chapter one

Internal Combustion Engine cooling system

CHAPTER ONE

INTERNAL COMBUSTION ENGINE COOLING SYSTEM

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chapter one 1-1 Introduction

Internal Combustion Engine cooling system

The function of the cooling system is to remove the heat from the engine adequately to keep the temperature inside the engine within certain limits. The cooling system could be by water circulated in the system or by air A typical energy balance in a DG set indicates following break-up : Input : 100% Thermal Energy Outputs: 33% of this total heat is converted into crankshaft horsepower (Electrical Output ) 30% is expelled through exhaust (Stack Loss through Flue Gases) 7% is radiated directly into the atmosphere from engine surfaces 30% must be dissipated through a carefully designed cooling system (coolant losses) The cooling system must remove heat in order to keep the engine at the correct operating temperature.
Figure(1-1):cooling system

1-2 Bad effect of high temperature in the engine

(i) (ii) Cylinder and piston may expand to such an extent that the piston would seize in the cylinder and stop the engine. lubricating quality of the oil inside the cylinder would be destroyed due to high temperature and there may not be sucking of air in the cylinder. Pr-ignition of fuel mixture would take place and would cause engine knocking as well as loss of power.

(iii)

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For satisfactory performance of the engine, neither overheating nor overcooling is desirable. Experiments have shown that best operating temperature of I.C engine lies between 140F to 200 F, depending upon types of engines and load conditions.

1-3 types of Cooling System

1- water cooling systems using a radiator and a fan to remove the heat from the engine and other systems on a machine. 2- air cooling systems using a heat exchanger, keel coolers, or cooling towers to remove heat.

1-4 Air cooling system

The air cooling system have metal FINS on the outer perimeter of the engine. Heat is transferred from the engine, through these fins, into the atmosphere. Principle of air cooling
Figure(1-2):air cooling system

The cylinder of an air cooled engine has fins to increase the area of contact of air for speedy cooling. The cylinder is normally enclosed in a sheet metal casing called Cowling. The flywheel has blades projecting from its face, so that it acts like a fan drawing air through a hole in the cowling and directing it around the finned cylinder. For maintenance of air cooling system, passage of air is kept clean by removing grasses etc. This is done by removing the cowling and cleaning out the dirt etc. by a stiff brush or compressed air. When separate fan is provided, the belt tension is to be checked and adjusted if necessary. Advantages of air cooling It is simpler in design and construction. Water jackets, radiators, water pump, thermostat, pipes, hoses etc. are not needed. It is more compact. It is comparatively lighter in weight.
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Disadvantages

Internal Combustion Engine cooling system

There is uneven cooling of the engine parts. Engine generally high during working period.

temperature

is

1-5 Water and air cooling system

Engines, using water as cooling medium is called water cooled engines. The liquid is circulated round the cylinders to absorb heat from the cylinder walls. In general, water is used as cooling liquid. The heated water is conducted through a radiator which helps in cooling the water. There are three common methods of water cooling: (i) Open jacket or hopper method, (ii) Thermo siphon method, and (iii) Forced circulation method. 1-5-1 Forced circulation method In this method, a water pump is used to force water from the radiator to the water jacket of the engine. After circulating the entire run of water jacket, hot water goes to the radiator, where it passes through tubes surrounded by air. A fan is driven with the help of a V-belt to suck air through tubes of the radiator unit, cooling radiator water. To maintain the correct engine temperature, a thermostat valve is placed at the outer end of cylinder head. Cooling liquid is by-passed through the water jacket of the engine until engine attains the desired temperature. Then thermostat valve opens and the by-pass is closed, allowing the water to go to the radiator.

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1-5-2 basic Components of Cooling System water pump engine oil Cooler water temperature Regulators fan radiator radiator cap
Figure(1-3):typical cooling system

coolant 1-5-3 Jacket Water After cooler (JWAC) Operation * coolant flows to jacket water pump (1) through an elbow that connects to the radiator or heat exchanger (11). Part of the coolant is sent to the aftercooler while most of the coolant is sent through engine oil cooler (3).

* the coolant that is sent to the aftercooler goes through the aftercooler core (7). The coolant then goes through an elbow. The coolant goes into a Figure(1-5):(JWAC) Operation passage in the block. The passage is near the center of the view at the rear of the block. The coolant that is sent to the engine oil cooler goes through the engine oil cooler. The coolant flows into the water jacket of the block at the right rear cylinder. The cooler coolant is mixed with the hotter coolant. The mixture goes to both sides of the block through distribution manifolds. The distribution manifolds are connected to the water jacket of all the cylinders. The main distribution manifold is located just above the main bearing oil gallery.

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* the coolant flows upward through the water jackets. The coolant flows around the cylinder liners from the bottom to the top. Near the top of the cylinder liners, the water jacket is made smaller. This is the area that has the hottest temperature. This smaller area causes the coolant to flow faster for better liner cooling. Coolant from the top of the liners flows into the cylinder head which sends the coolant around the parts that have the hottest temperature.
Figure(1-5):cooling system

* Coolant flows to the top of the cylinder head (one at each cylinder). The coolant flows out of the cylinder head through an elbow into water manifold (6). Coolant then flows through the manifold to the temperature regulator housing (thermostat). * regulator housing (8) has an upper flow section and a lower flow section. The regulator housing uses four temperature regulators. The sensing bulbs of the four temperature regulators are in the coolant in the lower section of the housing. Before the regulators open, cold coolant is sent through the bypass line back to the inlet of the water pump. As the temperature of the coolant increases, the regulators start to open. When the regulators open the coolant flow in the bypass line is then restricted. Coolant is sent through the outlets to the radiator or heat exchanger (11) . Separate Circuit Aftercooler (SCAC) Line Diagram 1. Cylinder block 2. Engine oil cooler 3. Regulator housing 4. Jacket water pump

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5. Coolant tank for jacket water 6. Aftercooler 7. Thermostatic valve 8. Separate circuit water pump 9. Radiator
Figure(1-5):(SCAC) Line Diagram

Separate Circuit After cooler (SCAC) Operation * coolant flows to separate circuit water pump (8). The coolant flows through an elbow that connects to the coolant tank for the separate circuit (9). The coolant flow is sent through aftercooler (6) . *coolant flows through aftercooler (6) and back to thermostatic valve (7). Before the thermostatic valve opens, cold coolant is sent back to separate circuit water pump (8). As the temperature of the coolant increases, the regulators start to open. When the regulators open the coolant flow in the bypass line is restricted . * the coolant is then sent through the outlet to radiator (9) for the separate circuit cooling system . Air to Air After Cooler The air is cooled by radiator fan which is fitted beside radiator or in front of radiator depending upon applications.

Figure(1-6):Air to Air After Cooler

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1-5-4 Water jacket Pump Jacket water pump Mounted on RH side of the engine, gear driven, supply and pump the coolant into the engine for cooling. The water pump (also called a coolant pump) is driven by a belt from the crankshaft or driven by the camshaft.

Figure(1-7):Water jacket Pump

1-5-5 Radiator Radiator : Reduces the coolant temperature with help of fan driven by belt, transfers heat from the coolant to air passing through it ,and is a series of tubes and fins that expose the heat from the engine coolant to the most surface area possible, maximizing heat transfer. Radiator is a device for cooling the circulating water Figure(1-8):Radiator in the engine. It holds a large volume of water in close contact with a large volume of air so that heat is transferred from the water to the air easily. Hot water flows into the radiator at the top and cold water flows out from the bottom. Tubes or passages carry the water from the top of the radiator to the bottom, passing it over a large metal surface. Air flows between the tubes or through the cells at right angles to the downward flowing water. This helps in transferring the heat from the water to the atmosphere. On the basis of fabrication, the radiator is of two types: tubular type and cellular type.

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Tubular type radiator It has round or flat water tubes, leading from the top to the bottom of the radiator. They may be soldered, brazed or welded in place or fastened by means of a stuffing box at each end. Fins or folded strips of light sheet metal, placed between the tubes, increase the radiating surface and improve the heat transfer. Cellular type radiator It has a core made of short air tubes which are laid horizontally and soldered together at the ends with space between them to allow water to flow. It is also called Honey comb type radiator. Radiators are also classified according to the direction of the water flow through them. In some, the water flows from top to bottom down flow type radiators. In other, the Figure(1-9):Cellular type radiator water flows horizontally from an input tank on one side to another tank on the other side cross flow type radiator .Radiators are usually made of copper and brass because of their high heat conductivity. The various sections of the radiator are most completely joined together by soldering. Radiator Pressure Cap Purpose The radiator cap contains a relief valve which limits the amount of pressure developed in the system. It is important to maintain the correct pressure in the cooling system because the boiling point of the coolant is increased as the pressure increases. By increasing the pressure of the cooling system by 7
Figure(1-10):Radiator Pressure Cap

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kPa (1 psi) the boiling point of the coolant is raised by 1.8C (3.25F). Operation The pressure cap contains a large spring and a pressure valve as shown in fig(1-11).When pressure in the cooling system is low, there is not enough force to lift the valve off its seat. Pressure will build up in the cooling Figure(1-11):Coolant expanding system until it is high enough to overcome spring force. The valve will then lift off its seat and prevent excessive pressure build up in the system. When the engine is shut down, the coolant contracts. If air in the top tank was vented during operation, this must now be made up to prevent a pressure less than atmospheric in the Figure(1-12):Coolant contracting cooling system. This is achieved by the small vacuum valve in the center of the large disc valve. The small valve opens when the atmospheric pressure is greater than the light spring pressure plus radiator pressure. Many highway vehicles use an expansion tank (or reservoir) which is piped to the vent tube on the right side of Fig(1-13). In this Figure(1-13): reservoir situation, the cooling system is replenished with coolant from the expansion tank when the system cools down. The pressure cap also allows for coolant level inspection and replenishment. In general the coolant should always come up to the bottom of the filler pipe. When the system is fitted with a coolant recovery system (expansion tank or reservoir), the level is normally checked in the recovery container.
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Functions of Radiator Cap * Seal during engine operation ,withstands high temperature, leak proof during engine operation, and operates at 7 psi depending upon radiator cap and releases excess pressure. * The pressure cap contains a pressure valve that allows for a pressure increase in the cooling system, which raises the coolants boiling point. The pressure is caused by coolant expansion as the engine warms *The cap also contains a vent (vacuum) valve to allow coolant to re-enter the radiator as the system cools and the coolant contracts. 1-5-6 Temperature Regulator The function regulators housing and the temperature bulb for opening and closing of the regulators. maintain engine working temperature and control the maximum outlet water temperature. Thermostat temperature control [3 ]

Figure(1-14):Thermostat

There is a normal operating temperature range between low temperature and high-temperature extremes, The thermostat controls the minimum normal temperature, The thermostat is a temperature-controlled valve placed at the engine coolant outlet, An encapsulated, wax-based, plastic-pellet heat sensor is located on the engine side of the thermostatic valve, As the engine warms, heat swells the heat sensor, A mechanical link, connected to the heat sensor,

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opens the thermostat valve, As the thermostat begins to open, it allows some coolant to flow to the radiator, where it is cooled.

1-6-7 Cooling fans Air is forced across the radiator core by a cooling fan on older engines used in rear-wheeldrive vehicles, it is attached to a fan hub that is pressed on the water pump shaft typical electric cooling fan assembly shown the radiator and related components.

Figure(1-15):Thermostat Operation

Figure(1-16):Cooling fans

Thermostatic fans The thermal fan is designed so that it uses little power at high engine speeds and minimizes noise. The thermal fan has a silicone coupling fan drive mounted between the drive pulley and the fan. A second type of thermal fan has a thermostatic spring added to the silicone coupling fan drive . The thermostatic spring operates a valve that allows the fan to freewheel when the radiator is cold As the radiator warms to about 150F (65C), the air hitting the thermostatic spring will cause the spring to change its shape.
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Radiator Shroud

Internal Combustion Engine cooling system

Fan and radiator design on high output engines usually incorporate a fan shroud. The fan shroud is a shaped metal or plastic cover that prevents the escape of fan air and directs air flow into the fan. Use of the shroud ensures that the maximum amount of air that the fan moves, actually passes through the radiator. Without a shroud, air may just circulate at the tip of the fan blades. The position of the fan within its shroud is important to the shroud's effectiveness. 1-6-8 BLOCK HEATER Fitted into the block to keep the engine warm during extremely cold weather. Water Jackets * Water jackets are hollow passages in the block and cylinder head(s) that surround the areas Figure(1-10):BLOCK HEATER closest to the cylinders and combustion chambers.
Figure(1-16):radiator shroud design

Figure(1-11):Water jackets

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1-6 Disadvantages of overcooling & under cooling

Engine should be cooled within a particular temperature limits. It should not be too cooled or too heated up. Getting the engine too much cooled is called overcooling. And if the engine is over heated it is to under cool. Both under cooling and over cooling have individual disadvantages. Over cooling results in the increase of viscosity of the lubricating oil, which in turn result in the increase of friction between the moving parts. If the engine gets warmed up excessively, it should be cooled so as to keep the correct alignment of the engine. Under cooling also keeps the engine in correct position and increase the life of the engine. Evaporation of lubricating oil that lubricates the piston and cylinder wall is also another reason of under cooling. This will result in metal to metal contact of the piston and cylinder wall leading to piston crown. Burning of and warping of exhaust valves setting up of thermal stresses in the cylinder, cylinder head and piston. This may lead to cracking of them.

1-7 Cooling System Maintenance

The condition must be found in coolant water Coolant - water combined with corrosion inhibitors or water combined with antifreeze and corrosion inhibitors Heat Transfer - Tendency of heat to move from a hot area to a cooler area. Protection Against Freezing of the Coolant - best protection against coolant freezing is the correct mixture/ratio of the coolant. The most common antifreezes is use of ethylene glycol to provide freeze protection. Corrosion Resistance - Coolant must prevent the formation of rust and pits in the engine and other components. For example Add Cat SCA (Supplemental Cooling Additive), or Cat ELC (Extended Life Coolant) or Cat DEAC (Diesel Engine Antifreeze/Coolant). Scale and Deposits - Water used as a coolant determine scale and deposit formations. The water must be pretreated.
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Compatibility - Coolant must not damage seals, hoses or any of the materials used in construction of cooling systems such as copper, aluminum, and steel. Non foaming - The coolant used in a system must not foam or make sludge that can damage the cooling system. Sediment - The coolant must be clear and not have mud or an oil residue in it. Cleaning the radiator exterior Overheating can result from exterior radiator plugging as well as internal plugging. External plugging is caused by dirt and insects. This type of plugging can be seen if you look straight through the radiator while a light is held behind it It is most likely to occur on off-road vehicles. The plugged exterior of the radiator core can usually be cleaned with water pressure from a hose. The water is aimed at the engine side of the radiator. The water should flow freely through the core at all locations. If this does not clean the core, the radiator should be removed for cleaning at a radiator shop. Flush And Refill Manufacturers recommend that a cooling system be flushed and that the antifreeze be replaced at specified intervals. Draining coolant when the engine is cool eliminates the danger of being injured by hot coolant.

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The radiator is drained by opening a petcock in the bottom tank, and the coolant in the block is drained into a suitable container by opening plugs located in the lower part of the cooling passage. Water should be run into the filler opening while the drains remain open. Flushing should be continued until only clear water comes from the system.(most antifreeze coolant is ethylene glycol-based) Quick and Easy Cooling System Problem Diagnosis If overheating occurs is slow, stop-and-go traffic, the usual cause is low airflow through the radiator. Check for airflow blockages or cooling fan malfunction. If overheating occurs at highway speeds, the cause is usually a radiator or coolant circulation problem. Check for a restricted or clogged radiator.

1-8 Common Causes Of Overheating

Overheating can be caused by defects in the cooling system , Some common causes of overheating include: Low coolant level Plugged, dirty, or blocked radiator Defective fan clutch or electric fan Incorrect ignition timing Low engine oil level Crankcase oil level too high: Crankshaft dips in oil and causes a corresponding increase in temperatures due to friction and parasitic load on the engine. Crankshaft oil dipping can also be encountered when operating an engine beyond the angles for which the oil pan was originally designed.[7]

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Poor circulation of coolant caused by collapsing of soft hose and restriction Dirty engine exterior: Heavy accumulations of dirt and grease can severely hinder normal heat dissipation through the exterior walls of all the engine components. Pressure of air in the cooling system: The following are the most common causes of air entrapment:a- Low coolant level due to leaking water pump or leaks at hose and/or coolant accessories. b- Leaking air intake aftercooler. c- Leaking engine or air compressor cylinder head gasket. d- Improperly seated injector sleeve. Inadequate cooling capacity: This condition can be the result of misapplication of one or any combination of the following cooling system components:A. Radiator C. Surge Tank E. Fan Shroud G. Auxiliary Coolers I. Fan Speed [7] Broken fan belt Defective radiator cap Dragging brakes Frozen coolant (in freezing weather) Defective thermostat
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B. Top Tank D. Fan F. Water Pump H. Re-circulation Baffles

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Internal Combustion Engine cooling system

Cavitation corrosion of liners and water pump impellers.[6] Hot spots that can cause piston scoring, cracked injector sleeves, and cracked heads.[6] Low coolant temperature.[6] Solder Corrosion.[6] Defective water pump (the impeller slipping on the shaft internally) How Much Coolant Can a Water Pump? A typical water pump can move a maximum of about 7,500 gallons (28,000 liters) of coolant per hour, or recirculate the coolant in the engine over 20 times per minute. This means that a water pump could be used to empty a typical private swimming pool in an hour! The slower the engine speed, the less power is consumed by the water pump. However, even at 35 miles per hour (56 kilometers per hour), the typical water pump still moves about 2,000 gallons (7,500 liters) per hour or 1/2 gallon (2 liters) per second! Common Causes of Water Pump Bearing Failure * improper drive belt tension (both too little or too much tension) * abent fan * a missing piece of fan blade * a cracked fan blade * fan mounting surfaces that are not flush * a worn fan clutch

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Testing The Cooling System Pressure Testing Pressure testing should be performed whenever there is a leak or suspected leak. The pressure tester can also be used to test the radiator cap. An adapter is used to connect the pressure tester to the radiator cap. Replace any cap that will not hold pressure. Testing The Cooling System Coolant Dye Leak Testing One of the best methods to check for a coolant leak is to use a fluorescent dye in the coolant. Operate the vehicle with the dye in the coolant until the engine reaches normal operating temperature. Use a black light to inspect all areas of the cooling system. When there is a leak, it will be easy to spot because the dye in the coolant will be seen as bright green. Use Distilled Water in the Cooling System Two technicians are discussing refilling the radiator after changing antifreeze. One technician says that distilled water is best to use because it does not contain minerals that can coat the passages of the cooling system. The other technician says that any water that is suitable to drink can be used in a cooling system. Both technicians are correct.
Figure(1-13):use dye specifically made for coolant when checking for leaks using a black light.

Figure(1-12): pressure tester.

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If water contains minerals, however, it can leave deposits in the cooling system that could prevent proper heat transfer. Because the mineral content of most water is unknown, distilled water, which has no minerals, is better to use. Although the cost of distilled water must be considered, the amount of water required (usually about 2 gallons [8 liters] or less of water) makes the expense minor in comparison with the cost of radiator or cooling system failure. Hydrometer Testing Coolant can be checked using a coolant hydrometer. The hydrometer measures the density of the coolant. The higher the density, the more concentration of antifreeze in the water. Most coolant hydrometers read the freezing point and boiling point of the coolant. Testing The Thermostat There are three basic methods that can be used to check the operation of the thermostat.1-Hot-water method ,2-Infrared pyrometer method,3-Scan tool method. Thermostat Replacement An overheating engine may result from a faulty thermostat. An engine that does not get warm enough always indicates a faulty thermostat. To replace the thermostat, coolant will have to be drained from the radiator drain petcock to lower the coolant level below the thermostat. It is not necessary to completely drain the system. The upper hose should be removed from the thermostat housing neck; then the housing must be removed to expose the thermostat.

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