5-1
5-1
TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
Charge Air Cooler
Charge Air Cooler
(Illustration 5-3)
(Illustration 5-3)
.
.
The
The
engine
engine
is equipped with a turbocharger which is driven by
is equipped with a turbocharger which is driven by
engine exhaust.
engine exhaust.
The exhaust
The exhaust
turbine of
turbine of
the turbo-
the turbo-
charger is
charger is
coupled to
coupled to
the intake
the intake
turbine.
turbine.
The
The
exhaust turbine
exhaust turbine
drives the
drives the
intake turbine.
intake turbine.
The
The
intake turbine compresses t
intake turbine compresses t
he intake air
he intake air
.
.
The act
The act
of compressing the intake air generates heat and
of compressing the intake air generates heat and
causes the air
causes the air
molecules to expand.
molecules to expand.
T
T
o increase
o increase
combustion efficiency, a charge air cooler is inte-
combustion efficiency, a charge air cooler is inte-
grated into the radiator
grated into the radiator
.
.
The charge
The charge
air cooler
air cooler
is
is
an air to
an air to
air cooler
air cooler
.
.
By reducing the t
By reducing the t
emperature
emperature
of the intake air before it enters the piston cham-
of the intake air before it enters the piston cham-
ber, the air becomes denser
ber, the air becomes denser
.
.
The denser the air
The denser the air
,
,
the more oxygen will be present in the piston
the more oxygen will be present in the piston
chamber during
chamber during
combustion.
combustion.
The more
The more
oxygen in
oxygen in
the chamber, the hotter the combustion cycle
the chamber, the hotter the combustion cycle
becomes.
becomes.
This results
This results
in a more
in a more
complete burn-
complete burn-
ing of t
ing of t
he fuel,
he fuel,
emitting fewer
emitting fewer
pollutants.
pollutants.
This
This
increase in combustion efficiency also creates
increase in combustion efficiency also creates
lower engine operating temperatures, which pro-
lower engine operating temperatures, which pro-
longs the life of the engine and its’ components.
longs the life of the engine and its’ components.
a d a o
o coo be o e
a d a o
o coo be o e
a e p
g o ope
a e p
g o ope
the radiator cap or drain cock.
the radiator cap or drain cock.
Severe injury may occur from
Severe injury may occur from
contact with
contact with
moving
moving
engine parts.
engine parts.
Always
Always
shut down engine before servicing or
shut down engine before servicing or
inspecting cooling system.
inspecting cooling system.
Severe injury or death may
Severe injury or death may
occur from
occur from
ingesting en
ingesting en
gine coolant.
gine coolant.
Coolant
Coolant
is toxic.
is toxic.
Keep away fro
Keep away fro
m children
m children
and pets.
and pets.
Dispose of coolant in accordance with federal
Dispose of coolant in accordance with federal
and local regulations.
and local regulations.
Checking The Coolant Level
Checking The Coolant Level
(Illustration 5-1)
(Illustration 5-1)
.
.
The coolant level should be
The coolant level should be
checked daily
checked daily
.
.
Nor-
Nor-
mally, the coolant level can be maintained by add-
mally, the coolant level can be maintained by add-
ing coolant to
ing coolant to
the recovery
the recovery
bottle.
bottle.
The coolant
The coolant
level is full when the coolant is visible at the cold
level is full when the coolant is visible at the cold
mark (engine has
mark (engine has
not been operated).
not been operated).
If the
If the
cool-
cool-
ant level is too low, add coolant until the coolant
ant level is too low, add coolant until the coolant
level reaches the cold mark on the side of the
level reaches the cold mark on the side of the
recovery
recovery
bottle.
bottle.
Do
Do
not overf
not overf
ill.
ill.
Cooling Requirements.
Cooling Requirements.
The
The
following
following
require-
require-
ments must be followed for trouble-free operation
ments must be followed for trouble-free operation
of the cooling system.
of the cooling system.
1.
1.
Alw
Alw
ays u
ays u
se a prop
se a prop
erl
erl
y cor
y cor
ros
ros
ion in
ion in
hib
hib
ite
ite
d
d
coolant.
coolant.
2.
2.
Mai
Mai
nta
nta
in pres
in pres
cri
cri
bed inh
bed inh
ibi
ibi
tor st
tor st
ren
ren
gth
gth
.
.
3.
3.
Use lo
Use lo
w sili
w sili
cat
cat
e anti
e anti
fre
fre
eze wi
eze wi
th an eth
th an eth
yle
yle
ne
ne
glycol base.
glycol base.
4.
4.
Alw
Alw
ays fo
ays fo
llo
llo
w the man
w the man
ufa
ufa
ctu
ctu
rer’
rer’
s reco
s reco
mme
mme
n-
n-
dations on
dations on
inhibitor usage
inhibitor usage
and handling.
and handling.
Refer
Refer
to the engine operation and maintenance
to the engine operation and maintenance
manual
manual
for coolant requirements.
for coolant requirements.
5.
5.
Do
Do
No
No
t u
t u
se
se
so
so
lu
lu
bl
bl
e o
e o
il
il
!
!
6.
6.
Seal
Seal
er ty
er ty
pe ant
pe ant
ifr
ifr
eez
eez
e sho
e sho
uld N
uld N
ot be us
ot be us
ed.
ed.
Draining / Flushing The Cooling System.
Draining / Flushing The Cooling System.
The
The
cooling system should be drained and flushed
cooling system should be drained and flushed
periodically (refer to the
periodically (refer to the
Preventive Maintenance
Preventive Maintenance
chart in the
chart in the
Appendices
Appendices
for cooling system drain /
for cooling system drain /
flush interval).
flush interval).
The cooling s
The cooling s
ystem is
ystem is
drained by
drained by
opening the drain cock on the bottom of the radia-
opening the drain cock on the bottom of the radia-
tor.
tor.
Removal of the radiator c
Removal of the radiator c
ap will allow air to
ap will allow air to
enter the cooling passages, decreasing drain time
enter the cooling passages, decreasing drain time
and ensuring that the coolant drains completely
and ensuring that the coolant drains completely
from the s
from the s
ystem.
ystem.
Leave the drain c
Leave the drain c
ock open until
ock open until
all coolant has been allowed to drain from the
all coolant has been allowed to drain from the
system.
system.
fully open when the coolant temperature reaches
fully open when the coolant temperature reaches
approximately 205
approximately 205
F (96
F (96
C).
C).
General Information
General Information
C
C
o
o
o
o
l
l
a
a
n
n
t
t
C
C
a
a
p
p
a
a
c
c
i
i
t
t
y
y
8
8
G
G
a
a
l
l
l
l
o
o
n
n
s
s
(30.3 Liters)
(30.3 Liters)
Inspection.
Inspection.
Components of the cooling system
Components of the cooling system
should be checked periodically to keep the engine
should be checked periodically to keep the engine
operating at peak ef
operating at peak ef
ficiency.
ficiency.
The radiator
The radiator
and
and
charge air cooler should be inspected externally
charge air cooler should be inspected externally
for excessive
for excessive
dirt or oil
dirt or oil
buildup.
buildup.
The radiator and
The radiator and
charge air cooler should be cleaned externally as
charge air cooler should be cleaned externally as
conditions warrant.
conditions warrant.
The cooling
The cooling
system
system
hoses
hoses
should be inspected and any hose that is abnor-
should be inspected and any hose that is abnor-
mally hard or soft should be replaced immediately.
mally hard or soft should be replaced immediately.
Check the hose clamps to make sure they are
Check the hose clamps to make sure they are
tight.
tight.
All external
All external
leaks should
leaks should
be corrected
be corrected
as
as
soon as
soon as
detected.
detected.
The shroud
The shroud
should be
should be
tight
tight
against the radiator core to prevent recirculation of
against the radiator core to prevent recirculation of
air which may
air which may
lower cooling ef
lower cooling ef
ficiency.
ficiency.
Check the
Check the
fan belts for proper tension.
fan belts for proper tension.
Charge Air Cooler Cleaning.
Charge Air Cooler Cleaning.
The charge air
The charge air
cooler must be cleaned internally upon engine
cooler must be cleaned internally upon engine
turbocharger failure or any other occasion where
turbocharger failure or any other occasion where
oil or debris enters
oil or debris enters
the charge air cooler
the charge air cooler
.
.
Refer to
Refer to
the engine manufacturers manual for cleaning
the engine manufacturers manual for cleaning
instructions.
instructions.
Drive Belt Tension.
Drive Belt Tension.
The proper tension should
The proper tension should
be maintained on
be maintained on
all drive belts
all drive belts
.
.
Refer to
Refer to
Drive
Drive
B lt T
i
B lt T
i
i
i
S
ti
1
S
ti
1
f
th
t
i
f
th
t
i
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