UNIT 4

Cooling Systems
Unit Objectives: The student will be able to: 1. Identify the components of engine cooling systems and explain their function. 2. Explain cooling system maintenance and characteristics of diesel engine coolant. 3. Remove, inspect, and install cooling system components on a Caterpillar 3406B or 3406C engine. Unit References: Cooling System Design Fundamentals Coolant and Your Engine A Close Look at Cat Extended Life Coolant 3406B Service Manual 3406C Service Manual Unit 4 Quiz Tooling: 8T0461 Serviceman's Tool Set or equivalent 9S8140 Pressurizing Group 5P0957 Battery/Coolant Tester 8T5296 Coolant Test Kit LEKQ7353 SEBD0970 LEDQ7330 SEBR0544 SEBR0550 Copy

Unit 4: Cooling Systems

Lesson 1: Identify Cooling System Components and Function

Objectives: The student will be able to explain the operation of the engine cooling system and identify related components. References: Cooling System Design Fundamentals Coolant and Your Engine A Close Look at Cat Extended Life Coolant Introduction: A diesel engine is dependent on the cooling system to achieve maximum performance and engine life. Cooling system problems may include small annoying leaks, fuel economy complaints, accelerated engine wear, or sudden catastrophic engine failure. If the flow of coolant in the engine stops for even a short amount of time, there is a high risk of significant damage to the engine. LEKQ7353 SEBD0970 LEDQ7330

Lesson 1: Cooling System Components

Unit 4 Lesson 1

4-1-2

Engine Fundamentals

Fig. 4.1.1 Cooling System and Energy Distribution

The cooling of an engine depends on the principles of conduction, convection, and radiation of heat energy in order to keep the engine running at the proper operating temperature. The coolant receives the heat that is conducted to it from the metal components of the engine; the engine block, the cylinder head, etc. The coolant is then forced by the water pump from the engine to the radiator. At the radiator the heat energy is transferred by convection to the air moving across the fins of the radiator. In addition the engine also radiates a certain amount of energy to the atmosphere directly in the form of heat that is given off from the engine to the surrounding air. The components of a cooling system for an engine are extremely simplistic. The basic components of every cooling system include: The water jacket The water temperature regulator(s) (thermostat(s)) The radiator (or heat exchanger) The pressure cap The water pump Hoses The engine may also have some type of coolant cooled aftercooler, oil cooler, hydraulic cooler, or transmission cooler. Some marine or stationary systems may have a heat exchanger in place of the radiator. The pump is what causes the coolant to flow in the cooling system. Inside the engine are coolant passages that the water flows in. These passages include what is sometimes called a "water jacket." The water jacket is the large cavity in the block and the head that surrounds the cylinders of the engine. This cavity is normally full of coolant and is what keeps the engine at a uniform temperature.

Unit 4 Lesson 1

4-1-3

Engine Fundamentals

Fig. 4.1.2 Water Temperature Regulator

The water temperature regulator(s) (thermostat(s)) regulate the flow of coolant to the radiator. When the engine is cold, the water temperature regulator is closed and the water coming from the engine is closed off from the radiator. The water is then recirculated through the water pump, back into the engine. This helps the engine acheive operating temperature more quickly. When the engine is warm, the water temperature regulator allows the coolant to flow to the radiator to be cooled before reentering the engine. The water temperature regulator is not strictly fully open or fully closed. The water temperature regulator modulates between open and closed in order to keep a constant temperature in the engine. Proper engine temperature is very important. An engine that runs too cold will not operate at a high enough temperature to have efficient combustion and will lead to sludge buildup in the lubrication system of the engine. An engine that runs too hot will overheat and may lead to serious damage of the engine.

Unit 4 Lesson 1

4-1-4

Engine Fundamentals

Fig. 4.1.3 Radiator

The radiator is the component of the cooling system that rejects the heat from the coolant to the air. A radiator has tubes that the coolant flows through most generally from the top of the radiator to the bottom. At the bottom of the radiator there is a hose leading to the pump to start the circulation over again. The tubes have fins attached to them that help to reject the heat to the air moving across the radiator.

Fig. 4.1.4 Pressure Cap

Perhaps the most overlooked component of the cooling system is the pressure cap. The pressure cap has a relief valve that will not allow the pressure of the cooling system to exceed a predetermined level. The pressure cap maintains a certain amount of pressure in the cooling system. This is very important because, by increasing the pressure of the cooling system by 1 psi, the boiling point of the coolant is raised 3.25 degrees F. This allows coolant to run hotter wihout boiling. A typical cooling system will have anywhere from a 7 psi to a 12 psi pressure cap, so this can have a significant effect on the cooling of an engine.

Engine Fundamentals

Unit 4 Lesson 1

4-1-5

Engine Fundamentals

NOTE: Handout "Cooling System Design Fundamentals" (Form LEKQ7353). Explain coolant flow (page 5). Explain cooling system components and types (pages 7 - 11). Explain cooling system water treatment (page 12). Review characteristics and benefits of Caterpillar Extended Life Coolant (page 13). Review cooling system design fundamentals (page 14). NOTE: Handout "Coolant and Your Engine" (Form No. SEBD0970). Explain the distribution of heat dissipated from fuel burned in a diesel engine and list the components that transfer heat to coolant (page 4). Explain cooling system components and operation (pages 4 - 5). Review effects of altitude, system pressure and antifreeze concentration on cooling system temperature (pages 6 - 7). Discuss water quality (pages 8 - 9). Explain the need for supplemental coolant additive for conventional antifreeze and emphasize that the level of concentration should be maintained between 3% - 6% (pages 9 - 12). Explain that antifreeze not only provides freeze protection for the coolant, but also raises the boiling point and helps prevent water pump cavitation. All Caterpillar engines with Air to Air Aftercooling (ATAAC) require at least 30% antifreeze in the coolant to prevent water pump cavitation. Review list on page 14 of recommendations to avoid coolant additive over-concentration. Review cooling system functional effects and failures that result from using improper coolant (pages 16 - 24). Review cooling system service and maintenance products (pages 25 30).

Unit 4 Lesson 1

4-1-6

Engine Fundamentals

NOTE: Handout "A Close Look at Cat Extended Life Coolant" Form No. LEDQ7330 Review advantages of using Extended Life Coolant emphasizing fewer maintenance intervals and longer life compared to conventional coolant.

Lesson 2: Remove and Install Cooling System Components

Objectives: Using the appropriate Caterpillar 3404 Service Manual, the student will demonstrate the ability to correctly remove, inspect, and install cooling system components. References: 3406B Service Manual 3406C Service Manual Introduction: To effectively perform diagnosis, repair, and service on a diesel engine cooling system, it is necessary to be able to remove, inspect, and install the related components. Tooling: 8T0461 Servicemans Tool Set or Equivalent 9S8140 Pressurizing Group 5P0957 Battery/Coolant Tester 8T5296 Coolant Test Kit SEBR0544 SEBR0550

Lesson 2: Remove and Install Cooling System Components

Unit 4 Lesson 2

4-2-2

Engine Fundamentals

Lab Exercises Using a lab engine or engine installed in a vehicle, show students cooling system components and explain their function including coolant pump, regulator, and radiator. Test radiator cap using 9S8140 Pressurizing Group. Test coolant using 8T5296 Coolant Test Kit. Using a lab tear-down engine, remove water pump and discuss failure mode (bad seal, loose, eroded, or cracked impeller). Remove temperature regulator (thermostat). Point out importance of the seal around the thermostat and trace flow of the bypass circuit.

Unit 4 Quiz 4.1.1

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Engine Fundamentals

Unit 4 Quiz Circle the best answer or fill in the blanks. Name_______________________

1. If cooling system pressure rises 1 PSI, the boiling point of the coolant: A. increases by approximately 3 degrees F. B. decreases by approximately 3 degrees F. C. doesn't change. 2. The acceptable range of Supplemental Coolant Additive for conventional antifreeze coolant used in Caterpillar engines is: A. B. C. D. 1 - 2%. 3 - 6%. 7 - 9%. not important.

3. The Supplemental Coolant Additive for conventional antifreeze coolant should be checked: A. every PM Level 1 B. every PM Level 2 C. every day 4. When the cooling system thermostat is closed, coolant circulates mainly through the: A. B. C. D. engine. radiator. engine and radiator. engine and bypass.

5. A 50/50 solution of water and antifreeze will give freeze protection to: A. B. C. D. -50 degrees F -67 degrees F -34 degrees F -20 degrees F

6. What percentage of heat energy from fuel burned in an engine actually produces power at the flywheel? A. B. C. D. 50% 30 - 40% 70 - 80% 100%

Instructor Copy: Quiz4.1.1

CATERPILLAR ENGINE FUNDAMENTALS

Unit 4 Quiz 4.1.1

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Engine Fundamentals

7. What thermodynamic principles are involved removing heat from an internal combustion engine? A. B. C. D. conduction convection radiation all of the above

8. True/False It is acceptable to run water without any additives in a diesel engine cooling system as long as the temperature of the environment stays above freezing. A. True B. False 9. True/False Extended Life Coolant lasts up to 3 times as long as conventional coolant and requires additive only once. A. True B. False 10. A cooling system with a keel cooler is often found on earthmoving equipment. A. True B. False

Unit 4 Quiz 4.1.1

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Engine Fundamentals

CATERPILLAR ENGINE FUNDAMENTALS Unit 4 Quiz Circle the best answer or fill in the blanks. Name_______________________

1. If cooling system pressure rises 1 PSI, the boiling point of the coolant: A. increases by approximately 3 degrees F. B. decreases by approximately 3 degrees F. C. doesn't change. 2. The acceptable range of Supplemental Coolant Additive for conventional coolant used in Caterpillar engines is: A. B. C. D. 1 - 2%. 3 - 6%. 7 - 9%. not important. antifreeze

3. The Supplemental Coolant Additive for conventional antifreeze coolant should be checked: A. every PM Level 1 B. every PM Level 2 C. every day 4. When the cooling system thermostat is closed, coolant circulates mainly through the: A. B. C. D. engine. radiator. engine and radiator. engine and bypass.

5. A 50/50 solution of water and antifreeze will give freeze protection to: A. B. C. D. -50 degrees F -67 degrees F -34 degrees F -20 degrees F

6. What percentage of heat energy from fuel burned in an engine actually produces power at the flywheel? A. B. C. D. 50% 30 - 40% 70 - 80% 100%

Student Copy: Quiz4.1.1

Unit 4 Quiz 4.1.1

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Engine Fundamentals

7. What thermodynamic principles are involved removing heat from an internal combustion engine? A. B. C. D. conduction convection radiation all of the above

8. It is acceptable to run water without any additives in an engine cooling system as long as the temperature of the environment stays above freezing. A. True B. False 9. Extended Life Coolant lasts up to 3 times as long as conventional coolant and requires additive only once. A. True B. False 10. A cooling system with a keel cooler is often found on earthmoving equipment. A. True B. False