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Technical Service Bulletin Re-Print From Baldwin Filter Company

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Cooling System Maintenance for Heavy Duty Engines

There are many cooling system problems and failures. Most of these problems have occurred due to incorrect information and maintenance practices. The following will address these problem area erroneous information and listing the proper maintenance practices. The chart shown below is a listing of the six most common problems seen in today's cooling systems. Along with each problem how it occurs, how it affects your engine and, most importantly, how to prevent it. PROBLEM Rust* Scale (Water Hardness) Acidity (pH) HOW IT HAPPENS Oxidation within the system. Present in all tap water are salt minerals, especially calcium and magnesium. These minerals can solidify and adhere to hot metal surfaces. Ethylene glycol antifreeze reacts with oxygen in the air and forms acid. A loose head gasket or other leakage can allow sulfuric acids formed by the burning of fuel to leak into cooling system. Constant vibration of the cylinder liner causes a momentary vacuum to form on its surface. Coolant boils into the vacuum and vapor bubbles implode on the surfaces of the liner, digging into unprotected liners. Foam - The aeration of coolant - occurs from air leakage into the system. WHAT IT CAN DO Clog the system. Cause accelerated wear. PREVENTION The inhibitors in a quality Supplemental prevent the oxidation for rust to occur.

1. Clog system passages. Deposit on high temperature areas and The Supplemental Coolant Additive kee reduce the heat transfer rate causing hot spots. This results in uneven metal expansion, scuffing, scoring, accelerated ring wear and, eventually, suspension so they cannot deposit on e surfaces or clog passages. cracked heads and/or blocks. Corrode iron, steel and aluminum.

A quality Supplemental Additive neutrali prevent corrosion. Coolant pH should be

Pitted Cylinder Liners

Cause pits which can extend over time, through the thickness of the liner and allow coolant to enter the combustion chamber or crankcase.

The Supplemental Coolant Additive coa thin film to protect it from erosion withou transfer.

Foam

A quality Supplemental Coolant Additive Adds to the Cavitation erosion problem, particularly in the areas of water agent to prevent formation of air bubble pump impellers. prevention agent is effective at all tempe during startup.

Flow rates and turbulence are high at the impeller blade. This Pitted Water Pump Impellers causes Cavitation. In addition, there is a possibility that abrasive Cause loss of pump efficiency and total pump failure. particles are present in the system.

The Supplemental Coolant Additives pro from Cavitation erosion and the filter ho matter to reduce abrasive wear on cool components.

*It should be noted that rust can appear even within a chemically protected system when oil is present in the coolant. If you do notice the presence of rust, the oil cooler should be inspected for STARTING RIGHT on the previous page. When filling a newly cleaned system with fresh antifreeze and water, a Before changing the coolant, the system should be Supplemental Coolant Additive is required. These thoroughly flushed to remove any contamination. A clean additives contain many inhibitors not found in system is free of solid and liquid contaminates including today's antifreezes or if present in the antifreeze, they are at very low concentration levels oil. (unacceptable for engine protection). MAKE-UP WATER When pre-charging, be sure to use the proper Proper coolant system maintenance requires a quality pre-charge filter for your size cooling system or 4 make-up water. All make-up water is corrosive but water ounces(120ml.) of liquid Supplemental Coolant with high mineral content cannot be made fit for use. As Additive per gallon(3.8 ltr.) of coolant (4 soft of tap water as possible should be used. Tap water oz.(120ml.) requirement based on the most that has been softened by some type of salt or chloride common Supplemental Coolant Additives). In process should not be used. Most engine manufacturers either case, be sure to follow the Supplemental have set up specifications for water used in their Coolant Additive manufacturer's specifications. engines. The following chart shows some of these SERVICE specifications. Caterpillar Cummins Detroit Hardness Chlorides 100ppm 50ppm 300ppm 100ppm 100ppm 500ppm 170ppm 40ppm 100ppm 340ppm Supplemental Coolant Additives are used up (depleted) while in the process of protecting the metal surfaces which are in contact with the coolant. These additives must be replenished through the use of filters containing SCA's or a liquid SCA at specified service intervals to maintain the proper concentration levels. PERIODIC DRAINING AND FLUSHING Antifreeze breaks down to corrosive acids due to temperature cycles within the cooling system . The coolant can also become contaminated by dirt, oil, combustion gases and spent inhibitors.

Sulfates 50ppm Total Dissolved Solids 250ppm

Note: When contacted, Mack informed us that there were no limits on water used in their engines. ( PPM Parts Per Million ) ANTIFREEZE

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Cavitation

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Antifreeze, ethylene glycol, propylene glycol or long life / extended life, should be used in the cooling system year around. The glycol in the antifreeze provides freeze protection. It also provides a stable environment for gaskets and seals. These same gaskets will shrink in straight water and leakage could occur.

While a high quality coolant filter will remove the solid contaminants, it will not remove the oil or combustion gases. Due to the breakdown of the antifreeze, all engine manufacturers recommend periodic draining and flushing. Caterpillar and Detroit Diesel recommend annually draining and flushing while Cummins and Mack recommend a Some of the major problems we see in cooling systems maximum of two years. today occur due to antifreeze related problems. One of the most publicized problems is silicate gelation/dropout. Silicate gel problems have increased in frequency since There are many specialized products on the the early 1980's. The two major causes of this problem market today which can help you develop a quality cooling system maintenance program. The are: antifreeze concentration level is a key area which could lead to silicate gelation and water pump 1. High Silicate Antifreezes leakage. The recommended range is 40-60% based on ambient temperature. The use of a 2. Over concentration of antifreeze and/or Supplemental refractometer or hydrometer will insure the glycol Coolant Additives. concentration levels are maintained properly. All antifreezes used in today's heavy duty engines should meet GM 6038M or ASTM D-4985 specifications for silicate content. The antifreeze concentration should be held between 40% and 60% (40% antifreeze and 60% water to 60% antifreeze and 40% water). A 50% / 50% blend is ideal. Another problem caused by over concentration is water pump leakage. In a study by Cummins Engine Company, 54% of the water pump failures they examined occurred due to over concentration. 78% of the total pumps examined showed over concentration regardless of the cause of the failure. There are several different types of Supplemental Coolant Additive test kits on the market. The primary types check one of the following: 1. Sodium Nitrite 2. MBT 3. pH

Use the test kit recommended by your Supplemental Coolant Additive supplier. CAUTION: Test strips or testers which register the pH as the sole determining factor in adding SUPPLEMENTAL COOLANT ADDITIVES your Supplemental Coolant Additive should not be used. For further information regarding antifreeze, Using the proper amount of a high quality Supplemental Coolant Additive is very critical in preventing the problem refer to TSB-96-6. mentioned in the chart

.All manufacturers' names, numbers, symbols and descriptions are for reference only. It is not implied that any part is the product of the manufacturer. Caterpillar and Cat are registered trademarks of Caterpillar, Inc., Cummins is a registered trademark of Cummins Engine Company, International/ Navistar is a registered trademark of Navistar International Transpor tation Corporation, Detroit Diesel is a registered trademark of Detroit Diesel Corporation, Ford is a registered trademark of Ford Motor Company, Waukesha is a registered trademark of Waukesha Engine Divisio of Dresser. Prices and items subject to change without notice

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