EC-1 LONG LIFE ENGINE COOLANT REQUIREMENTSJur CATERPILLAR INC. LONG URLEDLINE HO 781 P0324 LIFE ENGINE COOLANT REQUIREMENTS EC-1 10 1 INTRODUCTION BACKGROUND HEAVY DUTY ENGINES HAVE SPECIFIC ENGINE COOLANT REQUIREMENTS TO ADDRESS LINER PITTING, SOLDER BLOOM, SOLDER CORROSION, AND SCALING IN ADDITION TO FREEZE PROTECTION, HEAT TRANSFER, BOILOVER PROTECTION AND METAL CORROSION CONTROL. ‘THE INOUSTRY HAS FOR MANY YEARS TYPICALLY RECOMMENDED THE USE OF A FORMULATED ETHYLENE QLYCOL-BASED PRODUCT IN COMBINATION WITH A SUPPLEMENTAL COOLANT ADDITIVE (SCA) TO SATISFY THESE REQUIREMENTS. IN THE EARLY TO MID EIGHTIES, HEAVY DUTY ENGINE MANUFACTURERS BEGAN TO RECOMMEND THE USE OF LOW SILICATE CONTAINING ENGINE COOLANT (I.E. - ASTM 04985) IN COMBINATION WITH AN SCA TO REDUCE PROBLEMS FROM SILICATE DROP-OUT. IN 1885, CATERPILLAR INTRODUCED A TRUE HEAVY DUTY ENGINE COOLANT REQUIRING NO SCA WITH INITIAL FILL OR COOLING SYSTEM MAKE-UP, BUT NEEDING MAINTENANCE DOSES OF SCA EVERY 250 HOURS. THIS PRODUCT, AND OTHERS PRECEDING IT, REQUIRES REPLACEMENT AFTER 160,000-240,000 KILOMETERS (2000 - 2000 HOURS) OF USE TO REMOVE SPENT INHIBITORS, CORROSION PRODUCTS, AND CONTAMINANTS FROM THE SYSTEM. CATERPILLAR IS NOW INTRODUCING A NEW HEAVY DUTY ENGINE COOLANT WHICH REQUIRES NO SCA AT INITIAL FILL OR WHEN MAKING UP A LOW COOLING SYSTEM, REQUIRES AN INHIBITOR ADDITION AFTER 3000 HOURS, AND REQUIRES REPLACEMENT AFTER 6000 HOURS. THE ENGINE COOLANT IS FORMULATED WITH INHIBITORS THAT DO NOT DEPLETE AS RAPIDLY AS TRADITIONAL INHIBITOR TECHNOLOGY, THE ENGINE COOLANT EXTENDER (ECE) REQUIRED TO REINHIBIT THIS ENGINE COOLANT CONTAINS LOWER TOTAL DISSOLVED SOLIDS THAN CONVENTIONAL SCA'S TO REDUCE THE IMPACT OF SOLIDS BUILD-UP ON LIFE OF THE SYSTEM, THE DESIGNATION GIVEN THIS TYPE OF ENGINE COOLANT FOR USE IN ALL CATERPILLAR ENGINES 1S “CATERPILLAR EC-1". PRODUCTS MEETING THE EC-1 SPECIFICATION REQUIREMENTS ARE EXPECTED TO PERFORM EXCEPTIONALLY IN MOST MOBILE EQUIPMENT AND STATIONARY ENGINE APPLICATIONS INCLUDING GASOLINE AND NATURAL GAS-FUELED ENGINES. THIS DOCUMENT DEFINES ALL OF THE REQUIREMENTS THAT AN ENGINE COOLANT MUST MEET TO BE MARKETED AS A PRODUCT THAT MEETS CATERPILLAR EC-1 REQUIREMENTS, CATERPILLAR WILL NOT MONITOR OR APPROVE ANY PRODUCTS MARKETED UNDER THE EC-1 DESIGNATION. EACH INDIVIDUAL SUPPLIER IS RESPONSIBLE FOR THE QUALITY AND PERFORMANCE OF THEIR OWN PRODUCTS INCLUDING ANY ASSQCIATED LIABILITIES, FLUIDS ENGINEERING CATERPILLAR INC. ENGINE DIVISION P.0. BOX 619 MOSSVILLE, IL. 61552.0510 Usa PHONE (309) 578-6142 JuN-27-1997 15:22 303 692 s51¢vues ager va OP CATERPILLAR INC. EC-1 LONG LIFE ENGINE COOLANT REQUIREMENTS LVI FY eo: 1.2 OBJECTIVE THIS DOCUMENT IS INTENDED TO COMMUNICATE THE MINIMUM REQUIREMENTS FOR A LONG LIFE ENGINE COOLANT AND ENGINE COOLANT EXTENDER INTENDED FOR USE IN CATERPILLAR ENGINES, 1.8__GENERAL DESCRIPTION THE CATERPILLAR EC-1 REQUIREMENTS ARE ORGANIZED IN FOUR SECTIONS: PHYSICAL a CHEMICAL PROPERTIES, COMPATIBILITY CHARACTERISTICS, SENCH PERFORMANCE. TESTING, AND FIELD TESTING. 1.4° SUMMARY OF REQUIREMENTS. PHYSICAL AND CHEMICAL PROPERTIES (SECTION 2) ETHYLENE GLYCOL-BASED SOLUTION PROPERTIES PROPYLENE GLYCOL-BASED SOLUTIONS PROPERTIES ENGINE COOLANT EXTENDER PROPERTIES WATER QUALITY COMPATIBILITY (SECTION 3) ENGINE COOLANTS. ENGINE COOLANT EXTENDER WATER, BENCH PERFORMANCE TESTS (SECTION 4) FOAMING GLASSWARE CORROSION SIMULATED SERVICE, WATER PUMP CAVITATION HOT SURFACE ALUMINUM CORROSION FIELD TEST (SECTION §)198717224 UALUOLINE HO CATERPILLAR INC. LONG LIFE ENGINE COOLANT REQUIREMENTS 20 PHYSICAL & CHEMICAL PROPERTIES 2.1 ETHYLENE GLYCOL-BASED ENGINE COOLANT PROPERTIES ‘THE FOLLOWING TABLE IS APPLICABLE TO ALL ETHYLENE GLYCOL-BASEO SOLUTIONS GONGEN | 50 VOL% | 60 VOL% TRATE | aLycou | GLYCOL | SPECIFIC GRAVITY, 155/155°O (ASTM O1122) | 1.110 | 1.058 | 1.068 | 1145 | 1.092] J.092 FREEZING POINT, *G MAX (ASTM 01177) 13 “38 51 BOILING POINT, °C MIN (ASTM 01120) 170 106 108 ASH CONTENT. MASS% MAX (ASTM D1199) 50 25 25 CHLORIDE, PPM MAX (ASTM 03634) 25 25 3 HEAVY METALS, PPM MAX (ATOMIC ABSORPTION | ' ; SPECTROPHOTOMETER) JUN-27-1987 15:@2 waa 692 s512sun iow YALUOL I CALERPILLAR INC. LONG LIFE ENGINE COOLANT REQUIREMENTS JUN-27-1997 15:21 _ - CONCEN | 50 VOL% | 60 VOL TRaTE | @tycot | Gtycor SPECIFIC GRAVITY, 16.6/15.5°C (ASTM D1 128) 1.035 1.035. 1,095 1.080 7.060 1.060 FREEZING POINT, *C MAX (ASTM 01177) “56 29 44 BOILING POINT, °C MIN (ASTM 01120) 170 106 108 ASH CONTENT, MASS% MAX (ASTM D119) so | as 25 CHLORIDE, PPM MAX (ASTM 09634) 25 25 25 GRAVY METALS, PPM MAX (ATOMIG ABSORPTION 3 : . ‘SPECTROPHOTOMETER) CHEMICAL & PHYSICAL PROPERTIES 383 650 S510 exiriza VALUOL IIE HO CATERPILLAR INC. EC-1 LONG LIFE ENGINE COOLANT REQUIREMENTS 2.4 ENGINE COOLANT EXTENDER 2.3.1 IF NEEDED, ENGINE COOLANT EXTENDERS SHALL BE FORMULATED TO REPLENISH DEPLETED INHIBITORS OF EC-1 LONG LIFE ENGINE COOLANT AFTER 240,000 km OF USE SUCH THAT THE ENGINE COOLANT PROVIDES ACCEPTABLE PROTECTION AGAINST CYLINOER LINER PITTING AND. SORROSION FOR A MINIMUM OF AN ADOITIONAL 240,000 km (3000 HOURS) AS DEMONSTRATED. BY THE FIELD TEST DESCRIBED IN SECTION 5. 2.9.2 THE FOLLOWING TABLE IS,APPLICABLE TO ENGINE COOLANT EXTENDERS FOR EC-1 [Sebient. MASS % () MAX 04 ‘CHLORIDE, PPM (ASTM 03634) MAX 25 HEAVY METALS, PPM (ATOMIC ABSORPTION 6 SPECTROPHOTOMETER) MAX JUN-27-1987 1s: 323 69a 9518 se P.e5saeT UALUOLIN UAIEKPILLAR INC, EC 1 LONG LIFE ENGINE COOLANT REQUIREMENTS 24 WATER QUALITY ~ LE: TOTAL SOLIDS. PPM (D1608) MAX 340 TOTAL HARONESS, PPM (D1 126) MAX 170 CHLORIDE, PPM (0612 OR D497) MAX] ad SULFATE, PPM (D516 OR 04327) Max 100 pH, (01293) 55-90 Sa ES CHEMICAL & PHYSICAL PROPERTIES JuN-27-1997 15:10 323 69a ss1erete URLUOL INE HO CATERPILLAR INC. . EC-1 LONG LIFE ENGINE COOLANT REQUIREMENTS 3.0 COMPATIBILITY CHARACTERISTICS 3.1 ENGINE COOLANTS 3.4.1 SCOPE THIS TEST METHOD IS USED TO EVALUATE THE COMPATIBILITY OF THE ENGINE COOLANT WITH OTHER ENGINE COOLANTS, 3.1.2 SUMMARY OF METHOD ‘THE TEST MATERIAL IS MIXED WITH ASTM 04985 ENGINE COOLANT CONCENTRATE CONTAINING 6 VOL% SUPPLEMENTAL COOLANT ADDITIVE, AGED FOR 24 HOURS AT 68°C, AND CENTRIFUGED. TO DETERMINE THE AMOUNT OF MATERIAL THAT HAS PRECIPITATED FROM SOLUTION. 3.1.9 TEST EQUIPMENT GENERAL LABORATORY BALANCE, 1 TO 2 kg CAPACITY CENTRIFUGE TUBE, 100 mL CAPACITY PER'ASTM D1796 CENTRIFUGE CAPABLE OF MAINTAINING 500 ACF CONSTANT TEMPERATURE BATH, 88°C GLASS CONDENSER TUBE, APPROXIMATELY 5 mm 0.0. x3 mm 1.0. RUBBER STOPPERS TO FIT THE CENTRIFUGE TUBE GRADUATED CYLINDER, 100mL CAPACITY TD PIPETTE, TO DELIVER 6 mL 3.1.4 MATERIAL ‘SUPPLEMENTAL COOLANT ADDITIVE (SCA)* ASTM D4985 ANTIFREEZE CONCENTRATE DEIONIZED WATER, TYPE IV MIN. PER ASTM 01193 NICHROME WIRE CATERPILLAR 3°2044 COOLING SYSTEM CONDITIONER OR EQUIVALENT 07 SEP 94 JUN-27-1997 15:03 3e3 690 9510 98% P08CATERPILLAR INC. LONG LIFE ENGINE COOLANT REQUIREMENTS 17 URLUOLINE HO ans 3151 31.52 3183 an8.4 3155 3.1.6.6 B17 31.5.8 3.1.5.9 PROCEDURE MEASURE AND ADD 30mL OF THE COOLANT CONCENTRATE TO BE TESTED.TO THE 100 mL CENTRIFUGE TUBE USING THE GRADUATED CYLINDER. MEASURE AND ADD 30 mL OF THE ASTM 04985 COOLANT CONCENTRATE TO THE CENTRIFUGE TUBE FROM STEP 3.3.5.1 USING THE GRADUATED CYLINDER, MEASURE OUT AND TRANSFER 34 mL OF DEIONIZED WATER TO THE CENTRIFUGE TUBE FROM STEP 3.3.5.1. PIPETTE 6 mL OF THE SCA SOLUTION TO THE CENTRIFUGE TUBE. COVER WITH A RUBBER ‘STOPPER AND AGITATE THOROUGHLY. REPLACE THE RUBBER STOPPER WITH A CLEAN AIR CONDENSER PREPARED BY INSERTING A SHORT LENGTH (30 cm) OF GLASS TUBING THROUGH A PROPERLY SIZED ONE HOLE STOPPER. IMMERSE THE TUBE TO THE LEVEL OF THE SOLUTION IN A CONSTANT TEMPERATURE SATH AT ‘88°C FOR 24 HOURS, INSERT THE ORY WIRE INTO THE CONDENSER TO THE BOTTOM OF THE CONDENSER TUBE. AT THE END OF THE HEATING PERIOO, REMOVE THE CENTRIFUGE TUBE AND SOLUTION FROM THE BATH AND COOL TO AMBIENT TEMPERATURE (ALLOW AT LEAST ONE HOUR). CENTRIFUGE FOR 20 MINUTES AT 500 ACF. AFTER CENTRIFUGING, READ THE VOLUME OF SOLIDS IN THE BOTTOM OF THE TUBE TO THE NEAREST TENTH OR HUNDREDTH OF A ml. AS APPROPRIATE. ACCEPTANCE CRITERIA ACCEPTABLE MATERIAL SHALL HAVE NO MORE THAN 0.1 mL OF DEBRIS COLLECT IN THE CENTRIFUGE TUBE TIP, JUN-27-1987 15:10 323 680 9518 38x P.22Jun yo 1Pt24 YALUOL INE CATERPILLAR INC. EC-1 LONG LIFE ENGINE COOLANT REQUIREMENTS: 3.2 ENGINE COOLANT EXTENDER 3.2.1 SCOPE THIS MATERIAL MUST BE COMPATIBLE WITH ASTM D4985 CONTAINING 6 VOL% SUPPLEMENTAL COOLANT ADDITIVE AND CATERPILLAR LLG ENGINE COOLANT CONCENTRATES WHEN EVALUATED ACCORDING TO THE FOLLOWING PROCEDURE. 3.22 SUMMARY OF METHOD THE MATERIAL TO BE EVALUATED IS’ ADDED TO EACH APPROPRIATE ENGINE: COOLANT SOLUTION AT 6 VOL% CONCENTRATION: AGED FOR 24 HOURS AT 88°C AND CENTRIFUGED TO DETERMINE THE AMOUNT OF MATERIAL THAT HAS PRECIPITATED FROM SOLUTION, 3.29 TEST EQUIPMENT GENERAL LABORATORY BALANCE, 1 TO 2 kg CAPACITY CENTRIFUGE TUBE, 100 mL CAPACITY PER ASTM O1796 CENTRIFUGE CAPABLE OF MAINTAINING 500 ROF CONSTANT TEMPERATURE BATH. 88°C GLASS CONDENSER TUBE, APPROXIMATELY 5 mm 0.0. x 3 mm I,D. RUBBER STOPPERS TO FIT THE CENTRIFUGE TUBE GRADUATED CYLINDER, 100 mL CAPACITY TD PIPETTE, TO DELIVER 6 mL 3.24 MATERIAL ASTM D498 ANTIFREEZE/ENGINE COOLANT CONCENTRATE WI6% SUPPLEMENTAL COOLANT ADDITIVE CATERPILLAR LLC LONG LIFE ENGINE COOLANT CONCENTRATE, ETHYLENE GLYCOL- BASED CATERPILLAR LLC LONG LIFE ENGINE COOLANT CONCENTRATE, PROPYLENE GLYCOL- BASED DEIONIZED WATER, TYPE IV MIN. PER ASTM D1193 NICHROME WIRE JUN-27-1897 15:03 303 sa ss10 sex Pon28 URLUOL INE HO CATERPILLAR INC. EC-1 LONG LIFE ENGINE COOLANT REQUIREMENTS ee 3.25 PROCEDURE 3.25.1 MEASURE AND ADD 60 mL OF THE COOLANT CONGENTRATE TO THE CENTRIFUGE TUBE, $282 USING THE GRADUATED CYLINDER, MEASURE OUT AND TRANSFER 34 mL OF DEJONIZED WATER ‘TO THE CENTRIFUGE TUBE FROM STEP Dt $253 PIPETTE 6 mL OF MATERIAL TO THE CENTRIFUGE TUBE. COVER WITH A RUBBER STOPPER AND AGITATE THOROUGHLY. 3254 REPLACE THE RUBBER STOPPER WITH A CLEAN AIR CONDENSER PREPARED BY INSERTING A SHORT LENGTH (30 cm) OF GLASS TUBING THROUGH A PROPERLY SIZED ONE HOLE STOPPER, 9.28.6 IMMERSE THE TUBE TO THE LEVEL OF THE SOLUTION IN A CONSTANT TEMPERATURE BATH AT. Se FOR. 24 HOURS. INSERT THE ORY WIRE INTO THE CONDENSER TO THE BOTTOM oe THE CONDENSER TUBE. $2556 AT THE END OF THE HEATING PERIOD, REMOVE THE CENTRIFUGE TUBE AND SOLUTION FROM THE BATH AND COOL TO AMBIENT TEMPERATURE (ALLOW AT LEAST ONE HOUR). 3.25.7 CENTRIFUGE FOR 30 MINUTES AT S00 AGF. 3.2.8.8 AFTER CENTRIFUGING, READ THE VOLUME OF SOLIDS IN THE BOTTOM OF THE TUBE TO THE NEAREST TENTH OR HUNDREDTH OF A mL AS APPROPRIATE. 3.2.8 ACCEPTANCE CAITERIA ACCEPTABLE MATERIAL SHALL HAVE NO MORE THAN 0.1 mL OF DEBRIS COLLECT IN THE CENTRIFUGE TUBE TIP. i DATE JUN-27-1987 15:18 3e3 630 3510URLUDL INE HO CATERPILLAR INC. LONG LIFE ENGINE COOLANT REQUIREMENTS 33 WATER 33.1 SCoPE THIS TEST METHOD IS USED TO EVALUATE THE COMPATIBILITY OF THE ENGINE COOLANT WITH HARD WATER, 9.3.2 SUMMARY OF METHOD THE TEST MATERIAL IS MIXED WITH 600 PPM HARO WATER, AGED FOR 24 HOURS AT 98°C, AND CENTRIFUGED TO DETERMINE THE AMOUNT OF MATERIAL THAT HAS PRECIPITATED FROM SOLUTION. : 3.3.3 TEST EQUIPMENT GENERAL LABORATORY BALANCE, 1 TO 2 kg CAPACITY CENTRIFUGE TUBE, 100 ml CAPACITY PER ASTM 01796 CENTRIFUGE CAPABLE OF MAINTAINING 500 RCF CONSTANT TEMPERATURE 8ATH, 88°C GLASS CONDENSER TUBE, APPROXIMATELY § mm 0.0. x 3 mm 10. RUBBER STOPPERS TO FIT THE CENTRIFUGE TUBE GRADUATED CYLINDER, 100mL CAPACITY TD 33.4 MATERIAL 600 PPM HARD WATER TEST SOLUTION NICHROME WIRE JUN=27-1987 15:84 323 992 ss1a sex P28ALi CATERPILLAR INC. LONG LIFE ENGINE COOLANT REQUIREMENTS 33.5 PROCEDURE 3.3.6.1 MEASURE AND ADD 50 mL OF THE COOLANT CONCENTRATE TO BE TESTED TO THE 100 mL. CENTRIFUGE TUBE USING THE GRADUATED CYLINDER. 3.3.82 MEASURE AND ADD 50 mL OF THE 600 PPM HARD WATER TO THE ABOVE MENTIONED CENTRIFUGE TUBE. COVER WITH A RUBBER STOPPER AND AGITATE THOROUGHLY. 3.9.5.3 REPLACE THE RUBBER STOPPER WITH A CLEAN AIR CONDENSER PREPARED BY INSERTING A. SHORT LENGTH (30 cm) OF GLASS TUBING THROUGH A PROPERLY SIZED ONE HOLE-STOPPEA, 3.3.5.4 IMMERSE THE TUBE TO THE LEVEL OF THE SOLUTION IN A CONSTANT TEMPERATURE BATH AT. 88°C FOR 24 HOURS. INSERT THE DRY WIRE INTO THE CONDENSER TO THE BOTTOM OF THE CONDENSER TUBE. 3.3.5.5 AT THE END OF THE HEATING PERIOD, REMOVE THE CENTRIFUGE TUBE AND SOLUTION FAOM THE BATH AND COOL TO AMBIENT TEMPERATURE (ALLOW AT LEAST ONE HOUR). 3.9.5.6 CENTRIFUGE FOR 30 MINUTES AT 500 RCF. 3.35.7 AFTER CENTRIFUGING, READ THE VOLUME OF SOLIDS IN THE BOTTOM OF THE TUBE TO THE NEAREST TENTH OR HUNDREDTH OF A mL AS APPROPRIATE. 3.3.6 ACCEPTANCE CRITERIA ACCEPTABLE MATERIAL SHALL HAVE NO MORE THAN 0.25 mL OF DEBRIS COLLEGT IN THE CENTRIFUGE TUBE TIP. JUN-27-1987 15:89 323 6s@ 9510 se P.20L UALUOLINE, CATERPILLAR INC. EC-1 LONG LIFE ENGINE COOLANT REQUIREMENTS 4.0 BENCH PERFORMANCE TESTING 41 FOAMING 44.1 SCOPE THIS TEST METHOD COVERS A SIMPLE GLASSWARE TEST FOR EVALUATING THE FOAMIN TENDENCY OF ENGINE COOLANTS. 44.2 METHOD ASTM D1eo1 4.1.3 ACCEPTANCE CRITERIA FOAM VOLUME AT'S MIN, MAX, ml. 150 FOAM BREAK TIME, MAX, s 5 07 SEP 94 BENCH PERFORMANCE TESTING JUN-27-1597 15:24 383 692 S510 sex rae73BL P1824 gu UALUOLINIE. HD CATERPILLAR INC. EC-1 LONG LIFE ENGINE COOLANT REQUIREMENTS 4.2 GLASSWARE CORROSION TEST 4.21 SCOPE THIS TEST METHOD COVERS A SIMPLE GLASSWARE PROCEDURE FOR EVALUATING THE CORROSIVE EFFECTS OF ENGINE COOLANTS ON METAL SPECIMENS. 422 METHOD ASTM D1364 4.23 ACCEPTANCE CRITERIA THE ENGINE COOLANT CONCENTRATE SHALL PROVIDE SUFFICIENT PROTECTION AGAINST CORROSION AT 30% CONCENTRATION BY VOLUME SOLUTION TO MEET THE FOLLOWING LIMITS (MAX WEIGHT LOSS, mg PER SPECIMEN) COPPER | 10 SOLDER [15 BRASS 10 STEEL 10 CAST IRON | 10 ALUMINUM | 20 Tare . BENCH PERFORMANCE TESTING 07-SEP 94 JuN=27-1997 15:03 3a 69@ 9518 98% P19“1387 ATERPILLAR INC. LONG LIFE ENGINE COOLANT REQUIREMENTS VALVOLINE HO 4,3 SIMULATED SERVICE TEST 43.1 SCOPE THIS TEST METHOD EVALUATES THE EFFECT OF CIRCULATING ENGINE COOLANT ON METAL SPECIMENS AND COOLING SYSTEM COMPONENTS UNDER CONTROLLED, ESSENTIALLY ISOTHERMAL CONDITIONS. 432 METHOD ASTM 02570 4.33 ACCEPTANCE CRITERIA THE ENGINE COOLANT CONCENTRATE SHALL PROVIDE SUFFICIENT PROTECTION AGAINST CORROSION AT 44% CONCENTRATION BY VOLUME SOLUTION TO MEET THE FOLLOWING LIMITS (MAX WEIGHT LOSS, mg PER SPECIMEN) OGPPER | 20 souer [40 eras | 20 STEEL 20 cast iRON | 20 ALUMINUM JUN-27-1987 15:04 BS 680 9510 sex PiaCATERPILLAR INC. E C-1 LONG LIFE ENGINE COOLANT REQUIREMENTS _— 44 44s 442 443 WATER PUMP CAVITATION TEST SCOPE TPIS TEST METHOD EVALUATES THE CAVITATION EROSION-CORROSION CHARACTERISTICS OF ENGINE COOLANTS IN ALUMINUM WATER PUMPS, METHOD ASTM 02809 ACCEPTANCE CRITERIA THE ENGINE COOLANT CONCENTRATE SHALL PROVIDE SUFFICIENT PROTECTION AGAINST CAVITATION EROSION-CORROSION AT 16.67% CONCENTRATION BY VOLUME SOLUTION TO MEET ‘MINIMUM CORROSION RATING OF 8. x381 P1124 UPLUOL INE: HO CATERPILLAR INC. EC-1 LONG LIFE ENGINE COOLANT REQUIREMENTS SEER HOT SURFACE ALUMINUM TEST 45.1 SCOPE THIS TEST METHOD COVERS A LABORATORY SCREENING PROCEDURE FOR EVALUATING THE EFFECTIVENESS OF ENGINE COOLANTS IN CONTROLLING CORROSION OF ALUMINUM CASTING ALLOYS UNDER HEAT-REJECTING CONDITIONS, 45.2 METHOD ASTM 04349 4.5.3 ACCEPTANCE CRITERIA THE ENGINE COOLANT CONCENTRATE SHALL PROVIDE SUFFICIENT PROTECTION AGAINST CAVITATION EROSION-CORROSION AT 25% CONCENTRATION BY VOLUME ‘SOLUTION TO MEET A MAXIMUM CORROSION RATE OF 1 mg/omtiwoek BENCH PERFORMANCE TESTING es 822 ss10 sex Poin1n3 ‘CATERPILLAR INC. . EC-1 1 Pea ALUOLINE HO LONG LIFE ENGINE COOLANT REQUIREMENTS: . _ Oe 5.0 51 5.2 5.3 5.3.1 532 5.3.3 FIELD TESTING scope THIS SECTION DESCRIBES A RECOMMENDED PRACTICE FOR EVALUATING THE ABILITY OF LONG LIFE ENGINE COOLANT TO PROVIDE ACCEPTABLE CORROSION CONTROL AND COOLIt SYSTEM PERFORMANCE WITH SIGNIFICANTLY REDUCED OR NO MAINTENANCE ADDITIONS ¢ INHIBITOR IN FIELD SERVICE, SUMMARY OF METHOD EACH ENGINE COOLANT IS EVALUATED AT THE RECOMMENDED CONCENTRATION WITH WATE MEETING THE REQUIREMENTS OF THIS SPECIFICATION (SECTION 2.4), THE DUNATION SCoere TEST IS 560,000 KILOMETERS (7000 HOURS) WITH A MINIMUM DURATION OF 480,000 KlLOMerer RYSTEM CONDITION BY ANALYSIS OF COOLANT SAMPLES. AN ENGINE COOLANT EXTENDE MAY (BE USED DURING THE TEST PERIOD BUT IS NOT REQUIRED. THE CONDITION Or st NARIOUS ENGINE COMPONENTS INSPECTED AT THE ENO OF THE TEST PERIOD AND Th SOOLANT SAMPLE ANALYSIS RESULTS DETERMINE WHETHER OR NOT ACCEPTAGL PERFORMANCE WAS DEMONSTRATED. EQUIPMENT CRORE SX ENGINES TARGETEO FOR FULL INSPECTION, TWO MUST BE CATERPILLAR 31; ENGINES AND FOUR MUST BE CATERPILLAR 3406 ENGINES. THESE ENGINES ARE TO nave POWER RATING OF 260 KW OR GREATER, PAREAST | COPPER-BRASS RADIATOR AND 1 ALUMINUM RADIATOR MUST BE INCLUDED PART OF THE FULL INSPECTION, JHE PREFERRED APPLICATION IS LINE-HAUL TRUCKING SERVICE, BUT ANY VEHICL APPLICATION OPERATING AT GREATER THAN 60% LOAD FACTOR IS CONSIDERED AGCEPTADLI JUN-27-1887 303 659 9510 sex 43JuNe2 29 VALUOLINE Ha 1387 VIE ILLAM ING, LONG LIFE ENGINE COOLANT REQUIREMENTS EC-1 5.4 EQUIPMENT PREPARATION 544 542 5.4.3 5.44 46 COOLING SYSTEMS OF ENGINES PREVIOUSLY FILLED wer A DIFFERENT ENGINE COOLANT THAN THE TEST ENGINE COOLANT SHALL SE CLEANED AND FLUSHED PRIOR TO FILLING WITH. THE TEST. COOLANT PRIOR TO BEING PUT IN SERVICE, AZAD Ce ENGINES SHOULD BE INSPECTED FOR COOLING SYSTEM PROBLEMS (L. - LEAKING HEAD GASKETS OR EXCESS AIR INDUCTION INTO THE COOLING SYSTEM) OR DAMAGE IN THE COOLING SYSTEM PRIOR TO INCLUSION IN THE TEST PROGR INSPECT ALL ENGINES FOR LEAKS AND REPAIR IF FOUND, THE CONDITION OF THE FOLLOWING PARTS OF USED ENGINES TARGETED FOR FULL CSRECTION AT THE END OF THE TEST MUST BE DOCUMENTED WITH a Soren WRITTEN, ALL CYLINDER LINERS RADIATOR WATER PUMP COVER WATER PUMP IMPELLER ‘SPACER DECK (3176 ONLY) HEAD COOLANT PASSAGES THERMOSTAT HOUSING HEP UAtiG, OR CORROSION DAMAGE IS FOUND ON ANY OF THESE PARTS, THE PART MUST BE REPLACED. Fee a SUGSESTED THAT AN IDENTIFICATION SYSTEM: BE ESTABLISHED THAT ALERTS OPERATORS AND MAINTENANCE PERSONNEL THAT THE ENGINES ARE PART OF A TESTING SROGRAM AND ADVISES ‘THEM OF THE PROPER ENGINE COOLANT TO INSTALL WHER QOOMIONS ARE REQUIRED. THIS COULD INCLUDE LABELS ON OR NEAR THE FILL POINT IN Tre SNe ed IDENTIFYING THE COOLANT TO BE INSTALLEO OR USED AS MAKE-UP Id! THE ENGINE A RZCLOR CODING THE RADIATOR CAP WITH THE COLOR OF THE CAP ON THE COOLANT BARREL OR CONTAINER, 70, REOUCE PROBLEMS WITH CONTAMINATION DUE TO MAKE-UP, AN APPROPRIATELY SIZED CONTAINER OF THE TEST ENGINE COOLANT PREDILUTED TO THE RECOMMENDED TEST CONCENTRATION SHOULD ACCOMPANY THE VEHICLE AT ALL TIMES. FIELO TESTING JUN-27-1997 15:87 23 692 9510 98% FSeTIS1 P1624Jun 136 UALUDLINE HO CATERPILLAR INC. LONG LIFE ENGINE COOLANT REQUIREMENTS “EC. 1 5.5 TEST PROCEDURE 5.5.1 INSTALL THE TEST COOLANT IN THE ENGINE AT THE 50/50 VOL% CONCENTRATION OF GLYCOL/WATER MIX IN ALL CASES WHERE TEMPERATURES ARE NOT EXPECTED TO DROP BELOW -36°C(-34°F). IF LOWER TEMPERATURES ARE EXPECTED INSTALL THE TEST COOLANT AT THE 60/40 VOL% CONCENTRATION OF GLYCOLWATER, 5.5.2 DOCUMENT THE TYPE OF SERVICE FOR EACH VEHICLE INCLUDED IN THE TEST FLEET. 5.5.3 DOCUMENT THE HOURS AND DISTANCE ACCUMULATION FOR EACH VEHICLE IN THE TEST FLEET. 5.5.4 DOCUMENT THE INCIDENCE OF WATER PUMP SEAL LEAKAGE WITH ANY VEHICLE INCLUDED IN THE TEST FLEET. 5.55 TAKE A COOLANT SAMPLE EVERY 40,000 KILOMETERS (500 HOURS) AND SUBMIT FOR THE FOLLOWING ANALYSES: pH RESERVE ALKALINITY METALLIC CORROSION ELEMENTS (FE, AL, PB, SN, CU) CONTAMINANTS (CA, MG, CL, SULFATE) INHIBITOR CONCENTRATION 5.5.8 AN ENGINE COOLANT EXTENDER MAY BE USED’ OURING THE TEST PERIOD AS LONG AS IT MEETS THE REQUIREMENTS (SECTION 2.3) OF THIS SPECIFICATION. IF AN ENGINE COOLANT EXTENDER IS USED; IT MUST BE ADDED BETWEEN 240,000 TO 280.000 KILOMETERS (3000 - 3500 HOURS) INTO THE TEST AND IN ALL ENGINES FROM THE CORE TEST GROUP. JUN-27-1997 ‘age 15:06 303 699 9512 P.i3P52. — WRLUCLINE HO iia _— VADEOILLAK ING, LONG LIFE ENGINE COOLANT REQUIREMENTS EC-1 5.8 POST TEST INSPECTION AND REPORT ™~ 581 REPORT THE FOLLOWING INFORMATION FOR EACH ENGINE FROM THE CORE TEST.GROUP. 5.6.1.1 ENGINE MODEL AND CONFIQURATION 5.6.1.2 RADIATOR MAKE AND TYPE 5.6.1.3 TEST PERIOD AND LOCATION 5.82 INSPECT, AND REPORT THE CONDITION OF THE FOLLOWING PARTS OF ENGINES INCLUDED IN THE CORE TEST GROUP: ALL CYLINDER LINERS RADIATOR WATER PUMP COVER WATER PUMP IMPELLER ‘SPACER DECK (3176 ONLY) HEAD COOLANT PASSAGES THERMOSTAT HOUSING 583 REPORT ANY UNUSUAL CIRCUMSTANCES OR PROBLEMS INVOLVING COOLANT MAINTENANCE OR COOLING SYSTEM PERFORMANCE THAT MAY HAVE DEVELOPED. OURING THE TEST, 5.84 REPORT THE INCIDENCE OF WATER FUMP SEAL LEAKAGE FOR ALL VEHICLES IN-THE TEST FLRET. : 56.5 REPORT THE FOLLOWING RESULTS VS. DISTANCE (OR TIME) IN GRAPHICAL FORM FOR ALL VEHICLES IN THE TEST FLEET: 5.6.5.1 pH 5.8.8.2 RESERVE ALKALINITY 5.65.9 METALLIC CORROSION ELEMENTS (FE, AL, PB, SN, cu) 5.6.5.4 CONTAMINANTS (CA, MG, CL, SULFATE) 5.6.55 INHIBITOR CONCENTRATION FIELD TESTING 07 SEP 94 JUN-27-1987 15:87 323 59a 9sia sexJUN-2P-1987 18:26 3e3 650 ssia BL Plaza UALIOLINE BD CATERPILLAR INC. EC-1 LONG LIFE ENGINE COOLANT REQUIREMENTS, 8. ACCEPTANCE CRITERIA 57.1 THE ENGINE CONDITION MUST MEET THE FOLLOWING CRITERIA: S714 NO CYLINOER LINER SHALL HAVE PITTING OAMAGE DEEPER THAN 15% OF THE WALL THICKNESS, 8.7.1.2 RADIATOR TUBES MUST BE CLEAN WITH NO EVIDENCE OF BLOCKAGE 0A SLUDGE, 5:7-4.9 WATER PUMP COVERS, WATER PUMP IMPELLERS, ALUMINUM SPACER DECKS, HEAD COOLANT PASSAGES, AND THERMOSTAT HOUSINGS MUST BE FREE On CORROSION AND PITTING 5.7.1.4 THERE MUST BE NO REPORTED WATER PUMP SEAL LEAKS OURING THE TEST PERIOD, 57.2 ALL ENGINES IN THE TEST FLEET MUST MEET THE FOLLOWING CRITERIA: 572.1 pH MUST BE MAINTAINED WITHIN TWO UNITS OF THE INITIAL VALUE AT THE START OF THE TEST, 57.2.2 CORROSION METALS MUST BE UNDER CONTROL AND NOT TRENDING UPWARDS. - eax Pate