2003/08/11 Caterpillar

Machine Engines:

3114

3116

3126

3126B

3208

C-9

General Information on Coolant Recommendations

Maintenance of the coolant and maintenance of the temperature regulator are important in order to achieve the optimum cooling component and cooling system performance. Degradation of the coolant due to improper maintenance can lead to reduced life and/or damage of the temperature regulator and other cooling system components. Caterpillar recommendations are provided for guidance on the proper maintenance of the cooling system.

The following two coolants are used in Caterpillar diesel engines:

Preferred - Cat ELC (Extended Life Coolant) or a commercial heavy duty coolant that meets the Caterpillar EC-1 specification

Acceptable - Cat DEAC (Diesel Engine Antifreeze/Coolant) or a commercial heavy-duty coolant/antifreeze that meets current "ASTM D4985" or "ASTM D6210" specifications

Caterpillar recommends a 1:1 mixture of water and glycol. This mixture of water and glycol will provide optimum heavy-duty performance as a coolant/antifreeze.

Cat ELC (Extended Life Coolant)

Caterpillar provides Cat ELC for use in the following applications:

• Heavy-duty diesel engines

• Automotive applications

The anti-corrosion package for Cat ELC is different from the anti-corrosion package for most other coolants. Cat ELC is an ethylene glycol base coolant. However, Cat ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite. Cat ELC has been formulated with the correct amounts of these additives in order to provide superior corrosion protection for all metals in the cooling system of diesel engines.

Cat ELC extends the service life of the coolant to 12000 service hours or six years. Cat ELC does not require the frequent additions of a Cat SCA (Supplemental Coolant Additive). Cat ELC Extender is the only additional maintenance that is needed at 6000 service hours or three years.

Note: Replacement of the temperature regulator is required under the following circumstances. The temperature regulator has been in service for 6000 hours. The cooling system has been flushed, or the cooling system has been drained and filled with NEW coolant.

Cat ELC is available in a 50/50 premixed cooling solution with distilled water or deionized water. The 50/50 premixed cooling solution of Cat ELC provides a freezing point of -37°C (-34°F). Cat ELC Concentrate can be used to lower the freezing point to -51°C (-60°F) for arctic conditions. Do not exceed a 60/40 ethylene glycol and water mixture.

Consult your Caterpillar dealer for the part numbers of Cat ELC, Cat ELC Extender, and Cat ELC Concentrate.

In certain circumstances, Cat ELC can be filtered and reused. Refer to "Filtering and Reusing Cat ELC".

Cat DEAC (Diesel Engine Antifreeze/Coolant)

Caterpillar recommends using Cat Diesel Engine Antifreeze/Coolant (DEAC) for cooling systems that require a heavy-duty coolant/antifreeze. Cat DEAC is an alkaline single-phase ethylene glycol type antifreeze that contains corrosion inhibitors and antifoam agents.

Cat DEAC is formulated with the correct amount of Supplemental Coolant Additive (SCA). Do not use SCA at the initial fill with Cat DEAC. The coolant should be sampled and tested after every 250 hours of operation. The results of the test should regulate the additions of the Cat SCA. The service life of the Cat DEAC is 3000 hours or three years.

Cat DEAC is available as a concentrate. If concentrated Cat DEAC is used, Caterpillar recommends dilution with distilled water or deionized water. If distilled water or deionized water is not available, refer to General Coolant Information in order to determine the requirements for acceptable water.

Note: Replacement of the temperature regulator is required under the following circumstances. The temperature regulator has been in service for 6000 hours. The cooling system has been flushed, or the cooling system has been drained and filled with NEW coolant.

Cat SCA (Supplemental Coolant Additive)

The Cat SCA has the following benefits:

• Prevention of corrosion to metals

• Prevention of deposit formations of minerals

• Prevention of cavitation of the cylinder liners

• Elimination of foaming of the coolant

Test the Cat SCA concentration or submit a coolant sample to your Caterpillar dealer at every oil change. After every 250 service hours, a liquid Cat SCA or a Cat SCA maintenance element may be needed. The addition of Cat SCA is based on the result of coolant analysis. Your Caterpillar dealer has test kits that will evaluate the concentration of additives in Cat DEAC.

The following table indicates the amount of Cat SCA that is needed at the initial fill to treat commercial heavy-duty coolant/antifreezes. The table also shows the addition of an Cat SCA for either liquid SCA or for the maintenance elements of a SCA. These additions are for commercial heavy-duty coolant/antifreezes and for Cat DEAC.

Note: Due to the individual engine applications, the maintenance practices need to be periodically reviewed in order to maintain the cooling system.

Commercial Heavy-Duty Coolant/Antifreezes and SCA

If Cat DEAC is not used, select a heavy-duty coolant/antifreeze with a low silicate content that meets "ASTM D4985" or "ASTM D6210". When a commercial heavy-duty coolant/antifreeze is used, the system must be treated with the Cat SCA. Maintain a concentration level in the cooling system that is between 3 percent and 6 percent by volume. If the Cat SCA is not used, select a commercial SCA. The commercial SCA must contain a minimum concentration of 1200 mg/L (1200 parts per million) of nitrite content. Follow the recommended guidelines for adding SCA when you maintain the coolant. In all cases, the Caterpillar guidelines for acceptable water must be followed.

Note: Replacement of the temperature regulator is required under the following circumstances. The temperature regulator has been in service for 6000 hours. The cooling system has been flushed, or the cooling system has been drained and filled with NEW coolant.

Note: If you do not use the Caterpillar DEAC, you must drain the cooling system annually. The cooling system must be flushed at this time as well.

Commercial ELC

If ELC is not used, then select a commercial ELC that meets the Caterpillar specification of EC-1 and either the "ASTM D4985" specification or the "ASTM D6210" specification. Do not use an extended life coolant that does not meet the EC-1 specification. Follow the maintenance guide for the coolant from the supplier of the commercial ELC. Follow the Caterpillar guidelines for the quality of water and the specified coolant change interval.

Note: Replacement of the temperature regulator is required under the following circumstances. The temperature regulator has been in service for 6000 hours. The cooling system has been flushed, or the cooling system has been drained and filled with NEW coolant.

Changing to Caterpillar ELC

When a system is converted from heavy-duty coolant/antifreeze to Cat ELC, care must be taken in order to ensure that the proper cleaning and flushing procedures are followed. Refer to, SEBU6250, "Caterpillar Machine Fluids Recommendations". To change from heavy-duty coolant/antifreeze to Cat ELC, perform the following steps:

1. Drain the coolant into a suitable container.

2. Dispose of the coolant according to local regulations.

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NOTICE
Do not leave an empty SCA maintenance element on a system that is filled with ELC. The element housing may corrode and leak causing an engine failure. Remove the SCA element/canister base and plug off or by-pass the coolant lines.

3. Remove the empty SCA maintenance element and remove the element base. Plug the coolant lines or bypass the coolant lines.

4. Flush the system with clean water in order to remove any debris.

5. Use Caterpillar Cooling System cleaner to clean the system. Follow the instructions on the label.

6. Drain the cleaner into a suitable container. Flush the cooling system with clean water.

   Note: Deposits that remain in the system may be loosened and removed by the ELC.

7. In systems with heavy deposits, it may be necessary to disconnect the hoses. Clean the deposits and debris from the hoses and the fittings. Install the hoses and tighten the hose fittings. Pipe threads may also need to be cleaned and sealed. Seal the threads with 5P-3413 Pipe Sealant .

8. Fill the cooling system with clean water and operate the engine until the engine is warmed to 49 to 66°C (120 to 150°F).

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NOTICE
Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone.

9. Drain the cooling system into a suitable container and flush the cooling system with clean water.

   Note: The cooling system cleaner must be thoroughly flushed from the cooling system. Cooling system cleaner that is left in the system will contaminate the coolant. The cleaner may also corrode the cooling system.

10. Repeat Steps 8 and 9 until the system is completely clean.

11. Fill the cooling system with Cat ELC.

12. Operate the engine until the engine is warmed. While the engine is running, inspect the engine for leaks. Tighten hose clamps and connections in order to stop any leaks.

13. Attach the Special Publication, PEEP5027, "Label - ELC Radiator Label" to the radiator top tank in order to indicate the use of Cat ELC.

Note: Clean water is the only flushing agent that is required when the ELC is drained from the cooling system.

Cat ELC Extender

Cat ELC Extender is added to the cooling system halfway through the ELC service life. Treat the cooling system with ELC Extender at 6000 hours or three years of the coolant service life.

Use the formula in Table 3 to determine the proper amount of ELC Extender for your cooling system. Refer to Operation and Maintenance Manual, "Refill Capacities" in order to determine the capacity of the cooling system.

Proper additions to the Extended Life Coolant

In order to maintain the correct balance between the antifreeze and the additives, you must maintain the recommended concentration of ELC. Lowering the proportion of antifreeze lowers the proportion of additive. This will lower the ability of the coolant to protect the system from pitting, from cavitation, from erosion, and from deposits.

Contamination of the ELC Cooling System

In cooling systems that use the Cat ELC, do not add the Cat DEAC as a makeup coolant. Contamination of Cat ELC by Cat DEAC or another conventional coolant will defeat the advantages of Cat ELC. If the contamination exceeds ten percent of the total system capacity perform ONE of the following procedures:

1. Drain the cooling system into a suitable container and dispose of the coolant according to local regulations. Flush the system with clean water. Fill the system with ELC.

2. Maintain the system as a conventional Cat DEAC. Treat the system with SCA. Change the coolant at the interval that is recommended for the conventional Cat DEAC.

S O S Coolant Analysis

Testing the engine coolant is important to ensure that the engine is protected from internal cavitation and corrosion. The analysis also tests the ability of the coolant to protect the engine from boiling and freezing. S·O·S Coolant Analysis can be done at your Caterpillar dealer. Caterpillar S·O·S Coolant Analysis is the best way to monitor the condition of your coolant and your cooling system. S·O·S Coolant Analysis is a program that is based on periodic samples.

New Systems, Refilled Systems, and Converted Systems

Perform a Level 2 once per year or at the 500 service interval.

Perform the coolant analysis (Level 2) if the following conditions exist:

• Filling a new cooling system

• Refilled systems

• Converted systems that use Cat Extended Life Coolant (ELC) or Cat Diesel Engine Antifreeze/Coolant (DEAC)

This coolant analysis (Level 2) will also check for any residual cleaner that may have contaminated the system.

Recommended Interval for S·O·S Coolant Sample

Perform a coolant analysis (Level 1) at 250 service hour interval. Perform a coolant analysis (Level 2) annually, or perform a coolant analysis (Level 2) when a problem is identified by a coolant analysis (Level 1).

Perform a coolant analysis (Level 1) at every 250 service hour interval. Perform a coolant analysis (Level 2) annually, or perform a coolant analysis (Level 2) when a problem is identified by a coolant analysis (Level 1).

Note: Check the concentration of the standard coolant's Supplemental Coolant Additive (SCA) at every oil change.

S·O·S Coolant Analysis (Level 1)

A coolant analysis (Level 1) is a test of the properties of the coolant.

The following properties of the coolant are tested:

• Glycol concentration for freeze protection and boil protection

• Ability to protect from erosion and corrosion

• pH

• Conductivity

• Visual analysis

• Odor analysis

The results are reported, and appropriate recommendations are made.

S·O·S Coolant Analysis (Level 2)

A coolant analysis (Level 2) is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the inside of the cooling system.

The S·O·S Coolant Analysis has the following features:

• Full coolant analysis (Level 1)

• Identification of the source of metal corrosion and of contaminants

• Water hardness

• Identification of buildup of the impurities that cause corrosion

• Identification of buildup of the impurities that cause scaling

The results are reported, and appropriate recommendations are made.

For more information on S·O·S Coolant Analysis, consult your Caterpillar dealer.

Maintenance Interval Schedule

The following table for the maintenance interval should be followed in order to ensure optimum performance and quality of the coolant, cooling system, and temperature regulators. Refer to, SEBU6250, "Caterpillar Machine Fluids Recommendations" for more information.

Filtering and Reusing Cat ELC

Note: Coolant that has been drained and filtered must be returned to the same engine.

Note: This is not a recommended practice for Caterpillar machines and engines. However special circumstances may warrant this practice. Examples of special circumstances

• Early hour failure

• Service intervals which include draining of the coolant

Cat ELC can be filtered and reused. Refer to "Procedure for Draining the Coolant and Reusing the Coolant" for more detailed instructions. The coolant must have the glycol level and the nitrite level tested. Also, a S·O·S coolant analysis (Level 2) must be performed.

Note: If Cat ELC is not used, follow the maintenance guide for the coolant that is provided by the supplier of the commercial coolant.

Procedure for Draining the Coolant and Reusing the Coolant

Note: The following procedure is for engines and/or cooling systems with Cat ELC. The coolant must have less than 8,000 service hours or 4 years of service life. Coolant that has been drained and filtered must be returned to the same engine.

1. This procedure should be performed in an enclosed, controlled environment in order to minimize contamination of the coolant that might occur in the field.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

2. Drain the ELC from the coolant system into a suitable container. Use 222-6714 Fuel Filter Gp to filter the coolant as the coolant flows into the container.

3. Make any necessary repairs to the cooling system.

4. Flush the system with clean water in order to remove any debris. Refer to, SEBU6250, "Caterpillar Machine Fluids Recommendations". Allow the system to drain, and then reseal the system.

5. Check the glycol level of the coolant/antifreeze. Use 1U-7298 Coolant/Battery Tester or 1U-7297 Coolant/Battery Tester .

6. Check the nitrite level of the cooling system. Use 4C-9301 Coolant Conditioner Test Kit and follow the recommendations.

7. Submit a coolant sample for S O S Coolant Analysis (Level 2). Contact your Caterpillar Dealer for more information.

Special Tools

If the glycol levels and nitrate levels and the Level 2 Coolant Analysis are acceptable, return the ELC to the cooling system. Use the following Caterpillar tools in order to prevent debris from entering the cooling system:

• 222-6714 Fuel Filter Gp (100 mesh screen)

• 4C-7326 Diaphragm Pump Gp (30 gpm pump)

• 5P-0492 Adapter

Note: The adapters are used to convert the fitting to 1 inch pipe in order to facilitate the refilling and draining of the cooling system. Two adapters are required. Install one adapter in the inlet side of the coolant filter and install the other adapter in the outlet side of the coolant filter.

Aftermarket Products and Warranty