Manitowoc Grove TMS800E Service And Maintenance Manual page 258

POWER TRAIN
whether or not tubes are clean. Another good test is to
feel the core for cold spots.
5. Fins are thin metal sheets that dissipate heat picked up
by the tubes. They should be kept free of bugs, leaves,
straw etc., so as to allow the free passage of air. Bent
fins should be straightened.
Engine Water Jacket
The water jacket permits coolant to be circulated around the
cylinder walls, combustion chamber, and valve assemblies.
Some of these coolant passages are small and can easily
become clogged if the cooling system does not receive the
proper maintenance.
1. Core Plugs - These are sometimes mistakenly called
freeze plugs. They do not provide protection against
freezing expansion, but are only present because of
engine block casting methods. Remove and replace
core plugs that show signs of leaking or rusting through.
Use an installation tool for core plug replacement.
2. Drain Plugs - The water jacket of each engine has one or
more drain plugs. These should receive seasonal care
and be kept free of rust and scale.
3. Gaskets - Gaskets must be in good condition to prevent
both internal and external leaks. If there are external
leaks around gaskets, there may also be internal leaks
into the engine. Proper tightening of the head bolts with
a torque wrench is essential for preventing leaks around
the head gasket.
Water Pump
The pump should be checked carefully for leaks and proper
lubrication. Replace or rebuild if leaking, cracked, or worn.
Fans and Belts
The fan should be checked for cracked or broken blades.
Refer to Engine Drive Belts, page 7-8.
Thermostat
The thermostat is of the nonadjustable type and is
incorporated in the cooling system for the purpose of
retarding or restricting the circulation of coolant during
engine warm up. Engine overheating and loss of coolant is
sometimes due to an inoperative thermostat. To check for
t h i s c o n d i t i o n , r e m o v e t h e t h e r m o s ta t a n d t e s t b y
submerging it in hot water and noting the temperature at
which the thermostat opens and closes. Use an accurate
high temperature thermometer for making this test.
Hoses and Clamps
Hoses and their connections must be checked regularly
because they are often the source of hidden trouble. Hoses
may often times appear in good condition on the outside
while the inside will be partially deteriorated. If there are any
7-26
doubts about a hose doing its job, replacement should be
made. The clamps should be inspected to make sure they
are strong enough to hold a tight connection.
Test Equipment
The antifreeze/coolant concentration must be checked using
a refractometer. "Floating ball" type density testers or
hydrometers are not accurate enough for use with heavy
duty diesel cooling systems.
Radiator Assembly Removal and Installation
Refer to Figure 7-14 and Figure 7-15.
Removal
1. Set the outriggers and position the boom to over the
side.
2. Open the drain cock at the bottom of the radiator and
drain the coolant into a suitable container. Dispose of the
coolant in accordance with local and EPA regulations.
3. Disconnect the battery (Refer to Electric System, page
3-1).
4. Open the left and right hood access doors.
5. Remove the hardware securing the top center hood
panel to the front and rear cowls and remove the panel
with doors from the crane.
6. Disconnect the surge tank hoses from the radiator.
7. Remove the hardware securing the radiator baffles to
the front cowl and remove the baffles.
8. Remove the clamps securing the charge air cooler
(CAC) tubes to the CAC and disconnect the CAC tubes
from the CAC.
9. Disconnect the hoses from the top and bottom of the
radiator assembly.
10. Remove the bolts, washers, and lock washers attaching
the fan guards to the shroud. Remove the fan guards.
NOTE:
11. Attach an adequate lifting device to the radiator
assembly.
12. Remove the two nuts, hardened washers and mounts
securing the radiator assembly to the mounting brackets
and remove the assembly from the carrier.
Installation
1. Position the radiator/CAC assembly in the carrier using
a lifting device and secure to the mounting brackets
using the two mounts, hardened washers, and nuts. As
needed, use extra 1/2 inch inside diameter hard dock flat
Published 01-29-2014, Control # 496-00
TMS800E SERVICE MANUAL
The radiator assembly weighs approximately 93 kg
(206 lb).