99.009: Converting New Trucks to the Fill-For-Life Program

Introduction:

To cost-effectively convert existing heavy-duty truck cooling systems to Fill-For-Life, Penray has identified three possible procedures that can be followed. These recommendations will help customers minimize the initial cost of the upgrade.

Recommendations:

The flowchart will help easily identify the best conversion procedure:

Method “A”:

Drain and flush the cooling system with water until clear. Dispose of the old coolant properly

1. Warning: Never open a hot cooling system!
2. With the cooling system cool, open the stopcock and remove the thermostat. Drain the coolant, catching it for recycling or proper disposal.
3. Flush the system with tap water until clear. Drain the water. Replace the thermostat and close the stopcock.

Fill the system with a properly prepared Fill-For-Life approved coolant (see bulletin 01.001)

1. Mix 50% to 60% approved coolant and water -or- in temperate climates (-10 freeze point acceptable) 33% approved coolant, 1% Pencool® 3000 and 66% water -or- in warm climates (+32 freeze point acceptable) mix 5% Pencool 2000 or Pencool 3000 and water. Water needs to be relatively pure, as published in the Penray Cooling System TechFacts.
2. Fill the cooling system with the coolant, check to insure correct freeze point and nitrite concentration with a Penray test strip.

Install Need-Release® filter.

1. Label the filter with the date and mileage at installation.
2. Install the filter hand tight. Do not use a filter wrench.
3. Close and pressure-test the system.

Method “B”:

1. Convert the organic system to Fill-For-Life technology
   1. Warning: Never open a hot cooling system!
   2. With the cooling system cool, open the radiator cap and add 1 pint Pencool 3000 per 4 gallons of cooling system capacity.
2. If necessary, top-up the cooling system with a properly prepared Fill-For-Life approved coolant (see bulletin 01.001).
   1. a. Mix 50% to 60% approved coolant and water -or- in temperate climates (-10 freeze point acceptable) mix 33% approved coolant, 1% Pencool 3000 and 66% water -or- in warm climates (+32 freeze point acceptable) mix 5% Pencool 2000 or Pencool 3000 and water. Water needs to be relatively pure, as published the Penray Cooling System TechFacts
   2. b. Run the engine 30 minutes to mix the coolant, let the system cool, then check to insure correct freeze point and nitrite concentration with a Penray test strip.
3. Install Need-Rekease Filter
   1. Warning: Never open a hot cooling system!
   2. Mix 50% to 60% approved coolant and water -or- in temperate climates (-10 freeze point acceptable) mix 33% approved coolant, 1% Pencool 3000 and 66% water -or- in warm climates (+32 freeze point acceptable) mix 5% Pencool 2000 or Pencool 3000 and water. Water needs to be relatively pure, as published the Penray Cooling System TechFacts.
   3. Run the engine 30 minutes to mix the coolant, let the system cool, then check to insure correct freeze point and nitrite concentration with a Penray test strip.

Method “C”:

1. If necessary, top-up the cooling system with a properly prepared Fill-For-Life approved coolant (see bulletin 01.001).
   1. Warning: Never open a hot cooling system!
   2. Mix 50% to 60% approved coolant and water -or- in temperate climates (-10 freeze point acceptable) mix 33% approved coolant, 1% Pencool 3000 and 66% water -or- in warm climates (+32 freeze point acceptable) mix 5% Pencool 2000 or Pencool 3000 and water. Water needs to be relatively pure, as published the Penray Cooling System TechFacts.
   3. Run the engine 30 minutes to mix the coolant, let the system cool, then check to insure correct freeze point and nitrite concentration with a Penray test strip.
2. Install Need-Release filter.
   1. Label the filter with the date and mileage at installation.
   2. Install the filter hand tight. Do not use a filter wrench.
   3. Close and pressure-test the system.

Refer to technical bulletin 01.007 for long-term maintenance recommendations of Fill-For-Life systems.