COOLING SYSTEM MAINTENANCE

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 PRIMARY PURPOSE OF A
COOLING SYSTEM

An engine’s cooling system is responsible for

maintaining adequate engine temperatures.

If the cooling system fails, severe engine damage

could occur.

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Heat always moves from hot ‘source’ to a cooler ‘target’.
Source and target could be metal, fluid or air.
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The key is the difference in relative temperatures between the two.
The greater thee difference, the more heat will transfer.
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COOLING SYSTEM COMPONENTS

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ENGINE COOLING SYSTEM

Cylinder Head
Thermostat
Housing
Water Bypass
Radiator
Water Pump

Cylinder
Oil Cooler
Liners

Cylinder Block

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WATER PUMP

Weep hole

The pump create flow, pushing coolant through the other

components in the system.
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 OIL COOLER

Coolant flows through the tubes, removing heat from engine oil
that is in the housing. Coolant removes heat from the lubricating
properties.
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 COOLANT PASSAGES
(water jackets)

Water jackets are cavities inside the cylinder block which coolant flows.

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 CYLINDER BLOCK
(water jackets)

From the oil cooler, coolant flows into the engine block and around the
cylinder liner, removing the waste heat from the pistons, rings,&
liners. 16
 CYLINDER HEAD
(water jackets)

Coolant travels from the engine block passages to the cylinder head,
picking up heat from the valve seats and guides.
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TEMPERATURE REGULATOR

Once Coolant leaves the water passages coolant enters to the thermostat
or temperature regulator housing. Thermostat acts as the cooling system
“traffic cop”.
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 TEMPERATURE REGULATOR

The regulator’s job is to maintain a proper range of operating temp.

To do this, the regulator shunts coolant flow through the radiator, or
through bypass tube back to the water pump.
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Opening temperatures are stamp
on the regulator.

Temperatures are designed to be replaced periodically, and should be

routinely tested as part of regulator maintenance.
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HOW THE REGULATOR WORKS
(during cold temperature)

When the engine is cold, the regulator is closed. Coolant circulates back
to the pump, bypassing the regulator. This helps warm up the engine.
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HOW THE REGULATOR WORKS
(during increasing temperature)

As the engine heats up, coolant temp. increases until it reaches the
opening temp. for the regulator. As the regulator opens, some coolant
is directed into the radiator. The remainder bypasses to the water pump.
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HOW THE REGULATOR WORKS
(during high temperature)

As temp. increase, the regulator opens more and more coolant is

directed through the radiator. When the regulator is fully open, all
the coolant flow is directed into the radiator.
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 RADIATOR

Coolant flows through pipes or hoses to the radiator. Coolant transfer

its heat to the cooler atmosphere. Coolant flow from top to bottom.
Tubes and fins work together to dissipate heat.
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 RADIATOR

Radiators are usually mounted where they get the most air flow and
best heat transfer.
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 RADIATOR PRESSURE CAPS

Determines how much pressure will be present in the cooling system

during operation. Pressurized cooling system help prevent water
from boiling at higher altitudes.
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HOW THE RADIATOR CAPS WORKS
(exceeding the opening pressures)

Maintain pressure in the cooling system through two valves. If the

difference between the cooling system pressure and atmospheric
pressure exceeds the cap’s opening pressure, an outlet valve opens.
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HOW THE RADIATOR CAPS WORKS
(below atmospheric pressure)

When you stop the engine & it begins to cool, the pressure inside the
cooling system drops below of that of atmosphere. The cap’s inlet valve
opens, allowing some air into the radiator. This equalizes the two
pressures 30
 RADIATOR FANS

SUCTION TYPE FAN BLOWER TYPE FAN

Heat transfer across the radiator is aided by a fan. Fan increase the air
flow past the radiator fins and tubes.

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 RADIATOR FAN BELT

Some engines use belts to drive the fan, water pump or other components.

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COOLANT

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 COOLANT INGREDIENTS

Coolant is a mixture of water, antifreeze, and coolant conditioner.

Each element serves a different purpose, and they protect the engine
from overheating, freezing, and corrosion.
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FACTORS INFLUENCE THE OPERATING
TEMPERATURE RANGE OF COOLANT

Operating altitudes

system pressure

Concentration of Antifreeze

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 COOLANT MUST NOT BOIL

If coolant boils, steam bubbles form. These pockets of air do not

transfer heat well, which leads to overheating.
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 EFFECTS OF AIR IN COOLING SYSTEM

Steam bubbles can also interfere with the water pump’s

ability to make flow. This can lead to serious engine damage
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 CAVITATION EROSION

When steam bubbles break, they can remove small particles of

metal from components. This is called cavitation erosion.

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 COOLANT MUST NOT BOIL

Water has several drawback as a coolant.

It boils easily

It freezes

It is extremely corrosive

Water is basis for all coolant. Water transfer hear better than any
other substance.
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 ANTIFREEZE

Ethylene glycol is used to raise the boiling point and lower the freezing
point of water.
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 COOLANT

Prevents corrosion by coating all the components in the cooling system.

The thin coating prevents water and cavitation erosion from attacking
the metal.
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 SILICA DROPOUT

Turn the coolant into a thick gel, which damage the water pump and
clogs the radiator. High concentration of coolant conditioner also
reduce heat transfer.
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 EFFECT OF LOW COOLANT CONDITIONER

If the concentration is lower than recommended, engine components

may corrode or experience cavitation erosion.
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80% OF MAJOR REPAIRS ARE MADE AFTER
FAILURE
RAF
80%

RBF
20%

 80 % Of These Were Preventable (RAF)

Preventable
80%

Not
Prevenatable
20%
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COOLING SYSTEM MAINTENACE MANAGEMENT

Over 50% Of

Premature Engine Failures / Non

Performance incidences

Can Be Attributed To

Cooling System Problems.

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 THE IMPORTANCE OF COOLING SYSTEM

• Diesel Engine Manufacturers Have Increased Engine

Operating Temperatures To Improve Engine Efficiency

• Proper Cooling System Management Is As Important As The

Quality Of Your Oil & Fuel !

• Overheating, Overcooling, Pitting, Cavitation, Erosion,

Cracked Heads, Piston Seizures & Plugged Radiators Are
Classic Cooling System Failures

• Effective Preventative Maintenance Can Avoid These Costly

Failures & Repairs
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 COOLING SYSTEM FUNCTIONS
• Remove Heat Generated From Fuel Combustion
– Burn Temperatures Can Reach 1,937 Deg. C

• Transfer Heat From

– Transmission Oil Coolers
– Hydraulic Oil Coolers
– Water Cooled Exhaust Manifolds
– Water Cooled Turbocharger Shields / Housings
– Marine Gear Oil Coolers
– Torque Converter / Retarder Coolers
– Jacket Water After Coolers
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 COOLING SYSTEM PROBLEMS

• Overheating

• Overcooling

• Loss Of Coolant

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 TYPICAL OVERHEATING CAUSES
• Low Coolant Level
• Plugged Radiator Core
• Loose Fan Belts
• Reduced Airflow Through Radiator
• Insufficient Cooling System Pressure
• Coolant Overflow
• High Inlet Air Temperature Or Restriction
• Low Heat Transfer Though Scale Build Up For Example
• Exhaust Restriction
• Excessive Engine Load
• Water Pump Or Temperature Regulator Failure

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 SUMMARY OF OVERHEATING PROBLEM & CAUSES
PROBLEMS POSSIBLE CAUSES
LOW COOLANT A. external leaks cause by loose connections, radiator cap or cooling system
LEVEL relief valve with defect.
B. Internal leaks caused by cracked cylinder head, cracked cylinder block, loose
cylinder head damaged cooler core, damaged after cooler, damaged gaskets.

REDUCED AIR FLOW A. Plugged radiator core

THRUOGH RADIATOR B. Damaged or bent radiator fins
C. Low fan speed because of low engine high idle speed
D. Fan is damaged or installed backward
E. Loose or worn
F. Damaged fan shrowd, wrong diameter fan or incorrect number or blades
G. Incorrect fan blade position. (Fan projection out of the shrowd must be approx. 50%
H. Excessive fan tip to shrowd clearance. Should be .38 degree maximum clearance
I. Closed shutter (If equipped)
J. Fluid Coupling for fan not engaged

INSUFFICIENT COOLING A. Defective pressure gauge

SYSTEM PRESSURE B. Defective radiator cap
C. Defective cooling system pressure relief valve
D. Defective radiator top tank neck or stud

COOLANT OVERFLOW A. Air in cooling system because of incorrect cooling fill

B. Combustion gases in cooling system from loose or cracked-cylinder heads,

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 SUMMARY OF OVERHEATING PROBLEM & CAUSES
PROBLEMS POSSIBLE CAUSES
INSUFFECIENT COOLANT A. Stuck water temperature regulator
FLOW B. absence or non performance of water temperature regulator
C. Low engine high idle spped
D. Loose water pump impeller
E. Radiator Plugged on Inside

HIGH INLET AIR TEMP. OR A. High ambient non performance of water temperature regulator
RESTRICTION B. Plugged opennings in screens for engine compartment with a blower fan
C. Disconnected inlet air pipe in engine room
D. Dirty aftercooler core
E. Plugged air cleaner
F. Damaged or carbon packed turbocharger

LOW HEAT TRANSFER A. Insufficient flow raw water through heat exchanger
B.crusted over keel cooler
C. Hot air for radiator caused by overheating hydraulic oil cooler
D. Scale on cylinder liner or cylinder head

EXHAUST RESTRICITION A. Plugged air cleaner

B. Damaged turbocharger
C. Restriction in exhaust pipes
D. Water in muffler
E. Loose baffle in muffler
F. Excessively long exhaust pipe 62
 OVERHEATING EFFECTS

• Cracked Or Warped Cylinder Heads

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 OVERCOOLING
• Low Ambient Air Temperatures & Light Loading
• Water Temperature Regulators Stuck Open or Removed
• Defective Temperature Gauge
• Effects

– If Temperatures Less Than 80 Degree C, High Sulfur

Fuel Increases Wear On Engine Components
– Engines don’t reach the most effective operating
temperature consequently maximum performance is not
realized

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Water Is The Most Efficient Heat Transfer Agent

• Drawbacks
– Contains Chlorides, sulfates, suspended solids
– Causes Scales & Deposits Leading To Clogged
Radiators And Failed Water Pumps, Builds Sediment

• Improper pH Level
– Attacks Copper, Aluminum & Steel Engine
Components, Causing Corrosion & Damaged Seals

• Lower Boiling Point

– Lower Performance

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 COOLANT
• Function
– Transfer Heat From Hot Engine Components To A
Radiator Or Heat Exchanger.
– Additive protection is required to improve the properties of the water base.
• Desired Characteristics
– High Boiling Temperature
– Freeze Protection
– Corrosion Resistance
– Scale & Deposit Prevention
– Non Foaming
– Minimum Sediment
– Maintain pH

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 TRADITIONAL COOLANT PROBLEMS
• Wet Sleeve Liner Pitting • Hard Water Scale
• Measuring Nitrate Level • Water Pump Seal Failures
• Add SCA - When, How, • Overheating / Loss Of
How Much Heat Transfer
• Silicate Gel - Green Goo • Radiator Tube Deposits -
• Total Dissolved Solids plugging
• Solder Bloom
• Foaming

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CAVITATION AND PITTING ON CYLINDER WALL
1. Bubble Forms 2. Collapse
Begins

3. Implosion 4. Eventual Erosion

Dissipates & Pitting Without
Energy On Cylinder Additive
Wall Removing
Oxide Film

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 CAVITATION EFFECTS
• Cavitation Of The Cylinder Wall Will Eventually
Allow Coolant To Leak In To The Cylinder

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CAVITATION EROSION & PITTING EFFECTS
• Holes In A Cylinder Wall On A 3208 Engine Block
Caused By Cavitation Erosion & Pitting

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CORROSION CAUSED BY LACK OF COOLANT
ADDITIVES
• Corrosion On A Water Pump Passage

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THE EFFECTS OF CAVITATION EROSION
• Failure - Causing • An Example Of Cylinder
Corrosion On Wall Cavitation Erosion
A Pre-combustion
Chamber

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 RUST
• Examples Of Component Failure & Poor Performance
Caused By Rust
• Generally As A Result Of The Absence Of A Coolant
Additive
Rusting Inside A Water Pump
Temperature
Rust Deposits On Outside
Regulator
Cylinder Wall Surface
Failure As A Result
Of
Rust & Scale
Deposits

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 WATER QUALITY
• Water Characteristics Vary From Location To
Location

• However Must Meet Acceptability Guidelines

Established By Your Engine Manufacturer

• Contact Your Water Supply Company To

Determine Water Specifications

• Compare With The Minimum Acceptable Levels

Of Chlorides, Sulfates, Hardness, Total Solids
and pH Level From Your Engine Manufacturer

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 CAT EXTENDED LIFE COOLANT - ELC
• Benefits
– Premixed 50% ELC 50% Demonized Water
• Ensures Water Quality
• Ensures Correct Antifreeze To Water Mix
– Eliminates Hard Water Scale
– Reduces Coolant Costs From 42% - 63% Over Cat DEAC
– Requires No Coolant Conditioner Test Kit
– Environmentally Friendly Reduced Disposal Volume And Is
Recyclable

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 CAT EXTENDED LIFE COOLANT - ELC
• Benefits Continued
– Maintain Cylinder Liner Cavitation Resistance
– Low Level of Total Dissolved Solids Improves
Water Pump Seal Life & Reliability
• 3406C @ 3,000 SMU 53 % Reduction
• 3176 @ 3,000 SMU 73 % Reduction
– No Design Changes Required
– Factory Filled In All Cat Machines & Engines
– Can Be Used In Most OEM Diesel, Gasoline &
Natural Gas Engines (Inventory One Coolant For
Entire Fleet)

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CAT EXTENDER FOR MAXIMUM COOLANT LIFE

Machines & Commercial

Engines

Cat Diesel Engine Antifreeze /

Coolant
3,000 SMU
(Cat SCA Every 250 SMU)

Cat Extended Life Coolant

6,000 SMU or 6
Years
(Whichever Comes First)

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 Periodic Maintenance
• Initial Fill
– Select Proper Water, Coolant Additive & Antifreeze
– Always Premix Before Adding To Cooling System
– Do Not Fill faster Than 19 Liters (5 gal) / min
– After Filling Run Engine For Several Minutes W/ Radiator Cap Off
– Install Radiator Cap And Run Engine At Low Idle Until Engine
Becomes Warm
– Inspect Level In Top Tank. Add Coolant If Necessary

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 Maintenance Summary
• Check Your Cooling System Every Day

• Warm Engine By Idling Until Proper Cooling System Temperatures & Pressures Are
Reached

• Monitor And Maintain Correct Operating Temperature

• Test Coolant Conditioner Every 250 SMU (Maintain 3 - 6 % Concentration) & Change
Every 3,000 SMU For DEAC use

• Always Use Distilled Or Dionized Water W/ Supplemental Conditioners

• Cool Down Engine By Idling Before Shutdown

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