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3406E and 3456 Industrial Engines Testing and Adjusting – Cooling System – Check – Overheating

Above normal coolant temperatures can be caused by many conditions. Use the following procedure to determine the cause of above normal coolant temperatures:

  1. Check the coolant level in the cooling system. Refer to Operation and Maintenance Manual, “Cooling System Coolant Level – Check”. If the coolant level is too low, air will get into the cooling system. Air in the cooling system will cause a reduction in coolant flow and bubbles in the coolant. Air bubbles will keep coolant away from the engine parts, which will prevent the transfer of heat to the coolant. Low coolant level is caused by leaks or incorrectly filling the radiator.

 

  1. Check the mixture of antifreeze and water. The mixture should be approximately 50 percent water and 50 percent antifreeze with 3 to 6 percent coolant conditioner. Refer to Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) Obtain”. If the coolant mixture is incorrect, drain the system. Put the correct mixture of water, antifreeze, and coolant conditioner in the cooling system.

 

  1. Check for air in the cooling system. Air can enter the cooling system in different ways. The most common causes of air in the cooling system are not filling the cooling system correctly and combustion gas leakage into the cooling system. Combustion gas can get into the system through inside cracks, a damaged cylinder head, or a damaged cylinder head gasket. Air in the cooling system causes a reduction in coolant flow and bubbles in the coolant. Air bubbles keep coolant away from the engine parts, which prevents the transfer of heat to the coolant.

 

  1. Check the fan clutch, if equipped. A fan clutch or a hydraulic driven fan that is not turning at the correct speed can cause improper air speed across the radiator core. The lack of proper air flow across the radiator core can cause the coolant not to cool to the proper temperature differential.

 

  1. Check the water temperature gauge. A water temperature gauge which does not work correctly will not show the correct temperature. Refer to Testing and Adjusting, “Cooling System – Inspect”.

 

  1. Check the sending unit. In some conditions, the temperature sensor in the engine sends signals to a sending unit. The sending unit converts these signals to an electrical impulse which is used by a mounted gauge. If the sending unit malfunctions, the gauge can show an incorrect reading. Also if the electric wire breaks or if the electric wire shorts out, the gauge can show an incorrect reading.

 

  1. Check the radiator. 
    1. Check the radiator for a restriction to coolant flow. Check the radiator for debris, dirt, or deposits on the inside of the radiator core. Debris, dirt, or deposits will restrict the flow of coolant through the radiator.

     

    1. Check for debris or damage between the fins of the radiator core. Debris between the fins of the radiator core restricts air flow through the radiator core. Refer to Testing and Adjusting, “Cooling System – Inspect”.

     

    1. Ensure that the radiator size is adequate for the application. An undersized radiator does not have enough area for the effective release of heat. This may cause the engine to run at a temperature that is higher than normal. The normal temperature is dependent on the ambient temperature.

 

  1. Check the filler cap. A pressure drop in the radiator can cause the boiling point to be lower. This can cause the cooling system to boil. Refer to Testing and Adjusting, “Cooling System – Test”.

 

  1. Check the fan and/or the fan shroud. 
    1. The fan must be large enough to send air through most of the area of the radiator core. Ensure that the size of the fan and the position of the fan are adequate for the application.

     

    1. The fan shroud must be the proper size and the fan shroud must be positioned correctly. Ensure that the size of the fan shroud and the position of the fan shroud are adequate for the application.

 

  1. If the fan is belt driven, check for loose drive belts. A loose fan drive belt will cause a reduction in the air flow across the radiator. Check the fan drive belt for proper belt tension. Adjust the tension of the fan drive belt, if necessary. Refer to Operation and Maintenance Manual, “Belt – Inspect/Adjust/Replace”.

 

  1. Check the cooling system hoses and clamps. Damaged hoses with leaks can normally be seen. Hoses that have no visual leaks can soften during operation. The soft areas of the hose can become kinked or crushed during operation. These areas of the hose can cause a restriction in the coolant flow. Hoses become soft and/or get cracks after a time. The inside of a hose can deteriorate, and the loose particles of the hose can cause a restriction of the coolant flow. Refer to Operation and Maintenance Manual, “Hoses and Clamps – Inspect/Replace”.

 

  1. Check for a restriction in the air inlet system. A restriction of the air that is coming into the engine can cause high cylinder temperatures. High cylinder temperatures cause higher than normal temperatures in the cooling system. Refer to Testing and Adjusting, “Inlet Manifold Pressure – Test”. 
    1. If the measured restriction is higher than the maximum permissible restriction, remove the foreign material from the engine air cleaner element or install a new engine air cleaner element. Refer to Operation and Maintenance Manual, “Engine Air Cleaner Element (Dual Element) – Inspect/Clean/Replace “.

     

    1. Check for a restriction in the air inlet system again.

     

    1. If the measured restriction is still higher than the maximum permissible restriction, check the air inlet piping for a restriction.

 

  1. Check for a restriction in the exhaust system. A restriction of the air that is coming out of the engine can cause high cylinder temperatures. 
    1. Make a visual inspection of the exhaust system. Check for damage to exhaust piping or for a damaged diesel particulate filter (DPF). If no damage is found, check the exhaust system for a restriction. Refer to Testing and Adjusting, “Air Inlet and Exhaust System – Inspect”.

     

    1. If the measured restriction is higher than the maximum permissible restriction, there is a restriction in the exhaust system. Repair the exhaust system, as required.

 

  1. Check the shunt line, if the shunt system is used. The shunt line must be submerged in the expansion tank. A restriction of the shunt line from the radiator top tank to the engine water pump inlet will cause a reduction in water pump efficiency. A reduction in water pump efficiency will result in low coolant flow and overheating.

 

  1. Check the water temperature regulator. A water temperature regulator that does not open, or a water temperature regulator that only opens part of the way can cause overheating. Refer to Testing and Adjusting, “Water Temperature Regulator – Test”.

 

  1. Check the water pump. A water pump with a damaged impeller does not pump enough coolant for correct engine cooling. Remove the water pump and check for damage to the impeller. Refer to Testing and Adjusting, “Water Pump – Test”.

 

  1. Check the air flow through the engine compartment. The air flow through the radiator comes out of the engine compartment. Ensure that the filters, air conditioner, and similar items are not installed in a way that prevents the free flow of air through the engine compartment.

 

  1. Check the aftercooler. A restriction of air flow through the air to air aftercooler (if equipped) can cause overheating. Check for debris or deposits which would prevent the free flow of air through the aftercooler. Refer to Testing and Adjusting, “Aftercooler – Test”.

 

  1. Consider high outside temperatures. When outside temperatures are too high for the rating of the cooling system, there is not enough of a temperature difference between the outside air and coolant temperatures.

 

  1. Consider high altitude operation. The cooling capacity of the cooling system goes down as the engine is operated at higher altitudes. A pressurized cooling system that is large enough to keep the coolant from boiling must be used.

 

  1. The engine may be running in the lug condition. When the load that is applied to the engine is too large, the engine will run in the lug condition. When the engine is running in the lug condition, engine rpm does not increase with an increase of fuel. This lower engine rpm causes a reduction in air flow through the radiator. This lower engine rpm also causes a reduction in coolant flow through the system. This combination of less air and less coolant flow during high input of fuel will cause above normal heating.

 

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