cummins coolant requirements and maintenance. july, 1995

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e Service Bulletin

Cummins Coolant Requirements and MaintenanceSubject

3666132Bulletin No.

This Service Bulletin outlines the proper application andmaintenance of coolant for Cummins anginas. The pur-pose of this Service Bulletin is to update and simplifyCummins recommendations and guidelines for the endusar.

Cummins recommends the use of fully formulated anti-freeze or coolant containing a precharge of SupplementalCoolant Additives (SCA). The use of fully formulated an-tifreeze significantly simplifies cooling system mainte-nance. Antifreeze or coolant meeting The MaintenanceCouncil (TMC) Recommended Practica (RP) 329, "FleetPurchasing Specification for Nitrite Containing EthyleneGlycol Base Coolant", or TMC RP 330 "Fleet PurchasingSpecification for Nitrite Containing Propylene Glycol BaseCoolant"(which contain a precharge of SCA} form the ba-gis for these recommendations. Refer to Attachment 4,TMC Specification Summary, for more information con-cerning these antifreezes.

Summary of Recommendations

Cummins cooling system recommendations are listed be-low. Refer to Section 3 for complete instructions.

e FiIIup andtop off andtopoffcoolingsystemswitha fully formulated antifreeze or coolant meetingTMC RP 329 or RP 330 specifications.

e Replace the coolantfilter(s} at every oil changa.SCA in the filler must meetTMC RP 328standards.

e Testcoolantat leasttwice annually.e Replacecoolantevery2years,386,200km[240,000miles], or 6,000 hours.

Definition Of TermsASTM: American Society of Testing and MaterialsDCA: Diesel Coolant AdditiveEG: Glycol1: jitarMo04: MolybdatesNo.: NumberNO2: NitritesPG: ProplyeneRP: Recommended PracticaSCA: Supplement Coolant AdditivesTMC: The Maintenance CouncilTDS Total Dissolved Solids

I Date: July, 1995

'The following sections and attachments are ¡ncluded inthis Service Bulletin:

Section Title

Introduction1

2 Topping off and Dilution o{ Cooling Stems .

Recommended Maintenance Practicasfor Cooling Systems

3

4 Alternative Maintenance Practicas forCooling System

Unacceptable Maintenance Practicasfor Cooling Systems

5

6

7

Coolant Testing

Antifreeze

8

9

Maintenance Records

Cooling System Cleaners

1

2

Attachments

DCA4VersusDCA(Fleetcool)

SCA Application Charts3

4

Water Ouality Table

TMC Specification Summary

5

6

Monitor C Sample Report

Properties of Various Coolant Mixtures

7 EG Versus PG for Environmental Sociability

Cummlns Englne Company, Ine., Columbus, Indiana 47202-3005Cummlns Englne Company Ud., Daventry, Northants, England NN11 5NURegistered Offiee: 46-50 Coombe Road. New Malden. Surrey KT3 4QLRegistered No. 573951 EnglandCopyright @ 1995Cummins Engine Company, Ine.Al! rights reservad

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Cummins'Coolant Requirements and Maintenance

SECTION 1- INTRODUCTIONCummins coolant recommendations haya evolved ovartime to reflect changas in diesel angina technology, en-vironmental regulations, coolanttechnology and customerneeds. The need for simplification,coupled withthe avail-abilityofcommercial standards, has ledCummins to adoptnew recommendations using fullyformulated producís.

In arder to simplifyCummins coolant recommendationspublished in1992(CumminsService BulletinNo.3387910),new guidelines haya been established around the use of fullyformulated producís meeting TMC RP 329 and RP330. These fullyformulated antifreezes and coolants con-tain balanced amounts of antifreeze, SCAs,and bufferingcompounds but do not haya to contain 50 percent waterto comply with the new standards. Therefore, soma fullyformulated producís are labeled with the words Concen-trate or Antifreeze when water is not included. Other fullyformulated producís are labeled withthe words PÍ'emixorCoolant when the antifreeze is already premixed SO/50with deionized water.

Cummins previous guidelines permitted the use of fullyformulated antifreezes and coolants (such as FleetguardCompleatlMantifreeze) but primarilyaddressed the use of partially formulated producís referred to as heavy dutycoolants. The requirements involvedthe use of lowsilicatetype antifreezes (meeting ASTM D4985 or GM 6038M),which contained buffering compounds, but were not re-quired to contain SCAs or water. A mixing process wasrequired to add the necessary SCAs.This mixing processprovided opportunity for human error which often resultadin liner or block pitting from under-concentration duringinitial fill or SCA dilution during top off of the coolingsystem.

The use of fullyformulated antifreezes forms the basis forCummins new recommendations. The use of partiallyfor-mulated (heavy duty) antifreezes is an acceptable alter-nativa practica but is not preferred. Fullyformulated an-ifreezes significantlyreduce the opportunity forerror andhe need forSCAtracking since the SCAis premixed intheantifreeze.

Fully formulated antifreezes are ideally suited for toppingoff cooling systems but do not eliminate the need for SCAreplenishment during routine oil changas. Routine replen-shment has always been required to offset normal deple-ion processes. However,Cummins recommended replen-shment ratas haya been aimed at providinggradual SCA

growth.The gradual growthofSCAlevelsis desirable untilevels exceed 0.8 units par jitar [3.0 units par U.S. gallon].

Until such time, Cummins recommends the routine re-plenishment of depleted SCAs.

Over-concentrations of SCAs can be avoided by occa-ional test kit monitoring. However,the use of test kits to

maintaio a SCAconcentration near the minimum side ofhe acceptable ranga, 0.3 units par jitar [1.2 units par U.S.

gallon], has never been acceptable nor recommended.This practica alone is responsible for many pitting failures.

SECTION 2 - TOPPING OFFAND DIWTION OF COOL-ING SYSTEMS

Coolant loss leads to SCAdilution because of incorrect topoff practicas. This is the root cause of most liner pittingproblems. The top off process is simplified by the use offully formulated antifreezes or coolants because SCAs arealready included in the mix. Hoses, clamps, radiator caras,cylinder head gaskets, water pumps, etc., can be subjectto coolant loss ovar time. By using fully formulated prod-ucts during the coolant top off process, SCA dilution isavoided regardless of the degree of coolant loss.

SECTION 3 - RECOMMENDED MAINTENANCE PRAC-TICES FOR COOLING SYSTEMS

The following steps are required to comply with Cumminsrecommendations for initial filling and maintenance of cool-ing systems.

. FiII the cooling system with fully formulated coolantor with a SO/50 mixtura of good quality water* and

fully formulated antifreeze.The fully formulatedcool-ant or antifreeze must meet TMC RP 329 (ethyleneglycol) or RP 330 (propylene glycol). FleetguardCompleatlMcontaining DCA4 is the preferred prod-uct. It is available in both glycol forms and complieswith TMC standards.

. Top off the cooling system between filter changasby using TMC RP 329 or RP 330 fully formulatedcoolant.

. Replenish depleted SCAs at every oil changa byreplacing the coolant filter(s) with the correct filtersor liquid SCA. Refer to Attachment 2, SCA Appli-cation Charts, for filter sizes and part numbers. Verylarga cooling systems can require additionalliquidSCA if conventional coolant filters do not providesufficient SCA replenishment according to the chartprovided in Attachment 2 SCA must meet TMC 328requirements. Cummins preferred product isFleetguardlM DCA4.

. Test the coolant at least twice ayear for fre'ezeprotection and SCAlevels. Refractometer measure-ments are needed for accurate freeze protectionmeasurements. Teststrips will provide an indicationof SCA levels. Refer to Section 6, Coolant Testing,for further information.

. Drain and replace the coolant every 2 years,385,200 km [240,000 miles] or 6,000 hours of op-eration, whichever comes first. Disposal must bedone inaccordance with local, state,-orfederallaw.

* NOTE: Good quality water meets all of the followingspecifications:

Less than 40 PPM chloride

Less than 100 PPM sulfate

Less than 170 PPM Calcium/Magnesium (hardness)

Preferred water is deionized, distilled, or demineralized.



'-/ SECTION 4 - ALTERNATIVE MAINTENANCE PRAC-TICES FOR COOLING SYSTEMS

The following practicas are not preferred but are accept-able and will provide sufficient cooling system protectionand performance when correctly and consistently applied.These practicas utilizapartially formulated antifreezes (alsoknown as heavy duty antifreezes) and follow the guidelinespublished in 1992 in Service Bulletin No. 3387910.

. Follow the sama steps outlined in Section 3 andmanually precharge the coolant with SCAs. Par-tially formulated antifreeze must be manuallyprecharged with SCA.This applies to low silicateantifreeze producís that meet ASTM D4985 andGM 6038M. Producís meeting these standards donot contain SCAs.

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Precharge Instructions:Mix good quality water and low silicate antifreeze SO/50ina container. Add SCA in sufficient units* to achieve aminimum of 0.3 units par jitar [1.2 units par U.S. gallon].Stir the solution thoroughly mixing the contents.

* Use the following formula to calculate the required SCAunits:

Multiply the cooling system volume by 0.3 units par jitar[1.2 units par U.S. gallon].

Example: 75 liters [20 gallons] X 0.33 liters par gallon [1.2units par U.S. gallon] = 24 units

NOTE:Although not recommended, coolant mixtures con-taining less than 40 percent antifreeze can be usad. SCAlevels must be increased by an additional 0.26 unit par jitar [1 unit par U.S. gallon] to provide adequate pittingprotection. Therefore, the new precharge concentrationmust be a minimum of 0.56 unit par jitar [2.2 units par U.S.

gallon] to meet these requirements. The SCAunits neededto achieve this precharge level can be calculated by sub-stituting the new minimum of 0.56 unit par jitar [2.2 unitspar U.S. gallon] into the formula shown in the above ex-ample. The acceptable upper limit for this coolant com-bination is 1.06 units par jitar [4.0 units par gallon]. SCAconcentration ovar this level is not acceptable. For moreinformation retar toWater/Supplemental Coolant AdditivesMaintenance (No/Low Antifreeze Concentration, ServiceBulletin No. 3666101).

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SECTION5- UNACCEPTABLE MAINTENANCE PRAC-TICES FOR COOLING SYSTEMS

AII diesel anginas with wet liners are subject to liner pittingif the cooling system is not correctly maintained. Underconcentration (below 0.3 unit par jitar [1.2 units par U.S.gallon]) of SCAs results in liner cavitation and possibleangina failure. Ovar concentration (above0.8 units par jitar[3.0 units par U.S. gallon or]) of SCAs or the use of highsilicate antifreeze results in gelation or water pump sealleakage.The following practicas areconsiderad unaccept-able and can lead to angina failure:

Unacceptable Practicas. use of high silicate antifreeze. under or ovar concentration of SCAs

Cummins Coolant Requirements and MaintenancePa

. use of sealing additives (stop-Ieak) in the coolingsystem

. use of soluble oils in the cooling system

. use of test kit for maintaining mínimum concentrations of SCA

. filling or topping off cooling systems with low cate antifreeze but without proper SCAs

. use of peor quality water

. use of antifreeze or SCA formulations that do nomeet the specifications indicated in Sectíon 3 oSection 4 of this Service Bulletin

SECTION 6 - COOLANT TESTING

Coolant testing is recommended at least every 6 months.It is also recommended when:

. Coolant loss between service inter:valsexceeds 20percent of system capacity ,

. Water pump seal leakage is apparent

. Anytime the coolant condition is unknown or corosion is apparent within the cooling system

Coolant testing and monitoring are useful tools for trackingand controlling coolant conditíon and performance. The

two methods available for testing coolants include fieldtest kits and portable refractometers and coolant analysisprograms. Cummins recommends FleetguardTMCC26023-WayTMtest kit and CC2800 refractometer for en-sita test-ing, and the FleetguardTMCC2700 Monitor C program folaboratory testing. The CC2602 field test kit is appropriatefor testing nitrite-molybdate formulations such aFleetguardTMDCA4, as well as nitrite formulations such asFleetguardTMDCA (Fleetcool). The CC2700 Monitor C program can evaluate most newor usad coolant formulations.Field test kits offer the benefit of en-sita measurementsand are designad to approximate SCA levels. Soma testkits also incorporate freezepoint protection measurements.

FleetguardTMCC2602 test strips contain a test patch formeasuring this parameter. When required, freeze pointcan be more accurately determinad with en-sitrefractometer readings, such as FleetguardTMPart No.CC2800.

When using FleetguardTMCC2602 test kit, it is important tofollow the simple instructions provided in the kit. Coolamust be collected from the radiator or block drain bnevar from the surge tank or coolant recovery bottle. Eachtest strip contained in the kit has three test patches andcan be dipped directly into the coolant. No other chemicadilution is required. Each test patch has a specific functic". One test patch measures Nitrites (NO2), anothemeasures Molybdates (MoO4), and another measuresfreeze point protection. Because the kit measures nitritesand molybdates separately, it can reliably measure bothFleetguardTMSCA formulations. DCA (Fleetcool) utilizaNitrites while DCA4 utilizas a Nitrite-Molybdate formution. Cummins preference for a Nitrite-Molybdate formlatían for pitting protection is explained in Attachment

Coolant analysis programs are performed in laboratoriesand offer additional useful information, but require mailincoolant samples to a laboratory.Laboratory measurementstypically include:

. pH level



Cummins Coolant Requirements and Maintenance

. SCA level

. freeze protection

. buffer level

. dissolved solids

. silicate level

. metal corrosion products

Correct interpretation of laboratory data can provide ad-ditional guidance in coolant treatment effectiveness andearly warning detection. Interpretation and further treat-ment action(s) are generally provided with laboratory re-sults. Therefore, laboratory testing is typically very costeffective long term when usad to optimize cooling systemperformance and lita. However, it is not cost effectivewhen usad as a method for minimizing treatment.

Refer to Attachment 5 for a Sample Monitor C reportoSECTION 7 - ANTIFREEZE

The primary purpose of antifreeze is to lower the freeze

point of the coolant. Additional performance characteris-ics of coolants that are affected by the use of antifreezeinclude boiling point and vapor pressure. Antifreeze de-creases vapor pressure which is very beneficial to thereduction of cavitation. This characteristic is the primarybasis for Cummins requirements for increased SCA levelswhen antifreeze falls below 40 percent by volume.

A 50/50 mixtura of antifreeze and water provides optimumboiling point and freeze point protection for anginas. An-tifreeze concentrations in excessof 60 percent must neverbe usad since it increases the possibility offorming coolingsystem gel which results as silicates precipitate out ofsolution. However,concentration of antifreeze less than 40percent increases the possibility of coolant freezing andliner pitting. Therefore, Cummins recommends an anti-freeze ranga of 40 percent to 60 percent.

Fluids presently usad in antifreezes are ethylene glycol(EG) and propylene glycol (PG). Diesel angina antifreezeshaya primarily usad EG products because they are lessexpensive than PG products. Soma antifreeze applica-tions require less toxic substances which haya driven theuse of PG. Engine relatad applications of PG primarilyhaya been applications where environmental concernshayadisallowed the use ofthe more common EG products.

The comparativa properties are similar for EG and PG and

are listadoA 50/50 mixtura with water at 100°C [212OF]isassumed in the following data. Properties of purawater areshown for comparison.

Fleetguard CompleatTMproducts are available in EG andPG forms. Both forms are available with and withoutpremixed, deionized water. Products without water arereferred to as Concentrate. Products with water are re-ferred to as Premix. FleetguardTMpart numbers are listedbelow.

GallonsDrumsBulk

Compleat EGConcentrate Premix

CC2701 CC2801CC2755 CC2855CC2799 CC2899

Compleat PGConcentrate Premix

CC2711 CC2710CC2795 CC2796CC2895 CC2896

SECTION 8 - MAINTENANCE RECORDS

Good maintenance records are important. Maintenanceprograms must be accompanied by accurate record keep-ing practicas. Records must be capable of supplying in-formation required te:

. Support diagnostic and troubleshooting proceduresinvolving the cooling system

. Support the investigation of potentially warrantablefailures

. Forecast repairs leading to the prevention of fail-ures

Routine cooling system maintenance records must in-elude the following information:

. SCA level when measured

. Accumulated vehicle or coolant hours

. Freeze point or antifreeze concentration as a per-cent of coolant volume

. Coolant top off quantity .

. Laboratory analysis readings where available

. Date of service and actions taken during service

EG/H:>O PG/H:>O H:>OVaporPressure(mmHg) 633 678 758Density (g/cm3) 1.03 0.98 0.96Viscosity (cp) 0.65 0.70 0.29Surface Tension (dyne/cm) 47 36 59Specific Heat (cal/g°G) 0.87 0.92 1.01Thermal Conductivity (cal- 0.00099 0.00091 0.001cm/sec-cm2_K)Freeze Point (OF) Sea Attachment 6 32Boiling Point (°F) Sea Attachment 6 212



SECTION 9 - COOLlNG SYSTEM CLEANERS

Routine cleaning of cooling systems is not recommended.However,inadequate maintenance practicas, incorrect useof coolant producís, or an angina component failure suchas an oil cooler element can lead to problems that requirecleaning. Cummins recommends the use of cleaning prod-ucts when one or more of the conditions are present asindicated in the matrix below.

Correct selection of a cooling systemcleaner is important.Alkaline-type cleaners are best suited for silicate gelation.Acid-type cleaners work better on rust and scale. Soldarbloom can be cleaned with both cleaners.

Cummins recommends the use of Fleetguard RestoreTMorRestore PIUSTMwhen cleaning is necessary. RestoreTMis ahigh quality alkaline basad cleaner while Restore PIUSTM isan acid basad cleaner.

Cooling systems must be carefully cleaned when any ofthe above conditions are apparent. It is very important tocompletely and thoroughly flush the cooling systems ofchemical cleaners at the conclusion of the cleaning pro-cess. This must be done with water and will require morethan one flushing to purga the cooling system ofthe clean-ing chemicals. Failureto sufficiently purga cleaning chemi-cals can result in antifreeze contamination during the refillprocess which can lead to angina failure.

The use of other producís containing hydrochloric acid,oxalic acid, or sulfamic acid will not result in equivalentcleanup results and will be more aggressive at chemicallyattacking cooling system mataríais. However, regardlessof the cleaner selected, prolongad use (greater than 3hours) is not recommended.

Cummins Coolant Requirements and MaintenancePaga

Problem Fleetguard Re- Fleetguard Re-storeTM(Alkaline) store PlusTM(Acid)

Silicate gel Excellent PeorRust Peor GoodScale Fair ExcellentOil and Good ExcellentGreaseSoldar Bloom Good Good



Cummins Coolant Requirements and MaintenancePaga 6

ATTACHMENT1 - DCA4VERSUS DCA(FLEETCOOL)

What is different about DCA4 chemistry?

DCA4has a phosphate, molybdate, and nitritebase alongwith other effective chemical additives, to protect coolingsystem components. Mostother SCAchemistries, includ-ing DCA(Fleetcool), have a barata and nitrite base withmore silicate. Although the pitting protection characteris-

tics of DCA4are equivalent to DCA, DCA4offers somaother important benefits worth understanding.

What are the benefits of DCA4Versus DCA(Fleetcool)?

. Water pump seals are more tolerant of overconcentration of DCA4

. DCA4 is more tolerant of hard water conditions

. DCA4 is com patible with Dowtherm 209TMantifreeze

. DCA4 is less likelyto form gel since the formula hasless silicate

. DCA4 controls soldar bloom better

. DCA4protects against the corrosion of aluminumwithout using high amounts of silicate

. DCA4contains surfactant additives whichsuppressoil fouling that willotherwise lead to SCA interfer-enea and cause corrosion

WiII DCA4 provide adequate liner and block pittingprotection?

Ves,provided Cummins installation recommendations aremel. Cummins considers the pitting protection perfor-mance of DCA4equivalent to DCA(Fleetcool). Protectionfrom pitting damage using any SCA formula depends on

correct treatment practicas. Correct filling,SCA replen-ishment, top off,drain, and refillpracticas are required for

any SCA formula.

How do SCAs protect liners and blocks from pittingdamage?

SCAs work by becoming a sacrificial coating after adhering to freshly exposed liner and block surfaces that aresubjected to cavitation. Cavitation is the driving force re-sponsible for pitting damage. It is causad by the formation

and collapse of vapor bubbles created during liner move-maní following combustion. Vapor bubbles are formad anytime the localizad pressure of the coolant drops below thevapor pressure of the coolanl. Vapor pressure is a physicalcharacteristic of the coolant that is primarily controlled bythe antifreeze to water ratio and coolant temperatura. Thelocalizad pressure is a function of many factors includingangina design, load factor, piston slap, angina timing, andcooling system pressure.

If the pitting protection performance of DCA4 and DCAare equivalent, then why is DCA4 a preferred chemis-try? -

It is preferred because of the added benefits describedabove and because the SCA package of DCA4 contafewer dissolved solids to accomplish equivalent perfor-mance. DCA4 depends upon the combinad effect of ni-trites and molybdates where DCAdepends solely upon effect of nitrites. The presence of molybdates enhancesthe protective qualities of nitrites. However, molybdatesalonewill not provide adequate protection. Therefore, labo-ratory test results and test kit charts are specifically de-signed to warn of insufficient nitrite levels by indicating lowSCA levels. On the other hand, the absence of molybdateswill not trigger warnings if nitrite levels are sufficient toprovide pitting protection. That is why the CC2602 test kitworks well with both DCA and DCA4.



Cummins Coolant Requirements and MaintenancePage

ATTACHMENT 2 - SCA APPLICATION CHARTS

J Part No.WF2CflOWF2Cfl1WF2Cfl2WF2Cfl3WF2Cfl4WF2Cfl5WF2Cfl6WF2077

DCA4 Serviee Filters:SCA Units

2468121523

(blank filter without SCAs)

DCA (Fleetcool) Servlee Filters:Part No. SCA UnitsWF2050 2WF2051 4WF2052 6WF2053 8

Not Available 12WF2054 15WF2055 23

WF2Cfl7 (blank filter without SCAs)

DCA4 Liquid DCA (Fleeteool) LiquidPart No. Size SCA Part No. Size SCA Units

Units

DCA60L 0.47 1[1 U.S. pt) 5 DCA30L 0.47 I [1 U.S. pt) 5DCA65L 1.891 [2 U.S. qt.) 20 DCA35L 1.891 [2 U.S. qt.) 20DCA70L 3.78 I [1 U.S. gal) 40 DCA40L 3.78 I [1 U.S. gal) 40DCA75L 18.9 I [5 U.S. gal) 200 DCA45L 18.9 I [5 U.S. gal) 200DCA80L 2081 [55 U.S. gal) 2200 DCA50L 208 1[55 U.S. gal) 2200

MaintenaneeIntervals for Cooling Systemsup to 76 Liters [20 U.S. Gallons]Installservicefilter(s) and/or liquidcontainingnumberof SCAunitsbelow:

Service Interval SystemSizein Liters[U.S.Gallons)' Kilometers [Miles) [Hours) 4-19 19-38 42-57 60-76

[1-5) [6-10) [11-15) [16-20]72001-80000 [45001-50000] 1126-1250 8 12 23 3064001-72000 [40001-45000) 1001-1125 4 12 15 26

56001-64000 [35001-40000) 876-1000 4 8 12 2348001-56000 (30001-35000] 751-875 4 6 12 2040001-48000 [25001-30000) 626-750 4 6 10 1832001-40000 (20001-25000) 501-625 2 6 8 1524001-32000 [15001-20000] 376-500 2 4 6 1216001-24000 (10001-15000) 251-375 2 4 6 8

0-16000 [0-10000) 0-250 2 2 4 6

Maintenanee Intervals for Cooling System up to 1514 Liters [400 U.S. Gallons]Install service filter(s) and/or liquid containing number of SCA units below:

Service System Size in Liters (U.S. Gallons)Interval 79-144 117-189 193-284 288-378 382-568 572-757 761-946 950-1135 1139-1325 1329-1574Hours (21-30) (31-50] (51-75] (76-100] (101-150) (151-200] (201-250) (251-300) [301-350) (351-400]

751-1000 25 50 80 100 150 200 250 300 350 400501-750 20 35 60 75 110 150 190 225 260 300251-500 15 25 40 50 75 100 125 150 175 200

0-250 10 15 20 25 40 50 65 75 90 100




ATTACHMENT 3 - WATER QUALlTY TABLE

Cooling systems perform best with distilled or deionizedwater. If distilled or deionized water can not be usad, thequality of water must meet all the requirements listedbelow. Excessive levels of calcium and magnesium con-tribute to scaling problems, and excessive levels of chlo-ridesandsulfates causecoolingsystemcorrosion.Ifwaterquality is unknown,it canbe testadby FleetguardTM Moni-

torC program.Testdata must showthetollowingelementsand the levels must not exceed the pubJishedlimits toruse in coolingsystems:

Maximum Levels Of:Calcium, Magnesium (hardness) 170 PPM (as

CaC03)40 PPM (as CI)100 PPM (as S04)

ChlorideSultur (Sultates)

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ATTACHMENT 4 - TMC SPECIFICATION SUMMARY

There are three separata specitications:

1. Supplemental CooJantAdditives: RP 328 "Fleet Pur-chasing Specitication tor Nitrite-Containing Supple-mental Coolant Additives"

2. Precharged Ethylene Glycol Antifreeze: RP 329 "FleetPurchasing Specitication tor Nitrite-Containing

Ethylene Glycol Based Coolant"3. Precharged Propylene GlycoJ Antitreeze: RP 330

"Fleet Purchasing Specitiction tor Nitrite-ContainingPropylene Glycol Based Coolant"

Copies ot these specitications can be obtained by pur-chasing trom:

The Maintenance CouncilAmerican Trucking Association2200 Mili RoadAlexandria, VA 22314-5388 USAPhone: (703) 833-1763

Fax: (703) 836-6070NOTE: RP 329 and RP 330 antifreezes are low silicate andalso contain a precharge of SCA to provide liner pittingprotection and scale inhibition. However, low silicate an-titreezes meeting ASTM 04985 or GM 6038M do not con-trolliner cavitation and scale tormation due to the absenceof SCAs.



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Cummins Coolant Requirements and MaintenancePag

ATTACHMENT5 - MONITOR C SAMPLE REPORT

Monitor 'C' Coolant AnalysisCC2700

Fleetgu8nr

.MONITOR"C

Fleetguard, Inc.Service Engineering

P.o. Box 6001Cookeville, Tennessee 38502

(615) 526-95511-800-22-FIL TER(1-800-223-4583)

COOLANT ANAL YSIS

Customer:Address:

Acct#:Phone:

Unit # 34729921-1 D Fluid Type: EG Coolant (A/F Water SCA) Engine:

Date Sampled:Dated Tested:Miles on Unit:Miles/Hrs. on Coolant:Lab Sample Number:pH:% Glycol:Freeze Point F:TDS (%)Liner Pitting- SCA (Units par Gallon):- Nitrite (NaN02):- Molybdate (NaMo04):Corrosion Producís- Iron:-Aluminum- Copper:- Lead:Silicate (Na2Si03):Buffers- Phosphate (K2HPO4):- Borate (Na2B407):Water Quality- Hardness:-Chloride:- Sulfate:

NOTE: Chemical analysis results are PPM except where notad.

12/05/941/18/95

9170609.835*-2*

.6

2.51536

990

oOOO

880

12800480

O

!! MONITOR C TESTS ARE NOT SUFFICIENT TO EVALUATECOOLANT RECYCLlNG PROCESSES !!

RECOMMENDATIONS:

GLYCOL CONCENTRATION IS OUT OF RECOMMENDED RANGE FOR COOLANT USE (40-60 percent). REFERTO BACK OF REPORT AND REVIEW MAINTENANCE PRACTICES.

I have personally reviewed the data and recommendations for your sample.

Diagnostician Date




Explanation of Coolant Analysis With Maintenance Recommendations

Engine cooling systems must be filled and topped off with fully formulated heavy duty precharged antifreeze mixedwith quality water (see below). Precharged antifreeze is defined as follows:

1. Fully formulated antifreeze meeting TMC RP 329 or RP 330 specifications (preferred). Call FleetguardTMfor moreinformation.

2. Heavy duty (Iowsilicate) antifreeze meeting GM6038M or ASTM D4985specifications (acceptable) and prechargedwith SCA.

SCA: At initial fill, top off, and coolant changa-out, angina coolant should have a Minimum Precharge of 1.5 unitspar gallon [0.4 units par liter] using Supplemental Coolant Additives (SCA) meeting TMC RP 328 specifications. Useof fully formulated coolants meeting TMC specifications and a correct sized service filter will result in a precharge ofthe required minimum 1.5 units par gallon [0.4 units par liter].Failure to precharge and maintain SCA level willresult in cylinder liner pitting. For additional information, call FleetguardTMService Engineering and TechnicalAssistance Group at the number listed on the front paga.

Tested SCA Levels: 1.2 to 3.0 units par gallon [0.3 to 0.8 units par jitar]; continua to install a service filter containingthe appropriate dosage of SCA or equivalent liquid SCA dosage at each angina oil drain interval. Below 1.2'units pargallon [0.3 units par liter] ; precharge coolant using liquid SCA doga of 1.5 units par gallon [0.4 units par liters] andinstall service filter. Five fluid ounces (U.S.) of FleetguardTMDCA4 or Fleetcoolliquid equals 1.5 units par gallon [0.4units par jitar]. Above 3.0 units par gallon [0.8 units par liter]; do not install service filter or liquid doga. Testthe SCAlevel using FleetguardTMCC2602 or CC2602M (metric) test kit at each successive oil changa. When SCA units dropbelow 3.0 units par gallon [0.8 units par liter], resume changing the service filter or using the equivalent liquid SCAdosage.

Glycol: Engine manufacturers recommend coolants composed of 50/50 water/glycol solutions providing enhancedfreeze and boíl protection. An operating ranga of 40% to 60% antifreeze (glycol) is acceptable. Useof glycol percentagesexceeding 65% may cause SCA drop-out, water pump seal leakage, and angina overheating.

Water Quality: Major angina manufacturers recommend the following coolant make-up water specifications:

Hardness, less than 170 ppm Chlorides, less than 40 ppm Sulfates, less than 100 ppm

Water exceeding anyof the above specifications should not be usad. Usedistilled water, deionized water,or equivalent.Hardness is best determinad through testing of make-up water not usad coolants.

pH: Coolant pH values have a *normal ranga of 8.5 to 10.5when precharged with nitrite or nitrite-molybdate SCA. IfpH falls below 8.0, rapid nitrite depletion can resulto This will be shown as low SCA units. Continuad additions ofSCA into low pH coolant will have little effect on SCA units par gallon. When pH is less than 8.0, coolant should be

drained and flushed. Coolant pH exceeding 11.5 will cerrada aluminum and promete scaling. Drain and flush isrecommended. If no serious problems are encountered, flushing can be accomplished with tap water.Corrosion, scale,or gelation problems require use of chemical flushing agents. * (exceptions to this are coolants with benzoate orsebasate SCA with pH below 8.0)

TDS: Total Dissolved Solids (TDS) are composed of the basic inhibitor chemicals, silicates, active SCAs, spent SCAs,contaminants, and water hardness compounds. Gradual build up of TDS will be tolerated by water pump seals untila 5% level is achieved. If water pump seal leakage occurs, coolant should be drained and flushed with tap water.

Silicates: Silicates protect several metals in the cooling systems. Automotive antifreeze typically contains largaamounts of silicate. Use of automotive antifreeze and SCAleads to additive dropout which causes plugging of radiators,heaters, and restricts angina coolant passages. Sudden introduction of larga amounts of silicate through additions ofautomotive antifreeze or larga doses of nitrite-borate SCA (high silicates) may cause rapid failure of water pump seals.Reports of low silicates and low water hardness in usad coolants can be misleading. 80th silicates and hardnesscompounds will precipitate out in the presence of each other.Foran accurate evaluation of silicate levels, newantifreeze

must be testad.Buffering Agents: The function of phosphate and barata buffers is to counter acid formation. Acids are the productof thermal degradation of antifreeze. Without adequate buffers, corrosion and rapid additive depletion will occur dueto reduction in pH values. The result will be cylinder liner pitting.

Corrosion Producís: Typical sources for corrosion producís are:. IRON-liners, water pump, cylinder block, cylinder head. ALUMINUM-radiator tanks, coolant elbows, piping, spacer platas, thermostat housings. COPPER-radiator, oil cooler, aftercooler, heater cara. LEAD-solder found in radiator, oil cooler, aftercooler, heater cara

Caution: Coolants, cleaning and flushing chemicals containing 5 ppm or more lead are considerad ha~ardousaccording to federal law. Disposal must be done in accordance with local, state, or federallaw.

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Cummins Coolant Requirements and MaintPag

ATTACHMENT 6 - PROPERTIES OF VARIOUS COOLANT MIXTURES (Glycol Mixtures)

u:-~260e"O~en.515240ID

o

-10O--- -20..e"O-30~g' -40ÑCII-50f IL

-60

Boiling Points 01 Aqueous Glycols

14 PSI PRESSURE

280

PropyleneGlycol

22030 50 60

% Glycol In Water40 70

Freezing Point 01Aqueous Glycols(ASTM D-1177)

-70O

" / , , --------40 60

% Glycol In Water

8020

80

+32

+14

-4 ~E

-22i5D.

-40g'Ñ

-58eIL-76

-94100

0880002




ATTACHMENT 7 - EG VERSUS PG FOR ENVIRONMENTAL SOCIABILITV

Regulatory ComparisonHazardous Air PollutantMACTSuperfund Spill ReportingStorm Discharge ControlsOSHA Workplace Expo-sure StandardsEmployee Exposure Moni-toringHazardous Communica-tion Notification Require-maní

If usad coolant contains ovar 5 ppm of lead or ovar 0.5 ppm of benzene, EPA hazardous waste criteria apply if eitherEGor PG is usad. ~

EG/H2OVesVesVesVesVes

PG/H?ONoNoNoNoNo

Ves No

Ves No

Toxicity I Safety Performance EG PG

Number of human deaths by poisoning (US statistics from 1989t01992)

34 No known deaths

Human poisonings without death (US statistics for 1991) 3,209 None reportad

Percent of poisoned animals that died as a result of poisoning. (dogs and cats)

50% 0% (Often usadup to 10% in dogfood)

Affect on poultry Common toxicant Often usad asdietary supple-maní

cummins coolant requirements and maintenance. july, 1995

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