SPB 25 Coolant Specification and Maintenance

Service/Parts Topics
Date:
Application:
10.07.2007
No:
Generator Unit
Fuel Type: File Group
ESB-SPB 25
Natural Gas
08
CUMMINS CONFIDENTIAL ESB Internal Circulation Only Author: Subject: K. Leonard Coolant Specification & Maintenance
Publications Affected by This Service/Parts Topic Operation and Troubleshooting Shop Other Maintenance and Repair QSV81G/91G 4021313 QSK60G 4021396 QSK19G 4021382 NOTE: Publications identified as Other include the following: Parts Catalogue, Wiring Diagram. Engine This Service / Parts Topic applies to QSV81G and QSV91G 14 and 16Bar BMEP, QSV91G 18Bar BMEP 2MWE, QSK60G and QSK19G natural gas and low Btu/biogas fuelled Gensets and all model variants. Warranty Impact Cummins Inc has learned of an increasing number of installations where the quality of coolant used in the engine does not meet Cummins published specification. The Cummins warranty states that Cummins is not responsible for failures or damage resulting from what Cummins determines to be abuse or neglect, including but not limited to: operation without adequate coolants or lubricants; over fuelling; over speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorised modifications of the engine. It is important to understand that operating the engine with a coolant that does not comply with Cummins coolant specifications constitutes abuse or neglect of the engine. Therefore, while the use of such coolant will not void the Cummins warranty, it must be understood that Cummins will deny coverage on any resulting engine failure or damage that Cummins alone determines was caused by the use of improper coolant. NOTE: The information contained in this document does not authorise TRP or Campaign practices.
Cummins Inc. Box 3005, Columbus, Indiana 47202-3005 Cummins Engine Co. Ltd., Daventry, Northants, England, NN11 8NU Registered Office: Unit 1-B Uniongate, Ridgeway Trading Estate, Iver, Buckinghamshire SL0 9HX, England
Registered No. 573951 England Copyright 2007 Cummins Inc. All rights reserved Page 1 of 6
Date:
Application:
10.07.2007
No:
Generator Unit
ESB-SPB 25
Natural Gas
08
Document Overview The purpose of this Service / Parts Topic is to remind the field of the correct Cummins Inc. coolant specifications and maintenance procedures. Engine Coolant Specification It is important that the quality of coolant used in Cummins engines meets the Cummins specification as published in Service Bulletin 3666132, which is available on QuickServe Online. Whether using a premixed fully formulated coolant or a 50/50 mixture of highquality water (see section 9 in Service Bulletin 3666132) and fully formulated concentrated anti-freeze, the coolant must meet Cummins Engineering Standard 14603. Cummins Inc. and ESB recommend the use of Fleetguard Antifreeze Coolant ES Compleat containing DCA4 Plus. NOTE: It should be understood that a similar specification will apply to cooling system secondary circuits. Filling and Maintenance of Cooling Systems The following steps are required to comply with Cummins Inc. recommendations for initial filling and maintenance of cooling systems: Fill the engine cooling systems (HT & LT) with a premixed fully formulated coolant or with a 50/50 mixture of high-quality water (see section 9 in Service Bulletin 3666132) and fully formulated anti-freeze. The fully formulated coolant or water/anti-freeze mixture, either ethylene glycol or propylene glycol, must meet Cummins Engineering Standard 14603. Cummins Inc recommends using Fleetguard coolants containing DCA4 . If using a 50/50 mixture of high quality water and fully formulated antifreeze, it is important that the water and anti-freeze is fully mixed before filling the engine. Manually vent the air from both the HT and LT circuits, using the vent points provided on the engine, before starting the engine. The automatic vent system on the engine is not designed to bleed air following cooling system filling. Top off the cooling system as needed using only fully formulated antifreeze/premixed coolant meeting Cummins Engineering Standard 14603. If fitted, change the coolant filter(s) at every oil change. The coolant filter must meet Cummins Engineering Standard 14315.

Date:
Application:
10.07.2007
No:
Generator Unit
ESB-SPB 25
Natural Gas
08

Replenish depleted coolant additives at every oil change (or earlier as indicated by the coolant analysis) by replacing the coolant filter(s) (if fitted) or by adding Supplementary Coolant Additives (SCA). Very large cooling systems can require additional liquid SCA if the standard coolant filters do not provide sufficient SCA replenishment. Do not be tempted to over-charge the cooling system with SCAs, as this may result in damage to cooling system seals, etc. and loss of coolant through leakage. Test the coolant a minimum of twice per year (or sooner if engine maintenance guide dictates) for freeze protection and additive levels. Refractometer measurements provide the most accurate freeze protection measurements. Test strips, although less accurate than a Refractometer, will also provide an indication of freeze protection and additive levels (see section 6 in Service Bulletin 3666132). Test and replace the coolant in accordance with the appropriate Operation and Maintenance guide. Replace the coolant only if the replacement limits are exceeded. Accurately record the coolant test results in the engines operation and maintenance log.
SCA Levels Test the SCA level at 3000 hours or a minimum of twice a year, whichever occurs first (or earlier as dictated in the appropriate engine Operation and Maintenance manual). If the SCA concentration level is between 0.3 and 1.3 units/litre [1.2 and 5.0 units/gal], either install a new chemical filter (if fitted) containing the appropriate dosage of SCA or add the equivalent liquid SCA dosage and install a new chemical free filter. For larger cooling systems, it can be necessary to replenish SCA with both a new chemical filter and liquid SCA. If the SCA concentration level is less than 0.3 units/litre [1.2 units/gal], add 0.15 litres [5 ounces] of Fleetguard DCA4 per 3.8 litres [1 US gal] of cooling system capacity and install a new chemical filter (if fitted). If the SCA concentration level is greater than 1.3 units/litre [5.0 units/gal], install a new chemical free filter (if fitted). Do not install a new chemical coolant filter or add liquid SCA. Test the SCA at each successive oil change. When the SCA units drop below 1.3 units/litre [5.0 units/gal], resume installing new chemical filters or use the equivalent SCA dosage.

Topping Off and Dilution of Cooling Systems: Coolant loss can lead to dilution of corrosion and liner-pitting protection additives due to incorrect top-off practices. This is the root cause of most cases of linerCummins Inc. Box 3005, Columbus, Indiana 47202-3005 Cummins Engine Co. Ltd., Daventry, Northants, England, NN11 8NU Registered Office: Unit 1-B Uniongate, Ridgeway Trading Estate, Iver, Buckinghamshire SL0 9HX, England
Date:
Application:
10.07.2007
No:
Generator Unit
ESB-SPB 25
Natural Gas
08
pitting. The top-off process is simplified by the use of fully formulated anti-freezes and coolants because SCA addition is not required when topping-off the system. Even small leaks at hose clamps, radiator cores, cylinder head gaskets and water pumps result in significant coolant loss over time. Dilution of critical additives is avoided, regardless of the amount of coolant loss, by using fully formulated products for system top-off. Coolant Testing Coolant testing is required for two reasons: 1. To determine the additive concentration and glycol level of the coolant. This will make sure that adequate anti-corrosion inhibitor, cavitation and freeze-point protection are achieved. 2. To determine if the coolant must be replaced due to contamination. Coolant testing for additive and glycol levels must be performed at 3000 hours or twice per year (or earlier as dictated in the appropriate engine Operation and Maintenance manual). The coolant must be replaced every 15000 hours or every two years, whichever occurs first (or earlier as indicated in the appropriate engine Operation and Maintenance manual). Additive and Glycol testing is also recommended when the following occur: Coolant loss between test intervals exceeds 10 - 15% of system capacity Water pump seal, radiator core or other external leakage is apparent Anytime the coolant condition is unknown, or corrosion is apparent within the cooling system Anytime a cooling system component is repaired or replaced
Recording Coolant Test Results: The fact that the coolant has been tested should be recorded in the engines operation and maintenance log. The following data should be logged: o Date and time of coolant test o Engine hours o Visual condition of coolant should be recorded Note: If the coolant is contaminated with oil, fuel, grease, solder bloom, silica gel, rust or scaling, then the system must be drained, cleaned and refilled (see section 11 in Service Bulletin 3666132). o Actual test results not just the fact that a test has been performed for each of the engine cooling circuits
Date:
Application:
10.07.2007
No:
Generator Unit
ESB-SPB 25
Natural Gas
08
For example: Using the Fleetguard Three-Way Heavy Duty Coolant test Kit (CC2602, CC2602A or CC2602B) (carefully follow test instructions provided with test kit) total test time is 75 seconds. Coolant Test Strip:
A = Glycol Freeze Point Indicator B = Molybdate Level Indicator C = Nitrate Level Indicator GLYCOL FREEZE POINT ( C) (TOP PAD)
30%
40%
50%
60%
- 15 - 19 - 23 - 29 - 34 - 43 - 51
MOLYBDATE (MIDDLE PAD)
SCA Units per Litre

0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.4 0.4 0.4 0.3 0.2 0.2 0.1 0.7 0.6 0.5 0.4 0.3 0.2 0.2 0.9 0.7 0.5 0.4 0.4 0.2 0.2 1.0 0.9 0.6 0.6 0.5 0.4 0.3 1.1 0.9 0.7 0.7 0.6 0.5 0.4 1.3 1.1 1.0 0.9 0.8 0.7 0.6 1.5 1.3 1.2 1.1 1.0 0.9 0.9
300 PPM 150 PPM 0 PPM 600 PPM 1200 PPM
ROW 6 ROW 5 ROW 4 ROW 3 ROW 2 ROW 1 ROW 0
TEST
SERVICE
PRE CHARGE
A
0 PPM
B
300 PPM
D
800 PPM
F
1600 PPM
H
3200 PPM
NITRITE (LOWER PAD)
Date:
Application:
10.07.2007
No:
Generator Unit
ESB-SPB 25
Natural Gas
08
So, in this example, the results are as follows: Freeze point (top pad colour): 40% / -23 C Molybdate (middle pad colour) ROW 4, Nitrate Row F (lower pad colour) giving a result of 0.7 SCA units/litre Outcome of test Coolant is Serviceable.
Therefore, the entry in the engines Operation and Maintenance log should show that the Freeze Point was tested and found to be 40% / -23 C and that the SCA units per litre of coolant were tested and found to be 0.7 SCA units/litre. NOTE: An Operation & Maintenance log entry which just says that a test was conducted and the coolant was found to be serviceable is unacceptable as it does not give sufficient detail of the test result. IMPORTANT NOTE: For complete information and details on Cummins Coolant Specification and Maintenance refer to the following publications: Cummins Service Bulletin 3666132 Cummins Engineering Standard 14603.

SPB 25 Coolant Specification and Maintenance

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SCA Units per Litre

ROW 6 ROW 5 ROW 4 ROW 3 ROW 2 ROW 1 ROW 0

NITRITE (LOWER PAD)

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