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1-Manual Wartsila F 240
1-Manual Wartsila F 240
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Manual
F 240 CONTENTS
CHAPTER 0: GENERAL
0A PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--1
0B DOCUMENTATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--2
0C MANUAL SETUP/PAGE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--3
1. Manual setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--3
2. Page setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--3
0D DESCRIPTION OF THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
1. Crankshaft and bedplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
2. Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
3. Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
4. Piston with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
5. Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
6. Camshaft and valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
7. Injection equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--6
8. Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--6
9. Turbocharging and charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--6
10.Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--6
CHAPTER 1: OPERATION
1A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
1. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
3. Starting and stopping of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
5. Running--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
6. During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
7. After stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2
8. Long shut--downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2
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xx -- 5
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F 240 CONTENTS
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F 240 CONTENTS
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Manual
F 240 FUEL SYSTEM
5A INTRODUCTION
1. General Good performance of a diesel engine greatly depends on the correct timing, correct
quality and quantity of the fuel and good atomisation of the fuel injection.
2. Description of This paragraph is a general description of the function of engine parts in the fuel
engine parts system.
The main parts of the fuel system are given in the general diagram (Fig. 5--2 and 5--3).
These main parts have a number, which corresponds to the number in the diagram.
This number is placed between brackets in the description below.
Fuel feed pump For LFO/MDO operation only, the fuel system is equipped with an engine driven fuel
(01) feed pump, which is fed from the day tank (starting tank), placed approximately 2m
above the top of the engine.
The fuel flows via the fuel fine filter and main fuel feed line to the high pressure fuel
pumps. The high pressure fuel pumps supply the fuel to the nozzles.
For a good filling and cooling of the high pressure fuel pump the capacity of the fuel
feed pump is approximately 4x higher than the full load consumption of the engine.
The surplus fuel flows from the high pressure fuel pumps into the return line to the day
tanks (starting tank).
The amount of heat collected by the fuel during passage through the high pressure fuel
pump must be dissipated by the return piping and the tank.
Duplex fuel filter The duplex fuel filter serves to remove impurities from the fuel, so that they cannot
(02) enter the fuel system, and inflict damage on the high pressure fuel pumps or the nozz-
les. The fuel filter consists of two compartments, each fitted with a filter element, which
can be removed (also with the engine in operation).
The LFO/MDO filter elements have to be replaced periodically.
The HFO filter elements have to be cleaned and replaced periodically.
The filter elements can be removed separately, during operation.
High pressure The high pressure fuel pump pumps the fuel via the high pressure fuel line and the fuel
fuel pumps injector into the cylinder.
(03)
All fuel pumps have been calibrated accurately and provided with a sealed stop on the
fuel rack. The purpose of this stop is to limit the engine output. If this seal is broken
during the guarantee period, this may have as consequence, invalidation of the
guarantee!
Ver. 4--13154--56--57--58--59 5 -- 1
Manual
F 240 FUEL SYSTEM
5A INTRODUCTION
FIG. 5--1
Pressure For LFO/MDO operation only, a pressure regulating valve is placed at the end of the
regulating valve main fuel line to keep the fuel pressure constant.
(05)
Leak--off fuel The leak--off fuel coming from the nozzles and fuel pumps is drained to the clean
(103,104) leak–off fuel tank. The quantity mainly depends on the number of service hours of the
nozzle, but the quantity of the leak--off fuel is not indicative of the quality of the nozzles.
This fuel can be supplied to the day tank without treatment.
Fuel leakage from renewal of the fuel filter elements will be collected via drains and
has to be stored in a dirty--oil tank.
Ver. 4--13154--56--57--58--59 5 -- 2
Manual
F 240 FUEL SYSTEM
5A INTRODUCTION
3. Internal fuel
system
LFO/MDO
FIG. 5--2
Ver. 4--13154--56--57--58--59 5 -- 3
Manual
F 240 FUEL SYSTEM
5A INTRODUCTION
4. Internal fuel
system HFO
FIG. 5--3
--o--o--o--o--o--
Ver. 4--13154--56--57--58--59 5 -- 4
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS
1. General The engine is built for continuous operation on heavy fuel oil (HFO) and will operate
satisfactorily on Marine Diesel Oil and Light Fuel Oil (MDO and LFO). Avoid the use
of fuels having a lower viscosity than about 2.0 mm2/s at 40 °C as such fuels may cause
fuel injection pump plunger or fuel nozzle needle seizure.
2. HFO
requirements 2. 1. HFO bunker requirements.
Ver. 4--13154--56--57--58--59
5 -- 5
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS
3. LFO/MDO
requirements 3. 1. LFO/MDO bunker requirements.
LFO MDO
Viscosity at 40 °C max. [mm2/s] 6 11
Water content max. [%volume] -- 0.3
Sulphur content max. [% mass] 1.5 2.0
Ash content max. [% mass] 0.01 0.01
Sediment by extraction max. [% mass] -- 0.07
Cetane number min. 40 35
Carbon content (acc. to
Ramsbottom) max. [%] 0.2 0.3
Flash point min. [°C] 60 60
Pour point
-- Summer max. [°C] 0 6
-- Winter max. [°C] -- 6 0
LFO MDO
Water content max. [% vol] -- 0.2
Fineness filter back flushing filter [µm] 10 10
Fuel temperature max. [°C] 50 50
Ver. 4--13154--56--57--58--59
5 -- 6
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS
4. Fuel treatment
Heating
Keep the HFO temperature about 10 °C above the minimum storage temperature
indicated in the diagram to eliminate the risk of paraffin formation.
centi Stokes
FIG. 5--4
When converting viscosities from one of the units on the abscissa to centistokes
(=mm 2/s) or vice--versa, keep in mind that the result obtained is valid only at one and
the same temperature. When converting the viscosity in any unit at a given
temperature to a viscosity at another temperature a viscosity--temperature diagram or
conversion rule must be used.
Ver. 4--13154--56--57--58--59
5 -- 7
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS
mm2/s
FIG. 5--5
Example: A fuel oil with a viscosity of 380 mm 2/s (A) at 50 °C (B) or 80 °C (C) must be
preheated up till 115--130 °C (D--E) before entering the fuel injection pumps, up till
98 °C (F) at the centrifuge and till minimum 40 °C (G) in storage tanks. The fuel oil is
not transferable below 36 °C (H).
To obtain temperatures for intermediate viscosities, draw a line from the known
viscosity/temperature point in parallel to the nearest viscosity / temperature line in
diagram.
Example: Known viscosity 60 mm 2/s at 50 °C. The following can be read along the
dotted line: viscosity at 80 °C = 20 mm 2/s, temperature at fuel injection pumps
74--87 °C, centrifuging temperature 86 °C, minimum storage tank temperature 28 °C.
Conversion from various current and obsolete viscosity units to centi Stokes can be
made in the diagram, Fig. 5--5. The diagram should be used only for conversion of
viscosities at the same temperature. The same temperatures should then be used
when entering the viscosity / temperature point into the diagram.
Ver. 4--13154--56--57--58--59
5 -- 8
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS
Purification
Heavy fuel (residuals, and mixtures of residuals and distillate) must be purified in an
efficient working centrifuge before entering the day tank. The fuel is to be heated
before centrifuging.
Recommended temperatures, depending on the fuel viscosity, are stated in the
diagram, see fig. 5--5.
Be sure that the correct gravity disc is used. Never exceed the flow rates
recommended for the centrifuge for the grade of fuel in use. The lower the flow rate
the better the purification efficiency.
Sufficient separating capacity is required. The best and most disturbance--free results
are obtained with purifier and clarifier in series. Alternatively the main and stand--by
separators may run in parallel, but this makes heavier demands on correct gravity disc
choice and constant flow and temperature control to achieve optimum results. Flow
rate through the centrifuges should not exceed the maximum fuel consumption by
more than 10%.
In case pure distillate fuel is used, centrifuging is recommended as fuel may be
contaminated in storage tanks. The full rated capacity of the centrifuge may be used
provided the fuel viscosity is less than 12 mm2/s at centrifuging temperature. Marine
Gas Oil viscosity is less than 12 mm2/s at 50 °C.
Viscosity control
An automatic viscosity controller, or a viscosity meter at least, should be installed in
order to maintain the correct viscosity of the fuel before the fuel enters the engine fuel
system. See section 2.2, “HFO requirements on the engine”.
5. Steps to avoid The engine is built for operation on HFO with characteristics according to section 2.
difficulties under all operating conditions. Good running temperatures are important. In order to
during operation avoid difficulties mind the following points:
on heavy fuel
A Charge air temperature must be sufficiently high special at low load, (cold
corrosion).
B Injection fuel temperature. For requirements see ”Fuel viscosity / temperature
in the engine” section 2. Poor fuel quality will, adversely influence wear, engine
component life time and maintenance intervals.
C Clean the turbocharger turbine side regularly straight from the beginning. Fuels
with high vanadium and sodium contents in unfavourable ratio, may lead to
rapid contamination of the turbine and creates higher gas temperatures. More
frequent cleaning is necessary in that case.
Ver. 4--13154--56--57--58--59
5 -- 9
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS
6. Comments on A Viscosity is not a measure of the fuel quality, but determines the complexity of
fuel the fuel heating and handling system, which should be considered when
characteristics estimating installation economy.
B Fuel oils having high density in combination with low viscosity may have low
ignition quality.
C High sulphur content increases the risk for corrosion and wear, particularly at
low loads, and may contribute to high--temperature deposit formation. The
lubricating oil specification must be matched to this.
D High ash content causes abrasive wear, and may cause high temperature
corrosion and contributes to formation of deposits. The most harmful ash
constituents are vanadium--sodium combinations.
E High vanadium content causes hot corrosion on exhaust valves particularly in
combination with high sodium content. The corrosion increases with increased
temperatures (increased engine output).
F Sodium (Na)contributes to hot corrosion on exhaust valves in combination with
high vanadium (V) content. Sodium also contributes strongly to fouling of the
turbine blading of the turbocharger at high exhaust gas temperature. The
maximum content of Na is 30 mg/kg and Na max. ≤ 20% V content.
G High Conradson carbon may cause deposit formation in combustion chamber
and exhaust system, particularly at low engine output.
H High content of asphaltenes may contribute to deposit formation in combustion
chamber and exhaust systems (at low loads). Asphaltenes may under certain
circumstances, precipitate from the fuel and will block filters and/or cause
deposits in the fuel system. Precipitating asphaltenes may also cause
excessive centrifuge sludge.
I Heavy fuels may contain up to 1% water at delivery. Water may also originate
from the installation bunker tanks. To avoid difficulties in the engine fuel injection
system water must be removed.
Ver. 4--13154--56--57--58--59
5 -- 10
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS
J Reduced ignition and combustion quality can be caused by using HFO from
modern refinery processes compared with ”traditional” heavy fuels. HFO from
modern refinery processes may approach at least some of the limits of fuel
characteristics given in the table in section 2.
Ignition quality is not defined, nor limited, in marine residual fuel standards. The
same applies to ISO--F--DMC marine distillate fuel. The ignition quality of these
fuels cannot for a variety of reasons be determined by methods used for pure
distillates, i.e. Diesel Index, Cetane Index and Cetane Number.
Low ignition quality may cause trouble during starting and at low load operation,
especially at too low charge air temperature. This may also result in long ignition
delay and as a consequence, in high firing pressure rise ratio. The combustion
will be more noisy in this case, known as ”Diesel knock”, i.e. hard, high pitch
combustion noise. The effects of diesel knock are increased mechanical load
on components surrounding the combustion space, increased thermal load,
increased lube oil consumption and increased lube oil contamination. Basically
a low viscosity in combination with a high density will result in a low ignition
quality.
FIG. 5--6
Ver. 4--13154--56--57--58--59
5 -- 11
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS
Normal diesel engines should accept CCAI values up to 850 with no difficulties. CCAI
values between 850 and 870 may cause difficulties under unfavourable conditions:
low charge air temperatures, insufficient pre--heating of the engine at the start, fuel
injection system not functioning properly (in particular, badly maintained nozzles).
CCAI values between 870 and 890 are more demanding; the above mentioned
systems must function perfectly in order to avoid difficulties. In severe cases it is
advisable to increase the charge air temperature. CCAI values above 900 are
damaging.
Note:
Although low ignition quality produces long ignition delay, advancing the ignition timing
makes things only worse; fuel is injected at a lower compression temperature and this
will produce even longer ignition delay.
--o--o--o--o--o--
Ver. 4--13154--56--57--58--59
5 -- 12
Manual
F 240 FUEL SYSTEM
5C FUEL FILTER ELEMENT
1. General The fuel filter consists of two compartments, each having one filter element.
The fuel filter has a 3--way cock permitting change--over during operation and the
fouled filter to be renewed.
2. 2. Slacken the locking nut of vent screw A and open this screw.
B B
Ver. 4--13154--56--57--58--59 5 -- 13
Manual
F 240 FUEL SYSTEM
5C FUEL FILTER ELEMENT
3. Fitting
3. 1. Clean the filter compartment and the cover with clean gasoil.
3. 3. Check that the seat edges of the filter compartment and of the filter cover are
properly cleaned and undamaged.
3. 7. Place the cover on the filter compartment and secure it, using bolt C.
3. 9. Put the 3--way cock in the central position. Once the filter compartment has
been vented, tighten the vent screw and lock it with the relevant nut.
Then switch to the desired filter compartment.
--o--o--o--o--o--
Ver. 4--13154--56--57--58--59 5 -- 14
Manual
F 240 FUEL SYSTEM
5D INSPECTIONS, MOMENT OF INJECTION
capillary tube
union nut
constant
pressure valve
adjusting
plate
fuel cam
Ver. 4--13154--56--57--58--59 5 -- 15
Manual
F 240 FUEL SYSTEM
5D INSPECTIONS, MOMENT OF INJECTION
Tool C dummy The ”dummy” consists of a teflon model with the same dimensions as the constant
pressure valve, sealed by an O--ring or an old constant pressure valve with the inside
valves and springs removed.
EMPTY ”DUMMY”
TEFLON ”DUMMY”
Lubricate the fuel pump control rods, pivoted joints, guide rollers, and common fuel
control shaft with a mixture of 50% lubricating oil and 50% gas oil.
Governor
Ver. 4--13154--56--57--58--59 5 -- 16
Manual
F 240 FUEL SYSTEM
5D INSPECTIONS, MOMENT OF INJECTION
3. Verification of
moment of
injection 3. 1. Disconnect the high pressure fuel line.
pression stroke.
Constant
pressure
3. 5. Turn the crankshaft in the direction of rota- valve
tion until the fuel is seen to rise in the capillary
tube (without air bubbles). This means that the
fuel passages in the constant pressure valve
are filled with fuel.
For the correct moment of injection see the value specified in the test bed report. The
tolerance allowed for the setting is 1°. If a greater variation is found, the pre--lifting
must be adjusted.
Ver. 4--13154--56--57--58--59 5 -- 17
Manual
F 240 FUEL SYSTEM
5D INSPECTIONS, MOMENT OF INJECTION
4. Checking After fitting a new or reconditioned high pressure fuel pump, the pre lifting has to be
pre--lifting checked and/or adjusted. Proceed as follows:
4. 11. Re--check the setting of the fuel timing, from point 3.6 and further.
4. 12.If the setting is outside the permitted tolerance the fuel cam position must be
corrected.
--o--o--o--o--o--
Ver. 4--13154--56--57--58--59 5 -- 18
Manual
F 240 FUEL SYSTEM
5E CONSTANT PRESSURE VALVE
2. Testing
2. 1. Check, if tool B is still under pressure at 120 bar, when the line is plugged off.
(If necessary, inspect the non--return valve of this tool).
2. 4. Connect tools A and B to the high pressure fuel pump, with the help of tool A,
increase pressure to 120 bar.
2. 5. No go criteria is:
If the pressure drops from 120 bar to 80 bar within 5 seconds. In this case
renew the constant pressure valve.
--o--o--o--o--o--
Ver. 4--13154--56--57--58--59 5 -- 19
Manual
F 240 FUEL SYSTEM
5E CONSTANT PRESSURE VALVE
Ver. 4--13154--56--57--58--59 5 -- 20
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Manual
F 240 COOLING WATER SYSTEM
7A INTRODUCTION
1. General During the combustion process in the engine, heat is transfered to various engine
parts. To protect these parts against overly high temperatures it is necessary to
dissipate the heat by means of cooling water systems.
This paragraph is a general description of the function of engine parts in the cooling
water system.
The main parts of the cooling water system are shown in the general diagram
(paragraph 7H). These main parts have a number which corresponds to the number
in the diagram. Numbers placed between brackets in the description below also refer
to the numbers which can be found in the diagram.
2. Description of The cooling process (= heat dissipation) consists of two separate systems, namely the
engine parts high temperature system (HT--circuit) and the low temperature system (LT--circuit).
HT--circuit (Other system combinations are also possible).
To prevent the forming of rust and scale in the cooling water system, an inhibitor must
be added.
The HT--circuit includes the engine and if a two stage air cooler is fitted, the first stage
of the air cooler.
Cooling water Standard the engine is provided with an engine driven centrifugal cooling water pump,
pump that circulates the water through the HT--circuit. The cooling water pump is built onto
the gear box as standard and is driven by the crankshaft through gear transmission.
Valves directly before and after the cooling water pump have to be used in case of
emergency operation.
The cooling water pump pushes the cooling water via the cooling water inlet manifold,
through the engine block, the turbocharger and, if applied, through the first stage of
the air cooler. From the engine the cooling water flows through the cooling water outlet
manifold to the thermostatic three--way valve (standard).
De--aeration De--aeration points, with a Ø3 mm restriction, are provided on the cooling water outlet
points manifold of the engine and on the cooling water outlet pipe of the turbocharger.
For checking of the de--aeration, consult section 7C.
Thermostatic Standard the engine is provided with a thermostatic three--way valve. This valve
three--way controls the outlet temperature of the cooling water. Depending on this temperature
valve the cooling water flows back to the engine (by--pass), or via the cooling water cooler
to the engine.
For maintenance and checking, consult section 7E.
Water cooler A heat exchanger (cooler) is used to dissipate the heat of the HT--circuit. The heat
(05) exchanger can vary per installation.
For maintenance, consult section 7D.
Cooling water The purpose of the expansion tank is to compensate volume changes in the cooling
expansion tank water system and it also serves to vent the system and to provide sufficient static
(08) pressure.
Ver. 01a--13154--56--57--58--59 7 -- 1
Manual
F 240 COOLING WATER SYSTEM
7A INTRODUCTION
3. Describtion The LT--circuit includes the charge air cooler, or if fitted, only the second stage of a two
engine parts stage air cooler, the lubricating oil cooler and optionally heat exchangers.
LT--circuit
Cooling water The cooling water pump for the LT--circuit is of the same construction as the cooling
pump water pump of the HT--circuit. This pump is not of the self--suction type.
Charge air From the cooling water pump the cooling water flows to the charge air cooler. In the
cooler (03) LT--circuit 2 butterfly valves and a pneumatically controlled three--way valve are
provided, to control the quantity of cooling water to the charge air cooler. The quantity
of cooling water to the charge air cooler is dependent on the cooling water inlet
temperature.
Lube oil cooler After the charge air cooler the cooling water flows to the lubricating oil cooler and then
(04) and water to the water cooler.
cooler (06).
For checking and maintenance, consult section 7D.
--o--o--o--o--o--
Ver. 01a--13154--56--57--58--59 7 -- 2
Manual
F 240 COOLING WATER SYSTEM
7B REQUIREMENTS
1. Cooling water The cooling water requirements can be found in Operating Instruction 4619Q002GB,
requirements, which can be found at the end of this chapter.
treatment and
analysing
--o--o--o--o--o--
Ver. 01a--13154--56--57--58--59 7 -- 3
Manual
F 240 COOLING WATER SYSTEM
7C COOLING WATER DE--AERATION
General Cooling water de--aeration on the engine takes place via the highest points of the cooling
water system. Orifices are provided in the de--aeration connections.
These orifices must be checked periodically.
Checking and
inspection 1. Drain the cooling water expansion tank.
4. Check whether the orifices are open (diameter orifice openings 3 mm.).
5. Check whether the lines to and from the expansion tank are not clogged.
Attention!
In case the cooling water system is equipped with an automatic de--aeration
device, it must be removed, cleaned, and checked on good working and then
re--fitted.
Automatic de--aeration
device
Orifice
Orifice
Automatic de--aeration
device
--o--o--o--o--o--
Ver. 01a 7 -- 4
Manual
F 240 COOLING WATER SYSTEM
7D COOLERS
To ensure effective cleaning of the cooler, this job has to be carried out by a specialist
firm. However, if it is unavoidable to clean the cooler on the spot,
proceed as follows:
Water section:
The water section can be cleaned by means of chemicals, or mechanically, by
brushing. See sub--suppliers manuals.
Air section:
The air section must be cleaned with an agent capable of dissolving the deposits that
have been built up. See sub--suppliers manuals.
If the air cooler has soft iron sacrificial anodes, these must be examined each time the
cooler is cleaned. In some types of air coolers the air flow must have a specific direc-
tion, indicated on one side of the side plates. When assembling and mounting such
coolers make sure that the air flows in the proper direction.
--o--o--o--o--o--
Ver. 01a 7 -- 5
Manual
F 240 COOLING WATER SYSTEM
7E COOLING WATER THERMOSTATS
The thermostatic three--way valve is equipped with three elements. In cold condition, the
thermostatic elements are closed and no water can flow through the heat exchanger.
When the temperature of the water rises, the wax elements expand, and causes the
elements to open against spring pressure, so that the passage to the heat exchanger is
released.
If the water becomes excessively hot or remains too cold, the three thermostatic
elements must be examined.
Inspection of the thermostatic elements:
1. Drain the cooling water by removing the drain plug from the thermostat housing
(proceed carefully when the engine is still hot).
3. Place the elements in a basin filled with water. Heat the water and with the aid of a
calibrated thermometer check whether the element opens at the correct temperature.
If the element does not open at the correct temperature, it must be renewed.
Drain plug
Cover
Ver. 01a 7 -- 6
Manual
F 240 COOLING WATER SYSTEM
7F COOLING WATER PUMP
1. Disassembly If oil and / or water is seen to run out of the leak indicator F, all sealing rings have to
be renewed.
1. 6. Dislodge the impeller from its cone by tapping the nut with a hammer and
support the backside of the impeller. If the impeller is not coming loose, warm
up the impeller till approx. 120 °C.
1. 7. Unscrew the nut completely and withdraw the impeller, (and if applied the
key) the sliding ring seal B and pump shaft with bearings.
1. 8. Withdraw the oil sealing ring C and the ceramic stationary seal ring D from
the pump bracket.
1. 9. If the inner ring E of the pump shaft shows wearing grooves, it must be
renewed.
Release the inner ring by heating it to approx. 200 °C.
Remove all the residual Loctite from the pump shaft.
1. 10.Inspect the double--ball angular contact bearing and the single ball bearing.
In most cases they shall have to be renewed.
pump casing
D
E
C B
A
O--ring
Ver. 01a 7 -- 7
Manual
F 240 COOLING WATER SYSTEM
7F COOLING WATER PUMP
2. 1. Clean and degrease the pump shaft on the location, for the inner ring.
2. 2. Degrease the new inner ring.
2. 3. Lubricate the ball bearings sparingly with bearing grease to prevent Loctite
from adhering to the balls of the bearing.
2. 4. Smear the location for the inner ring with Loctite.
2. 5. Slide the inner ring onto the pump shaft and up to the correct position.
2. 6. Remove all surplus Loctite.
2. 7. Allow the Loctite to harden at least 20 minutes before fitting the shaft.
After fitting the new inner ring, reassemble and fit the cooling water pump as follows:
2. 8. Clean and inspect all parts of the cooling water pump thoroughly and check if
the leak indicator hole (F) is open.
2. 9. Rub the pump shaft splines with Molykote. Just smearing the splines is
not enough.
2. 10.Fit the oil sealing ring (two--side seal) in the cooling water pump bracket.
2. 11. Fill the space formed by the V of the oil sealing ring with grease.
2. 12.Fit the ceramic stationary seal ring carefully in the pump bracket.
2. 13.Fit the bearings on the pump shaft and position the shaft in the pump bracket
and fit the inner circlip.
2. 14.Check that the pump shaft runs lightly.
2. 15.Position the sliding ring seal.
2. 16.Degrease the cone of the pump shaft with a solvent agent. Do the same with
the conical inside part of the impeller and the nut.
2. 17.Warm up the impeller till 100 °C.
2. 18.Sparingly apply Loctite to the shaft cone and the nut thread.
2. 19.Fit the impeller in a turning movement, fit immediately the impeller nut to the
correct torque (50 Nm.).
2. 20.Remove all surplus Loctite.
2. 21.Fit the pumping casing with gasket to the pump bracket.
2. 22.Place the O--ring onto the pump bracket.
2. 23.Fit the pump to the gearbox.
2. 24.Reconnect the suction pipe and the delivery pipe.
Note :
When the engine has been started a slight cooling water leakage may be observed,
but this should stop after approx. 1 hour. Such leakage is due to the fact that the sliding
ring seal may require time to wear in on the ceramic stationary seal ring.
--o--o--o--o--o--
Ver. 01a 7 -- 8
Manual
F 240 COOLING WATER SYSTEM
7G INSPECTION COOLING WATER SPACE
This consists of a general visual examination of the cylinder block cooling water space.
Attention should be paid to the following:
-- Serious corrosion
-- Signs of cavitation
-- Sludge formation
-- Line deposits and other undesirable phenomena
-- Gas leakage
--o--o--o--o--o--
Ver. 01a 7 -- 9
Manual
F 240 COOLING WATER SYSTEM
7H GENERAL DIAGRAM
1. Cooling water
system HT/LT
System components
01 Engine and turbocharger (5x) 09 Three way valve thermostat
02 HT air cooler (5x) 10 LT cooling water pump
03 LT air cooler (5x) 11 HT cooling water pump
04 Lub oil cooler (5x) 12 Valve
05 Central HT cooler 13 Flexible pipe connection
06 Central LT cooler 14 Flow meter
07 Expansion tank LT system 15 Adjustable restriction
08 Expansion tank HT system
Ver. 01a--13154--56--57--58--59 7 -- 10
Manual
F 240 COOLING WATER SYSTEM
7H GENERAL DIAGRAM
2. HT Cooling water
system / engine
System components
3 Turbocharger
5 Flexible pipe connection
6 Needle valve
7 Pressure gauge
8 Thermometer
9 Valve
11 Air cooler
16 Valve
Ver. 01a--13154--56--57--58--59 7 -- 11
Manual
F 240 COOLING WATER SYSTEM
7H GENERAL DIAGRAM
3. LT Cooling water
system / engine
System components
2 Air cooler(s)
3 Lubricating oil cooler
5 Flexible pipe connection
12 Pneumatic operated three way valve
13 Valve
--o--o--o--o--o--
Ver. 01a--13154--56--57--58--59 7 -- 12
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