Tài liệu Cooling and Lubrication System Maintenance P1 doc

CONTENTS==contd Page Study Unit 4 _8ervicing the Lubrication System Lesson 1 Lubrication Servicing Oil ..... Given characteristics and design features of the two types of cooling systems

UNITED STATES MARINE CORPS

MARINE CORPS INSTITUTE ARLINGTON, VA 22222-0001

IN REPLY REFER TO 35.13b

6 Aug 92

MCI 35.13b COOLING AND LUBRICATION SYSTEM MAINTENANCE

1 Purpose MCI course 35.13b, Cooling and Lubrication System Maintenance, has been published to provide instruction to all

Marines in the 3521 MOS

2 Scope MCI 35.13b addresses the duties associated with

inspecting, testing, and servicing the cooling and lubrication

systems of motor transport equipment

3 Applicability This course is intended for instructional purposes only It is designed for use by Marines in the grades

of Pvt - Sgt :

4 Recommendations Comments and recommendations on the content

of the course text are invited and will aid in subsequent course revisions Please complete the course evaluation questionnaire

located at the end of the text and return it to:

Director (CDD #4) Marine Corps Institute

Arlington, VA 22222-0001

hf by le

H L HUGHES

Director of Education

Contents

COOLING AND

CONTENTS

Student Information .e ee °

Course Introduction .ee-

Exercise e eee

Basic Components of Liquid-Cooled Systems .e-

Servicing the Cooling System

Draining and Flushing the Cooling System 2 2 « © © «© © we Exercise ¬ 6 8 Coolant Testing and Refilling Procedures e eee

Exercise - Lubricant Contamination Exercise e

CONTENTS==contd

Page

Study Unit 4 _8ervicing the Lubrication System

Lesson 1 Lubrication Servicing (Oil) 4-1

Exercise .« « « « « « « «© «© « e« « « 4-7

Lesson 2 Disposal of Used Lubricants, Parts,

and Shop Materials e¢.-.- 4-9 Exercise « « « © TT ai « « 4-13 Review Lesson 2 +6 6 «© © © © © © © © ee ew ew R-1 Bibliography oe ee tt lt lt lt lt lt lw lt lt lt le lt lt lt lt lel lt

7596 or DSN 325-7596

111

e YOU ARE PROPERLY MOTIVATED You have made a positive decision to get training on your own Self-motivation is perhaps the most important force in learning or achieving anything Doing whatever is necessary to learn is motivation You have it!

e YOU SEEK TO IMPROVE YOURSELF You are enrolled to improve those skills you already possess, and to learn new skills When you improve yourself, you improve the Corps!

e YOU HAVE THE INITIATIVE TO ACT By acting on your own, you have shown you are a self-starter, willing to reach out for opportunities to learn and grow

e YOU ACCEPT CHALLENGES You have self-confidence and believe

in your ability to acquire knowledge and skills You have the self- confidence to set goals and the ability to achieve them, enabling you to meet every challenge

e YOU ARE ABLE TO SET AND ACCOMPLISH PRACTICAL

GOALS You are willing to commit time, effort, and the resources

necessary to set and accomplish your goals These professional traits will help you successfully complete this distance learning course

Continued on next page

Study Guide, Continued

To begin your course of study, familiarize yourself with the structure of the course text One way to do this is to read the table of contents Notice the table of contents covers specific areas of study and the order in which they are presented You will find the text divided into several study units Each study unit is comprised of two or more lessons, lesson exercises, and finally, a study unit exercise

Leaf through the text and look at the course Read a few lesson exercise questions to get an idea of the type of material in the course If the course has additional study aids, such as a handbook or plotting board, familiarize

yourself with them

Turn to the first page of study unit 1 On this page, you will find an introduction to the study unit and generally the first study unit lesson Study unit lessons contain learning objectives, lesson text, and exercises

Learning objectives describe in concise terms what the successful learner, you, will be able to do as a result of mastering the content of the lesson text Read the objectives for each lesson and then read the lesson text As you read the lesson text, make notes on the points you feel are important

To determine your mastery of the learning objectives and text, complete the exercises developed for you Exercises are located at the end of each lesson, and at the end of each study unit Without referring to the text, complete the exercise questions and then check your responses against those provided

Continued on next page

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Study Guide, Continued

To prepare for your final exam, you must review what you learned in the course The following suggestions will help make the review interesting and challenging

e CHALLENGE YOURSELF Try to recall the entire learning sequence without referring to the text Can you do it? Now look back at the text to see if you have left anything out This review should be interesting

Undoubtedly, you’ll find you were not able to recall everything But with

a little effort, you’ll be able to recall a great deal of the information

e USE UNUSED MINUTES Use your spare moments to review Read your notes or a part of a study unit, rework exercise items, review again; you can do many of these things during the unused minutes of every day

e APPLY WHAT YOU HAVE LEARNED It is always best to use the skill or knowledge you’ve learned as soon as possible If it isn’t possible

to actually use the skill or knowledge, at least try to imagine a situation in which you would apply this learning For example make up and solve your own problems Or, better still, make up and solve problems that use most of the elements of a study unit

e USE THE “SHAKEDOWN CRUISE” TECHNIQUE Ask another Marine to lend a hand by asking you questions about the course Choose

a particular study unit and let your buddy “fire away.” This technique can

be interesting and challenging for both of you!

e MAKE REVIEWS FUN AND BENEFICIAL Reviews are good habits that enhance learning They don’t have to be long and tedious In fact, some learners find short reviews conducted more often prove more beneficial

Continued on next page

Vil

Study Guide, Continued

Your training NCO or officer will administer the final examination and return the examination and the answer sheet to MCI for grading Before taking your final examination, read the directions on the DP-37 answer sheet carefully

The sooner you complete your course, the sooner you can better yourself by applying what you’ve learned! HOWEVER you do have 2 years from the date of enrollment to complete this course

As a graduate of this distance education course and as a dedicated Marine, your job performance skills will improve, benefiting you, your unit, and the Marine Corps

Semper Fidelis!

Vill

STUDY UNIT 1 DETERMINING COOLING SYSTEM SERVICEABILITY

Introduction Since the beginning of the automotive era, the one system associated with the internal combustion engine that has changed little is the cooling system The

conventional cooling system originally consisted of just a

few basic components such as the radiator, fan, water pump,

and hoses Today, when the engine is challenged to operate

at maximum efficiency, yet produce maximum power, it needs the addition of clutch driven fans, hydraulically driven

fans, and other components These components allow the

engine to operate at maximum efficiency and still produce maximum horsepower by using its cooling system only when

2 Given characteristics and design features of the two

types of cooling systems, identify in writing the type of cooling system from the design feature or characteristic

3 Given a function of the cooling system, identify in

writing the component that performs the function

1101 Types of Cooling Systems

Tremendous heat is generated by an automotive engine enough to keep the average house warm in the winter! Unless this heat is controlled and quickly removed after it has done its job, it will cause great damage to the equipment by ruining lubricants and allowing parts to melt or expand so much that they will seize The two basic cooling systems used in equipment today are the air-cooled and liquid-cooled systems Let's see how they are constructed and just how they operate

a Air-cooled systems You're more than likely saying to

yourself that all engines are air-cooled, and in a sense, you're right As air passes through the radiator, it cools the coolant; however, the difference is that the air-cooled engine doesn't use

a liquid at all, but instead, transfers the engine heat directly

1-1

from the engine metal to the

air Air cooling of a

reciprocating piston engine

requires the constant

Circulation of a lot of air

For example, air-cooled |

Motorcycle engines are designed

to use the air flow created by

motion to cool the engine Cool

air flows over the cylinder head

and block to remove the heat

Forced air on engines such as

the one illustrated in figure

1-1 is provided by either a fan |

which is usually driven from the

engine crankshaft or by fan

blades cast into the flywheel

Air-cooled engines, other than

motorcycle engines, are usually

surrounded by a metal housing

and baffle plates that direct

the cooling air where it is Fig 1-1 Air cooled engine

needed When the engine is

running, heat is dissipated by

forced air directed over and around the cylinders and cylinder

heads A thermostat connected to control flaps is used to

regulate the engine temperature on large air-cooled engines As the engine becomes hotter, the flaps open wider to admit more air |

Radiation fins (cooling fins) are provided on the cylinders and cylinder heads (fig 1-2) In many applications, the crankcase is also "finned." These fins are the key to the operation of the air-cooled engine The cylinder and cylinder head are cast in

such a way as to greatly increase the metal surface exposed to

air This exposure is enhanced by casting the outer portion of the cylinder with thin fins leading outward from the heated area This increases by as much as ten times the surface available to the air for cooling

ERA

| 200°F

350° Ads Yee COOLING COOH ct | <— 100°F o

Fig 1-2 Cooling fins Fig 1-3 Transfer of heat from

on cylinder and cylinder combustion chamber to cooling fins

head

While the fins at first might seem to represent excess weight,

they actually form an integral portion of the engine structure

by increasing its rigidity and decreasing the thickness required

in the main structure The outer ends of the cooling fins may

seem to be far from the heated surface, but they in fact carry a

lot of the heat to the cooling air The metal fins are

excellent heat conductors (fig 1-3)

Remember, this type engine relies solely on air to remove the

excess heat Air-cooled engines as a rule run hotter than

liquid-cooled engines and require greater clearances between

moving parts

Now that you have an understanding of the air-cooled systen,

let's move on to the most common type of cooling system which is the liquid-cooled system

b Liquid-cooled system Like the air-cooled system, the

liquid-cooled system is designed to prevent damage caused by the extreme heat the engine generates during its operation The

engine heat results from the burning of fuel in the combustion chambers Temperatures within the cylinders can reach 3,000 to 6,000°F; the average cylinder temperature during the entire cycle

is about 1,500°F If an average 200-pound engine block were

subjected to these excessively high temperatures without a way to cool itself, it would melt in a very short period of time

The liquid-cooled system removes the excess heat absorbed by the cylinders, cylinder heads, pistons, and valves by circulating the

coolant around these components (fig 1-4) The heated coolant is then directed to the radiator, where the excess heat transfers

into the passing air

1 CYLINDER BLOCK 5 RADIATOR

2 CYLINDER HEAD 6 COOLANT PUMP

Fig 1-4 Liquid-cooled system components and flow of coolant

Several thousand gallons of coolant must be circulated through the cooling system every hour to absorb the heat and carry it to

the radiator for disposal The circulation is created by a pump

It also means that several thousand cubic feet of air must flow

through the radiator every hour to dissipate the heat into the atmosphere Most designers place the radiator in front of the

vehicle to take advantage of natural air flow A fan creates air

flow when the vehicle is sitting still

Just as the air-cooled system uses a thermostat to control air

flow around the engine, the liquid-cooled system uses a

thermostat to control the circulation of the coolant When the engine is operating below its minimum operating temperature, the

thermostat acts as a gate valve to keep coolant from entering the

radiator and prevent any cooling of the liquid Once the engine

temperature reaches its normal operating level, the coolant flows

to the radiator to dissipate engine heat

Let's pause for a minute and think about what we have just

covered Better yet, let's have some fun I'll give you the answer; you give me the question Ready Round one

Answer: Air-and liquid-cooled systems Now it's your turn

What's the question?

I hope your question was "What are the two types of cooling

systems used in motor transport equipment?" If you didn't state

the right question, you should go back and review the material

just covered

1102 System Usage

Air-cooled engines are primarily used on equipment that requires auxiliary engines such as generators, pump stations, or refuelers (fig 1-5)

All the transportation prime

movers in use today, including

the military motorcycle, (fig

1-6), are equipped with liquid-

cooled engines They rely

heavily on the engine cooling

system to cool other major

components such as the |

transmission and hydraulic

system As we continue, we

will discuss in detail the

operation of the liquid cooling

system and the methods used to

provide cooling for these

components

The design, location, and

Operation of the components

vary from one vehicle to the

Fig 1-6 Military motorcycle

next Figures 1-7 and 1-8 show the general locations of some of the components All of these variations among vehicles have

created a challenge for you, the mechanic, but the general

principles of operation of both the air-cooled and the liquid-

cooled systems remain the same as those we have just discussed

6 ENGINE OIL COOLER

7 TRANSMISSION OIL COOLER

Fig 1-8 M900 Series cooling

system

Since the liquid-cooled system is the primary system used in

motor transport equipment, we will concentrate on this system throughout the rest of the course Lesson Summary This lesson provided you with the skills

necessary to identify the two types of cooling systems used in motor transport equipment It also provided you with an overview

of cooling system functions, design features, and the

characteristics of each system In the next lesson you will

identify the functions of basic cooling system components

Exercise: Complete items 1 through 4 by performing the action

required Check your responses against those listed

at the end of this unit

1 transport equipment Name the two types of cooling systems used in motor

2 What type of cooling system has the engine designed with cooling fins attached to the cylinders and cylinder

heads?

3 What type of cooling systems use a thermostat to control

the temperature of the engine?

4 The liquid-cooled engine uses a (an) to transfer heat into the atmosphere

Lesson 2 BASIC COMPONENTS OF LIQUID-COOLED SYSTEMS

system Like a master builder who builds a building one brick at

a time, we will start building our knowledge of the cooling

system one part at a time

1201 Engine Water Jacket

Heat transfer allows the engine to Operate at a temperature that

prevents the binding or seizing of internal components This

transfer of heat takes place primarily in the water jacket of the engine block (fig 1-9)

WATER THERMOSTAT <-> — JACKET BYPASS

Fig 1-9 Circulation of coolant

The water jacket consists of a series of channels that surrounds

the cylinders The channels allow the coolant to circulate

through the engine and absorb excess heat from the metal parts

Iron, aluminum, and copper, the materials that engines and

cooling system components are made of, are all excellent

conductors of heat The coolant that flows through these

components is also a good conductor of heat

The transfer of heat from the

metal parts to the coolant

occurs until the parts become

insulated from the coolant by

lime or rust Lime is a

white deposit formed by the

heating of the water As the

water heats up, the lime

separates from the water

When the water cools down,

these lime deposits are left

on the metal surfaces Rust,

a combination of iron, water,

and oxygen can also

accumulate in any engine

There is iron in the engine;

water and oxygen come from

the coolant itself

Lime And Rust

Cylinder Wall Accumulation

Fig 1-10 Water jacket lime and

rust accumulation