0199 - 99 - 2091/9 ENThis Circular supersedes:0199 - 99 - 2091/8

Technical BulletinCoolant 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

- Coolant conditioning

- Cooling water properties

- Addition of chemical corrosion protection agents

- Addition of antifreezes

- Limit values of the coolant

- Engine circuit

- Heating circuit

- 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 inhibitorsImprint:MWM GmbHService DocumentationS. Hartmann, FS-K5Carl-Benz-Str. 1D-68167 MannheimPhone: +49 (0) 621 384-8711Fax: +49 (0) 621 384-8841www.mwm.netDate:

OBJ_DOKU-29078-001.fm 1 MWM GmbH

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 70102011-08-12

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Technical Bulletin

General information

See also:

MWM documentation - Installation Guideline, Layout of Power Plants

The cooling water referred to in this bulletin is water with suitable properties for preparingthe coolant for MWM engines. See Colling water properties (page 8-9)

The coolant for he MWM engines consists of cooling water with cooling system protectionagents added. See Preparation of the coolant (page 8-10)

The coolant must be suitable for all the components in the engine (different metals, elas-tomers) and meet the different requirements in the engine circuit, heating circuit and mix-ture cooling circuit or charge air cooling circuit. Appropriate properties of the coolant arenecessary to avoid damage especially to the exhaust heat exchanger due to poor quality ofthe coolant. See Limit values of the coolant (page 11)

The products which are released as cooling system protection agents for MWM engines arelisted in the chapter Cooling system protection agents.

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.

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.OBJ_DOKU-29078-001.fm 2 MWM GmbH

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Technical Bulletin

Cooling systemsCooling systems are designed differently depending on the requirements.

The designs of cooling circuits, which can normally be installed for MWM engines, areshown in simplified terms below:

A) Cooling system without heat utilisation:

1 Engine cooling circuit

2 Temperature sensor engine inlet

3 Engine

4 Temperature sensor engine outlet

5 Safety valve (3 bar)

6 Diaphragm expansion vessel

7 Coolant pump

8 CoolerOBJ_DOKU-29078-001.fm 3 MWM GmbH

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Technical Bulletin

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

1 Engine cooling circuit

2 Temperature sensor engine inlet

3 Engine

4 Temperature sensor engine outlet

5 Safety valve (3 bar)

6 Diaphragm expansion vessel

7 Coolant pump

8 Heat exchanger

9 Exhaust gas

10 Exhaust gas heat exchanger

11 Heating circuitOBJ_DOKU-29078-001.fm 4 MWM GmbH

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Technical Bulletin

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

1 Engine cooling circuit

2 Temperature sensor engine inlet

3 Engine

4 Temperature sensor engine outlet

5 Safety valve (3 bar)

6 Diaphragm expansion vessel

7 Coolant pump

8 Heat exchanger

9 Exhaust gas

10 Exhaust gas heat exchangerOBJ_DOKU-29078-001.fm 5 MWM GmbH

11 Heating circuit

12 Safety valve (10 bar)

13 Temperature sensor exhaust heat exchanger outlet

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Technical Bulletin

Cooling system protection agents

In the system protection agents a distinction is made between:

Checmical corrosion protection agents which form a protective film on metal surfacesby chemcial reactions and therefore prevent damage such as corrosion and cavitationon the cooling system but do not act as an antifreeze.

Antifreezes with corrosion inhibitors which avoid freezing of the coolant and also offercorrosion protection.

Chemical corrosion protection agents

Chemical corrosion protection agents have the following properties:

Chemical corrosion protection agents, which contain silicates, can damage the floating

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 nit-rosamines under certain circumstances.

PropertiesCorrosion protection good

Cavitation protection satisfactory

Antifreeze none

Care low

Operational reliability goodOBJ_DOKU-29078-001.fm 6 MWM GmbH

seals of water pumps. These agents are therefore not listed under the released products.

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Technical Bulletin

Antifreezes with corrosion protection inhibitors

Antifreezes with corrosion inhibitors have the following properties:

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.

PropertiesCorrosion protection good

Cavitation protection satifactory

Antifreeze up to -45 C depending on the mixing ratio

Care low

Operational reliability good

Note

Antifreezes with corrosion protection are used for MWM engines when sub-zero ambient temperatures can occur, e.g. containers on dumps. OBJ_DOKU-29078-001.fm 7 MWM GmbH

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Technical Bulletin

Preparing the coolantThe coolant is prepared by adding a chemical corrosion protection agent or an antifreezewith corrosion inhibitors to the cooling water.

Cooling water properties

The local water board will provide information about the properties of the water and can alsobe determined by means of an MWM test set, order no. 1215 8292 or in a suitable chemicallaboratory.

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 wa-ter for MWM engines:

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 ob-served when preparing the cooling water.

Limit values of the cooling water for the cooling systems A and B without exhaust heat exchangerpH value at 25 C 6.5 to 8.5

Chloride-ion content maximum 100 mg/l

Sulphate-ion content maximum 100 mg/l

Total hardness 3 to 12 dH

Carbonate hardness proportion of the total hard-ness

at least 3 dH

Limit values of the cooling water for cooling system C with exhaust heat exchangerpH value at 25 C 6.5 to 8.5

Chloride-ion content less than 20 mg/l

Sulphate-ion content maximum 100 mg/lOBJ_DOKU-29078-001.fm 8 MWM GmbH

Total hardness less than 1 dH

Carbonate hardness proportion of the total hard-ness

less than 1 dH

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Technical Bulletin

In case of deviation from the limit values listed above the cooling water is prepared as fol-lows:

pH value too low:Addition of diluted sodium or potassium lye. It is advisable to make small sample mix-tures 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.

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 OBJ_DOKU-29078-001.fm 9 MWM GmbH

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Technical Bulletin

Addition of chemical corrosion protection agents

The corrosion protection agent is mixed with the cooling water first and then filled into thecooling system as described in job card B 9-0-4 Emptying and filling the cooling sys-temin the appropriate operating manual.

The necessary concentrations of the chemical corrosion protection agent in cooling circuitsare determined according to the specifications of the manufacturer or supplier.

Addition of antifreezes with corrosion inhibitors

The antifreeze is mixed with the cooling water first and then filled into the cooling systemas described in job card B 9-0-4 Emptying and filling the cooling systemin the appropri-ate 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:

When using an antifreeze with corrosion inhibitors for corrosion protection the antifreezemust stay in the cooling system even at temperatures above freezing point.

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.

Antifreeze Cooling water Freezing protection up to

35% 65% -23 C

40% 60% -29 C

45% 55% -35 C

50% 50% -40 C

Note

The concentration of the antifreeze must be at least 35% to ensure an adequate corrosion protection.OBJ_DOKU-29078-001.fm 10 MWM GmbH

The limits values of the coolant listed below must be observed:

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.

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Technical Bulletin

Limit values of the coolant

Engine circuit

Heating circuit

Limit values of the coolant for the cooling systems A and B without exhaust heat exchanger in the engine circuitIf 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 circuitpH value at 25 C 7.5 to 8.5

Chloride-ion content less than 20 mg/l

Total hardness less than 1 dH

Filling volumes maximum 2 m3

Temperature at exhaust heat exchanger outlet maximum 110 C

Note

The filling volume is limited to 2 m3 to avoid heat build-up deposits due to escaping carbon-ate at the limit surfaces of the exhaust heat exchanger.

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 cir-cuit.

Limit values of the coolant for the heating circuitpH value at 25 C 9 to 10.5

Electrical conductivity less than 0.1 mS/cm

Oxygen (O ) less than 0.05 mg/lOBJ_DOKU-29078-001.fm 11 MWM GmbH

2

Chloride less than 20 mg/l

Copper (Cu) less than 0.05 mg/l

Total iron (Fe) less than 0.05 mg/l

Phosphate (PO4) 5 to 10 mg/l

Earth alkalis less than 0.02 mmol/l

Total hardness less than 0.1 dH

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Technical Bulletin

Testing and changing the coolantThe cooling system must be inspected regularly and maintained at the given intervals. Thisalso includes inspecting the properties of the coolant and the concentrations of the coolingsystem protection agents as well as refilling and changing the coolant.

The cooling system protection agent in the coolant must be checked and the concentrationcorrected according to job card B 9-1-1 Checking corrosion protection agents or anti-freezes in coolant in the appropriate operating manual.

When checking the chemical corrosion protection agents using a refractometer, the manu-facturer's instructions for the conversion of %Brix to Vol.% must be observed.

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

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 sched-ule.

The coolant in cooling circuits must be inspected at least every 6 months and changes at least every two years.

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 manu-facturer specifications and composition of the products).

In case of incompatibility the entire cooling system must be cleaned thoroughly before changing the product.OBJ_DOKU-29078-001.fm 12 MWM GmbH

Obviously only products released by MWM may be used.

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Technical Bulletin

Cleaning the cooling systemClean 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 byMWM. These are listed in the operating manual and in the workshop manual, chapter 4,Operating Media.OBJ_DOKU-29078-001.fm 13 MWM GmbH

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Technical Bulletin

Disposal of the coolantCoolant 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 andspecifications of the manufacturer or supplier by a licenced disposal company.OBJ_DOKU-29078-001.fm 14 MWM GmbH

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Technical Bulletin

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 BL2CORACON 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.OBJ_DOKU-29078-001.fm 15 MWM GmbH

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Technical Bulletin

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: Diesel and gas engines

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

OMVOBJ_DOKU-29078-001.fm 16 MWM GmbH

Coolant plus

Shell

Glyco Shell

TOTAL

Glacelf MDX

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Technical Bulletin

Product group B

Addinol

Antifreeze Extra

Aqua-Concept

CORACON BF6

ARTECO

Havoline XLCHavoline 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 InformationOBJ_DOKU-29078-001.fm 17 MWM GmbH

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

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Technical BulletinOBJ_DOKU-29078-001.fm 18 MWM GmbH

Technical BulletinCoolant for MWM engines and systems0199 - 99 - 2091/9 ENGeneral informationCooling systemsCooling system protection agentsChemical corrosion protection agentsAntifreezes with corrosion protection inhibitors

Preparing the coolantCooling water propertiesAddition of chemical corrosion protection agentsAddition of antifreezes with corrosion inhibitors

Limit values of the coolantEngine circuitHeating circuit

Testing and changing the coolantCleaning the cooling systemDisposal of the coolantReleased cooling system protection agentsChemical corrosion protection agentsAntifreezes with corrosion protection inhibitors