Evans Cooling Systems, Inc.

255 Gay Street Sharon, CT 06069

INSTALLATION PROCEDURE Detroit Diesel Series 60

Procedure for installing Evans Waterless HDTC, 205 F thermostats1, and a ResistorPac into a Detroit Diesel Series 60 engine VER12Aug2011 CAUTIONARY NOTE: DO NOT FLUSH COOLING SYSTEM WITH WATER! REGARDING OLDER ENGINES: Metal to metal connections may be corroded. Do not apply force that can damage such connections and cause leaks. The ResistorPac raises the fan-on, fan-off, and derating temperatures by making the ECM think the temperatures are cooler than they really are. An ECM-driven Coolant temperature gauge will reflect what the ECM thinks the temperature is.

About ResistorPacs for Detroit Diesel Series 60 engines

RP2-C70-DD3-0530 A clip-in ResistorPac for most Series 60 engines [engines having a coolant temperature sensor (CTS) with P/N 23518092 or P/N 23515251]. It attaches directly to existing connectors and no cutting of wires or soldering is required. This ResistorPac WILL NOT FIT Series 60 engines having a P/N 23527830 CTS.

Evans P/N RP2-C70-DD3-0530

RPS-C70-DD3-0530 A solder-in ResistorPac for the Series 60 engine if the coolant temperature sensor is P/N 23527830. Installation instructions are available by email from Evans Cooling Systems, Inc. (860-668-1114) or on www.evanscooling.com. 1

EXCEPTION Evans has learned that Detroit Diesel has an upgrade for the P/N 23527830 CTS. To persons seeking to buy a new P/N 23527830 CTS, DD distributors offer, under the same part number, a CTS that has the desirable connector, along with a pigtail adaptor to interface with the existing wiring. If the engine is equipped with the upgrade that has the pigtail adaptor, the RP2-C70-DD3-0530 can be used. Note of caution - a distributor would likely prefer to sell out his old stock of P/N 23527830 CTS units before offering the upgrade combination. 1. Supplies, information, and special tools needed: a. Obtain this information from the owner: 1) What are the year, make and model of the truck? 2) What is the VIN? 3) What is the ESN? 4) Is the engine equipped with a coolant filter? b. Obtain this information from a Freightliner dealer: 1) Is the coolant temperature sensor P/N 23527830? Important if the CTS is P/N 23527830 you must use the solder-in ResistorPac. c. Purchase this item from the Freightliner dealer or an aftermarket source: 1) If the engine is equipped with a coolant filter, a non-chemical coolant filter element, e.g. Baldwin B5134. d. The following items are sourced from Evans Cooling Systems, Inc.: 888-990-2665 1) Enough Evans waterless Heavy Duty Formula coolant. (15 gallons should suffice.) 2) Evans-provided labels to warn against the addition of water. 3) Two (2) Evans-supplied thermostats that actuate at 205 F (P/N E3032-205). No thermostat housing gaskets are needed beyond the gaskets that are on the thermostats. 4) If the CTS is NOT P/N 23527830, one RP2-C70-DD3-0530 ResistorPac. 5) If the CTS IS P/N 23527830, one RPS-C70-DD3-0530 ResistorPac as well a copy of Installation Instructions for ResistorPacs (version 08-12-11 or later). 6) Refractometer for measuring water content Evans Part No. E2190. 7) An Evans Water-Chaser P/N E2195, a device useful for inserting coolant into hoses for flushing. e. A high-volume air source (rather than high pressure) such as Makita blower Model UB 1101, widely available from the internet. A shop doing installations commercially should consider a Model MB 3CD Master Blaster. A powerful (and clean) shop vac., used in the blower mode, is also an acceptable high-volume air source. e. An angled pick for difficult hoses. f. Funnels. g. A tennis ball. 2. If the engine is hot, wait for it to cool to a safe temperature. Never open a cooling system pressure cap if the engine is hot. 2

3. Place containers to catch coolant at draining locations. 4. Remove the pressure cap. 5. Drain radiator from the petcock (bottom left corner on a Freightliner). If there is no petcock, drain from the bottom radiator hose, using a screwdriver to provide a drain path. 6. While coolant is draining, remove air filter and ducting. 7. Close radiator petcock (if there is one). 8. Pull off bottom radiator hose completely. Leave it to drain. 9. Blow air into the expansion tank. 10. The following devices have source connections and return connections: Cab heater Sleeper heater Fuel tank heaters Fuel heater (at fuel filter) APU units The returns all connect to the inlet side of the pump. In general, when air is blown into the source side of each device, old coolant is pushed out of the device, through its return line, and out the bottom radiator hose. Evans waterless coolant is then introduced into each source side and blown through to chase residual coolant from each device. Use the Water-Chaser for these operations. 11. Special device information: a. Cab and sleeper heaters, in order to be drained properly, require that the temperature controls for these units be turned to MAX, the blowers turned ON, and the key ON. b. The coolant to fuel tank heaters generally passes through a thermostatically controlled valve (sometimes labeled Arctic) that is probably closed. The connections must be opened downstream of the valve to blow out the coolant in the fuel tank heaters. c. The APU unit may hold significant amounts of old coolant. In general, the air is blown into the outlet of the APU back through the unit and out the inlet side. There may be a thermostat in the APU that requires removal in order to blow coolant out of the unit. d. Look for the possibility of a transmission cooler that uses engine coolant that would need to be drained. 12. At the bottom of the thermostat housing there is either a petcock or a drain plug. Drain the coolant from this location, then replace the plug or close the petcock. 13. Open the thermostat housing and remove the existing thermostats. 14. Block one of the thermostat housing holes with the tennis ball. 15. Blow high-volume air into the unblocked thermostat housing hole until coolant stops draining through the bottom hose. 3

16. Pour a gallon of Evans waterless HD coolant into the unblocked thermostat housing hole and then blow high-volume air into the hole until coolant stops draining through the bottom hose. 17. If the engine is equipped with a coolant filter, remove it and blow air into the thermostat housing until no fluid emerges from the filter housing. Install a new non-chemical coolant filter. 18. Remove the tennis ball. Install the 205F thermostats and reassemble the thermostat housing. 19. Re-attach the bottom radiator hose, clamping it securely. 20. If you are installing the RP2-C70-DD3-0530 ResistorPac, proceed as follows: a. Remove connector from the coolant temperature sensor. b. Insert connector into ResistorPac plug. c. Insert other end of the ResistorPac into the coolant temperature sensor. d. Zip-tie the Resistor-Pac to a suitable location. e. Zip-tie the wires appropriately.

Location of the coolant temperature sensor 20. If you are installing the RPS-C70-DD3-0530 ResistorPac, follow the procedures in Installation Instructions for ResistorPacs. 21. Police the hose connections to assure that they are tight. 22. Re-install the air filter and associated ducting. 23. Fill the cooling system with Evans waterless Heavy Duty Formula coolant. 24. Operate the engine to assure the opening of the thermostats and thorough circulation of the coolant. Add coolant as required to maintain the hot level. 25. The coolant in the expansion tank will get hot due to the coolant entering the expansion tank from the vent line attached to the thermostat housing. High temperature in the expansion tank assures that the coolant is well-circulated. A refractometer reading may be taken at the expansion tank under the following conditions: The thermostats are clearly open. The coolant in the expansion tank is hot. No coolant was recently added to the expansion tank. 4

Alternatively, take the reading after several days of operation. 26. Measuring the water content with the refractometer. Calibrate the refractometer by placing a drop of new Evans waterless HD coolant on the refractometer glass and setting the reading to 55.70. After cleaning the glass, place a drop of coolant, obtained from a location in the cooling system where the coolant well-mixed, on the glass. The reading must be 54.40 or higher to verify that the water content is 3 percent or less (a required condition). 27. Place the labels to warn against the addition of water or water-based coolant. 28. The equipment is ready for use. Upon cool-down and for a couple of days, small amounts of coolant may be necessary. The expansion tank should be about 1/3 full when the engine is cold. 29. Use the same radiator cap without modifications. Although it is possible to run an openvented system, the pressure cap will give you a virtually sealed system. Because there will be no vapor component, the pressure will remain quite low within the system (the only pressure will come from the expansion of the liquid against the air in the top of the expansion tank). It is unlikely that the pressure will ever breathe outward and that outside air will enter the system on a cool-down. 30. Bars Leaks Liquid Aluminum Stop Leak is compatible with Evans HDTC and is effective in stopping small leaks.
The procedures contained herein are subject to revision as techniques evolve that speed up the work and that conserve materials. The latest revision can be found on www.evanscooling.com. Evans Cooling Systems solicits suggestions from installers to help improve the procedures. If you have a suggestion, please call Tom Light 860-435-2418.
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In earlier versions of this procedure, 215F thermostats are used. To prevent overlap between the thermostat temperature and the operation of the fan, Evans now recommends the use of 205F thermostats. Note: Evans thermostat P/N E3032-205 is stamped 210 but it is calibrated for 205F.