GUIDE TO COOLANT ANALYSIS AND COOLING SYSTEM MAINTENANCE

COOLANT FORMULATIONS & RECOMMENDED TEST PACKAGES

Conventional Coolant Extended Life Coolant Extended Life Coolant
• Automotive, Light Duty & Heavy Duty engines (1st Generation) (2nd Generation)
• Ethylene glycol, propylene glycol or glycerin base (OAT, NOAT & HOAT) (NAP-Free or NAPS-Free & P-OAT)
• Inorganic inhibitor package for metal corrosion and
cavitation pitting protection Organic Acid Technology (OAT) North American & European Formulated Coolants
• Typical color: Orange • Typical color: Red
Components • Automotive and Light Duty • Heavy- and light-duty diesel, natural gas, and
Typical Color: Green/Yellow, Pink, Blue, Purple • Controls corrosion gasoline engines
Ethylene/Propylene Glycol or Glycerin based • Nitrite, Amine, Phosphate Free
• Freeze point suppression Nitrite Organic Acid Technology (NOAT) • Combination of organic acids as inhibitor package
• Boil point elevation • Typical color: Red/Orange • Requires a different glycol curve than
Borate • Heavy Duty engines traditional coolant
• Iron protection • Nitrite added for cavitation corrosion protection
• pH buffer P-OAT (Asian Formulated Coolants)
Hybrid Organic Acid Technology (HOAT) • Typical color Red/Orange or Blue
Nitrate
• Aluminum and solder corrosion protection • Typical color: Fluorescent Yellow • Heavy- and light-duty diesel, natural gas, and
Nitrite • Automotive and Diesel engines gasoline engines
• Cast iron and steel corrosion protection • Combination of conventional and OAT technologies • Nitrite, Amine, Borate & Silicate Free
Phosphate • Not restricted to any particular type of additive • Includes Phosphates
• Iron protection • Low-Silicate and Phosphate free • Combination of organic acids as inhibitor package
• pH control Components • Requires a different glycol curve than
Silicate traditional coolant
Ethylene Glycol
• Aluminum corrosion protection • Freeze Point Suppression Components
Azoles (Mercaptobenzothiazole - MBT, Tolytriazole – • Boil Point Elevation Ethylene Glycol
TTZ or Benzothiazole - BZT) Potassium Soap of Dibasic Carboxylic Acid • Freeze Point Suppression
• Yellow metal protection (copper & brass) • Iron, Solder and Aluminum Protection • Boil Point Elevation
Silicon & Block Polymers Potassium Soap of Monobasic Carboxylic Acid Carboxylic Acids – Standard
• Defoamant • Aluminum and Iron (w/sebacate) Protection • Benzoate, 2-Ethylhexanoic, Sebacic, Octanoic,
• Scale and deposit control Nitrite p-toluic, Adipic or Dodecanedioic acid
SCA & Water • Cast Iron and Steel Protection • Iron, Solder and Aluminum Protection
• Marine engines, Locomotives, Cooling towers Molybdenum Azoles (Mercaptobenzothiazole - MBT, Tolytriazole –
• Inorganic inhibitor package for metal corrosion and • Iron Corrosion Protection (w/nitrite) TTZ or Benzothiazole - BZT)
cavitation pitting protection Azoles (Mercaptobenzothiazole - MBT, Tolytriazole – Phosphate
• General use in India, China, Brazil, Mexico, etc. TTZ or Benzothiazole - BZT) • Iron protection
• General recommendation is to not use where there Modified Silicone Defoamant • pH control
is a chance of freezing • Inhibit foaming tendencies Modified Silicone Defoamant
Recommendations • Inhibit foaming tendencies
Recommendations • Sample high hour/mileage or high asset engines
• Sample high hour/mileage or high asset engines Recommendations
quarterly
quarterly • Sample engines less critical to production semi- • Sample high hour/mileage or high asset engines
• Sample engines less critical to production semi- annually quarterly
annually • Monitor glycol, nitrite and pH levels at every PM • Sample engines less critical to production
• Monitor glycol, nitrite, molybdenum and pH levels at • When changing from a conventional to an extended semi-annually
every PM life coolant, first flush the system thoroughly unless • Monitor glycol and pH levels at every PM
– High glycol could indicate an air leak that is using a conversion fluid - mixing the two degrades • Test organic acids by High Pressure Liquid
allowing the water in the coolant to evaporate the benefit of using an ELC Chromatography (HPLC) or test strip is necessary
due to excessive under-hood heat to determine suitability for continued use
– Submit samples with a significant drop in SCA for NOTE: Components listed above do not reflect all com- — Mixing ELC coolant formulations with conventional
laboratory testing to determine cause ponents used in all ELCs manufactured coolant will degrade ELC benefits.
— If changing from a conventional to an ELC product
Test Package Test Package flush the system thoroughly first unless conversion
fluid is used.
Standard Conventional Coolant Standard Extended Life Coolant
• Visuals (color, foam, oil, fuel, magnetic precipitate, — Coolant components listed above do not reflect all
• Visuals (color, foam, oil, fuel, magnetic precipitate, components utilized in all 2nd generation ELC
non-magnetic precipitate, & odor) non-magnetic precipitate, & odor)
• pH coolants manufactured.
• pH • Glycol %
• Glycol % • Freeze Point • Nitrite
• Freeze Point • SCA Number • Specific Conductance
Test Package
• Nitrite • Carboxylic Acid Pass/Fail
• SCA Number Standard Extended Life Coolant
• Total Hardness
• Total Hardness • Corrosion Metals & Inhibitors by ICP (Iron, Copper, • Visuals (color, foam, oil, fuel, magnetic precipitate,
• Specific Conductance Aluminum, Lead, Tin, Zinc, Silver, Calcium, non-magnetic precipitate, & odor)
• Corrosion Metals & Inhibitors by ICP (Iron, Copper, Magnesium, Borate, Silicon, Molybdenum, • pH • Glycol %
Aluminum, Lead, Tin, Zinc, Silver, Calcium, Mag- Phosphorus, Potassium, Sodium) • Freeze Point • Nitrite
nesium, Borate, Silicon, Molybdenum, Phosphorus, • SCA Number • Specific Conductance
Potassium, Sodium) Premium Extended Life Coolant • Carboxylic Acid Pass/Fail
Standard ELC Coolant test package plus: • Total Hardness
Premium Conventional Coolant • Contaminant and Inhibitor Anions by IC (Fluoride, • Corrosion Metals & Inhibitors by ICP (Iron, Copper,
Standard Conventional Coolant test package plus: Chloride, Sulfate, Nitrite, Nitrate, Phosphate, Aluminum, Lead, Tin, Zinc, Silver, Calcium,
• Contaminant and Inhibitor Anions by IC (Fluoride, Glycolate, Formate, Acetate, Oxalate) Magnesium, Borate, Silicon, Molybdenum,
Chloride, Sulfate, Nitrite, Nitrate, Phosphate, • Organic Acid and Azoles by HPLC(Benzoate, Phosphorus, Potassium, Sodium)
Glycolate, Formate, Acetate, Oxalate) 2-Ethylhexanoic Acid, Sebacic Acid, Octanoic Acid, Premium Extended Life Coolant
p-Toluic Acid, Mercaptobenzothiazole, Tolytriazole,
Benzothiazole) Standard ELC Coolant test package plus:
• Contaminant and Inhibitor Anions by IC (Fluoride,
Chloride, Sulfate, Nitrite, Nitrate, Phosphate,
Glycolate, Formate, Acetate, Oxalate)
• Organic Acid and Azoles by HPLC(Benzoate,
2-Ethylhexanoic Acid, Sebacic Acid, Octanoic Acid,
p-Toluic Acid, Mercaptobenzothiazole, Tolytriazole,
Benzothiazole)

NOTE: Test package selection should be based on application, OEM coolant formulation and program goals.
COOLANT MAINTENANCE
Visual Appearance
PROBABLE CAUSE POTENTIAL DAMAGE
Color
• should be clear and bright Coolant mixing, glycol degradation, outside contaminants,
• Should match the color of original coolant used precipitation
Oil in Coolant loss of heat transfer, liner, hose and water pump
• free from oil or petroleum products oil cooler rubber seal or core leaks; seal damage, block head water passage
(can cause seal and hose failures) combustion gas blow-by into the coolant seal damage
Non-Magnetic/Magnetic Precipitate
• free from precipitate, flocculent, algae, bacteria, and/or improper coolant use, over-inhibiting, defective water pump seal abrasion, scores soft metal surfaces
sludge (outside contaminants entering the system or electrical grounds (copper & aluminum), liner pitting around lower seals
coolant chemical dropout); magnetic 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 %
SPECIFICATIONS PROBABLE CAUSE POTENTIAL DAMAGE
• Antifreeze level will vary by OEM specifications, • Improper mixing of bulk coolant • Internal boiling
application and elevation at which the • Topping off with water only • Frozen and cracked block
system operates Too Low • Cavitation and pitting
• Engines operating at 195º or above must be at
50% for boil point control
• Engines operating at 10,000 ft. and above should • Improper mixing of bulk coolant • Loss of heat transfer
maintain a 55-60% antifreeze level to prevent • Topping off with glycol concentrate • Cavitation
coolant boiling Too High • Evaporation of water
• Pitted liners
• Marine applications should maintain 30-60% • Seals may fail
antifreeze if the system operates above 195º

pH
SPECIFICATIONS PROBABLE CAUSE POTENTIAL DAMAGE
• Conventional Coolant: 8.0 to 11 • Coolant is water only • Corrosion on iron components as well as
• ELC Formulation: typically 7.0 to 9.5; if • Source water does not meet engine other metals in the system
pH is above 9.5, possible ELC and manufacturer specifications • Electrolysis pitting through liners
conventional coolant mixing • Ethylene glycol is beginning to degrade • Corrosive attack on engine block
• Correct cause of drop in pH Too Low or coolant is burnt • Possible corrosion protection chemicals
• Combustion gas blow-by from cracked head, precipitate out of solution
head gasket failure, perforated hole in cylinder
liner, etc…
• Acid type cleaner used and not flushed thoroughly
• Coolant mixing of different formulations • Severe aluminum corrosion
• Severe aluminum corrosion; aluminum is an • Inhibitor precipitation
Too High alkaline metal
• Overtreating the system with SCAs
• Outside contaminant entering the system
 COOLANT FORMULATIONS & RECOMMENDED TEST PACKAGES (continued)
Specific Conductance
SPECIFICATIONS PROBABLE CAUSE POTENTIAL DAMAGE
• Normally this level will be between 1000 and • Improper source water • The inability of the coolant to resist carrying an
6500 micromhos • Combustion gas leak electrical current between the dissimilar metals
• Less than 10,000 micromhos • Antifreeze level too high of an engine’s cooling system
• When level is excessive, find cause and correct Too High • Inhibitor level too high • Engine becomes a wet cell battery
• Inhibitor being added too many times over an
extended period of time
• Coolant mixing

Total Corrosion Metals (NOTE: Limits below are guidelines only. Type, make, model, service time, maintenance procedures and operating environment can affect machine severity level.)
SUGGESTED LIMITS BY SEVERITY (ppm) PROBABLE CAUSE POTENTIAL DAMAGE
Metals A B C D • Air leaks • Metal component corrosion
Aluminum (Al) 0-4 5-9 10-14 >/=15 • Combustion gas leaks • Copper or aluminum erosion
Copper (Cu) 0-4 5-9 10-14 >/=15 • Localized over heating or hot spots • Liner pitting
Iron (Fe) 0-14 15-24 25-34 >/=35 • Electrical ground problems
Lead (Pb) 0-14 15-24 25-34 >/=35 • Improper coolant maintenance
Tin (Sn) 0-14 15-24 25-34 >/=35 • Improper source water being used
Zinc (Zn) 0-14 15-24 25-34 >/=35
Silver (Ag) 0-14 15-24 25-34 >/=35

Inhibitors and Additives

SPECIFICATIONS PROBABLE CAUSE POTENTIAL DAMAGE
• The SCA level refers to an additive in • Maintenance chemicals are not sufficient • Corrosion protection chemicals insufficient for
conventional coolant for metal protection and to prevent sludge proper metal protection
• Corrosion protection chemicals refer to nitrite from forming • Liner pitting and cavitation
or nitrite/molybdate in Extended Life Coolants • Air leak into the cooling system • Loss of heat transfer due to foaming
or Extenders • Combustion gas blow-by from cracked • Coolant becomes acidic under heat
• Levels will vary depending on brand of coolant
Too Low head, head gasket failure, perforated hole
used: 780 ppm minimum for proper protection in cylin­der liner, etc.
with nitrite no less than 300 ppm • Localized overheating or hot spots
• Supplemental coolant additive/corrosion • Stray electrical current going to ground through
protection levels should be tested every PM in the coolant
the field by strip and every quarter on high
mileage engines or semi-annually on low
mileage engines in the lab • Addition of chemicals excessive for • Silicate and/or phosphate can form deposits
engine application • Silicate and/or phosphate can precipitate to
Too High • Adding inhibitor without checking present level cause plugging and cavitation due to
• Coolant mixing of different formulations restriction of flow.
• Coolants can form sludge over time

Organic Acids
SPECIFICATIONS PROBABLE CAUSE POTENTIAL DAMAGE
• Coolant manufacturer specific • Coolant mixing of different formulations • Corrosion protection chemicals insufficient for
causing dilution of organic acids proper metal protection

SCALING POTENTIAL
Total Hardness
SPECIFICATIONS PROBABLE CAUSE POTENTIAL DAMAGE
(calcium and • Conventional coolant: less than 85 ppm • Improper source water • Scale formation that can be hard
magnesium as • ELC coolant: less than 85 ppm • Venting problem and insulating
CaCo3) • Have source water analyzed • Sea water contamination • Lack of heat transfer that can lead to cracked
heads, head gasket failure, burnt valves, ring
and bearing wear, etc

Silicon
SPECIFICATIONS PROBABLE CAUSE POTENTIAL DAMAGE
(corrosion inhibitor • Depends on coolant formulation; ASTM • Improper source water • Loss of lubrication
for aluminum and seal specification is not to exceed 250 ppm silicon • Poor coolant maintenance practices • Increased ring bearing wear
protection; also found in in a conventional coolant for heavy-duty • Mixing coolant formulations • Hot spots
some source water) diesel engines • Leaching from hoses • Loss of heat transfer
• ELC coolants normally have lower levels • Burnt valves
• OAT, NOAT, NAPS-Free and P-OAT coolants do • Silica gelation (green goo)
not have silicon
• Automotive coolants have higher levels due to
more aluminum in system

Phosphate
SPECIFICATIONS PROBABLE CAUSE POTENTIAL DAMAGE
(corrosion inhibitor • Best not exceed 10,000 ppm • Over treatment of SCA • Inability for the coolant to maintain the
for iron protection) • Over treatment of glycol phosphate in a soluble state
• Excessive phosphate in antifreeze • Scale formation due to phosphate combining
formulation with calcium or magnesium
• Mixing coolant formulations • Plugging of radiator and coolers

ACID PITTING POTENTIAL

Sulfate
SPECIFICATIONS PROBABLE CAUSE POTENTIAL DAMAGE
• Lower the better • Improper source water • Can form sulfuric acid
• Less than 300 ppm • Combustion gas leaks • Combine with calcium to form scale
• Sulfuric acid cleaner left in system • Severe metal corrosion and
component damage

Glycolate
SPECIFICATIONS PROBABLE CAUSE POTENTIAL DAMAGE
• Less than 1000 ppm • Localized overheating • Ethylene glycol continuing to break down to
• Less than 2500 ppm Total Degradation Acids • Air leak form acids such as formic, acetic, oxalic
• Combustion gas leak • Coolant will be burnt and produce a foul
solvent odor as well as take on a varnish
characteristic
• Severe metal corrosion and damage
to components

Chloride
SPECIFICATIONS PROBABLE CAUSE POTENTIAL DAMAGE
• Less than 110 ppm • Improper source water • Severe metal corrosion
• Defective pressure relief valve or cap • Decarbonize iron
• Aging coolant • Hydrochloric acid formation
• Presence of hydrochloric acid cleaner • Localized aluminum corrosion
• Improper venting
• Sea water leak

PREVENTIVE MAINTENANCE CHECKLIST

Inspect belt tension & condition, hoses, radiator, fan, fan clutch
Check for leaks, stains or streaks around hose clamps or cylinder block and wet areas around the radiator and on the ground
Check radiator for damaged fins, dirt or debris
Inspect pressure cap – check pressure
Check fan operation, clutch activation
BP Lubricants USA
Check temperature variances with infrared heat gun
1500 Valley Road, Wayne NJ 07470
Check coolant level www.labcheckonline.net
Perform appropriate PM field testing Coolant Technical Support Desk
Pull sample for scheduled laboratory testing 1-800-655-4473