The Cooling System

Approximately 50% Of

Premature Engine Failures or

Non-Performance Incidents

Can Be Attributed To

Cooling System Problems

 Objectives

 Develop Awareness of Coolant & the Cooling System.

 Augment the Coolant Analysis Interpretation Guides
Coolant Analysis Overview – PEGP9818.
 Colors
 Odors
 Provide S•O•S Analysts with the ability to respond to
customers question and concerns.
 Understand the benefits of using coolant in all climates.
 Understand the benefits of Level 2 Coolant Analysis.
 Cooling System Maintenance

 Objective
 Improve Preventive Maintenance to avoid
overheating problems
 Lower Operating Costs through good system
maintenance
 Lower Cost per Hour
The Importance Of The Cooling System

Diesel Engine Manufacturers Have Increased Engine

Operating Temperatures To Improve Engine Efficiency

Proper Cooling System Management Is As Important As The

Quality Of Your Oil & Fuel !

Overheating, Overcooling, Pitting, Cavitation, Erosion,

Cracked Heads, Piston Seizures & Plugged Radiators Are
Classic Cooling System Failures

Effective Preventative Maintenance Can Avoid These Costly

Failures & Repairs
 Cooling System Functions

 Remove Heat Generated From Fuel Combustion

 Combustion Temperatures Can Reach 1,937 Deg. C

 Transfer Heat From

 Cylinder head
 Block & Liners
 Engine Oil Cooler
 Transmission Oil Coolers
 Hydraulic Oil Coolers
 Water Cooled Exhaust Manifolds
 Water Cooled Turbocharger Shields / Housings
 Marine Gear Oil Coolers
 Torque Converter / Retarder Coolers
 Jacket Water After Coolers
 Cooling System Function
Proportional Amount Of Heat Dissipated From
Engines Exhaust
Energy

Radiated
Energy

Cooling
Flywheel HP System
Energy
 Engine Power Dissipation

30% Exhaust HP

7%
Radiated HP

30%
Cooling HP
33%
Flywheel HP
 Engine Cooling System

Thermostat
Cylinder Head Housing
Water Bypass
Radiator
Water Pump

Cylinder Oil Cooler

Liners Cylinder Block

Fan
Coolant
Water Temperature
Regulator
 Cooling System Problems

 Overheating

 Overcooling

 Loss Of Coolant
 Typical Overheating Causes

 Low Coolant Level

 Plugged Radiator Core – Air side or Coolant side
 Loose Fan Belts
 Reduced Airflow Through Radiator
 Coolant Overflow
 High Inlet Air Temperature Or Restriction
 Low Heat Transfer Through Scale Build Up For Example
 Exhaust Restriction
 Excessive Engine Load
 Water Pump Or Temperature Regulator Failure
Summary Of Overheating Problems & Causes
1. Low coolant level A. External leaks caused by loose connections, radiator cap or cooling system relief valve
with defects
B. Internal leaks caused by cracked cylinder head, cracked cylinder liner, loose cylinder
heads, failed cooler core, failed after cooler, damaged gaskets.
2. Reduced Air Flow A. Plugged radiator core
Through Radiator B. Damaged or bent radiator fins
C. Low fan speed because of low engine high idle speed
D. Fan is damaged or installed backwards
E. Loose or worn fan belts and pulleys
F. Damaged fan shroud, wrong diameter fan or incorrect number or blades.
G. Incorrect fan blade position. (Fan projection must be approx. 50% -65% in the Upstream flow direction
H. Excessive fan tip to shroud clearance. Should be 3/8 inch maximum clearance
I. Closed shutter (if equipped)
J. Fluid coupling not fully engaging fan speed
3. Insufficient Cooling A. Verify pressure gauge
System Pressure B. Defective radiator cap or Cooling System pressure relief valve
C. Defective radiator top tank filler neck or stud
4. Coolant Overflow A. Air in cooling system because of incorrect cooling fill
B. Combustion gases in cooling system from loose or cracked - cylinder heads, pre-
combustion chamber, defective cylinder head gasket, worn cylinder liner counterbore
C. Steam in cooling system
D. Torque Converter overload
Summary Of Overheating Problems & Causes
C. Low engine high idle speed
D. Failed water pump impeller or slipping drive belt
E. Radiator tubes plugged
6. High Inlet Air A. High ambient air temperature
Temperture Or B. Plugged openings in screens for engine compartment with a blower fan
Restriction C. Disconnected inlet air pipe in engine room
D. Dirty aftercooler core
E. Plugged air cleaner
F. Damaged or carbon packed turbocharger
7. Low Heat Transfer A. Insufficient flow of raw water through heat exchanger
B. Fouled heat exchanger or crusted over keel cooler
C. Hot air to radiator caused by overheating hydraulic oil cooler
D. Scale on cylinder liners or cylinder head
8. Exhaust Restriction A. Damaged turbocharger
B. Restriction in exhaust pipes or excessively long exhaust pipe
D. Water in muffler
E. Loose baffle in muffler
 Overheating Effects

 Cracked Or Warped Cylinder Heads

 Overcooling

 Low Ambient Air Temperatures & Light Loading

 Water Temperature Regulators Stuck Open or Removed

 Leaking Regulators or Unregulated Vent Line Flow

 Defective Temperature Gauge? Verify

 Effects

 If Temperatures are Less Than 80 Degrees C, High Sulfur Fuel

Increases Wear On Engine Components
 Engines don’t reach the most effective operating temperature
consequently maximum performance is not realized
Water -The Most Efficient Heat Transfer Agent

 Drawbacks
 Contains chlorides, sulfates, and suspended solids
 Causes Scales & Deposits That Plug Radiators And Fail
Water Pumps, Builds Sediment

 Improper pH Level
 Attacks Copper, Aluminum & Steel Engine Components,
Causes Corrosion & Damaged Seals

 Lower Boiling Point

 Lower Boiling Point than Coolant mixture
 Elements of a healthy coolant

 Elements  Characteristics: pros & cons

 Water  J The best heat transfer vehicle, but
L … low boiling point
L … high freezing point
L … high corrosive power
L … when impure, allows scaling
 Glycol  J Increases boiling point
J Decreases freezing point
J Decreases corrosive power, but
L … reduces heat transfer
L … oxidizes and becomes acidic
 Additives  J Decrease corrosion
J Decrease scaling
Improper Chemical Protection Concerns
Hard water scale Fouling of the heater core Corrosion of the Thermostat
buildup on the cold with silica gel & phosphate water pump malfunctions
side of the liner, sludge, resulting in impellors
creating an insulating reduced heat to the cab &
effect & consequent bunk heaters Solder corrosion &
hot spots consequent solder
bloom fouling

Corrosion of the
copper or aluminum
Corrosion of the steel Thermostat radiator core
& cast iron surfaces Cylinder Head
Housing Radiator
Water Bypass

Water Pump Fouling of the radiator

with silica gel or
Severe pitting of Oil Cooler phosphate sludge
Cylinder from the antifreeze
wet sleeve liners
Liners
Cylinder Block

Gel insulates fan

temperature sensors
causing improper
air fan operation
Water pump seal failure leading to overheating
Short-outs in block Water pump cavitation
due to excess dissolved
heater due to foaming Hoses can become soft
solids and / or high
due to phosphate scale and brittle if the wrong
phosphate levels
buildup additives are used
 Coolant

 Function
 Transfer Heat From Hot Engine Components To A
Radiator Or Heat Exchanger
 Additive protection is required to improve the properties of the base
source water

 Desired Characteristics
 Higher Boiling Temperature
 Lower Freeze Protection
 Corrosion Resistance
 Scale & Deposit Prevention
 Non Foaming
 Minimum Sediment
 Maintain pH between 5.5 -9
 Traditional Coolant Problems

 Wet Sleeve Liner Pitting  Hard Water Scale

 Measuring Nitrate Level  Water Pump Seal Failures

 Add SCA - When, How,  Overheating / Loss Of Heat

How Much Transfer

 Silicate Gel - Green Goo  Radiator Tube Deposits -

plugging
 Total Dissolved Solids
 Solder Bloom

 Foaming
Cavitation & Pitting On Cylinder Wall

1. Bubble Forms as 2. Bubble

Coolant pressure Collapse Begins
drops as Pressure rises

3. Implosion Dissipates 4. Eventual Erosion

Energy On Cylinder & Pitting Without
Wall Removing Additive protection
Oxide Film
 Cavitation Effects

 Cavitation Of The Cylinder Wall Will Eventually

Allow Coolant To Leak Into The Cylinder
 Cavitation Erosion & Pitting Effects

 Holes In A Cylinder Wall On A 3208 Engine Block Caused

By Cavitation Erosion & Pitting
Corrosion Caused By Lack Of Coolant Additive

 Corrosion On A Water Pump Passage

 The Effects Of Cavitation Erosion

 Failure - Cavitation Erosion  An Example Of Cylinder

Of A Pre-combustion Liner Cavitation Erosion
Chamber
 Rust

 Examples Of Component Failure & Poor Performance

Caused By Rust

 Generally As A Result Of The Absence Of A Coolant

Additive

Rusting Inside A Water Pump

Rust Deposits On Cylinder Temperature Regulator

Liner Outside Surface Failure As A Result Of
Rust & Scale Deposits
Critical Evaluation Of Corrosion Inhibitors
Formation of nitrosamines in the
presence of amines

Mercaptobenzothiazole Forms insoluable calcium salts

Phosphates Poor high temperature stability

Relatively rapid depletion rate

Silicates Precipitate if pH drops or hard water

gets in to the system
Can form hard (insulating) scale

Borates Corrosive to aluminum at high

temperatures

Sebacates Expensive
Poor aluminum protection
Functions Of Engine Coolant Additives
Additive Function
Phosphate Iron Protection & pH Control
Borate Iron Protection & pH Control
Molybdate Iron Protection
Dicarboxylates Iron & Aluminum Protection
Carboxylates Iron & Aluminum Protection
Mercaptobenzothiazole(MBT) Copper & Brass Protection
Tolytrazole(TT) Copper & Brass Protection
Nitrate Cast Iron & Steel Protection
Liner Cavitation Protection
Aluminum & Solder Protection
Silicate Aluminum Protection
Silicones Antifoaming Agent
Black Polymers Antifoam / Scale & Deposit Control
Dispersants Scale & Deposit Control
Surfactants Scale & Deposit Control
 Corrosion Inhibitor Depletion Rates

120
Percent Protection
IRON
100 BORATE
ALIMINUM
& SOLDER
NITRATE
COPPER & BRASS
80 TT
IRON
PHOSPHATE
60

40 CYLINDER LINERS
MBT NITRITE
SILICATE
20

ALUMINUM COPPER & BRASS

0
0 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000 60,000
Mileage
250 500 750 1000 1200
Hours
 Water Quality

 Water Characteristics Vary From

Location To Location

 However Must Meet Acceptability

Guidelines Established By Your Engine
Manufacturer

 Contact Your Water Supply Company

To Determine Water Specifications

 Compare With The Minimum

Acceptable Levels Of Chlorides,
Sulfates, Hardness, Total Solids and
pH Level From Your Engine
Manufacturer
 Water Quality

 Must Conform To Cat Established Levels Of:

 Chloride 2.4 gr./gal max

 Sulfates 5.9 gr./gal max
 Total Hardness 10 gr./gal max
 Total Solids 20 gr./gal max
 pH Level 5.5 - 9.0

 Cat Recommends Distilled Or Deionized Water

 Water as a Coolant is not recommended

 ELC Recommendations

Compartment First Choice: Second Choice:

Cat Spec* Industry Spec*
CAT ELC
EXTENDED LIFE (Factory Fill)
COOLANTS *Life: 6,000 Hours or 6 Years
*Add Cat Extender 3,000 Hours
or 3 Years
*No SCAs Needed at 250 Hours
*Lowest Operating Cost
Compared to Cat DEAC

* Please see SEBU6250 for the latest Cat Machine

Coolant Recommendations.
 Coolants - Features Comparison
Extended Life Diesel Engine Coolants
Coolant Antifreeze / Coolant
Coolant Change Interval 6,000 SMU 3,000 SMU 3,000 SMU
or or or
300,000 Miles 150,000 Miles 150,000 Miles
Inhibitor Addition Cat Extender Cat SCA Cat SCA
(One Time Only 3,000 SMU) Every 250 SMU or Equilvalent
Every 250 SMU
Ethylene Glycol Base Yes Yes Yes
Additive Technology Carboxylic Acid Toytriazole Nitrates Nitrate, Silicates
(Some) Silicates (Some) Borates, Phosphates
Nitrates (Some) Borates (Some) Molybdates*
Meets Cat EC-1 Yes No No
Aluminum Compatible Yes Yes Many
Mixed Fleet Use Yes Limited Many
SCA Required No Yes Yes
Color Strawberry Red Pink Green Or Yellow Green
SCA Test Kit Not Required Required Required
Initial FIII No Cat Extender Required No Cat SCA Required Most Require Some SCA
 Cat Extended Life Coolant - ELC
 Benefits
 Premixed 50% ELC 50% Deionized Water
 Ensures Water Quality
 Ensures Correct Antifreeze To Water Mix

 Eliminates Hard Water Scale

 Reduces Coolant Costs By

42% - 63% Over Cat DEAC

 Requires No Coolant Conditioner

Test Kit

 Environmentally Friendly
Reduced Disposal Volume
And Is Recyclable
 Cat Extended Life Coolant - ELC

 Benefits Continued
 Maintain Cylinder Liner Cavitation Resistance

 Low Level of Total Dissolved Solids Improves Water Pump

Seal Life & Reliability
 3406C @ 3,000 SMU 53 % Reduction
 3176 @ 3,000 SMU 73 % Reduction

 No Design Changes Required

 Factory Filled In All Cat Machines & Engines

 Can Be Used In Most OEM Diesel, Gasoline & Natural Gas

Engines (Inventory One Coolant For Entire Fleet)
 Cat Extended Life Coolant - ELC
 Lasts Twice As Long As DEAC In Cat Machines & Commercial
Engines, And Three Times As Long In Cat Truck Engines
6,000 SMU vs. 3,000 SMU

 Reduced Coolant Disposal

 No Cleaner Required, Flush with water

 Improved Aluminum Corrosion Protection

 Reduced Service Additions

 DEAC requires SCA addition at Every Oil Change
 Cat ELC Extender AT Half Life only, Requires No Supplemental
Coolant Additives
Cat Extender For Maximum Coolant Life

Machines & Commercial Engines

Cat Diesel Engine Antifreeze /

Coolant
3,000 SMU
(Cat SCA Every 250 SMU)

Cat Extended Life

Coolant
6,000 SMU or 6
Years
(Which ever comes first)
 Customer’s Perception

ELC requires coolant analysis.

ELC does not require coolant analysis.
Standard coolant does not require coolant
analysis.
Coolant analysis is used to determine if the
coolant is fit to use.
 Reality

ELC is much more stable than standard coolant --

nitrites and nonferrous passivators deplete much
slower and no significant carboxylate depletion
occurs under normal conditions.
Fluid analysis is much more effective at predicting
system, maintenance, and operational problems
when the fluid is more stable -- i.e. the chemical
changes in the fluid, itself, are minimal.
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 Cat Extended Life Coolant

Part No. Package Size Description

119-5148 Bulk (5,000 Gallons) Premixed (50/50)
101-2845 55 Gallons Premixed (50/50)
101-2844 1 Gallon Premixed (50/50)
119-5150 1 Gallon Concentrate
119-5152 Quart Bottle Cat Extender
 Cat Extender

Quantity of Extender
Needed at Cat Long Life Coolant/Antifreeze Half-Life*
Approximate Amount at
Cooling System Capacity 150,000 Miles or 3,000 Hours* *

Gal. (L) Qty (119-5152)

6-8 22-30 0.5 (Bottle)

8-13 30-49 1 (Bottle)
13-22 49-83 1.5 (Bottles)
22-30 83-114 2 (Bottles)
30-41 114-155 3 (Bottles)
41-52 155-197 4 (Bottles)
52-64 197-243 5 (Bottles)
 Periodic Maintenance

 Initial Fill
 Select Proper Water, Coolant Additive & Antifreeze
 Always Premix Before Adding To Cooling System
 Do Not Fill faster Than 19 Liters (5 gal) / min
 After Filling, Run Engine For Several Minutes With Radiator
Cap Off
 Install Radiator Cap And Run Engine At Low Idle Until
Engine Becomes Warm
 Inspect Level In Top Tank. Add Coolant If Necessary
 Never mix DEAC and Cat ELC
 Cooling System Maintenance

 Objective
 Improve PM To Avoid Overheating Problems
 Lower Operating Costs Through Good System Maintenance
 Lower Cost Per Hour
Preventative Maintenance - 10 / 250 SMU

 10 Hour / Daily Check

 Inspect Coolant Level
 Inspect Radiator Core
/ Clean as needed
 250 Hour / Monthly Check
 Inspect Coolant Level
 Clean Radiator Core
 Inspect Condition & Tension Of Fan Belts - Adjust / Replace As
Required
 IF NOT Using Cat Extended Life Coolant Add Supplemental
Coolant Additive
 Test Coolant For Freeze Protection If necessary
 Inspect Radiator Cap & Gaskets
 Inspect Hoses, Engine Electrical Grounds
Preventative Maintenance - 3,000 SMU

 3,000 SMU /24 Months

 Perform All 250 SMU Checks
 Add Cat Extender if using Cat Extended Life Coolant
 Otherwise:
Drain, clean & refill the cooling system
 Replace the Water Temperature Regulators
 Inspect condition of fan blades & guards, hoses & clamps
 Tighten all clamps
 Perform a Coolant Analysis

 6,000 SMU Or 6 Years Whichever Comes First

 If using Cat Extended Life Coolant, drain, flush with clean water
and refill
 Replace the Water Temperature Regulators
 Otherwise: repeat the 3,000 SMU PM
 Cooling System Cleaners

 Mild solvents which dissolve & depress mineral scale,

corrosion products, light oil contamination & sludge. Two
formulations available:

 A “Fast Acting" formulation which takes ~30 - 90 min to clean

the system - 4C4611
 A slower-acting formulation that remains in the engine for the
duration of oil change cycle - 6V4511

 For heavy scale build up stronger commercial solvents

should be used with care
 Maintenance Summary
 Visually Inspect your cooling system every day.

 Warm engine by idling until the proper cooling system

temperatures & pressures are reached.

 Monitor and maintain correct operating temperature.

 Test coolant conditioner every 250 SMU (maintain 3 - 6 %

concentration) & change every 3,000 SMU for DEAC use.

 Always use distilled or deionized water with supplemental

conditioners.

 Cool down engine by idling before shutdown.

Cooling System Management - Summary

 An effective cooling system preventative maintenance

program & the use of Cat Extended Life Coolant (ELC)
will:

 Significantly reduce engine failures & problems

 Improve engine operating performance and consequently

production

 Reduce operating costs

 Improve parts reusability at overhaul point

Diesel Engine Antifreeze/Coolant Concentrate

 Diesel Engine Antifreeze/Coolant Concentrate

 A fluid, usually containing corrosion inhibitors and ethylene
or propylene glycol, which is added to the water in an
engine’s cooling system to prevent freezing.

 SCA
 A Supplemental Coolant Additive, usually containing nitrite
and other corrosion inhibitors, which is used to replenish
depleted corrosion inhibitors to assure good protection of
wet sleeve cylinder liners and other cooling system
components.
Cat Supplemental Coolant Additive (SCA)

 WATER ALONE AS A COOLANT

IS NEVER RECOMMENDED
 Add SCA to Achieve 6% Concentration
 Cat Diesel Engine Antifreeze & Coolant
(DEAC)
 No Need To Add SCA At Initial Fill
 SCA Required Every 250 SMU
 Check SCA Concentration Using The SCA
Test Kit
 8T5296
 Test Equipment

 Supplemental Coolant Additive Test Kit - 8T5296

 Checks Concentration SCA
 Checks Ethylene Glycol Concentration Range
 Only Takes A Few Minutes To Perform

 Coolant Testers - 5P3514

 Accurate Reading Of Coolant Freeze Point Temperature

 Blowby / Air Flow Indicator Group - 8T2700

 Hand Held Digital Indicator And Remote Pickup
 Measure Air Velocity Through Radiators
Focus of Coolant Analysis Program

Coolant analysis can predict short comings in

equipment operation practices, maintenance
procedures, and design limitations.
Coolant analysis can pin-point cooling system
problems either before or after a component fails.
Coolant analysis can define problems with the
coolant chemistry (both new & used coolant).
 Coolant Sample Study

 8,000 samples reviewed…Cat and competition

 77% of Cat samples had a problem
 All “bad”samples ….36% abnormal, 38% urgent
 ELC = 1/3 the urgent results vs. competition
 Green coolant = 5x urgent results over ELC
 10% ... coolant oxidation problem
 Glycol oxidizes same rate in both DEAC & ELC
 30% of urgent results ... glycol level problem
 15% of urgent results … high lead
 Key benefits of Coolant Analysis

Fluid condition
More vital now: systems are high performance, and good heat
dissipation is essential
Reduce risk of component failure
Half of engine problems
caused or accelerated by
poor cooling system
performance
Leads to
before-failure repairs
Another clue in the life cycle management process
 S•O•SSM Coolant Analysis

Level 1: Basic Coolant System Check – verifies that levels of

heat and corrosion control are consistent with Cat O&M
guidelines
Chemistry
 glycol % (refractometer),
nitrite % (titration)
water hardness
 acidity (pH meter)
Conductivity
 total dissolved solids
(conductivity meter)
Physical attributes
 appearance, color, odor
 foam
 S•O•SSM Coolant Analysis

Multi-level analysis
Field screening
 Cooling system obvious problems awareness
 Generally done by visiting dealer personnel
 Basic tests done with a coolant analysis kit
– Refractometer for glycol %
– Test strips for nitrite check
– pH meter for pH
– Odor and appearance
Level 1 analysis
 Generally done in a dealer lab
Level 2 analysis
 Generally done in a specialized lab
 S•O•SSM Coolant Analysis

 Verifies The Proper Chemistry Of Your Coolant

 Diagnoses The Condition Of Your

Coolant / Cooling System

 Allows You To Correct Coolant

Or Cooling System Problems
Before Costly Failures Occur
 S•O•SSM Coolant Analysis

Level 2: Cooling System Analysis - coolant properties +

cooling system condition complete evaluation – augments
oil analysis
Engine, transmission, hydraulic cooling system
Degradation
 hardness, ammonia
level, reserve alkalinity
Chemistry
 source of inhibitor depletion,
source of oxidation products,
source of contaminants
(electrophoresis instrument)
 corrosion and scaling products identification
(spectrophotometer)
Coolant Colors
 Coolant Precipitates
Amount •Brown-White
•None •Other
•Slight Appearance
•Moderate •Flocculent
•Heavy •Dense
Color •Granules
•Black •Chunks
•Brown •Flakes
•White •Other
•Gray Magnetism
•Tan •None
•Black- •Somewhat
Brown
•Mixture
•Black-White
•Magnetic
Coolant Precipitates
 Coolant Odors

•Ammonia
•Burnt Odor
•Diesel Fuel
•Solvent
•Ketone
•Fungal
•Sulfide
•Other
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xi
dat
i
on
u
sual
l
yind
ic
at
ese
it
he
rov
erh
ea
ti
ng
o
fthe
cool
ant
(g
en
er
al
lyo
rl
oca
ll
y)
o
ranano
di
c s
tr
ay
cur
r
ent
(po
si
ti
ve
).
N
i
tri
te/
Ni
tra
tevs
.Gl
ycolO
x
id
ati
on
Pro
du
cts
vs.Co
ol
antHo
ur
s

Therel
a t
iverat
e ofnit
rit
e ox
idatio
n vs.
gl
ycoloxidat
ion c
a nb eused t
o
di
sti
ngu i
sh bet
w e
e nco ol
antove r
heati
ng
a
n dpos i
ti
vestraycurrent.Str
a ycurr
en t
wi
lloxi
d i
ze t
he ni
tri
teb u
t wi
llhaveno
e
ffecton t
he gl
ycol.A rapiddec r
easein
t
he ni
tri
te c
oncentrati
on coupl
ed wit
h a
mini
m alincr
easein gl
y c
olat
e & for
m at
e
poi
ntsto st
raycurrent.A ra
p i
d
oxi
dati
o nofbothn i
tri
te& gl
y c
o lpoi
nts
t
o over
h eat
ing.
 L
e
ad
/T
i
n L
e
ve
l&R
a
ti
o

Leadconcentr
at
ionsg r
eat
erthan1
0
t
imes t
heti
n concent
rat
ion(whent
he
l
ead l
eveli
s gr
eat
er t
han30p pm)
i
ndicat
esthatahighlea
d sol
derex
is
ts
i
n t
he co
oli
n gsyst
em .Thi
s t
ypeof
sol
derismu c
h har
d e
r t
oprot
ect(w
it
h
convent
i
on alco
olant
)thana60/4
0or
70/
30solder
.Ifi
t i
s p
resenti
n t
he
syst
em t
he cool
antm ustb
e mai
nta
ine
d
neari
tsnew condi
ti
on.
 C
a
r
bo
na
t
eLe
v
el

Ar
api
dri
sei
nth
ec
arb
ona
tel
eve
l
,
u
sua
ll
ycou
pl
edwi
t
h a
rap
idde
cr
ea
se
i
npH(
usua
ll
ybe
l
ow6.
0)i
ndi
ca
te
st
he
i
ngr
e
ssofex
hau
s
tgas
esi
ntot
he
c
ool
ant
.Che
ckf
or
a b
lo
wnhead
g
ask
etor
acra
ck
edbl
ock
.
 A
mm
on
i
a

Ats
uffi
ci
entl
yhig
h pH,amm oni
um
s
alt
s ar
e de
tect
abl
e byt
heirodor(
at
l
evel
snear50 p
pm amm oni
a).Ift
he
pHisle
ss t
han8.
5,a por
ti
on oft
he
s
am pl
e s
houldbetr
eat
ed wit
h KOHor
NaOHbefor
e smel
li
ng.Thistes
t c
an
a
nd sho
uldbe p
erf
ormed i
n t
hefie
ld
(
part
icul
arl
yaft
ercl
eani
ng t
he sy
st
em
wi
than ammoni
a c
ontai
nin
g cl
eaner
).
 C
o
ol
ing
Sy
st
emC
l
ean
e
rs

Co
oli
ng s
yst
em cl
eanersare
,b ythei
r
n
atu
re,agg
ress
ive t
ocom po
n ent
s o
f t
he
c
ool
ingsys
tem.F as
tacti
ng cl
eaners
mus
t bees
peci
all
y agg
ressi
ve t
o work
r
api
dly.The
sep r
o d
uctsshoul
d be
r
ins
ed t
hor
oughl
y bef
orenew coola
ntis
a
dded t
oth
e sy
stem.Ifthecleaner
c
ont
ainsammonia,t
he a
m mon i
a sp
ot
t
ests
h o
uldberunon t
herinses.
Ov
er
heat
in
gw
it
hNo
Oxy
ge
n
(
NoFl
ow)
V
ery
hight
em per
atur
es(>4
00oF)i
n
t
hea
bsens
e ofoxyge
n wi
llc
rackt
he
g
lyc
o
lm ol
ecul
e t
o f
orm k
eton
esand
a
lde
h
ydes.Thesesol
vent
sw i
l
lgive
t
hec
ool
antad i
sti
nct
iv
e od
or(si
m i
l
ar
t
oac
et
one)and,i
n suf
fi
ci
ent
q
uan
ti
ti
es,wi
llr
educetheni
tr
it
esin
t
heb
ul
k cool
ant(but
notconv
ert
t
hemt
onit
rat
e).
O
v
er
hea
t
ing
wi
thL
ow
Ox
yg
en
(
Low
fl
ow)
Veryhightemperat
ures(>40
0oF)in
l
ow fl
ow condit
ionscancrackthe
gl
ycolm ole
culetofor
m ketonesand
al
dehydes andatthesame t
ime cr
eate
oxi
dati
on product
sand burn
t odor
s.
Underlow f
lowcondit
ions(e.
g.turbo
l
ineslacki
ng pr
essuredif
fer
enti
alor
poorcir
culat
ionw/exhaustgas
cool
er)som ecool
antbu r
ni
ng wil
l
occur(burntod
or,al
so).Agai
n ni
tri
tes
may depl
ete(wi
thoutbeingoxi
dizedto
ni
trat
es).
 C
o
ol
an
tA
n
al
ys
isP
r
og
r
am
B
en
ef
i
ts
t
oC
at
e
rp
il
l
ar

P
r
ov
i
des
Pr
od
uc
t
Sup
p
or
t

R
e
du
c
es
Po
l
i
cya
n
dWa
r
r
an
ty

A
s
si
st
si
nCo
n
tr
a
ct
ua
lM
an
a
ge
me
n
t
C
o
ol
ant
Ana
l
ysi
s P
r
ogr
amB
e
ne
fi
ts
t
oth
eD
ea
l
er

G
o
od
Co
mmu
ni
cat
i
onT
oo
l

E
nh
anc
es
Cus
t
ome
rS
up
po
r
t
A
gr
eem
en
ts

E
x
pa
nd
sKno
wl
edg
eo
fSu
pp
or
t
P
e
rs
on
ne
l

M
e
et
s/
Exc
ee
ds
Com
p
et
i
ti
veC
ha
l
len
ge
s
 C
o
ol
ant
Ana
l
ysi
sPr
og
ra
m
B
en
ef
it
s
t
ot
heC
u
st
ome
r

I
mpr
ov
es
Cu
st
ome
rU
nd
e
rs
t
and
i
ng

I
ncr
ea
se
sE
ng
i
neP
e
rf
or
man
c
e

I
ncr
ea
se
sE
ng
i
neL
i
fe

H
A
PP
YC
US
T
OM
ER
!
!!
 Glycol’s Boil Protection

Glycol Solutions water 212oF

Boil Point at 25% glycol 216oF
1 Atmosphere 40% glycol 220oF
50% glycol 225oF
60% glycol 229oF
75% glycol 245oF

Due to increased ionic strength chemical reactions

occur at a faster rate in water than in glycol solutions.
 Pressure’s Boil Protection

Water’s Boiling Point At Various Pressures

Atmos. Press. 0 psig 14.7 psia 212oF

plus 5 psia 5 psig 19.7 psia 227oF
plus 10 psia 10 psig 24.7 psia 240oF
plus 15 psia 15 psig 29.7 psia 250oF
plus 20 psia 20 psig 34.7 psia 259oF
 Altitude’s Boil Point Effect

Water’s Boil Point At Various Altitudes

Sea Level 14.7 psia 212oF

5,000 ft. 12.2 psia 203oF
10,000 ft. 10.1 psia 194oF
 Design Improvements

Optimum Cooling
 Higher Pressures
 Better Flows
Vapor Pressure vs. Temperature

Water’s Vapor Pressure at Various

Temperatures

Temperature Pressure
160oF 4.74 psia
180oF 7.5 psia
200oF 11.5 psia
212oF 14.7 psia
225oF 18.9 psia
250oF 29.8 psia
 Coolant recommendations

Application: Caterpillar machine vehicular Diesel

engines

Recommend* Alternative
ELC DEAC
Coolant meeting Coolant meeting ASTM D4985
Caterpillar EC-1 spec or D5345 spec

* Always check most recent

guidelines : Cat Machines - SEBU 6250
 Engine Coolant Term Glossary
Alkaline - Having properties of an alkali -- having a pH greater than 7
Amines - One of a class of organic compounds which can be considered to be derived from
ammonia (NH3) by replacement of one or more hydrogens by functional groups.
Block Copolymer - A commonly used antifoamant composed of blocks of ethylene oxide and
propylene oxide, polymerized together. At elevated temperatures, these surfactants become
insoluble due to loss of water of hydration in the molecule. This insoluble polymer defoams
the coolant then redissolves when the coolant temperature decreases below its cloud point.
Carboxylic Acid - Monobasic - An organic acid containing a single carboxylic acid group (-
COOH)
Carboxylic Acid -- Dibasic - An organic acid containing two carboxylic acid groups (-COOH)
Coolant -- DEAC - Caterpillar’s Diesel Engine Antifreeze Coolant
Coolant - ELC -Caterpillar’s Extended Life Coolant, formerly Long-Life Coolant Antifreeze
Corrosion - Cathodic - Corrosion at a negatively charged conductor in contact with a
conductive solution.
Corrosion - Cavitation - Corrosion activated by creation and implosion of vapor pockets near a
metal surface. Mechanical energy initiates surface corrosion.
Conductivity (mhos) - The reciprocal of the electrical resistance (in ohms) of two parallel 1 cm
electrodes separated by 1 cm of the solution of interest.
Entrainment (of Air) - The pickup and dispersion of air in a liquid (e.g.. Engine coolant) in a
semi-stable condition.
Extender - Caterpillar’s reinhibition additive for ELC.
Flocculent - Cloudlike and non-crystalline (precipitate).
 Engine Coolant Term Glossary
Ionic Strength - Concentration of ions.
Ionize - To convert wholly or partly to ions.
Ppm - parts per million which is equivalent to milligrams per liter.
Umho - Micro mhos - which is 1 /(mega ohms). A umho is 1/1,000,000th of a mho, which is a
measure of the electrical conductance (1/resistance) of a liquid.
Opaque - Not pervious to radiant energy and especially visible light (I.e. not at all transparent).
pH - The negative log 10 of the activity of the hydrogen ion concentration of the solution of
interest.
Precipitate - A substance separating, in solid particles, from a liquid as the result of a chemical
or physical change.
SCA - Caterpillar’s Supplemental Coolant Additive for use in Caterpillar DEAC to re-inhibit the
used fluid. Contains sodium silicate, sodium borate, sodium nitrite, and either sodium
mercaptobenzothiazole or sodium tolytriazole.
Silane - An effective dispersant for Silicates in standard antifreeze. A molecule with a silane
backbone {H(-Sih2)x H} with organic groups replacing some or all of the hydrogens.
Silicone (Modified) - Very effective antifoamants. A molecule with a silicone backhoe H(-Sih2-
O-)x H} with organic groups replacing some or all of the hydrogens. Generally insoluble (but
made dispersible) in both aqueous and petroleum based liquids.
Soap - A reaction product of a carboxylic acid and alkali (normal) or alkaline earth (hard water)
hydroxide (e.g.. Potassium Sebacate.
Surfactant or Surface-active Agent - A soluble compound that reduces the surface tension of
liquids, or reduces the interfacial tension between two liquids or a liquid and a solid (e.g..
Make water wetter).
 ELC Cost Comparison

Cooling System Cost Comparison

6000 Hour Evaluation
10 gallon system
Cat ELC pre-mix Cat DEAC concentrate
price per gallon $7.00 $7.50
price of distilled water $0.00 $?
gallons required 10 10
total cost of coolant $70.00 $75.00

Cat ELC Extender Cat DEAC SCA

price per bottle $8.50 $2.50
bottles required 1 23
total cost of additives $8.50 $57.50

cost of coolant drain $?

coolant disposal cost $?
drains required 0 1
labor & disposal cost $0 ++$?

Total Cost $78.50 ++$132.50

Minimum Savings $54.00 or 41%