5-15-1TX / TXH / TXB 180S - 400L (Rev. 4/23/07)TX / TXH / TXB 180S - 400L (Rev. 4/23/07)
Charge Air CoolerCharge Air Cooler
(Illustration 5-3)(Illustration 5-3).. The The engineengine
is equipped with a turbocharger which is driven byis 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. TheThe
exhaust turbine exhaust turbine drives the drives the intake turbine. intake turbine. TheThe
intake turbine compresses tintake turbine compresses the intake airhe intake air. . The actThe act
of compressing the intake air generates heat andof compressing the intake air generates heat and
causes the air causes the air molecules to expand. molecules to expand. TTo increaseo increase
combustion efficiency, a charge air cooler is inte-combustion efficiency, a charge air cooler is inte-
grated into the radiatorgrated into the radiator. . The charge The charge air cooler air cooler isis
an air to an air to air coolerair cooler. . By reducing the tBy reducing the temperatureemperature
of the intake air before it enters the piston cham-of the intake air before it enters the piston cham-
ber, the air becomes denserber, the air becomes denser. . The denser the airThe denser the air,,
the more oxygen will be present in the pistonthe more oxygen will be present in the piston
chamber during chamber during combustion. combustion. The more The more oxygen inoxygen in
the chamber, the hotter the combustion cyclethe chamber, the hotter the combustion cycle
becomes. becomes. This results This results in a more in a more complete burn-complete burn-
ing of ting of the fuel, he fuel, emitting fewer emitting fewer pollutants. pollutants. ThisThis
increase in combustion efficiency also createsincrease 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 ea d a o o coo be o e a e p g o opea e p g o ope
the radiator cap or drain cock.the radiator cap or drain cock.
Severe injury may occur fromSevere injury may occur from
contact with contact with moving moving engine parts. engine parts. AlwaysAlways
shut down engine before servicing orshut down engine before servicing or
inspecting cooling system.inspecting cooling system.
Severe injury or death maySevere injury or death may
occur from occur from ingesting eningesting engine coolant. gine coolant. CoolantCoolant
is toxic. is toxic. Keep away froKeep away from children m children and pets.and pets.
Dispose of coolant in accordance with federalDispose of coolant in accordance with federal
and local regulations.and local regulations.
Checking The Coolant LevelChecking The Coolant Level(Illustration 5-1)(Illustration 5-1)..
The coolant level should be The coolant level should be checked dailychecked 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 coolantThe coolant
level is full when the coolant is visible at the coldlevel 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 coolantant level is too low, add coolant until the coolant
level reaches the cold mark on the side of thelevel reaches the cold mark on the side of the
recovery recovery bottle. bottle. Do Do not overfnot overfill.ill.
Cooling Requirements.Cooling Requirements. The The following following require-require-
ments must be followed for trouble-free operationments must be followed for trouble-free operation
of the cooling system.of the cooling system.
1.1. AlwAlways uays use a propse a properlerly cory corrosrosion inion inhibhibiteitedd
coolant.coolant.
2.2. MaiMaintantain presin prescricribed inhbed inhibiibitor sttor strenrengthgth..
3.3. Use loUse low siliw silicatcate antie antifrefreeze wieze with an ethth an ethyleylenene
glycol base.glycol base.
4.4. AlwAlways foays follollow the manw the manufaufactucturer’rer’s recos recommemmen-n-
dations on dations on inhibitor usage inhibitor usage and handling. and handling. ReferRefer
to the engine operation and maintenanceto the engine operation and maintenance
manualmanualfor coolant requirements.for coolant requirements.
5.5. Do Do NoNot ut use se sosolulublble oe oilil!!
6.6. SealSealer tyer type antpe antifrifreezeeze shoe should Nuld Not be usot be used.ed.
Draining / Flushing The Cooling System.Draining / Flushing The Cooling System. TheThe
cooling system should be drained and flushedcooling system should be drained and flushed
periodically (refer to theperiodically (refer to the Preventive MaintenancePreventive Maintenance
chart in thechart in the AppendicesAppendicesfor cooling system drain /for cooling system drain /
flush interval). flush interval). The cooling sThe cooling system is ystem is drained bydrained 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 cRemoval of the radiator cap will allow air toap will allow air to
enter the cooling passages, decreasing drain timeenter the cooling passages, decreasing drain time
and ensuring that the coolant drains completelyand ensuring that the coolant drains completely
from the sfrom the system. ystem. Leave the drain cLeave the drain cock open untilock open until
all coolant has been allowed to drain from theall coolant has been allowed to drain from the
system.system.
fully open when the coolant temperature reachesfully open when the coolant temperature reaches
approximately 205approximately 205
F (96F (96
C).C).
General InformationGeneral Information
CCoooollaannt t CCaappaacciittyy 8 8 GGaalllloonnss
(30.3 Liters)(30.3 Liters)
Inspection.Inspection. Components of the cooling systemComponents of the cooling system
should be checked periodically to keep the engineshould be checked periodically to keep the engine
operating at peak efoperating at peak efficiency. ficiency. The radiator The radiator andand
charge air cooler should be inspected externallycharge air cooler should be inspected externally
for excessive for excessive dirt or oil dirt or oil buildup. buildup. The radiator andThe radiator and
charge air cooler should be cleaned externally ascharge air cooler should be cleaned externally as
conditions warrant. conditions warrant. The cooling The cooling system system hoseshoses
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 areCheck the hose clamps to make sure they are
tight. tight. All external All external leaks should leaks should be corrected be corrected asas
soon as soon as detected. detected. The shroud The shroud should be should be tighttight
against the radiator core to prevent recirculation ofagainst the radiator core to prevent recirculation of
air which may air which may lower cooling eflower cooling efficiency. ficiency. Check theCheck the
fan belts for proper tension.fan belts for proper tension.
Charge Air Cooler Cleaning.Charge Air Cooler Cleaning. The charge airThe charge air
cooler must be cleaned internally upon enginecooler must be cleaned internally upon engine
turbocharger failure or any other occasion whereturbocharger failure or any other occasion where
oil or debris enters oil or debris enters the charge air coolerthe charge air cooler. . Refer toRefer to
the engine manufacturers manual for cleaningthe engine manufacturers manual for cleaning
instructions.instructions.
Drive Belt Tension.Drive Belt Tension. The proper tension shouldThe proper tension should
be maintained on be maintained on all drive beltsall drive belts. . Refer toRefer to DriveDrive
B lt T iB lt T i ii S ti 1S ti 1 f th t if th t i
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