Service Training

MALAGA
3600 Engines - Basic
Thorben
MARCH 1998
IV. COOLING SYSTEM
CHAPTER : Cooling system
3600 Engines - Basic
2 Page:
Instructor notes
Two cooling
systems
Caterpillar is providing two cooling systems:
Combined circuit cooling & separate circuit cooling.
Temperatures in the two systems are the same.
50 C (122 F) nominal water temperature to the AC
and OC (DFE).
32 C (90 F) nominal water temperature to the AC
and OC (HFE).
90 C (194 F) nominal jacket water temperature to the
cylinder block circuit (DFE).
93 C (199 F) nominal jacket water temperature to the
cylinder block circuit (HFE).
85 C (185 F) nominal oil to bearing temperature.
Over time, as the performance of the heat
exchanger decreases due to fouling, the water
temperature to the AC will increase. At higher
ambient conditions, the water to the AC and OC is
allowed to rise to 65 C (149 F) for DFE or 38 C (100
F) for HFE maximum before engine deration is
required.
System temeratures
Basic operating
parameters
Max. temperatures
CHAPTER : Cooling system
3600 Engines - Basic
3 Page:
AC/OC
Pump
Cylinder Block,
Head & Turbo
H
e
a
t
E
x
c
h
a
n
g
e
r
Expansion
Tank
JW
Pump
A
B
C
C
D
D
D
(3612/3616)
(3606/3608)
E
E
Oil Cooler
Aftercooler
D
A - Mixed temp. from engine and coolers
B - Mixing chamber from AC & OC
C - Regulator
D - Factory orifices
E - Factory or customer orifices
Coolant going to Expansion Tank - 50C for DO & 32C for HFO
Coolant going to Cylindeer Block etc. - 90C for DO & 93 C for HFO
CHAPTER : Cooling system
3600 Engines - Basic
4 Page:
Instructor notes
Advantage
combined system
The combined circuit system is also known as the
single circuit - two pump system.
The main advantage of the combined circuit system
is that it requires only one external cooling circuit
with only one heat exchanger or radiator. There is
less coolant and cooling system piping can be
relatively simple.
Combined system
3600 Engines - Basic
5 Page:
CHAPTER : Cooling system
CHAPTER : Cooling system
3600 Engines - Basic
6 Page:
H
e
a
t
E
x
c
h
a
n
g
e
r
(
A
C
/
O
C

C
i
r
c
u
i
t
)
C
AC/OC
Pump
C
Expansion
Tank
Cylinder Block,
Head & Turbo
D
D
F
JW
Pump
F
Oil Cooler
Aftercooler
D
H
e
a
t
E
x
c
h
a
n
g
e
r
(
J
W

C
i
r
c
u
i
t
)
E
E
Vent
Line
Makeup
Line
A - Mixed temp. from engine and coolers
B - Mixing chamber from AC & OC
C - Regulator
D - Factory orifices
E - Factory or customer orifices
F - Customer orifices
Coolant going to AC/OC - 50C for DO & 32C for HFO
Coolant going to Cylindeer Block etc. - 90C for DO & 93 C for HFO
CHAPTER : Cooling system
3600 Engines - Basic
7 Page:
Instructor notes
Makeup line
(separate circuit)
The only connection between the AC / OC circuit
and the engine jacket water circuit is a makeup line
that goes from the expansion tank to the water
pump supply line. This line keeps the AC / OC
circuit filled when it shares the expansion tank with
the jacket water circuit. There is no active flow
between the circuits.
The total radiator surface area may be 20 % less at
45 C (110 F) ambient and up to 30 % less at higher
ambients, when compared to a combined circuit.
Maintains nominal water temperature to the AC and
OC while rejecting heat from the cylinder block and
heads at higher temperatures.
The total external flow is approximately twice the
external flow of the single circuit system. Half of the
flow (high temperature circuit) must be cooled to
nominal jacket water temperature and the low
temperature circuit cooled to nominal AC / OC
water temperature.
Advantage separate
system
CHAPTER : Cooling system
3600 Engines - Basic
8 Page:
CHAPTER : Cooling system
3600 Engines - Basic
9 Page:
Instructor notes
LEGV0928 - #109
Explain combined and separate circuit cooling
systems.
Show slides about piston and liner removal and
piston assembly disassembling.
Connecting rod cap bolts.
Lower the connecting rod cap.
Install crank protectors.
Piston $ connecting rod assembly.
Removal of piston retaining rings.
Piston pin guide.
Piston ring removal.
Measure piston and rings.
Cylinder liner removal tool.
Installation of liner removal tool.
Remove piston and liner and disassemble piston
assembly.
Show and explain the three kinds of different liners.
LEGV0928 - #110
LEGV0928 - #111
LEGV0928 - #115
LEGV0928 - #117
LEGV0928 - #118
LEGV0928 - #119
LEGV0928 - #120
LEGV0928 - #121
LEGV0928 - #123
Lab exercises
CHAPTER : Cooling system
3600 Engines - Basic
10 Page:
1) Removal of piston & connecting rod assemblies.
Disassembly & Assembly (SENR3594-03) page 203
2) Removal of cylinder liner.
Disassembly & Assembly (SENR3594-03) page 210.
3) Measurement of piston rings.
Guideline for reusable parts (SEBF8107).
4) Removal and installation of crankshaft main bearings.
Disassembly & Assembly (SENR3594-03) page 222
5)Installation of cylinder liner.
Disassembly & Assembly (SENR3594-03) page 211
6) Installation of piston & connecting rod assemblies.
Disassembly & Assembly (SENR3594-03) page 205
7) Installation of cylinder head.
Disassembly & Assembly (SENR3594-03) page 187