The Table Of Contents

1 Fill with Fleetguard Lifetime Coolant ___________________________________

STEP
3
Cooling System Changeover Procedure

2 Test / Maintain with Fleetguard Additive Program_______________________

STEP

3-Way Test Kit Testing Procedure

3

Additive Replenish Chart for Fleetguard® Fully Formulated Coolants

3 Check Overall Coolant Condition _______________________________________

STEP

Test Coolant Overall Quality

6

Miscellaneous _ ________________________________________________________ 7

Coolant Maintenance Summary ________________________________________ 8

For Standard Service Intervals (SSI)
For Extended Service Intervals (SSI)
Easy Maintenance System
Fleetguard® Cooling System Maintenance is as Simple as 1,2,3.

STEP
1 Fill with Fleetguard Lifetime Coolant

Cooling System Changeover Procedure

1. Check the vehicle model & serial number to
determine the total coolant capacity.
2. Drain the used and depleted coolant by removing
the drain plug. Remove radiator cap to facilitate
the draining of used coolant.
6. It is recommended NOT to fill the cooling system
faster than 20 litres per minute to prevent air
pockets from developing, which can be damaging
to the engine.
7. Run the engine for several minutes with the

3. Check the condition of radiator cap and the seal. radiator cap open.
4. Flush Cooling System. (use Restore Cooling 8. Install the radiator cap and run the engine at low

System Cleaner if necessary; See Step 3) idle until the engine becomes warm.
5. Fill with Fleetguard Fully Formulated Coolant. 9. Inspect the top level again, adding additional

Fleetguard recommends using Premix Coolant to coolant if necessary. Check the system for leaks; if
prevent coolant contamination from an unknown no leaks are found, engine is ready for service.
source. Make sure the drain plug is closed 10. Attach Fleetguard label to the engine to prevent

properly and provide for 1% coolant expansion at maintenance error.

working temperature.

STEP
2 Test / Maintain with Fleetguard Additive Program

3-Way Test Service Interval

ESI Extended Service Interval
Every 75,000 miles (125,000 km), 2,000 hours interval or twice a year

SSI Standard Service Interval

Every 30,000 miles (50,000 km), 500 hours interval or twice a year

3-Way Test Kit Testing Procedure

Pre-test Instructions
1. Recommended testing frequency is at every lube service interval.
2. Collect coolant sample from the radiator or petcock.
3. DO NOT collect from the coolant recovery or overflow system.
4. Coolant must be between 50°F and 130°F when tested.
5. Testing at room temperature is recommended.
6. For accurate results, test must be completed within 75 seconds.
7. Follow recommended test times – please use a stopwatch.
8. Record and track the results.

3
 Test Instructions
1. Remove one strip from the bottle and replace cap immediately. Do not touch the pads on the end of
the strip. Discard kit if nitrite test pads of unused strips has turned brown.
2. Dip strip for 1 second in coolant sample, remove, then shake strip briskly to remove excess liquid.

3. 45 seconds after dipping the strip, compare the results to the color chart included in the test kit.

END PAD A: Freeze Point

MIDDLE PAD B: Molybdate

TOP PAD C: Nitrate

4. All three readings must be completed no later than 75 seconds after dipping strip.
5. If uncertain about the color match, pick the lower column or row (ex.: if nitrite color is not quite F, then
use column E).
6. The amount (of coolant additive units per gallon for Imperial, per litre for Metric) in the cooling system is indicated

where the following occurs: for DCA4 - the MOLYBDATE level intersects the NITRITE level; for SCA without
Molybdate - the NITRITE column intersects Row 0

FREEZEPOINT
MOLYBDATE

NITRITE
7. Summary of Chart Reading

Maintenance Actions Based on Results

ABOVE NORMAL

ABOVE NORMAL Do not replace service filter or add DCA4 liquid

until the concentration falls below 3.0 units per litre.

NORMAL
NORMAL
Continue to replace the coolant filter at your normal
interval.

BELOW NORMAL

Replace the coolant filter and add 1 pint of additive

BELOW NORMAL
per each 4 gallons of coolant (equals 1.2 units per
litre).

4
Additive Replenish Chart for Fleetguard® FFC
■■ Maintain minimum of approx. 3% additive in cooling system with Fully Formulated Coolant (0.3 Units per
Litre). Do not allow additive to be above approx 13% of cooling system (1.3 Units per Litre).
■■ Cummins Guideline ( CES 3666132-04 ) recommends using Fully Formulated Coolant. Engines using

cooled exhaust gas recirculation (EGR) must not use treated water coolant, which does not contain
glycol. The use of coolant with 40 to 60% glycol is mandatory on these engines due to increased
coolant temperatures.
■■ Use following chart to maintain additive level.

Service Chart 1: Additive Maintenance Overview

OPTION A: LIQUID ADDITIVE PRODUCTS OPTION B: CHEMICALLY CHARGED FILTER PRODUCTS
ADDITIVE CONTENT IN ESI SSI ESI SSI
COOLING SYSTEM
Unit per Gallon Unit per Litre Using ES Extender Using DCA4 Using Extended Service Using Standard Service
(Imperial (Metric 3-Way Water Filters Water Filters
3-Way Test Kit) Test Kit)

< 1.2 < 0.3 Replenish cooling system Replenish cooling system Replenish cooling system Replenish cooling system
(less than 3% with 3.3% of ES Extender with minimum 3% of DCA4 with 3.3% of ES Extender with minimum 3% of DCA4
additive in total additive (2 quarts per 15 additive additive (2 quarts per 15 additive
volume) gallons of coolant or 1.89 or service as per Additive gallons of coolant or 1.89 or service as per Additive
litres per 56.78 litres) Replenishment Guide litres per 56.78 litres) Replenishment Guide

1.2 - 3.0 0.3 - 0.8 Replenish cooling system Continue to service DCA4 Continue with yearly Continue with change of
(between 3% to with 1.7% of ES Extender additive dose at each oil change of ES Water Filter. Standard Water Filter at
8% additive in additive (1 quart per 15 change interval Do not add ES Extender. every oil change. Refer
total volume) gallons of coolant or 0.95 - refer to Additive to Additive Replenishment
litres per 56.78 litres) Replenishment Guide Guide for standard Water
Filter selection.

> 3.0 > 0.8 Do not replenish cooling Do not replenish cooling Do not replenish with ES Do not add / replenish with
(more than 8% system with ES Extender system with DCA4 additive Extender liquid additive DCA4 liquid additive
additive in total additive until additive until additive concentration
volume) concentration falls below falls below 0.8 units per litre
0.8 units per litre

5
 STEP

3 Check Overall Coolant Condition

Test Coolant Overall Quality

Quik-Chek Test Kit Procedure

1. Collect coolant sample from the radiator or petcock. DO NOT collect the sample from the coolant recovery
or overflow system. Coolant must be between 50ºF and 110ºF when rested. Room temperature is preferred.
2. Remove one strip from bottle and REPLACE CAP IMMEDIATELY. DO NOT touch the pads on the end of the

strip.
3. Dip strip in coolant sample for 5 seconds, remove and then shake briskly 3-4 times making sure all excess

coolant is completely removed from the pad.

STRIP HANDLE

4. At 30 seconds, match coolant pH to the closest color block. Complete by 40 seconds. (Note: Color on pad

will appear black/gray for pH values above 11.)

5. At 45 seconds, match Sulfate to closest color block. Complete by 50 seconds.

6. At 70 seconds, match Chloride to closest color block. Complete by 30 seconds.

7. It is okay to estimate a value BETWEEN color blocks but if uncertain about the color match, pick the lower

numbered block. (Note: When taking the coolant sample, also check visually for the presence of fuel,
lubricant or other foreign matter. If present, drain, clean and flush the cooling system.)
8. For best results, follow test times carefully. Use a stop watch or clock with a sweep second hand.

Comparing the test strip to the color chart too soon or too late after the required test time will result in
incorrect readings and improper treatment which could result in liner pitting and engine damage.

Coolant Flushing Procedure

1. Drain the cooling system and dispose of used coolant. Backflush the system.
2. Immediately add 1 litre of Restore or Restore Plus for each 10-15 litre of cooling system capacity and fill the
™ ™

system with plain water.

3. Turn heater temperature switch to high to allow maximum coolant flow through heater core. Blower does not

need to be turned on.

4. Run the engine at normal operating temperature for 2 hours.

5. Drain and flush the system with plain water and change your water filter if applied.

6. Refill with a fully formulated coolant (such as Fleetguard ES Compleat ).

™

6
Miscellaneous
Installation of Water Filters

Coolant Filter Flow Path

RADIATOR

HIGH PRESSURE ENGINE

WFK1 RETROFIT KIT B A

PUMP

FILTER
LOW PRESSURE

Notes Once the connection points have

1. Installation of a coolant filter may be accomplished
by using any one of a variety of locations or
methods.
2. The coolant filter is a bypass type filter that limits
coolant flow through the element 1-2 gallons per
minute (GPM).
3. The inlet of filter mounting head should be
connected to a point that has a relatively higher
been determined, the following
guidelines should be followed:
■■ ilter should be mounted vertical;
F
■■ Location should be below the radiator top tank;
■■ Inlet line as short as possible;
■■ 3/8" minimum ID hoses;
■■ Unrestricted inlet and outlet;
■■ Easily accessible for servicing;

pressure than what the outlet would see. ■■ Rigid mounts and remote from engine block where

possible (reduced filter vibration);

Select Mounting Option ■■ Coolant filter mounting heads and mounting

1. Filter Mounting Head INLET brackets can be found in Coolant Products

Brochure (CFS-B0807).
From the pump pressure or delivery side, choose
one of the following bleed off points:
■■ Tee into the cab heater inlet line or feed pipe;
Single Head Mounting Kit
■■ Connect into thermostat housing; 1. Part number WFK1
■■ Coolant manifold; 2. This includes:

■■ Coolant header opening; ■■ ead (Part No. 204163S) screwed to mounting

H
■■ Connect into any available cylinder head port; bracket (3/8 NPT);
■■ Connect into any coolant pump perimeter port. ■■ Choice of water filter (11/16”-16UN) including

2. Filter Mounting Head OUTLET Extended Service slow release filter (Part No.
WF2121);
From the pump suction or low-pressure side,
■■ Bracket (right angled);
choose one from below points for the filter return
■■ Two right angle brass shut off valves (3/8 NPT x
line entry:
3/8 tail);
■■ Tee into the cab heater outlet line;
■■ Two right angle brass tail fittings (3/8 NPT x 3/8
■■ Tee into return line from radiator to coolant
tail);
pump or bottom radiator pipe;
■■ For those applications where mounting head
■■ Connect into any available on the low-pressure
thread durability is of concern, a threaded steel
side of the pump.
spud version of the standard mounting head is
available as an option, not included in kit (Part
No. 3904378S).

7
 Coolant Maintenance
Recommendations
For Standard Service Intervals (SSI)
1. Fill the cooling system with a fully formulated coolant meeting TMC or ASTM standard. Install service coolant
filter(s) matched to oil drain interval.
2. Top-off the cooling system with a fully formulated coolant and not plain water only.

3. Replenish depleted SCAs by replacing the service coolant filter(s) at every oil change interval OR by adding

appropriate dose of DCA4 Liquid.

4. Test coolant at least twice annually or when major coolant loss occurs and adjust the DCA4 level as required,

using 3 Way test kit.

3 Way™ Coolant Additive Test Kit

The following action is required after testing coolant at the normal oil drain interval:
Below 0.3 units per litre
Replace service filter and add 1 litre of DCA4 per 32 litres of coolant.
0.3 - 0.8 units per litre
Continue to replace service coolant filter or add DCA4 liquid service dose at each oil
drain interval.
Above 0.8 units per litre
Do not replace service filter or add DCA4 liquid until the concentration falls below 0.8
units per litre.

Note: Colour chart

representative only.
Do not use with strips

Units of Supplemental Coolant Additive (SCA) Added

Maintenance Intervals for Cooling Systems up to 76 litres. Maintenance Intervals for Cooling Systems above 76 litres.
Install service filter(s) and/or liquid containing number of SCA units below Install service filter(s) and/or liquid containing number of SCA units below
Service Interval System Size in Litres
Service Interval System Size in Litres
Hours 77 - 117 118 - 189 190 - 284 285 - 378 379 - 568
Hours Kilometres 4-19 20-38 39-57 58-76
751 - 1000 25 50 80 100 150
251 - 37 16001 - 24000 2 4 6 8
501 - 750 20 35 60 75 110
0 - 25 0 - 16000 2 2 4 6
251 - 500 15 25 40 50 75
Units of DCA4
0 - 250 10 15 20 25 40
Units of DCA4

Quik-Chek Test Kit

■■ est Fully Formulated Coolant using Quik-Chek Test Kit for condemnation limit. Discard and renew entire Fully
T
Formulated Coolant if any of 3 Test fails.
■■ Test every 150,000 miles (250,000 km) or 4000 hrs, or 12 months.

8
For Extended Service Intervals (ESI)
1. Top Off Correctly: Use PGPlus™ or ES Coolant™ premixed and use for all top off.” to “Fill the cooling system
with a fully formulated coolant meeting TMC or ASTM standard.
2. Top-off the cooling system with a Fully Formulated Coolant and not plain water only.

3. Replenish Spent Chemicals: Install a slow release chemical containing ES Filter for every 80 litres of system

capacity OR Install a non-chemical ES Filter, then add 1 litre of ES Extender™ per 80 litres of system
capacity AFTER the first service interval (250,000 kms, 4,000 hours, or 1 year of engine operation).

3 Way™ Coolant Additive Test Kit

The following assurance testing is recommended: Use 3 way test strips CC2602M or
CC2602AM
Below 0.3 units per litre
Add 2 litres of ES EXTENDER™ (2 x CC2840) per 60 litres of coolant.
0.3 - 0.8 units per litre
Add 1 litre of ES EXTENDER™ (1 x CC2840) per 60 litres of coolant.
Above 0.8 units per litre
Do not add ES EXTENDER™ to the system.

Note: With correct top-off, protection should not be below 0.3 units per litre at each service interval
Note: Colour chart and no less than 0.5 units per litre. The ideal level is 0.7
representative only.
Do not use with strips

Quik-Chek Test Kit

■■ Test Fully Formulated Coolant using Quik-Chek Test Kit for condemnation limit. Discard and renew entire Fully
Formulated Coolant if any of 3 Test fails.
■■ Test every 150,000 miles (250,000 km) or 4000 hrs, or 12 months.

CHART FOR ADJUSTING TO 50% GLYCOL AFTER TESTING COOLANT

INSTRUCTIONS: Match up glycol % with system capacity. The intersection of these two is the amount of Compleat 50 Concentrate™ or
PGPlus™ Concentrate to add to achieve a 50/50 mix of glycol and water in the cooling system. Retest after adjusting to ensure levels are correct.
System
Capacity
Drain Coolant and add Compleat 50 Concentrate“
Litres
or PG Pus“ Concentrate (Litres Undiluted)
20 10 9 8 8 7 6 4 3 2 0
24 12 11 10 9 8 7 5 4 2 0
28 14 12 11 11 9 8 6 5 2 0
32 16 14 13 12 11 9 7 5 2 0
36 18 16 15 14 12 10 8 6 3 0
40 20 18 17 15 13 11 9 7 3 0
44 22 20 19 17 15 13 9 7 3 0
48 24 21 20 18 16 14 11 8 4 0
52 26 23 22 20 17 15 12 9 4 0
56 28 25 23 22 18 16 13 10 4 0
60 30 27 25 23 20 17 14 10 5 0
64 32 28 26 24 21 18 15 11 5 0
68 34 30 28 26 23 19 15 11 6 0
72 35 32 30 27 24 21 17 12 6 0
76 38 34 32 29 26 22 18 13 7 0
80 40 36 33 30 27 23 18 13 7 0
Glycol % 0 10 15 20 25 30 35 40 45 50

9
 For more information, visit
cumminsfiltration.com

Cummins Filtration
International Corporation
8 Tanjong Penjuru
Singapore 609019
Tel: (65) 6266 3833
Fax: (65) 6265 6909
CFS-B0805
©2008 Cummins Filtration
Printed in USA on Recycled Paper

Coolant for the REAL™ World