LI33020-GB.pdf

7/29/2019 LI33020-GB.pdf

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Protection

of cooling systems

for heavy-duty engines

Keep it coolIf you’d like to know more about coolants or any other

Fleetguard product or technology please contact your local

Fleetguard Distributor or Fleetguard Customer Assistance.

Belgium (32) 15 28 93 11

France (33) 298 76 49 49

U.K. (44) 1455 542 222

S ou th Af ri ca ( 27 ) 3 3 3 55 581 5

Visit as well our w ebsite

http://www.fleetguard.com

The Filtration Technology Leader The Filtration Technology Leader

C o o l i n g Sy s t e m P r o d u c t s

© F

l e e t g u a r d 1 9 9 9

L I 3 3 0 2 0 G B

Your Fleetguard distributor

7/29/2019 LI33020-GB.pdf


Cooling is vitalIf not pro perly cooled the temperature of a

heavy-duty diesel engine during operation can

rise up to 2,000°C, which would easily be

enough to melt the engine if it wasn’t properly

cooled.

The heat must be dissipated or the engine can’t

operate at its maximum potential.

(Only one third o f the 2,000°C is in fact

converted into mechanical energy.)

This clearly shows that correct coolant

maintenance is the key to r educing operating

costs, minimising engine downtime and

ensuring better reliability and durability from

engines and cooling systems alike.

Over a 24 hour period,

about 720,000 litres of cooling

fluid circulate round an

average heavy-duty engine.

That’s enough to fill a huge

swimming pool.

Long live the machineEvery fleet owner know s

how important r egular

service intervals are for an

engine. Ho wever, at theseservices, attention is mainly

paid to air, lube and fuel

filtration.

The regular and proper

maintenance of an engine’s

cooling system is usually

considered to be of minor

importance. This however,

can be an extremely costly

mistake.

Research has shown that

40% o f all engine problems

in heavy-duty diesel engines

are directly or indirectlyrelated to improper cooling

system maintenance.

This figure is a very clear

indication that regular

cooling system maintenance

is vital.

7/29/2019 LI33020-GB.pdf


More and more engine manufacturers are using

aluminium to reduce weight in cooling systems.

But you have to pay th e price for weight reduction,

because aluminium is the most sensitive material in the

system and corrosion is its biggest prob lem.

N ot many people are aware of it, but corrosion is not

a question of age, it can start to attack an engine as

early in its working life as 2,000 hours or 400,000 km.

s oxygen in the cooling system reacts

with metal parts in the engine = oxidation rust

s water pumps, radiators, thermostats

and manifolds are affected

s radiators get blocked,

s engine overheats = r epair costs, downtime

s leaks appear

“Some com panies probably

know a lot abou t chemicals,

while others know a lot

about engines.Fleetguard kno ws all

about both.”

Fleetguard has developed coolant additives that have

different inhibitors which create a protective layer on all the

metal parts in the cooling system. Fleetguard’s major advan-

tage is the combination of chemical research and the close

co-operation with its holding company, a major diesel

engine manufacturer: Cummins.

If you use appropriate DC A* or ES (longlife) liquid from

the very start of an engine’s life, you can prevent oxidation.

If you start to use DC A at a later stage, you can at least stop

the corrosion from getting any worse.

*DCA = Diesel Chemical Additive

“We use Fleetguard DCA4

cooling additive for all the

cooling systems in the engines

we maintain, and

we haven’t had any engine

breakdowns due to cooling

system failures for at least

5 years now. That DCA really

pays off”.

Corrosion has nothing to do w ith age

Protective layer created by

Fleetguard’s DCA prevents

the aluminium from corroding.

Corrosion affects all metal parts,

especially the aluminium ones.

Tiny metal particles begin

to circulate in the cooling circuit,

causing damage

to any mechanical part.

Aluminium corrosion

T o p p e r f o r m a n c e i n h a r s h c o n d i t i o n s

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Cavitation or liner pitting

The pistons in your engine move up and down about 2,000

times a minute. While they move vertically, the crankshaft is

performing a completely different movement by rotating

horizontally. These contradictory movements will cause your

engine’s liners to vibrate a lot.

Although the out er wall of the liner is surrounded by cooling

fluid, its inertia creates tiny vacuum pockets, causing bubbles

of vapour form on the liner wall.

When the liner vibrates back, these bubbles collapse under

an enormous p ressure of 1,000 bar and take small chunks

out of the liner.

You can’t c hange the law s of physics,

but Fleetguard can neutr alise the consequencesor change the inertia of the cooling fluid, but

Fleetguard DCA can neutralise the fatal effect

on your engine by creating a protective layer on the

liner wall.

The implosion will still take place, but it will take

place on the protective layer and won’t damage the

liner wall.

Another b enefit with Fleetguard’s DCA is th at any

damage to the layer on the liner surface

is immediately reinhibited.

To maintain the layers’ effectiveness, DCA must be

added at frequent service intervals.

Fleetguard can’t stop y our

engines’ liners vibrating,

“We’ve seen too many liners

that looked like the sur face of

the moon, so we know very

well why we use DCA4.”

Liners’ surface deforms during

vibration; in combination with

the coolant’s inertia this creates

vacuums, and the formation of

tiny vapour bubbles.

Vibration continues and the liner

slams back, causing the bubbles to

implode.

As this process goes on several

thousand times a second, small

chunks are kicked out of the liner.

Fleetguard’s DCA can neutralise the

fatal effect on your engine by

creating a protective layer on the

liner wall: implosions now take

place on this layer and spare the

liner surface.


7/29/2019 LI33020-GB.pdf


As the engine functions,

the heat causes the

formation of scale on

the hot surfaces.

Scaling

Coolant consists of 48% good-q uality water, 48% G lycol

and 4% co olant additives. Tap water is always slightly hardbecause of minerals such as calcium, magnesium, etc.

The detrimental effect of scale takes place in the hot spots

of your engine, just as it does when you boil water in your

kettle. These hot spots are the liners and the cylinderheads.

When you think that 1 mm of scale has the same insulating

effect as 75 mm of cast iron, it becomes obvious that scale is

a major insulator, and that heat cannot easily dissipate from

your engine’s combustion chamber.

The consequences are worn p iston rings, higher oil

consumption and, in the w orst cases, total engine failure.

We make hard coolant water a soft issue

Fleetguard’s DCA’s contain an intelligent

polymer system that ‘wraps up’

the scale particles so that they can’t attach

themselves to the liner wal l.

Acidity

Corr osion in an engine usually occurs when the pH value

of your cooling fluid is lower than 7. Your cooling fluidbecomes acidic due to the degradation of antifreeze and sul-

phates entering the cooling system.

That leads to general corrosion of y our liners, cylinder

blocks and heads, and in the waterways and ho ses.

A very high pH value is also bad news as you r isk damage

to your gaskets and to the softer metal components.

Therefor e, the pH value in an ideal cooling system always

needs to be between 8 and 10.

To achieve that, you need buffers in your cooling fluid that

neutralise the formation of acids or alkalis.

We make sure that acidit y doesn’t upset you

Fleetgu ard’s DC A’s

contain an intelligent

polymer system that

‘wraps up’ the scale

particles so that they

can’t attach themselvesto t he liner wall.

The scale shell acts as an

insulator, preventing the coolant

liquid from absorbing the heat of

the engine.


7/29/2019 LI33020-GB.pdf


D CA4 and it’s fu lly form ula ted coola nt equ iv a-

lent, Compleat EG , were first introduced in

1984 on all Cumm ins diesel engines, where it

is still used today. DCA 4 is less toxic than

typical nitrite/borate chemistry and provides

improved prot ection against solder and alu-

minium corrosion, liner pitting and is more

tolerant to SCA under- or overtreatment.

In to day’s competitive environment, reducing

maintenance costs by extending coolant life

meets critical fleet needs. To meet these needs,

Fleetguard has launched an extended service

coolant, ES Com pleat.

For u se in Extended Service Long Life coolant

maintenance programs, simply fill the cooling

system with ES Comp leat and once a year

(250,000km or 4,000 running hou rs) service

the system with ES Slow Relea se Filters or ES

Extender L iqui d Booster. For use in

standard coolant maintenance

programs, simply use ES

Compleat in combination with

DCA4 mentioned above.

*ES = Extended Service

Besides additives, coolants and cleaners

Fleetguard offers a wide range of water

filters.

Many different sources have shown th at

there is a direct beneficial relationship

between filtering contaminate from the

coolant, and reducing wear, corrosion,

pitting and plugging.

O ne of the most significant studies com-

pared 11,000 trucks, half of which used

water filters, half of wh ich did not.

The trucks with water filters had two thirds

fewer failures due to leaking water pump

seals as those without filters.

This data also indicates that there is a

close correlation between filtration and

a reduction in scale formation, which h elps

the engine to maintain effective heat

transfer for optimum performance.

F l e e t g u a r d s o l u t i o n sF l e e t g u a r d s o l u t i o n s

To reduce operating costs and minimize engine

downt ime, correct coolant maintenance is vital.

Because everyone has their ow n

preferences when it comes to cooling system

maintenance, Fleetguard o ffers choices in both

cooling system chemistry and water filters.

Supplemental Coolant Additives (SCA) from

Fleetguard meet ISO-standards and are fully

approved by major engine manufacturers such

as;

A lot can happen to your cooling system, but Fleetguard has even more productsthat can solve the problems.

s Cummins

s Caterpillar

s D AF

s Scania

s M.A.N.

s Komatsu

s Liebherr

and others

Fully form ula ted coola nt s such as

ES C om plea t E G eliminate the need for

SCA pre-charging and provide the

greatest opportunity for success-ful

cooling system maintenance. They are

designed to last until engine rebuilt.

They also meet the A STM low silicate

recommendations and are u niversal

for use in all heavy-duty diesel and

automotive engines. Fleetguard’s

D CA2 Coo lan t A dd it iv e an d it’s fu lly

form ula ted Coo lan t, Fleetco ol, have

been pro tecting diesel engines since

1972. DCA2 uses nitrite for liner pit-

ting protection and has a borate

buffering system.

C o o l a

n t A d

d i t v e

s C o o l i

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C l e a n

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M e c h

a n i c a l f i l

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p r o d u

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f o r m

u l a t e d

A n t i f r

e e z e

E x t e n d

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c e p r o d

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Documents

LI33020-GB.pdf