3208 Marine Engine Extended Life Coolant (ELC) Cooling System Maintenance Caterpillar


Extended Life Coolant (ELC) Cooling System Maintenance
`
1.1. Proper additions to the Extended Life Coolant
2.1. Caterpillar ELC Extender
3.1. ELC Cooling System Cleaning
4.1. Changing to Caterpillar ELC
5.1. ELC Cooling System Contamination
6.1. Commercial ELC

Proper additions to the Extended Life Coolant


NOTICE

Use only AVSpare products or commercial products that have passed AVSpare's EC-1 specification for pre-mixed or concentrated coolants.

Use only AVSpare Extender with Extended Life Coolant.

Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. Failure to follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed.


In order to maintain the correct balance between the antifreeze and the additives, you must maintain the recommended concentration of Extended Life Coolant (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.


NOTICE

Do not use a conventional coolant to top-off a cooling system that is filled with Extended Life Coolant (ELC).

Do not use standard supplemental coolant additive (SCA). Only use ELC Extender in cooling systems that are filled with ELC.


AVSpare ELC Extender

AVSpare 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 one half of the coolant service life. Use Table 1 in order to determine the proper amount of ELC Extender that is required.

Containers of several sizes are available. Consult your AVSpare dealer for the part numbers.

Use the formula in Table 1 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.

Table 1
Formula For Adding ELC Extender To ELC 
V × 0.02 = X 
V is the total capacity of the cooling system. 
X is the amount of ELC Extender that is required. 

Table 2 is an example for using the formula that is in Table 1.

Table 2
Example Of The Equation For Adding ELC Extender To ELC(1) 
Total Volume of the Cooling System (V)  Multiplication Factor  Amount of ELC Extender that is Required (X) 
9 L (2.4 US gal)  × 0.02  0.18 L (0.05 US gal) or (6 fl oz) 
(1) This example is based on the capacity of a C2.2 Generator Set with a cooling system capacity of 9 L (2.4 US gal).


NOTICE

When using Cat ELC, do not use standard SCA's or SCA filters. To avoid SCA contamination of an ELC system, remove the SCA filter base and plug off or by-pass the coolant lines.


ELC Cooling System Cleaning

Note: If the cooling system is already using ELC, cleaning agents are not required to be used at the specified coolant change interval. Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage.

Clean water is the only cleaning agent that is required when ELC is drained from the cooling system.

ELC can be recycled. The drained coolant mixture can be distilled in order to remove the ethylene glycol and the water. The ethylene glycol and the water can be reused. Consult your AVSpare dealer for more information.

After the cooling system is drained and after the cooling system is refilled, operate the engine while the cooling system filler cap is removed. Operate the engine until the coolant level reaches the normal operating temperature and until the coolant level stabilizes. As needed, add the coolant mixture in order to fill the system to the proper level.

Changing to AVSpare ELC

To change from heavy-duty coolant/antifreeze to the AVSpare ELC, perform the following steps:


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, "AVSpare Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on AVSpare products.

Dispose of all fluids according to local regulations and mandates.


  1. Drain the coolant into a suitable container.

  2. Dispose of the coolant according to local regulations.


    NOTICE

    Do not leave an empty SCA filter on an ELC system.

    The filter housing may corrode and leak causing an engine failure.

    Remove the SCA filter base and plug off or by-pass the coolant lines.


  3. Remove the empty SCA filter and remove the filter 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 AVSpare cleaner to clean the system. Follow the instruction on the label.

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

  7. 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).


    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.


  8. 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.

  9. Repeat Steps 7 and 8 until the system is completely clean.

  10. Fill the cooling system with the AVSpare premixed ELC.

  11. Attach the Special Publication, PEEP5027, "Label" to the cooling system filler for the engine in order to indicate the use of AVSpare ELC.

ELC Cooling System Contamination


NOTICE

Mixing ELC with other products reduces the effectiveness of the ELC and shortens the ELC service life. Use only AVSpare products or commercial products that have passed the AVSpare EC-1 specification for premixed or concentrate coolants. Use only AVSpare ELC Extender with AVSpare ELC. Failure to follow these recommendations can result in shortened cooling system component life.


ELC cooling systems can withstand contamination to a maximum of ten percent of conventional heavy-duty coolant/antifreeze or SCA. If the contamination exceeds ten percent of the total system capacity, perform ONE of the following procedures:

  • Drain the cooling system into a suitable container. Dispose of the coolant according to local regulations. Flush the system with clean water. Fill the system with the AVSpare ELC.

  • Drain a portion of the cooling system into a suitable container according to local regulations. Then, fill the cooling system with premixed ELC. This should lower the contamination to less than 10 percent.

  • Maintain the system as a conventional Diesel Engine Antifreeze/Coolant (DEAC). Treat the system with an SCA. Change the coolant at the interval that is recommended for the conventional Diesel Engine Antifreeze/Coolant (DEAC).

Commercial ELC

If AVSpare ELC is not used, then select a commercial ELC that meets the AVSpare specification of EC-1 and either the "ASTM D5345" specification or the "ASTM D4985" 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 AVSpare guidelines for the quality of water and the specified coolant change interval.

Information System:

793C and 793C XQ Off-Highway Truck Hydraulic System Hoist Cylinder
IT28G Integrated Toolcarrier Cab Air Filter - Clean/Replace
950G Wheel Loader, 962G Wheel Loader and IT62G Integrated Toolcarrier Braking System Service Brakes
3208 Marine Engine Water/Supplemental Coolant Additive (SCA)
IT28G Integrated Toolcarrier Battery Disconnect Switch
3208 Marine Engine Conventional Coolant/Antifreeze Cooling System Maintenance
950G Wheel Loader, 962G Wheel Loader and IT62G Integrated Toolcarrier Braking System Vane Pump (Implement, Pilot and Braking)
3208 Marine Engine Coolant Recommendations
3208 Marine Engine General Coolant Information
3208 Marine Engine S·O·S Oil Analysis
3208 Marine Engine Fuel Recommendations
3208 Marine Engine Lubricating Grease
IT28G Integrated Toolcarrier Bucket Rated Load
3208 Marine Engine Cooling System Supplemental Coolant Additive (SCA) - Test/Add
IT28G Integrated Toolcarrier Material Handling Arm Rated Load
3208 Marine Engine Cooling System Coolant Extender (ELC) - Add
793B Off-Highway Truck Air System and Brakes Service and Parking Brake (Front)
322B, 322B L, 325B and 325B L Excavators Operation
793B Off-Highway Truck Air System and Brakes Service and Parking Brake (Rear)
631E Series II Wheel Tractor-Scrapers Tire Inflation with Nitrogen
561M Pipelayer Cooling System Additive (DEAC) - Add
IT28G Integrated Toolcarrier Pallet Fork Rated Load
322B, 322B L, 325B and 325B L Excavators Operating Technique Information
561M Pipelayer Seat Adjustment