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Coolants and Cooling System Maintenance BOATKEEPER Coolants and Cooling System Maintenance From Pacific Fishing, February 2001 By Terry Johnson, University of Alaska Sea Grant, Marine Advisory Program 4014 Lake Street, Suite 201B, Homer, AK 99603, (907) 235-5643, email: [email protected] Marine diesel engine specialists say the most A 50-50 mix will stay fluid down to succinctly: “The importance of a properly frequent source of premature engine failure minus 34°F and will prevent freeze dam- inhibited coolant cannot be overstressed.” is the cooling system. Improper coolants age to a somewhat lower temperature. Ves- An intricate maze of cast iron, steel, and inadequate cooling system maintenance sels that winter at temperatures colder than bronze, brass, and sometimes aluminum can result not only in catastrophic overheat- 40 below may go as high as 60-40, while passages comprise a marine diesel cooling ing, but also in corrosion damage and even those that operate in warm waters may go system, an ideal breeding place for galvanic vessel flooding. Because most of the cool- as low as 30-70. Straight antifreeze should corrosion, particularly if seawater is ing system is internal to the engine and diffi- never be used as a coolant because it doesn’t present. (Some engines with keel coolers cult to observe, damage can occur gradually transfer heat as well as a mixture, nor does for the engine block still incorporate raw over time, essentially rotting the core of an it protect against freezing as well. Minor over- water for exhaust elbows and other periph- otherwise hearty diesel. heating sometimes can be remedied by di- eral cooling.) Zinc plugs should protect the Nearly all marine diesels are cooled by luting the coolant with more water, or by raw-water side, but are not normally fitted either a keel cooler (or some variant such switching to an antifreeze with different in the freshwater system. Furthermore, vi- as grid cooler or skin cooler), or by a heat heat transfer properties. According to a re- bration inside the block, particularly around exchanger. Both systems depend on circu- cent posting on an Internet diesel message wet cylinder liners, causes tiny pockets of lating coolant to remove heat from the en- board, adding the proper mix of Nalcool reduced pressure, where heated coolant gine block and transfer it to the 3000 will lower the engine operating tem- vaporizes, forming bubbles of steam. As environment. Closed systems are called perature 7-10 degrees, which can be impor- these bubbles collapse against internal sur- “freshwater cooling” because seawater is not tant in a high-output engine. faces they physically erode the metal. This circulated through the block, but straight Select carefully the water to be used in “cavitation erosion” can eat pinholes right fresh water should not be used in diesel coolant, since the oxygen and chlorine in through liners and cooling jacket walls, al- engines. Coolants normally consist of a mix city water enhance corrosion, and mineral lowing coolant into the cylinder. of water, antifreeze, and a conditioner or impurities contribute to scale buildup. Chlo- Scale, a hard coating of mineral solids inhibitor. rine is particularly corrosive to aluminum, derived from magnesium, calcium carbon- which is used in blocks, heads, and heat ate, and other impurities in the water, may Coolant must: exchangers of some lightweight, high-speed clog passages and diminish the transfer of • effectively remove heat diesels. Well water should never be used in heat through the water jacket walls into the • prevent freezing and resultant block cooling systems due to mineral content. You coolant. A quarter inch of scale on top of damage can get your water lab tested for impuri- one inch of cast iron slows heat transfer to • prevent deposits of scale and sludge ties, and in a pinch you can use a water- the same rate as four inches of cast iron on interior passages softening additive. Some antifreeze brands alone, enough to cause overheating. Sus- • inhibit corrosion are blended to compensate for impurities pended solids also grind away seals, caus- • prevent cavitation erosion in city water. Most municipal water is sat- ing water pumps to leak. • lubricate components such as water isfactory for cooling systems, but “de-ion- Popular supplement additives include pumps ized” or distilled water is best. Baldwin’s BTE, Penray’s Pencool (for- • be compatible with hoses and seals merly known as Nalcool), and DCA by Use a Conditioner Fleetguard. Sold as either liquid or pack- Most operators know that a 50-50 mix- However, you can’t rely on pure water and ages of water-soluble powder, they are ture of ethylene glycol antifreeze and wa- antifreeze alone to protect your cooling sys- mixed into the water-antifreeze coolant. ter provides good heat transfer and freeze tem. Any high quality, heavy-duty, low-sili- Some brands of antifreeze (Caterpillar and protection. (It’s usually yellow or green. cate antifreeze is appropriate for marine Fleetguard among them) are formulated The pink stuff, sometimes called “RV anti- diesel use, but most need a coolant condi- with conditioners included. freeze,” is propylene glycol, and is non- tioner, also known as inhibitor or supple- Conditioners become depleted with use, toxic for winterizing drinking water mental coolant additive, formulated to and coolant should be tested twice a year. systems. It transfers heat poorly and should protect surfaces from both galvanic corro- Some makers sell test strip kits that allow not be used as a coolant. Unfortunately, the sion and cavitation erosion, and also pre- you to check your coolant for conditioner color doesn’t always indicate the contents, vent or reduce the accretion of scale. The strength, and also may indicate presence of so read the label.) Detroit Diesel 71-series manual states it combustion gasses, electrical current, etc. Going a step further, you can send coolant samples to a test lab (testing kits are sold for this purpose) which will return an analysis indicating total dissolved solids, pH (acid- ity), glycol percentage, and the freeze point. Be sure to use only the test strip made for the coolant you are using, and don’t mix ad- ditives from different makers, or add a condi- tioner formulated for one antifreeze to a dif- ferent antifreeze. They may not be compat- ible because different manufacturers use dif- ferent bases. If changing brands, drain the sy- stem and flush before adding fresh coolant. Because solids usually are present in coolant, some mechanics say a coolant fil- ter is a good idea, even essential, while oth- ers say it’s unnecessary. Follow your engine manufacturer’s recommendation. If you do decide to use a filter, select carefully—some have surface filtering elements in the 15-60 If you have a heat exchanger, once every Coolant can also escape through faulty micron size range, others have deep filters couple hundred hours check the zinc plugs. seals elsewhere in the cooling system, in- at 1-5 microns. Obviously the latter take more Bang them with a hard object or scrub with cluding the cylinder head water seal rings crud out of your coolant but also need more a wire brush and most of the corrosion should or the head gasket, and through leaks in oil frequent replacement. Some companies, flake off, exposing nearly bright metal. If not, coolers, fuel coolers, gear oil coolers, cabin Baldwin and Gulf Coast Filter included, or if they are more than 50 percent dimin- heaters and other devices that are plumbed make filter devices that incorporate a con- ished in size, replace them. At around 500 to coolant lines. Don’t use any antifreeze trolled-release coolant conditioner. The fil- hours, drain the raw water side and clean containing methyl alcohol, which can dis- ter should be changed in accordance with with a wire brush. At the time of engine over- solve seals and hoses, and don’t put any manufacturer recommendations. haul or if there is a coolant problem, disas- soluble oil or any kind of radiator sealer in Antifreeze doesn’t deteriorate or lose its semble the heat exchanger, removing the your cooling system. (Oil mixed with eth- ability to prevent freeze damage very quickly. core, and inspect the tubes. Minor deposits ylene glycol forms a varnish that can cause Some sources say that as long as it is rea- can be pushed out with a rod of soft mate- engine failure.) Coolant can also leak sonably clean and the conditioner potency rial, such as a wooden dowel, or a rifle-clean- through a faulty pressure cap or pinhole is maintained, it is good for several years. ing rod and brush with oxalic acid solution leaks due to corrosion in castings such as Follow your engine manufacturer’s recom- can be used. Don’t use a hard rod that could the heat exchanger or expansion tank. You mendation; for example the recommended damage the thin copper tubes. If rodding can use a pressure tester to detect breaches change time for Caterpillar’s ELC is three doesn’t clear the deposits, take the core to a of system integrity. years or 3,000 hours, and with addition of radiator shop for cleaning in a chemical bath. Remember, if one gasket has started to an extender is good for six years or 6,000 Periodically, and any time coolant level leak, it’s time to replace all such gaskets, hours. Otherwise, it’s a good idea to test in the expansion tank drops, check the because the others will soon start to leak also. the conditioner annually or each 500 hours. “weep hole” at the bottom of the freshwa- Inspect hoses and hose clamps at least A word on draining antifreeze: the stuff ter circulating pump.
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