Maintaining Your Heavy-Duty Truck’s Cooling Systems for Optimal Performance
You expect a lot from your truck’s engine. Your vehicle’s performance is paramount and downtime can cost you big time. Your business’ success is why it’s important to perform proper inspection and maintenance of all your heavy-duty truck systems/components, especially when it comes to your heavy duty cooling systems.
If you are a fleet owner, oversee an agriculture company or an independent operator, you know that if your vehicle is in the shop or service center, you are losing money due to downtime. Knowing how to properly maintain your cooling system to ensure continual efficient performance and dependability, can help prevent this.
Avoid unnecessary repairs and downtime by maintaining your cooling system. In this article, we’ll explain the importance of your engine’s cooling system, break down the main components of your engine’s cooling system, and explain how to prevent costly repairs from neglect of basic maintenance. We’ll answer some of your top questions:
- Why Is Your Engine’s Cooling System So Important?
- Engine Cooling System’s Main Components
- How Exactly Does Your Truck’s Engine Cooling System Work?
- Common Signs and Symptoms Your Cooling System May Need Maintenance
- Recommended Cooling System Brands, Parts & Tools
Check out Wheelco’s Buyer’s Guide for Your Heavy-Duty Cooling Systems!
Why Is Your Engine’s Cooling System So Important?
Simply put, your engine’s cooling system keeps the engine from overheating by the transfer of engine heat to the coolant and dissipated in exchange with moving air. If the cooling system fails in any way or is affected by poor maintenance, the result can be costly engine repairs and even disastrous engine replacement from extreme overheating. Even transmissions using the cooling loop from a radiator can be affected and sustain damage.
Five Essential Duties of Your Engine’s Cooling System
The primary duties of your heavy-duty cooling system are:
- Efficiently transfers engine heat
- Controls critical metal temperatures
- Increases the cooling index (helps prevent overheating failures)
- Provides protection against freezing.
- Inhibits rust and corrosion for cooling system metals
Engine Cooling System’s Main Components
The main two major components are the radiator and charge air cooler for the turbocharger. These two parts are vital to your engine’s overall cooling system. However, they would not be able to properly achieve all aspects of cooling and protecting your diesel engine without the following:
- Radiator Caps
- Surge Tanks
- Oil Coolers
How Exactly Does Your Truck’s Engine Cooling System Work?
Basically, there are 2 means of dissipating engine generated heat. Air to liquid exchange and air-to-air exchange.
Your truck's radiator is the integral component in this cooling process. Via an engine driven water pump, it circulates a coolant loop which supplies coolant to the engine and returns it back through the radiator. As the coolant flows through the fins and tubes inside the radiator, it transfers the heat from the coolant to the air. Once the excess heat is removed, the radiator then re-circulates the cooled coolant back through the engine chambers. This is an ongoing process of pushing cooled coolant from the radiator into the engine and taking the hot coolant from the engine and pumping it into the radiator.
Wheelco Recommendation: If the coolant levels or mixtures are not properly maintained, the engine may overheat. Serious and/or costly problems could develop.
Instead of transferring heat via coolant, charge air coolers lower the engine’s temperature by transferring heat into the air. The charge air cooler, which is essentially an air-to-air heat exchanger, is designed for recirculating and cooling exhaust air along with ambient air back into the engine air intake system via a turbocharger.
Wheelco Quick Tip: When properly working, the charge air cooler cools the air from anywhere between 180°C to 220°C, down to around 40°C.
Common Signs and Symptoms Your Cooling System May Need Maintenance
Like all wearable parts in your truck, the parts and components of your cooling system can eventually wear down.
Inspect your radiator if you see some of these common signs and/or symptoms:
- Leaking coolant which is dripping from a crack in your radiator or in your radiator hose. If you notice coolant under your truck or are constantly refilling your coolant, it is a sign that you have a leak. One of our service technicians/mechanics can perform a pressure test. This can help determine the source of the leak. We can repair the source of the leak.
- Coolant Contamination: If rust is present in the radiator, it can cause significant damage to your engine block. Often when rust mixes with coolant, it becomes thick and sludge-like which can lead to engine corrosion. At Wheelco, we recommend flushing your radiator in order to remove all the contaminants.
- Overheating: Over time, the radiator can become plugged by outside debris in the fins and also be affected by internal conditions such as coolant contamination and corrosion. If your radiator is working properly, the high temps could be a sign that your coolant package is exhausted, the engine thermostat has gone bad, or the water pump is not working properly.
Inspect your charge air cooler if you see some of these common signs and/or symptoms:
- Loss of engine power
- Increased fuel consumption
- Elevated coolant temperatures
- Exhaust manifold failure
- Premature piston, ring, and valve failure
- Turbocharger failure
- Increased particulate levels in emissions
At Wheelco, we suggest testing your charge air cooler if you notice signs and/or symptoms that your charge air cooler is failing.
Recommended Cooling System Brands, Parts & Tools
At Wheelco, we recommend using Northern Radiator or Dorman when you are looking to replace your cooling system components. These are the brands we trust if you are in the heavy-duty market for new cooling systems.
Charge Air Coolers
We recommend using Northern Radiator charge air coolers. They feature a two-year limited warranty, meet OEM specifications, feature a laser-scanned design, and are built brand new.
Common part numbers for Northern Radiator’s Charge Air Coolers are:
There are multiple different core types available on the market. Learn more about their advantages and disadvantages with Northern Radiator’s CAC Core Types Guide.
We recommend using Northern Radiator radiators. They feature a one-year limited warranty, have an all makes, all models coverage, meet OEM specifications, and are built to perform.
Common part numbers for Northern Radiator’s radiators are:
- 238601 (Navistar Radiator)
- 238602 (Navistar Radiator)
- 239208 (Peterbilt Radiator)
- 239297 (Peterbilt Radiator)
- 239298 (Peterbilt Radiator)
- 239311 (Freightliner Radiator)
- 239312 (Hendrickson Radiator)
You should replace your radiator cap as needed too. Common signs a radiator cap needs to be replaced include overheating the engine, overflowing reservoir, leaking coolant, collapsed radiator hose, or air bubbles in the cooling system.
Common part numbers for Norther Radiator’s caps are:
- RW0021-1 (7 lbs. 3/4" Neck)
- RW0021-40 (10 lbs. 3/4" Neck)
- RW0021-5 (10 lbs. 3/4" Neck)
- RW0021-294B (15 lbs. 3/4" Neck)
- RW0021-22 (16 lbs. 3/4" Neck)
Radiator Mounting Pad
If you need to replace your radiator mounting pad, we recommend using Northern Radiator (Part number: Z72009) for replacement on these Northern Freightliner radiators: 239137, 239138, 239139, 238603, 239326, 239368, 239013, 239285, 239336, 239117.
Hydro Flush Gun
We recommend using Northern Radiator’s Hydro Flush Gun (Part number: RW0054-5) for cleaning your radiators and charge air coolers. It features a Pro-Tec cone nozzle and a heavy-duty squeeze trigger air valve with a molded handle. The 24” wand keeps water from spraying you as you clean.
Charge Air Cooler Tester Kit
We recommend using Northern Radiators Charge Air Cooler Tester Kit (Part number: RW0090-11). The kit includes a set of 2 pads, regulator gauge, safety valve, and instructions.
Heavy Duty Pressurized Coolant Reservoir
We recommend using Dorman’s Pressurized Coolant Reservoirs. They feature a clear plastic construction to easily read fluid levels and no longer requires indicator ports, reducing potential coolant fluid loss. Plus, the durable construction resists the expansion and cracking that extreme temperature fluctuations can cause.
Common part numbers for Dorman’s Coolant Reservoirs are:
- 603-5103 (International Coolant Reservoirs)
- 603-5105 (International Coolant Reservoirs)
- 603-5201 (Freightliner Coolant Reservoirs)
- 603-5203 (Freightliner Coolant Reservoirs)
- 603-5403 (Kenworth, Peterbilt Coolant Reservoirs)
- 603-5505 (Mack, Volvo Coolant Reservoirs)
Still Have Questions or Need Help with Your Cooling System?
Questions? We can help? Are you looking to upgrade, replace, or service your heavy-duty engine cooling system? We can help you get the exact part you need. Our service technicians can provide service help on the diagnosis, part installation, maintenance work and/or repair jobs. Simply give us a call or stop by one of our stores today.
Related Guide: Cooling System Quick Guide