Special Instruction Heat Exchanger

3516B Marine Auxiliary Engine S2R00001-UP(SEBP3920 - 51)/Basic ...
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Product: MARINE AUXILIARY

Model: 3516B MARINE AUXILIARY S2R00839
Configuration: 3516B Marine Auxiliary Engine S2R00001-UP
Special Instruction
Cleaning the Engine Mounted Heat Exchanger{1379}
Media Number -REHS2599-01Publication Date -07/05/2014Date Updated -07/05/2014
i05798770
Cleaning the Engine Mounted Heat Exchanger{1379}

SMCS - 1379
Engine:
3508B (S/N: S2A1-UP; S2B1-UP; S2D1-UP; S2E1-UP; S2F1-UP; BAG1-UP;
2BM1-UP; 3DM1-UP; 7SM1-UP; 1TW1-UP; 3DW1-UP; CTC1-UP; 1FZ1-
UP)
3512B (S/N: NSC1-UP; S2K1-UP; S2N1-UP; S2J1-UP; MRG1-UP; S2G1-
UP; MKH1-UP; S2H1-UP; S2L1-UP; S2M1-UP; 7HM1-UP; 8EM1-UP;
BRN1-UP; 4TN1-UP; 1PW1-UP; 2GW1-UP; 2EZ1-UP; CTB1-UP; 1GZ1-
UP)
3516B (S/N: S2P1-UP; S2R1-UP; S2S1-UP; S2T1-UP; S2W1-UP; 2TD1-UP;
CDE1-UP; B5G1-UP; PAG1-UP; CBN1-UP; 8CN1-UP; 8KN1-UP; 9AN1-
UP; 2FW1-UP; 3CW1-UP; 4BW1-UP; S2X1-UP; S2Y1-UP; CTA1-UP;
1HZ1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you read this
information and you understand this information.
This Special Instruction contains procedures for cleaning the heat exchangers that are
listed in Table 1. This instruction also covers the usage of the 248-6745 Bars (service
tool) and 162-7120 Pins that are listed in Table 2.
Table 1
Heat Exchangers for the 3500B Marine Engines
Part Number Engine Model
249-1021
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnur... 2/18/2016
3516B Marine Auxiliary Engine S2R00001-UP(SEBP3920 - 51)/Basic ... Page 2 of 26
3508B
3512B
245-9841 3516B
Table 2
Required Service Tools
Part Number Description Qty
(248-6745) Bars 2
(162-7120) Pin 2
Unless the water system for the heat exchanger is sealed, debris may enter the water.
Examples of debris are seaweeds, wood chips, mussels, barnacles, etc. Debris in the
water will reduce the efficiency of the heat exchanger. This can result in excessive
water temperatures that may require an engine shutdown. Preventing debris from
entering the water and/or filtering the water will reduce the need for cleaning.
The quality of the water can also affect the performance of the heat exchanger. Buildup
such as sediment and scale reduces the heat transfer characteristics of the plates. The
pressure differential of fluids that flow through the heat exchanger is increased.
Corrosion can occur beneath the buildup. The buildup can result from sources that are
organic or inorganic.
The combination of these two factors indicate that the heat exchanger requires
cleaning:
• Inability of the heat exchanger to maintain the desired temperatures
• Increased pressure differential of the fluids that flow through the heat exchanger
Frequently record these parameters during operation if a concern is present:
• Aftercooler inlet water temperature
• Inlet manifold air temperature
• Jacket water coolant temperature
• Pressure differential of the fluids that flow through the heat exchanger
Compare the data to previously recorded data. Clean the heat exchanger, if necessary.
Ensure that the engine will not operate when this maintenance is performed. Attach a
"DO NOT OPERATE" tag or similar warning tag to the controls before performing
maintenance or repairs.
Draining the Cooling System

Note: Refer to Operation and Maintenance Manual for information on the interval for
changing the coolant.
Pressurized System: Hot coolant can cause serious burns. To

open the cooling system filler cap, stop the engine and wait
until the cooling system components are cool. Loosen the
cooling system pressure cap slowly in order to relieve the
pressure.
NOTICE
Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, testing,
adjusting, and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component containing
fluids.
Refer to Special Publication, NENG2500, "Dealer Service

Tool Catalog" for tools and supplies suitable to collect and
contain fluids on Cat products.
Dispose of all fluids according to local regulations and

mandates.
Note: If the heat exchanger is hot, wait until the temperature of the heat
exchanger is reduced to approximately 40 °C (104 °F) before proceeding.
1. Prepare a suitable container for the coolant.
Note: For complete draining, all of the circuits of the heat exchanger must be
ventilated. If the installation does not have vent valves, remove the filler caps
from the expansion tanks.
2. Drain the heat exchanger.
Removal and Installation of the Heat Exchanger (If

Required)
It is not necessary to remove the heat exchanger in order to clean the plates.
Do not remove the heat exchanger unless a complete disassembly of the heat
exchanger is desired. Breaking the seals on the rear of the heat exchanger will require a
complete disassembly in order to remove collar (6). A complete disassembly is also
required in order to replace liner (8). Refer to Illustration 1.
Illustration 1 g01153325
Heat exchanger
(1) Tightening bolts
(2) Washer
(3) Spacer
(4) Front frame
(5) Spacer
(6) Collar
(7) Rear plate
(8) Liner
(9) Washer
(10) Bolt
The heat exchanger will require removal if there is a leak at location (A) or at location
(B).
Removal Procedure
Fuel leaked or spilled onto hot surfaces or electrical

components can cause a fire. To help prevent possible injury,
turn the start switch off when changing fuel filters or water
separator elements. Clean up fuel spills immediately.
1. Before removing the heat exchanger, stop the engine. Ensure that the engine will
not start during this procedure.
2. Shut off the fuel supply valve to the engine.
Purge valve for the fuel
3. Open the purge valve for the fuel.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean

the area around a fuel system component that will be
disconnected. Fit a suitable cover over disconnected fuel

system component.
NOTICE
Use a suitable container to catch any fuel that might spill.

Clean up any spilled fuel immediately.
Connections for the fuel lines
4. Disconnect fuel lines from connections (11) and (12) on the front frame.
5. The heat exchanger weighs approximately 36 kg (80 lb). Use a suitable lifting
device before attempting to begin the removal of the heat exchanger.
(13) Bolts
(14) Liners
(15) Elbows
(16) O-rings
6. Loosen and remove bolts (13) on elbows (15) at all four connections.
7. In order to remove the heat exchanger from the engine, there are six mounting
bolts that need to be removed. Remove three bolts (17) that are on each side of
the expansion tank.
8. Remove the heat exchanger. Place the heat exchanger on the work bench or in an
appropriate place in order to perform the work.
9. Discard liners (14) and O-rings (16) .
10. Open the heat exchanger in order to clean the plates. Refer to ""Opening the Heat
Exchanger" ".
Installation Procedure
During operation, the fluid in the lines of the cooling system is

hot and pressurized. A rupture of the coupling could cause
parts and hot fluid to be expelled. Improper selection,
installation, or use of the coupling could result in property
3516B Marine Auxiliary Engine S2R00001-UP(SEBP3920 - 51)/Bas... Page 10 of 26
damage, personal injury, or death. Install couplings that are

proper for the application according to the instructions.
1. Close the heat exchanger. Refer to ""Closing the Heat Exchanger" ".
(17) Mounting bolts
2. Install the heat exchanger on the engine and secure the three mounting bolts (17)
that are on each side of the expansion tank.
(13) Bolts
(14) Liners
(15) Elbow
(16) O-ring
3. Replace O-rings (16) and replace liners (14) at all four connections.
4. Place bolts (13) in elbows (15) at all four connections.
5. Ensure that O-rings (16) are in the groove before securing bolts (13) .
6. Tighten the bolts.
Opening the Heat Exchanger
Heat exchanger
(1) Tightening bolts
(2) Washer
(3) Spacer
(4) Front frame
(5) Spacer
(6) Collar
(7) Rear plate
(8) Liner
(9) Washer
(10) Bolt
Fuel leaked or spilled onto hot surfaces or electrical

components can cause a fire. To help prevent possible injury,
turn the start switch off when changing fuel filters or water
separator elements. Clean up fuel spills immediately.
1. Before opening the heat exchanger, stop the engine. Ensure that the engine will
not start during this procedure.
2. Shut off the fuel supply valve to the engine.
3. Open the purge valve for the fuel.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly clean

the area around a fuel system component that will be
disconnected. Fit a suitable cover over disconnected fuel
system component.
NOTICE
Use a suitable container to catch any fuel that might spill.

Clean up any spilled fuel immediately.
Connections for the fuel lines
4. Disconnect the fuel lines from connections (11) and (12) on the front frame.
Locations for the 248-6745 Bars
5. Remove bolts, washers, and spacers from the locations for the bars.
248-6745 Bars (service tool)
6. Install the 248-6745 Bars .
Note: The 248-6745 Bars require the use of 162-7120 Pins . The pins have a
diameter of 8.9 mm (0.3504 inch). Insert the pins in the drilled holes at the ends
of the bars in order to prevent the heat exchanger from falling.
7. Remove the remaining bolts (1) and washers (2) from the front frame (4) .
Removal and Installation of the Plates
Diagonally marked plates
1. Mark the outside of the plates diagonally and/or number the plates in sequence. If
the plates are removed, this is useful for reassembly.
2. Slide the front frame on the 248-6745 Bars .
Note: When possible, clean debris from the plates without removing the plates.
Refer to the ""Cleaning the Plates" " topic.
Bare hands can be injured by the plates of the heat

exchanger. To help prevent hand injuries, always wear
protective gloves when handling the plates.
Note: Handle the plates carefully. Do not damage the gaskets.
3. Only remove the plates if the material that is fouling the heat exchanger cannot be
easily removed. Remove the plates, if necessary. Clean the plates. Refer to the
""Cleaning the Plates" " topic.
4. After the plates are clean, hang the plates.
Hang the number one plate against the front frame. Orient the plates so that the
plates have the side without the gasket toward the rear plate.
5. Inspect the sealing surfaces for cleanliness.
Inspect the gaskets for proper installation and for good condition. Ensure that the
two tabs for each gasket are seated correctly. For instructions on installing the
gaskets, refer to the literature that is supplied by the OEM of the heat exchanger.
Ensure that the plates are hanging in the correct order.
When the plates are assembled correctly, the edges form a honeycomb pattern.
Inspect the edge of the plate assembly for this condition. To ensure that the plates
are hanging in the correct order, check the plates with the data that is provided by
the OEM of the plates.
Cleaning the Plates
NOTICE
Improper methods of cleaning will damage the plates. Do not

scrape or scratch the plates. Do not use a wire brush for
cleaning the plates. Use a brush with soft bristles. Be careful
not to damage the gaskets.
Locations of the gaskets
1. Use a brush with soft bristles for cleaning.
Be careful not to damage the gaskets.
Cleaning Buildup From the Plates

Note: Do not use hydrofluoric acid to clean titanium plates. Do not use water with
more than 300 ppm chlorine for the preparation of the cleaning solutions. Do not
allow paraffinic or naphtha based solvents (kerosene) to remain in contact with
the gaskets for more than 30 minutes. Contact with this cleaning solvent must be
limited to 30 minutes or less in order to prevent swelling of the rubber gasket..
Different types of buildup may require different cleaning solutions. To determine the
cause of the buildup, obtain an analysis of the material and of the water. The following
list contains the types of buildup that may be encountered.
• Incrustation and/or scaling
• Sediment
• Biological growth and/or slime
• Fouling
• Oils
Personal injury can result from improper handling of

chemicals.
Make sure you use all the necessary protective equipment

required to do the job.
Make sure that you read and understand all directions and
hazards described on the labels and material safety data sheet
of any chemical that is used.
Observe all safety precautions recommended by the chemical

manufacturer for handling, storage, and disposal of
chemicals.
Personal injury can result from acid.
Wear all necessary protective equipment, such as rubber

gloves and goggles when working with acid.
The bottle containing the etchant should be properly marked

ACID and should be stored in a protective place.
Add acid to the water at normal room temperature. Do not

add water to the acid. Add neutralizing agents to the water.
Do not add water to the neutralizing agents. There are many
safety precautions when handling acid. Therefore, this should
only be done by qualified personnel.
NOTICE
Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, testing,
adjusting, and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component containing
fluids.
Refer to Special Publication, NENG2500, "Dealer Service

Tool Catalog" for tools and supplies suitable to collect and
contain fluids on Cat products.
Dispose of all fluids according to local regulations and

mandates.
Use the following procedure to clean incrustation, scaling, and sediment.
Clean the gaskets by using one of the following solvents:
• Nitric acid
• Sulfamic acid
• Citric acid
• Phosphoric acid
• Complexing agents EDTA and/or NTA
• Sodium polyphosphates
1. Mix the solvent with water. Use a maximum concentration of 0.15 Liters (5
ounces) for every 3.8 Liters (1 gallon) of water.
2. Heat the cleaning solution to a maximum temperature of 60 °C (140 °F).
3. Use running water and a brush with soft bristles for cleaning debris. Pressurized
water at a maximum of 275 kPa (40 psi) may be used.
Avoid damaging the gasket.
Use the following procedure to clean biological growth (slime).
• Sodium hydroxide
• Sodium carbonate
1. Mix the solvent with water. Use a maximum concentration of 0.15 Liters (5
ounces) for every 3.8 Liters (1 gallon).
2. Heat the cleaning solution to a maximum temperature of 80 °C (176 °F).
3. Use running water and a brush with soft bristles for cleaning debris. Pressurized
water at a maximum of 275 kPa (40 psi) may be used.
Use the following procedure to clean deposits of oil from the plates.
• Paraffinic based solvent
• Naphtha based solvent
1. Use a brush with soft bristles and paraffinic or naphtha based solvents (kerosene)
in order to clean deposits of oil. Use the solvent at full strength.
Note: Do not allow paraffinic or naphtha based solvents (kerosene) to remain in

contact with the gaskets for more than 30 minutes. Contact with this cleaning
solvent must be limited to 30 minutes or less in order to prevent swelling of the
rubber gasket.
Do not use solvents that contain the following:
◦ Ketones (acetone, methylketone, or methylisobutyketone)
◦ Esters (ethylacetate or butylacetate)
◦ Halogenated hydrocarbons (chlorothene, carbon tetrachloride, or freons)
◦ Aromatics (benzens, or toluene)
Dry the plates with a clean cloth.
Closing the Heat Exchanger
Bolt tightening sequence
1. Press the plate assembly together.
2. Install bolt (1) through bolt (8) and hand tighten the bolts.
3. Remove the 248-6745 Bars and install the remaining bolts (9) and (10) with
washers and spacers.
4. Torque the bolts in sequence. Refer to Illustration 16 for the bolt tightening
sequence.
5. Connect fuel line connections (11) and (12) on the front frame.
6. Close the purge valve.
7. Turn the fuel supply valve to the ON position.
Note: Make sure that the fuel system is primed before attempting to start the
engine.
Filling the Cooling System
NOTICE
Only use coolant/antifreeze mixtures that are recommended

by the Operation and Maintenance Manual for the engine.
Failure to do so can cause damage to the engine and the
equipment.
NOTICE
Never use water alone without Supplemental Coolant

Additives (SCA) or without inhibited coolant. Water alone is
corrosive at engine operating temperatures. Water alone
does not provide adequate protection against boiling or
freezing.
1. Remove the filler caps for the expansion tanks.
NOTICE
The vent valve or vent plug for the aftercooler must be

opened in order to allow the aftercooler system to fill
properly. Failure to do this will cause an air lock which will
result in damage to the engine. Open the vent for the
aftercooler in order to allow the system to fill properly.
Typical example
Location for the vent plug for the aftercooler on 3500B Engines
2. Vent the aftercooler circuit. Open the vent valve or remove the vent plug. See
Illustration 19.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal) per

minute to avoid air locks.
3. Add the proper coolant mixture into the jacket water and aftercooler cooling
systems.
When the coolant flows from the vent for the aftercooler, close the vent. Shut the
vent valve or install the vent plug.
4. Do not install the filler caps for the expansion tanks. Start the engine.
Operate the engine in order to purge air from the cavities of the engine block.
Allow the coolant to warm and allow the coolant level to stabilize. Inspect the
cooling system for leaks and for proper operating temperature.
5. Stop the engine. Top off the expansion tanks. Install the filler caps.
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3516B Marine Auxiliary Engine S2R00001-UP(SEBP3920 - 51)/Basic ...

Product: MARINE AUXILIARY

Cleaning the Engine Mounted Heat Exchanger{1379}

• Inability of the heat exchanger to maintain the desired temperatures

Frequently record these parameters during operation if a concern is present:

• Aftercooler inlet water temperature

• Inlet manifold air temperature

• Jacket water coolant temperature

Draining the Cooling System

Pressurized System: Hot coolant can cause serious burns. To

Care must be taken to ensure that fluids are contained

Refer to Special Publication, NENG2500, "Dealer Service

Dispose of all fluids according to local regulations and

1. Prepare a suitable container for the coolant.

2. Drain the heat exchanger.

Removal and Installation of the Heat Exchanger (If

(1) Tightening bolts

(4) Front frame

(7) Rear plate

Fuel leaked or spilled onto hot surfaces or electrical

2. Shut off the fuel supply valve to the engine.

Purge valve for the fuel

3. Open the purge valve for the fuel.

Do not allow dirt to enter the fuel system. Thoroughly clean

disconnected. Fit a suitable cover over disconnected fuel

Use a suitable container to catch any fuel that might spill.

Connections for the fuel lines

9. Discard liners (14) and O-rings (16) .

During operation, the fluid in the lines of the cooling system is

damage, personal injury, or death. Install couplings that are

(17) Mounting bolts

4. Place bolts (13) in elbows (15) at all four connections.

6. Tighten the bolts.

Opening the Heat Exchanger

(1) Tightening bolts

(4) Front frame

(7) Rear plate

Fuel leaked or spilled onto hot surfaces or electrical

2. Shut off the fuel supply valve to the engine.

3. Open the purge valve for the fuel.

Do not allow dirt to enter the fuel system. Thoroughly clean

Use a suitable container to catch any fuel that might spill.

Connections for the fuel lines

Locations for the 248-6745 Bars

248-6745 Bars (service tool)

6. Install the 248-6745 Bars .

Removal and Installation of the Plates

Diagonally marked plates

2. Slide the front frame on the 248-6745 Bars .

Bare hands can be injured by the plates of the heat

Note: Handle the plates carefully. Do not damage the gaskets.

4. After the plates are clean, hang the plates.

5. Inspect the sealing surfaces for cleanliness.

Ensure that the plates are hanging in the correct order.

Cleaning the Plates

Improper methods of cleaning will damage the plates. Do not

Locations of the gaskets

1. Use a brush with soft bristles for cleaning.

Be careful not to damage the gaskets.

Cleaning Buildup From the Plates

• Incrustation and/or scaling

• Biological growth and/or slime

Personal injury can result from improper handling of