Freightliner FLA/FLB/FLC/FLD/FLL. Manual - part 11

Title of Maintenance Operation (MOP)

MOP Number

Fan Drive and Clutch Checking (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03

Radiator Cap Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01

Radiator Pressure Flushing and Coolant Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–02

Engine Cooling/Radiator

Index, Alphabetical

Heavy-Duty Trucks Maintenance Manual, January 2007

20–01 Radiator Cap Checking

WARNING

Do not remove or loosen the radiator cap until the
engine and cooling system have completely
cooled. Use extreme care when removing the cap.
A sudden release of pressure from removing the
cap prior to the system cooling can result in a
surge of scalding coolant that could cause seri-
ous personal injury.

CAUTION

The radiator cap currently installed may not be the
same one installed when the vehicle was built. If
the radiator cap must be replaced, make sure that
it is the correct cap for the cooling system of the
vehicle. Because the radiator cap pressure rating
affects the operating temperature of the engine,
installing an improperly rated radiator cap may
have adverse effects on the cooling system, and
engine operating temperatures. This could cause
premature engine wear or damage.

Using a radiator-cap tester, check the pressure
cap to see if it maintains pressure to within 10
percent of the pressure rating marked on the
cap. If it doesn’t, replace the cap. Make sure that
the replacement radiator cap is correctly rated for
the cooling system of the vehicle.

There is a second valve in the radiator cap that
opens under vacuum. This prevents the collapse
of hoses and other parts that are not internally
supported when the system cools. Inspect the
vacuum-relief valve to be sure it is not stuck.

Make sure that the cap seals properly on the
coolant filler neck seat, and that the radiator cap
gasket is not damaged. On vehicles with screw
on caps with O-rings, make sure that the O-ring
is not cracked or deteriorated. Replace the cap if
the gasket shows deterioration or damage.

20–02 Radiator Pressure

Flushing and Coolant
Changing

NOTE: For additional instructions on cleaning
and flushing the cooling system, see the appli-

cable engine manufacturer’s maintenance and
operation manual.

If necessary, remove the aerodynamic cover
from the front bumper.

Drain the radiator as follows:

For a low-flow cooling system,

disconnect the

radiator bottom tank inlet and outlet hoses, and
tighten the radiator cap. Attach the flushing gun
nozzle to the outlet hose.

For a high-flow cooling system,

disconnect the

radiator upper and lower hoses, and tighten the
radiator cap. Attach the flushing gun nozzle to
the lower hose.

Run the water until the radiator is full.

CAUTION

Excessive pressure can damage the radiator or
heater core.

Gradually, apply air pressure to help dislodge
sediment built up in the radiator core. Do not
apply more than 15 psi (103 kPa) air pressure to
the radiator. Pressures exceeding 15 psi (103
kPa) could damage the radiator core.

Shut off the air at the pressure gun nozzle and
allow the radiator to refill with water.

Repeat the previous two steps until clean water
flows from the radiator.

Remove the radiator side tank drain plug and
allow the radiator to drain. Install and tighten the
side tank drain plug and the radiator outlet pipe
drain plug after the radiator has been drained.
Do not overtighten the plugs.

Connect the hoses. Your hose clamps can be
either T-bolt clamps (see

Fig. 1

) or Breeze

Constant-Torque clamps (see

Fig. 2

When working with T-bolt hose clamps, tighten
the clamps 55 lbf·in (620 N·cm). These clamps
are now standard on hoses with an inside diam-
eter greater than 2 inches (51 mm).

When installing Breeze Constant-Torque hose
clamps, the clamps must be tightened to the cor-
rect torque. The screw tip of the clamp must ex-
tend about 1/4 inch (6 mm) from the clamp hous-
ing, and the belleville washer stacks must be
collapsed almost flat. Use a torque wrench to

Engine Cooling/Radiator

Heavy-Duty Trucks Maintenance Manual, January 2007

20/1

install these clamps correctly. Correct installation
torque for Breeze Constant-Torque hose clamps
is:

For clamps with a 5/16-inch tightening screw
hex:

55 lbf·in (620 N·cm).

For clamps with a 3/8-inch tightening screw hex:

90 lbf·in (1020 N·cm).

NOTE: All hose clamps will lose torque after
installation due to "compression set." However,
when correctly installed, Breeze Constant-
Torque clamps will hold enough torque to auto-
matically adjust and keep consistent sealing

pressure. During vehicle operation and shut-
down, the screw tip may adjust according to
temperature and pressure changes. The torque
may need to be adjusted for individual applica-
tions.

IMPORTANT: On vehicles with EPA07 compliant
engines, the coolant capacity varies depending
on the engine and accessory installation. After
servicing the cooling system, always verify that
the coolant level is between the MIN and MAX
lines on the surge tank.

Fill the radiator with new coolant. See Group 20
of the

Heavy-Duty Trucks Service Manual

for

guidelines. See

Table 1

for FLA, FLB, and FLD

120 cooling system capacities,

Table 2

for FLC

112 cooling system capacities,

Table 3

for FLD

112 cooling system capacities. See

Table 4

for

antifreeze protection information. Certain equip-
ment such as fuel heaters, water filters and auxil-
iary heaters may increase the coolant capacity
and require additional coolant. The cooling sys-
tem is filled when the coolant level reaches the
MAX line on the surge tank. Freightliner recom-
mends the use of a precharged and premixed
antifreeze when refilling the cooling system. See

Table 4

for a list of some of the precharged anti-

freeze available. Use of an equivalent antifreeze
to those listed in the table is also acceptable.
Always check that the antifreeze used meets
Freightliner’s specifications and is at the proper
concentration for protection in the vehicle operat-
ing area. See

Table 5

for antifreeze protection

information. Freightliner specifies that the anti-
freeze must be an ethylene glycol solution that
meets GM 6038 M Engineering Standards or a
ethylene glycol solution that has less than 0.1%
anhydrous sodium metasilicate, and meets either
GM 1825 M or GM 1899 M Engineering Stan-
dards. If supplemental coolant additives are
being used, add the supplements to the coolant
as necessary. See the coolant additive manufac-
turer’s instructions for the correct amount of addi-
tive required. Don’t forget to consider the volume
of the supplemental coolant additive being added
to the system when determining the amount of
coolant required to refill the system.

02/28/96

f200326

Fig. 1, T-Bolt Type Hose Clamp

08/15/94

f200286

A. The screw tip must extend about 1/4 inch (6 mm).
B. The belleville washer stacks must be collapsed

almost flat.

Tightening Screw Hex

Fig. 2, Breeze Constant-Torque Hose Clamp Installation

Engine Cooling/Radiator

Heavy-Duty Trucks Maintenance Manual, January 2007

20/2

Engine Cooling System Capacity for FLA, FLB, and FLD 120 (pre-EPA07 engines)

Engine Make

Engine Model

Radiator Core and System Capacity

2 Row:

quarts (liters)

3 Row:

quarts (liters)

4 Row:

quarts (liters)

Caterpillar

3176

49.0 (46.4)

50.0 (47.3)

3306 JWAC

51.9 (49.1)

52.9 (50.0)

53.9 (51.0)

3306 ATAAC

49.5 (46.8)

50.5 (47.8)

51.5 (48.7)

3406 JWAC

57.2 (54.1)

58.2 (55.1)

59.2 (56.0)

3406 ATAAC

55.2 (52.2)

56.2 (53.2)

57.2 (54.1)

Cummins

L10

46.6 (44.1)

47.6 (45.0)

48.6 (46.0)

L10 OA (low flow)

46.0 (43.5)

47.0 (44.5)

Big Cam III

55.1 (52.1)

56.1 (53.1)

57.1 (54.0)

Big Cam IV (low flow)

51.1 (48.4)

52.1 (49.3)

Detroit Diesel

Series 60

56.0 (53.0)

57.0 (53.9)

58.0 (54.9)

Series 55

47.0 (44.4)

48.0 (45.3)

49.0 (46.3)

System capacity includes all hoses, fittings, and the heater core.

Table 1, Engine Cooling System Capacity for FLA, FLB, and FLD 120 (pre-EPA07 engines)

Engine Cooling System Capacity for FLC 112

Engine Make

Engine Model

Radiator Core and System Capacity

2 Row:

quarts (liters)

3 Row:

quarts (liters)

4 Row:

quarts (liters)

Caterpillar

3176

49.0 (46.4)

50.0 (47.3)

3306B

51.0 (48.3)

3406B

58.0 (54.9)

58.5 (55.4)

Cummins

L10

41.0 (38.8)

41.5 (39.3)

Big Cam III

56.0 (53.0)

56.5 (53.5)

Big Cam IV (low flow)

49.5 (46.8)

50.0 (47.3)

Detroit Diesel

Series 60

58.6 (55.5)

Series 55

47.0 (44.4)

48.0 (45.3)

49.0 (46.3)

System capacity includes all hoses, fittings, and the heater core.

Table 2, Engine Cooling System Capacity for FLC 112

Engine Cooling System Capacity for FLD 112

Engine Make

Engine Model

Radiator Core and
System Capacity

quarts (liters)

Caterpillar

3176, 3306 ATAAC

38.0 (36.0)

Engine Cooling/Radiator

Heavy-Duty Trucks Maintenance Manual, January 2007

20/3

Content .. 9 10 11 12 ..