Scania DI12, DC12. Industrial engine. Operator’s Instruction - page 1
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Operator’s Manual
DI12 DC12
Industrial engine
opm96-12a en
1 588 546
2001-05:1
Industrial & Marine Engines
IMPORTANT INFORMATION
When working on the engine, e.g. when adjusting the belts, changing oil or adjusting the clutch it is
important that the engine does not start. The engine may be damaged but above all there is -
SERIOUS RISK OF INJURY.
For this reason, always secure the starting device or disconnect a battery cable
before working on the engine.
This is especially important if the engine has a remote starter or automatic starting.
This warning symbol and text is reproduced beside those maintenance points where it is
especially important to consider the risk of injury.
!
START-UP REPORT - WARRANTY
When the start-up report has been filled in and sent to Scania there is a 1 year warranty starting from
the start-up date. Also enter the below information since this will facilitate contacts with e.g. service
workshops.
Engine number
Start-up date
User’s name and address
Signature
Engine type
Variant
Engine type and variant are indicated on the engine type plate
2
FOREWORD
This operator’s manual describes the operation and maintenance of Scania
DC12 and DI12 Industrial Engines. The instructions apply to engines
in programme 96 from engine serial number 5 997 001 onwards.
The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder
inline diesel type. The engines are equipped with turbocharger and charge air
cooler, refer to page 10.
The engines are typically used in earthmoving equipment, generator sets,
agricultural, railway and forestry machinery as well as power units in
irrigation systems.
The engines are available with different power output and engine speed
settings.
The normal output setting of the engine (performance code) is indicated on
the type plate, see page 10.
Note:
Only standard components are described in the operator’s
manual. Regarding special equipment, refer to the instructions of
the relevant manufacturer.
In order to obtain the best value and service life from your engine, there are a
few points to bear in mind:
- Read the manual before starting to use the engine. You will find new
information in this Operator’s Manual even if you have previous
experience of Scania engines.
- Follow the maintenance instructions. Proper maintenance is essential to
keep the engine operating correctly and to increase engine life.
- Pay special attention to the safety information beginning on page 6.
- Get to know your engine so that you know what it can do and how it
works.
- Whenever necessary, always contact an authorised Scania workshop.
They have special tools, genuine Scania parts and trained staff with
practical experience of Scania engines.
Note:
Always use genuine Scania parts in service and repair to keep the
engine operating correctly.
The information in this manual was correct at the time of going to press.
However, we reserve the right to make changes at any time, without prior
notice.
Scania CV AB
Industrial and Marine Engines
S-151 87 Södertälje, Sweden
During the warranty period,
only use genuine Scania parts in
service and repair for the
warranty to be valid.
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENVIRONMENTAL RESPONSIBILITY . . . . . . 4
CERTIFIED ENGINES . . . . . . . . . . . . . . . . . . . . 5
SAFETY DETAILS . . . . . . . . . . . . . . . . . . . . . . . 6
Safety precautions for operation . . . . . . . . . . . . 7
Safety precautions for handling materials . . . . . 8
Safety precautions for care and maintenance . . 8
TYPE DESIGNATIONS . . . . . . . . . . . . . . . 10
DEC2 CONTROL SYSTEM . . . . . . . . . . . . 12
STARTING AND RUNNING . . . . . . . . . . . 19
AT FIRST START . . . . . . . . . . . . . . . . . . . . . . . 19
CHECKS BEFORE RUNNING . . . . . . . . . . . . . 21
STARTING THE ENGINE . . . . . . . . . . . . . . . . 21
At temperatures below 0 °C: . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Coolant temperature . . . . . . . . . . . . . . . . . . . . 23
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STOPPING THE ENGINE . . . . . . . . . . . . . . . . . 24
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CHECKS AFTER RUNNING . . . . . . . . . . . . . . 25
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 26
ENGINES WITH FEW HOURS OF
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MAINTENANCE SCHEDULE . . . . . . . . . . . . . 27
LUBRICATING OIL SYSTEM . . . . . . . . . 28
OIL GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CHECKING THE OIL LEVEL . . . . . . . . . . . . . 29
Checking oil level during operation . . . . . . . . 29
OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CLEANING THE OIL CLEANER . . . . . . . . . . 30
RENEWING THE OIL FILTER . . . . . . . . . . . . 32
COOLING SYSTEM . . . . . . . . . . . . . . . . . . 32
CHECKING THE COOLANT LEVEL . . . . . . . 32
CHECKING THE COOLANT . . . . . . . . . . . . . . 33
CLEANING THE COOLING SYSTEM . . . . . . 36
Internal cleaning . . . . . . . . . . . . . . . . . . . . . . . 37
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 38
CLEANING OR CHANGING THE
FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . 38
RENEWING THE SAFETY CARTRIDGE . . . . 39
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 40
CHECKING THE FUEL LEVEL . . . . . . . . . . . . 40
RENEWING THE FUEL FILTER . . . . . . . . . . . 40
CHECKING THE INJECTORS . . . . . . . . . . . . . 41
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 42
CHECKING THE ELECTROLYTE LEVEL IN
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CHECKING THE STATE OF CHARGE IN
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CLEANING THE BATTERIES . . . . . . . . . . . . . 42
CHECKING THE COOLANT LEVEL
MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CHECKING THE TEMPERATURE
MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CHECKING THE TEMPERATURE SENSOR . 44
CHECKING THE OIL PRESSURE
SENSOR/MONITOR . . . . . . . . . . . . . . . . . . . . . 45
CHECKING THE OIL PRESSURE MONITOR
FOR DEC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
RENEWING THE BATTERY . . . . . . . . . . 46
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 46
CHECKING THE DRIVE BELT . . . . . . . . . . . . 46
CHECKING FOR LEAKAGE, RECTIFY AS
NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CHECKING/ADJUSTING VALVE
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CHANGING (
CRANKCASE VENTILATION VALVE. . . . . . 50
LONG-TERM STORAGE . . . . . . . . . . . . . . 51
Preservative fuel . . . . . . . . . . . . . . . . . . . . . . . 51
Preservative oil . . . . . . . . . . . . . . . . . . . . . . . . 52
Preparations for storage . . . . . . . . . . . . . . . . . 52
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Taking out of storage . . . . . . . . . . . . . . . . . . . 53
TECHNICAL DATA . . . . . . . . . . . . . . . . . . 54
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4
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 operator’s manual contains highlighted text urging you to protect the
environment in different service and maintenance operations.
Refer to example
Always use suitable containers
to avoid spillage when bleeding
systems or renewing
components.
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 10.
The following is required for the engine to meet the emission standards after
being commissioned:
- Service and maintenance must be performed according to this
Operator’s Manual.
- Only genuine Scania parts must be used.
- Service work on the injection equipment must be performed by an
authorized Scania workshop.
- The engine must not be modified with equipment not approved by
Scania.
- Seals and setting data may only be broken/modified after approval by
Scania, Södertälje. Changes should only be made by qualified
personnel.
- 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.
Important!
If service and maintenance are not performed as stated
above, Scania cannot guarantee that the engine corresponds
to the certified configuration and will not assume liability for
any damage occurring.
6
SAFETY DETAILS
General
This Operator’s 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
Note
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
The safety precautions that must be observed in the operation and
maintenance of Scania engines are compiled on the following three pages.
The corresponding text is also often stated next to the maintenance step
concerned, shown with different degrees of significance as described above.
All items are marked with a
!
to highlight the importance of reading each
item in the section.
A general safety rule is that no smoking is allowed:
•
Near the engine and the engine bay
•
When refuelling and near the filling station
•
When work is performed on the fuel system
•
Near flammable or explosive materials (fuel, oils, batteries, chemicals
etc.)
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK
OF INJURY.
Only use Scania genuine fuel
filter.
7
Safety precautions for operation
Daily inspection
Always perform visual inspection of the engine
and engine bay before the engine is started and
when the engine has been stopped after oper-
ation.
This will make it easy to detect any leakage of
fuel, oil or coolant or any other abnormal condi-
tion that may require remedial action.
Refuelling
When refuelling, there is a risk of fire and explo-
sion. The engine must be stopped and smoking
is not allowed.
Do not overfill the tank, since the fuel may ex-
pand, 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 in-
jectors.
This could cause engine damage and possibly
personal injury.
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.
Starter lock
If the control panel is not fitted with a key
switch, the engine bay should be fitted with a
lock to prevent unauthorized starting of the en-
gine.
Alternatively, a lockable main switch or battery
master switch may be used.
Starting spray
Never use starting spray or similar as a starting
aid. An explosion may occur in the intake pipe,
which could cause personal injury.
Operation
The engine should not be operated in environ-
ments 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 en-
gine 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.
8
Safety precautions for handling
materials
Fuel and lubrication oil
All fuels and lubricants as well as many chemi-
cals are flammable. Always follow the instruc-
tions stated on the container.
All work on the fuel system must be performed
when the engine is cold. Fuel leakage and spill-
age on hot surfaces may cause fire.
Store drenched rags and other flammable ma-
terials in a safe way to avoid spontaneous com-
bustion.
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 in-
hibitors, preservation oils, degreasers etc. are
hazardous. Always follow the safety precau-
tions 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.
Safety precautions for care and
maintenance
Stop the engine
Always stop the engine before any mainte-
nance and service work unless otherwise
stated.
Prevent unauthorized starting by removing the
starter key and turning off the power by the
main switch or the battery disconnect switch,
locking it in the off position. Also attach a warn-
ing tag, stating that work on the engine is in
progress, at a suitable location.
It is always a safety hazard to work on an en-
gine that is running. Parts of your body or cloth-
ing, or a dropped tool may get stuck in rotating
parts, causing bodily injury.
Hot surfaces and fluids
A hot engine always presents a risk of scalding.
Always take care not to touch the exhaust
manifold, turbocharger, oil pan, hot coolant and
oil in pipes and hoses.
Lifting the engine
Use the engine lifting eyes when lifting the
engine. First check that the lifting equipment is
in proper condition and has sufficient lift capac-
ity rating.
Auxiliary equipment fitted to the engine may
cause the centre of gravity to be displaced.
Thus, additional lift devices may be required in
order to provide proper balance and a safe lift.
Never work below a suspended engine!
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 author-
ized waste disposal contractor.
9
Electrical system
Before work is performed on the electrical sys-
tem, turn off the power by the main switch or the
battery disconnect switch.
Also disconnect any external power supply to
auxiliary equipment on the engine.
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 con-
nect it to the engine or in such a way that the
current can pass through a bearing.
After the welding is completed, connect the ca-
bles 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 fill-
er cap removed since oil will be ejected force-
fully.
Dispose of used oil through an authorized
waste disposal contractor.
Cooling system
Never open the coolant filler cap while the en-
gine is hot. Steam and hot coolant can come
out forcefully and cause scalding.
If the cooling system must still opened or disas-
sembled 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.
Dispose of used coolant through an authorized
waste disposal contractor.
Fuel system
Always use gloves when checking for leaks in
or performing other work on the fuel system. Al-
ways wear eye protection when testing injec-
tors.
Fuel escaping under high pressure can pene-
trate 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 be-
fore 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 in-
stalled. Otherwise there is a risk of objects en-
tering the compressor wheel or a risk of
personal injury from contact with it.
10
TYPE DESIGNATIONS
The engine designation indicates, in the form of a code, the type of engine, its
size and intended use, 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 serial
number is also stamped into the cylinder block on the right hand side.
See arrow in the illustration.
Engines that are certified regarding smoke and emissions are fitted with a
certification plate specifying the documents they conform to.
DI 12 40 A 01 E
Type
DC
Supercharged diesel engine with air-cooled charge air cooler
DI
Supercharged diesel engine with liquid-cooled charge air cooler
Displacement in whole dm
3
Performance and certification code
Indicates, together with the application code, the normal gross engine
output.
The actual output setting of the engine is indicated on the engine card.
Application
A
For general industrial use
Variant 01-99
Type of governor
E
Electronically controlled governor (DEC2)
D
RQ, single-speed governor and electronically controlled auxiliary
governor (GAC)
T
RQ, single-speed governor
11
The illustrations show a typical DI12 engine configuration.
Your engine may have different equipment from the one shown.
1.
Type plate
2.
Engine serial number,
stamped into the cylinder
block
3.
Oil cooler
4.
Oil dipstick
5.
Oil cleaner
6.
Oil filter
7.
Draining, engine oil
8.
Coolant pump
9.
Charge air cooler
10.
Turbocharger
11.
Injection pump
12.
Fuel filter
13.
Starter motor
14.
Alternator
15.
Automatic belt tensioner
16.
Draining, coolant
17.
Oil top up
3
4
1, 2
12
15
8
17
7
10
16
9
5
13
6
14
11
12
DEC2 CONTROL SYSTEM
This engine has an injection pump with an electromagnetic actuator which
adjusts the control rack to give the correct amount of fuel.
The system which controls the pump is called DEC2 (Digital Engine Control,
generation 2).
The control unit (DEC2) continuously receives signals from sensors for
engine speed, charge air temperature and pressure, coolant temperature, oil
pressure, throttle position and control rack travel in the injection pump. Using
this input data and a control program, the correct amount of fuel for the
current operating conditions can be calculated.
The system’s sensors may be used only for DEC2, not for other instruments
or other monitoring purposes.
The control unit contains monitoring functions to protect the engine in the
event of a fault which would otherwise damage it. Faults and the more
important monitoring functions are indicated on the control unit in the form
of light emitting diodes. See illustration on page 15 for a description.
In case of a fault, the Power - or Shutdown indicator on the DEC2 control
unit as well as the main indicator lamp on the main supply box and the
instrument panel will illuminate.
If a fault has been indicated on the main indicator lamp the operator can
determine the cause of the fault with the help of the LEDs on the control unit
and the troubleshooting schedule on page 18, and carry out the required
investigation and remedy.
Depending on the nature of the fault, the control system will take different
actions to protect the engine such as reducing the power output, keeping the
engine running at a constant low speed or, in case of a function impairing
fault, shutting down the engine (Shutdown).
To enable readout of LED fault codes there is a lamp test/fault code switch
located in the main supply box near the control unit.
A PC based program is also available to help service personnel to detect and
rectify faults and to adjust certain parameters in the operating program.
Diagnostics and changes to programs must only be performed by
authorized personnel.
The locations of the sensors and monitors that send signals to the control unit
are shown in the illustrations on pages 13 and 14.
There is a description of the functions of the LEDs during normal operation
on page 15.
On page 16 there is a description of the functions of the LEDs in case of a
fault and actions in case of Power- and Shutdown indication.
Troubleshooting and fault code reading are described on pages 17 and 18.
13
Location of sensors for DEC2 on DI12
1.
Connection of lead to charge air
temperature sensor
2.
Charge air temperature sensor
3.
Oil pressure monitor
4.
Connector panel
5.
Coolant temperature sensor
6.
Engine speed sensors
6
14
Location of sensors for DEC2 on DC12
1.
Connection of lead to charge air
temperature sensor
2.
Charge air temperature sensor
3.
Oil pressure monitor
4.
Connector panel
5.
Coolant temperature sensor
6.
Engine speed sensors
15
LED functions during normal operation
Note:
The lamp test/fault code switch should not be
depressed. All LEDs come on briefly when
the control unit is powered up.
CONTROL STATUS
✹
The LED flashes continuously when the control
unit is supplied with current, regardless of
whether the engine is running or not.
SHUTDOWN
❍
The LED is out.
STARTING
✹
The LED lights up as soon as the engine turns
over on cranking and follows the programmed
starting sequence until it has been completed
and then goes out.
RUNNING
✹
The LED comes on when the engine has started
and the "Starting" LED goes out. It remains on
until the engine is stopped.
TORQUE LIMIT
✹
The LED comes on when the control unit
detects that the engine has received the
maximum permissible quantity of injected fuel
according to its power curve. This means 100%
power output at the current rpm. If the load
increases, engine rpm will decrease.
BOOST LIMIT
✹
The LED comes on when the control unit smoke
limiter restricts the maximum fuel quantity.
Operation of the smoke limiter is dependent on
the charge air pressure.
POWER
-
❍
The LED remains out during normal operation
as long as no fault is detected by the control
unit. See next page for the procedure to be
adopted in the event of a fault.
POWER
+
✹
If the control unit is programmed to allow the
engine to be operated according to more than
one power/torque curve (map), the following
applies.
The LED comes on when the engine is run at
more than 100% power output (MAP 2). It goes
out when the engine returns to the 100% power
output curve (MAP 1) or when the power output
required is less than 100%.
16
Action in case of a fault
LED indications in case of a fault
Note:
The main indicator lamp in the main supply
box and at the instrument panel has
indicated a fault. The lamp test/fault code
switch should not be depressed.
CONTROL STATUS
✹
The LED will continue to flash even in case of a
fault as long as voltage is supplied to the control
unit.
POWER
-
✹
If the LED comes on, the control unit has
detected a defect that could cause damage to the
engine if operation continues.
The control unit automatically reduces engine
power output to a predefined level if the
corresponding function has been selected.
Action: Reduce engine speed to idle if possible
and conduct troubleshooting according to
instructions on page 17 and the chart on page 18
SHUTDOWN
✹
The LED comes on and the engine is switched
off automatically in case of a severe fault that
could cause damage to the engine if operation
continues.
Action: Conduct troubleshooting according to
instructions on page 17 and the chart on page 18
If the engine has not stopped, reduce engine
speed to idle and conduct troubleshooting.
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