Let’s Get to the Root of the - Spartan Emergency Response...you can – tire looks good. Tire...
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Let’s Get to the Root of the Root Cause Emergency Vehicle Technician Training 2019 2019 Gates All Rights reserved
Transcript of Let’s Get to the Root of the - Spartan Emergency Response...you can – tire looks good. Tire...
Let’s Get to the Root of the
Root Cause
Emergency Vehicle Technician Training
2019
2019 Gates All Rights reserved
SAFETY FIRST 2
SHUT OFF POWER
Turn Off
Test
Lock
Tag
SAFETY FIRST 3
USE PROPER SAFETY EQUIPMENT
Wear proper clothing
Eye protection
Hearing protection
Safety shoes
Hard hat
Gloves
SAFETY FIRST 4
SAFE WORKING ENVIRONMENT
Keep area around drive clean and uncluttered
Drives should be properly guarded
SAFETY AWARENESS
A “Mindset”….
• Understand policies and procedures
• Understand safe from unsafe behavior
• Pay attention; no distractions
• Don’t take risky shortcuts
• Be aware of surroundings and changes
• High noise levels can dull senses and slow reactions
PINCH POINTS & POINT OF OPERATION HAZARDS 5
NEVER PLACE HANDS, FINGERS ETC.
INTO PINCH POINTS
Points of operation of moving equipment or machinery
BE AWARE OF THE ABSENCE OF PROPER
GUARDING
Operating without guard?
DRIVE COMPONENTS CAN MOVE WHEN
MACHINERY / EQUIPMENT IS NOT IN
OPERATION
Windmilling equipment
Movement and inertial energy
Let’s Get to the Root of the
Root Cause
Emergency Vehicle Technician Training
2019
2019 Gates All Rights reserved
AGENDA
•Be System Smart
•Accessory Belt Drive System (ABDS)
•Belt Wear
•Use the Right Belt
•PAT
•Tensioners
•Decoupler Pulleys
•Industrial Belts
•Key Issue in Cooling Systems
•Coolant
•Water Pumps
•Flush Process
•Stats and Caps
Click to
play
video
LIFE'S REALITY
• The technology and engineering behind components that we might take for granted have changed over the
last several model years. Our approach to the maintenance and inspection of these components has to
change because visual indicators of impending failure are not always present.
• Technicians should be educated on the real cost of letting a component operate outside of it’s intended
design life.
The last thing you want is a breakdown while in transit!
THINK ABOUT THE COMPLETE SYSTEM
• The primary reason for replacement is failure
Lack of the latest technical knowledge
Not doing the complete job
Component performing outside of their duty cycle
Supplier not offering solutions
Worn components put the entire system at risk!
Surveys Say!
Up TO:
• 40% of Radiator failures due to condition of coolant
• 40% of Batteries returned, just needed charging
• 70% of Rotating Electrical performed as intended
• 90% of Timing Belts fail after just a belt is installed
• 91% - OE coolant hose failures are spiking at 10-11 years
• 95% of Water Pumps fail from lack of flushing
• 99.8% of Serpentine Belts returned were forced to fail
YOU ARE MISSING SOMETHING IMPORTANT!
Sampling of alleged warranties returned to factory
Surveys Say!
Up TO:
• 40% of Radiator failures due to condition of coolant
• 40% of Batteries returned, just needed charging
• 70% of Rotating Electrical performed as intended
• 90% of Timing Belts fail after just a belt is installed
• 91% - OE coolant hose failures are spiking at 10-11 years
• 95% of Water Pumps fail from lack of flushing
• 99.8% of Serpentine Belts returned were forced to fail
Sampling of alleged warranties returned to factory
YOU ARE MISSING SOMETHING IMPORTANT!
SIMPLE ANALOGY “THE GIFT THAT KEEPS ON GIVING“
SOMETIMES IT’S SIMPLE – SOMETIMES IT’S NOT
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• Check the tire pressure. Fill with
air... Repeat as necessary…
• Tire repair in a can?
• Ignore the problem for as long as
you can – tire looks good. Tire
pressure doesn’t get that low. It
will be OK.
• Suggest finding the root cause of
the failure first. Anything else may
be a band aid solution!
CAN’T DO IT LIKE WE USED TO!
Correct Tension is Critical – Accessory Belt Drive System (ABDS)
THE BIRTH OF THE RUBBER V-BELT
Flat belts rely on friction only – can slip and track off pulleys
1917 – John Gates invents the reinforced rubber V-belt
Sidewall provides additional surface area
“V” shaped groove captures belt for stability
Wedging action multiplies frictional forces
• Vertical Fv applied perpendicular to belt top creates high sidewall forces Fn to transmit higher loads
Rubber material used for flexibility to bend around sheaves
Fabric reinforcement layers are added for extra strength
AUTOMATIC TENSIONERS
1998 – 40% of engines had a heavy duty
tensioner
2012 – Over 95% of engines have one or
more heavy duty tensioners
AC Belt
Tensioner
Fan / Alternator Belt Tensioner
Freightliner FLD W/ Cat C12 Motor
MICRO-V® BELT
WE CAN’T DO IT LIKE WE USED TO SIMPLY DUE TO THE TECHNOLOGY ADVANCES
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Serpentine Belt
Advantages
One belt runs everything!
Reduced space
Less weight
Better friction compared to
multiple single v-belts
Increased belt life and
mechanical efficiency
Fuel saving
Eliminates belt “flip over”
Traditional v-belt have
the tendency to “flip
over”
Disadvantages
One belt runs everything !
Belt depends on correct tension to
operate properly!
Loses multiple critical accessory
functions when the belt is worn
Loss of engine cooling (water
pump)
Battery not charging (alternator)
Loss of power steering (PS pump)
Loss air condition (AC compressor)
Fan not working (Fan)
BELTS TODAY ARE HIGHLY ENGINEERED
Manufactured With:
EPDM Material (Ethylene Propylene Diene Monomer Rubber)
• Hi Temp Rubber Material
• Fabric Back Material
• Aramid Fibers in the Undercord
• Nylon Cord
• Polyester Cord
• Aramid Cord
• Carbon Cording
• Special Gum Properties
• Material can be modified for special applications
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
ACCESSORY BELT DRIVE SYSTEM (ABDS)
Belt Whip
• Belt whips as it rotates over the
back side of the system
• Creates Torsional Vibration
Solution Create a Aramid cord belt
Traditional belt wear signs no longer apply for EPDM belt !
Replacement Rate by Mileage Ranges for the Serpentine Belt and Related Belt Driven Component
TIME LINE IS IMPORTANT ! / WHEN TO SUGGEST
Parts in the System:
Serpentine Belt
Tensioner
Related Accessories
• Alternator Decoupler Pulley
System Pulleys
ABDS (ACCESSORY BELT DRIVE SYSTEM)
Definition: The Accessory Belt Drive System (ABDS) is a system, on the engine, made up of idlers and accessory
components performing various rolls throughout the vehicle that depend on the belt, under tension, to transfer
power from the crank for peak operational efficiency.
ABDS SYSTEM
What are the wear and tear parts of serpentine belt drive components ?
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Serpentine belt
Transfers power from the crankshaft pulley to all belt driven accessories
Automatic Tensioner
Maintains the correct tension on the belt at all times throughout its duty cycle and dampens Torsional vibration
Idler Pulley
Is a free-spinning pulley around which the belt travels to optimize belt routing and suppress belt flutter
Torsional vibration damper
New type of crankshaft pulley with a rubber damping element to absorb crankshaft vibrations and extends the lifespan of the crankshaft, the belt and all belt driven components
Overrunning Alternator Pulley
New type of alternator pulley that allows the alternator to “free wheel” or “overrun” every time the engine decelerates. It also dampens Torsional vibrations at the alternator. This component extends the lifespan of the alternator, belt and all belt driven components.
BELT MATERIAL HAS CHANGED BECAUSE OF SYSTEM REQUIREMENTS
• Belt material change from Neoprene to EPDM in 1996
• EPDM is an acronym for Ethylene Propylene Diene Monomer Rubber
and is used in both belts and hoses
• Benefits of EPDM material used in belts today
Handles heat better
Eliminates rib cracking
Increased duty cycle providing long life
• Belt cording can be Cotton, Polyester or Aramid cord depending on the
quality of the belt purchased
• Belt Inspection process has changed from looking for rib cracks to
inspecting for rib wear.
Just 5% of belt wear will
facilitate belt slip.
BELT MATERIAL HAS CHANGED BECAUSE OF SYSTEM REQUIREMENTS
• Belt material change from Neoprene to EPDM in 1996
• EPDM is an acronym for Ethylene Propylene Diene Monomer Rubber
and is used in both belts and hoses
• Benefits of EPDM material used in belts today
Handles heat better
Eliminates rib cracking
Increased duty cycle providing long life
• Belt cording can be Cotton, Polyester or Aramid cord depending on the
quality of the belt purchased
• Belt Inspection process has changed from looking for rib cracks to
inspecting for rib wear.
Just 5% of belt wear will
facilitate belt slip.
• EPDM wears differently so cracks are minimal, if any
• Just 5% of belt wear will allow the belt to slip under load
• Rib wear is the predominant wear indicator and visually difficult to see
unless using a belt wear tool!
• The belt most always points to the root cause of the failure!
MICRO-V® BELT
QUICK AND EASY WAY TO INSPECT YOUR SERPENTINE BELT IN SECONDS
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2017 Gates Inc. All rights reserved.
How to use the belt wear gauge
Order on line or call local Gates rep
With the engine off, press the
gauge ribs into the belt grooves
using gentle pressure too hold the
gauge against the belt and seat
the ribs.
Attempt to rock the gauge
in a lateral motion (left and
right)
GO
OD
BE
LT
When the gauge remains
tightly seated and resists
movement, the belt has
sufficient service life left.
The gauge ribs will contact
the sides of the belt
material and the body may
rest slightly above the belt
surface.
When the gauge allows lateral
rocking motion, the belt is in
need of replacement.
The gauge ribs will not
contact the belt material
and the gauge body will
rest flat on the belt,
allowing movement in the
tool.
WO
RN
BE
LT
DETROIT DIESEL
ABDSYSTEM “PAT”
› Pulleys
› Alignment
› Tension
Off Tracking
!00% System Inspection if belt is remove for any reason.
PULLEY CHALLENGES
SPRAY BOTTLE TEST FOR NOISE
• Spray ABDS and “If” the noise goes up it is tension related
What Happens When a Belt Slips?
• Annoying belt squeal or noise
• Accessories operate at a diminished output
• Potential for DTCs such as PO300 Engine Misfire
• Creation of heat for the bearings/ premature bearing failure
• Excessive pulley wear as the belt slips
• Comeback if root cause is not found and corrected
• Reference Industry Warranty slide for percentages
PAT Related Belt Failures
My Belts Squealing!
Tension Related Noise:
Observe the system in Operation before
removing the belt
• Check ribs for wear using a belt wear
tool
• Inspect the tensioner for failure
• Clean all pulleys to improve belt/
pulley interface
Click to
play
video
Misalignment
•Serpentine belts can only tolerate 1°of misalignment
•Add 30°of heat for each additional degree of misalignment
•Noise normally begins at the shortest pulley spans
Gates Laser Alignment Tool
MISALIGNMENT CHALLENGES
• Maximum recommended misalignment for V-ribbed
belts is 1/16 inch per 12 inches of belt span length
(1/3 degree).
• Check using a straight edge or a Laser Alignment tool
• Spray and “if” the noise goes away and then comes back it is alignment related
My Belts Chirping!
Click to
play
video
Using the
new laser
alignment
tool
Alignment Related Chirp / Engine off
• Observe system running noting tensioner operation/ belt
tracking
• Note any accessory that has been replaced recently and
check its alignment first
• Remove belt and review rib wear pattern
• Use Laser Alignment tool #91075
• Check harmonic balancer for wear
• Check pulleys for bearing wear (Off tracking)
• Check for bent or broken brackets
• Check for accessory run out
• “Spin Cycle” tensioner for pivot bushing failure
Gates Laser Alignment Tool
MISALIGNMENT CHALLENGES
COMMON “PERCEIVED” BELT FAILURES (PAT) 32
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#1 Pilling
# 5 Contact with Engine
Broken
Belt
Rib Shear
#2 Pulley Problem
# 3 Pulley Misalignment
# 7 Belt Cracking
Sand Penetration Glazing
# 4 Contamination
#6 Normal Wear
Belt normally
points to the
corrective action
CORRECT BELT TENSION IS ABSOLUTELY CRITICAL!
The tensioner performs two job functions
• Maintains the correct belt tension throughout the tensioners duty cycle
• Dampens the impulses from the engine as each cylinder fires (Torsional Vibration)
Cycles a billion times in 100,000 miles
THE ACCESSORY OPERATION REVOLVES AROUND THE TENSIONER!
TENSIONER TEST – SPIN CYCLE
Tensioner Has Four Failure Modes
1. Spring begins to fail creating belt slippage
2. Internal pivot bushing is worn out, creating
misalignment and belt off tracking
3. Damper has failed allowing the tensioner arm
to hammer the system to death. (Torsional
Vibration.)
4. Tensioner pulley bearing worn out
• Value line tensioner/case failure
• Minimal damping ability
Spin Cycle Test
With the engine running, observe the tensioner in
operation. If you notice the tensioner arm bouncing, it is an
indication the damper has worn and both the belt and
tensioner should be replaced.
HAVE YOU SEEN ONE OF THESE?
Torsional Vibration / Hammering
Click for
video
BELT TROUBLESHOOTIING EXAMPLES
COMPRESSOR INSTALLATION
INSTRUCTIONS
Follow all Federal, State and Local
Regulations.
Proper A/C performance is dependent on
all systems performing properly. Make
certain that the engine cooling system is
at peak operation, and that the cooling
fan / fan clutch is operating properly.
Worn belts, idlers and tensioners can
cause poor cooling system performance
due to belt slippage. Low voltage at the
A/C clutch assembly can cause
premature compressor failure.
38 38
TIRE / BELT ANALOGY for PERFORMANCE
• A Tire has to have 4 things to insure Proper Performance
• Proper Tread
• Proper Alignment
• Proper Balance
• Proper Air Pressure
• A Belt has to have 4 things to insure Proper Performance
• Proper Rib Depth (Tread)
• Proper Alignment
• Proper Damping (Balance)
• Proper Belt Tension (Air Pressure)
Belts and tensioner were designed as a system
Correct alignment and tension are critical to the system
For best results preplace both together !
TIRE / BELT ANALOGY for PERFORMANCE
ROOT CAUSE FAILURE ANALYSIS
BELT FAILURE BEGINS WITH ALIGNMENT / TENSION RELATED CHALLENGE
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
Observe the ABDSystem in operation before removing belt
• Is this the second time replacing the same component?
• Perform simple belt analysis (look at the bottom)
• Is there belt system noise?
• Is there a DTC like 0300 Engine Misfire code that won’t recycle?
• Spray bottle test for tension/alignment challenges
• Use laser alignment tool to check for alignment issues
• Review trouble shooting guide for latest information
• Inspect all accessories / clean all the pulleys
• Spin Cycle tensioner to test for failure Cotton Ball Test
Spray Bottle Test
Spin Cycle Test
Observe
MICRO-V® BELT TROUBLE SHOOTING GUIDES
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2017 Gates Inc. All rights reserved.
Simple STEPs of diagnosing the noise problems by using the spray bottle test
Step1. Ask if the problem is more noticeable under what
conditions?
1. In the morning while the engine is cool
2. During highway driving
3. When idling or accelerating
4. A/C is under full load (switch on)
Step 2. Attempt to recreate the problem in the service bay
1. Spray water between the belt and pulley – if the noise level recedes for a
few seconds then returns = misalignment
2. If the noise immediately increases after the belt is sprayed with water,
lack of belt tension is the problem = rib wear or under-tensioned
Important Note : Never use Belt Dressing or Carb cleaner!
Collects dirt and grit
Deteriorates belt material
Click for
video
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Up to 70%
Up to 40%
SIMPLE ANALOGY
Click for
video
BELT NOISE IS AS SIMPLE AS RIGHT HAND / LEFT HAND 43
Right Hand Left Hand
Tension
Related
Problems
Alignment
Related
Problem
• Check for belt wear
• Check the Tensioner
for correct operation
Alignment Challenges
• Angular
• Parallel
• Run Out
ALTERNATOR DECOUPLER PULLEY
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
Power Hungry!
ALTERNATOR DECOUPLER PULLEY (ADP)
IT’S A “SACRIFICIAL” COMPONENT DEVELOPED TO SAVE THE ALTERNATOR!
Moved to Hi Amp Alternators
The purpose of an ADP is to allow the alternator to declutch/free
wheel/overrun from the ABDSystem upon deceleration
Used primarily on 4 cylinder engines and high revving engines
Removes torsional vibration from the ABDSytem
Saves gas when the engine is at idle stage
Easily replaced with proper tool
Prevents belt slip/wear
Referred to as : ADP (Alternator Decoupler Pulley),
OAP (Overrunning Alternator Pulley, OWC (One Way
Clutch Pulley)
Power Hungry!
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
WHAT IS IT’S PURPOSE ?
HOW DOES THIS AFFECT THE SERPENTINE SYSTEM?
Each time a cylinder fires
• Crankshaft speeds up and slows down creating Torsional Vibration.
• These firing pulses speed up and slow down the alternator
• The lower the RPM, the higher the Torsional Vibration
• Without a Decoupler Pulley, the pulses create vibration for the driver and cause the belt
tensioner to exhibit increased movement
• Increased tensioner movement equals less durability for both the tensioner and belt, as
well as all the other components within the belt drive system (including the alternator).
Click For
Video
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
UNDERSTANDING FAILURES
• It’s a Sacrificial component and failure can show up as early as 40 to 60,000 miles
– Identify that the alternator does have an ADP first
– Alternator light is on but “ No Charge”
– Alternator has stopped charging because of insufficient rotor rpm (slipping belt, failing tensioner or
failed ADP)
– The failing decoupler pulley rotates in both directions “free spin failure” when turned by hand
– Decoupler pulley is locked in both directions, when spun by hand
– System may experience excessive tensioner motion / belt squeal
– Buzzing noise heard 5-10 seconds after the engine is turned off (indicates bearing failure)
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
REMOVAL TOOL IS SIMPLE TO USE
Simple!
Click
for
video
ROOT CAUSE FAILURE ANALYSIS
BELT FAILURE BEGINS WITH ALIGNMENT / TENSION RELATED CHALLENGE
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
Observe the ABDSystem in operation before removing belt
• Is this the second time replacing the same component?
• Perform simple belt analysis (look at the bottom)
• Is there belt system noise?
• Is there a DTC like 0300 Engine Misfire code that won’t recycle?
• Spray bottle test for tension/alignment challenges
• Use laser alignment tool to check for alignment issues
• Review trouble shooting guide for latest information
• Inspect all accessories / clean all the pulleys
• Spin Cycle tensioner to test for failure Cotton Ball Test
Spray Bottle Test
Spin Cycle Test
Observe
› Belts and Tensioners
› Belt Kit
School Bus Kits
Class 8 Trucks Kits
Automotive Serpentine Belt Kits
Timing Belt Kits
PROBLEM SOLVING PRODUCTS (SOLUTIONS)
GATES SOLUTION TO THE PROBLEM
Industry Challenges
• Lack of knowledge on the latest changes creates a challenge for
any “system” asking its components to perform past their intended
lifecycle
Why Kits?
• Without proper tension, even the best new belt can’t efficiently
transfer power
• Kits get to the root of the problem. A worn or noisy belt is only part
of the issue
• Tensioners wear at the same rate as the belt and should be replaced
together
• A worn tensioner can make a new belt wear up to 2x faster
• Loose parts take more time to source /or forgotten about during
the repair
• Performing a complete system repair doesn't add much time, but
adds a lot of value ( and protects against returns)
To be eligible for Lifetime Warranty Shop Registers at www.Gates.com/CompleteKits
TRAINING 24 / 7 FROM GATES CORPORATION
http://gatesaftermarkettrainingcenter.com/
http://navigates.gates.com
www.gates.com/hub
https://www.youtube.com/user/GatesAutoAftermarket
https://youtu.be/w6CCMHmXn74
QUESTIONS
Don’t end up as part of the
survey, Offer the solution!
Solution to the Lack of Maintenance Problem in the ABDS
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
IR BELT INTERCHANGE
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
POWERBAND INTERCHANGE
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
Gates Industrial Belt Interchange Chart https://assets.gates.com/content/dam/gates/home/resources/resource-
library/application-specs/gatescorporationbeltidchart.pdf
Coolant Condition Creates Failure Technician Training
2019
COOLANT CONDITION IS CREATING PROBLEMS FOR THE COOLANT SYSTEMS!
PROBLEMS FOR THE COOLANT SYSTEM
Gates fully supports the coolant manufactures claim, that if you want to enjoy the extended life of their
product, you must fully flush and refill!
Parts in the System:
• Radiator
• Heater Core
• Radiator Hoses
• Radiator Cap
• Water Pump
• Thermostat
• Coolant
COOLING SYSTEM
Coolant System Purpose
• Cool the engine
• Warm the engine
• Prevent oil sludge
• Warm the transmission
• Warm the occupants
Surveys Say!
Up TO:
• 40% of Radiator failures due to condition of coolant
• 40% of Batteries returned, just needed charging
• 70% of Rotating Electrical performed as intended
• 90% of Timing Belts fail after just a belt is installed
• 91% - OE coolant hose failures are spiking at 10-11 years
• 95% of Water Pumps fail from lack of flushing
• 99.8% of Serpentine Belts returned were forced to fail
YOU ARE MISSING SOMETHING IMPORTANT !
Sampling of alleged warranties returned to factory
1. “If” certain conditions exist in the coolant system, mixing dissimilar coolants can create a reaction
2. Metals failing because of lack of protection from diluted inhibitors
3. Suspended solids in the contaminate solutions are destroying the water pump seal prematurely
THREE SPECIFIC PROBLEMS FOR THE INDUSTRY
Partial replacements of coolants are part of the problem!
95% of the water pump warranty claims submitted indicated
“no flush” completed.
When water pumps fail, there is almost always something wrong in the cooling system. Mechanical failure rate on water pumps is only about 2%.
Common symptoms:
• Debris in cooling system
• Exhausted add packs in coolant
• Restrictions in radiator
• Blending of coolants
• Incorrect coolant mix
• Introduction of hard water
WATER PUMPS
Water pumps are designed to last over 150K
Not all chemistries are the same
Not all colors are the same
17% Intermix = Contamination 44oz in a 2 gallon (256 oz) system
Uncontaminated
Contaminated
› What happens when some coolants are mixed?
› Depletion of inhibitors
› Metal failure
› Build up of rust and scale
› Particles lodged between WP seals
› Resulting in component failure
Condition of Coolant
Contamination – The inadvertent addition or presence of a component in a coolant that may reduce the
effectiveness of the coolant to provide corrosion protection/freeze/ boil protection
Certain conditions will affect the degree and rate at which metal surfaces corrode
• Balanced PH (9.5-10 PH )
• High concentration of dissolved oxygen and carbon dioxides in a coolant
Closed loop systems oxygen is normally consumed over time
• Incorrect coolant system temperature
• Acids form as the coolant wears
• Metal stress
• Corrosion inhibitors diluted or not present in the coolant
Overheating
Depleted coolant not
protecting Protection package
inadequate
Additive Package – Inorganic or organic chemicals in all
coolant that provide corrosion protection for coolant
systems
Corrosion – Damage to a coolant systems metal components due to improper coolant protection leading to
component failure and leaks ( Metals revert back to original form)
COOLANT CORROSION
66
COOLANT CORROSION
Coolant corrosion can cause many problems
• Reduce heat transfer due to surface scaling
• Perforation (holes) creating leakage
• Stopped up water passages
• Damage to mechanical seals
The most common form of corrosion for aluminum is pitting
The most common form of corrosion for iron is rust
Coolant system corrosion can be reduced through PH control and active inhibitors
Inhibitors – Chemical compounds which are part of the coolants additive package that prevent
corrosion
67
WATER / WHAT TO USE?
Use only distilled, demineralized, deionized water or a 50/50 premix
Chloride found in most tap water is corrosive
Hard water should not be considered as it introduces calcium and magnesium into the
coolant system
Abrasion Solids – Corrosion Inhibitors plus hard water components that have dropped out of the coolant solution that leads to premature water pump failure,
plugging of radiator heater core
Statements /Disclaimers on Compatibility Or Reliability
Will provide extended mileage up to 5 years with complete flush
No Warranty for Partial Replacement or Top Off!
Disclaimer Gates Fully Supports the Coolant Manufactures!
The next couple of slides are examples of information that leads to
misunderstandings during the repair process
Statements /Disclaimers on Compatibility Or Reliability
Will provide extended mileage up to 5 years with complete flush
No Warranty for Partial Replacement or Top Off!
Can be used to Top Off , However , to realize the 150k or 5 year maximum they recommend a complete
cooling system flush …….
Statements /Disclaimers on Compatibility Or Reliability
No Warranty for Partial Replacement or Top Off!
Statements /Disclaimers on Compatibility Or Reliability
• Very Direct Statement: OAT chemistry “may” be damaging to cooling systems that specify HOAT chemistry ….. It Will!
HOW WEEP HOLE LEAKS CAUSE BEARING FAILURE
Coolant travel path
Bearing
Unitized Bearing with
seals
Dynamic Seal Ring
.
Coolant travel path
Static Seal Ring Water Pump Seal
Water Pump Seal Weep Hole
Undamaged Seal Ring
Surface
Coolant contamination damages water pump seal
Contamination
Corrosion Inhibitors
Water
Freeze Depressant
Protection Package
Physical properties limit its use Freezes at 0 degrees C (32 degrees F) Boils at 100 degrees C (212 degrees F)
– Lower freeze point of solutions – Higher boiling point of solutions
Forms a thin coating on metal and restricts access to the metal
THE COOLANT TRIANGLE OF PROTECTION
THE COOLANT TRIANGLE OF PROTECTION
Corrosion Inhibitors
Water
Protection Package
Forms a thin coating on metal and restricts access to the metal
Physical properties limit its use Freezes at 0 degrees C (32 degrees F) Boils at 100 degrees C (212 degrees F)
– Lower freeze point of solutions – Higher boiling point of solutions
Freeze Depressant
Two Separate Issues Create Water Pump Failures
Cross coolant
contamination and
inhibitors not protecting
the metal!
Cross coolant
contamination and
inhibitors not protecting
the metal!
Suspended solids just
waiting to strike the water
pump seal, Full flush to
wash it out!
Two Separate Issues Create Water Pump Failures
WATER PUMP FAILURES MAY BE IN INDICATION OF FAILURES TO COME!
Flush the system if the pump looks like this!
Cavitation Bearing seal leak due to
water pump seal leak
Suspended debris in
coolant
Incompatible fluid
Protection package
inadequate
Mineral deposit buildup
If Flush and Fill has not been performed, the average vehicle may see water pump failure begin around 7,700 miles
Weep hole leak due to contamination
Source: Spectra Premium
Coolant mixture failure Plain water
Inappropriate rust inhibitor Hard tap water with heavy minerals and scale
build-up
WATER PUMP FAILURE MAY BE AN INDICATION OF IMPENDING FAILURES TO COME!
Results of Stop Leak Thermo Cycling Thermostat/Cap
Improper flush - contaminated system left debris that
clogs the radiator, can cause erosion and other problems
Depleted inhibitors not protecting
the cooling system from corrosion
EXAMPLE of RADIATOR FAILURES
Results of Stop Leak Thermo Cycling Thermostat/cap
Improper flush -Once contaminated system left debris that
clog the radiator and cause erosion and other problems. Source: Spectra Premium
Depleted inhibitors not protecting the cooling
system from corrosion.
WATER PUMP FAILURE MAY BE AN INDICATION OF IMPENDING FAILURES TO COME!
CONDITION OF COOLANT
Source: Spectra Premium
Over Heating
Coolant without corrosion inhibitors become
acid and oxidizes the aluminum making it black.
Source: Spectra Premium
CONDITION OF COOLANT
OLD TECHNIQUES AND TESTING METHODS ARE INADEQUATE TODAY
• Refractometer (Used only to verify the coolant mix is correct)
• Hydrometer (Measures specific gravity but no longer approved by ASTM)
• PH Test strips (Used to measure PH but may measure components that may or may not be in the coolant package providing incorrect results)
• Conductivity meters
• OAT contamination test kits
• Nitrite titration test kits
• Lab test kits
Current coolant flushing methods are ineffective at cleaning the system!
Testing and Servicing
• Refractometer to test protection - no hydrometer (no longer ASTM approved) coolants have different specific gravities
• Don’t worry about electrolysis. If a system has measurable voltage the coolant is already bad or you have another problem.
• Dip Strips are only accurate +-10 degrees, coolant must be under 120 F
• Determine clarity and color by drawing a sample off the bottom of the system after a short cool down.
• Old school flushing techniques are no longer adequate
THERMOSTAT
• Lower temp regulator - helps engine maintain a
minimum temperature
• Helps engine warm up
• Activates bypass system
• Has no effect on upper engine temperature
unless it sticks closed or it is missing.
• Replaced following an overheat
• Replaced anytime vehicle warm up time
increases
• Replaced during a modern flushing operation.
Copyright C 2018 Donald L Seyfer all rights reserved
MAP Control
Thermostat
• The pressure valve uses spring pressure so the cooling system can maintain above ambient pressure.
• 50/50 coolant boils at about 227 f. under ambient pressure
• At 14psi it climbs to 263F.
• The pressure valve allows small amount of coolant to be pushed into the recovery to account for expansion.
It is critical to keep air out of cooling systems
• When a system cools it contracts creating
vacuum
• The vacuum valve normalizes system
vacuum by drawing cooling back from the
overflow reservoir.
• A failed vacuum valve will generally result
in hoses sucked flat when the engine is
cooled down.
Radiator CAP
Copyright C 2018 Donald L Seyfer all rights reserved
Barrier Coatings, Damage Debris
• Add packs in antifreeze react with engine parts.
• Different in each formula - not mixable
• Mixing can create a slimy coating that impedes heat sink effect with coolant
• OAT Coolants like Dexcool can take many miles to lay down a barrier coating. If there is too much of any other package in there rapid corrosion can occur.
• Using an OAT coolant in a system not designed for it can cause cavitation resulting in water pump and cylinder wall damage
• If a system has been contaminated you will have to flush with water and a mild chemical cleaner to remove contamination and old barrier coating.
BARRIER COATINGS, DAMANGE DEBRIS
Damage can be caused by:
• Over-mixing coolant causing too high of
viscosity and low protection levels
• Engine overheat - coolant should be flushed
and replaced following an overheat along with
cap and t-stat.
• Wrong mixed of coolants
• Depleted add packs allowing corrosion or
cavitation
Debris in system can be a result of:
• Add pack exhaustion causing fall out of
silicates or rust formation.
• Sand left in block from casting
• Component damage from cavitation breaking
off small pieces.
• Oxygen entering system due to leaks, low
coolant, bad cap
Copyright C 2018 Donald L Seyfer all rights reserved
When Should Coolant be Replaced
• Whenever a component larger than a bypass hose is
replaced
• After an overheat
• About 3-5 years/60K
• If there has been an air leak into the system - radiator
cap failure or other leak
• When the engine is replaced
• Anytime there is a cooling system component failure
• Anytime debris is found in the system or the coolant
takes on a cloudy appearance
Flushing • Flushing equipment should be updated to a
pulsing component by component approach
• Pick a tool that is recommended by OE’s for
backflushing heater cores. The Gates tool
works extremely well to flush the engine and
radiator
• It is most effective to flush components
backwards and then forwards
• Many vehicles will need the thermostat removed
to effectively flush the engine
• If you capture the debris you wash out of the
system, customers will have a visual
understanding of how this is a benefit
• Some water is left behind so you must blow out,
add virgin antifreeze and use your refractometer
to get the mix right.
Copyright C 2018 Donald L Seyfer all rights reserved
WHEN SHOULD COOLANT BE REPLACED
Part# 91002
COOLANT EXCHANGE REVIEW PROCESS
Flush and Fill Procedure – (Acceptable Procedure)
Coolant drained, repair made. Flush and Fill manually or with proper machine utilizing a flushing solvent. Add 50/50
coolant to water ratio. Test Glycol level after run & cool down . Provides best protection to years or mileage
Water Hose Wash Procedure (Unacceptable results)
Coolant drained, repairs made and system flushed with a garden hose; new coolant/water added, possible
contamination once the engine is restarted
Drain and Refill Procedure (Unacceptable results)
Coolant drained from radiator, repair made, radiator refilled with new coolant. Engine block can hold 15 to 30 percent
after drained contaminating new coolant. (Depending on automotive or HD Vehicle)
Only a 17% inter-mix of coolants can create catastrophic failures!
Engine Flush Results – Garden Hose vs. Flush Tool
Flush Tool Garden Hose
Engine Flush Results
Radiator Flush Results
Heater Core Flush Results
FLUSH TOOL RESULTS
FLUSH TOOL
• Flushing with a garden hose will not get all the contaminants out
• Need a flush tool: attaches to your shop’s air supply and the water hose
• Most effective when rad, heater core and engine are flushed separately
• Creates a scrubbing action from pulsating water and lifts out debris
Clear
System refill after power wash
• Some water left behind - blow it out
• Use an air lift system to ensure there are no leaks
• Add approximate amount of virgin antifreeze first to offset left over water in
engine.
• Fill rest of system with 50/50 premixed coolant leaving it about a pint to a
quart low depending on system capacity
• Run engine for a couple of minute to mix coolant
• Use your refractometer to get the mix right.
Copyright C 2018 Donald L Seyfer all rights reserved
Part# 91002
FLUSHING THE SYSTEM
Flushing
• Flushing equipment should be updated to a pulsing component by component approach
• As a solution, Gates has a tool that is recommended by OE’s for back flushing heater cores. This tool works extremely well to flush the engine and radiator
• It is most effective to flush components backwards and then forwards
• Many vehicles will need the thermostat removed to effectively flush the engine
• If you capture the debris you wash out of the system customers will have a visual understanding of how this is a benefit
• Some water is left behind so you must blow out, add virgin antifreeze and use your refractometer to get the mix right.
If you have a
flush machine ….
Use It!! Part# 91002
Click For
Power
Clean
Flush Tool
Video Click For
Power
Clean
Flush Tool
Set Up
FLEETRUNNER EPDM VS SILICONE HOSE
2019
ASK
COOLANT HOSE
What’s Your Why – Ask Questions
• Does your customer require silicone?
• Why do you want to replace with silicone
• Application information
• Hose routing? Near a heat source?
• Are you replacing the OE hose
• Age of the vehicle
• Coolant loss issues
• Type of vehicle use
Silicone is not always the best solution
EPDM VERSUS SILICONE
DID YOU KNOW - THE GLOSSIER THE HOSE THE LESS RELIABLE ?
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
EPDM
Superior cut/abrasion resistance
Heat resistant to 300⁰F
Designed to work to 257⁰F where a
typical engine overheats & for
ambient temps to 300⁰F
Use of heat sleeve recommended
when near exhaust
Resists under hood fluids
Silicone
Soft cover and tube
Requires special lined clamp for best performance
Higher heat resistance
Only required if temperature is above 300⁰F
• Necessary when in proximity to exhaust or hot side turbo
Low resistance to under hood fluids
EPDM VS SILICONE - WRAP UP
EPDM = Lowest Cost Per Mile
Price advantage
Far less cold water leaks
Substantially decreased permeation
Special lined clamps not needed
Better resistance to abrasion
It is critical to understand the application when specifying a coolant hose product
Improved EPDM manufacturing techniques have created an alternative to silicone for many applications
STICK HOSE
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
EPDM VERSUS SILICONE
EPDM VS SILICONE
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
EPDM
Less costly, better profitability
Better sealing capability
Expands and contracts closer to the
rate of the spout
Adheres to spout
Less cold water leaks
50% higher pressure rating
Low H2O permeation
Cold Water Leaks
• EPDM is a better fit
• Less expansion and contraction
Silicone
23% more costly than the
FleetRunner
Less sealing ability
Expands and contracts at a higher rate
Inert, so it will not adhere to spout
Greater risk of cold water leaks
Requires special lined clamps
Lower pressure rating
High H2O permeation
15 X EPDM
WATER PERMEATION SILICONE VS. EPDM
Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
• Silicone permeates water at a much
great rate
• Use a Refractometer to minimize
coolant imbalance and internal metal
damage
Click
for
video
TRAINING 24 / 7 FROM GATES CORPORATION
http://gatesaftermarkettrainingcenter.com/
http://navigates.gates.com
www.gates.com/hub
https://www.youtube.com/user/GatesAutoAftermarket
https://youtu.be/w6CCMHmXn74
Questions?
For additional information contact
Your local Gates Representative or Bobby Bassett at
Thank You!
Gates: Keeping your vehicles on the road and safe!
2019 Gates All Rights reserved
