Technical Bulletin

0199 - 99 - 2091/9 EN
This Circular supersedes: 0199 - 99 - 2091/8

Coolant for MWM engines and systems

The 9th replacement was made because of: Updating the approved cooling system protection agents For text revisions, see revisions column

Contents: General information Cooling systems Cooling system protection agents Chemical corrosion protection agents Antifreezes with corrosion inhibitors Cooling water properties Addition of chemical corrosion protection agents Addition of antifreezes Engine circuit Heating circuit

Coolant conditioning

Limit values of the coolant

Testing and changing the coolant Cleaning the cooling system Disposal of the coolant Released cooling system protection agents Chemical corrosion protection agents Antifreezes with corrosion inhibitors

Imprint: MWM GmbH Service Documentation S. Hartmann, FS-K5 Carl-Benz-Str. 1 D-68167 Mannheim Phone: +49 (0) 621 384-8711 Fax: +49 (0) 621 384-8841 www.mwm.net Date: 2011-08-12 OBJ_DOKU-29078-001.fm

Note: The part numbers stated in this documentation are not subject to the modification service. For identifying spare parts, the spare part documentation has to be referred to.

Copies to: - TR - According to SIT 7010

MWM GmbH

Technical Bulletin

0199 - 99 - 2091/9 EN

General information
The owner is solely responsible for compliance with the regulations described in this Technical Bulletin. The owner is responsible for observance of the respective national legal provisions.

CAUTION Danger of destruction MWM accepts no liability for damages caused by the use of non-approved cooling system protection agents and components not belonging to the scope of delivery of MWM, or for improper operation. Only the cooling system protection agents approved by MWM may be used for MWM engines. See also: MWM documentation - Installation Guideline, Layout of Power Plants Note All the data in this Technical Bulletin correspond to the latest state of knowledge. Please contact MWM Service or your authorised Service Partner if you have any queries. The cooling water referred to in this bulletin is water with suitable properties for preparing the coolant for MWM engines. See Colling water properties (page 8-9) The coolant for he MWM engines consists of cooling water with cooling system protection agents added. See Preparation of the coolant (page 8-10) The coolant must be suitable for all the components in the engine (different metals, elastomers) and meet the different requirements in the engine circuit, heating circuit and mixture cooling circuit or charge air cooling circuit. Appropriate properties of the coolant are necessary to avoid damage especially to the exhaust heat exchanger due to poor quality of the coolant. See Limit values of the coolant (page 11) The products which are released as cooling system protection agents for MWM engines are listed in the chapter Cooling system protection agents.

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MWM GmbH

Technical Bulletin

0199 - 99 - 2091/9 EN

Cooling systems
Cooling systems are designed differently depending on the requirements. The designs of cooling circuits, which can normally be installed for MWM engines, are shown in simplified terms below: A) Cooling system without heat utilisation:

1 2 3 4 5 6 7 8

Engine cooling circuit Temperature sensor engine inlet Engine Temperature sensor engine outlet Safety valve (3 bar) Diaphragm expansion vessel Coolant pump Cooler

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MWM GmbH

Technical Bulletin

0199 - 99 - 2091/9 EN

B) Cooling system with exhaust heat exchanger in the heating circuit:

1 2 3 4 5 6 7 8 9 10 11

Engine cooling circuit Temperature sensor engine inlet Engine Temperature sensor engine outlet Safety valve (3 bar) Diaphragm expansion vessel Coolant pump Heat exchanger Exhaust gas Exhaust gas heat exchanger Heating circuit

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MWM GmbH

Technical Bulletin

0199 - 99 - 2091/9 EN

C) Cooling system with exhaust heat exchanger in the engine cooling circuit:

1 2 3 4 5 6 7 8 9 10 11 12 13

Engine cooling circuit Temperature sensor engine inlet Engine Temperature sensor engine outlet Safety valve (3 bar) Diaphragm expansion vessel Coolant pump Heat exchanger Exhaust gas Exhaust gas heat exchanger Heating circuit Safety valve (10 bar) Temperature sensor exhaust heat exchanger outlet

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MWM GmbH

Technical Bulletin

0199 - 99 - 2091/9 EN

Cooling system protection agents

CAUTION Danger of destruction Cooling system protection agents which are made from different raw products may not be mixed. When changing over the cooling circuit to a different product, the compatibility of the products must be clarified. The cooling system must be purged if necessary before changing over. DANGER Danger of poisoning Mixing of agents containing amines is prohibited as these can generate carcinogenic nitrosamines under certain circumstances. In the system protection agents a distinction is made between: Checmical corrosion protection agents which form a protective film on metal surfaces by chemcial reactions and therefore prevent damage such as corrosion and cavitation on the cooling system but do not act as an antifreeze. Antifreezes with corrosion inhibitors which avoid freezing of the coolant and also offer corrosion protection.

Chemical corrosion protection agents Chemical corrosion protection agents have the following properties: Properties Corrosion protection Cavitation protection Antifreeze Care Operational reliability good satisfactory none low good

Chemical corrosion protection agents, which contain silicates, can damage the floating seals of water pumps. These agents are therefore not listed under the released products.

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MWM GmbH

Technical Bulletin

0199 - 99 - 2091/9 EN

Antifreezes with corrosion protection inhibitors Note When using antifreezes the heat transition value (heat capacity and heat conductance) of the coolant is reduced. Make sure that the cooling systems are designed for it.

Antifreezes with corrosion inhibitors have the following properties: Properties Corrosion protection Cavitation protection Antifreeze Care Operational reliability Note Antifreezes with corrosion protection are used for MWM engines when sub-zero ambient temperatures can occur, e.g. containers on dumps. good satifactory up to -45 C depending on the mixing ratio low good

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MWM GmbH

Technical Bulletin

0199 - 99 - 2091/9 EN

Preparing the coolant

The coolant is prepared by adding a chemical corrosion protection agent or an antifreeze with corrosion inhibitors to the cooling water. Cooling water properties CAUTION Danger of destruction Sea water, river water, brackish water or industrial waste water is unsuitable as cooling water for MWM engines and systems. Depending on the structure of the cooling circuit, the following limit values must be observed when preparing the cooling water. The local water board will provide information about the properties of the water and can also be determined by means of an MWM test set, order no. 1215 8292 or in a suitable chemical laboratory. Sampling and water analysis must be carried out with great care and accuracy. Only clean and odourless water with the following properties may be used as a cooling water for MWM engines:

Limit values of the cooling water for the cooling systems A and B without exhaust heat exchanger pH value at 25 C Chloride-ion content Sulphate-ion content Total hardness Carbonate hardness proportion of the total hardness 6.5 to 8.5 maximum 100 mg/l maximum 100 mg/l 3 to 12 dH at least 3 dH

Limit values of the cooling water for cooling system C with exhaust heat exchanger pH value at 25 C Chloride-ion content Sulphate-ion content Total hardness Carbonate hardness proportion of the total hardness 6.5 to 8.5 less than 20 mg/l maximum 100 mg/l less than 1 dH less than 1 dH

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MWM GmbH

Technical Bulletin

0199 - 99 - 2091/9 EN

Note In line with the SI dimension system, the water hardness is specified in mol per litre or, for low concentrations, in millimol per litre (mmol/l). The unit degree German hardness (dH) is still the most commonly used in Germany. The degree German hardness (dH) is converted into mmol/l as follows: 1 dH = 0.178 mmol/l, 1 mmol/l = 5.6 dH

In case of deviation from the limit values listed above the cooling water is prepared as follows: pH value too low: Addition of diluted sodium or potassium lye. It is advisable to make small sample mixtures before adding. Total hardness and/or carbonate hardness too low: Mixing with harder water Harder water is usually available in the form of drinking water (city mains water). Total hardness, chloride and/or sulphates too high: Mixing with softened water Softened water is distilled water or water treated with an ion exchanger. Another water analysis must be carried out after preparing the cooling water.

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MWM GmbH

Technical Bulletin

0199 - 99 - 2091/9 EN

Addition of chemical corrosion protection agents The corrosion protection agent is mixed with the cooling water first and then filled into the cooling system as described in job card B 9-0-4 Emptying and filling the cooling systemin the appropriate operating manual. The necessary concentrations of the chemical corrosion protection agent in cooling circuits are determined according to the specifications of the manufacturer or supplier. CAUTION Danger of destruction An under-concentration of the chemical corrosion protection agent has a damaging effect on the cooling system, especially aluminium parts. Observe the correct dosing of the chemical corrosion protection agent.

Addition of antifreezes with corrosion inhibitors The antifreeze is mixed with the cooling water first and then filled into the cooling system as described in job card B 9-0-4 Emptying and filling the cooling systemin the appropriate operating manual. The coolant must be checked for the necessary freezing protection after preparation. The freezing protection of the antifreeze depends on the mixing ratio with the water: Antifreeze 35% 40% 45% 50% Note The concentration of the antifreeze must be at least 35% to ensure an adequate corrosion protection. When using an antifreeze with corrosion inhibitors for corrosion protection the antifreeze must stay in the cooling system even at temperatures above freezing point. CAUTION Danger of destruction Pure antifreeze may not be filled into the cooling system. Freezing protection below -40 C is only possible in consultation with MWM Service. The limits values of the coolant listed below must be observed: Cooling water 65% 60% 55% 50% Freezing protection up to -23 C -29 C -35 C -40 C

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Technical Bulletin

0199 - 99 - 2091/9 EN

Limit values of the coolant

Engine circuit Limit values of the coolant for the cooling systems A and B without exhaust heat exchanger in the engine circuit If the specifications for cooling water quality of the cooling system protection agent are complied with, the quality of the coolant is sufficient. Limit values of the coolant for the cooling system C with exhaust heat exchanger in the engine circuit pH value at 25 C Chloride-ion content Total hardness Filling volumes Temperature at exhaust heat exchanger outlet Note The filling volume is limited to 2 m3 to avoid heat build-up deposits due to escaping carbonate at the limit surfaces of the exhaust heat exchanger. 7.5 to 8.5 less than 20 mg/l less than 1 dH maximum 2 m3 maximum 110 C

Heating circuit CAUTION Danger of destruction This coolant, which is exclusively for use in heating circuits of iron materials, is unsuitable for an engine cooling circuit. MWM will not be liable for damage caused by using this coolant in an engine cooling circuit. Limit values of the coolant for the heating circuit pH value at 25 C Electrical conductivity Oxygen (O2) Chloride Copper (Cu) Total iron (Fe) Phosphate (PO4) Earth alkalis Total hardness
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9 to 10.5 less than 0.1 mS/cm less than 0.05 mg/l less than 20 mg/l less than 0.05 mg/l less than 0.05 mg/l 5 to 10 mg/l less than 0.02 mmol/l less than 0.1 dH 11
MWM GmbH

Technical Bulletin

0199 - 99 - 2091/9 EN

Testing and changing the coolant

The cooling system must be inspected regularly and maintained at the given intervals. This also includes inspecting the properties of the coolant and the concentrations of the cooling system protection agents as well as refilling and changing the coolant. The cooling system protection agent in the coolant must be checked and the concentration corrected according to job card B 9-1-1 Checking corrosion protection agents or antifreezes in coolant in the appropriate operating manual. When checking the chemical corrosion protection agents using a refractometer, the manufacturer's instructions for the conversion of %Brix to Vol.% must be observed. Note The specifications of the cooling system protection agent manufacturer must be observed when checking the coolant. All inspections must be documented in the log book according to the maintenance schedule. The coolant in cooling circuits must be inspected at least every 6 months and changes at least every two years.

Also change the coolant in case of: in case of penetration by lubricating oil lubricating oil penetration in case of heavy turbidity due to corrosion residue or other foating particles

CAUTION Danger of destruction Non-observance of these instructions and requirements when producing and using the coolants will lead to increased component wear and damage. The same product must be used again when refilling the coolant. If a product change is necessary, check the compatibility of the products (note manufacturer specifications and composition of the products). In case of incompatibility the entire cooling system must be cleaned thoroughly before changing the product. Obviously only products released by MWM may be used.

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Technical Bulletin

0199 - 99 - 2091/9 EN

Cleaning the cooling system

Clean the entire cooling system in case of: soiling lubricating oil penetration in case of penetration by lubricating oil product change (incompatible products) maintenance work

The coolant must be drained completely and purged with a cleaning agent released by MWM. These are listed in the operating manual and in the workshop manual, chapter 4, Operating Media.

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Technical Bulletin

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Disposal of the coolant

Coolant and cooling system protection agents may not be disposed of in the environment. They must be disposed properly according to the respective, national, legal regulations and specifications of the manufacturer or supplier by a licenced disposal company.

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MWM GmbH

Technical Bulletin

0199 - 99 - 2091/9 EN

Released cooling system protection agents

Chemical corrosion protection agents

Valid for:

Diesel and gas engines Series: 2016, 2020, 2032, 616, 620, 632

Addinol Protect Extra Aqua-Concept CORACON BL2 CORACON BL6 Arteco Havoline XLI Caltex XL Corrosion Inhibitor Concentrate Chevron/Texaco Extended Life Corrosion Inhibitor Total Total WT Supra

Note The above products can also be used for earlier engine series which are not listed here.

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MWM GmbH

Technical Bulletin

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Antifreezes with corrosion protection inhibitors Note The released antifreezes with corrosion inhibitors are divided into product groups A and B due to their different compositions.

CAUTION Danger of destruction Non-observance of these instructions and requirements when producing and using the coolants will lead to increased component wear and damage. Products of group A may not be used with products of group B. Valid for: Product group A Aral Antifreeze Extra BASF Glysantin G48 / Protect Plus BP BP anti-frost Code No. X 2270 A Castrol Antifreeze NF Fuchs Europe MAINTAIN FRICOFIN INEOS Napgel C2270/1 Mobil Antifreeze Extra OMV Coolant plus Shell Glyco Shell TOTAL Glacelf MDX
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Diesel and gas engines

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Technical Bulletin

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Product group B Addinol Antifreeze Extra Aqua-Concept CORACON BF6 ARTECO Havoline XLC Havoline XLC-PG Caltex Extended Life Coolant Chevron/Texaco Havoline Extended Life Coolant HELAC (no nitrite or molybdate) Extended Life Coolant TELC (with nitrite and molybdate) DELO Extended Life Coolant/Antifreeze PG Fuchs Maintain Fricofin LL TOTAL Glacelf CHP Supra Glacelf Supra Note Some manufacturers also offer ready mixtures. These mixtures can also be used if they are made with the above mentioned products in the respective necessary concentration.

Service Information This document has been created digitally and is valid without a signature.

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