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COOLANT MAINTENANCE Visual Appearance PROBABLE CAUSE POTENTIAL DAMAGE Color • s

COOLANT MAINTENANCE Visual Appearance PROBABLE CAUSE POTENTIAL DAMAGE Color • should be clear and bright Oil in Coolant • free from oil or petroleum products oil cooler rubber seal or core leaks; loss of heat transfer, liner and water pump (can cause seal failures) combustion gas blow-by into the coolant seal damage, block head water passage seal damage Non-Magnetic/Magnetic Precipitate • free from precipitate, flocculent, algae, bacteria, improper coolant use, air leaks, water pump seal abrasion, increased soft metal and/or sludge (outside contaminants entering the defective electrical grounds corrosion (copper & aluminum), liner pitting system or coolant chemical dropout); magnetic around lower seals precipitate should be a trace or less NOTE: Sample appearance alone does not determine whether a potentially harmful problem exists within the cooling system. Antifreeze/Glycol % RECOMMENDATIONS PROBABLE CAUSE POTENTIAL DAMAGE Too Low •Antifreeze level will vary by •Improper mixing of bulk coolant •Coolant may boil or the block application and elevation at which may freeze the system operates •Topping off with water only •Can cause cavitation and/or •Engines operating at 195˚ or above corrosion damage must be at 50% for boil point control Too High •Engines operating at 5000 ft. and above •Improper mixing of bulk coolant •Loss of heat transfer should maintain a 55-60% antifreeze level •Topping off with glycol concentrate •Cavitation to prevent coolant boiling •Pitted liners •Marine applications must maintain •Seals may fail 50-60% antifreeze if the system operates above 195˚ pH RECOMMENDATIONS PROBABLE CAUSE POTENTIAL DAMAGE Too Low •Conventional Coolant: 8.5 to 11 •Coolant is plain water •Corrosion on iron components as •ELC Formulation: typically 7.0 to 8.5; •Source water does not meet engine well as other metals in the system if pH is above 9.0, possible ELC and manufacturer specifications •Electrolysis pitting through liners conventional coolant mixing •Ethylene glycol is beginning •Corrosive attack on engine block •Correct cause of drop in pH to decompose •Possible corrosion protection •Coolant is burnt chemicals precipitate out of solution •Combustion gas leak •Acid type cleaner used and not flushed thoroughly Specific Conductance RECOMMENDATIONS PROBABLE CAUSE POTENTIAL DAMAGE •Normally this level will be between •Improper source water •The inability of the coolant to resist 1000 and 6500 micromohos •Combustion gas leak carrying an electrical current between •When level is excessive, find cause •Antifreeze level too high the dissimilar metals of an engine’s and correct •Inhibitor level too high cooling system •Inhibitor being added too many times •Engine becomes a wet cell battery over an extended period of time Total Metals RECOMMENDATIONS PROBABLE CAUSE POTENTIAL DAMAGE Metal Borderline Concern Problem •Air leaks •Metal corrosion •Electrical ground problems •Liner Pitting •Combustion gas leaks •Corrosion or erosion of any iron •Localized over heating components •Improper coolant maintenance •Improper source water being used Conventional Coolant Components Ethylene/Propylene Glycol • Freeze Point Suppression • Boil Point Elevation Phosphate • Iron Protection • pH Control Borate • Iron Protection • pH Control Silicate • Aluminum Corrosion Protection Nitrite • Cast Iron and Steel Protection Nitrate • Aluminum and Solder Corrosion Protection Mercaptobenzothiazole (MBT) and Tolytriazole (TT) • Copper and Brass Protection Block Polymers • Defoamant • Scale and Deposit Control NOTE: Be sure to check your supplemental coolant additive and glycol levels at every oil change to ensure proper protection. Coolant should be tested immediately if there is a drop in SCA levels. Extended Life Coolant Components Ethylene Glycol • Freeze Point Suppression & Boil Point Elevation Potassium Soap of Dibasic Carboxylic Acid • Iron, Solder and Aluminum Protection Potassium Soap of Monobasic Carboxylic Acid • Aluminum and Iron (w/sebacate) Protection Nitrite • Cast Iron and Steel Protection Molybdate • Iron Corrosion Protection (w/nitrite) Tolytriazole • Copper Corrosion Protection Modified Silicone Defoamant • Defoamant NOTE: Mixing ELC formulations with a conventional coolant will degrade ELC benefits. If changing from a conventional to an ELC product, be sure to clean and flush the system thoroughly first unless conversion fluid is used. GUIDE TO COOLANT AND COOLING SYSTEM MAINTENANCE COOLANT COMPOSITION AND FUNCTION Iron 15 25 35 Copper 5 10 15 Aluminum 5 10 15 Lead 15 25 35 Zinc 15 25 35 Tin 15 25 35 SCALING POTENTIAL Total Hardness RECOMMENDATIONS PROBABLE CAUSE POTENTIAL DAMAGE (calcium and •Conventional coolant: less than 80 ppm •Improper source water •Scale formation that can be hard magnesium) •ELC coolant: less than 60 ppm •Venting problem and insulating •Have source water analyzed •Seawater contamination •Lack of heat transfer Silicon RECOMMENDATIONS PROBABLE CAUSE POTENTIAL DAMAGE (corrosion inhibitor •Depends on coolant formulation; ASTM •Improper source water •Loss of lubrication for aluminum specification is not to exceed 250 ppm •Poor coolant maintenance practices •Increased ring bearing wear protection; also found silicon in a conventional coolant for •Hot spots due to loss of heat transfer in some source heavy-duty diesel engines •Burnt valves water) •ELC coolants normally have lower levels •Automotive coolants have higher levels due to more aluminum in system Phosphate RECOMMENDATIONS PROBABLE CAUSE POTENTIAL DAMAGE (corrosion inhibitor •Should not exceed 10,000 ppm •Over treatment of SCA •Inability for the coolant to maintain for iron protection) •Over treatment of glycol the phosphate in a soluble state •Excessive phosphate in antifreeze •Heavy precipitation due to phosphate formulation falling out of solution •Plugging of radiator and oil coolers Supplemental Coolant Additives RECOMMENDATIONS PROBABLE CAUSE POTENTIAL DAMAGE Too Low •The SCA level refers to an additive •Electrical ground problem •Coolants can form sludge over an in conventional coolant •Maintenance chemicals are not extended period of time •Corrosion protection chemicals refer sufficient for metal protection •Corrosion protection chemicals to Extended Life Coolants or Extenders and to prevent sludge from forming insufficient for proper metal •Levels will vary depending on brand protection of coolant used; 1000 ppm combined of nitrite and molybdate is sufficient for proper protection Too High •Supplemental coolant additive/corrosion •Addition of chemicals excessive •Silicate and/or phosphate protection levels should be tested every for engine application can form deposits 500 hours in the field by strip or dropper •Adding inhibitor without •Can plug radiator core method and every 1000 hours or 6 months checking present level and after coolers in the lab APPLICATION RECOMMENDATIONS – DRY LAND AND MARINE •Use only water you know meets specifications, preferably distilled or deionized water. •Maintain proper levels of antifreeze (50-60%) and supplemental coolant additives. May use antifreeze if desired in older engines operating at 160˚. •Change coolants as per engine manufacturer’s specifications. •Make sure all systems are airtight and hold pressure. •Be sure electrical grounds are clean and secure; one-half volt will destroy an engine in a very short period of time. •Have coolants analyzed every 1000 hours or every 6 months, whichever comes first. Corporate Headquarters: 7898 Zionsville Rd • Indianapolis, IN 46268 • Phone: 877-808-3750 • www.polarislabs.com Products and Services • Coolant Analysis-Levels I, II & III • Failure Analysis • Field Testing Training •Cooling Systems-Maintenance Training & Consultations NOTE: Even the best coolant maintenance cannot prevent some catastrophic engine failures. COOLANT MAINTENANCE (continued) INDIANAPOLIS HOUSTON SALT LAKE CITY ACID PITTING POTENTIAL Sulfate RECOMMENDATIONS PROBABLE CAUSE POTENTIAL DAMAGE •The lower the better •Improper source water •Sulfate can build or form acid •Sulfate at 600 ppm and greater •Combustion gas leaks such as sulfuric •Sulfuric acid cleaner previously used •Combine with calcium to form scale and not properly removed from system Glycolate RECOMMENDATIONS PROBABLE CAUSE POTENTIAL DAMAGE •Less than 1000 ppm •Localized overheating •Ethylene glycol breaking down to •Correct the localized overheating •Air leak form acids such as oxalic or air leak •Coolant will be burnt and produce a foul solvent odor as well as take on a varnish characteristic •Metal pitting Chloride RECOMMENDATIONS PROBABLE CAUSE POTENTIAL DAMAGE •Less than 80 ppm •Improper source water •Extremely corrosive to engine •Correct source of chloride •Defective pressure relief valve or cap components on radiator •Decarbonizes iron •Aging coolant •Can form hydrochloric acid •Use of hydrochloric acid type cleaners •Failure to remove all the cleaner upon flushing the engine •Improper venting •Seawater leak uploads/Geographie/ coolant-guide.pdf