Scania DI16 PDE. Marine engine en-GB 2 805 697. Operator’s manual - part 4

 

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Scania DI16 PDE. Marine engine en-GB 2 805 697. Operator’s manual - part 4

 

 

Cooling system
Antifreeze and corrosion protection
concentration 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
48
Cooling system
Checking the coolant level
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.
IMPORTANT!
It is not permissible to top up large amounts of
coolant via the expansion tank. Filling via the ex-
pansion tank leads to air locks in the cooling sys-
tem which can lead to e.g. cavitation damage to
the coolant pump shaft seal. If a large amount of
coolant needs to be added, follow the instruc-
tions in the section Filling coolant.
Only pour pre-mixed coolant into the cooling
system.
The following instructions apply to Scania ex-
pansion tanks. For other types of expansion
tanks, follow the manufacturer's instructions.
1. Check the coolant level through the sight
glass on the expansion tank.
2. Top up with coolant as necessary.
49
Cooling system
Checking coolant antifreeze
and corrosion protection
Tools
Designation
Illustration
Refractometer
WARNING!
Avoid skin contact with coolant as this may
cause irritation to the skin. Wear protective gog-
gles and gloves when handling coolant.
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 and corrosion inhibi-
tor content with the refractometer.
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.
50
Cooling system
Checking sacrificial anodes
IMPORTANT!
Corrosion of sacrificial anodes depends on the
operating environment. Therefore, check the
sacrificial anodes every third month during the
first year of commissioning or when changing
the operating environment.
1. Drain the sea water circuit as described in the
Draining the sea water circuit section.
2. Remove all sacrificial anodes.
Position of sacrificial anodes.
3. Check all sacrificial anodes:
17 mm
- Scrape off all loose material and check the
corrosion.
- Renew all sacrificial anodes if there is less
than ¾ (2) remaining of any of the sacrifi-
cial anodes.
- If the sacrificial anodes are very corroded
(3), the length of the intervals for checking
the sacrificial anodes should be halved. If
the sacrificial anodes are very corroded,
they often come loose entirely.
4. Renew the gasket when fitting.
1
2
3
1. New sacrificial anode.
2. Approx. 3/4 remains.
3. Approx. 1/4 remains.
51
Cooling system
Checking the sea water pump
impeller
1. Drain the sea water circuit as described in the
Draining the sea water circuit section.
2. Remove the sea water pump cover. See illus-
tration.
3. Check that the vanes of the impeller are not
heavily splintered or damaged.
Renewing the sea water pump impel-
ler
Special tools
Number
Designation
Illustration
98 482
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 and puller 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. Pull out the impeller using the puller. Note
the direction of rotation of the impeller
vanes.
2. Fit a new impeller and cap. Check that the
cap seal is not hard or damaged.
IMPORTANT!
When fitting the new impeller, bend the vanes in
the same direction as on the old one.
52
Cooling system
Changing the coolant and
cleaning the cooling system
Draining coolant
Special tools
Number, designation
Illustration
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.
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.
Drain nipple in the cylinder block (behind the heat
5. Repeat the procedure at the cooling system's
exchanger).
lowest drainage point. The location of the
lowest drainage point on the engine may dif-
fer depending on engine application.
53
Cooling system
Draining the sea water circuit
1. Close the bottom valve on the sea water inlet
and remove the connection pipe (1) on the
1
outlet from the heat exchanger.
2
2. Remove the cover (2) from the sea water
pump to empty the pump completely.
3
The lowest point in the sea water circuit may be
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 cooler core of the charge air cooler
needs cleaning, the charge air cooler must be re-
moved if there is no space behind it to take out
the cooler core.
1. Make sure that the cooling system is empty
as described earlier.
2. Unscrew and remove the catwalk, protective
plate and the protective casing.
54
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.
55
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.
56
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 core. See
previous section.
1. 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
2. Press in the cooler core (5) slightly on one
2
side and pull it out from the other side.
5
3. 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!
1.
Cover.
Do not use caustic soda as this could damage the
2.
O-rings.
aluminium.
3.
Spacer.
4.
Charge air cooler housing.
4. Renew damaged or hard O-rings (2).
5.
Cooler core.
5. Assemble the charge air cooler. Tighten the
M8 screws on the covers to 15 Nm (11 lb-ft).
57
Cooling system
Removing the heat exchanger
When the cooler core of the heat exchanger
needs cleaning, the heat exchanger must be re-
moved.
1. Make sure that the cooling system is empty
as described earlier.
2. Remove the sea water pipe between the
charge air cooler and heat exchanger.
3. If the engine has a water-cooled exhaust pipe
bend: Remove the sea water pipe between
the heat exchanger and the exhaust pipe
bend.
4. Remove the coolant pipe with the thermostat
housing cover.
58
Cooling system
5. Remove the coolant pipe from the heat ex-
changer.
6. Remove the screws on the heat exchanger
and the 2 upper screws on the exhaust mani-
fold bracket.
7. Remove the heat exchanger by holding it in
the bracket, moving the heat exchanger
slightly to the side and removing it.
59
Cooling system
Cleaning the heat exchanger
1. Remove the screws on the heat exchanger
covers (1) and remove the covers. Mark the
covers so that you can put them back on the
1
correct side.
5
2. Press in the cooler core (5) slightly on one
3
side and pull it out from the other side.
3. Clean the cooler core on the outside with par-
affin-based engine detergent. Remove any
4
3
internal deposits using a round rod. Renew
2
1
the cooler core if it is damaged.
1. Cover.
IMPORTANT!
2. Spacer.
3. O-rings.
Do not use caustic soda as this could damage the
4. Heat exchanger housing.
aluminium.
5. Cooler core.
4. Renew damaged or hard O-rings (3).
5. Assemble the heat exchanger. Tighten the
M8 screws on the covers to 15 Nm (11 lb-ft).
60
Cooling system
Fitting the heat exchanger
1. Fit the heat exchanger by holding it in the ex-
haust manifold bracket, moving it slightly to
the side and fitting it.
2. Fit all screws by hand and then tighten them.
Tightening torque 50 Nm (37 lb-ft).
1
2
3. Lubricate and fit the coolant pipe from the
heat exchanger. Angle the pipe from the ther-
mostat housing inwards and push it onto the
connection.
61
Cooling system
4. Fit the coolant pipe with the thermostat hous-
ing cover.
5. Fit the sea water pipe between the charge air
cooler and heat exchanger.
6. If the engine has a water-cooled exhaust pipe
bend: Fit the sea water pipe between the heat
exchanger and the exhaust pipe bend.
62
Cooling system
Fitting the charge air cooler
1. Fit the charge air cooler. Tighten the 4
screws to 50 Nm (37 lb-ft).
2. Carefully fit the charge air pipe from the left-
hand turbocharger and tighten the V-clamp
to 20 Nm (15 lb-ft).
3. Fit the charge air pipe from the left-hand tur-
bocharger. Fit the V-clamp first and then the
screw on the bracket.
4. Fit the sea water pipe from the sea water
pump, first to the charge air cooler (the inner
pipe) and then from the charge air cooler to
the heat exchanger (the outer pipe).
63

 

 

 

 

 

 

 

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