ddc cooling system training.pdf -...
TRANSCRIPT
![Page 1: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/1.jpg)
1
Cooling System Training
Copyright 2003 The Penray Companies, Inc.
![Page 2: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/2.jpg)
2
Understanding and Maintaining Diesel Engine
Cooling Systems
![Page 3: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/3.jpg)
Understanding Cooling System Requirements
![Page 4: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/4.jpg)
4
The Functions of Coolant
Removes excess heat from the engine.Protects the engine components from corrosion.Protects the engine from freeze damage in cold weather.Prevents wet sleeve liner cavitation in diesel engines.
![Page 5: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/5.jpg)
5
Introduction to Cooling System Problems
Corrosion family.Cylinder liner cavitation/erosion.
Component corrosion.
Radiator metal corrosion.
![Page 6: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/6.jpg)
6
Cylinder Liner Cavitation-Erosion(Liner Pitting)
This problem happens when air enters the cooling system.It is aggravated by the vibration of the liner caused by the movement of the piston.Nitrite prevents cavitation-erosion.
![Page 7: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/7.jpg)
7
Cavitation-erosion(Liner Pitting)
In untreated systems, imploding bubbles of air bore through the steel liners.
![Page 8: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/8.jpg)
8
Cavitation-erosion(Liner Pitting)
In treated systems, imploding bubbles of air are blocked by nitrite.
![Page 9: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/9.jpg)
9
Water Pump Damage
Water pumps may fail in one of two ways:Corrosion or erosion of water pump metal components (pictured).Premature wear of water pump seals from solids in the coolant. Water pump from failed
ASTM 2809 test
![Page 10: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/10.jpg)
10
Corrosion of the Block or other Engine Components
Metals susceptible to corrosion are: Aluminum, Iron, Solder, Steel, Copper, and Brass.
To protect the engine from corrosion attack, a well designed coolant inhibitor package must be used.
![Page 11: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/11.jpg)
11
Radiator Corrosion
Direct attack on radiator metals, including solder bloom.
Plugging of passages from either unstable inhibitors or corrosion products.
![Page 12: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/12.jpg)
12
Cooling System Problems(Cont.)
Scale and precipitate family.
Water pump seal failure.
Radiator plugging.
Silicate drop-out (green goo).
Scale formation on cylinder heads.
Overheating.
![Page 13: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/13.jpg)
13
Water Pump Seal Failure
Solids in poorly formulated coolants may drop out and damage seals.
![Page 14: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/14.jpg)
14
Drop-Out in Radiators
Radiator passages can become plugged by unstable inhibitors, especially phosphate and silicate.
Plugged radiators can no longer efficiently dissipate heat to the atmosphere, and the engine may overheat.
![Page 15: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/15.jpg)
15
Drop-Out (Green Goo)
Plugged radiators.
Plugged heaters cores and oil coolers.
Costly downtime and unnecessary wear on engine and cooling system.
![Page 16: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/16.jpg)
16
Cylinder Head Scale
Scale forms from chemicals found in drinking water.
This is the problem that is prevented when customers follow DDC water quality recommendations.
Scale can totally destroy an engine by causing overheating.
![Page 17: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/17.jpg)
17
Phosphate (PO4)
Iron protection/pH control.Limited solubility in water and Ethylene Glycol.Does not dissipate.Drops-out easily, especially in the presence of hard water.
![Page 18: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/18.jpg)
18
Molybdate (MoO4)
Reduces the nitrite concentration.Does not deplete in use, therefore topping off the system adds unnecessary solids. Needs oxygen to function.It is very expensive.The use of Molybdate complicates the evaluation of coolant chemistry.
![Page 19: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/19.jpg)
19
Total Dissolves Solids (TDS)
Solids Contribute To Corrosion.
Drop-Out Caused By Solids.
Minimizes The Life Of The Coolant.
Minimizes The Life Of The Water Pump.
![Page 20: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/20.jpg)
Understanding Cooling System Requirements
![Page 21: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/21.jpg)
21
Initial Fill (Factory-Fill or Replacement After
Cooling System Service)
Coolant Composition.Extended Service Antifreeze.
Fully-Formulated Conventional Technology (TMC RP-329 type A).
Non-Nitrited Organic Acid Technology (OAT).
Deionized Water.
![Page 22: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/22.jpg)
22
Extended Service Fully Formulated Technology
Nitrite
Nitrate
Silicate
Borate
MBT/TT
The formulation uses a low silicate and phosphate free technology. It is engineered to protect all of the metals and components in any cooling system. It is the foundation of a Fill-For-Life®coolant program.
![Page 23: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/23.jpg)
23
Coolant Maintenance1. Traditional Extended Service Life Program
P.M. interval:20,000 miles.3 months.Or 500 operating hours.
Test the coolant with PowerTrac test strip.
Nitrite concentration.Freeze point (glycol concentration).Molybdate.
![Page 24: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/24.jpg)
24
Coolant Maintenance1. Traditional Extended Service Life Program (continued)
Add antifreeze if the freeze point is weak, add water if the freeze point is too strong.Finally, add coolant additive (or change filter) only if the nitrite concentration is less than 1,200 ppm.
![Page 25: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/25.jpg)
25
Coolant Maintenance2. Extended Service Life Need-Release
Filter Program
With proper initial fill coolant, spin on the Need-Release filter.
![Page 26: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/26.jpg)
26
Coolant Maintenance2. Extended Service Life Need-Release Filter
Program (continued)
At oil P.M. intervals, use a PowerTrac test strip to check coolant condition.
Change the Need-Release filter at:15 months or
150,000 miles or
3,000 operating hours.
Replace coolant at 600,000 miles.
![Page 27: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/27.jpg)
Products
![Page 28: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/28.jpg)
28
POWERCOOL
Extended Service Life Cooling System Products:
POWERCOOLExtended Service Fully-Formulated Antifreeze
POWERCOOL NeedNeed--ReleaseRelease® Extended Service Life Filters
![Page 29: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/29.jpg)
29
POWERCOOL
Advanced Cooling System Products:POWERCOOL 3000
Supplemental Coolant AdditivesLiquidsSpin-On Filters
POWERCOOL 2000 Supplemental Coolant Additives
Liquids
POWERCOOL 3149Supplemental Coolant Additives for Series 149
LiquidsSpin-On Filters
![Page 30: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/30.jpg)
30
POWERCOOL
Common Features
Low in Total Dissolved Solids.
Premium Cooling System Protection.
Phosphate-free technology to optimize water pump life.
Distinctive color.
![Page 31: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/31.jpg)
31
POWERCOOL
![Page 32: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/32.jpg)
32
POWERCOOL 2000 SCA
Keeps “water only” systems running clean.
Controls metal corrosion, cavitation erosion and formation of scale deposits.
Adds minimum solids to the cooling system, optimizing the water pump life.
Available only as liquid.
![Page 33: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/33.jpg)
33
POWERCOOL 3000 SCA
Contains corrosion inhibitors and Stabil-Aid®.
Protects all metals against corrosion and cavitation.Prevents coolant gel.Prevents hot surface scale.Reduces downtime, maintenance expense and engine wear.Available in 6 sizes of spin-on filters and in 5 liquid containers.
![Page 34: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/34.jpg)
34
POWERCOOL 3149 SCA
Formulated specifically for SERIES 149 Engines.Silicate-free and phosphate-free.Available in liquid or convenient spin-on filters.
4 oz. Maintenance 2351806932 oz. Pre-charge 2351807053 oz Pre-charge 23518071
![Page 35: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/35.jpg)
35
POWERCOOLExtended Service Antifreeze/Coolant
Fully-Formulated. (Requires no SCA pre-charge)
Low silicate, non-phosphate.formula eliminates gel problems.Protects against hot surface scale formation.Excellent cylinder liner protection.Protects for the life of the engine.
![Page 36: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/36.jpg)
36
POWERCOOLExtended Service Life Need-Release®
2 Sizes:Cooling System Capacity
1-8 Gallon 235164888-20 Gallon 23516489
150,000 miles, 15 months, 3,000 hours between changes.
![Page 37: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/37.jpg)
37
POWERCOOLExtended Service Life Need-Release®
POWERCOOL Extended Service Life Antifreeze used with POWERCOOL Need-Release filters, tested regularly, can run up to 600,000 miles.Need-Release lasts 150,000 miles, 15 months, or 3,000 hours.Releases SCA as needed, maintaining proper inhibitor levels.Reduces costs.
A Single Need-Release Filter replaces up to 10 standard filters.
![Page 38: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/38.jpg)
POWERCOOL Fill-For-Life®
Extended Service LifeCoolant Maintenance Program
![Page 39: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/39.jpg)
39
Fill-For-Life® Program
Fully-formulated Extended Service POWERCOOL antifreeze / coolant. (TMC RP-329 Type A or ASTM D-6210 specification).
Extended Service Life Need-Releaseinstalled.
Change at 15 months/150,000 miles.
PowerTrac test strips.To detect road service invasion.
![Page 40: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/40.jpg)
40
SummaryUse Extended Service Life POWERCOOL antifreeze and pure water.Maintain with Extended Service Life Need-Release or POWER COOL SCAs.When coolant change is necessary, recycle with reverse osmosis, fractional distillation, or ion exchange technologies.DDC approves this coolant program in service for 600,000 miles.Lowest operating cost.
![Page 41: DDC COOLING SYSTEM TRAINING.PDF - …ddcsn-ddc.freightliner.com/.../ddcsn/DDC_Cooling_System_Training.pdf9Premium Cooling System Protection. 9Phosphate-free ... Adds minimum solids](https://reader031.vdocuments.mx/reader031/viewer/2022021820/5ad9fbb17f8b9add658bfed2/html5/thumbnails/41.jpg)
41
Thank You
Copyright 2003 The Penray Companies, Inc.