Scania DI12, DC12. Industrial engine. Instruction — part 3
33
6. Every 2400 hours:
CHECKING THE COOLANT
Coolant should be checked as follows:
a)
Check the appearance of the coolant.
b)
Coolant with only glycol: Check the glycol content.
c)
Coolant with only Scania Anti-corrosive:
Check the corrosion inhibitor.
The composition of the coolant is described in detail under
"Starting and running"
a)
Checking the appearance of the coolant
- Fill a container with a little coolant and check that it is clean and clear.
- If the coolant is contaminated or cloudy: consider changing the coolant
- Water added to the coolant should be clean and free from dirt of any
kind.
- Use drinkable water with a pH value of 6 - 9.
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.
- A content of 30% glycol by volume protects against freezing down to
-16°C. If further protection is needed, refer to the table on the next page
for calculating the required amount of glycol.
We recommend only nitrite-free anti-freeze glycol with the following
supplier designations:
BASF G48 or BASF D542
- Always top up the anti-freeze if its glycol content drops below 30% by
volume. A glycol content above 60% by volume will not provide greater
protection against freezing.
- 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
starts to form.
Note:
Change the coolant when cleaning the cooling system: every 4800
hours or minimum every 5 years.
Important!
If a coolant filter is used in the cooling system it must not
contain an inhibitor.
Coolant composition:
If there is a danger of freezing:
minimum 30% glycol by
volume
maximum 60% glycol by
volume
If there is no danger of freezing:
7-12% by volume
Scania Anti-corrosive
The coolant should be ready
mixed when it is poured into the
cooling system.
Never top up with only water or
only glycol.
Ethylene glycol is highly
dangerous if ingested and can
prove fatal.
Avoid skin contact with glycol.
The recommended glycol must
not be mixed with glycol having
nitrite-based anti-corrosive.
Risk for build up of sludge and
reduced cooling capacity.
34
A
A= Area to be avoided. Only for calculating glycol mix.
Coolant freezing temperature when ice starts to form at different glycol mixes
% glycol by
volume
15
20
25
30
35
40
45
50
60
Cooling
system
capacity, dm
3
Ice slush starts
to form at °C
-6
-9
-12
-16 -22 -27 -36 -46 -55
Glycol dm
3
(litres)
5
6
8
9
11 12 14 15 18
30
6
8
10
12 14 16 18 20 24
40
8
10 13
15 18 20 23 25 30
50
9
12 15
18 21 24 27 30 36
60
11 14 18
21 25 28 32 35 42
70
12 16 20
24 28 32 36 40 48
80
14 18 23
27 32 36 41 45 54
90
15 20 25
30 35 40 45 50 60
100
17 22 28
33 39 44 50 55 66
110
18 24 30
36 42 48 54 60 72
120
20 26 33
39 46 52 59 65 78
130
21 28 35
42 49 56 63 70 84
140
23 30 38
45 53 60 68 75 90
150
24 32 40
48 56 64 72 80 96
160
26 34 43
51 60 68 77 85 102
170
27 36 45
54 63 72 81 90 108
180
29 38 48
57 67 76 86 95 114
190
30 40 50
60 70 80 90 100 120
200
Curve A: Ice build up starts (slush)
Curve B: Temperature at which damage due to
freezing can occur
1. Safe range
2. Malfunctions may occur (ice slush)
3. Risk of damage by freezing
Properties of glycol at low temperatures:
- Example with 30% glycol by volume
- Ice slush starts to form at -16°C.
- There is risk for malfunctions at -30°C
- No risk of damage by freezing with a
minimum content of 30% glycol by volume
% glycol by volume
35
c)
Checking the corrosion inhibitor
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 Anti-corrosive should be used
in the coolant.
The inhibitor in Scania Anti-corrosive is free of nitrite.
The correct proportion of anti-corrosive is 7-12% by volume.
- Topping up with 1.0% Scania Anti-corrosive by volume should be done
after every 2400 hours of operation.
- Never top up with only water or only anti-corrosive!
Fluid losses must always be replaced with premixed coolant:
water + 10% by volume of Scania Anti-corrosive.
Note:
The coolant should be changed when the cooling system is
cleaned: every 4800 hours or minimum every 5 years.
Changing the coolant
1.
Remove the filler cap from the expansion tank.
2.
The coolant is drained at two points:
- the "lowest point" of the engine block, see illustration.
- the "lowest point" of the cooling system.
3.
Close the cocks.
4.
Fill up with coolant through the expansion tank’s filler hole.
Mix coolant as described on page 33.
Always collect fluid in a suitable
container to avoid spillage when
changing coolant.
Dispose of used coolant through
an authorized waste disposal
contractor.
If a coolant filter has been fitted
it must not contain inhibitor.
Mixing corrosion inhibitor with
glycol or adding too much
corrosion inhibitor may cause
deposits and reduced cooling
capacity.
Corrosion inhibitor, if
swallowed can be fatal.
Avoid contact with the skin.
36
7. Every 4800 hours:
CLEANING THE COOLING SYSTEM
Note!
If necessary, the cooling system should be cleaned more often.
External cleaning
Radiator
- Check that the radiator is not clogged on the air side and that the cooling
fins are not damaged.
- Carefully scrape the deposit off the radiator’s cooling fins. If necessary,
a paraffin-based engine cleaner can be used.
- Bent fins can be straightened using a wire brush, for example, and
exercising care.
The cooling system must never
be cleaned with caustic soda.
There is a risk of damage to
aluminium parts.
Charge air cooler (DI engine)
1.
Drain the coolant from the engine, refer to "Changing the coolant".
2.
Detach the intake manifold from the turbo.
3.
Detach the charge air cooler inlet and outlet connections.
4.
Unbolt the charge air cooler assembly from the intake manifold. The
charge air element is integrated into the housing.
Be careful - do not damage the core water connections.
5.
Clean the outside of the element. This is especially important if the
engine is equipped with closed crankcase ventilation. Use a paraffin-
based engine cleaner.
6.
Clean and degrease the sealing surfaces on the core and the air intake
pipe with a spirit based cleaner.
7.
Apply sealant (silicone 816 064) in a uniform bead, approximately
2-3 mm, on the sealing surface of the air intake pipe.
8.
Install the charge air cooler within 15 minutes of applying the sealant.
Torque tighten the bolts to 26 Nm.
9.
Refit the inlet and outlet connections with new O rings..
10.
Refit the delivery pipe clamps.
11.
Connect the intake manifold from the turbo.
12.
Fill up with coolant according to the specification
on page 33.
Important
Allow the sealant to cure for minimum
24 hours before the engine is used.
1.
Charge air
cooler housing
with core
2.
O-ring
3.
Sealant 816 064
4.
Air intake pipe
1
2
3
4
37
Internal cleaning
Removing oil and grease
- If possible, run the engine until it has reached the operating temperature
and then drain the cooling system.
- Remove the thermostat.
- Fill the system with clean, hot water mixed with liquid dishwasher
detergent intended 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
approximately 20-30 minutes.
- Drain the water from the system.
- Refit the thermostat.
- Fill up with new coolant according to the specification on page 33.
Removing deposits
- If possible, run the engine until it has reached operating temperature and
then drain the cooling system.
- Remove the thermostat.
- Fill the system with clean, hot water mixed with a commercially
available radiator cleaner based on sulphamic acid and containing
dispersing agents. Follow the manufacturer’s instructions for mixing
proportions and cleaning times.
- Run the engine for the specified time and then drain the cooling system.
- Refill the system with hot water and run the engine for approximately
20-30 minutes.
- Drain the water from the system.
- Refit the thermostat.
- Fill up with new coolant according to the specification on page 33.
Handling cleaning agents for
the cooling system:
Read the warning label on the
container.
Always collect fluid in a suitable
container to avoid spillage when
draining coolant.
Dispose of used coolant through
an authorized waste disposal
contractor.
38
AIR CLEANER
8. Daily:
CHECKING THE VACUUM INDICATOR
If the entire red plunger of the indicator is visible, renew or clean the air filter
element, paragraph 10. This is especially important if the engine is operated
under heavy load and at high engine speed.
9. Every 200 hours:
CLEANING THE AIR CLEANER
COARSE CLEANER
1.
Remove the cover from coarse cleaner 2.
2.
Remove the conical coarse separator. Empty out the particles of dirt and
clean it.
3.
Fit the coarse separator as shown in the figure and screw the cover in
place.
4
3
2
1
1.
Filter element
2.
Coarse cleaner
3.
Cover
4.
Vacuum sensor
Air cleaner with safety cartridge
The coarse cleaner must always
be fitted in an upright position.
10. Every 1200 hours:
CLEANING OR CHANGING THE
FILTER ELEMENT
Note:
Earlier if the vacuum indicator shows red
Dismantling
1.
Remove the side cover from the air cleaner.
2.
Change or clean the element.
Note
Cleaning the element always entails a risk of damaging it. The
element can be cleaned a maximum of four times. After cleaning,
it has less dust separation capacity than a new element.
3.
Mark the filter when it has been cleaned.
Cleaning the element
- Carefully blow the filter element clean using dry compressed air from
the inside.
Note
This filter element must not be washed with water.
1.
Cover
2.
Filter element
3.
Filter housing
Only use Scania genuine air
filter. Change the filter element
if it is damaged.
Danger of engine damage if the
filter element is damaged.
Never start the engine unless
the air filter is installed.
Danger of personal injury or
engine damage.
1
2
3
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 vacuum indicator by depressing the button.
11. Every 2400 hours:
RENEWING THE SAFETY CARTRIDGE
Note
Not all filters 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.
Remove the side cover from the air cleaner.
2.
Remove the filter element.
3.
Remove the safety cartridge.
4.
Fit a new genuine Scania safety cartridge.
5.
Renew or clean the filter element, refer to paragraph 10.
6.
Assemble the air cleaner.
1. Safety cartridge
Air cleaner with safety cartridge
1
Do not remove the safety
cartridge unnecessarily.
Never clean the safety cartridge
40
FUEL SYSTEM
12. Daily:
CHECKING THE FUEL LEVEL
- Top up with fuel if necessary.
- If the tank has been run dry, bleed the fuel system, refer to paragraph 13.
13. Every 1200 hours:
RENEWING THE FUEL FILTER
Fuel tanks
- Drain any water from the fuel tanks.
Filter
The filter consists of a filter unit.
- Wash the outside of the filter and unscrew it.
- Tighten the new filter by hand.
Never use a tool for tightening. The filters can be damaged,
obstructing circulation.
- Bleed the fuel system as described below.
- Start the engine and check for leaks.
Bleeding the fuel system
- Turn on the power so that the fuel shut-off valve opens.
- Undo the connection on fuel filter outlet 1 (upwards).
- Pump hand pump 3 until fuel without air bubbles flows out of the
opened connection.
- Tighten the connection on the filter.
- Undo the overflow valve 2 at the fuel shut-off valve outlet.
- Pump with the hand pump until the fuel coming out of the open
overflow valve is free of air bubbles.
- Tighten the overflow valve and pump the hand pump an additional 10
strokes.
If the engine fails to start after bleeding. . . . . . .
- Open the overflow valve again and pump the hand pump until fuel
without air bubbles flows out.
- Close the overflow valve firmly and start the engine.
1
3
2
Always collect fuel in a suitable
container to avoid spillage when
bleeding system or renewing
components.
Only use Scania genuine fuel
filter.
Observe the utmost cleanliness
when working on the fuel
system.
Malfunctions could easily occur
and the injection equipment
could be damaged.
14. Every 2400 hours:
CHECKING THE INJECTORS
Injectors should be inspected by trained personnel with access to the
necessary equipment. Inspection should be carried out at least once a year or
every 2400 hours.
Removal
1.
Clean around the injectors and connections, including clamps and
brackets.
2.
Detach the delivery pipe bundle and leak-off fuel lines.
3.
Unscrew the injector.
4.
Fit protective plugs on the injector and delivery pipe.
5.
Lift up the seal from the bottom of the injector seat if it does not come
out together with the injector.
6.
Fit a core plug in the injector seat in the cylinder head.
7.
Clean the injectors and check/adjust in a nozzle tester.
Correct opening pressure, see Technical data, page 54.
Fitting
1.
Check that there is no old seal in place and fit a new seal in the bottom
of the injector seat.
2.
Fit a new O-ring in the socket nut and a new seal under the socket nut.
3.
Fit the injector.
4.
Tighten the socket nut to 70 Nm (7.0 kpm).
5.
Fit the delivery pipe and tighten the union nuts to 20 Nm (2.0 kpm). Fit
clamps and brackets.
Important
Take care to fit the delivery pipe without tension and make sure
that the cone on it is correctly positioned in the connection.
6.
Fit the leak-off fuel line. Tighten the bolts to 11 Nm (1.1 kpm).
1.
Threaded
socket nut
2.
O-ring
3.
O-ring
4.
Stop ring
5.
Guide pin
6.
Seal
1.
Delivery pipe
2.
Union nut
3.
Washer
4.
Cone
5.
Connection on injector or
injection pump
The delivery pipes must
not be bent.
All clamps must be refitted.
Always wear gloves and eye
protection when testing
injectors.
Fuel escaping under high
pressure can penetrate body
tissue and cause serious injury.
42
ELECTRICAL SYSTEM
15. Every 200 hours:
CHECKING THE ELECTROLYTE
LEVEL IN BATTERIES
1.
Unscrew the plugs and check the electrolyte level in all cells.
2.
Top up with distilled water until the level is 10-15 mm above the plates.
16. Every 200 hours:
CHECKING THE STATE OF CHARGE IN
BATTERIES
Note:
Every 200 hours applies to generator sets and the like. Other
installations every 1200 hours.
- Check the density with an acid tester.
In a fully-charged battery it should be:
1.280 at +20°C
1.294 at 0°
1.308 at -20°C
- If the density is below 1.20, the battery must be charged. A discharged
battery freezes at -5°C.
Do not rapid-charge the batteries. This will damage the battery in the
long run.
17. Every 200 hours:
CLEANING THE BATTERIES
Note:
Every 200 hours applies to generator sets and the like. Other
installations every 1200 hours.
1.
Clean batteries, cables and cable terminals.
2.
Check that all cable terminals are firmly tightened.
3.
Grease battery terminal posts and cable terminals with vaseline.
Wear gloves and eye protection
when charging and
handling batteries.
Batteries contain a highly
corrosive acid.
Do not connect the cables to the
wrong terminals.
This could cause serious
damage to the electrical system.
If the terminals are
shortcircuited, sparks
will be generated.
Do not let open flame or sparks
come near the batteries.
When batteries are charged,
they emit highly flammable
fumes that can explode.
Do not let open flame or sparks
come near the batteries.
When batteries are charged,
they emit highly flammable
fumes that can explode.
43
18. Every 1200 hours:
CHECKING THE COOLANT LEVEL
MONITOR
(optional equipment)
1.
Start the engine.
2.
Lower the coolant level in the expansion tank.
3.
Automatic stop in case of fault: The engine stops, the indicator lamp
comes on and the buzzer sounds if the level monitor is OK.
4.
Without automatic stop in case of fault: The indicator lamp comes on
and the buzzer sounds if the level monitor is OK.
5.
Top up coolant to the correct level, refer to page 32.
2-pin level monitor installed in
coolant expansion tank delivered
by Scania
Always use a suitable container
to avoid spillage when
draining coolant.
Dispose of used coolant through
an authorized waste disposal
contractor.
44
19. Every 1200 hours:
CHECKING THE TEMPERATURE
MONITOR
1.
Drain the coolant, allowing the temperature monitor to be removed.
2.
Remove the temperature monitor cable(s).
3.
Unscrew the monitor.
4.
Refit the cable(s) to the monitor.
5.
Submerge the monitor sensor body in water. Heat the water slowly
(approx. 1° minute) using e.g. an immersion heater.
6.
Set the control switch to "ON". Use a thermometer to check that the
warning lamp comes on or that an alarm is initiated at the correct
temperature.
The correct temperature is stamped on the hexagonal part of the
monitor.
The monitor tolerance is
±
3°.
CHECKING THE TEMPERATURE
SENSOR
1.
Drain the coolant, allowing the temperature sensor to be removed.
2.
Remove the temperature sensor cable(s).
3.
Unscrew the sensor.
4.
Connect an ohmmeter to the temperature sensor.
5.
Submerge the sensor body in water. Heat the water slowly
(approximately 1° per minute) using e.g. an immersion heater.
6.
Check the resistance at the temperatures given below.
7.
The sensor should give the following readings:
At temp. °C
Resistance
Ω
Tolerance °C
60
134
±
13.5
±
4
90
51.2
±
4.3
±
3
100
38.5
±
3
±
3
2-pole temperature sensor
C =Common connection
1 = Connection C -1 closes at the
stamped temperature
2 =Connection C -2 opens at the
stamped temperature
2-pole temperature monitor
Always use a suitable container
to avoid spillage when
draining coolant.
Dispose of used coolant through
an authorized waste disposal
contractor.
20. Every 1200 hours:
CHECKING THE OIL PRESSURE
SENSOR/MONITOR
Sensor function
Measure the sensor output voltage (pin 3) at different oil pressures. The
sensor output voltage shall be as follows:
0.85-1.15 bar = 2.45 volt
1.80-2.20 bar = 3.70 volt
2.75-3.25 bar = 4.50 volt
3.79-4.20 bar = 5.20 volt
4.55-5.45 bar = 5.70 volt
5.40-6.6 bar
= 6.10 volt
The tolerances apply at +30°C - 110°C. At lower temperatures the tolerance
range is wider, e.g. 0°C = x 1.4.
Monitor function
Connect a test lamp to the oil pressure monitor, pin 4 (
-
ground), and check
that the monitor switches on at the correct pressure when the engine is started
and stopped. The monitor shall switch on at 0.7
±
0.15 bar when the engine is
stopped.
Important
The sensor/monitor must be supplied with voltage during the
measurement. Maximum 4 W load from a test lamp.
CHECKING THE OIL PRESSURE
MONITOR FOR DEC 2
Connect an ohmmeter or a test lamp to the oil pressure monitor and check
that the monitor switches off/on at the correct pressure when the engine is
started and stopped. The monitor shall switch off at 1.1
±
0.15 bar when the
engine is started and switch on at 0.7
±
0.15 bar when the engine is stopped.
4
1
3
2
46
RENEWING THE BATTERY
Removal
1.
Disconnect the negative cable (-) from the battery (cable connected to
ground).
2.
Disconnect the positive cable (+) from the battery (cable connected to
starter motor).
Fitting
1.
Connect the positive cable (+) to the battery (cable connected to starter
motor).
2.
Connect the negative cable (-) to the battery (cable connected to
ground).
MISCELLANEOUS
21. Every 1200 hours:
CHECKING THE DRIVE BELT
Replace the drive belt (1) (poly V-belt) if worn or damaged.
Also check that the automatic belt tensioner (2) is working and keeps the
drive belt correctly tensioned.
On installations with dual belt circuits, the second belt circuit has a drive belt
with manual belt tensioner.
This drive belt should be tensioned to 15-20 Nm as shown in the figure.
Do not connect the cables to the
wrong terminals.
This could cause serious
damage to the electrical system.
If the terminals are short-
circuited, sparks will be
generated.
Dispose of used batteries
through an authorized waste
disposal contractor.
47
22. Daily:
CHECKING FOR LEAKAGE, RECTIFY
AS NECESSARY
- Start the engine.
- Check for oil, coolant, fuel, air and exhaust leakage.
- Tighten or change 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, refer to illustration.
a) If coolant is evident, the O-ring is leaking.
b) If oil is running out, the liner shelf is leaking.
- Check that the coolant pump drain hole (2) is not clogged, refer to
illustration. If there is leakage, renew the pump seal or the coolant pump
assembly.
A small amount of leakage from the overflow holes during the engine
running-in period is normal. (Seals and O-rings are lubricated with soap
or oil when fitted).
This leakage normally stops after a time.
Ensure that any leakage does
not pollute the environment.
In case of major leakage,
contact the nearest Scania
workshop.
48
23. Every 2400 hours:
CHECKING/ADJUSTING VALVE
CLEARANCE
Note:
Checking/adjusting valve clearance 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 changed as necessary. Tightening
torques: 26 Nm.
Intake valve clearance: 0.45 mm
Outlet valve clearance: 0.70 mm.
Alternative 1
- Position No. 1 cylinder at TDC by turning the crankshaft in its normal
direction of rotation until all four valves are closed.
- Adjust the following valves. The correct valve clearance is also stated
on the instruction plate on one of the valve covers:
- Position No. 6 cylinder at TDC by turning the crankshaft one revolution
in its normal direction of rotation and adjust the following valves:
Cylinder
1
Intake and outlet
2
Intake
3
Outlet
4
Intake
5
Outlet
Cylinder
2
Outlet
3
Intake
4
Outlet
5
Intake
6
Intake and outlet
TDC
no. 6 cylinder
TDC
no. 1 cylinder
Intake valve
exhaust valve
5
4
3
2
1
6
Cylinder numeration
FLYWHEEL
FLYWHEEL
WARNING
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK
OF INJURY.
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