Unit 4: Cooling Systems

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 LEKQ7353

Coolant and Your Engine SEBD0970
A Close Look at Cat Extended Life Coolant LEDQ7330
3406B Service Manual SEBR0544
3406C Service Manual SEBR0550
Unit 4 Quiz Copy

Tooling:

8T0461 Serviceman's Tool Set or equivalent

9S8140 Pressurizing Group
5P0957 Battery/Coolant Tester
8T5296 Coolant Test Kit
NOTES
 Lesson 1: Cooling System Components
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 LEKQ7353

Coolant and Your Engine SEBD0970
A Close Look at Cat Extended Life Coolant LEDQ7330

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.
Unit 4 4-1-2 Engine Fundamentals
Lesson 1

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 4-1-3 Engine Fundamentals
Lesson 1

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 4-1-4 Engine Fundamentals
Lesson 1

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.
 Lesson 2: Remove and Install Cooling System Components
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 SEBR0544

3406C Service Manual SEBR0550

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 Serviceman’s Tool Set or Equivalent

9S8140 Pressurizing Group
5P0957 Battery/Coolant Tester
8T5296 Coolant Test Kit
Unit 4 4-2-2 Engine Fundamentals
Lesson 2

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.
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