Cooling System Troubleshooting 20.

00
General Information

General Information The surge tank holds extra coolant, which travels
down through the fill hose to the engine as needed.
The low coolant level sensor in the surge tank warns
Freightliner Columbia uses radiators that are 1000-
the driver when coolant is running low. The surge
square-inch and 1200-square-inch front areas. Both
tank is translucent polypropylene so you can see the
sizes are high-flow, single-pass radiators with plastic
coolant level and compare it to the maximum and
end-tanks. Both are two-row radiators with 14 fins
minimum levels marked on the tank. See Fig. 2.
per inch and are cross-flow.
To prevent gas from getting trapped in the radiator or
In high-flow cooling systems, most coolant in a warm
engine, vent lines run from the highest point in the
engine is routed through the radiator. The coolant
radiator and engine to the surge tank. To prevent the
moves relatively quickly through the radiator in a
coolant from boiling, the coolant is pressurized 11 to
single pass.
12 psi.
In a typical engine and radiator system, coolant flows
To add coolant, remove the large cap on the out-
from the radiator outlet to the water pump, from the
board end of the tank. The standard, metal SAE cap
water pump through the oil cooler, then the engine
on top of the tank is used for pressure relief and
cylinder block water jacket, then the head. For typical
vacuum-break functions only. If too much pressure
engine coolant plumbing, see Fig. 1.
builds up in the coolant system, excess coolant will
If the engine is cold, the engine thermostat stays vent through the SAE cap and escape through an
closed, and water leaving the head flows back down overflow hose.
to the water pump and the oil cooler.
When the cab heater is activated, hoses carry some
If the engine is warm, the thermostat opens and of the coolant into the cab where it flows through the
coolant is forced to flow into the upper end of the heater core to warm the cab air. This coolant returns
driver-side radiator end tank. The coolant flows to the engine/radiator cooling system.
across the core, where is is cooled by ram air enter-
ing through the vehicle grille. When the coolant For more information about the radiator and surge
reaches the bottom end of the radiator passenger- tank, see Section 20.01.
side end tank, the coolant flows back out to the wa-
ter pump. For the temperature that opens the ther-
mostat on each model of engine, see Table 1.

Cooling System Control Temperatures

Cooling Component Detroit Diesel Caterpillar Engines Cummins Engines
Series 60
C10/C12 C15/C16 N14/ISM ISX/Signature
Temperature F (C)
Thermostat Starts to Open 190 (88) 190 (88) 190 (88) 180 (82) 180 (82)
Thermostat Fully Open 205 (96) 208 (98) 208 (98) 200 (93) 200 (93)
Engine Fan Activates 208 (98) 205 (96) 216 (101) 205 (96) 210 (99)
Engine Fan Stops 198 (92) 198 (92) 208 (98) 195 (91) 205 (96)
High Coolant Temperature Warning 221 (105) 218 (103) 226 (108) 220 (104) 225 (107)
Activates
High Coolant Temperature Engine 225 (107) 224 (106) 234 (88) 223 (106) 228 (109)
Shutdown Activates
Intake Air Temperature Activates the 150 (66) 188 (87) * 108 (87) * 160 (71) 160 (71)
Engine Fan
* The fan is activated at 162F (72C) if the turbo boost pressure is greater than 10 psi (69 kPa).

Table 1, Cooling System Control Temperatures

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20.00 Cooling System Troubleshooting
General Information

1
2

09/28/95 f011021
NOTE: Optional heater hose shut-off valves shown here.
1. Heater Supply Hose 2. Heater Return Hose

Fig. 1, Coolant Plumbing (typical)

050/2 Columbia Workshop Manual, Supplement 0, April 2000

Cooling System Troubleshooting 20.00
General Information

1 2

06/08/95 f500244

1. Low Coolant Level Sensor 3. Fill Cap

2. SAE Cap (for coolant overflow pressure relief only)

Fig. 2, Surge Tank

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Cooling System Troubleshooting 20.00
Troubleshooting

Troubleshooting Tables sections of this manual or to the engine and compo-

nent manufacturers service publications.
Possible causes of hot or cold engine coolant tem-
peratures are listed below. For repairs, refer to other
ProblemCoolant Temperature Above Normal
ProblemCoolant Temperature Above
Normal
Possible Cause Remedy
Coolant leakage (see possible sources Perform the repairs necessary to stop leakage. Fill to the bottom of the
below) is causing a low coolant level. radiator fill neck with the correct mixture of antifreeze and water.
External Leakage: hoses and hose
connections, radiator seams, core,
draincock and cap, block core and drain
plugs, water pump thermostat housing(s),
overflow and surge tank, heater hoses and
core, temperature sending unit(s), cylinder
head(s) mating (gasket) surfaces, coolant
filter, oil cooler(s)
Internal Leakage: cylinder head gasket,
warped head or block surfaces, cracked
cylinder head or block, cylinder head
capscrews loose, missing, or tightened
unevenly; oil cooler, air compressor
cylinder head and gasket cylinder liners,
liner seals aftercooler
The temperature gauge is not working. Check the gauge circuit wires, circuit breaker, and sending unit. If the gauge
circuit is okay, replace the temperature gauge. If the gauge circuit is broken,
repair it and then check temperature gauge operation
The radiator fins, the aftercooler, or the air Clean the outside of the core, the aftercooler, and the condenser with
conditioner condenser fins are clogged. compressed air directed from the fan side, or with water and a mild laundry
soap. Straighten bent fins.
A radiator hose is collapsed or plugged. Replace hoses.
A fan drive belt or the water pump belt is Adjust belt tension.
loose.
The cooling fan shroud is damaged. Repair or replace the shroud.
The radiator cap is incorrect or Make sure the correct radiator cap is installed. If the cap does not hold the
malfunctioning. correct pressure, replace it.
The on-off fan clutch is not working. Check the solenoid valve in the fan clutch air supply line, the sending unit for
the valve, and the operating air pressure to the valve. If valve operation and
air pressure are okay, repair or replace the fan clutch. If the valve doesnt
work or if air pressure is low, make repairs and then check fan clutch
operation.
The engine oil level is incorrect. Fill to the high (H) mark on the dipstick.
There is too much antifreeze or coolant Clean and flush the cooling system. Refill the system with the correct mixture
additive in the system. of antifreeze and water, and install the correct additive and filter, or treatment
filter.

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20.00
Troubleshooting
ProblemCoolant Temperature Above
Normal
Possible Cause
One or both of the thermostats is incorrect Make sure the correct thermostat is installed. Test the thermostat according to
or inoperative.
The water pump is not working correctly.
The radiator core is internally plugged or
damaged.
Air or combustion gases are entering the
cooling system.
The aftercooler is plugged or damaged.
The oil cooler is plugged or damaged.
The engine is receiving too much fuel.
The wrong fan (replacement unit) is
installed.
The wrong radiator (replacement unit) is
installed.
There is exhaust blockage.
There is frozen coolant in the radiator.
ProblemCoolant Temperature Below Normal
ProblemCoolant Temperature Below
Normal
Possible Cause
The temperature gauge is not working.
The on-off fan clutch operates
continuously.
One or both thermostats are incorrect or
inoperative.
300/2
Cooling System Troubleshooting
Remedy
the engine manufacturers instructions. Replace it if it does not operate
correctly.
Repair or replace the water pump.
To check for blockages, warm the engine to normal operating temperature.
Turn off the engine, and run your hand over the finned surface of the radiator.
If there is a blockage in the radiator, it should cause an obvious temperature
difference from one area of the core to another. An obvious difference
between inlet and outlet temperature is normal.
If blockage is suspected, clean and flush the cooling system.
Repair or replace a damaged core.
Check the cylinder head(s), head gasket(s), cylinder liners, aftercooler, air
compressor cylinder head, and fan/shutter air control valve (if applicable) for
leaks. Repair or replace parts, as necessary.
Repair or replace the aftercooler.
Repair or replace the oil cooler.
Refer to the engine manufacturers fuel delivery system adjustment
procedures
Install the correct fan.
Install the correct radiator.
Repair the exhaust system.
Use the proper antifreeze-to-water ratio needed for winter temperatures.
Remedy
Check the gauge circuit wires, circuit breaker, and sending unit. If the gauge
circuit is okay, replace the temperature gauge. If the gauge circuit is broken,
repair it and then check temperature gauge operation.
Check the solenoid valve in the fan clutch air supply line, the sending unit for
the valve, and the operating air pressure to the valve. If valve operation and
air pressure are okay, repair or replace the fan clutch. If the valve doesnt
work or if air pressure is low, make repairs and then check fan clutch
operation.
Make sure the correct thermostat is installed. Test the thermostat according to
the engine manufacturers instructions. Replace it if it does not operate
correctly.
Columbia Workshop Manual, Supplement 0, April 2000