Department Customer Service

Category Service Manual

Section Cooling System
Title Extended Life Coolant (ELC)

Number KM812010

Service Date

Model
07/11/05
W900, T2000, T600, T800, T300,

Manual Page
C500
1 of 4

W900 T2000 T600 T800 T300 C500

C500

Extended Life Coolant (ELC)

(also known as Long Life Coolant)

Cooling System: Extended Life Coolant (ELC)
ELC Coolant
Click on this link for important information concerning
Extended Life Coolant.
Top-off of Cooling System
If a chassis has Extended Life Coolant, always top-off the
engine’s cooling system with Chevron Delo or Texaco
Prediluted 50/50 Extended Life Coolant. Proper top-off
will assure excellent corrosion and freeze protection and
minimize the need for routine coolant testing and remedi-
ation. The addition of Extender at 300,000 miles will fur-
ther protect the system against corrosion to a total of
600,000 miles.
If there is a possibility that the engine’s coolant has been
diluted with either water or with another conventional
coolant, the following additional routine maintenance
practices must be followed. These practices will ensure
the engine’s cooling system is properly protected against
damage that may be caused by corrosion or coolant
freeze-up. These recommended procedures must be fol-
lowed at routine maintenance intervals when system dilu-
tion is a possibility.
1. Allow engine to cool before attempting to open the
engine’s cooling system or to perform any other cool-
ing system maintenance.
2. Check all cooling system hoses and clamps to insure
they are in good condition and well secured. Before
proceeding, replace worn or leaking components and
tighten leaking fittings as warranted.
3. Take a sample of the engine coolant (either from the
radiator or from the system’s in-line surge or overflow
tank) using a dropper, such as that supplied with the
shop’s refractometer.
4. Using the refractometer, check the coolant for proper
freeze point protection. Follow the manufacturer’s
instructions for proper use of the refractometer. A
properly maintained coolant will have a freeze point
between -15° F and -60° F. If the refractometer indi-
cates that an acceptable freeze point is achieved,
please skip to step 6 below.
5. If the refractometer indicates that a freeze point cor-
rection is needed, the coolant will have to be
adjusted using a Chevron Delo Extended Life Cool-
ant Concentrate product.
If the Refractometer indicates that the system is
under-concentrated (insufficient freeze protection),
Page 2 of 4
Number KM812010
use “TABLE 2: Freeze Protection Adjustment: Added
Freeze Protection” on page 3) to determine the
amount of coolant that must be removed from the
engine's cooling system and replaced with an equal
amount of ELC Concentrate.
If the system is over-concentrated (freeze protection
greater than -60oF) use “TABLE 3: Freeze Protection
Adjustment: Over-Concentration” on page 4 to deter-
mine the amount of coolant that must be removed
from the engine's cooling system and replaced with
an equal amount of good quality water.
After making the recommended corrections, close
the system and run the engine until it comes up to
operating temperature. Allow the system to cool once
again, then proceed to step 6 below.
6. The cooling system has adequate freeze protection.
Now check for adequate corrosion protection using
either
• the Extended Life Coolant Dilution Test Kit
or
• the FleetFix Test Strip
Carefully follow the instructions that come with either
the kit or the test strip. If the kit or the test strip indi-
cate acceptable inhibition, the coolant has adequate
inhibitors to insure corrosion protection. Proceed to
step 8. If a coolant fail is indicated, please proceed to
step 7.
7. The test strip or test kit has indicated that the coolant
is lacking extended life corrosion protection. This
may indicate that the coolant has been topped off
with a conventional coolant; its Extended Life corro-
sion inhibitors have been diluted and the coolant is
no longer providing extended protection. At this point
you may choose to send a sample of coolant to a
commercial laboratory offering analysis for extended
life coolant to verify the test results. If you know that
the cooling system has been topped of with conven-
tional coolant or if laboratory testing indicates protec-
tion is lacking, you should replace the coolant with
fresh Extended Life Coolant.
If hot, let engine cool; drain coolant by opening radia-
tor and engine block drain plugs*. Close the coolant
filter shut off valve, if present. Close drain plugs and
fill cooling system with flush water. Replace radiator
cap. Start up engine and allow to idle until thermostat
opens. Turn on cab heater after engine reaches oper-
ating temperature and continue to idle engine for 15
 Page 3 of 4

Cooling System: Extended Life Coolant (ELC) Number KM812010

minutes. Let engine cool. Drain all flush water from

cooling system and dispose of properly*. Remove old
coolant filter and install a new non-chemical coolant
filter or plug off. Open the coolant filter shut off valve.
(*Collect and dispose of all drained coolant in accor-
dance with all local laws and regulations.) Fill cooling
system with Chevron Extended Life Prediluted 50/50.
Leave some room to allow for freeze point adjust-
ment. Close radiator cap and run engine until the
thermostat opens. Allow system to circulate for 15
minutes after thermostat opens. Allow engine to cool.
Test coolant freeze point using a refractometer.
Adjust if needed. After adjusting freeze point, top up
system to full line with ELC Extended Life Prediluted
50/50. Appropriate labeling/tagging to identify con-
verted engines.
8. The cooling system has adequate freeze and corro-
sion protection. Close the system. It is now ready to
operate. Remember, if coolant top-up is required
before the next scheduled PM, be sure to top-up with
a Chevron Delo Prediluted 50/50 Extended Life Cool-
ant product. If top-up is required to bring the coolant
level to the cold-fill mark, always allow the system to
cool before checking coolant level. Then add a Chev-
ron Delo Prediluted 50/50 Extended Life Coolant
product until the coolant level reaches the required
mark.

TABLE 2: Freeze Protection Adjustment: Added Freeze Protection

FREEZE POINT ADJUSTMENT CHART FOR UNDERCONCENTRATED SYSTEMS
(USE THIS CHART TO ADJUST YOUR FREEZE POINT UP TO - 35F)
FOR USE WITH ETHYLENE GLYCOL BASED FLUIDS.
%
TESTED AF
FREEZE IN TOTAL COOLANT SYSTEM VOLUME
PROTECTION COOLANT 7-GAL 8-GAL 9-GAL 10-GAL 11-GAL 12-GAL 13-GAL 14-GAL 15-GAL
VOLUME TO DRAIN AND REPLACE WITH COOLANT CONCENTRATE
25 10 3 3 1/2 4 4 1/2 5 5 1/4 5 3/4 6 1/4 6 3/4
20 16 2 3/4 3 1/4 3 3/4 4 4 1/2 4 3/4 5 1/4 5 3/4 6
15 21 2 1/2 3 3 1/4 3 3/4 4 4 1/2 4 3/4 5 1/4 5 1/2
10 25 2 1/4 2 3/4 3 3 1/4 3 3/4 4 4 1/4 4 3/4 5
5 29 2 2 1/4 2 3/4 3 3 1/4 3 1/2 3 3/4 4 1/4 4 1/2
0 33 1 3/4 2 2 1/4 2 1/2 2 3/4 3 3 1/4 3 1/2 3 3/4
-5 36 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 2 3/4 3 3 1/4
-10 39 1 1/4 1 1/2 1 1/2 1 3/4 2 2 1/4 2 1/4 2 1/2 2 3/4
-15 42 1 1 1 1/4 1 1/2 1 1/2 1 3/4 1 3/4 2 2
-20 44 3/4 3/4 1 1 1 1/4 1 1/4 1 1/2 1 1/2 1 1/2
-25 46 1/2 1/2 3/4 3/4 3/4 1 1 1 1
-30 48 1/4 1/4 1/4 1/2 1/2 1/2 1/2 1/2 1/2
-35 50 0 0 0 0 0 0 0 0 0

USING A REFRACTOMETER MEASURE FREEZE POINT OF COOLANT. MATCH READING WITH VALUE UNDER THE
"TESTED FREEZE PROTECTION" COLUMN. DETERMINE COOLING SYSTEM VOLUME AND USING CHART
DETERMINE VOLUME OF COOLANT TO DRAIN FROM COOLING SYSTEM. REPLACE DRAINED VOLUME WITH
COOLANT CONCENTRATE.

USE REFRACTOMETER TO CHECK FREEZE PROTECTION

 Page 4 of 4

Cooling System: Extended Life Coolant (ELC) Number KM812010

TABLE 3: Freeze Protection Adjustment: Over-Concentration

FREEZE POINT ADJUSTMENT CHART OVERCONCENTRATED SYSTEMS

(USE THIS CHART TO ADJUST FREEZE POINT DOWN TO -35F)

FREEZE %
PROTECTION AF
OF SAMPLE IN
MIXED 50/50 COOLANT TOTAL COOLANT SYSTEM VOLUME
WITH WATER 7-GAL 8-GAL 9-GAL 10-GAL 11-GAL 12-GAL 13-GAL 14-GAL 15-GAL
VOLUME TO DRAIN AND REPLACE WITH DI WATER
+10 50 0 0 0 0 0 0 0 0 0
+7 55 3/4 3/4 3/4 1 1 1 1/4 1 1/4 1 1/4 1 1/2
+5 60 1 1/4 1 1/4 1 1/2 1 3/4 1 3/4 2 2 1/4 2 1/4 2 1/2
0 65 1 3/4 1 3/4 2 1/4 2 1/4 2 1/2 2 3/4 3 3 1/4 3 1/2
-5 70 2 2 1/4 2 3/4 2 3/4 3 1/4 3 1/2 3 3/4 4 4 1/4
-6 75 2 1/4 2 3/4 3 3 1/4 3 3/4 4 4 1/4 4 3/4 5
-12 80 2 3/4 3 3 1/2 3 3/4 4 1/4 4 1/2 5 5 1/4 5 3/4
-18 85 3 3 1/4 3 3/4 4 1/4 4 1/2 5 5 1/2 5 3/4 6 1/4
-23 90 3 3 1/2 4 4 1/2 5 5 1/4 5 3/4 6 1/4 6 3/4
-29 95 3 1/4 3 3/4 4 3/4 4 3/4 5 1/4 5 3/4 6 1/4 6 3/4 7 1/4
-34 100 3 1/2 4 4 1/2 5 5 1/2 6 6 1/2 7 7 3/4

IF REFRACTOMETER READING IS OFF SCALE OR SHOWS A FREEZE POINT FOR THE SAMPLE LOWER
THAN -62F USE THE CHART ABOVE TO ADJUST THE FREEZE POINT TO -35F. TO DO THIS TAKE THE
COOLANT SAMPLE AND DILUTE IT 50/50 WITH WATER. TAKE A NEW REFRACTOMETER READING AND MATCH
THIS VALUE TO THE READING UNDER THE "FREEZE PROTECTION OF SAMPLE MIXED 50/50 WITH WATER"
COLUMN. DETERMINE YOUR COOLING SYSTEM VOLUME AND BASED ON THE CHART ABOVE DRAIN THE
RECOMMENDED AMOUNT OF COOLANT AND REPLACE THAT VOLUME WITH WATER. RECHECK FREEZE
POINT.

USE REFRACTOMETER TO CHECK FREEZE PROTECTION