Engine cooling system KAMAZ Euro-2-3

The system that regulates the cooling of KamAZ is a complex structure associated with the technical components of the vehicle. For the famous cars produced by the Kama Automobile Plant, a temperature of 80 to 120 degrees Celsius is recommended for the fluid. In this case, the engine temperature sometimes reaches 220 degrees. Such technical characteristics determine the mandatory maintenance of the system used.

Important elements of the system

KamAZ vehicles have a cooling system reminiscent of classic versions. Moreover, each unit is important, because it is responsible for the functionality of the system and the correct movement of coolant.

Note! It should be noted that there are two thermostats. They are required for the full operation of the installed engines. Also, special blinds are installed on the radiator, and in the cold season they are closed to speed up the heating of the power unit.

Thermostat malfunctions

The main signs of a thermostat malfunction include:

warming up the engine takes longer than usual;
there is a problem of engine overheating;
The speedometer needle starts jumping when accelerating;
the lower mount of the mechanism always remains warm;
Euro thermostat valve is leaking;
The thermostat is closed, but its upper part remains cold when closed.

Damage to the thermostat may be hidden, so it is necessary to carry out regular diagnostics and, if necessary, carry out repair work yourself or at a service station.

Vulnerabilities of the cooling system

It is important not only to know where the temperature sensor of the KamAZ vehicle and other elements of the system are located, but also to understand the problems. In most cases, motorists encounter the following unpleasant problems:

leakage of technical fluids used;
overcooling of installed units;
overheating of the antifreeze used;
coolant enters the oil system.

You need to understand that these problems can be successfully dealt with only with proper maintenance of the vehicle and taking into account the differences in the system.

Antifreeze leaks most often through pipe connections. Sometimes this process is caused by destruction of rubber hoses. You need to understand that pipes are one of the most vulnerable points of KamAZ, and their poor technical condition leads to various undesirable problems. The liquid level gradually decreases, and the system begins to actively heat up, as a result of which overheating of the units may occur. To eliminate a leak, you need to carefully tighten everything and press the system, because there should not be even the slightest risk of leakage.
Thermostats are also considered a weak point. Failure of the element can lead to overheating or hypothermia of the motor. It depends on the location of the valve, which needs to be adjusted correctly. If the thermostat is open, fluid will flow in a large circle through the installed radiator. If the engine does not warm up, the temperature drops excessively. If the shutters are open, the motor may be overcooled. Knowing where the thermostat is located on a KamAZ vehicle, you need to carefully monitor its technical condition. Initially, the situation can be saved by the vehicle fan being used, but sooner or later the malfunctions become too obvious, as a result of which the temperature regime is disrupted.
In most cases, the fan installed on a KamAZ truck with a coupling is classified as a weak point. If the unit fails, the system ceases to cope with its own tasks. If you keep a close eye on your vehicle and do regular maintenance checks, problems can be successfully prevented.

These potential problems are important to consider in order to keep your vehicle in good condition.

Symptoms and malfunctions

Two-valve thermostats equipped with a combined locking mechanism are not without their faults. The breakdowns are similar to those of conventional thermostats. Symptoms of failure are:

The engine heats up for a long time even with the metal radiator curtains closed. The cause of this malfunction is the jamming of one or two valves at once. Failure occurs as a result of damage to the rod, dirt getting into the gap between the valve bowl and the seat.
Rapid warm-up followed by overheating. The reason lies in the penetration of dirt, scale or foreign objects into the gap between the small stop bowl and the channel. Also, the bowl may be closed due to depressurization of the thermoelement. The pressure of the melted wax is not capable of creating a load on the pusher rod. With such a malfunction, one valve works towards the small circulation circle, and the other is open towards the large one. The antifreeze supply system to the engine is disrupted. High pressure from the pump begins to damage the sealing gaskets.
Overheating as a result of increased load on the power unit. This problem occurs among owners of EURO 4 series cars. The cause is the failure of the thermostat or fan thermocouples. The thermostat resistor does not heat the valve at the right time; it is delayed in opening. As a result, the control unit cannot calculate the fan activation period for additional cooling of the radiator.

All these malfunctions with steam valves require intervention for a subsequent test of the thermostat for performance.

Cooling radiator

The radiator is one of the most significant units. It can be 3 or 4 row. In this case, the unit is made according to the classic version, therefore it necessarily includes the following components:

a lower tank equipped with a discharge pipe;
central tubes, which are installed in rows;
On top there is a tank with a supply pipe.

Radiator mounting can be three-point. In this case, special brackets are used for fastening on the sides, ensuring reliable fastening of the units. For guaranteed reliability, a bottom radiator connection is also provided.

The radiator has special shutters, which are metal plates. If necessary, blinds block access to air. To control the blinds, a special drive installed in the cabin is used, and it is enough to change the position of the existing handle. Proper adjustment helps extend the life of the cooling system. By properly regulating your radiator, you can successfully maintain your vehicle and protect it from excessive heating or cooling.

What malfunctions can occur in the KamAZ-740 engine cooling system?

The most common malfunction of the KAMAZ 740 cooling system is called an antifreeze leak. To identify the problem, in most cases it is enough to carefully inspect all structural elements. The water pump, coupling, all connecting parts, and radiator require special attention. It is recommended to replace old and worn pipes.

Scheme of the KamAZ-740 engine cooling system

To eliminate leaks, they resort to soldering problem areas. Leaky pipes can be plugged. It is not advisable to replace the radiator. This unit is repairable. If necessary, it can be washed, which will significantly increase operating efficiency. If problems with the drive belt are detected in the engine cooling system, it is recommended to replace it. This element cannot be repaired if wear or delamination is detected.

To check the efficiency of KAMAZ thermostats, it is necessary to observe the heating of the lower radiator tank. When the temperature reaches 85°C, the valve opens. At this moment the tank should heat up. If this is not observed, then the thermostat is faulty and needs to be replaced.

The last problem that can happen to KAMAZ is antifreeze getting into the lubrication system. This is easy to detect if a decrease in coolant volume is detected, but there are no signs of leakage. Such a nuisance can occur due to worn cylinder head gaskets. No less often, the problem arises due to leakage through the sealing points of the block liners. To fix the problem, it is enough to replace all worn gaskets.

Fan

The fan is made in the form of 5 blades, and it is located on the fluid coupling shaft. The unit can be switched on and off automatically, and this process takes into account the ambient temperature. The KamAZ cooling fan operates according to switching on and off. The presence of a casing made of metal ensures that air flows only to the radiator, so side struts can be avoided. Knowing the features of the design and operation of the KamAZ 65115 fan switch on, where it is located, you can correctly determine the specifics of using the units and carefully monitor their technical condition.

Water pump

Important! In accordance with Euro standards, a water pump is also provided. The main function of the unit is to circulate coolant through the technical system and engine used.

The unit determines the flow, functionality and technical condition of the vehicle. To protect internal working cavities, special seals are traditionally used. To prevent breakdowns, it is important to use a lubricant with which you can pump in lubricant.

The operating principle of the thermostat and instructions for replacing it on KamAZ vehicles: we tell you all the nuances

Thermostats and pipes

The system pipes require mandatory supervision. Only with sealed connections can the engine temperature be properly regulated and the loss of excessive amounts of coolant prevented. The places where the pipes are connected to other spare parts and where the increased vulnerability of the units is noted deserve attention.

Important! Thermostats are required to use antifreeze. If the temperature of the technical fluid reaches 80 degrees, the fluid transfer is disrupted. At a temperature of 93 degrees, circulation is disrupted, as a result of which coolant flows through the engine radiator and this leads to a decrease in the service life of the equipment.

Only proper maintenance of thermostats and pipes guarantees that the installed units will remain in good condition.

How to flush?

Flushing the engine cooling system with a washing gun
Flushing the engine cooling system can be done in several ways. If minor contamination is detected, ordinary water can be used for this. To do everything correctly, you need to completely drain the antifreeze. Instead, plain water is pumped into the tubes. After this, start the engine, which should warm up at idle speed. The water is drained and everything is repeated several times until the unit can be completely cleaned.

If significant contamination is detected, it is best to use special flushing liquids. It can be added to the tubes without draining the antifreeze, after which it is removed along with it. But experts recommend using solutions that are poured into an empty system.

The KAMAZ engine radiator is always washed separately, using special liquids. This ensures a more thorough cleaning. In this case, experts recommend using a weak solution of hydrochloric acid.

Additional recommendations for performing high-quality rinsing

To perform high-quality flushing, you should not forget that the supply of cleaning liquid must occur in the opposite direction to the movement of antifreeze. It is especially effective to do this using special equipment that creates additional pressure.

To drain the coolant in a KAMAZ, you need to open all the valves - radiator, heat exchanger, pump, antifreeze supply pipes. Be sure to unscrew the expansion tank cap. The taps are closed only after the liquid has completely drained.

Flushing the KamAZ 740 engine

Cooling system features

Maintenance and adjustment of cooling system units are mandatory taking into account the technical parameters of KamAZ. The engine operates normally if the temperature conditions are maintained. Overheating and hypothermia are potentially dangerous. Incorrect temperature conditions reduce the service life of the units used. At the wrong temperature, the use of fuel is impaired, as it does not evaporate, ignite and burn well, so the engine runs with less power and consumes more fuel.

Advice! The cooling system is designed for harsh conditions and full engine load, high air temperatures. Units can be adjusted to maintain optimal performance in light operating conditions.

The installed KamAZ fan sensor helps in monitoring the characteristics and maintaining them under different weather conditions.

The best analogues

When choosing a new shut-off valve for a Kamaz thermostat, you must be guided by the following nuances:

Purchase only products from trusted companies.
Inspect the devices for build quality. There should be no curvature of the rod or the surface of the bowls.
The spring should fit tightly to the bowls, without gaps or bending.
It is important that the thermoelement container is made of copper or brass. These materials heat up faster than steel.
It is also worth paying attention to the marking of the temperature threshold and choosing a complete analogue of the factory mechanism.

Next, we will describe the 3 best models of thermostats for Kamaz.

Pramo Electro

The original thermostats of this company are marked with the article number TS107.1306100-01M. A distinctive feature is the material from which the locking bowls of the mechanism are made.

The manufacturer uses a thin stainless alloy, which ensures a long service life of the device and immunity to oxidation. The kit also includes a gasket to seal the thermostat cover.

High build quality.
Service life up to 75,000 kilometers.
Average price.
Using “stainless steel” for the manufacture of mechanism elements.

The company has been on the market for more than 10 years and is highly popular.

LUZAR

The LUZAR company marks its products with the article number LT (for example, LT 03022). Thermostats have an opening period of 80 ± 2 degrees. The mechanisms are made from stainless steel. The thermoelement material is purified copper. A special feature is an additional anti-corrosion coating, which increases service life.

Average price.
Complete with corrosion-resistant gasket.
Low opening threshold difference.
High build quality.

Thermostats from this company can be used for Euro 1–3 series vehicles.

PEKAR

Another well-known manufacturer of spare parts. PEKAR marks thermostats with article number 107-1306100-01.

A special feature is the use of stainless steel and additional anti-corrosion coating for the component elements of the mechanism. The opening period of the devices is 80–82 degrees.

Acceptable price.
Long service life.
Build quality.
Selection of models with different opening periods.

The company has long earned a high reputation among car enthusiasts in Russia and the CIS.

Cooling system prevention

When connecting units, remember about regular preventive maintenance, which determines the condition of KamAZ.

Use the liquid taking into account the optimal temperature of use.
When pouring technical fluid, follow the basic rules of the procedure.
Monitor the temperature of the liquid. The minimum indicator is 80 degrees, the maximum is 98. This temperature is optimal for the equipment.
Regularly check the amount of fluid available. The normal level should be two thirds of the volume of the used tank.
The fluid is changed regularly. The procedure is carried out once a year. Over time, the characteristics of the liquid deteriorate and it is difficult for units to connect to the system and perform work tasks.
Monitor the condition of equipment and the tightness of structures. Liquid leakage is unacceptable, as it reduces the service life of the technical system.
If the temperature regime is violated, check the condition of the thermostats and the fluid coupling switch sensor.
In summer, the units are regularly monitored. If necessary, carry out cleaning measures to eliminate contamination.
Prevention and maintenance are carried out taking into account the condition of the equipment. The circuit diagram for switching on the KamAZ Euro 2 cooling fan and other parts is taken into account.
The tension of the vehicle belts is important. The tension is checked by pressing on the middle of the branch with a force of 4 kgf. Belts usually bend by 15-22 millimeters. In other cases, adjust the tension.
Maintenance involves regularly draining the old cooling system. It is forbidden to start the engine for short-term operation after the procedure. This leads to overheating of parts and premature failure of equipment, since it cannot be connected properly after the procedure.

The use of a reliable sensor for turning on the KamAZ cooling fan and other devices is mandatory, taking into account the condition of the vehicle, weather conditions, and driving characteristics. Careful monitoring of technical characteristics and regular maintenance are carried out to ensure the full operation of the equipment responsible for the cooling process.

The KamAZ thermostat is designed to automatically maintain the optimal temperature regime of the power unit under various operating conditions. This is facilitated by the redirection of medium flows in the cooling system of the KamAZ engine. On a cold unit, antifreeze moves in a small circle: pump - cylinder block jackets - thermostat - pump. After the coolant reaches 80°C, part of the medium is redirected by the thermostat to the radiator. This circulation pattern is called a great circle.

The operating principle of the thermostat and instructions for replacing it on KamAZ vehicles

Where is it located and how is it arranged?

Due to the large volume of the KamAZ engine cooling system, they are equipped with 2 thermostats, which are located in one housing, located on the front wall of the right cylinder block. This arrangement is due to the fact that the coolant is first supplied by the pump to the left cylinder block, and then through the bypass pipe to the right one. Once in the thermostat box, hot antifreeze is directed either to the pump suction (warming up the engine) or to the radiator. The fan, pumping air, takes heat from the coolant. Cooled antifreeze from the lower tank enters the pump suction.

The thermostat is a simple but important device in the engine cooling system. It consists of:

housings;
two valves;
rod;
cylinder with wax;
springs.

The principle of operation is based on increasing volume when melting solids. The latter is ceresin, which is a mixture of wax and aluminum powder. The actuators (valve) are fixed to the stem. When starting a cold engine, one of them (the main one) is in the closed position, and the other (the small circle valve) is open.

Basic faults

A common malfunction of the thermostat is the valve not closing tightly. After starting the engine, antifreeze circulates in a large circle. This leads to a long time to reach the nominal temperature. In winter, the engine may not reach the required 90°C at all. By operating a car with such a breakdown, the owner reduces the engine's life every day, since prolonged warming up is contraindicated for the engine.

A valve stuck in the closed position can have more serious consequences. After reaching a temperature above the nominal temperature, the liquid continues to circulate in a small circle. If the car owner does not check whether the thermostat is working, the engine will boil. Unlike gradual excessive wear when the valve is constantly open, its closed position can lead to a major overhaul of the engine at the first emergency situation. Jamming of pistons, warping of metal parts, destruction of rubber products and other serious consequences accompany engine boiling, so if the first signs of a thermostat malfunction appear, it is necessary to diagnose it and, if necessary, replace the jammed product with a new one.

If the heat-sensitive fill material leaks, the valve may be delayed in response. If the time interval is large enough, the consequences will be similar to jamming. In some cases, coolant enters the sealed cavity, changing the temperature coefficient of expansion.

How to change

Before replacing the thermostat, you will have to perform related dismantling work. To change it, you need to remove the generator belt, loosen the fastening bolts and move the mechanism to the side. Before removing the hose from the radiator pipe, drain 2-3 liters of coolant, dismantle the clamps and carefully pull the corrugation off the fitting. After this, the thermostat box is removed

To replace them, the cover is dismantled. After installing functional parts, the oil seal is replaced and the box is closed. Reinstallation is carried out in reverse order.

Thermostat Cummins ISLe, 6L, QSL – Removal, inspection and installation

The thermostat allows you to regulate the temperature of the coolant in the engine cooling system. If the temperature of the antifreeze (antifreeze) is below the operating level, the coolant passes in a small circle directly around the cylinder head and the block itself.

The thermostat allows you to regulate the temperature of the coolant in the Cummins - Cummins engine cooling system. If the temperature of the antifreeze (antifreeze) is below the operating level, the coolant passes in a small circle directly around the cylinder head and the cylinder block itself, immediately entering the coolant pump (pump), which speeds up engine warming up. When the temperature of the antifreeze (antifreeze) rises to the operating level, the temperature-sensitive element reacts to this and opens. After which the coolant enters a large circle passing through the radiator (cooler), providing complete cooling of the Cummins engine and maintaining the desired thermal operating conditions. The thermostat opening temperature is

Operating a Cummins engine without a thermostat is not allowed. Without a thermostat, the coolant will follow the path of least resistance in a small circle to the pump inlet, which can lead to overheating and engine failure.

Do not open the coolant radiator cap when the engine is hot; allow the antifreeze to cool to a temperature below 50°C. Release of hot antifreeze or antifreeze vapor can cause burns and injury.

1) Disconnect power from the battery.

2) Drain the antifreeze from the Cummins ISLe, 6L, QSL engine cooling system.

3) Disconnect the radiator hose from the water pipe

4) Unscrew the bolts of the water pipe, remove it and take out the Cummins ISLe, 6L, QSL thermostat.

5) Clean the mating surfaces of the cylinder head and pipe.

7) Check the Cummins ISLe, 6L, QSL thermostat, thermostat gasket and O-rings for damage. Be sure to replace damaged gaskets. The serviceability of the thermostat and the integrity of its seals ensure that the engine operates at optimal temperature conditions. Overheating or low engine temperature will shorten its service life.

Check the operation of the Cummins engine thermostat ISLe, QSL, 6L. To check the thermostat, heat the water, place the thermostat and thermometer there, they should not touch its side walls.

The check is carried out as follows - the nominal operating temperature is indicated on the thermostat body, it is

82°C (180°F). The thermostat must meet the following requirements - the thermostat must begin to open when the temperature is within 1°C [2°F] of the nominal temperature. It should open fully when the temperature is within 12°C [22°F] of the nominal temperature. For a fully open thermostat, the distance between the thermostat flange and the housing is at least

9.4 mm (0.370 in)

9) Install the Cummins ISLe, 6L, QSL thermostat in the reverse order. Check the presence and correct location of the O-rings. Install the water pipe and tighten the bolts. Tightening torque: 24 Nm

10) Pour coolant into the Cummins internal combustion engine cooling system. Be sure to bleed air from the entire engine cooling system and charge air cooler when adding coolant. When starting the engine, check for antifreeze leaks.

Some installations use a remote thermostat supplied by the OEM. For installation locations of individual components and parts, see the equipment manufacturer's documentation. Refer to the equipment manufacturer's documentation for instructions on removing and installing the remote thermostat.

Source: cum-motor.ru

where is it located, how to change it, replacement, how much does it cost

Where is it located and how is it arranged?

The thermostat is a simple but important device in the engine cooling system. It consists of:

housings;
two valves;
rod;
cylinder with wax;
springs.

When the coolant is heated, the wax in the cylinder passes into the liquid phase. Having reached a temperature of 80°C, ceresin displaces the rod, as a result of which the main (upper) valve opens and the small circle valve (lower) closes. Part of the antifreeze enters the cooling radiator. At a coolant temperature of 93°C, the upper valve opens completely. The entire flow is directed to the radiator, because the bottom valve shuts off the liquid supply to the pump suction.

As the coolant cools, the valves begin to move in the opposite direction, and the process repeats. The parameters in the cooling system are automatically maintained.

How to change

To replace them, the cover is dismantled. After installing functional parts, the oil seal is replaced and the box is closed. Reinstallation is carried out in reverse order.

Operating principle

The operating principle of the KAMAZ thermostat is also no different. The difference is the engine cooling principle. The system works as follows:

Cold coolant, after the engine starts, circulates through the channels of the power unit, pumped into the system by a water pump.
At this time, both valves are closed by large bowls, only small bowls are open. The valve is designed so that the small bowls have a factory seat clearance.
Initially, the left cylinder block is heated, and after it the antifreeze flows to the right side.
After the antifreeze temperature has reached a threshold of 80 degrees, the small bowls close. Large bowls are opened. This occurs due to the heating and melting of the mixture of wax and aluminum in the thermoelement bulb. Due to melting, the pressure on the rods increases, they open, closing the passage channels with small locking bowls.
The liquid opens the way to the radiator for cooling and temperature stabilization.
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This process is repeated as the load on the engine increases, when operating modes and engine speed change.

This system allows you to quickly and evenly warm up both cylinder blocks of the power unit.

Modern KamAZ EURO-4 vehicles are equipped with more advanced thermostats. They received an addition in the form of an electrical thermistor. The on-board computer regulates the temperature and timing of valve opening by heating this element. This is necessary to quickly cool the liquid when heavy loads are placed on the engine.

These cars also received fans for additional cooling. During operation, the engine temperature can cross the threshold of 97 degrees. To cool such a volume of antifreeze, manufacturers equipped an electric fan with a temperature sensor. It automatically operates to activate an additional cooling mechanism.

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Home » Clips » How to change the thermostat on a KAMAZ 740 video

Models of Kamaz thermostats

Manufacturers now install various thermostats on trucks. Let's look at their main types:

Electronic thermostat. This is the most modern device, it is installed on advanced versions of KamAZ 6520 and 65115. It does not overheat when the degrees rise, as it has a special thermal resistance device. They usually work with Euro-4 engines. The use of this device significantly reduces fuel consumption. You may notice that KamAZ owners install this type of thermostat on Euro-2, 3 engines.

A two-valve thermostat is usually installed on Kamaz 5320 and 740 models. One device has two valve outputs: main and auxiliary. The main one is designed to ensure the movement of antifreeze in a large circle of circulation. The auxiliary performs a similar function, but on a small circle of revolution. This type is very common on heavy vehicles in the CIS countries.

The two-stage thermostat KAMAZ 43118 also includes two valves in its design. It is installed in devices with increased antifreeze pressure.