APLTCL030 – Cooling System

Cooling System
APLTCL030 – Cooling System

Topic 1

Cooling System Safety

 SAFETY
APLTCL030 – Cooling System

• Material Safety Data Sheet (MSDS)

• General Safety Guidelines:
ƒ Wear protective footwear and clothing
ƒ Follow general safe work practices
ƒ Wear safety glasses and other PPE
ƒ Use guard and seat covers to protect
the vehicle
ƒ Beware of hot or moving components
 SAFETY
APLTCL030 – Cooling System

• Pressures:
ƒ Up to 150 kPa (22 psi)
• Temperature:
ƒ Approaching 1100C (2300F)
• Pressure or Temperature controlled fans
may operate at any time
• Special precautions required when
removing radiator cap
• Sudden release of pressure causes
steaming or spray of water
 SAFETY
APLTCL030 – Cooling System

• Coolants may contain:

ƒ Corrosion inhibiters
ƒ Anti-freeze solutions
ƒ Ethylene glycol and constituents that
may be toxic
 SAFETY
APLTCL030 – Cooling System

• Safe handling of coolants:

ƒ Maintain adequate ventilation
ƒ Do not inhale vapours
ƒ Should not be taken internally
ƒ If spilt on the skin – wash off immediately
ƒ Do not spill on vehicle paint
ƒ Drain coolant into a clean container
 Disposal of Coolant
APLTCL030 – Cooling System

• Must not be drained into storm water

drains or sewerage system
• Refer to company policies and
procedures for correct disposal
procedures
APLTCL030 – Cooling System

Activity Workbook

Questions 1.1 to 1.8

APLTCL030 – Cooling System

Topic 2

Cooling System Fundamentals

 Purpose of the Cooling
System
APLTCL030 – Cooling System

• Allows engine to heat up quickly to

operating temperature
• Maintain the correct operating
temperature regardless of load
 Need for a Cooling System
APLTCL030 – Cooling System

• Combustion produces heat and high

temperatures
• Protects engine parts
• Prevents oil from breaking down
• Removing too much heat would
lower engine’s thermal efficiency
 Energy Distribution
RADIATED HEAT
7%
APLTCL030 – Cooling System

EXHAUST
FUEL IN
30%
100%
JACKET WATER
30%

FLYWHEEL
HORSEPOWER
33%
 Everyday Terms
APLTCL030 – Cooling System

200 HP diesel engine operating and 70% of full load

produces enough heat to supply warmth to five 5-room
houses with the outside temperature below freezing
 Heat and Temperature
APLTCL030 – Cooling System

• Heat
ƒ Form of energy – molecule activity
• Temperature
ƒ Degree of hotness (or coldness) – measure of
molecule activity
• Hot is referred to as something being
above normal atmospheric temperature
and cold is when it is below normal
atmospheric temperature
• Heat will move from a hot object to a cold
object
 Effects of Heat
APLTCL030 – Cooling System

• Change of Temperature
• Change of Colour
• Change of State
• Change of Volume
 Physical Properties of Water
APLTCL030 – Cooling System

• Contracts when cooled until a

temperature of 40C is reached
• From 40C to 00C (freezing) – it expands
• 00C and below – it contracts
 Heat Transfer
APLTCL030 – Cooling System

• Conduction
• Convection
• Radiation
 Conduction
APLTCL030 – Cooling System

• Flow of heat through solids –

combustion chamber through
the metal parts to the cooling
system
• Metal is a good conductor
• Bad conductor
ƒ Asbestos
ƒ Wood
ƒ Paper
ƒ Most non-metallic substances
ƒ Classified as heat insulators
 Convection
APLTCL030 – Cooling System

• Method of heat transfer

by the actual movement
of the molecules
• Relates to gas and liquids
but not solids
• Heated particles expand –
volume increases but
density reduces
• Heated particles are less
dense and float upward
 Radiation
APLTCL030 – Cooling System

• Heat is transferred across space

ƒ Heat from a fire
ƒ Heat from the sun
• Dark colours radiate heat better than
light colours
• Dark colours also a good absorber of
radiated heat
 Electrolysis
APLTCL030 – Cooling System

• Conductors are
known as
electrodes
• The liquid is
known as an
electrolyte
• The chemical
action which
occurs is called
electrolysis
 Cavitation Erosion
APLTCL030 – Cooling System

• Occurs when vapour

bubbles collapse
against metal
surfaces
• Bubbles form in low
pressure areas
• When bubbles enter
high pressure areas –
they implode, sending
a fluid ‘jet’ against the
metal surface at
supersonic speed
 Cavitation Erosion
APLTCL030 – Cooling System

• Bubbles can form when:

ƒ Liquid reach boiling point
ƒ Fluids move rapidly across cavities
ƒ Parts move within a fluid to create low
pressure areas
ƒ System pressure is low
ƒ Inlet restrictions cause pump cavitation
ƒ There are leaks in the suction line
ƒ There is low fluid levels
 Results of Cavitation Erosion
APLTCL030 – Cooling System
 Results of Cavitation Erosion
APLTCL030 – Cooling System
APLTCL030 – Cooling System
Engine Coolant
 Engine Coolant
APLTCL030 – Cooling System

• In the correct concentration:

ƒ Provides and heat transfer medium
ƒ Protects against cavitation damage
ƒ Provides corrosion/erosion resistance
ƒ Prevents scale and sludge
ƒ Compatible with system materials
ƒ Provides freeze protection
 Water
APLTCL030 – Cooling System

• Best heat transfer properties, but has

drawbacks:
ƒ Boils easily
ƒ Freezes
ƒ Corrosive to metal
• Antifreeze and conditioner are added
to correct these deficiencies
 Antifreeze
APLTCL030 – Cooling System

• Ethylene Glycol
ƒ Raises the boiling point of water
ƒ Lowers the freezing point of water
• The amount of antifreeze determines
how much the temperature changes
• Frozen coolant
ƒ No flow – no cooling
ƒ Expands – cracks castings
 Conditioners
APLTCL030 – Cooling System

Conditioners or Corrosion Inhibiters

May be added to the coolant using a spin on element
 Conditioners
APLTCL030 – Cooling System

Conditioners or Corrosion Inhibiters

Coat all engine components and protect against
corrosions and scaling
 Operating Range
APLTCL030 – Cooling System

• Is influenced by operating altitude

and system pressure as well as
concentration of antifreeze
• Increasing altitude lowers the boiling
point of water
• Increasing system pressure raises
the boiling point of water
 Operating Range
APLTCL030 – Cooling System

Water will boil at 1000C (2120F)

If pressure in cooling system is increased by 40 kPa

(6 psi) the boiling point will increase to 1100C (2300F)
APLTCL030 – Cooling System
Operating Range

When antifreeze is added, the concentration

should be between 30% and 60%
Below 30% is not enough protection
Above 60%, the heat removal properties are effected
 Corrosion Inhibiters
APLTCL030 – Cooling System

• Additives dissolved in the water

• Protect various metal parts against
corrosion
• Correct concentration must be maintained
to achieve correct PH level
• Concentration level should be kept
between 3% and 6%
• If concentration is low – corrosion occurs
• If concentration is high – heat transfer
properties effected
APLTCL030 – Cooling System
Extended Life Coolant
 Extended Life Coolant
APLTCL030 – Cooling System

• Provides
ƒ Coolant life 6000 hours or 4 years
ƒ Corrosion protection
ƒ Good water pump seal life
ƒ Protection against freezing
ƒ Good anti-boil properties
 Extended Life Coolant
APLTCL030 – Cooling System

• ELC Extender after 3000 hours or 2 years

• ELC contains:
ƒ Organic acid inhibiters
ƒ Antifoam agents
ƒ Few nitrates than other ethylene glycol based
coolants
ƒ Comes premixed with water (50/50)
ƒ Provides freezing protection to –370C (-350F)
ƒ Boiling protection at 90 kPa (13 psi) to 1290C
(2650F)
APLTCL030 – Cooling System

Activity Workbook

Questions 2.1 to 2.23

APLTCL030 – Cooling System

Topic 3

Cooling System Components

 Overview
APLTCL030 – Cooling System

1. Water Pump
2. Oil cooler
3. Cylinder Block
4. Thermostat
5. Lower Radiator Tank
6. Pressure Cap
7. Hoses
APLTCL030 – Cooling System
Internal Cooling Passages
APLTCL030 – Cooling System
Cylinder Head
 Coolant Flow
Water Manifold
APLTCL030 – Cooling System

Head

Thermostat
Housing

Cylinder
Liners

Water Radiator
Oil Cooler Pump
APLTCL030 – Cooling System
Water Pump
APLTCL030 – Cooling System Water Pump

1. Curved Blades 4. Input Shaft

2. Impeller 5. Centre of Housing
3. Housing and Outlet
APLTCL030 – Cooling System
Radiator – Centre Fins
 Radiator – Horizontal Fins
APLTCL030 – Cooling System
APLTCL030 – Cooling System
Coolant Flow
APLTCL030 – Cooling System
Shunt Type Cooling System
APLTCL030 – Cooling System
Folded Core
APLTCL030 – Cooling System
IMRM
APLTCL030 – Cooling System
AMOCS
 Hoses
APLTCL030 – Cooling System

• Connect the radiator to water pump

and engine block (normally at
thermostat housing)
• Allow flow of coolant to and from the
radiator and susceptible to
temperature variations
• Appearance of hose and connections
usually indicate their condition
 Hoses
APLTCL030 – Cooling System

• If a hose is soft or spongy and collapses

easily when squeezed
ƒ It has deteriorated internally
ƒ Should be replaced
• If hose is hard and no longer flexible
ƒ Should be replaced
• Some hoses have internal reinforcement
• Hose clamps should be checked regularly
for tightness and connections checked for
leaks
 Cooling Fans
APLTCL030 – Cooling System

Blower Fan Suction Fan

 Cooling Fans
• Blower fans used on vehicles operating in
APLTCL030 – Cooling System

extremely dusty environments

• Road Transport vehicles usually use
conventional suction fans
• It is not possible to simply turn the fan
around – the pitch of the blades will be
incorrect
• Normally manufactured of steel
• Can be plastic
ƒ lighter and allows for blade flexing
ƒ Reduces power requirements
ƒ Drive belt life, bearing life and reduced noise are advantages
APLTCL030 – Cooling System
Viscous Fans
 Electric Fan
Connector
Fan Shroud
APLTCL030 – Cooling System

Fuses
Fan Switch

Fan Electric
Motor

Fan Relay
APLTCL030 – Cooling System
Hydraulic Motor
 Multiplate Fan Drive
APLTCL030 – Cooling System

• Engaged by spring pressure forcing

the fan to rotate
• Disengagement of the fan is by
compressed air
• This type of drive is either ‘on’ or ‘off’
APLTCL030 – Cooling System
Radiator Shroud
APLTCL030 – Cooling System
Thermostat
APLTCL030 – Cooling System
Thermostat Operation
 Thermostat Coolant
Temperature
APLTCL030 – Cooling System
 Operation – Wax Pellet Type
APLTCL030 – Cooling System
 Temperature Indicators
APLTCL030 – Cooling System

• Temperature Gauge
• Warning Light
• Thermosensor used to operate the
gauge or warning light
APLTCL030 – Cooling System
Radiator Pressure Caps
APLTCL030 – Cooling System
Radiator Cap Operation
APLTCL030 – Cooling System
Radiator Cap Operation
APLTCL030 – Cooling System
Coolant Level Inspection
 Expansion Plugs
(Frost Plugs)
APLTCL030 – Cooling System
 Coolant Conditioner
Element
APLTCL030 – Cooling System
APLTCL030 – Cooling System
After-Coolers
APLTCL030 – Cooling System
After-Coolers
APLTCL030 – Cooling System
After-Coolers
APLTCL030 – Cooling System
After-Coolers
APLTCL030 – Cooling System
Engine Oil Cooler
APLTCL030 – Cooling System
Engine Oil Cooler
APLTCL030 – Cooling System
Engine Oil Cooler
APLTCL030 – Cooling System
Water Cooled Exhaust
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
APLTCL030 – Cooling System
Cooling System Review
 Air Cooling
APLTCL030 – Cooling System

• Air cooling relies on air to contact

metal fins on the surface of the
engine
• Good heat dissipation depends on:
ƒ Cooling fin design
ƒ Velocity of air passing over the fins
ƒ Temperature difference between the air
and the fin surface
APLTCL030 – Cooling System
Methods of Air Cooling
APLTCL030 – Cooling System
Methods of Air Cooling
APLTCL030 – Cooling System

Activity Workbook

Questions 3.1 to 3.30

APLTCL030 – Cooling System

Topic 4

Cooling System Service

 Visual Inspection
APLTCL030 – Cooling System

• Check coolant level

• Check for leaks in the system
• Check for bent radiator fins
• Inspect fan belt drives
• Check fan blades
• Check for air or combustion gases
• Inspect cap
 Water Pump Seals
APLTCL030 – Cooling System

• A small amount of coolant leakage

across the surface of a ‘face type’
seal is normal, and required, to
provide lubrication for the seal
• A hole is provided in the water pump
housing to allow this coolant to drain
from the pump
 Visual Inspection – Air Flow
• Adequate air flow required to enable
APLTCL030 – Cooling System

release of heat
• Air flow may be severely restricted by
foreign matter
• A visual inspection necessary to determine
fin air restrictions:
ƒ Use of a light
ƒ May be removed by water, steam cleaning or air
• Inspect fan
ƒ Cracks
ƒ blades
ƒ operation
 Coolant Circulation
APLTCL030 – Cooling System

• Correct circulation must occur to

prevent localised overheating
• Volume may be reduced through
sludge, sediment or scale (rust)
• Water pump may be damaged
• Thermostat checked for correct
operation (80C (450F) above opening
temperature indicated)
 Radiator Core Flow
APLTCL030 – Cooling System

• Radiator cores do become blocked

with:
ƒ Dirt
ƒ Rust
ƒ Scale
ƒ Foreign material
• May be able to inspect core through
filler neck
 Radiator Core Restrictions
APLTCL030 – Cooling System

• Indication of Core Restrictions:

ƒ Remove hoses
ƒ Plug hose connections
ƒ Fill radiator leaving cap off
ƒ Remove bottom plug
ƒ Water should gush out in a solid stream
• If flow is not quick enough, the top and
bottom tanks may need to be removed and
cores cleaned
 Air in Coolant
APLTCL030 – Cooling System

• Aeration requires immediate repair action

• Install clear sight glasses
ƒ Run engine
ƒ Aeration will show as bubbles
ƒ Aeration in the bottom sight glass indicate
radiator leakage or core restrictions
ƒ Aeration in the top glass indicates the problem
is engine based
 Air in Coolant
APLTCL030 – Cooling System

• Sources or aeration (engine based):

ƒ Worn water pump seals
ƒ Loose hose connections
ƒ Head gasket failure
ƒ Combustion chamber cracks
ƒ Air compressor
 Inspecting Water Pump
APLTCL030 – Cooling System

• May need to be removed to inspect

impeller
• Rotating the drive pump pulley
ƒ Check bearing slack
ƒ Roughness or looseness of bearing
• Carbon face seal test
• Inspect weep hole
APLTCL030 – Cooling System
Pressure Test
APLTCL030 – Cooling System
Checking Pressure Cap
 Water Temperature
APLTCL030 – Cooling System

• If the indicator (gauge or light) shows

the engine is hot
ƒ Inspect for coolant leakage
ƒ Check the accuracy of the gauge/light
ƒ A temperature indicator of known
accuracy should be used
 Thermostat Testing
• Thermostat should be fully open at 80C
APLTCL030 – Cooling System

(450F) above opening temperature indicated

• DO NOT clean the thermostat before testing
• Procedure:
ƒ Immerse in water and heat until it opens
ƒ Remove thermostat and place a strip between
valve and seat
ƒ Let water cool
ƒ Immerse thermostat, holding by the strip
ƒ Add thermometer to water and heat water
ƒ Read temperature when strip is released
ƒ Heat water more to determine full opening
temperature
APLTCL030 – Cooling System
Cleaning Radiator Cores
APLTCL030 – Cooling System
Folded Core Radiator
APLTCL030 – Cooling System
Multiple Row Radiator
 Cleaning Cooling System
APLTCL030 – Cooling System

• Determining if system needs more than a

mild cleaning:
ƒ Flow Restrictions
• Remove cap and inspect tubes
ƒ Constant Overheating
• If belts, thermostat and pump are functioning properly,
then cleaning will be needed
ƒ Water Pump Failure
• If pump fails and heavy contamination was the cause, the
system will need a thorough clean
ƒ Visible Heavy Rust and Green Slime
• If it is present the system will need a clean
 Contamination
APLTCL030 – Cooling System

• If contamination is present, normal heat

transfer is not possible
• Oil is a contaminant
• If the oil cooler has a defect:
ƒ Oil can enter the cooling system when the
engine is running
ƒ When the engine stops, water will settle into
the sump
ƒ Pressure check may determine a defect
ƒ Oil sampling may determine presence of
coolant in the oil
 Cleaning the System of Oil
APLTCL030 – Cooling System

• Drain coolant
• Fill system with clean water
• Start engine and reach operating
temperature
• Add two cups of non-foaming soap
• Run engine for 20 minutes
• If oil patches still present, add more soap
and run engine for 10 minutes
• Drain system
• Fill and check
 Scale or Rust
APLTCL030 – Cooling System

• Scale or Rust can effect heat transfer

• Can be cleaned using a two-step type
heavy duty radiator cleaner:
ƒ Oxalic acid
ƒ Neutraliser
• Caterpillar cleaners are available
• Adhere to manufacturer’s
specifications
APLTCL030 – Cooling System
Reverse Flush
APLTCL030 – Cooling System

Activity Workbook

Questions 4.1 to 4.12

APLTCL030 – Cooling System

Topic 5

Test Equipment
 Coolant Inspection and
Concentration Testing
APLTCL030 – Cooling System

• ALWAYS
ƒ Use the specific engine manufacturer’s test kit
ƒ Use the manufacturer’s specified coolant and
water filters
• DO NOT
ƒ Mix different manufacturer’s coolants and
water filters
ƒ Add excessive concentrates of additives
 Blowby/Air Flow Indicator
Group
APLTCL030 – Cooling System
APLTCL030 – Cooling System
Digital Thermometer
APLTCL030 – Cooling System
Self Probing Adapters
 Coolant and Battery Tester
APLTCL030 – Cooling System
 Coolant Additive Test Kits
APLTCL030 – Cooling System
 Thermocouple Temperature
Adaptor
APLTCL030 – Cooling System
APLTCL030 – Cooling System
Multitach
APLTCL030 – Cooling System
Pressurising Pump
APLTCL030 – Cooling System
Pressure Probe
APLTCL030 – Cooling System

Activity Workbook

Questions 5.1 to 5.5

APLTCL030 – Cooling System

Topic 6

Cooling System Evaluation

 Evaluation
APLTCL030 – Cooling System

• CHECK THE EASY AND OBVIOUS

THINGS FIRST
• Overheating is the most common
problem
 Troubleshooting
APLTCL030 – Cooling System

• Check machine history

ƒ What repairs have been completed
recently?
ƒ Could the repairs effect the cooling
system?
• This information may give an
indication of a possible cause
 Troubleshooting
APLTCL030 – Cooling System

• Talk to the Operator

ƒ Ask questions:
• When?
• How often?
• Under what conditions?
• What symptoms were seen?
• Does coolant need to be added regularly?
• What application is the machine used for?
• Is the load factor higher than normal?
ƒ Operator can generally give and indication of
where the problem is
 Troubleshooting
APLTCL030 – Cooling System

• There are three basic problems:

ƒ Overheating
ƒ Loss of coolant
ƒ Overcooling
• Should be first diagnosed by visual
inspection
• If cause can not be found:
ƒ Use diagnostic tools
ƒ Removal of components for inspection
 Overheating – Visual Inspection
Coolant Level
APLTCL030 – Cooling System

Warning!
Do not loosen the filler or pressure cap on a hot engine.
Steam or hot coolant can cause severe burns. Check for
coolant leaks or steam coming out of the overflow on the
radiator when the engine is stopped. Wait for the engine to
cool or open the cap according to the correct procedures.
 Coolant Level
APLTCL030 – Cooling System

• Rule of Thumb:
ƒ Coolant must be covering the internal tubes or
core elements
ƒ In a non-recovery system, the top tank should
have a coolant level at approx. 12 to 20 mm
(½” to ¾”) below the neck
ƒ In a recovery system, the level should be up to
the neck when the system is hot and indicated
by a mark on the bottle when the system is
cold
APLTCL030 – Cooling System
Radiator
APLTCL030 – Cooling System
Fan Shroud
 Fan
APLTCL030 – Cooling System

Belts should flex approximately 10 mm (½”) when

pushed in – on the longest length
APLTCL030 – Cooling System
Fan Clutch
APLTCL030 – Cooling System
Shutter System
APLTCL030 – Cooling System
Hoses
 Water Pump and Cylinder
Head
APLTCL030 – Cooling System

• Check drain (weep) hole on the Water

Pump
• Check for leaks around the seal of
the Cylinder Head Gasket
 Other Checks
APLTCL030 – Cooling System

• Check sealing surface

• On gas engines – manifolds and
converters may have an internal leak
• Check heater circuit for leaks
• Tighten the cap and feel for contact
• Check air compressors for internal leaks
• Inspect recovery pipes and hoses for
leakage
 Other Checks
APLTCL030 – Cooling System

• Check relief valve condition (if fitted)

• Check Governor Seal to see if fuel setting
has been changed
• Check transmission and steering clutch
slippage
• Ensure machine brakes are not dragging
• Check vehicle retarding device (if fitted)
• Check glycol concentration level in
coolant
 Overheating Tests
APLTCL030 – Cooling System

• Digital Thermometer
Probes
ƒ Top tank
ƒ Bottom tank
ƒ Pump outlet
ƒ Thermostat housing
ƒ Torque converter
ƒ Oil cooler
 Overheating Tests
APLTCL030 – Cooling System

• Cooling System
Relief Valve
 Overheating Tests
APLTCL030 – Cooling System

• Air, Gases and Steam

ƒ Correctly filled
ƒ Foaming
ƒ Aeration
ƒ Engine gases
• Bottle Test
APLTCL030 – Cooling System
Temperature Gauge
 Radiator Ambient
Temperature Differential
APLTCL030 – Cooling System
 Torque Converter
Temperature
APLTCL030 – Cooling System
APLTCL030 – Cooling System
Retarder
 Radiator Coolant Flow
Resistance
APLTCL030 – Cooling System
APLTCL030 – Cooling System
Thermostat
APLTCL030 – Cooling System
Water Pump
 Radiator Air Flow
Resistance
APLTCL030 – Cooling System

• Before air velocity is checked:

ƒ Parking Brakes must be “ON”
ƒ Lower all implements
ƒ Make all checks at rated speed
ƒ Radiator grill swung out of the way
ƒ Check air velocity with a Blowby/Air
Flow Indicator
APLTCL030 – Cooling System
Fan Speed
 Manifold and Aftercooler
Temperatures
APLTCL030 – Cooling System

• Oil cooler manifold temperature is

approximately 60C to 110C (420F –
520F) higher than water pump outlet
temperature
• If the temperature is 190C to 220C
(660F – 720F) higher, then scaling
may be the cause
 Manifold and Aftercooler
Temperatures
APLTCL030 – Cooling System

• A dirty aftercooler will result in high

inlet air temperature
• For every 10 (C or F) increase of air
inlet temperature - exhaust
temperature rises by 30 (C or F)
• High exhaust temperatures will cause
overheating
APLTCL030 – Cooling System
Engine Timing
 Loss of Coolant
APLTCL030 – Cooling System

• Check for leaks

APLTCL030 – Cooling System
Loss of Coolant
APLTCL030 – Cooling System
Gases in the System
APLTCL030 – Cooling System
Gases in the System
APLTCL030 – Cooling System
Water in the Oil
APLTCL030 – Cooling System
Oil in Coolant
APLTCL030 – Cooling System
Torque Converter Oil
 Engine Overcooling
APLTCL030 – Cooling System

• Can cause damage to an engine

• Occurs when normal operating
temperature cannot be reached
• High sulpher fuel increases wear if the
temperature is not over 800C (1750F)
• Caused by:
ƒ Low ambient air temperature and light loads
ƒ Thermostat held open or removed
ƒ Coolant bypasses the thermostat
APLTCL030 – Cooling System
Inspection
 Shutter System
APLTCL030 – Cooling System

• Check operation of shutter system (if

fitted)
• If they are stuck open or partially
open – coolant is cooled too much
APLTCL030 – Cooling System
Fan Clutches
APLTCL030 – Cooling System
Thermostat
APLTCL030 – Cooling System
Thermostat
APLTCL030 – Cooling System
Thermostats
 Vent Line
APLTCL030 – Cooling System

Overcooling may occur on some truck

engines due to an open vent line
installed by Other Equipment
Manufacturers (OEM). This line allows
unrestricted flow to the radiator top tank
and creates overcooling
This can be eliminated by installing a
check valve in the vent line
 Components that Effect the
Cooling System
APLTCL030 – Cooling System

• Battery ground conditions

• Oil cooler cores
• After cooler cores
• Radiator cap
• Relief valve
• Fan belts
• Pulleys
• Fan assembly
• Fan shroud and baffles
 Components that Effect the
Cooling System
APLTCL030 – Cooling System

• Radiator mounts
• Fan guards
• Hoses and clamps
• Thermostats
• Temperature gauges
• Water pump
• Cylinder heads
• Electrical Ground Problems
• Standing Vehicles
• Afterboil
APLTCL030 – Cooling System

Activity Workbook

Question 6.1 to 6.23

APLTCL030 – Cooling System