21 - Cooling System

Acronyms Glossary

ECMEngine Control Module

Notes:

00 - General

Introduction

During the working cycle of the engine a great deal of heat is generated. It is important that the engine is kept at its normal operating temperature to achieve maximum efficiency. It is the function of the cooling system to allow the engine to reach this temperature quickly and then maintain it.

Health and Safety

CAUTION The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system.

CAUTION Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze.

Fault-Finding

Fault

Coolant - Loss.

Coolant - Over Temperature.

Coolant - Under Temperature.

Coolant - Contaminated.

Table 8. Coolant - Loss.

Table 8. Page 21-5

Table 9. Page 21-5

Table 10. Page 21-6

Table 11. Page 21-6

Cause Remedy

Incorrect coolant level. Check the level.

Coolant leaking from engine radiator or cab heater. Visually inspect the radiator heater, hoses and connection to locate the leak. If oil is present in the coolant, check for a transmission or engine oil cooler leak.

External engine coolant leak. Visually inspect the engine and components for seal, gasket hose connection leaks. Make sure all hose clips are in good condition and torqued to the recommended figure. Make sure all spring band clamps are in good condition and apply sufficient pressure to the hoses.

Overheating or compression gases leaking, resulting in loss through the radiator overflow.

See Also: Table 9. Coolant - Over Temperature. If installed, transmission cooler leak. Check/replace the transmission cooler. Check for coolant in the inlet manifold and in the oil.

Lubricating oil cooler leak. Check/replace the oil cooler. Check for coolant in the oil.

Cylinder head gasket leak. Check/replace the head gasket.

Cylinder head cracked or porous. Check/replace the cylinder head. Crankcase coolant passages leaking. Check/replace the crankcase.

Table 9. Coolant - Over Temperature. Cause Remedy

Incorrect coolant level (low). Check the level.

See Also: Table 8. Coolant - Loss.

External radiator matrix blocked with dirt or chaff. Clean exterior or radiator matrix. Air flow to the radiator inadequate or restricted. Check/repair fan shroud, anti-recirculation sealing, shutters, fan sensors, fan speeds as required.

Coolant pump or fan drive belts loose. Check/correct belt tension.

Radiator hose collapsed, restricted or leaking. Check/replace hose.

Oil level overfilled. Check oil level.

Cooling system pressure cap incorrect or faulty. Replace cap with the correct rating for the system. Over concentration of anti-freeze. Remove part of the coolant from cooling system and replace with water.

Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the gauge and temperature sensor are accurate.

Thermostat faulty, incorrect or missing. Check/replace the thermostat.

Air or combustion gases in the cooling system. Make sure the fill rate is not exceeded and the correct vented thermostat is installed. If aeration continued, check for a compression leak through the head gasket.

Coolant pump faulty. Check/replace the coolant pump.

Vent line from engine and/or radiator blocked or incorrectly routed (sudden overheating).

Check routing and operation or vent line.

Cause Remedy

Leak between the top tank and the auxiliary tank (sudden overheating).

Check for coolant leakage between radiator auxiliary tank and radiator top tank.

Cooling passages in radiator, cylinder head, head gasket or crankcase blocked. Flush the system and fill with clean coolant.

ECM (Engine Control Module) or electrical sensor fault. Check the electronic fault codes. Check the electrical connections at the ECM and sensors.

One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical connections at the injectors.

Cause Remedy

Air flow across the radiator excessive.

Check/repair fan shroud, anti-recirculation sealing, shutters, fan sensors, fan speeds as required.

Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the gauge and temperature sensor are accurate.

Thermostat faulty, (open - not sealing). Check/replace the thermostat.

Coolant not flowing by temperature sensor. Check/clean coolant passages. A total coolant loss may result in the gauge showing low temperature initially. In which case, check the level.

Cause Remedy

Coolant rusty, operation without correct mixture of antifreeze and water.

Engine oil cooler, or cooler housing allowing cross contamination of coolant with engine oil.

Transmission lubricating oil cooler leaking (if applicable).

Lubricating oil leaks from lubricating oil cooler, head gasket, head and crankcase.

Drain and flush the cooling system. Fill with correct mixture of antifreeze and water. Review the coolant change interval.

Remove the oil cooler assembly and check relevant sealing elements for damage.

Check/replace lubricating oil cooler. Refer to equipment manufacturer's procedures.

See Also: Table 8. Coolant - Loss.

Drain and Fill

Visually check the coolant level daily.

Check the quality of the antifreeze mixture and change it according to the service schedule.

1.Open the engine compartment cover. Refer to (PIL 06-06).

2.Make sure that the coolant level should be between the MIN and the MAX marks on coolant reservoir.

3.If the level in the expansion bottle is low, then continue with steps 4 to 9.

4.Carefully loosen the cap just enough to let any pressure escape.

5.Remove the cap when all pressure is released.

6.Fill with pre-mixed water/antifreeze until it reaches the correct level.

7.Fill the expansion tank, using the necessary antifreeze solution, to the level indicated.

Consumable: Antifreeze HP/Coolant ASTM D6210 Concentrate

8.Run the engine for a while to raise the coolant to working temperature and pressure.

9.Stop the engine and checks for leaks.

Check (Leaks)

Before you start the machine, inspect the system for leaks:

1.Make the machine safe. Refer to (PIL 01-03).

2.Get access to the cooling pack. Refer to (PIL 06-06).

3.Check under the cooling pack and cooling hoses for signs of leaks.

4.Repair or replace any damaged components before starting the machine.

Check (Level)

The graphic shows a typical engine cooling system, the system you are working on may look slightly different.

1.Make the machine safe. Refer to (PIL 01-03).

2.Open the access cover to get access to the engine.

3.Check the level of coolant in the coolant expansion tank. If necessary remove the filler cap and top up to the level indicated.

4.Install the filler cap and make sure it is tight.

5.Run the engine for a while to raise the coolant to working temperature and pressure.

6.Stop the engine and check for leaks.

00 - General

The cooling pack contains the following major components:

•Radiator

•Cooling fan

•Condenser (air conditioning machines)

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