SECTION 4.25 COOLING SYSTEM MAINTENANCE COOLING SYSTEM MAINTENANCE

Transcription

1 SECTION 4.25 SYSTEM MAINTENANCE SYSTEM MAINTENANCE STANDARD HOT SYSTEM MAINTENANCE Always wear protective CAUTION clothing when venting, flushing, or blowing down the cooling system. Operational coolant temperatures can range from C ( F). Contact with hot coolant or coolant vapor can cause severe personal injury or death. Corrosion, scale, cavitation, and micro-biological growth are the major problems in all types of cooling systems. Of these, corrosion is the most important. PRETREATMENT Pretreatment is preparation of the water system to ensure that the treatment program itself can work effectively from startup. New systems, or existing systems being returned to service, can contain contaminants. These include films of oil, grease, or other protective coatings, biological contamination, rust spots, dirt, casting sand, and welding sludge. These materials are an unavoidable result of the system's construction, transport, and storage. If these materials are not removed by suitable pretreatment, the subsequent treatment program may not be effective. Common pretreatments are water flushing and acid cleaning. Water flushing may reduce solid contaminants, but may not be very effective on films. Untreated flushing water may react with unprotected metal surfaces to form corrosion. Acid cleaning removes corrosion products and some mineral scale but has little effect on organic material. Improper cleaning may lead to severe metal attack. Improper neutralization may leave metal surfaces in a highly reactive state and vulnerable to rapid corrosion. CORROSION The actual corrosion process is electrochemical. Where corrosion will occur in a water system and to what degree depends on a number of factors: quality of water, type of treatment, metals in the system, surface temperature, and mechanical conditions (vibration, stress, relative motion of two adjacent parts, etc.). Several types of corrosion can be found in engine cooling water systems: Crevice Cavitation related Fretting Selective leaching Galvanic MINERAL SCALES AND FOULING Compounds and minerals dissolved in water tend to come out of solution when the water is heated. They form either a scale on the metal surfaces or a fouling precipitate (sludge) in the water system. Being a closed system, very little make-up water is required so proper treatment of the original cooling water will ensure trouble-free service for longer periods of time than ebullient systems where make-up water may be constantly added. For complete information on cooling system guidelines and water treatment refer to Service Bulletin E (or current version). TREATMENT Standard (solid water) closed heat exchanger or radiator cooled coolant systems operating up to 100 C (210 F) must be treated with either inhibited antifreeze products or with one of the commercial coolant water treatment products. These products generally work by forming a film on the surfaces of the cooling system or corrosion protection and a scale suppressant for modifying or conditioning the dissolved scaleforming minerals. Both the inhibited antifreeze and FORM 6284 Third Edition

2 water treatment products require a system free of dirt, oil, scale and rust for the inhibitors to be effective in protecting the system. Although treated water is recommended in climates where antifreeze is not required, using ethylene glycol is also beneficial during hot day operation since it raises the boiling point of the coolant solution. The proportion of ethylene glycol to water required depends on the lowest ambient temperature levels from which the system must be protected. A mixture is recommended with a minimum of 30% ethylene glycol for adequate antifreeze and corrosion protection. The mixture should not exceed 67% to avoid impairing the heat transfer processes (antifreeze concentration beyond this does not lower the freezing point any further). NOTE: The radiator cooling system effectiveness drops by approximately 3% for each 10% of antifreeze concentration. For heat exchanger cooling systems, including the intercooler circuit, the circulation of the antifreeze solution protects only the closed system coolant from freezing. The heat exchanger water supply must also be antifreeze protected. NOTE: Refer to Service Bulletin E (or current version) for complete information on cooling system recommendations. JACKET INITIAL FILL, F18/H24 1. Open the petcock at the top of the water thermostat housing and jacket water header to vent air when filling the jacket water system with coolant (see Figure and Figure ). THERMOSTAT HOUSING AIR BLEED HEADER AIR BLEED Figure Jacket Water Header Air Bleed Petcock 2. Add treated coolant to the filler neck of the surge tank or radiator until the coolant begins to escape from the water header and top of the jacket water thermostat housing. 3. Close the petcocks and continue filling the system until the coolant reaches the correct level (see Table ). Table Jacket Water Capacity Engine Only F18 60 (16) H24 75 (20) 4. Close the cooling system and run the engine at idle speed. System requires a pressure cap rated at 7psi (48kPa). 5. Recheck the coolant level and add additional coolant as required. Air in the cooling system speeds up the for- CAUTION mation of rust, increases corrosion and produces hot spots within the engine. Disregarding this information could result in product damage and/or personal injury. 6. Bleed trapped air from the cooling system (See Cooling Water System Air Bleed, F18/H24 on page ). NOTE: The engine cooling system is properly filled with coolant only when all air has been removed. 7. Top off the surge tank or radiator. Figure Thermostat Housing FORM 6284 Third Edition

3 AUXILIARY INITIAL FILL, F18/H24 1. Open the petcock at the top of the intercooler to vent air while filling (see Figure ). AIR BLEED 6. Continue filling the auxiliary cooling water circuit until coolant level reaches top of surge tank or radiator. Air in the cooling system speeds up the for- CAUTION mation of rust, increases corrosion and produces hot spots within the engine. Disregarding this information could result in product damage and/or personal injury. 7. Bleed trapped air (see Cooling Water System Air Bleed, F18/H24 ). 8. Top off the surge tank or radiator. SYSTEM AIR BLEED, F18/H24 Figure Intercooler Air Bleed 2. Add treated coolant to the system until the coolant begins to escape from the petcock. 3. Close the petcock and continue filling the system until the coolant reaches the correct level (see Table ). NOTE: The engine cooling system is properly filled with coolant only when all air has been removed. Table F18/H24 Auxiliary Water Capacity Engine Only F18 23 (6) H24 23 (6) 4. Close cooling system and run engine at idle speed. 5. Recheck coolant level and add additional coolant as required. NOTE: Occasionally open the intercooler and thermostat housing air bleed petcocks in the cooling systems to allow any accumulated air to escape. Always wear protective equipment when venting the cooling system. Misuse, misapplication, or improper adjustment and maintenance of cooling fans and related parts can result in serious personal injury or death. Always follow basic safety precautions and proper preventive maintenance procedures. Always wear protective clothing when bleeding the cooling system on a heated engine. Slowly loosen the air bleed petcock to relieve any excess pressure. Escaping steam and/or hot water could Air bleed the jacket water and auxiliary cooling water circuits at least once each day. Open and close the air bleed petcocks in the order that they are listed below, starting at the lowest petcock in the system and ending at the highest. Bleed one petcock at a time. The number of air bleed petcocks and their locations are as follows (see Table ). Table F18/H24 Air Bleed Petcocks S 1 Cluster thermostat housing Jacket Water 1 Jacket Water Header Auxiliary Water 1 Intercooler 1. Initial Bleed: Open each air bleed petcock prior to engine startup. A hissing sound often accompanies the escape of trapped air. Close the petcock when the hissing stops and water begins to flow out in a solid steady 2. Check Bleed: Start the engine and reopen each petcock. Close the petcock when the hissing stops and water begins to flow out in a solid steady FORM 6284 Third Edition

4 3. Final Bleed: Once the temperature of the jacket water circuit has stabilized (as indicated by the panel mounted temperature gauge), reopen each petcock. Close the petcock when the water begins to flow out in a solid steady Air can be drawn into CAUTION the engine through small leaks in the jacket water system. The problem is compounded when the void created by the loss of coolant is filled by more air. If aeration causes the coolant to foam, the probability of engine damage due to overheating is greatly increased. Disregarding this information could result in product damage and/or personal injury. 4. Carefully inspect the jacket water system for coolant leaks while the engine is running. JACKET AND AUXILIARY S DRAIN AND FLUSH, F18/H24 Unless evidence of corrosion or sediment buildup demonstrates the need for more frequent maintenance, clean and flush both the jacket water and auxiliary cooling water circuits at least once each year. Antifreeze and water treatment products require a clean system in order to work effectively. If contaminants such as dirt, rust, scale, lime, grease, oil and/or cleaning agents are not completely flushed out, they can destroy the corrosion inhibitors and scale suppressants intended to keep freshly filled cooling systems clean. NOTE: To facilitate draining and flushing of the engine jacket water, replace one of the 3/4 inch NPT countersunk headless pipe plugs (just below the level of the jacket water header) with a customer supplied ball valve. The ball valve must be threaded to accept both a hose connection and pipe plug. After the jacket water maintenance is complete, install the pipe plug in the ball valve to prevent inadvertent draining of the cooling system. 1. Start engine. Run engine for 10 minutes. Always wear protective clothing when draining the cooling systems on a heated engine. As air bleed petcocks are opened, escaping steam and/or hot water could result in severe personal injury or death. NOTE: Drain the coolant from the jacket water and auxiliary water circuits immediately after shutting down the engine. Draining the coolant immediately prevents any sediment from re-settling. 2. Shut down engine. Open air bleed petcocks located at highest point in jacket water and auxiliary cooling water circuits, whether it be on top of the surge tank, radiator or other heat transfer device. 3. Verify that customer supplied ball valve is closed. Remove pipe plug and attach drainage line. 4. Open ball valve and drain coolant from jacket water. 5. Open all air bleed petcocks (see Table ). Table Air Bleed Petcocks S 1 Cluster Thermostat Housing Jacket Water 1 Jacket Water Heater Auxiliary Water 1 Intercooler 6. Open all water drain petcocks. Remove all drain plugs (see Table ). Table Water Drain Petcocks Jacket Water Auxiliary Water S 1 Jacket water pump housing 1 Crankcase (left side) 1 Intercooler 1 Auxiliary water pump 7. Close all water drain petcocks. Install all drain plugs. 8. Fill water circuits with clean, soft water (through ball valve) (see Table ). NOTE: Always fill the engine from the bottom up to minimize the formation of air pockets. As the engine fills, air is pushed up and out. Table Jacket Water Capacity Engine Only F18 60 (16) H24 65 (17) 9. Close each air bleed petcock when water begins to flow out in a solid steady 10. Close cluster thermostat housing petcock(s) and continue filling jacket water system until level reaches top of surge tank or radiator. 11. Add clean, soft water to surge tank or radiator of auxiliary cooling water circuit FORM 6284 Third Edition

5 12. Continue filling auxiliary cooling water circuit until level reaches top of surge tank or radiator. 13. Perform Initial Bleed procedures. See Cooling Water System Air Bleed, F18/H24 in this section. Always wear protective clothing when venting the cooling system on a heated engine. Slowly loosen the air bleed petcock to relieve any excess pressure. Escaping steam and/or hot water could 14. Perform Check Bleed procedures. 15. Perform Final Bleed procedures. 16. Let engine run for at least 10 minutes to stir up any rust or sediment in the cooling water system. 17. Stop engine. Drain crankcase and all cooling system accessories. Drain auxiliary cooling water circuit. NOTE: Follow the manufacturer s recommendations for the proper concentration of cleaning solution and length of cleaning time. Use a non-acidic, noncorrosive, biodegradable compound that prevents the loss of metal in engine and avoids damage to internal gaskets and seals. 18. Fill jacket water and auxiliary cooling water circuits with a suitable cleaning solution. 19. Perform Initial Bleed procedures. See Cooling Water System Air Bleed, F18/H24 this section. Always wear protective clothing when venting the cooling system on a heated engine. Slowly loosen the air bleed petcock to relieve any excess pressure. Escaping steam and/or hot water could 20. Perform Check Bleed procedures. 21. Perform Final Bleed procedures. 22. Top off surge tank or radiator for jacket water and auxiliary water circuits. Let engine run for at least 10 minutes. NOTE: Drain the coolant from the jacket water and auxiliary water circuits immediately after shutting down the engine. Draining the coolant immediately prevents any sediment from re-settling. 23. Shut down engine and drain cooling systems. 24. Inspect internal surfaces. If the results are not satisfactory, refill the engine with cleaning solution. Repeat Steps 18 through 23 as necessary. 25. Fill jacket water and auxiliary cooling circuits with clean, soft water. Drain immediately. NOTE: Inspect the drain water for cleanliness. Fill and flush the systems again, if necessary. The best results are obtained when the drain water runs clear. 26. Fill jacket water and auxiliary cooling water circuits with coolant. 27. Perform Initial Bleed procedures. See Cooling Water System Air Bleed, F18/H24 this section. 28. Perform Check Bleed procedures. 29. Perform Final Bleed procedures. 30. Carefully inspect jacket water and auxiliary cooling water circuits for leaks. JACKET INITIAL FILL, L36/P48 1. Open petcock on jacket water thermostat housing (see Figure ). THERMOSTAT HOUSING Figure Jacket Water Thermostat Housing 2. If equipped, open petcock on top of jacket water heater tube (see Figure ). JACKET HEADER AIR BLEED BUTTERFLY VALVE HOUSING Figure Jacket Water Heater Air Bleed FORM 6284 Third Edition

6 3. Add coolant to engine until it overflows from petcock (see Table ). Table L36/P48 Engine Jacket Water Capacity Engine Only L (44) P (58) 4. Close petcock and continue filling system until coolant level reaches top of surge tank or radiator. 5. Bleed trapped air from cooling system (see Cooling Water System Air Bleed, L36/P48 ). 6. Top off surge tank or radiator. Close petcock on top of jacket water heater tube, if equipped. AUXILIARY INITIAL FILL, L36/P48 NOTE: The following description is not applicable to permanent vent systems. 1. Open petcocks located on top of intercooler (see Figure ). Figure Intercooler Air Bleed 2. Open petcock located on rear oil bonnet (see Figure ). 3. Add coolant to auxiliary water circuit from top of surge tank or radiator. Table L36/P48 Auxiliary Water Capacity Engine Only L36 57 (15) P48 57 (15) 4. Continue filling until coolant overflows from intercooler petcocks. Close petcock(s) when water begins to flow out in a solid steady 5. Continue filling until coolant level reaches top of surge tank or radiator. 6. Bleed trapped air (see Cooling System Air Bleed, L36/P48 ). 7. Top off the surge tank or radiator. SYSTEM AIR BLEED L36/P48 The jacket water and auxiliary water circuits should be bled of all air at least once each day. Carefully inspect both the jacket water and auxiliary water circuits for coolant leaks while the engine is running. Air can be drawn into the engine through small leaks in the jacket water system. The problem is compounded when the void created by the loss of coolant is filled by more air. If aeration causes the coolant to foam, the probability of engine damage due to overheating is greatly increased. Air in the cooling system speeds up the formation of rust, increases corrosion and produces hot spots within the engine. Always wear protective clothing when bleeding the cooling system on a heated engine. Slowly loosen the air bleed petcock to relieve any excess pressure. Escaping steam and/or hot water could Table L36/P48 Air Bleed Petcocks Figure Oil Cooler Rear Bonnet Jacket Water Auxiliary Water S 1 Jacket water pump housing 1 Cluster thermostat housing 1 Jacket water heater 2 Intercooler 1 Oil cooler rear bonnet NOTE: Always start by bleeding the air from the lowest petcock in the system and end at the highest petcock in the system. Bleed one petcock at a time FORM 6284 Third Edition

7 INITIAL AIR BLEED (ENGINE NOT RUNNING) Jacket Water System 1. Open jacket water pump air bleed fitting (petcock) (see Figure ). Allow air to escape. Close petcock NOTE: The jacket water pump housing petcock may be located differently than depicted (see Figure ). JACKET HEATER AIR BLEED Figure Jacket Water Heater Air Bleed Auxiliary Water System 1. Open oil cooler rear bonnet petcock (see Figure ). Close petcock when coolant begins to flow out in a solid steady Figure Jacket Water Heater Air Bleed 2. Open thermostat housing petcock. Close petcock stream (see Figure and Figure ). Figure Oil Cooler Rear Bonnet THERMOSTAT HOUSING Figure Jacket Water Thermostat Housing 2. Open intercooler petcock. Close petcock when coolant begins to flow out in a solid steady Repeat for second intercooler petcock (see Figure ). Figure Intercooler Air Bleed FORM 6284 Third Edition

8 CHECK AIR BLEED (ENGINE NOT RUNNING) Jacket Water System 1. Start engine and open jacket water pump housing petcock. Allow air to escape. Close petcock when coolant begins to flow out in a solid steady 2. Open thermostat housing petcock. Close petcock 3. Open jacket water heater petcock. Close petcock Auxiliary Water System 1. Start engine and open oil cooler rear bonnet petcock. Close petcock when coolant begins to flow out in a solid steady 2. Open intercooler petcock. Close petcock when coolant begins to flow out in a solid steady Repeat for second intercooler petcock. FINAL AIR BLEED (ENGINE NOT RUNNING) Jacket Water System 1. With engine running open jacket water pump housing petcock. Allow air to escape. Close petcock 2. Open thermostat housing petcock. Close petcock 3. Open jacket water heater petcock. Close petcock Auxiliary Water System 1. Start engine and open oil cooler rear bonnet petcock. Close petcock when coolant begins to flow out in a solid steady 2. Open intercooler petcock. Close petcock when coolant begins to flow out in a solid steady Repeat for second intercooler petcock. JACKET AND AUXILIARY S DRAIN AND FLUSH, L36/P48 Unless evidence of corrosion or sediment buildup demonstrates the need for more frequent maintenance, clean and flush both the jacket water and auxiliary cooling water circuits at least once each year. Antifreeze and water treatment products require a clean system in order to work effectively. If contaminants such as dirt, rust, scale, lime, grease, oil and/or cleaning agents are not completely flushed out, they can destroy the corrosion inhibitors and scale suppressants intended to keep freshly filled cooling systems clean. NOTE: To facilitate draining and flushing of the engine jacket water, replace one of the 3/4 inch NPT countersunk headless pipe plugs (just below the level of the jacket water header) with a customer supplied ball valve. The ball valve must be threaded to accept both a hose connection and pipe plug. After the jacket water maintenance is complete, install the pipe plug in the ball valve to prevent inadvertent draining of the cooling system. 1. Start engine. Run engine for 10 minutes. Always wear protective clothing when draining the cooling systems on a heated engine. As air bleed petcocks are opened, escaping steam and/or hot water could result in severe personal injury or death. NOTE: Drain the coolant from the jacket water and auxiliary water circuits immediately after shutting down the engine. Draining the coolant immediately prevents any sediment from re-setting. 2. Shut down engine. Open air bleed petcocks located at highest point in jacket water and auxiliary cooling water circuits, whether it be on top of the surge tank, radiator or other heat transfer device. 3. Verify that customer supplied ball valve is closed. Remove pipe plug and attach drainage line. 4. Open ball valve and drain coolant from jacket water. 5. Open all air bleed petcocks (see Figure ). Table Air Bleed Petcocks S 1 Cluster Thermostat Housing Jacket Water 1 Jacket Water Heater Auxiliary Water 1 Intercooler 6. Open all water drain petcocks. Remove all drain plugs (see Figure ). Table Water Drain Petcocks Jacket Water S 1 Jacket water pump housing 1 Crankcase (left side) FORM 6284 Third Edition

9 7. Close all water drain petcocks. Install all drain plugs. 8. Fill water circuits with clean, soft water (through ball valve) (see Table ). NOTE: Always fill the engine from the bottom up to minimize the formation of air pockets. As the engine fills, air is pushed up and out. Table Jacket Water Capacity Engine Only L36 60 (16) P48 65 (17) 9. Close each air bleed petcock when water begins to flow out in a solid steady 10. Close cluster thermostat housing petcock(s) and continue filling jacket water system until level reaches top of surge tank or radiator. 11. Add clean, soft water to surge tank or radiator of auxiliary cooling water circuit. 12. Continue filling auxiliary cooling water circuit until level reaches top of surge tank or radiator. 13. Perform Initial Bleed procedures. See Cooling Water System Air Bleed, L36/P48 in this section. Always wear protective clothing when venting the cooling system on a heated engine. Slowly loosen the air bleed petcock to relieve any excess pressure. Escaping steam and/or hot water could 14. Perform Check Bleed procedures. 15. Perform Final Bleed procedures. 16. Let engine run for at least 10 minutes to stir up any rust or sediment in the cooling water system. 17. Stop engine. Drain crankcase and all cooling system accessories. Drain auxiliary cooling water circuit. NOTE: Follow the manufacturer s recommendations for the proper concentration of cleaning solution and length of cleaning time. Use a non-acidic, non-corrosive, biodegradable compound that prevents the loss of metal in engine and avoids damage to internal gaskets and seals. 18. Fill jacket water and auxiliary cooling water circuits with a suitable cleaning solution. 19. Perform Initial Bleed procedures. See Cooling Water System Air Bleed, L36/P48 this section. Always wear protective clothing when venting the cooling system on a heated engine. Slowly loosen the air bleed petcock to relieve any excess pressure. Escaping steam and/or hot water could 20. Perform Check Bleed procedures. 21. Perform Final Bleed procedures. 22. Top off surge tank or radiator for jacket water and auxiliary water circuits. Let engine run for at least 10 minutes. NOTE: Drain the coolant from the jacket water and auxiliary water circuits immediately after shutting down the engine. Draining the coolant immediately prevents any sediment from re-settling. 23. Shut down engine and drain cooling systems. 24. Inspect internal surfaces. If the results are not satisfactory, refill the engine with cleaning solution. Repeat Steps 18 through 23 as necessary. 25. Fill jacket water and auxiliary cooling circuits with clean, soft water. Drain immediately. NOTE: Inspect the drain water for cleanliness. Fill and flush the systems again, if necessary. The best results are obtained when the drain water runs clear. 26. Fill jacket water and auxiliary cooling water circuits with coolant. 27. Perform Initial Bleed procedures. See Cooling Water System Air Bleed, L36/P48 this section. 28. Perform Check Bleed procedures. 29. Perform Final Bleed procedures. 30. Carefully inspect jacket water and auxiliary cooling water circuits for leaks. JACKET HEATER MAINTENANCE F18/H24 The F18/H24 jacket water heater element can be serviced without draining the cooling system. The heater water circuit has two shutoff valves to isolate the heater. 1. Turn off the electrical power to the heater. NOTE: The shutoff lever is parallel to the valve. When the shutoff lever is in-line with the piping, the valve is open. When the shutoff lever is perpendicular to the piping, the valve is closed. 2. Close both valves by rotating the shutoff lever (see Figure ). FORM 6284 Third Edition

10 SHUTF LEVER HEATER ELEMENT JACKET HEATER MAINTENANCE L36/P48 The L36/P48 jacket water heater element can be serviced without draining the cooling system. The heater water circuit has two shutoff valves to isolate the heater. 1. Turn off the electrical power to the heater. NOTE: The shutoff lever is parallel to the valve. When the shutoff lever is rotated in-line with the piping, the valve is open. When the shutoff lever is rotated perpendicular to the piping, the valve is closed. 2. Close both valves by rotating the shutoff lever (see Figure ). SHUTF LEVER Figure F18/H24 Jacket Water Heater 3. Open the heater element cover. Tag and disconnect the controller wiring. Remove the heater element from the heater housing. 4. Install the new element in the heater housing. Apply pipe sealant to the threads between the element and housing. 5. Open both valves by rotating the shutoff lever. 6. Refill the engine with coolant and check for leaks. 7. Bleed trapped air from the jacket water system (see See Cooling Water System Air Bleed, F18/H24 on page for complete instructions). 8. Turn on the electrical power to the heater. SHUTF LEVER SHUTF LEVER Figure L36/P48 Jacket Water Heater 3. Open the heater element cover. Tag and disconnect the controller wiring. Remove the heater element from the heater housing. 4. Apply pipe thread sealant to the threads of the new heater element and install the heater in the housing. Connect the controller wiring to the element. 5. Open both valves by rotating the shutoff lever. 6. Bleed trapped air from the jacket water heater system (see See Jacket Water And Auxiliary Water Circuits Drain And Flush, L36/P48 on page for complete instructions). Open both shutoff CAUTION valves before turning on the electrical power. Turning on the power without having the shutoff valves open can cause the heater element to burn out. 7. Turn on the electrical power to the heater FORM 6284 Third Edition