Scania DI12, DC12 EMS with S6/PDE. Industrial engine. Instruction — part 4
49
19. Daily:
Look for leakage, rectify as necessary
- Start the engine.
- Check for oil, coolant, fuel, air and exhaust leaks.
- Tighten or renew leaking connections. Check the overflow holes (1)
(below the side covers) which show whether the O-rings between the
cylinder liners and crankcase are leaking, see figure.
a) If coolant is running out, the O-ring is leaking.
b) If lubricating oil is running out, the liner shelf is leaking.
- Check that the coolant pump drain hole (2) is not clogged, see figure. If
there is a leak, renew the pump seal or the complete coolant pump.
A small amount of leakage from the overflow holes during the engine
running-in period is normal. (Sealing rings and O-rings are lubricated
with soap or oil when fitted).
- This leakage normally stops after a time.
Take care to ensure that any
leaks do not cause pollution.
If serious leakage occurs,
contact your nearest Scania
workshop.
Important
!
Help protect our
environment!
50
20. Every 2,400 hours:
Check and adjust valve clearance
Note:
Checking and adjusting valve clearances should also be done
after the first 400 hours of operation.
Valve clearances should be adjusted when the engine is cold, at least
30 minutes after running.
The rocker cover gaskets should be renewed as necessary. Tightening
torques: 26 Nm.
Intake valve clearance: 0.45 mm.
Exhaust valve clearance: 0.70 mm.
Tightening torque for lock nut: 35 Nm.
Block the starting device when
working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK OF INJURY.
Openings for reading
on the flywheel housing
Readings can be taken from the flywheel through covers in the flywheel
housing either from above or underneath depending on access when fitting.
Up or down is shown on the flywheel. Both openings are fitted with a cover at
delivery.
WARNING
!
51
Order of adjustment
- Turn the flywheel counterclockwise so that the marks on the flywheel
can be seen in the lower opening in the flywheel housing (depending on
which opening the reading is to be taken from). Refer to table.
- 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.
- Checking and adjustment of the rocker arms for the PDE injectors
should be done together with the valve clearance check/adjustment. See
step 21.
- If it is not possible to take a reading in one of the covers, observe the
valve overlap, turn the flywheel counterclockwise 120
° (1/3 turn) at a
time and adjust the valves according to the table below and the unit
injectors as described on the next page.
Mark on flywheel
(reading taken through the
lower opening)
Valve overlap on
cylinder
Adjust the valves
on cylinder
TDC Down (0°)
1
6
120°
5
2
240°
3
4
TDC Down (360°)
6
1
120°
2
5
240°
4
3
Mark on flywheel
(reading taken through the
upper opening)
Valve overlap on
cylinder
Adjust the valves
on cylinder
TDC Up (0°)
1
6
300°
5
2
60°
3
4
TDC Up (360°)
6
1
300° 2
5
60°
4
3
5
4
3
2
1
6
FLYWHEEL
Cylinder numbering
52
21. Every 2,400 hours
Checking and adjusting the unit
injector rocker arms
Note:
Checking/adjusting the rocker arms for the PDE injectors
should also be done together with the valve clearance
check/adjustment after the first 400 hours of operation.
Important!
The PDE 31 unit injector is adjusted using setting tool
99 414 or a digital sliding calliper.
The PDE32 unit injector is adjusted using setting tool
99 442 or a digital sliding calliper.
This adjustment is essential as a fault in the position of the
unit injector can result in poor performance and possible
breakdown.
Readings can be taken from the flywheel through covers in the flywheel
housing either from above or underneath depending on access when fitting.
Up or down is shown on the flywheel. Both openings are fitted with a
blanking piece on delivery; see illustration on page 46.
Measurement A=
PDE31: 66.9 ±0.1 mm
PDE32: 69.9 ±0.1 mm
Measurement B=
PDE31: 36.5 mm
PDE32: 38.8 mm
53
Order of adjustment
Turn the flywheel counterclockwise so that the marks on the flywheel can be
seen in the lower opening in the flywheel housing (depending on which
opening the reading is to be taken from). Refer to table.
Mark on flywheel
(reading taken through the
lower opening)
Valve overlap on
cylinder
Adjust injector
rocker arm on
cylinder
TDC Down (0°)
1
2
120°
5
4
240°
3
1
TDC Down (360°)
6
5
120°
2
3
240°
4
6
Mark on flywheel
(reading taken through the
upper opening)
Valve overlap on
cylinder
Adjust injector
rocker arm on
cylinder
TDC Up (0°)
1
2
300°
5
4
60°
3
1
TDC Up (360°)
6
5
300°
2
3
60°
4
6
54
PDE31:
1.
Firstly, measure the distance (A) between plane (a) and the top edge of
the valve spring washer on the unit injector using a digital sliding
calliper. See figure.
2.
Dimension (A) should be 66.9 mm for PDE31 (dimension B=36.5 mm).
3.
The dimension is adjusted by undoing the lock nut and screwing the
rocker arm adjusting screw (1) to the correct measurement.
WARNING! Take care when carrying out the adjustment if the
dimension is well outside the adjustment dimension. The
spring is pre-tensioned and can cause personal injury if it is
released.
4.
Position setting tool 99 414 with the metal plate around the injector
spring.
5.
Finely adjust dimension (A ) by simultaneously using a finger to sense
that the small piston (2) is level with the flat upper surface of the tool. It
is possible to feel differences of less than a tenth of a millimetre.
6.
If the setting tool is not available, a digital sliding calliper can also be
used for fine adjustment. The rocker position is adjusted using 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:
No further checking or adjustment of the unit injector, such as
checking the opening pressure, must be done. If an injector is
defective, the whole injector must be replaced.
Piston level with the flat surface.
Adjustment is correct.
Piston above or below the flat
surface. Adjustment necessary.
66.9
99 414
55
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 sliding
calliper. See figure.
2.
Dimension (A) should be 69.9 mm for PDE32 (dimension B=38.8 mm).
3.
The dimension is adjusted by undoing the lock nut and screwing the
rocker arm adjusting screw (1) to the correct measurement.
WARNING! Take care when carrying out the adjustment if the
dimension is well outside the adjustment dimension. The
spring is pre-tensioned and can cause personal injury if it is
released.
4.
Position setting tool 99 442 with the metal plate around the injector
spring.
5.
Finely adjust dimension (A ) by simultaneously using a finger to sense
that the small piston (2) is level with the flat upper surface of the tool. It
is possible to feel differences of less than a tenth of a millimetre.
6.
If the setting tool is not available, a digital sliding calliper can also be
used for fine adjustment. The rocker position is adjusted using 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:
No further checking or adjustment of the unit injectors, such as
checking the opening pressure, must be done. If an injector is
defective, the whole injector must be replaced.
Piston above or below the flat
surface. Adjustment necessary.
Piston level with the flat surface.
Adjustment is correct.
69.9
99 442
56
22. Every 2,400 hours:
Renewing (or cleaning) the closed
crankcase ventilation valve
Alternative 1:
Renew the valve at the specified interval.
Alternative 2:
- Dismantle the valve after the specified interval.
- Clean the valve by placing it in a bath of diesel fuel oil overnight. Then
rinse it several times in diesel oil and allow it to drip dry.
- Refit the valve.
- The valve may be reused (cleaned), but not more than twice after the
first 2,400 hours of use. Take care to mark the valve after cleaning it.
57
Preparing the engine for
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 for 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 renewal, lubrication,
etc.).
Preservative coolant
If the engine is being stored with coolant in the system, the coolant should
contain 50% glycol by volume. Glycol without nitrite-based inhibitor should
be used. For example BASF G48 or BASF D542.
Preservative fuel
- Use diesel fuel oil mixed with Lubrizol 560H or equivalent.
- Mix 1 cm
3
(ml) Lubrizol 560H in 10 dm
3
(l) of fuel.
Ethylene glycol is highly
dangerous if imbibed and can
prove fatal.
Avoid contact with the skin.
HANDLING LUBRIZOL 560H
Hazardous!
Contains aromatic hydrocarbons
Use spot extractors where there is a danger of vapour build-up.
Wear protective gloves and goggles when handling Lubrizol. Do not use contaminated clothing.
If it gets in your eyes: Rinse with a gentle stream of water (at least 15 minutes). Seek medical attention.
If it gets on your skin: Wash the affected area with soap and water.
If inhaled:
Fresh air, rest and warmth.
Flammable:
Fire class 2A. Flashpoint +27°C.
In the event of fire: Extinguish with carbon dioxide, powder or foam.
Storage:
In well-sealed receptacle in a dry, cool place. Keep out of reach of children.
!
WARNING
!
58
Preservative oil
Suitable preservative oils are available from most oil companies.
For example Dinitrol 40 or equivalent.
Preparations for storage
- Drain and flush the cooling system. Top up with preservative coolant.
- Warm up the engine on normal fuel. Stop the engine and drain the oil.
- Renew the fuel filter.
- Fill the engine with preservative oil up to the minimum level on the
dipstick.
- Mix preservative fuel in a can. Detach the fuel pipe at the feed pump
suction line and connect a hose from the can.
- Detach the fuel pipe at the overflow valve and connect a return hose to
the can.
- Start the engine and run it at about 1,000 rpm (not single-speed engines)
for 20-25 minutes.
- Stop the engine, remove the hoses and connect the normal fuel pipes.
- Remove the rocker covers and lubricate the valve mechanisms and unit
injector mechanisms with preservative oil. Refit the rocker covers.
Note:
The unit injectors are not to be removed.
- Drain the preservative oil from the engine. Fresh engine oil can be filled
directly or when the engine is taken out of storage.
- Drain the coolant if the engine is not to be stored with coolant in the
system. Plug and tape over all coolant connections (if the cooling system
is not completely assembled).
- Air cleaner: Clean or renew the filter element.
- Cover air intakes and exhaust pipes.
- Alternator and starter motor:
- Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or the
equivalent.
- Spray the outside of bright engine parts with penetrating preservative
oil, for example Dinitrol 25B, and then with Dinitrol 112 or equivalent.
Use a container to avoid spills
when draining the oil and
coolant.
Dispose of used oil and coolant
through an authorised waste
disposal contractor.
Help protect our
environment!
59
- Attach a label to the engine, clearly stating the storage preparation
date and that the engine must not be started or cranked.
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 applies to short-term storage, even 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).
Taking out of storage
(Procedure for taking the engine into operation)
- Remove plugs and tape from coolant connections, air intakes and
exhaust pipes.
- Fill the system with coolant, see page 24.
- Check the oil level in the engine or fill up with fresh motor oil.
- Lubricate the valve mechanisms and their pushrods and valve tappets as
well as the unit injector mechanisms.
- Drain the preservative fuel from the fuel manifold and fuel filter.
- Connect and bleed the fuel system, see page 44.
- Wash off any externally applied preservative oil using white spirit.
ENGINE PREPARED FOR
LONG-TERM STORAGE
Date. . . . . . . . . . . .
Do not start or crank!
Wear gloves and protective
goggles when charging and
handling batteries.
The batteries contain a highly
corrosive acid.
WARNING
!
60
Technical data
General
DC12
DI12
Number of cylinders
6 in line
Cylinder diameter
mm
127
Piston stroke
mm
154
Displacement
dm
3
(litres)
11.70
No. of main bearings
7
Firing order
1 - 5 - 3 - 6 - 2 - 4
Compression ratio
18:1
Engine direction of rotation viewed from rear
Counterclockwise
Fan direction of rotation viewed from front
Clockwise
Cooling
Liquid
Valve clearances, cold engine
intake valve
mm
outlet valve
mm
0.45
0.70
Weight, without coolant or oil
kg
*With charge air cooler, radiator, expansion tank and
pipes
1,065*
§
995
Power
see "Engine record card"
Lubrication system
Maximum oil pressure
(warm engine at a speed above
1,000 rpm
bar (kp/cm
2
)
6
Normal oil pressure
(hot engine at operating speed)
bar (kp/cm
2
)
3-6
Minimum oil pressure
(hot engine 1,000 rpm
bar (kp/cm
2
)
1.0
Oil capacity, see page 33
Crankcase pressure with closed crankcase
ventilation
mm VP
-55 - +20
61
Fuel system
DC12
DI12
Pump setting BTDC
See plate on rocker cover
Low idling
rpm
700 (adjustable 500-800)
Maximum full load speed
See engine card
Fuel
Diesel fuel oil
1
1
see page 62
Cooling system
Number of thermostats
1 (dual thermostat)
Thermostat, opening temperature
°C
75
Coolant temperature:
system at atmospheric pressure
°C
system at overpressure
°C
70-93
70 - approximately 100
Capacity, including radiator, engine and expansion tank
and, for DI12, also charge air cooler
with 0.75 m
2
radiator
dm
3
(litres)
with 1.0 m
2
radiator
dm
3
(litres)
with 1.2 m
2
radiator
dm
3
(litres)
54
56
59
61
63
65
Electrical system
System voltage
V
24
Alternator, current
A
65 or 100
Starter motor output
kW (hp)
6.7 (9.1)
Monitors, threshold values:
oil pressure monitor
bar (kp/cm
2
)
temperature monitor
°C
1.0
±
0.15
Stamped on hexagonal part of monitor
62
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 workshop manual in sections which can be ordered from
Scania dealers or directly from Scania. Scania’s address 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.
Environmentally friendly fuels (low sulphur fuels)
There are three classes of environmentally friendly fuels (SS15 54 35).
Class 1 is sulphur-free and class 2 is low in sulphur. Compared with class 3
(normal fuel), these fuels are less dense and this reduces engine power output.
Only class 1 fuel should be used with a catalytic converter.
Short term use of fuel with a higher sulphur content than 0.05% by weight
will not cause permanent damage to the catalytic converter.
The catalytic converter may, however, require fuel with low sulphur content
for some time after this to regain its normal efficiency.
Property
Requirements
Viscosity at 40°C
2.0-4.5 mm
2
/s (cSt)
Density at 15°C
0.82-0.86 kg/dm
3
Sulphur (concentration by mass)
max. 0.3%
Ignitability (CET rating)
min. 49
Flashpoint
56°C
63
Temperature dependence of diesel fuel
At temperatures lower than those specified for the diesel fuel, paraffin wax
may precipitate from the fuel and block filters and pipes. The engine can then
lose power or stop.
The diesel fuel is adapted for use in the specific climate of each country. If a
vehicle or an engine is to be operated in a temperature zone with lower
temperature than normal, first identify the temperature properties of the fuel
concerned.
The properties of the fuel when cold can be improved by adopting one of the
following measures before the temperature drops:
- If the fuel concerned cannot cope with the expected temperatures, and
diesel fuel is not available with the correct temperature properties, we
recommend that an electric fuel heater is installed as a preventative
measure.
- The low temperature properties of diesel fuel may be improved by
adding kerosene as a preventative measure. Maximum 20% may be
added. When refuelling, the kerosene should be added first, so that it
mixes thoroughly with the diesel fuel.
Note:
It is prohibited to use kerosene in engine fuel in
some countries.
- To prevent water in the fuel from freezing and forming ice, a maximum
of 0.5-2% alcohol (isopropanol) may be added.
Drain fuel tanks and drain or renew fuel filters regularly.
It is not permitted to mix
kerosene with diesel fuel that is
already adapted for the climate
concerned. The unit injectors
can fail. All use of paraffin
other than kerosene is
forbidden, as it causes engine
damage.
It is not permissible to mix
petrol with diesel fuel. In the
long term, petrol may cause
wear to the unit injectors and at
worst it may also cause damage
to the engine.
Important
!
WARNING
!
64
Alphabetical index
Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Unit injector. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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