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Scania DI16 XPI. Marine engine en-GB 2 741 685. Operator’s manual - part 3

Air cleaner

Air cleaner

Reading the vacuum indicator

If the indicator's red plunger is fully visible, re-

new the air cleaner filter element following the

instructions below.

Renewing the filter element

A

B

WARNING!

Never start the engine without the air filter being

in place. If you do, this could cause injury and se-

vere engine damage.

IMPORTANT!

Renew the filter element earlier than the mainte-

nance interval if the indicator shows red.

There is always a risk that the filter element will

be damaged when it is cleaned.

The filter element must not be cleaned in water

or be blown clean with compressed air.

1. Remove the cover from the air cleaner.

2. Renew the filter element.

3. Insert a torch into the element and check

from the outside that there are no holes or

cracks in the filter paper.

4. Assemble the air cleaner.

5. Reset the vacuum indicator by pressing the

button.

32

Air cleaner

Renewing the safety cartridge

WARNING!

Never start the engine without the air filter being

in place. If you do, this could cause injury and se-

vere engine damage.

4

2

IMPORTANT!

When you renew the safety cartridge, take great

care to ensure that no dirt or other impurities get

into the engine. Do not remove the safety car-

3

tridge unnecessarily.

1

1. Remove the cover from the air cleaner.

2. Remove the filter element.

3. Remove the safety cartridge.

4. Fit a new safety cartridge from Scania.

5. Renew or clean the filter element.

6. Check the condition of the O-ring. Renew

the O-ring if it is damaged or hard.

7. Assemble the air cleaner. Ensure that the O-

ring is not outside the edges.

Renewing an air filter with a

non-renewable element

IMPORTANT!

If the engine has air filters with a non-renewable

Scania element, they should be renewed instead

of cleaned.

33

Cooling system

Coolant resistance to cold

The following example shows coolant properties

with 30 percent by volume of antifreeze and cor-

rosion inhibitor:

• Ice slush starts to form at -16°C (3°F).

• At -30°C (-22°F), there is a risk of cooling

system malfunction.

• There is no risk of damage by freezing with a

minimum antifreeze and corrosion inhibitor

content of 35 percent by volume.

0

10

20

30

40

50

%

0

-10

-16

1

-20

-30

3

2

-40

-50

°C

B

A

The chart depicts coolant properties at different

percents of antifreeze and corrosion inhibitor

concentration by volume.

Curve A: Ice formation starts (ice slush)

Curve B: Damage by freezing occurs

Area 1: Safe range

Area 2: Malfunctions may occur (ice

slush)

Area 3: Risk of damage by freezing

35

Cooling system

Antifreeze and corrosion protection con-

centration table, litres

35% by volume of Scania antifreeze provides

sufficient protection against corrosion.

Example:

• The total volume of the cooling system is 40

litres.

• The measured concentration of ethylene gly-

col is 35% by volume (freezing point -21°C).

According to the table there are 14 litres of

ethylene glycol in the cooling system.

• The required concentration of ethylene glycol

is 45% by volume (freezing point -30°C). Ac-

cording to the table, 18 litres of ethylene gly-

col are required in the cooling system.

• Since there are already 14 litres in the cooling

system, 4 litres of ethylene glycol must be

added to the cooling system (18 - 14 = 4 li-

tres).

Adequate protection against corrosion

Volume of ethylene glycol (%)

35

40

45

50

60

Cooling system volume

Ice slush forms (°C)

-21

-24

-30

-38

-50

(litres)

11

12

14

15

18

30

14

16

18

20

24

40

18

20

23

25

30

50

21

24

27

30

36

60

25

28

32

35

42

70

28

32

36

40

48

80

32

36

41

45

54

90

35

40

45

50

60

100

39

44

50

55

66

110

Volume of ethylene glycol (litres)

42

48

54

60

72

120

46

52

59

65

78

130

49

56

63

70

84

140

53

60

68

75

90

150

56

64

72

80

96

160

60

68

77

85

102

170

63

72

81

90

108

180

67

76

86

95

114

190

70

80

90

100

120

200

36

Cooling system

Antifreeze and corrosion protection con-

centration table, US gallons

35% by volume of Scania antifreeze provides

sufficient protection against corrosion.

Example:

• The total volume of the cooling system is

10.6 US gallons.

• The measured concentration of ethylene gly-

col is 35% by volume (freezing point -6 °F).

According to the table there are

3.7 US gallons of ethylene glycol in the cool-

ing system.

• The required concentration of ethylene glycol

is 45% by volume (freezing point -22 °F). Ac-

cording to the table, 4.8 US gallons of ethyl-

ene glycol are required in the cooling system.

• Since the cooling system already contains

3.7 US gallons, fill another 1.1 US gallons of

ethylene glycol in the cooling system (4.8 -

3.7 = 1.1 US gallons).

Adequate protection against corrosion

Volume of ethylene glycol (%)

35

40

45

50

60

Cooling system volume

Ice slush forms (°F)

-6

-11

-22

-36

-58

(US gallons)

2.9

3.2

3.7

4

4.8

7.9

3.7

4.2

4.8

5.3

6.3

10.6

4.8

5.3

6.1

6.6

7.9

13.2

5.5

6.3

7.1

7.9

9.5

15.9

6.6

7.4

8.5

9.2

11.1

18.5

7.4

8.5

9.5

10.6

12.7

21.1

8.5

9.5

10.8

11.9

14.3

23.8

9.2

10.6

11.9

13.2

15.9

26.4

Volume of ethylene glycol (US gal-

10.3

11.6

13.2

14.5

17.4

29.1

lons)

11.1

12.7

14.3

15.9

19

31.7

12.2

13.7

15.6

17.2

20.6

34.3

12.9

14.8

16.6

18.5

22.2

37

14

15.9

18

19.8

23.8

39.6

14.8

16.9

19

21.1

25.4

42.3

15.9

18

20.3

22.5

26.9

44.9

16.6

19

21.4

23.8

28.5

47.6

17.7

20.1

22.7

25.1

30.1

50.2

18.5

21.1

23.8

26.4

31.7

52.8

37

Cooling system

Antifreeze and corrosion protection

products

Only Scania coolant or other products that Scan-

ia has tested to provide proper antifreeze and cor-

rosion protection, may be used in Scania

engines. Products that do not satisfy the require-

ments for use in a Scania engine can result in

faults in and damage to the cooling system. This

can lead to the invalidation of Scania's warranty

for faults and damage caused by the use of inap-

propriate coolant.

The antifreeze and corrosion protection products

used in Scania engines should be of the ethylene

glycol type.

Below is a list of Scania antifreeze and corrosion

protection products.

Scania concentrate

Coolant with antifreeze and corrosion inhibitor

in the form of a concentrate.

Part no.

Volume

Volume

litres

US gallons

1 894 323

5

1.3

1 894 324

20

5.3

1 894 325

210

55

1 894 326

1,000

264

Scania Ready Mix

Coolant with antifreeze and corrosion inhibitor

Ready Mix 50/50.

Part no.

Volume

Volume

litres

US gallons

1 921 955

5

1.3

1 921 956

20

5.3

1 921 957

210

55

1 896 695

1,000

264

38

Cooling system

Checking the coolant's anti-

freeze and corrosion protec-

tion

Tool

Designation

Illustration

Refractometer

IMPORTANT!

Use only pure fresh water that is free from parti-

cles, sludge and other impurities.

1. Pour a small amount of coolant into a con-

tainer and check that the coolant is pure and

clear.

2. Change the coolant if it is contaminated or

cloudy.

3. Measure the antifreeze content with a refrac-

tometer.

The following rules apply to ethylene glycol-

based coolant:

• The antifreeze and corrosion inhibitor content

must be minimum 35 percent by volume for

corrosion protection to be sufficient.

• An antifreeze and corrosion inhibitor content

greater than 55 percent by volume impairs the

ability to protect against frost.

• If ice forms in the coolant, there are disrup-

tions initially, but there is no immediate risk

of damage. The engine should not be subject-

ed to heavy loads when ice starts to form.

40

Cooling system

Checking sacrificial anodes

1. Drain the sea water circuit. See the section

Draining the sea water circuit.

2. Check the sacrificial anodes and scrape off

all loose material from them.

3. Renew the sacrificial anode if less than half

of it is left. A new sacrificial anode is 60 mm

long with a diameter of 17 mm.

4. Renew the gasket when fitting.

5. If the sacrificial anodes are very corroded,

the inspection intervals must be reduced.

Checking the sea water pump

impeller

1. Drain the sea water circuit. See the section

Draining the sea water circuit.

2. Check that the vanes of the impeller are not

heavily splintered or damaged.

41

Cooling system

Renewing the sea water pump impel-

ler

Special tool

Number

Designation

Illustration

2 443 680

Puller

Note:

If the impeller must be renewed frequently, the

cleaning of the sea water needs to be improved.

There should be a spare impeller on board.

The impeller can be deformed during extended

periods of inactivity. Renew the impeller before

starting or remove the impeller before longer pe-

riods of stoppage.

1. Thread the puller stud into the rubber impel-

ler using an internal hexagon key until the

stud reaches the bottom.

Note:

Note the direction of rotation of the impeller

vanes.

2. Screw the puller into the rubber impeller us-

ing the handle until it reaches the stud. Then

continue to screw until the impeller comes

loose.

3. Unscrew the stud.

IMPORTANT!

Check that the direction of rotation of the impel-

ler vanes is the same as during removal.

4. Lubricate the impeller with pump grease and

then fit it using a rubber mallet.

5. Fit the sea water pump cover. Tightening

torque 7.5 Nm (5.5 lb/ft).

42

Cooling system

Changing the coolant and

cleaning the cooling system

Draining coolant

Special tool

Number, designation

2 443 679, coolant

pump

WARNING!

Do not open the coolant filler cap in the expan-

sion tank if the engine is hot. Hot coolant and

steam may spray out and cause burns. If the cap

has to be opened do it slowly to release the pres-

sure before removing the cap.

Use protective gloves as coolant can cause irrita-

tion if it comes in contact with the skin. Hot cool-

ant can also cause scalding.

Environment

Use a suitable container. Used coolant must be

disposed of as specified in national and interna-

tional laws and regulations.

1. Open the expansion tank cap.

2. Position the hose from the coolant pump in

an empty container.

3. Connect the pump to the draining nipple in

the cylinder block. See illustration.

4. Connect the pump's 2 cable terminals to the

battery's negative and positive terminal.

Make sure that the drainage starts. If the

drainage does not start: Change the position

of the cable terminals.

5. Repeat the procedure at the cooling system's

lowest drainage point. The location of the

lowest drainage point on the engine may dif-

fer depending on engine application.

43

Cooling system

Draining the sea water circuit

1. Close the bottom valve on the sea water inlet

and remove the connection pipe on the outlet

from heat exchanger (1).

1

2. Remove the cover from the sea water pump

to completely drain the pump (2).

2

The lowest point in the sea water circuit may be

3

at different points, but it is usually in the sea wa-

ter pump intake (3).

IMPORTANT!

Plug the connections to prevent dirt ingress into

the engine.

Removing the charge air cooler

When the charge air cooler core needs cleaning,

the charge air cooler must be removed if there is

no space behind it to take out the core.

1. Make sure that the cooling system is com-

pletely drained as described in the previous

section.

2. Unscrew and remove the catwalk, protective

plate and the protective casing.

44

Cooling system

3. On the left-hand turbocharger, remove the

hose between the oil mist separator and the

air filter flange. Use a screwdriver to pull out

the lock.

4. Loosen and remove the hose clamps for the

charge air pipe.

5. Remove all sea water pipes to and from the

charge air cooler.

45

Cooling system

6. Right-hand turbocharger: Remove the V-

clamp and the screw for the bracket. Remove

the charge air pipe.

7. Left-hand turbocharger: Remove the V-

clamp and carefully turn the charge air pipe

during removal.

8. Remove the screws securing the charge air

cooler.

9. Lift out the charge air cooler.

46

Cooling system

Cleaning the charge air cooler

The charge air cooler must be removed if there is

no space behind it to take out the cooler cores.

See previous section.

1. Remove the sea water pipes to and from the

charge air cooler. Remove flanges and

charge air pipe from the charge air cooler.

Remove the old gaskets and scrape off any

gasket residue.

2. Remove the screws on the charge air cooler

covers (1) and remove the covers. Mark the

covers so that you can put them back on the

correct side.

1

3. Press in the cooler core (5) slightly on one

2

side and pull it out from the other side.

5

4. Clean the cooler core on the outside with par-

2

affin-based engine detergent. Remove any

internal deposits using a round rod. Renew

4

the cooler core if it is damaged.

2

3

2

1

IMPORTANT!

Do not use caustic soda as this could damage the

aluminium.

5. Renew damaged or hard O-rings (2).

6. Assemble the charge air cooler. Tighten the

M8 screws on the cover to 15 Nm (11 lb-ft).

47

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