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12. COOLING SYSTEM

12-0

PEOPL E 25 0

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COOLING SYSTEM

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SCHEMATIC DRAWING ---------------------------------------------- 12- 1

SERVICE INFORMATION -------------------------------------------- 12- 2

TROUBLESHOOTING ------------------------------------------------- 12- 2

COOLING SYSTEM TESTING --------------------------------------- 12- 4

RADIATOR -------------------------------------------------------------- 12- 4

WATER PUMP ---------------------------------------------------------- 12- 9

THERMOSENSOR ------------------------------------------------------ 12-14

THERMOSTAT---------------------------------------------------------- 12-15

Summary of content (17 pages)

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12. COOLING SYSTEM PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. • The engine must be cool before servicing the cooling system. When the coolant temperature is over 100℃ , never remove the radiator cap to release the pressure because the boiling coolant may cause danger.
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12. COOLING SYSTEM PEOPL E 250 SPECIFICATIONS Radiator cap relief pressure Begins to open Thermostat temperature Full-open Valve lift 0.9±0.15kg/cm_ 80±2℃ 90℃ 3.5_ 4.5mm 1000±20cc Total system 1400±20cc Radiator: Reserve tank: 400±20cc Coolant capacity COOLANT GRAVITY Temp. ℃ Coolant concentration 5% 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 0 5 10 15 20 25 30 35 40 45 50 1.009 1.018 1.028 1.036 1.045 1.053 1.063 1.072 1.080 1.086 1.095 1.100 1.009 1.107 1.027 1.035 1.044 1.051 1.062 1.
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12. COOLING SYSTEM PEOPL E 250 COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. Radiator Tester ＊ Apply water to the cap sealing surface before testing. Radiator Cap Relief Pressure: 0.9±0.15kg/cm_ Radiator Cap Install the radiator tester onto the radiator and apply specified pressure to it. It must hold specified pressure for at least six seconds.
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12. COOLING SYSTEM PEOPL E 250 Radiator Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator, wash them off. Carefully straighten any bent fins. Outlet Tube of Reserve Tank RADIATOR REMOVAL Drain the coolant. (!3-9) Disconnect the outlet tube of the reserve tank. Air Vent Tube Remove the overflow tube clamp and disconnect the overflow tube. Disconnect the air vent tube from the radiator filler.
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12. COOLING SYSTEM Remove the two bolts and two nuts on the radiator. Remove the radiator. PEOPL E 250 Radiator Nuts Bolts RADIATOR DISASSEMBLY Remove the three bolts and then remove the fan/shroud from the radiator. Fan/Shroud Bolts Battery Check fan motor by battery.
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12. COOLING SYSTEM PEOPL E 250 Thermostatic Switch CHECK THERMOSTATIC SWITCH When coolant temperature lower then 88~92℃ the thermostatic switch OFF. When coolant temperature over 88~92℃ the thermostatic switch ON. Install the fan shroud on the radiator with the three bolts.
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12. COOLING SYSTEM PEOPL E 250 Nuts RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts and two nuts. Radiator Bolts Connect the upper and lower hoses and secure them with hose bands. Connect the thermostatic switch wire. Connect the fan motor wire couplers. Connect the overflow tube and secure with the tube clamp. Fill the radiator with coolant. (!3-9) Connect the vent tube to the radiator filler. After installation, check for coolant leaks.
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12. COOLING SYSTEM PEOPL E 250 Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal. Water Pump Telltale Hole Inlet Hose WATER PUMP/IMPELLER REMOVAL Remove the coolant inlet hose and outlet hose. Outlet Hose Bolts Remove the four bolts and the water pump cover, gasket and 2 dowel pins.
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12. COOLING SYSTEM Inspect the mechanical (water) seal and seal washer for wear or damage. PEOPL E 250 Impeller Mechanical Seal ＊ The mechanical seal and seal washer must be replace as a set. Seal Washer (Porcelain) Bolts WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove the eight bolts attaching the right crankcase cover. Water Pump Assembly Remove the water pump bearing snap ring from the water pump assembly. Remove the water pump shaft and inner bearing.
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. COOLING SYSTEM Remove the water pump shaft outer bearing. PEOPL E 250 Water Pump Assembly Inner Bearing Water Pump Assembly MECHANICAL S EAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside. Mechanical Seal (Water Seal) Drive in a new mechanical seal using a mechanical seal driver. ＊ Apply sealant to the right crankcase cover fitting surface of a new mechanical seal and then drive in the mechanical seal.
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12. COOLING SYSTEM WATER PUMP SHAFT INS TALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside. PEOPL E 250 Outer Bearing Water Pump Assembly Snap Ring Water Pump Shaft Install the water pump shaft and shaft inner bearing into the waster pump assembly. Install the snap ring to secure the inner bearing properly. Inner Bearing Bolts Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover.
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12. COOLING SYSTEM PEOPL E 250 Impeller Mechanical Seal WATER PUMP/IMPELLER INSTALLATION When the mechanical seal is replaced, a new seal washer must be installed to the impeller. Seal Washer (Porcelain) Install the impeller onto the water pump shaft. Torque: 9.8_ 13.7N-m Impeller (Left Hand Threads) ＊ The impeller has left hand threads. Install the two dowel pins and a new gasket. Dowel Pins Bolts Install the water pump cover and tighten the 4 bolts. Torque: 7.8_ 11.
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12. COOLING SYSTEM PEOPL E 250 Thermosensor THERMOSENSOR THERMOSENSOR REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor Wire THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up.
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12. COOLING SYSTEM THERMOSTAT THERMOSTAT REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the thermosensor wire from the thermosensor. Disconnect the water hose from the thermostat housing. Disconnect the air vent tube from the thermostat housing. Remove the mounting bolt and the thermostat housing from the cylinder head.
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12. COOLING SYSTEM THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation. Technical Data Begins to open Full-open Valve lift PEOPL E 250 Thermostat Thermometer 80±2℃ 90℃ 3.5_ 4.5mm ＊ • Do not let the thermostat touch the pan O-ring as it will give a false reading. • Replace the thermostat if the valve stays open at room temperature.