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Cooling Systems SEBD0518-09 c 2008 Caterpillar Printed in U.S.A. Contents Understanding Cooling Systems . .4 Cleaning of Heavy-Duty Coolant/Antifreeze Function . 4 Systems . 26 Function of Components. 4 Commercial Heavy-Duty Coolant/Antifreeze Cooling System Temperature . 6 and Supplemental Coolant Additive . 26 Factors That Affect the Cooling System . .8 Water and Supplemental Coolant Additive . .27 Sources of Heat. 8 Cooling Systems with Larger Capacities . 28 Oil Coolers . 8 Adding the Cat SCA to Water at the Aftercoolers. 9 Initial Fill. 28 Transmission, Marine Transmission, or Torque Adding the Cat SCA to Water for Converter Oil Coolers. 9 Maintenance . 28 Retarder Coolers . 10 S•O•S Services Coolant Analysis . .29 Water Cooled Exhaust Manifolds and Water New, Refilled, or Converted Systems. 29 Cooled Turbocharger Shields . 10 Recommended Interval for S•O•S Coolant Hydraulic Oil Coolers. 10 Sampling . 29 Safety Recommendations . .11 S•O•S Coolant Analysis (Level 1) . 29 S•O•S Coolant Analysis (Level 2) . 29 Cooling System Maintenance . .12 Coolant . 12 Caterpillar® Conditioner Elements . .30 Heat Transfer. 12 Functional Effects . .32 Protection Against Freezing of the Coolant . 12 Corrosion Resistance. 12 Pitting and Cavitation-erosion . 33 Scale and Deposits . 12 Rust . 35 Compatibility . 12 Acidity-Alkalinity Imbalance . 36 Non-Foaming . 12 Galvanic and Electrolytic Corrosion. 36 Sediment . 12 Scale and Deposit Formation . 37 Cylinder Wall Pitting . 13 Aeration. 37 Coolant Properties . .14 Coolant-Related Failures . .38 Water . 14 Cracked or Warped Cylinder Heads . 38 Additives . 15 Cylinder Block . 39 Glycol . 15 Piston Seizure . 39 Testing Glycol Concentrations . 16 Cold Operating Temperatures . 40 Coolant Recommendations . .17 Service and Periodic Maintenance . .41 Cat® ELC (Extended Life Coolant) . .19 Periodic Maintenance . 41 Troubleshooting Checklist . 42 Cat ELC Cooling System Maintenance . 20 Cat ELC Extender. 20 Troubleshooting Overheating . .43 Cat ELC Cooling System Cleaning . 21 Visual Inspections for Overheating. 43 Changing to Cat ELC . 21 Cooling System Tests . 46 Cat ELC Cooling System Contamination. 22 Test Water Temperature Regulators . 46 Commercial Extended Life Coolant . 22 Check Air Velocity . 47 Diesel Engine Antifreeze and Coolant Additives .23 Check for Air, Gases, and Steam in the Cooling System. 47 Cat DEAC . 23 Check the Cooling System Relief Valve. 48 Supplemental Coolant Additive . 23 Test During Machine Operation . 48 Conventional Coolant/Antifreeze Cooling Measure Manifold and Aftercooler Temperatures48 System Maintenance . 23 Summary of Overheating Problems and Causes 49 Cooling Systems with Larger Capacity . 25 Adding at the Initial Fill . 25 Troubleshooting Overcooling . .50 Adding for Maintenance . 25 Engine Overcooling . 50 Causes of Overcooling . 50 - 2 - SEBD0518-09 Contents Reconditioning the Cooling System . .51 Thermocouple Temperature Adapter . 69 Cleaning the Outside of a Standard Radiator Recorder Group. 69 Core. 51 Thermometers . 69 Cleaning the Outside of a Folded Radiator Core 52 Air Flow Test Tool . .70 Cleaning the Outside of a Multiple Row or Multitach II Tool Group . 70 AMOCS Radiator . 54 Blowby/Air Flow Indicator. 70 Cleaning Inside Parts of the Cooling System. 54 Pressure Test Tools . .71 Components that Affect the Cooling System . .56 Pressurizing Pump . 71 Battery Ground Connections. 56 Pressure Probe. 71 Sea Water Inlet Screens . 56 Pressure Gauge . 71 Oil Cooler Cores . 56 Digital Pressure Indicator . 71 After Cooler Cores . 57 Engine Pressure Group . 72 Radiator Cap . 58 Relief Valve. 58 Leak Detection Tool . .73 Fan Belts . 58 Ultraviolet Lamp Group . 73 Pulleys. 58 Attachments . .74 Fan Assembly . 58 Fan Shroud and Baffles. 58 Hood and Engine Enclosures . 74 Radiator Mounts . 58 Abrasion Resistant Grid for Radiators and Fan Guards . 58 Ejector-type Fans . 74 Water Temperature Regulators . 58 Crankcase Guards . 75 Hoses and Clamps. 59 Reversible Fan. 75 Temperature Gauges . 59 Hinged Radiator Guard. 76 Water Pump. 59 Coolant Flow Indicators . 76 Cylinder Heads . 60 Jacket Water Heater . 76 Cylinder Block . 61 Summary . .77 Cylinder Liners . 61 Test Equipment . 61 Reference Material Available . .77 Cooling System Maintenance Products . .62 Foreword Cat ELC . 62 Diesel engine manufacturers have increased engine Supplemental Coolant Additive . 62 operating temperatures to improve engine efficiency. Supplemental Coolant Additive Elements . 62 This increase in temperature means proper cooling Antifreeze . 63 system maintenance is especially important. Cooling System Cleaners . 63 Overheating, overcooling, pitting, cavitation-erosion, Coolant Sampling Tools . .64 cracked heads, piston seizures, and plugged radiators Fluid Sampling Bottle Kit. 64 are classic cooling system failures. Vacuum Pump . 64 Proper coolant selection and maintenance are your Probe Adapter Groups. 65 choice, and coolant is vital to successful engine Coolant Condition Test Tools . .66 service life. In fact, coolant is as important as the Cat ELC Dilution Test Kit . 66 quality of your fuel and lubricating oil. Coolant Condition and Ethylene Glycol This booklet tells the coolant story: its composition, Test Kit . 66 contamination, and typical consequences. This Coolant Condition Test Kit . ..
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