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d3500 master mechanic

Cooling System
Module 3 - Text Reference

SERV1971

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and may not be used without permission. © 2017 Caterpillar Inc. All Rights Reserved.
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SERV1971 - 01/17 -2- Module 3 - Cooling System

LEARNING OUTCOMES
You will meet the following learning outcomes during this Cooling System
module of the D3500 Master Mechanic course:
• Trace the flow of coolant through the engine.
• Identify the major components of the cooling system.
• Explain specifications of the cooling system.
• Identify common troubleshooting issues related to the cooling
system.
• Demonstrate the ability to remove and install the major components
of the cooling system.
• Demonstrate the ability to disassemble and assemble the major
components of the cooling system.

LEARNING OUTCOMES

You will meet the following learning outcomes during this Cooling System module of
the D3500 Master Mechanic course:

• Trace the flow of coolant through the engine.

• Identify the major components of the cooling system.
• Explain specifications of the cooling system.
• Identify common troubleshooting issues related to the cooling system.
• Demonstrate the ability to remove and install the major components of
the cooling system.
• Demonstrate the ability to disassemble and assemble the major
components of the cooling system.

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 SERV1971 - 01/17 -3- Module 3 - Cooling System

3_1

Cooling System

Diesel engines operate by converting the heat energy from diesel fuel into usable
mechanical energy. Ideally, 100% of the heat produced could be converted into
mechanical energy. In reality, a four-stroke diesel engine is about 33% efficient.
Roughly 67% of the heat produced is dissipated by the cooling system (30%),
exhaust system (30%), and radiated heat (7%).

The cooling system performs several functions which are critical to proper engine
operation:

• Maintains proper engine temperature for optimum performance.

• Cools compressed inlet air to optimize combustion.
• Dissipates excess heat from other engine system components, such as lube
oil and turbochargers.

Instructor Bullet Points go here

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SERV1971 - 01/17 -4- Module 3 - Cooling System

1
4_1

Cooling System

The illustration above shows the major components of the cooling system:

• Water pump (1)

• Oil cooler (2)

• Aftercooler (3)

• Coolant manifold (4)

• Regulator housing (5)

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SERV1971 - 01/17 -5- Module 3 - Cooling System

Water Temperature Cooling Device

Water Manifold
Regulators (Housing) (Radiator)

Expansion
Turbo Cylinder Heads Tank

After Cooler
Engine Block Water Pump
Engine Oil Cooler

5_1

Jacket Water Aftercooling Circuit (JWAC)

The illustration above shows a block diagram of a jacket water aftercooling circuit.
Coolant flows to the jacket water pump through an elbow that connects to the
radiator or heat exchanger. Part of the coolant is sent to the aftercooler, while most
of the coolant is sent through the engine oil cooler.

The coolant sent to the aftercooler flows through the aftercooler core. The coolant
then travels through an elbow and coolant flows into a passage in the block. The
passage is near the center of the vee at the rear of the block. The coolant flows
through the oil cooler into the water jacket of the block at the right rear cylinder. The
cooler coolant mixes with the hotter coolant. The mixture flows to both sides of the
block through distribution manifolds, which are connected to the water jacket of all
the cylinders. The main distribution manifold is located just above the main bearing
oil gallery.

The coolant flows upward through the water jackets. The coolant flows around the
cylinder liners from the bottom to the top. Near the top of the cylinder liners, the water
jacket is smaller. This area has the hottest temperature. This shelf (smaller area)
causes the coolant to flow faster for better liner cooling. Coolant from the top of the
liners flows into the cylinder head, which sends the coolant around the components
that have the hottest temperature. Coolant flows to the top of the cylinder head (one
at each cylinder). The coolant flows out of the cylinder head through an elbow into a
water manifold. Coolant then flows through the manifold to the temperature regulator
housing (thermostat).

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SERV1971 - 01/17 -6- Module 3 - Cooling System

The water temperature regulator housing has an upper flow section and a lower
flow section. The regulator housing uses four temperature regulators. The sensing
bulbs of the four temperature regulators are in the coolant in the lower section of the
housing. Before the regulators open, cold coolant is sent through the bypass line,
back to the inlet of the water pump. The coolant flow in the bypass line is restricted
when the temperature of the coolant increases enough to open the regulators.
Coolant is sent through the outlets to the radiator or to the heat exchanger.

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SERV1971 - 01/17 -7- Module 3 - Cooling System

Water
Temperature
Regulators Radiator Thermostat Radiator
(Housing)

Water Water
Turbo
Pump Pump

Engine Oil
Engine Block Aftercooler
Cooler

7_1

Separate Circuit Aftercooling Circuit (SCAC)

The illustration above shows a block diagram of a separate circuit aftercooling circuit.

• Aftercooler has its own cooling Separate circuit aftercooling provides the aftercooler its own cooling circuit. As with
circuit. the engine circuit, the aftercooler circuit has a water pump, water temperature
regulators, and a radiator or heat exchanger.

• Advantage: Cooler inlet air Separate circuit aftercooling has the advantage of producing cooler combustion air
temperatures. which has higher oxygen density. This allows higher ratings and improves engine
efficiency.

• Disadvantage: requires two The disadvantage of the separate circuit system is it requires two complete cooling
cooling systems. systems. Some marine applications use seawater aftercooling which pumps
seawater directly through the aftercooler with no water temperature control.

• Most HD and C series use SCAC. Most D3500 high displacement engines and series C engines use separate circuit
aftercooling.

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SERV1971 - 01/17
1 2
• SCAC pump (1)
• Inlet elbow (2)
• Aftercooler (3)
• Thermostatic valve (4)
• SCAC outlet (5)
-8- Module 3 - Cooling System
4 5
8_1
Separate Circuit Aftercooling Circuit (SCAC) (cont.)
The separate circuit water pump (1) is located on the front left side on the engine.
Coolant is drawn from the source of the coolant through an elbow (2) into the
separate circuit water pump. The coolant is directed to the aftercooler (3).
Coolant flows from the aftercooler to the thermostatic valve (4). Before the
temperature of the coolant rises, the coolant is diverted to the separate circuit water
pump .
When the temperature of the coolant increases enough to open the thermostatic
valve, the path of the coolant flow changes. The coolant flow from the thermostatic
valve to the water pump is restricted. Coolant is circulated back to the source of the
coolant (5).
The rest of the coolant flow throughout the engine is the same as the JWAC system.
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SERV1971 - 01/17 -9- Module 3 - Cooling System

9_1

Water Pump

This illustration shows a cutaway of the water pump. The green highlighted areas
indicate coolant flows through those passages.

• Vane pump driven off front gear The water pump is a vane pump and is driven off the front gear train. Coolant flows
train. to the water pump through an elbow (1) that connects to the radiator or heat
exchanger.

• Remote pump outlet can be There is one opening on the pump outlet (2) so a remote pump can be connected to
connected if primary pump fails. the system. The remote pump can be used if there is a failure of the pump on the
engine.

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SERV1971 - 01/17 -10- Module 3 - Cooling System

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Oil Cooler

The purpose of the engine oil cooler is to lower the temperature of the engine oil.
The coolant flows through the engine oil cooler (arrow) from the front of the engine,
towards the rear of the engine. This is the opposite flow direction than the engine oil.
This process maximizes the amount of heat that can be drawn from the engine oil.

With this process, the amount of time the engine oil is located inside the engine oil
cooler is much longer than the time the coolant is flowing through the cooler. Thus
allowing for more heat to be transferred from the engine oil to the coolant.

This heat transfer will result in an approximately a 15 - 20ºF decrease in engine oil
temperature, and an approximately 3ºF increase in coolant temperature. Coolant
exits the engine oil cooler and flows into the water jacket of the block at the right rear
cylinder.

NOTE: Coolant flows through the tubes; engine oil flows around the outside
of the tubes.

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SERV1971 - 01/17 -11- Module 3 - Cooling System

11_1

Coolant Flow to Aftercooler

In a Jacket Water Aftercooler Cooling (JWAC) system, part of the coolant is sent
to the aftercooler, while most of the coolant is sent through the engine oil cooler.
Coolant is supplied to the aftercooler through a tube (arrow). The tube shown in the
illustration has been cut away.

NOTE: The passages colored green indicate coolant flow.

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SERV1971 - 01/17 -12- Module 3 - Cooling System

12_1

Coolant Flow to Aftercooler (cont.)

The coolant sent to the aftercooler flows through the aftercooler core (arrow). The
coolant then flows through an elbow to supply coolant to the cylinder block.

NOTE: The passages colored green indicate coolant flow.

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SERV1971 - 01/17 -13- Module 3 - Cooling System

13_1

Coolant Flow to Cylinder Block

The coolant flows into a passage in the block (1). The passage is near the center
of the vee at the rear of the block. Coolant flows to both sides of the block through
distribution manifolds. The distribution manifolds are connected to the water jacket
of all the cylinders (2). The main distribution manifold is located just above the main
bearing oil gallery.

The coolant flows upward through the water jackets. The coolant flows around the
cylinder liners from the bottom to the top. Near the top of the cylinder liners, the water
jacket is smaller. This area has the hottest temperature. This shelf (smaller area)
causes the coolant to flow faster for better liner cooling. Coolant from the top of the
liners flows into the cylinder head which sends the coolant around the components
that have the hottest temperature.

NOTE: The passages colored green indicate coolant flow.

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SERV1971 - 01/17 -14- Module 3 - Cooling System

14_1

Coolant Flow to Cylinder Heads

Coolant from the top of the liners flows into the cylinder head, which sends the
coolant around the components that have the hottest temperature. There are eight
passages per cylinder head. Each passage must have a water seal (arrows) installed
in the spacer plate. A damaged or uninstalled seal will result in coolant entering the
combustion chamber and/or oil passages. Coolant flows to the top of the cylinder
head (one at each cylinder). The coolant flows from the cylinder head through an
elbow into a water manifold.

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SERV1971 - 01/17 -15- Module 3 - Cooling System

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Coolant Flow to Water Manifolds

The coolant flows out of the cylinder head through an elbow (arrow) into a water
manifold (removed in the illustration).

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SERV1971 - 01/17 -16- Module 3 - Cooling System

3
2

16_1

Coolant Flow to Water Manifolds (cont.)

The coolant flows out of the cylinder head through an elbow (1) into a water
manifold (2). Coolant then flows through the manifold into the temperature regulator
housing (3).

The water manifold shown is a wet manifold design in which the coolant and exhaust
are contained in the same manifold. This design is used on early model engines
or applications in which the possibility of exhaust leaks is not allowed. Newer
applications use a separate manifold for coolant and exhaust.

NOTE: The passages colored green indicate coolant flow.

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SERV1971 - 01/17 -17- Module 3 - Cooling System

17_1

Water Temperature Regulator Housing

The water temperature regulator housing has an upper flow section and a lower flow
section. The regulator housing uses four temperature regulators. The sensing bulbs
of the four temperature regulators are located in the coolant in the lower section of
the housing. Before the regulators open, cold coolant is sent through the bypass line
back to the inlet of the water pump (1). The coolant flow in the bypass line is restricted
when the temperature of the coolant increases enough to open the regulators.
Coolant is sent through the outlets to the radiator or to the heat exchanger (2).

NOTE: The passages colored green indicate coolant flow.

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SERV1971 - 01/17 -18- Module 3 - Cooling System

18_1

Coolant to Turbochargers

Most D3500 turbochargers are coolant cooled. Coolant is supplied to each

turbocharger by a tube supplied from the coolant manifold (1). Coolant is returned from
the turbocharger (2) to the water temperature regulator housing. The turbocharger
coolant supply tube is a larger diameter than the return tube. This allows coolant to
stay inside the turbocharger housing longer in order to remove more heat.

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SERV1971 - 01/17 -19- Module 3 - Cooling System

19_1

Cooling System Specifications

Following are the cooling system specifications:

• Maximum Coolant Temperature = 220°F (typical shutdown event)

• Minimum Coolant Temperature = 175°F

• Coolant Temperature increase across oil cooler = ~3°F

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SERV1971 - 01/17 -20- Module 3 - Cooling System

Common Cooling System Troubleshooting Issues

• Coolant temperature is too high (overheating)
• Coolant temperature is too low (overcooling)
• Engine oil in cooling system
• Fuel in cooling system
• Air in cooling system (coolant to air leaks in the
aftercooler)
• Cooling system component wear (poor coolant quality)

20_2

Common Cooling System Troubleshooting Issues

Some of the common troubleshooting issues are:

• Coolant temperature is too high (overheating)

• Coolant temperature is too low (overcooling)

• Engine oil in cooling system

• Fuel in cooling system

• Air in cooling system (coolant to air leaks in the aftercooler)

• Cooling system component wear (poor coolant quality)

NOTE: These troubleshooting procedures are typical for D3500 engines.

Always refer to SIS Web for the most current troubleshooting procedures
for the specific engine serial number being serviced.

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SERV1971 - 01/17 -21- Module 3 - Cooling System

• Coolant Temperature is Too High

-- Faulty temperature regulator
-- Radiator
-- Low coolant level
-- Faulty jacket water coolant pump
-- Faulty engine cooling fan
-- Faulty pressure relief valve

21_2

Coolant Temperature is Too High

An engine that runs too hot will also have hotter engine oil. Hotter oil will be thinner,
thus reducing the lubricating ability. The oil film between moving parts will be thinner
so there will be less running clearance between the moving parts which may increase
friction. Inadequate lubrication will cause failure from scuffing of the moving parts in
contact with each other and, in extreme conditions, will result in a failure due to
moving surfaces seizing.

Probable causes and recommendations:

•  aulty temperature regulator: Check the water temperature regulator. A

F
water temperature regulator that does not open (stuck closed) or a water
temperature regulator that only opens part of the way may cause overheating.
• Radiator: Check the cooling fins on the radiator for dirt and/or debris. Remove
the dirt and/or debris. Inspect the cooling fins on the radiator for damage.
Check the radiator for internal blockage. Check the temperature difference
between the top and the bottom of the radiator.
• Low coolant level: Verify the cooling system is filled to the proper level. If
the coolant level is too low, air will enter the cooling system. Air in the cooling
system will cause a reduction in coolant flow and bubbles in the coolant. Air
bubbles will keep coolant away from the engine parts, which will prevent
the transfer of heat to the coolant. Low coolant level is caused by leaks or
incorrectly filling the radiator.

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SERV1971 - 01/17 -22- Module 3 - Cooling System

•  aulty jacket water coolant pump: Inspect the impeller vanes at the jacket
F
water pump for damage and/or erosion. Repair and/or replace the impeller
vanes.
• Faulty engine cooling fan: If the fan is belt driven, check for loose drive
belts. A loose fan drive belt will cause a reduction in the air flow across the
radiator. Check the fan drive belt for proper belt tension. Adjust the tension
of the fan drive belt, if necessary. Refer to the Operation and Maintenance
manual for more information. If a fan clutch or a hydraulic driven fan is used,
check that it is turning at the correct speed. If not, this can cause improper air
speed across the radiator core. The lack of proper air flow across the radiator
core may cause an improper coolant temperature differential.
• Faulty pressure relief valve: Check operation of the pressure relief valve
and the radiator cap. If necessary, clean the pressure relief valve and/or
radiator cap. Check the seating surface of the valve is clean and undamaged.
If necessary, install new components.

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SERV1971 - 01/17 -23- Module 3 - Cooling System

• Coolant Temperature is too low

-- Water temperature regulators stuck open
-- Low engine load
-- Low ambient temperature
-- Faulty pressure relief valve

23_2

Coolant Temperature is Too Low

Overcooling reduces the efficiency of operation and enables a more rapid

contamination of the engine oil. This may result in the formation of sludge in the
crankcase, condensation, high wear rates, and carbon deposits on the valves.

Probable causes and recommendations:

• Water temperature regulators stuck open: Perform the Water Temperature

Regulator - Test (refer to Troubleshooting manual).
• Low engine load: Run the engine at higher loads.
• Low ambient temperature: Block off a portion of the radiator.
• Faulty pressure relief valve: Check operation of the pressure relief valve
and the radiator cap. If necessary, clean the pressure relief valve and/or the
radiator cap. Ensure the seating surface of the valve is clean and undamaged.
If necessary, install new components.

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SERV1971 - 01/17 -24- Module 3 - Cooling System

• Engine Oil in Cooling System

-- Engine oil cooler core
-- Cylinder head gasket
-- Water pump

24_2

Engine Oil in Cooling System

Probable causes and recommendations:

•  ngine oil cooler core: Inspect the engine oil cooler core for leaks. If a leak
E
is found, replace the oil cooler core.
• Cylinder head gasket: Check the cylinder liner projection. Refer to Systems
Operation/Testing and Adjusting for more information.
• Water pump: Check the weep hole in the water pump for blockage. Check
the water pump seals.

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SERV1971 - 01/17 -25- Module 3 - Cooling System

• Fuel in Cooling System

-- Leaking injector sleeve and/or damaged seal

25_2

Fuel in Cooling System

Probable causes and recommendations:

•  eaking injector sleeve and/or damaged seal: Remove the fuel injectors
L
from the cylinder head. Pressurize the cooling system in order to identify the
leaking injector sleeve. Closely inspect the sealing joint around the top of the
injector sleeve. Small amounts of coolant will be dripping from the leaking
injector sleeve.

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SERV1971 - 01/17 -26- Module 3 - Cooling System

• Air in Cooling System

-- Leaks

26_2

Air in Cooling System

Air in the cooling system causes cavitation. Cavitation occurs when mechanical
forces cause the formation of air bubbles in the coolant. The bubbles can form on
the cylinder liners. Collapsing bubbles can remove the oxide film from the cylinder
liner, allowing corrosion and pitting to occur. If the pressure of the cooling system is
low, the concentration of bubbles increases. The concentration of bubbles is reduced
in a pressure type cooling system.

Probable causes and recommendations:

• Leaks: Air can enter the cooling system in different ways. The most
common causes of air in the cooling system are the incorrect filling
of the cooling system and combustion gas leakage into the cooling
system. Combustion gases can enter the cooling system through
internal cracks, a damaged cylinder head, or a damaged cylinder
head gasket. Coolant can leak into the intake air through cracks in the
aftercooler and lead to hydro lock.

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SERV1971 - 01/17 -27- Module 3 - Cooling System

• Cooling system component wear

-- Poor coolant quality

27_2

Cooling System Component Wear

This is the most common cooling system problem. It causes accelerated cavitation
erosion of cylinder liners, corrosion, and failure of pump seals.

Probable causes and recommendations:

•  oor coolant quality: Poor coolant quality is due to not maintaining adequate
P
levels of coolant additives, using coolant that does not meet Caterpillar’s
minimum recommendations, not keeping the cooling system properly filled,
or using coolant exceeds its useful life. Check the mixture of antifreeze and
water. The mixture should be approximately 50 percent water and 50 percent
antifreeze with 3 to 6 percent coolant conditioner. Refer to the Operation and
Maintenance Manual manual for more information. If the coolant mixture is
incorrect, drain the system and fill the cooling system with the correct mixture
of water, antifreeze, and coolant conditioner.

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SERV1971 - 01/17 -28- Module 3 - Cooling System

28_1

Recommended Test Tools for Cooling System Troubleshooting

Multi-Tool Group - 348-5430

The Multi-Tool Group (348-5430), shown in the illustration above, can be used
in the diagnosis of overheating conditions and in the diagnosis of overcooling
conditions. This group can be used to check temperatures in several different
parts of the cooling system. Refer to the Tool Operating Manual (NEHS1087),
348-5430 Multi-Tool GP, for the testing procedure.

Pressurizing Pump - 9S-8140

The Pressurizing Pump (9S-8140) can be used to test the filler caps and to
pressure test the cooling system for leaks.

Coolant/Battery Tester Group - 245-5829

Check the coolant frequently in cold weather for the proper glycol concentration.
Use the Coolant/Battery Tester Group (245-5829) to ensure adequate freeze
protection. The tester provides immediate, accurate readings. The tester may be
used for antifreeze and coolants containing ethylene or propylene glycol.

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SERV1971 - 01/17 -29- Module 3 - Cooling System

LEARNING OUTCOMES
You have met the following learning outcomes during this Cooling System
module of the D3500 Master Mechanic course:
• Traced the flow of coolant through the engine.
• Identified the major components of the cooling system.
• Explained specifications of the cooling system.
• Identified common troubleshooting issues related to the cooling
system.
• Demonstrated the ability to remove and install the major components
of the cooling system.
• Demonstrated the ability to disassemble and assemble and the
major components of the cooling system.

LEARNING OUTCOMES

You have met the following learning outcomes during this Cooling System module of
the D3500 Master Mechanic course:

• Traced the flow of coolant through the engine.

• Identified the major components of the cooling system.
• Explained specifications of the cooling system.
• Identified common troubleshooting issues related to the cooling system.
• Demonstrated the ability to remove and install the major components of
the cooling system.
• Demonstrated the ability to disassemble and assemble and the major
components of the cooling system.

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