Service Bulletin

Volvo Trucks North America, Inc.

Greensboro, NC USA Trucks
This Service Bulletin replaces Service Bulletin 184–01 Date Group No. Page
“Coolant Requirements Volvo D12 Engines VN, VHD 12.2002 184 01 1(13)
VERSION2” (11. 2002), Publication no.
PV776–TSP1821861. Coolant Requirements
Volvo D12 Engines
VN, VHD VERSION2

Coolant Requirements
(Effective from November 2002)

Contents
Specifications “Coolant Requirements” page 2

Design “Coolant” page 5

Service Procedures “Changing to Extended Life Coolant” page 11

“SCA Level, Checking” page 12

PV776-TSP183491 USA12946
Page 2

Specifications
Coolant Requirements
Regular Coolant
Standard Factory Fill. Color: Purple (Pink)

Coolant Type . . . . . . . . . . . . . . . . . . . . . A 50/50 mixture of clean water and Antifreeze that meets or exceeds
ASTM D6210 or TMC RP329.
ASTM D6210: Standard Specification for Fully-Formulated Ethylene-
Glycol-Base Engine Coolant for Heavy-Duty Engines.
NOTE: A coolant mixture should never have less than 40% an-
tifreeze and 60% clean water.
Coolant Change Interval . . . . . . . . . . . . . Replace the coolant every 400,000 km (250,000 miles) or 4000
hours or every two years, whichever comes first.
Coolant Filter Change Interval . . . . . . . . The coolant filter is suitable for 80,500km (50,000 miles). The
charged coolant filter contains eight units of SCA that are released
slowly over time to maintain the recommended level during opera-
tion. If the SCA level tests above 3.0, DO NOT replace the coolant
filter. When testing indicates that the SCA level has dropped below
1.5 units per US gallon (0.4 unit per liter) start changing the filter
with the oil changes again.
(SCA) Test Cycle .................. Coolant SCA level must be tested at least twice a year and when-
ever coolant loss occurs. For maximum cooling system efficiency,
test the system every 40,000 to 56,000 km (25,000 to 30,000 miles)
depending on oil change interval or every 1000 hours or every 6
months (whichever comes first).
(SCA) Test Kit . . . . . . . . . . . . . . . . . . . . . Fleetguard® CC2602
3-WayTM Heavy Duty Test Kit.
(SCA) Type . . . . . . . . . . . . . . . . . . . . . . . Fleetguard® DCA 4 or Nalcool
(SCA) level ...................... Between 0.4 and 0.8 units per liter (1.5 and 3.0 SCA units per gal-
lon) of coolant.

Cooling System Capacities*

VN and VHD D12 43 liters

(11 US gal.)

* approximate capacities
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2002 184 01 3(13)

Extended Life Coolant (ELC)

(Optional) Color: Red

Coolant Type . . . . . . . . . . . . . . . . . . . . . ELC Antifreeze is a single-phase, ethylene glycol type heavy duty
diesel engine coolant/antifreeze. ELC must meet or exceed ASTM
D6210 or TMC RP 329 for heavy-duty diesel service.
Coolant Change Interval . . . . . . . . . . . . . Replace coolant every 960,000 km (600,000 miles) or every 12,000
hours or every four years, whichever comes first. A one-time ex-
tended package must be added to the cooling system after 480,000
km (300,000 miles) or 12,000 hours or four years, whichever comes
first.
Coolant Filter Change Interval . . . . . . . . When using ELC Antifreeze, instead use a coolant filter that does
not contain SCAs. Replace filter every 240,000 km (150,000 miles)
or 2500 hours or 15 months, whichever comes first, to prevent
external rusting of the can). For vendor engines, refer to each manu-
facturer for information.
Test of Coolant . . . . . . . . . . . . . . . . . . . . The slow depleting additive chemistry does not require regular test-
ing, but the coolant can be tested with both the nitrite and ELC test
kits. The freeze protection level should be checked at least twice per
year with a standard refractive index type tester.
Page 4

Extended Service Coolant (E/S)

(Optional) Color: Blue

FleetGuard® E/S CompleatTM

Coolant Type . . . . . . . . . . . . . . . . . . . . . E/S Antifreeze /Coolants are Extended Life formulations that contain
Ehylene Glycol base fluids and are designed specifically for Ex-
tended Service use in heavy-duty diesel engines. ES COMPLEAT
contains conventional heavy-duty chemical inhibitors and eliminates
hard water scale deposits.
Coolant and Filter Change Interval . . . . . When using E/S Antifreeze, use a coolant filter with ES slow release
coolant filters or liquid ES extender to provide simplified coolant main-
tenance while extending coolant service intervals to 12 months or
150,000 miles. ES COMPLEAT can also be used in standard coolant
service intervals with the use of SCA’s and standard coolant filters.
Replace filter every 240,000 km (150,000 miles) or 2500 hours or 12
months, whichever comes first, to prevent external rusting of the
can). For vendor engines, refer to each manufacturer for information.
(SCA) Test Cycle Coolant SCA level must be tested at least twice a year and when-
ever coolant loss occurs. For maximum cooling system efficiency,
test the system every 40,000 to 56,000 km (25,000 to 30,000 miles)
depending on oil change interval or every 1000 hours or every 6
months (whichever comes first).
For more details refer to the coolant manufacturer’s guidelines.

E/S Compleat is a trademarks of FleetGuard®.

Water Specifications

Parts per Grains per

million Gallon
(ppm)
Chlorides, maximum < 40 < 2.34
Sulfates, maximum < 100 < 5.8
Total dissolved solids, maximum < 340 < 20
Total < 170 < 10
hardness
pH 5.5-9
Silica < 20 < 1.17
Iron < 0.10 < 0.0058
Manganese < 0.05 < 0.0029
Conductivity < 500 S/cm
CODMn < 15 mg/KmnO4/l
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2002 184 01 5(13)

Coolant
NOTE: DO NOT mix different coolant products, such
as regular antifreeze and extended life antifreeze. etc.

Coolant Requirements
Volvo Trucks North America recommends the use of low
silicate ethylene glycol base coolant for heavy duty en-
gines. This coolant must meet or exceed ASTM D6210
or TMC RP329.

Volvo does not recommend the use of antifreeze based

on propylene glycol.

There are two types of coolants recommended for the

Volvo engines. One type requires the addition of SCAs
(Supplemental Coolant Additives) to maintain the desired
properties of the coolant.
The other type uses no SCAs. This type of coolant is of-
ten referred to as ELC (Extended Life Coolant).

NOTE: The two types of coolant are not to be mixed

since this would have negative effects on the coolant’s
properties.

NOTE: Antifreeze or premixed coolant meeting the stan-

dards ASTM D3306 or ASTM D4656 are primarily for
automotive gasoline engines, containing high levels of
silicate, and are unacceptable for heavy duty diesel
engines. The silicates will clog the radiator and leave un-
wanted deposits in the engine.
Page 6

General Cooling System Information

A coolant mixture of clean water and antifreeze (with
proper SCA level) not only protects the cooling system
from freezing, it protects against corrosion and cylinder
liner pitting.

A well functioning and maintained cooling system is as

important to the engine as performing regular oil
changes or using good fuel. To get the best results it is
very important to use quality products and to service the
system at the correct intervals.

Many engine failures can be traced back to a problem in

the cooling system. Always make sure that the coolant
level is above the MIN. mark on the expansion tank. If
the coolant level is allowed to go below the bottom of the W2002056

tank, there is a risk of the engine shutting down. See the

Operator’s Manual for more information on the warning
functions.

Coolant is made up of a mixture of clean water and an-

tifreeze. The coolant should be used year-round to
provide freeze and boil over protection as well as provid-
ing a stable environment for seals and hoses. The
solution needs to be tested for proper additive levels at
regular intervals unless coolant of extended life type is
used. Adjust additive concentration if not at the proper
levels.

W2003913
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2002 184 01 7(13)

Regular Coolant
Purple / Pink
Regular coolant uses additives called SCA (Supplemen-
tal Coolant Additives) to achieve the desired properties
of the coolant.

Coolant SCA level must be tested at least twice a year

and whenever coolant loss occurs. For maximum cooling
system efficiency, test the system every 40,000 to
56,000 km (25,000 to 30,000 miles) depending on oil
change interval or every 1000 hours or every 6 months
(whichever comes first).

NOTE: Be careful to maintain the appropriate level of

SCA in the coolant. An over concentration can cause ad-
ditives to solidify and drop out of the solution, depositing
inside the cooling system or form a gel in the radiator.
Deposits can be in the form of sludge or scales that ac-
cumulate on hot engine surfaces. This will reduce the
efficiency of the cooling system or cause water pump
leakage. An under concentration may lead to corrosion W2004117
in the cooling system and/or liner pitting.

Extended Life Coolant

Red
The organic acid technology uses the same antifreeze
and water mix that can be found in the regular coolant.
However, it uses a combination of carboxylate inhibitors
to accomplish the corrosion and cavitation protection.
Depleted inhibitors are replenished by extenders which
are typically in a liquid form.

The use of ELC–type coolant allows an extended on-the

road-use compared to coolants with SCA additives.

A decal is positioned on the expansion tank to notify the

operator/technician that ELC coolant is installed. Add de-
cal when changing to ELC. See page 7.

W2003928

Decal indicating ELC installed

Extended Service Coolant

Blue
Refer to “Coolant type” page 4 for description of the E/S
Coolant.
Page 8

NOTE: DO NOT add supplemental coolant additives

(SCAs) to ELC-type coolant. The SCA will reduce the
extended life benefits of the ELC, however, up to 15%
traditional coolants can be added with little other effect
than change in color.

Should the system become contaminated with regular

coolant exceeding 15% of the system’s total capacity or
if SCAs is added to the system, either drain the system
and refill with new extended life coolant or maintain the
system as for regular coolant. Continue treating with
SCA and change the coolant at the intervals recom-
mended for regular coolant.

Coolant Functions
Apart from transporting heat from the engine to the radi-
ator, the coolant must:

• Protect against pitting and cavitation erosion

damage of the water pump and cylinder liners.

• Protect against freezing and boiling.

• Prevent formation of scale, sludge deposits and

clogging.

• Be harmless to polymer materials and sealings in

the cooling system.

• Maintain its liquid properties in cold climates.

Coolant should consist of three components:

• Clean water

• Additives

• Antifreeze (Glycol)
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2002 184 01 9(13)

Clean Water
CAUTION
Volvo Trucks North America Inc. does not recom-
mend the use of only plain water in the cooling
system. Water alone is corrosive at engine operating
temperatures and does not provide adequate boiling
protection. The engine may develop corrosion and
cavitation problems in the engine and radiator, and
the boiling point of the coolant is lowered compared
to an antifreeze/water mixture. The warranty is not
valid when using only plain water in the cooling sys-
tem.

Always use clean water in the coolant mixture. DO NOT

use hard tap water or salt-softened tap water in the en-
gine cooling system.

If you are not sure of the quality of the water in your

area, contact your local Volvo Truck dealer, your local
water department, agricultural agent or an independent
laboratory to analyze the water.

NOTE: If clean water is not available, using distilled

water is ideal.

Additives
Coolant additives are part of most antifreeze and should the recommended level during operation.
be tested for and added to all coolant mixtures using
normal antifreeze. If extended coolant is used, the addi-
tives are in the product when mixed. Both types need to
have additives added after a time.

Additives help prevent rust, scale and mineral deposits

from forming. Additives also protect metals from corro-
sion, prevent water pump and cylinder liner cavitation
and contain anti-foaming agents. Additives are depleted
during normal engine operation and need to be
replaced. For normal coolant mixture, this means the ad-
dition of Supplemental Coolant Additives (SCA) at any
time the additive goes below the recommended level.
For extended life coolant mixture, this means an exten-
der package added halfway through the coolant lifetime.
If the vehicle is delivered with extended life coolant,
there is a label attached to the expansion tank.

Nitrites or nitrite and molybdate additives protect the

cylinder liner from cavitation erosion. Nitrites deplete
over time, creating the need for SCAs or extender. Other
coolant additives also deplete and need replacement.

Too low a concentration of additives in the coolant will

not provide the protection required by the cooling sys-
tem. Too high a concentration of additives can cause
additives to solidify and drop out of the solution, deposit-
ing inside the cooling system.

The coolant filter changed with additives contains 8 units

of SCA that are released slowly over time to maintain
Page 10

Antifreeze
Antifreeze not only protect the cooling system from NOTE: 60% concentration of antifreeze in the coolant

freezing but also against corrosion and cylinder liner pit- gives the maximum lowering of the freezing point, -46 C

ting. Antifreeze typically comes in one of two glycol (-51 F). Any increase over 60% antifreeze in the coolant
types, ethylene or propylene. There is also regular and will instead impair the freeze protection level.
extended-life antifreeze.
NOTE: Never use a mixture weaker than 40% concen-
Recommended antifreeze meeting the ASTM D6210 trated coolant. Ignoring this enhances the risk of
standard is a low silicate ethylene glycol based an- corrosion in the cooling system and cylinder liner pitting
tifreeze for heavy duty diesel engines. leading to damage of the engine.

Regardless of type and make, acceptable antifreeze or

pre-mixed coolant must meet or exceed the standards of CAUTION
ASTM D6210 or TMC RP329, and be formulated for
heavy duty diesel engines. Use of recycled antifreeze or coolant by filtration is
not approved by Volvo Trucks North America, Inc. If
Water and antifreeze should generally be filled as a the recycled antifreeze or coolant has been passed
50/50 mixture. The mixture should never be less than through a fractional distillation or similar process that
40% antifreeze and 60% clean water. The mixture has removed all hazardous and contaminating mate-
should also not be stronger than 60% antifreeze to 40% rials, including dissolved solids and acids, it will
clean water. produce a sufficient base antifreeze. Correctly inhib-
ited to meet the ASTM D6210 standard, it can be
Mix the antifreeze and the water to the required concen- regarded as a new coolant which is fully accepted.
tration before adding to the cooling system. Use of non-approved coolant may result in reduced
engine life.
The following table gives approximate freezing protection
for certain mixture concentrations.

Percentage of An-
Freeze Protection down to:
tifreeze in Mixture
 
-25 C (-13 F) 40%
 
-30 C (-22 F) 46%
 
-38 C (-36 F) 50%
 
-46 C (-51 F) 60%

Maintenance
Keep the radiator (including charge air cooler) and the
frontal area free from bugs, dirt, leaves etc. For cleaning,
refer to Service Information in group 26.

Inspection of the whole cooling system is important.

Check for swollen or deteriorated heater and radiator
hoses, loose hose clamps and connections, and radiator
leaks.

NOTE: DO NOT use a winter front for the cooling sys-

tem. For more information, please refer to the Operator’s
manual, Engine Start and Operation.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2002 184 01 11(13)

Service Procedures
Changing to Extended Life 2
Fill the system with pre-mixed Ex-
Coolant tended Life Coolant (ELC). Check
See also “Coolant Requirements” page 2. specifications for the engine type in
question for the refill quantity.
You must read and understand the precautions and
guidelines in Service Information Group 20 "General
3
Safety Practices" before performing this procedure. If
you are not properly trained and certified in this proce-
dure, ask your supervisor for training before you
perform it.

WARNING
DO NOT raise the engine hood or cab if you see or
hear steam or coolant escaping from the engine
compartment. Wait until steam or coolant cannot be
seen or heard before raising the hood or cab.
DO NOT remove the coolant fill cap if the coolant in
the expansion tank is boiling. Also, DO NOT remove
the cap while the engine and radiator are still hot.
Scalding fluid and steam may be blown out under
pressure if the cap is taken off too soon.

Drain the system of old coolant and dispose of properly. W2003928

Regardless of radiator material type, the cooling system
Decal indicating ELC installed
should be cleaned with a good commercial cleaner for
heavy duty diesel engines with aluminum radiators fol- Attach label shown in illustration to
lowing the procedures described in Service Information the expansion tank to indicate that the
26. system is now filled with Extended
Life Coolant. The label can be or-
1
dered from your Volvo Truck dealer
spare parts department.
NOTE: When changing over from reg-
ular to extended life antifreeze, tighten
all hose clamps and fasteners in the
cooling system. Extended life coolant
tends to leach out deposited silicate
and leaks may appear.

W2003082

After having properly cleaned and

flushed the cooling system, mix the
antifreeze and water to the required
concentration before adding to the
cooling system.
Page 12

1841-06-03-01 2
Shut off the engine and allow it to
SCA Level, Checking cool. Test the coolant with Fleetguard®
See also “Coolant Requirements” page 2. CC2602 3-WayTM Heavy Duty Test Kit.

You must read and understand the precautions and • Below 0.4 units per liter (1.5 units
per gallon) of SCA, calculate the
guidelines in Service Information Group 20 "General units of SCA per gallon required
Safety Practices" before performing this procedure. If to reach the desired SCA level.
you are not properly trained and certified in this proce-
dure, ask your supervisor for training before you EXAMPLE
perform it.
Step 1

Desired 2.3 units Recom-

SCA level per gallon mended
level 1.5-
Before working on a vehicle, set the parking brakes, 3.0 units
place the transmission in neutral, and block the per gal
wheels. Failure to do so can result in unexpected ve-
hicle movement and can cause serious personal Subtract:
injury or death. Coolant 1.5 units
test results per gal
NOTE: Coolant SCA level must be tested at least twice
per year and whenever coolant loss occurs. For maxi-
mum coolant system efficiency, test the system every Required 0.8 units
40,000 to 56,000km (25,000 to 30,000 miles) depending SCA per per gal
on oil change interval or every 1,000 hours or every 6 gal in-
months (whichever comes first). crease

Other special equipment: Supplemental Step 2

Coolant Additive (SCA), Fleetguard ®
CC2602 3-Way TM Heavy Duty Test Kit. Cooling 13 US gal Use actual
System system
1 Capacity capacity
Run the engine up to operating tem-
perature. After the engine has reached Multiply
operating temperature, move the by:
heater controls to warm and run the Required 0.8 units
engine for 10 minutes. SCA per per gal
gal in-
crease

Total SCA 10.4 units Round up

units re- (11 units) to the
quired nearest
whole
number
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2002 184 01 13(13)

3
• Between 0.4 and 0.8 units per
Add the necessary SCAs to achieve
liter (1.5 and 3.0 units per gallon),
no action necessary. Test at next the desired level.
oil change or scheduled mainte-
nance.

• Above 0.8 units per liter (3.0 units

per gallon). DO NOT add SCA un-
til further testing at subsequent oil
changes indicate the level has
dropped below 0.6 units per liter
(2.3 units per gallon).
NOTE: SCA levels deplete during nor-
mal operation and when the system is
topped off. SCA levels should be
maintained at the middle to high end
of the recommended level.
Units per Liter:
0.4 LOW-0.6 MID-0.8 HIGH
Units per Gallon:
1.5 LOW-2.3 MID-3.0 HIGH