Overhaul of Charging Air Cooler

08028-0D/H5250/94.08.12

Safety precautions:

Stopped engine

Shut-off starting air

Shut-off cooling water

Shut-off fuel oil

Shut-off cooling oil

Stopped lub. oil circul.

Description:

Overhaul of charging air cooler.

Starting position:

Related procedure:

Special tools:

Hand tools:

Ring and open end spanner, 13 mm. Ring and open end spanner, 19 mm. Ring and open end spanner, 24 mm. Allen key, 10 mm.

Wire rope. Tackle.

Replacement and wearing parts:

The charging air cooler is normally cleaned and overhauled at the intervals indicated in the "Planned Maintenance Program", or if observations prove that the cooler does not work satisfactory, see section 502.

Overhaul of Charging Air Cooler.

1)Close the cooling water inlet and outlet valves and disconnect the pipes.

2)Remove the screw (1), fig 1, which secure the end cover of the cooler element to the cooler housing, and pull the cooler element half-way out.

Place a wire rope round the cooler element and attach a tackle hook, after which the elements are lifted and pulled out of the cooler housing and landed on a couple of wooden planks on the floor.

Fig 1.

3) Remove screws (2) and end cover (3) reversal chamber (4) and side plates (5).

4) Clean the cooler element of the water and air sides.

After using cleaning agents the manufacting recommendation must be followed.

The greatest care must be exercised when dismantling cleaning and mounting the cooler element, as the thin fins of the tubes cannot stand impacts and pressure.

If nevertheless, the metal is bended, it should be carefully straightened, as bent fins will increase the pressure drop across the cooler considerably.

Should one ore more cooler tubes become leaky it/ they must immediately be made tight, either by expending the tube ends into the tube plates or by blanking of the tube(s) concerned with plugs.

It is important that the charging air cooler is not leaky as any sea water that leaks in will be carried along with the air to the cylinders where the salt contained in the water will damage valves, piston rings, and cylinder liners.

5) Also clean end cover and coat it on the inside with an anti-corrosion blocks agent. Inspect the anticorrosion (6) and renew if necessary.

Note: That paint or similar must not be applied to these blocks.

6)Fouling and deposite in the pipes can be removed by using a hand or machine operated circular steel brush. The pipe inner diameter is 13 mm.

7)When mounting the air cooler, renew all gas-

kets.

Out of Service Periods.

At longer periods out of service the air cooler is drained if the coolant is sea water followed by flushing with fresh water and left with drain and venting cocks open.

At fresh water coolant systems recommendations for the entire system is followed.

08028-0D/H5250/94.08.12

08028-0D/H5250/94.08.12

Safety precautions:

Stopped engine

Shut-off starting air

Shut-off cooling water

Shut-off fuel oil

Shut-off cooling oil

Stopped lub. oil circul.

Description:

Water washing of compressor side. Turbocharger cleaning with engine in service.

Starting position:

Related procedure:

Special tools:

Hand injector.

Hand tools:

Ring and open end spanner, 17 mm.

Replacement and wearing parts:

See the special instructions for turbocharger.

5, 6L23/30H

Cleaning Procedure.

The cleaning process is only to be carried out, when the engine is at operating temperature and when it is loaded as close as possible to full load.

The engine must not be shut off immediately after cleaning but should be allowed to operate continuously for some time to ensure drying out of the charge air system.

Sequence of Operations.

1)Run the engine with as high a load as possible.

2)Unscrew the plug, see fig 1, together with the seal ring from air filter silencer.

3)Fill the hand injector with clean fresh water and insert it through the screw plug opening.

4)Inject the complete content of the hand injector within a period of 4 - 10 sec.

5)Run the engine for about 10 minutes at unaltered high load.

6)Make comparative measurements of the operating data. This comparison will indicate the success or lack of same of the washing procedure.

If necessary, carry out the washing once more.

Compressor cleaning by inspection of water with a hand injector is sufficient if a normal degree of fouling is present.

In case of serve dirt being deposited in the compressor, dismantling of the compressor, is necessary.

Components for mechanical and manual cleaning are necessary.

For manual cleaning of compressor, see special instruction.

For water washing of compressor side, see also description for water washing.

Seal ring

Screw plug

Hand injector

Fig 1.