Académique Documents
Professionnel Documents
Culture Documents
In order for the Scania organisation to be able to handle the engine, it is required that the engine is
registered as put into operation. This registration means that preparedness to take care of service
and spare parts matters can be built up and that a correct warranty handling can take place.
It is you as the user of the engine who should report when the engine is put into operation.
The easiest way for you is to report the start-up via the INTERNET:
http://www.scania.com/products/engines/Start_up_report_ASURIM/start_up_report.asp
An alternative with longer handling time:
Fill in the information below, tear off the page, fold it, tape it, stamp it and send it to Scania.
The address is already printed. Or send it by telefax: +46 8 553 858 20.
Normally the warranty is valid for one year from the date of start-up.
If the start-up report is not submitted to us - within 12 months from the date of delivery the warranty period will be regarded as having started on the date of delivery from Scania.
Operator's Manual
DI12
EMS with S6/PDE
Marine engine
opm04-12m-ems en 1 588 962
2004-11:2
START-UP REPORT
(From end user)
Engine No.
Start-up date
Name of company
Contact person
Address (street)
Postal code
Name of town
State or Territory
Country
For
stamp
Scania CV AB
Industrial and Marine Engines
Marketing & Communications
S-151 87 SDERTLJE
Sweden
IMPORTANT INFORMATION
When working on the engine, for example adjusting drive belts, changing the oil or adjusting the
clutch, it is important not to start the engine. The engine may be damaged and there is
Operator's Manual
DI12
EMS with S6/PDE
Marine engine
opm04-12m-ems en 1 588 962
2004-11:2
Engine number
Commissioning date
User's name and address
Signature
Engine type
Variant
Engine type and variant are indicated on the engine type plate
FOREWORD
This Operator's Manual describes the handling and maintenance of Scania
DI12 Marine Engines with EMS S6/PDE injection system.
The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder inline, Diesel type. The engines are turbocharged and equipped with a charge
air cooler which is coolant-cooled, see page 14.
The engines may have two different cooling systems, a heat exchanger which
is cooled by sea water or keel cooling which has cooling coils on the keel in
which the engine coolant is cooled.
Common areas of usage include forward propulsion engines in small boats
like fishing boats and ferries, and in larger pleasure crafts, or as aggregate
engines on-board ships.
The engines can have different output and speed settings and are classified in
different class categories (classed engines must be used in certain marine
installations).
The normal output setting of the engine (performance code) is indicated on
the type plate, see page 14.
Note: Always use genuine Scania parts during service and repair so as
to keep your engine in the best possible working order.
The information in this manual was correct at the time of going to press.
However, we reserve the right to make alterations without prior notice.
Scania CV AB
Industrial and Marine Engines
S-151 87 Sdertlje, Sweden
2004-11:2
FOREWORD . . . . . . . . . . . . . . . . . . . . . . CONTENTS
.... 2
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
ENVIRONMENTAL RESPONSIBILITY . . . . . .4
CERTIFIED ENGINES . . . . . . . . . . . . . . . . . . . .5
SCANIA INDUSTRIAL AND MARINE ENGINE
WARRANTY FOR MARINE ENGINES . . . . . .6
SAFETY DETAILS . . . . . . . . . . . . . . . . . . . . . .10
Safety precautions for operation . . . . . . . . . . .11
Safety precautions for handling materials . . . .12
Safety precautions for care and maintenance .12
TYPE DESIGNATIONS . . . . . . . . . . . . . . . 14
Troubleshooting using flashing codes
for the EMS control unit . . . . . . . . . . . . . . . . .18
Overview of flashing codes for
EMS control unit . . . . . . . . . . . . . . . . . . . . . . .19
Troubleshooting using flashing codes
for the EMS coordinator . . . . . . . . . . . . . . . . .20
Overview of flashing codes
for EMS coordinator . . . . . . . . . . . . . . . . . . . .21
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 28
ENGINES WITH FEW OPERATING HOURS .28
MAINTENANCE SCHEDULE . . . . . . . . . . . . .29
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 44
READING THE
LOW PRESSURE INDICATOR . . . . . . . . . . . .44
CLEANING THE AIR CLEANER
COARSE CLEANER . . . . . . . . . . . . . . . . . . . . .44
CLEANING OR CHANGING THE
FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . .44
CHANGING THE SAFETY CARTRIDGE . . . .45
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 46
CHECKING THE FUEL LEVEL . . . . . . . . . . . .46
CHANGING THE FUEL FILTER . . . . . . . . . . .46
Bleeding the fuel system . . . . . . . . . . . . . . . . .47
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 48
CHECKING THE ELECTROLYTE LEVEL IN
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
CHECKING THE STATE OF CHARGE
IN BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . .48
CLEANING BATTERIES . . . . . . . . . . . . . . . . .48
CHECKING THE COOLANT
MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 50
CHECKING THE DRIVE BELT . . . . . . . . . . . .50
LOOK FOR LEAKAGE,
TAKE NECESSARY ACTION . . . . . . . . . . . . .50
CHECKING/ADJUSTING VALVE
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . .51
CHECKING/ADJUSTING THE PDE
INJECTOR ROCKERS . . . . . . . . . . . . . . . . . . . 52
LONG-TERM STORAGE . . . . . . . . . . . . . . 55
Preservative fuel . . . . . . . . . . . . . . . . . . . . . . .55
Preservative oil . . . . . . . . . . . . . . . . . . . . . . . .56
Preparations for storage . . . . . . . . . . . . . . . . .56
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Taking out of storage . . . . . . . . . . . . . . . . . . .57
TECHNICAL DATA . . . . . . . . . . . . . . . . . . 58
COOLING SYSTEM . . . . . . . . . . . . . . . . . . 35
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
ALPHABETICAL INDEX . . . . . . . . . . . . . . 62
2004-11:2
ENVIRONMENTAL RESPONSIBILITY
Scania has always been at the forefront in the development and production of
environmentally safe engines.
We have made great progress in reducing harmful exhaust emissions to be
able to meet the stringent emission standards that are mandatory for almost
all markets.
We have done this without compromising the high quality of Scania
industrial and marine engines in terms of performance and cost effective
operation.
To maintain these superior properties throughout the life of the engine it is
important that the operator/owner follows the instructions of this manual as
regards operation, maintenance and choice of fuel and lubricants.
To further contribute to protecting the environment in service, maintenance
and repair, ensure that harmful waste (oil, fuel, coolant, filters, batteries etc.)
is disposed of and destroyed according to applicable local regulations.
This operators manual contains highlighted text urging you to protect the
environment in different service and maintenance operations.
Refer to example
2005-03:1
CERTIFIED ENGINES
An emission certified engine has been approved according to a specific
certification standard. The certified engines delivered by Scania meet the
most compelling emission standards in the European (EU) and non-European
(USA) markets.
Scania guarantees that all engines of a certified engine type that are delivered,
correspond to the engine approved for certification.
The engine is fitted with a certification plate, stating according to which
certification rules (standard) the engine has been approved. Refer to page.
The following is required for the engine to meet the emission standards after
being commissioned:
- Service and maintenance must be performed according to this
Operators Manual.
- Only genuine Scania parts or equivalent must be used.
- Service work on the injection equipment must be performed by an
authorized workshop.
- The engine must not be modified with equipment not approved by
Scania.
- Seals and setting data may only be broken/modified by an authorised
workshop.
- Changes affecting the exhaust system and intake system must be
approved by Scania.
Otherwise, follow the instructions in this manual for operation, care and
maintenance of the engine. Also observe the safety precautions described in
the following four pages.
2005-03:1
Table of contents
General Warranty Provisions . . . . . . . . . . . . . . . . . . . 6
Warranty Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parts covered by the Warranty . . . . . . . . . . . . . . . . . . 7
General Warranty Limitations . . . . . . . . . . . . . . . . . . 8
Specific Warranty Exclusions . . . . . . . . . . . . . . . . . . 9
Customer Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2005-03:1
Warranty Period
This warranty shall apply for one of the following periods, whichever occurs
first:
Except that the warranty period shall apply for a period not less than
any mechanical warranties provided by Scania to the owner.
"On the date the marine vessel is delivered to the first retail purchaser,
or
3. Exhaust manifold
4. Combustion chamber
a. Piston
b. Cylinder head
2005-03:1
2005-03:1
4. Replacement items which are not genuine Scania parts or not authorized
by Scania.
Customer Support
In the event that you do not receive the warranty service to which you believe
you are entitled under the Warranty, or if you need additional support or
information concerning the Warranty, please contact:
2005-03:1
SAFETY DETAILS
General
This Operators Manual contains safety information that must be observed in
order to avoid personal injuries and damage to the product or property. Refer
to page 1.
The text boxes to the right on the pages provide information that is important
for the proper operation of the engine and to avoid damage to the engine.
Failure to follow these instructions may void the warranty.
Refer to example.
Corresponding texts may also appear in the text column, headed Caution! or
Important
The warning text in text boxes to the right on the pages provided with a
warning triangle and headed WARNING is extremely important and warns
of serious defects to the engine or improper handling that may lead to
personal injury.
Refer to example
10
2005-03:1
Starter lock
Starting spray
Refuelling
When refuelling, there is a risk of fire and explosion. The engine must be stopped and smoking
is not allowed.
Do not overfill the tank, since the fuel may expand, and close the fuel filler cap properly.
Only use fuel recommended in the service
literature. Fuel of an incorrect grade may cause
malfunctions or stoppage by interfering with the
operation of the fuel injection pump and the injectors.
This could cause engine damage and possibly
personal injury.
Operation
The engine should not be operated in environments with surrounding explosive materials
since electrical or mechanical components of
the engine may emit sparks.
It is always a safety hazard to be near an engine that is running. Body parts or clothing, or a
dropped tool may get stuck in rotating parts,
such as the fan, causing bodily injury.
Always cover rotating parts and hot surfaces as
much as possible to ensure personal safety.
Harmful gases
Only start the engine in a properly ventilated area. The exhaust emissions contain carbon
monoxide and nitrogen oxides that are toxic.
When operating the engine in an enclosed area, an effective extraction device for exhaust
gases and crankcase gases must be used.
2005-03:1
11
All fuels and lubricants as well as many chemicals are flammable. Always follow the instructions stated on the container.
Always stop the engine before any maintenance and service work unless otherwise
stated.
Store drenched rags and other flammable materials in a safe way to avoid spontaneous combustion.
Batteries
Batteries, particularly when being recharged,
emit highly flammable fumes that can explode.
Do not smoke or let open flame or sparks come
near the batteries or the battery compartment.
Incorrect connection of a battery cable or jump
start cable may cause a spark, which in tun
may cause the battery to explode.
Chemicals
Most chemicals, such as glycol, corrosion inhibitors, preservation oils, degreasers etc. are
hazardous. Always follow the safety precautions stated on the container.
Some chemicals, e.g. preservative oil, are
flammable.
Always store chemicals and other hazardous
materials in approved and distinctly marked
containers and out of reach of unauthorized
persons. Always dispose of superfluous or
used chemicals through an authorized waste
disposal contractor.
It is always a safety hazard to work on an engine that is running. Parts of your body or clothing, or a dropped tool may get stuck in rotating
parts, causing bodily injury.
Batteries
Batteries contain a highly corrosive electrolyte
(sulphuric acid). Always take care to protect
your eyes, skin and clothing when charging and
handling batteries. Wear protective gloves and
goggles.
If electrolyte splashes on the skin, wash the
affected part of the body with soap and plenty
of water. If electrolyte splashes into the eyes,
rinse eyes immediately with plenty of water and
seek medical attention.
Dispose of used batteries through an authorized waste disposal contractor.
12
2005-03:1
Electrical system
Cooling system
Before work is performed on the electrical system, turn off the power by the main switch or
the battery disconnect switch.
Never open the coolant filler cap while the engine is hot. Steam and hot coolant can come
out forcefully and cause scalding.
If the cooling system must still opened or disassembled while the engine is hot, open the filler
cap very cautiously and slowly to release the
pressure before the cap is removed. Use
gloves since the coolant is still very hot.
Arc Welding
Before welding near or on the engine, remove
the battery and alternator cables. Also remove
the control unit connector.
Connect the weld clamp to the component to be
welded, close to the weld location. Never connect it to the engine or in such a way that the
current can pass through a bearing.
After the welding is completed, connect the cables to the alternator and the control unit before
connecting the batteries.
Lubrication system
Hot oil may cause scalding and skin irritation.
Avoid skin contact with hot oil.
Make sure that the pressure in the lubrication
system is relieved before work is carried out.
Never start or operate the engine with the oil filler cap removed since oil will be ejected forcefully.
Dispose of used oil through an authorized
waste disposal contractor.
Fuel system
Always use gloves when checking for leaks in
or performing other work on the fuel system. Always wear eye protection when testing injectors.
Fuel escaping under high pressure can penetrate body tissue and cause serious injury.
Never use non-genuine parts in the fuel system
and the electrical system. Genuine parts are
designed and manufactured to minimize fire
and explosion hazard.
Before starting
Install any guards that have been removed before the engine is started. Check to ensure that
no tools or other objects have been left on the
engine.
Never start the engine unless the air filter is installed. Otherwise there is a risk of objects entering the compressor wheel or a risk of
personal injury from contact with it.
2005-03:1
13
TYPE DESIGNATIONS
The engine type designation indicates, in the form of a code, the type of
engine, its size and applications, etc.
The type designation and engine serial number are indicated on a type plate
affixed to the right-hand side of the flywheel housing. The engine number is
also stamped on the engine block on the right-hand side. See arrow in the
illustration.
Engines which hold certification in respect of smoke and emissions are
fitted with a plate which indicates the documents in accordance with which
they are certified.
DI 12 60 M 10 P
Type
DI
Application
M
Variant 01-99
Type of regulator
P
14
2004-11:2
16
15
2, 3
4
5
14
13
6
12
11
10
24
8
17
18
23
22
19
21
20
The illustrations show a normal version of a DI12-engine
Your engine may have different equipment from that illustrated
1. Expansion tank
2. Engine number,
stamped into the engine
block
3.
4.
5.
6.
7.
8.
Type plate
Coolant pump
Draining, coolant
Oil cooler
Oil filter
Centrifugal cleaner
2004-11:2
9.
10.
11.
12.
13.
14.
15.
16.
17.
Oil dipstick
Draining, engine oil
Heat exchanger
Sea water outlet
Sea-water pump with seawater inlet
Air filter (disposable)
Turbocharger
Filling coolant
Fuel filter
ventilation filter
Fuel pump with hand pump
Starter motor
Control unit
Alternator
Oil pressure sensor
Charge air cooler
15
16
2004-11:2
1
2
2004-11:2
17
The diagnostics lamp will stay on for as long as a fault is active. Even
if the lamp has gone off and the fault is no longer active, the code can
generally be read off in accordance with the instruction below.
3. A fault code will then flash on the diagnostics lamp. This flashing code
consists of long flashes (approximately 1 second long) and short flashes
(0.3 seconds long). Long flashes are equivalent to tens and short flashes
to units.
Example: long - short - short = fault code 12.
4. Repeat this procedure until the first flashing code is repeated. This
means that the entire fault code memory has been flashed up. If the fault
code memory is empty, only one long flash approximately 4 seconds
long will be given.
5. See the flashing code table on the next page for a description and
localisation of the fault.
7. When a fault has been rectified the fault code can be erased as described
below.
3. Switch on the ignition and keep at the same time the diagnostics switch
activated, to the right (COO) or to the left (EMS), for 3 seconds.
4. This will erase passive fault codes which can be read off via flashing
code for the relevant system. The rest of the fault code will remain in the
EEPROM and can only be deleted using the PC tool.
18
2004-11:2
Description
Code
Description
No fault detected.
53
11
54
12
55
13
56
14
57
15
58
16
59
17
61
18
66
20
69
23
82
24
83
25
84
27
85
28
86
31
87
32
88
33
89
37
93
43
94
47
96
48
98
49
99
51
52
2004-11:2
19
Even if the lamp has gone off and the fault is no longer active, the code
can generally be read off in accordance with the instruction below.
3. A fault code will then flash on the diagnostics lamp. This flashing code
consists of long flashes (approximately 1 second long) and short flashes
(0.3 seconds long). Long flashes are equivalent to tens and short flashes
to units.
Example: long - short - short = fault code 12.
4. Repeat this procedure until the first flashing code is repeated. This
means that the entire fault code memory has been flashed up. If the fault
code memory is empty, only one long flash approximately 4 seconds
long will be given.
5. See the flashing code table on the next page for a description and
localisation of the fault.
7. When a fault has been rectified the fault code can be erased as described
below.
3. Switch on the ignition and keep at the same time the diagnostics switch
activated, to the right (COO) or to the left (EMS), for 3 seconds.
4. This will erase passive fault codes which can be read off via flashing
code for the relevant system. The rest of the fault code will remain in the
EEPROM and can only be deleted using the PC tool.
20
2004-11:2
Description of fault
111)
112)
121)
122)
Incorrect signal from the resistor module for idle and fixed speed setting.
13
14
15
17
18
19
21
22
23
24
25
26
27
The signals from the RCB (Remote Control Box) switches are implausible.
28
29
31
32
Short circuit in the signal cable to the coolant temperature warning lamp.
33
34
35
2004-11:2
21
Coolant composition:
22
2004-11:2
- Open the inlet valve for the sea water system (if fitted).
- Open any fuel valve.
- Disengage the engine.
- Engines with battery master switch: Switch on the power by means of
the battery master switch.
- Start the engine with the key in the control panel (SCP) or the start
button (only from RCB).
- S6: The diagnostics lamp should go out after approximately 2 seconds
when starting.
2004-11:2
23
DRIVING
Check instruments and warning lamps at regular intervals.
Rotation speed
The Scania tachometer is divided into sectors of different colours, as follows:
0-500 rpm
red area:
500-700 rpm
yellow area:
700-2200 rpm
green area:
2200-2600 rpm
yellow/green
striped:
2600-3000 rpm
red area:
24
2004-11:2
Limp-home mode
If there is a fault on the normal accelerator pedal or if CAN communication is
interrupted, the following limp-home option is provided:
CAN open circuit or accelerator pedal fault (both signal and idling switch):
- The accelerator pedal value is 0% and the engine is running at normal
idling speed.
- The accelerator pedal value is 0% and the engine is running at raised
idling speed (750 rpm) if this function is activated.
Accelerator pedal fault but the idling switch is working:
- The accelerator pedal value can be increased slowly between 0% - 50%
by using the idling switch.
CAN open circuit:
- The engine is switched off if the shutdown function is activated.
Coolant temperature
Normal coolant temperature when the engine is running should be 70 - 90C.
The EMS/S6 control system has the following alarm levels:
- If the temperature is high, 98C - 103C, for a certain period (1 second),
S6 will send a CAN message which switches on the warning lamp and
diagnostics lamp via the coordinator.
- If the temperature exceeds 103 C, the warning lamp and diagnostics
lamps will come on. If torque reduction is activated, the control system
will reduce the fuel quantity to 70%. A fault code is generated in the
control unit.
- At temperatures exceeding 103C and with engine shutdown activated,
the warning lamp and diagnostics lamp come on and the engine is
switched off. If the override function is activated, only torque reduction
takes place when this function is activated. A fault code is generated in
the control unit.
After an alarm, approved values should be registered for more than 2
seconds to reset the alarm.
Excessively high coolant temperature can damage the engine.
If run for extended periods under an extremely light load, the engine may
have difficulty in maintaining normal operating temperature. However, the
temperature will rise to a normal level again when the load on the engine is
increased.
2004-11:2
25
Oil pressure
Max. oil pressure:
warm engine running at a speed above 800 rpm
6 bar
3 - 6 bar
2.3 bar
26
2004-11:2
2. Stop the engine with the stop button. Keep the stop button depressed
until the engine is completely stationary.
4. Engines with battery master switch: Switch the power off with the
battery master switch.
- Switch off inlet valve for the sea water system (if fitted).
- If there is danger of freezing the sea water system must be emptied.
- At temperatures below 0C: Prepare for the next start by connecting the
engine heater (if fitted).
27
MAINTENANCE
The maintenance programme covers 21 points, divided into the following
main groups:
Lubricating oil system . . . . . . . . . . . . . . . . . page 30
Cooling system . . . . . . . . . . . . . . . . . . . . . . . page 35
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . page 44
Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . page 46
Electrical system, batteries, etc . . . . . . . . . . page 48
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . page 50
The maintenance points are divided into intervals as follows:
Daily maintenance
Maintenance before the first start
28
2004-11:2
MAINTENANCE SCHEDULE
1.
2.
3.
4.
5.
6.
z1
z1
z1
z5
Annually
At least
4800 h
2400 h
1200 h
400 h
Interval
200 h
400 h
First start
Daily
First
time at
z
z5
z6
6
z1
z3
z1
z2
z
z2
z2
z
z
2004-11:2
29
- ACEA E3, E4 or E5
- The Total Base Number (TBN) should be minimum 12-13 (ASTM
2896).
- Check with your oil supplier that the oil meets these requirements.
- The oil change intervals stated apply provided that the
sulphur content of the fuel is not in excess of 0.3% by weight. If the
sulphur content is greater than 0.3% but no more than 1.0%, the oil
change interval must be halved (200 h).
Oil analysis
Some oil companies can offer analysis of the engine oil. Such analysis
measures the oil's TBN (Total Base Number), TAN (Total Acid Number),
fuel dilution, water content, viscosity and the quantity of wear particles and
soot in the oil.
The result of a series of analyses is used as the basis for establishing a
suitable oil change interval.
If the conditions are changed, a new oil analysis programme must be carried
out to establish the new change interval.
-40
-30
-20
-10
10
20
30
40 C
SAE 20W-30
SAE 30
SAE 40
SAE 50
SAE 5W-30
SAE 10W-30
SAE 15W-40
30
2004-11:2
1. Daily:
CHECKING OIL LEVEL
Note: Before checking oil level: Allow the engine to remain stationary
for at least 1 minute.
- The oil is at the correct level when it comes to between the marks on the
dipstick. Top up when the oil level is at the lower mark on the dipstick.
- Correct type, see "Oil grade" on page 30.
Max
Min.
Max. 33 dm3
Min. 28 dm3
WARNING
The oil may be hot.
Wear protective gloves and
goggles
2004-11:2
Max. 28 dm3
Min. 20 dm3
1 dm3 = 1 litre
31
25
25
25
25
35
35
35
35
- Lift out the rotor and wipe the outside. Unscrew the rotor bowl nut about
one and a half turns.
- Hold the rotor and tap lightly on the rotor nut with a plastic mallet or
against the workbench, so that the rotor bowl comes loose from the
bottom plate. Never strike on the rotor directly as this may damage the
bearings.
32
2004-11:2
- Make sure the shaft is not loose. If it is loose, use locking compound
561 200 and tighten it to 34 Nm using tool 98 421.
2004-11:2
33
Functional inspection
The rotor rotates very fast and should continue to rotate when the engine has
stopped.
- Stop the engine when it is warm.
- Listen for a whirring sound from the rotor or feel whether the cleaner
housing is vibrating.
The rotor normally continues spinning for 30 - 60 seconds after the engine
has stopped.
If not: Dismantle and check.
2004-11:2
- Fit the new filter and press into the centre of the filter head.
- Refit the container and lock firmly.
- If the indicator 3 on top of the filter showed red, remove the plastic
cover and press the indicator button.
- Refit the drainage line.
1
2
COOLING SYSTEM
5. Daily:
CHECKING COOLANT LEVEL
- Open the expansion tank filler cap and check the coolant level.
- Correct level:
- Cold engine: Coolant level must be approx. 50 mm below the Full
line.
- Hot engine:
35
Note: If the corrosion bars are very corroded they need to be checked
more often, for example every 200 hours.
Note: If the impeller must be changed frequently, the cleaning of the sea
water must be improved.
36
2004-11:2
Coolant composition:
b)
Checking the glycol content
If there is a danger of freezing, use only glycol as an anti-corrosive in the
coolant.
- Cooling systems with glycol should contain at least 30% glycol by
volume to provide acceptable protection against corrosion.
Ethylene glycol is
corrosion inhibitor.
Avoid skin contact
with glycol.
- The table shows the temperature at which ice starts to form. The engine
will freeze and break at appreciably lower temperatures, see diagram.
- Ice forming in the coolant often causes malfunctioning without any risk
of damage. The engine should not be subjected to heavy loads when ice The recommended glycol must
starts to form.
not be mixed with glycol having
nitrite-based anti-corrosive.
Note: The coolant should be changed when the cooling system is
cleaned: every 4800 hours or at least every 5th year.
Risk for build up of sludge and
contain an inhibitor.
2004-11:2
37
A
% glycol by
volume
15
20
25
-6
-9
Ethylene glycol
dm3 (litres)
5
6
8
9
11
12
14
15
17
18
20
21
23
24
26
27
29
30
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
8
10
13
15
18
20
23
25
28
30
33
35
38
40
43
45
48
50
30
9
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
35
11
14
18
21
25
28
32
35
39
42
46
49
53
56
60
63
67
70
40
12
16
20
24
28
32
36
40
44
48
52
56
60
64
68
72
76
80
45
50
14 15
18 20
23 25
27 30
32 35
36 40
41 45
45 50
50 55
54 60
59 65
63 70
68 75
72 80
77 85
81 90
86 95
90 100
Cooling
system
capacity,
dm3
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
2004-11:2
c)
Checking protection against corrosion
There must always be sufficient corrosive inhibitor in the coolant to protect
the cooling system against corrosion.
If there is no danger of freezing, only Scania Corrosion Inhibitor should be
used in the coolant.
It is highly dangerous to
consume corrosion inhibitor.
Avoid contact with the skin.
2004-11:2
39
External cleaning
Heat exchanger
1. Empty the sea water circuit and detach the heat exchanger sea water
inlet and outlet pipes.
11. Refit the heat exchanger assembly. Tighten the flange nuts to 50 Nm.
12. Refit the inlet and outlet pipes, the thermostat housing, the coupling
housing and the charge air cooler pipes.
40
2004-11:2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
2004-11:2
17. Screw
18. Seal
19. Protective anode
20.
21.
22.
23.
24.
25.
26.
(3 off)
Plug
Seal
Flange nut
Return pipe to coolant pump
Outlet pipe from engine
O-ring
Pressure cap
41
3. Detach the charge air cooler inlet and outlet connections for the coolant. Use a container to avoid spillage
Remove the cover with thermostat housing and the intake manifold from
when
the element connection.
changing the coolant.
4. Remove the screws between the upper and lower parts of the intake
Dispose of used coolant through
manifold and lift off the upper part of the intake manifold.
an authorised waste disposal
Take care not to damage the element's water connections.
contractor.
5. Plug the holes in the element and unscrew the element retaining screws.
Lift off the charge air cooler element.
8. Fit a new gasket on the lower part of the charge air cooler and screw on
the upper part. Tighten the screws to 26 Nm.
9. Lubricate and fit new O-rings in the connecting pipe (8) for the coolant
inlet and push it onto the element inlet pipe. Fit a new V-seal (6) on the
pipe.
10. Lubricate and fit new O-rings in the connection pipe on the cover with
thermostat housing (7). Fit the cover on the inlet and outlet on the
element, and screw it onto the upper part of the manifold (4) with a new
gasket (5). Tighten the screws to 26 Nm.
11. Refit the turbo air pipe to the upper part of the intake manifold. Tighten
the screws to 26 Nm.
8 5
7
1.
2.
3.
4.
5.
6.
7.
42
2
6
9
2004-11:2
Internal cleaning
Removing oil and grease
- If possible, run the engine until it has reached operating temperature and
then drain the cooling system.
- Remove the thermostats.
- Fill the system with clean, hot water mixed with liquid dishwasher
detergent designed for household use.
Concentration 1% (0.1/10 l).
- Run the engine until warm for about 20-30 minutes. Do not forget the
cab heating system (if fitted).
- Drain the cooling system.
- Fill the system again using clean, hot water and run the engine for about
20-30 minutes.
- Drain the water from the system.
- Refit the thermostats.
- Top up the system with new coolant according to the specification on
page 37.
Removing deposits
- If possible, run the engine until it has reached operating temperature and
then drain the cooling system.
- Remove the thermostats.
- Fill the system with clean, hot water mixed with some of the radiator
cleaning agent available on the market which is based on sulphamic acid
and contains dispersing agents. Follow the manufacturer's instructions
for the concentration and cleaning period.
- Run the engine for the specified time and then drain the cooling system.
- Refill the system with hot water and run the engine for about 20-30
minutes.
- Drain the water from the system.
- Refit the thermostats.
- Top up the system with new coolant according to the specification on
page 37.
2004-11:2
43
AIR CLEANER
10. Daily:
READING THE
LOW PRESSURE INDICATOR
If the red indicator telltale is entirely visible, change or clean the air cleaner
filter element, point 12. This is particularly important if the engine is run at
high loads and high speed.
3. Fit the coarse separator as shown in the figure and screw the cover in
place.
1.
2.
3.
4.
Filter element
Coarse cleaner
Cover
Vacuum indicator
Air cleaner with coarse
cleaner
Dismantling
Only use Scania genuine air
filter.
Change the filter element if it is
damaged.
3
Never start the engine without
the air filter.
There is a risk of injury or
serious engine damage.
1. Cover
2. Filter element
3. Filter housing
44
2004-11:2
Checking
- Insert a torch into the element and check from the outside that there are
no holes or cracks in the filter paper.
- Change the filter element if it has the slightest damage. Danger of
engine damage.
Assembly
1. Assemble the air cleaner in reverse order.
2. Reset the red plunger in the low pressure indicator by depressing the
button.
1. Pour the cleaning solution into the element outlet at the same time as
turning the element so that the cleaning solution pours through the
element against the direction of the air flow.
2. Leave the element in the cleaning solution for 5 minutes and then take it
out so that all the cleaning solution drains away.
3. Rinse the element with ca 30 litres clean water at 30 - 40C. Pour the
rinsing water into the element in the same way as the cleaning solution.
4. Take out the element and allow the rinsing water to drain off.
5. Repeat the procedure until the rinsing water is clean.
6. Leave the element to dry in a warm place for approximately 24 hours.
Note: The filter must not be dried with compressed air.
Note: Not all elements are equipped with a safety cartridge. When
changing the safety cartridge, take great care to ensure that no
dirt or other impurities can get into the engine.
1.
2.
3.
4.
5.
6.
1. Safety cartridge
Air cleaner with safety cartridge
2004-11:2
45
FUEL SYSTEM
14. Daily:
CHECKING THE FUEL LEVEL
- Top up with fuel if necessary. At the same time, drain the water
separating filter.
- If the tank has been run dry, bleed the fuel system, see point 15.
Main filter
The filter consists of a filter unit.
- Wash the outside of the filter and unscrew it.
- Fit the new filter and tighten it by hand.
Never use tools for this. The filters can be damaged, obstructing
circulation.
- Bleed the fuel system according to the instructions overleaf.
- Start the engine and check for leaks.
46
2004-11:2
1. Shut-off cock
2. Filter
3. Drain valve
After renewing the fuel filter, it will take approximately 170 strokes.
Important The starter motor may only be used for 30 seconds at a time.
After that time it must rest for 2 minutes.
If the engine fails to start after bleeding. . . . . . .
- Open the bleeder nipples again and pump the hand pump until fuel
without air bubbles flows out.
- Tighten the bleed nipples. Start the engine and check for leaks.
2004-11:2
47
ELECTRICAL SYSTEM
16. Every 200 hours:
CHECKING THE ELECTROLYTE
LEVEL IN BATTERIES
48
2004-11:2
motor).
2. Connect the negative cable (-) to the battery (cable connected to earth).
3. Automatic stop in the event of a fault: The engine stops, the indicator
lamp comes on and the buzzer (if fitted) sounds if there is no fault in the
level monitor. If the function is connected via the coordinator, the
emergency stop fault code will be generated and can be read off on the
diagnostics lamp.
2004-11:2
49
MISCELLANEOUS
20. Every 1200 hours:
CHECKING THE DRIVE BELT
- If the drive belt (1), which is a poly-V belt, is worn or damaged it must
be changed.
- Also check that the automatic belt tensioner (2) is in proper working
order and keeps the drive belt correctly tensioned.
21. Daily:
LOOK FOR LEAKAGE,
TAKE NECESSARY ACTION
- Start the engine.
- Check for oil, coolant, fuel, air and exhaust leakages.
50
2004-11:2
WARNING
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK OF INJURY.
Order of adjustment
- Turn the flywheel (anti-clockwise) so that the marks on the flywheel can
be seen in the lower opening in the flywheel housing. Refer to table.
2
3
- Measure the valve clearance with a feeler gauge and adjust the valves as
per the order of adjustment in the table below. Correct valve clearances
are also given on the instruction plate on one of the rocker covers:
- If readings can only be taken through the upper cover and not from
underneath: Start at TDC Up and turn the flywheel anti-clockwise
120(1/3 turn) at the time, observe the valve overlap and adjust the
valves according to the table below.
6
FLYWHEEL
Cylinder numbering
Mark on
flywheel
(reading taken
through the lower
opening)
Valve
overlap on
cylinder
Adjust the
valves on
cylinder
120
240
480
600
2004-11:2
51
Note:
Readings can be taken from the
flywheel through covers in the
flywheel housing either from
above or underneath depending
on access when fitting.
It says up resp down on the
flywheel
Both openings are fitted with a
cover at delivery.
Important The unit injectors PDE31 are adjusted using setting tool
99,414 or a digital sliding calliper. The unit injectors PDE32
are adjusted using setting tool 99 442 or a digital sliding
calliper. This adjustment is important as incorrect positioning
of the unit injector can lead to poor performance and possible Measurement
damage.
A=PDE31: 66.9 0.1 mm
Order of adjustment
The table below does only apply when readings are taken through the lower Measurement
B=PDE31: 36.5 mm
opening. If readings are taken through the upper opening, see previous page.
PDE32: 38.8 mm
Mark on flywheel
(reading taken
through the lower
opening)
Valve
overlap on
cylinder
Adjust
injector
rocker arm
on cylinder
120
240
480
600
52
2004-11:2
PDE31:
1. Firstly, measure the distance A between plane a and the top edge of the
valve spring washer on the PDE injector using a digital slide rule. See
figure.
6. If the setting tool is not available, a digital slide rule can also be used for
fine adjustment. The rocker position is adjusted by means of the
adjusting screw to 66.9 +/-0.1 mm as stated above.
7. Tighten the adjusting screw lock nut to 39 Nm and remove the tool.
Note: Any additional checking/adjustment of the PDE injectors,
e.g. checking the opening pressure, should not be carried out.
Faulty injectors must always be replaced completely.
99 414
66.9
2004-11:2
53
PDE32:
1. Firstly, measure the distance A between plane a and the top edge of the
valve spring washer on the PDE injector using a digital slide rule. See
figure.
6. If the setting tool is not available, a digital slide rule can also be used for
fine adjustment. The rocker position is adjusted by means of the
adjusting screw to 69.9 +/-0.1 mm as stated above.
7. Tighten the adjusting screw lock nut to 39 Nm and remove the tool.
Note: Any additional checking/adjustment of the PDE injectors,
e.g. checking the opening pressure, should not be carried out.
Faulty injectors must always be replaced completely.
99 442
69.9
54
2004-11:2
LONG-TERM STORAGE
If the engine is not to be used for a lengthy period of time, special measures
should be taken to protect the cooling system, fuel system and combustion
chamber from corrosion and the exterior from rusting.
The engine can normally stand idle for up to six months. If it remains unused
for longer than this the following measures, which provide protection for
about four years, should be adopted. An alternative to preparing the engine
for long-term storage is to start the engine and warm it up every 6 months.
Preparing the engine for long-term storage means:
- Thoroughly cleaning the engine
- Running the engine for a certain time using special preservative fuel, oil
and coolant.
- Otherwise preparing the engine for storage (filter changes, lubrication,
etc.).
Preservative coolant
If the engine is to be stored with a full cooling system, use coolant containing
50 % glycol by volume. Glycol without nitrite-based inhibitor should be
used. For example BASF G48 or BASF D542.
Ethylene glycol is
toxic if ingested.
Avoid contact with the skin.
Preservative fuel
- Use diesel fuel oil mixed with Lubrizol 560H or the equivalent.
- Mix 1 cm3 (ml) Lubrizol 560H in 10 dm3 (l) of fuel.
Inflammable:
Storage:
2004-11:2
55
Preservative oil
Suitable preservative oil can be supplied by most petroleum companies.
E.g. Dinitrol 40 or the equivalent.
- Detach the fuel pipe at the overflow valve and connect a return hose to
the can.
- Start the engine and run it at about 1000 rpm (not single-speed engines)
for 20-25 minutes.
- Stop the engine, remove the hoses and connect the regular fuel lines.
- Remove the rocker covers and lubricate the valve mechanisms and PDE
mechanisms with preservative oil. Refit the rocker covers.
Winter storage
- To reduce the risk of condensation in the fuel tank during winter storage,
fill the tank with fuel.
56
2004-11:2
STORED ENGINE
Date . . . . . . . . . . .
Do not start or crank!
Batteries
Remove the batteries for trickle charging at the battery charging station.
(Does not apply to batteries which according to the manufacturer do not
require any maintenance). The same is applicable for short-term storage if the
engine has not been prepared for storage as above.
Storage
After the preparations, the engine should be stored in a dry and warm place
(room temperature).
2004-11:2
57
TECHNICAL DATA
GENERAL
DI12
Number of cylinders
6 in line
Cylinder diameter
mm
127
Stroke
mm
154
Capacity
dm3 (litres)
11,70
Firing order
1-5-3-6-2-4
Compression ratio
16:1
Anticlockwise
Cooling
Valve clearances, cold engine
intake valve
exhaust valve
Liquid
mm
mm
0,45
0,70
1130
1070
see engine card, "Engine record card"
LUBRICATION SYSTEM
Max. oil pressure
hot engine at engine speeds
above 1000 rpm
bar (kp/cm2)
bar (kp/cm2)
3-6
bar (kp/cm2)
3,0
bar (kp/cm2)
1,4
58
-55 - +20
mm VP
2004-11:2
FUEL SYSTEM
DI12
rpm
Fuel
1
see page 60
COOLING SYSTEM
Number of thermostats
1 (dual thermostat)
83
Coolant temperature:
system at atmospheric pressure
system at overpressure
C
C
70 - 93
70 - approx. 100
Volume
with heat exchanger
without heat exchanger (keel cooling engine)
dm3 (litres)
dm3 (litres)
approx. 42
approx. 24
ELECTRICAL SYSTEM
System voltage
24
Alternator, current
65 or 2x65
2004-11:2
kW (hp)
bar (kp/cm2)
C
6,7 (9,1)
1,0 0,15
Stamped on hexagonal part of monitor
59
FUEL
Diesel fuel oil
The composition of the diesel fuel oil has a great influence on the functioning
and the service life of the engine and the injection system. The engine output
and exhaust emissions are also dependent on the fuel quality. The
requirements and testing standards for the most important properties are
described in the service manual in sections which can be ordered from Scania
dealers or directly from Scania. The address of Scania is printed on the cover.
Diesel fuel must comply with the following standard: EN 590 (European
standard).
The table below shows the requirements for some of the most important
properties:
Property
Viscosity at 40C
Density at 15C
Sulphur (concentration by mass)
Ignitability (CET rating)
Flashpoint
Requirement
2.0 - 4.5 mm2/s (cSt)
0.82 - 0.86 kg/dm3
max. 0.3%
min. 49
56C
60
2004-11:2
The diesel fuel is adapted for use in the specific climate of each country. If a
kerosene with diesel fuel that is
vehicle or an engine is to be operated in a temperature zone with lower
already
adapted for the climate
temperature than normal, first identify the temperature properties of the
fuel concerned.
concerned. This can damage the
2004-11:2
61
ALPHABETICAL INDEX
Leakage ............................................................ 50
Lubricating oil system ..................................... 30
Lubrication pressure ........................................ 26
Maintenance ..................................................... 28
Maintenance Schedule ..................................... 29
Oil analysis ...................................................... 30
Oil capacity ...................................................... 31
Oil change ........................................................ 31
Oil cleaner ........................................................ 32
Oil filter ........................................................... 34
Oil grade .......................................................... 30
Oil level ........................................................... 31
Oil pressure ...................................................... 26
PDE injectors ................................................... 52
Preface ............................................................... 2
Prefilter, air cleaner ......................................... 44
Preparations for storage ................................... 55
Safety cartridge, air cleaner ............................. 45
Safety details .................................................... 10
Safety precautions for care and maintenance .. 12
Safety precautions for handling materials ....... 12
Safety precautions for operation ...................... 11
Starting the engine ........................................... 23
Stopping the engine ......................................... 27
Storage ............................................................. 57
Taking out of storage ....................................... 57
Technical data .................................................. 58
Troubleshooting, control unit .......................... 18
Troubleshooting, coordinator .......................... 20
Type designations ............................................ 14
Vacuum indicator ............................................ 44
Valve clearances .............................................. 51
Warranty ............................................................ 1
Glycol .............................................................. 37
62
2004-11:2