test in-chassis to determine the thermostat opening temperature. Start the engine and monitor the water temperature with an electronic service tool or a gauge. Keep the engine speed below 1500 rpm during the test. Thermostat Initial Opening Temperature C F 81 MIN MAX 182 Shut off the engine when the coolant starts to flow. If coolant does not start flowing into the container during the initial opening temperature range, the thermostat must be replaced. Refer to Procedure Install ( ) Install the new thermostat into the thermostat housing. Make sure the top and bottom o-rings are in place.

20 ( ) Page Valve, 8.3 Liter Engine 10 mm Install the water outlet tube and capscrews. Torque Value: 24 N m [18 ft-lb], CAUTION, Be sure to vent the engine and aftercooler during filling, to remove air from the coolant system or overheating will result. Fill the cooling system. Operate the engine and check for leaks. ( ) General Information The function of the cooling system is to maintain a specified operating temperature for the engine. Some of the heat generated by the engine is absorbed by the coolant flowing through the passages in the cylinder block and head. Then, heat is removed from the coolant as it flows through the radiator. The accompanying chart illustrates the coolant flow through the engine. For more detail, refer to the coolant flow diagrams. 1. Water pump 2. Engine block, oil cooler, cylinder head, other accessories (e.g., heater core) 3. Thermostat 4. Radiator

21 24 Valve, 8.3 Liter Engine ( ) Page 17 Open the petcocks at the bottom of the radiator and at the bottom of the oil cooler housing. Remove the lower radiator hose. A 20 liter [4 U.S. gallons] drain pan will contain the coolant in most applications. When you troubleshoot overheating, remember that too much oil in the oil pan can cause additional heat from friction when the rod journals are submerged in oil. Overfilling with oil raises the oil temperature that is transferred to the cooling system at the oil cooler. The system is designed to use a specific quantity of coolant. If the coolant level is low, the engine will run hot. NOTE: The engine or system has a leak if frequent addition of coolant is necessary. Find and repair the leak., CAUTION, The engine coolant passages must be completely filled with coolant. During operation, entrapped air mixes with the coolant, which results in cavitation corrosion and poor heat transfer. Highly aerated coolant can cause localized overheating of the cylinder head and block that can result in a cracked head, scored cylinder liner, or blown head gasket.

22 ( ) Page Valve, 8.3 Liter Engine Obstructions in the coolant passages will reduce coolant flow, which can lead to overheating. NOTE: The small holes in the head gasket are especially susceptible to plugging. Their size is critical. Do not enlarge the size of the orifices. To do so will disturb the coolant flow and will not solve an overheating problem., CAUTION, Never use water alone for coolant. Damage from corrosion can result. Water will cause rust formation, reducing the flow in the smaller coolant passages. Also, water used as a coolant for even a relatively short period can result in the expansion plugs rusting through, which will allow the coolant to leak. NOTE: A sudden loss of coolant from a heavily loaded engine can result in severe damage to the pistons and cylinder bore. Overfueling and Loading, CAUTION, Overfueling can cause the engine to overheat. Make sure that the correct engine electronic control module (ECM) calibration is being used., CAUTION, Constant overloading (lugging) can cause the engine to run hot.

23 24 Valve, 8.3 Liter Engine ( ) Page 19 Fully Formulated Coolant/Antifreeze CDC recommends using either a 50/50 mixture of good quality water and fully formulated antifreeze, or fully formulated coolant when filling the cooling system. The fully formulated antifreeze or coolant must meet TMC RP329 or TMC RP330 specifications. Good quality water is important for cooling system performance. Excessive levels of calcium and magnesium contribute to scaling problems, and excessive levels of chlorides and sulfates cause cooling system corrosion. Fully formulated antifreeze must be mixed with good quality water at a 50/50 mix (40 to 60 percent working range). A 50/50 mixture of antifreeze and water gives a -36 C [- 34 F] freezing point and a boiling point of 110 C [228 F], which is adequate for locations in North America. The actual lowest freezing point of ethylene glycol antifreeze is at 68 percent. Using higher concentrations of antifreeze will raise the freezing point of the solution and increase the possibility of a silicate gel problem. Sealing Additives Do not use sealing additives in the cooling system. The use of sealing additives will: Build up in coolant low flow areas Clog coolant filters Plug radiator and oil cooler.

24 Fan Clutch, On-Off ( ) Page Valve, 8.3 Liter Engine Soluble Oils Do not use soluble oils in the cooling system. The use of soluble oils will: Corrode brass and copper Damage heat transfer surfaces Damage seals and hoses. Fan Clutch, On-Off ( ) General Information Many fan clutches can be controlled by the engine's electronic control module (ECM). The ECM monitors coolant temperature and intake manifold temperature to determine when to engage the cooling fan. Some applications have additional sensors monitored by the ECM for fan control (for example, air conditioner pressure and transmission temperature). These are various fan clutch types, such as air engaged, air disengaged, electric, viscous, and ON/OFF. Refer to the equipment manufacturer's service manual to determine fan clutch type. The ECM is capable of using either a zero VDC or 12 VDC signal to engage the fan clutch. The enable logic is contained in the ECM calibration and can be programmed using an electronic service tool. Refer to the vehicle service manual for fan clutch troubleshooting and repair information. Fan Shroud Assembly ( ) General Information The radiator or fan shroud is used to direct all air flow across the radiator fins rather than around the edges of the radiator. An incorrect fan shroud or obstructions can reduce air flow and cause the engine to run hot. NOTE: Check to be sure air is not recirculating. Check for missing baffles.

25 24 Valve, 8.3 Liter Engine Fan Spacer and Pulley ( ) Page 21 Initial Check ( ), CAUTION, The fan shroud must be installed correctly, be in good condition, and the shroud to fan clearance must be within the manufacturer's specifications to ensure proper air flow through the radiator to provide adequate engine cooling. Inspect the fan shroud for proper fan clearance, cracks, air leaks, and damage. Replace if necessary. CDC recommends that fan clearance be between 5.08 to cm [2 to 4 in] from the radiator core. Fan Spacer and Pulley ( ) Remove ( ) 3/8-Inch Square Drive Lift the tensioner to relieve tension in the belt. Remove the belt. Refer to Procedure NOTE: The belt tensioner is spring loaded and must be pivoted away from the drive belt. Pivoting in the wrong direction can result in damage to the belt tensioner. 15 mm Remove the fan capscrews, fan, and spacer. Remove the fan pulley.

26 Fan, Cooling ( ) Page Valve, 8.3 Liter Engine Install ( ) 15 mm Install the fan pulley. Install the spacer, fan, and fan capscrews. Torque Value: 51 to 62 N m [37 to 45 ft-lb] 3/8-Inch Square Drive Lift the tensioner and install the belt. Refer to Procedure Service Tip: If difficulty is experienced installing the drive belt (i.e., the belt seems too short), position the belt over the grooved pulleys first and then, while holding the tensioner up, slide the belt over the water pump pulley. Fan, Cooling ( ) Remove ( ) 15 mm Remove the fan capscrews, the fan, and spacer. Inspect for Reuse ( ), WARNING, Do not rotate the engine by pulling or prying on the fan. The fan blade(s) can be damaged and cause the fan to fail and cause serious personal injury or property damage. Use the engine barring gear to rotate the crankshaft.

27 24 Valve, 8.3 Liter Engine Fan, Cooling ( ) Page 23 Inspect the cooling fan daily. Check for cracks, loose rivets, and bent or loose blades. Check the fan to make sure it is securely mounted. Tighten the capscrews if necessary., WARNING, Do not straighten a bent fan blade or continue to use a damaged fan. A bent or damaged fan blade can fail during operation and cause serious personal injury or property damage. Replace any fan that is damaged with a fan of the identical part number. CDC must approve any other fan changes. Install ( ) 15 mm Install the spacer, fan, and fan capscrews. Torque Value: 51 to 62 N m [37 to 45 ft-lb]

28 Radiator ( ) Page Valve, 8.3 Liter Engine Radiator ( ) General Information Air forced through the fins of the radiator by a fan cools the coolant pumped through the radiator. Environmental debris (such as paper, straw, lint, and dust) can obstruct the fins and stop the flow of air that will reduce the cooling effect of the radiator. Initial Check ( ), CAUTION, Wear appropriate eye and face protection when using compressed air. Improper use can cause bodily injury from flying debris and dirt. Inspect for plugged radiator fins. Use compressed air to blow out the dirt and debris. Air Pressure: 552 kpa [80 psi] Inspect for bent or broken fins. Inspect for radiator core and gasket leaks. If the radiator must be replaced, refer to the equipment manufacturer's replacement procedures., WARNING, If a liquid refrigerant system must be removed before removing the radiator, wear eye and face protection. Wrap cloth around the fittings before removal. Liquid refrigerant can cause serious eye and skin injury. Recycle refrigerant according to accepted practices.

29 24 Valve, 8.3 Liter Engine Radiator Hoses ( ) Page 25 Radiator Hoses ( ) Inspect for Reuse ( ) Inspect all hoses for cracks, cuts, or collapsing. Radiator Pressure Cap ( ) General Information The system is designed to use a pressure cap to prevent boiling of the coolant. Radiator Cap Pressure Test System Cap A (Normal Duty) 104 C [220 F] 103 kpa [15 psi] An incorrect or malfunctioning cap can result in the loss of coolant and the engine running hot. Air in the coolant can result in loss of coolant from the overflow when the aerated coolant is hot. The heated air expands, increasing the pressure in the system, causing the cap to open. Similarly, coolant can be displaced through the overflow if the head gasket leaks compression gases to the coolant system.

30 Water Pump ( ) Page Valve, 8.3 Liter Engine The operating pressure of the cooling system and the lubricating system can result in the mixing of the fluids if there is a leak between the systems such as the head gasket or oil cooler. Refer to Section 10, Chapter14, Lubricating Oil System. Transmission fluid can also leak into the coolant through radiator bottom tank transmission oil coolers. Inspect for Reuse ( ) Be sure the correct radiator cap is being used. Refer to Procedure , General Information. Inspect the rubber seal of the pressure cap for damage. Inspect the radiator fill neck for cracks or other damage. Refer to the equipment manufacturer's service manual for instructions if the fill neck is damaged. Pressure test the radiator cap. The pressure cap must seal within 14 kpa [2 psi] of the value stated on the cap, or it must be replaced. Refer to the vehicle service manual for radiator cap test procedure. Water Pump ( ) General Information The water pump pulls coolant from the bottom of the radiator and pumps it through the engine back to the top of the radiator for cooling. Reduced or interrupted flow will result in the engine running hot.

31 24 Valve, 8.3 Liter Engine Water Pump ( ) Page 27 The pump is belt driven from the crankshaft pulley. An automatic belt tensioner is used to prevent the belt from slipping on the pump pulley. A malfunction of the tensioner will cause the water pump impeller to rotate at a slower speed, reducing the amount of coolant flow. The coolant flow can also be reduced if the inlet hose to the water pump collapses. A hose will usually not collapse while the engine is running at low speed. Check the hose while the engine is running at rated speed. NOTE: Be sure the engine is warm, a minimum of 90.6 C [195 F], so the thermostat is open. A worn or malfunctioning water pump will not produce the flow required to prevent the engine from running hot. However, be sure to check the other possibilities indicated in the Coolant Temperature Above Normal symptom chart in Section TS, Troubleshooting Symptoms, before checking the flow or replacing the pump. Preparatory ( ) Drain the coolant. Refer to Procedure Remove the drive belt. Refer to Procedure

32 Water Pump ( ) Page Valve, 8.3 Liter Engine Remove ( ) 13 mm Remove the water pump capscrews and water pump. Clean ( ) Clean the o-ring sealing surface on the water pump housing. Inspect for Reuse ( ) Inspect the water pump housing and impeller for cracks or damage. Inspect the water pump weep hole for an indication of a steady leak. NOTE: A streak or chemical buildup at the weep hole is not justification for water pump replacement. If a steady flow of coolant or oil is observed, replace the water pump with a new or rebuilt unit. Install ( ) Install a new sealing ring into the pump groove.

33 24 Valve, 8.3 Liter Engine Water Pump ( ) Page mm Install the water pump. Torque Value: 24 N m [18 ft-lb] 3/8-Inch Square Drive Lift the tensioner and install the belt. Refer to Procedure Service Tip: If difficulty is experienced installing the drive belt (i.e., the belt seems too short), position the belt over the grooved pulleys first and then, while holding the tensioner up, slide the belt over the water pump pulley. Fill the cooling system. Refer to Procedure Close the drain valves. Install all hoses previously removed. Install the pressure cap. Operate the engine until it reaches a temperature of 80 C [180 F], and check for coolant leaks.

34 Water Pump ( ) Page Valve, 8.3 Liter Engine