Scania DI09 Bedienungsanleitung

02:02 Issue 4.0 en-GB

Installation manual

Intake system and ventilation

Marine engines

DI09, DI13, DI16

338 170

INSTALLATION

MANUAL

02:02 Issue 4.0 en-GB 2

Changes from the previous issue............................................................................ 3

Intake air .................................................................................................................. 4

Intake air taken from outside engine room.......................................................... 5

Intake air taken from engine room ...................................................................... 8

Air cleaner..............................................................................................................10

Air cleaners with precleaner.............................................................................. 11

Air cleaners without precleaner......................................................................... 11

Turbo-mounted filter ......................................................................................... 12

Clean air ............................................................................................................ 12

Air pressure............................................................................................................13

Crankcase ventilation............................................................................................14

Important data.......................................................................................................15

INSTALLATION

MANUAL

Changes from the previous issue

02:02 Issue 4.0 en-GB 3

Changes from the previous issue

The changes made in this document compared with the previous issue are marked

with a line in the left-hand margin. The changes are also described below.

• Information about the safety cartridge for the air cleaner with precleaner has been

removed, as a safety cartridge is no longer included. See Air cleaner.

• Clearances for Air cleaners with precleaner and Air cleaners without precleaner

have been corrected.

INSTALLATION

MANUAL

Intake air

02:02 Issue 4.0 en-GB 4

Intake air

If the intake line is located close to exhaust pipes or other hot parts, radiation protec-

tion should be used to limit unnecessary heating of the intake air.

REQUIREMENT!

The intake air temperature upstream of the turbocharger must be below 30°C.

Measure the temperature when the installation is complete. Refer to 02:08 Measur-

ing instructions for installation inspection.

If the intake air temperature upstream of the turbocharger continuously exceeds

30°C, then engine power may drop. If the engine is enclosed in some manner, make

sure that there is an adequate flow of intake air.

The dependence of the engine power on intake air temperature is shown in the chart

on the right. 100% engine power is shown under actual test conditions at the factory.

The engine air consumption in kg/min at full power and at different engine speeds is

indicated in the tables showing the air consumption and radiated heat for the relevant

engine type in 02:06 Technical data.

100

10 20 30

25 40 50 °C

340 422

Engine power dependence on intake air temperature. 100 % at 25°C, 1,000 mbar, en-

gine power setting not corrected.

A = Engine power.

B = Intake air temperature.

INSTALLATION

MANUAL

Intake air

02:02 Issue 4.0 en-GB 5

Intake air taken from outside engine room

In engine systems where the engine intake air comes from outside the engine room

and is led via a fresh air line to the engine, the vacuum for the intake system should

be measured.

The air intake should be located so that the intake air is as clean as possible and so

that neither the engine exhaust gases nor heated air from the engine room can mix

with the intake air. The air intake should be designed to exclude water, snow and con-

tamination.

The intake air must not contain chemical pollutants, such as CFCs.

REQUIREMENT!

The maximum permissible vacuum in the intake system is 30 mbar. This value in-

cludes the vacuum in the new air filter, connected coarse filter and in the fresh air

line.

Measure the vacuum when the installation is complete. Refer to 02:08 Measuring in-

structions for installation inspection.

INSTALLATION

MANUAL

Intake air

02:02 Issue 4.0 en-GB 6

The following applies to the fresh air line:

• The fresh air line must not be routed with any sharp bends.

• The inside of the fresh air line must be flat and even.

• If a hose is used as a fresh air line, it must be reinforced so that it does not collapse

onto itself.

It is not necessary to check the vacuum in the following cases:

• If the intake system is comprised of air hoses and air pipes from Scania's standard

range.

• If the fresh air line is a maximum of 5 m and has an inner diameter of a minimum

of 210 mm.

If the planned fresh air line is longer than 5 m, the required diameter must be calcu-

lated as illustrated. The vacuum upstream of the turbocharger must then be measured.

Refer to 02:08 Measuring instructions for installation inspection.

REQUIREMENT!

The total vacuum in the intake system with a blocked air filter must not exceed

65 mbar.

Engine damage will not occur up to 100 mbar, but fuel consumption and smoke will

increase. Above 100 mbar there is a risk that the air volume to the engine will be in-

adequate, resulting in breakdowns.

B (kg/min)

365 744

A (mm)

500

400

300

200

100

10 20 30 40 50 60

25 m

50 m

Calculation of minimum diameter of the intake line.

A = Intake line diameter.

B = Air consumption.

INSTALLATION

MANUAL

Intake air

02:02 Issue 4.0 en-GB 7

Ventilation of the engine room with fresh air line to the engine

If the intake air to the engine is taken from outside the engine room, it is important

to check that the temperature in the engine room does not get too high.

REQUIREMENT!

The temperature in the engine compartment must not exceed 60°C.

Measure the temperature when the installation is complete. Refer to 01:08 Measur-

ing instructions for installation inspection.

If the temperature exceeds 60°C, there is a risk of malfunction in the engine electrical

components and engine control unit. If there is a risk that the temperature will exceed

this value, the engine room must be ventilated.

When dimensioning the engine room ventilation, other air consumers in the engine

room must also be considered. The amount of radiated heat emitted by the various

engines is indicated in 02:06 Technical data.

The exhaust pipes should be insulated to reduce the radiated heat in the engine room.

See 02:04 Exhaust system.

INSTALLATION

MANUAL

Intake air

02:02 Issue 4.0 en-GB 8

Intake air taken from engine room

When the engine intake air is taken from the engine room, the air intake must be lo-

cated in the engine room. The opening area should be large enough to ensure that no

vacuum arises in the engine room. The air intake should also be designed and posi-

tioned so that it cannot be closed or accidentally blocked by water, snow or contam-

inants.

The air intake should be located so that the intake air is as clean as possible and so

that neither the engine exhaust gases nor heated air from the engine room can mix

with the intake air to the engine.

In the chart on the right-hand side, the recommended minimum area for the air intake

can be read from the engine air consumption.

If several engines or other air consumers are located in the same engine room, the

diameter should be increased correspondingly.

REQUIREMENT!

The vacuum in the engine compartment must not exceed 2 mbar.

Measure the vacuum when the installation is complete. Refer to 01:08 Measuring in-

structions for installation inspection.

0,1 0,2 0,3 0,4

kg/min

340 420

Calculation of minimum air intake area.

INSTALLATION

MANUAL

Intake air

02:02 Issue 4.0 en-GB 9

For installations where the engine draws the intake air directly from the engine room,

the engine room must normally be equipped with a ventilation system. This system

should extract the air heated by radiation etc. in order for the requirement of a low

intake air temperature to be met.

If there is a refrigerator compressor in the engine room, it is important that any leak-

age of refrigerant does not contaminate the intake air.

The radiated heat from the engine exhaust pipe downstream of the engine must also

be taken into account. The heat radiation depends on how much of the line is inside

the engine room and how much of it is insulated.

There is also additional heat due to efficiency losses in driven units located in the en-

gine room.

The amount of radiated heat emitted by the engine is indicated in the tables showing

the radiated heat for the relevant engine type in 02:06 Technical data .

INSTALLATION

MANUAL

Air cleaner

02:02 Issue 4.0 en-GB 10

Air cleaner

The engines can be supplied with a turbo-mounted air filter or with an air filter

mounted separately. The air cleaner is available with or without integrated self-clean-

ing precleaner.

Bear in mind the following when installing the air cleaner:

• The air cleaner must be fitted so that it is easily accessible for cleaning and filter

renewal.

• The vacuum indicator must be positioned so that it can be read easily.

• In order to be able to remove the filter element, clearance in the air cleaner exten-

sion is required. Refer to the subsequent page.

• The intake line between the air cleaner and the turbocharger must be sealed so that

no unfiltered air can be drawn into the engine. The intake line must be designed

in such a way that it cannot collapse onto itself as a result of a large pressure drop.

The intake line should be able to withstand a vacuum of 200 mbar before it col-

lapses onto itself.

• The material and composition of the intake line between the air filter and turbo-

charger must be such that it cannot release rust or objects that could damage the

engine.

It is also important to make sure that any insulation in the engine room and around

the exhaust pipes cannot come loose and be drawn into the intake line.

If a non-Scania air filter is used, engine air consumption and filter element pore size

must be considered.

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