Scania D11, DC11, DI11. Industrial engine. Instruction — part 1
IMPORTANT INFORMATION
When working on the engine, for example adjusting drive belts, oil change or adjusting the clutch,
it is important not to start the engine. The engine may be damaged and 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, you have a 1-year warranty from the date of
start-up. Also fill in the particulars below as this can make things easier if you need to contact for example a
service workshop.
Operator’s Instruction
D11 DC11 DI11
Industrial engine
opm96-11a en
1 588 293
1997-11:2
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
!
Industrial & Marine Engines
2
FOREWORD
This instruction instruction describes the operation and maintenance of the
Scania D11, DC11 and DI11 Industrial Engines. These instructions apply to
engines in program 96 from engine number 5 364 870.
The engines are direct injection, fluid-cooled, four-stroke diesel engines with
6 cylinders in line. The engines are available with or without charge air
cooler, see page 4.
Common applications are construction machinery and gensets, in agricul-
tural, railway and forestry machinery and as power for irrigation installa-
tions.
The engines may have different powers and speed settings.
The normal power setting of the engine (performance code) is indicated on
the type plate, see page 4.
Note!
Only standard components are described in the instruction man-
ual. For special equipment, refer to the instructions issued by the
manufacturer.
In order to obtain the best value and service life from your engine, there are
several points to bear in mind:
- Read through the Instruction Instruction before starting to use your engine.
Even those experienced with Scania engines may find new information
in this instruction.
- Follow the maintenance instructions. Maintenance according to the
instructions forms the basis of good function and service life.
- Get to know your engine so that you know what it can do and how it
works.
- When necessary, always turn to an authorised Scania workshop. These
have special tools, genuine parts and staff with training and practical
experience of Scania engines.
The information in this instruction was correct at the time of going to press.
However, we retain the right to make alterations without prior notice.
Scania CV AB
Industrial and Marine Engines
S-151 87 Södertälje
3
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TYPE DESIGNATIONS . . . . . . . . . . . . . . . 4
STARTING AND RUNNING . . . . . . . . . . . . 6
AT FIRST START . . . . . . . . . . . . . . . . . . . . . . . . 6
CHECKS BEFORE RUNNING . . . . . . . . . . . . . . 7
STARTING THE ENGINE . . . . . . . . . . . . . . . . . 7
At temperatures below 0 °C: . . . . . . . . . . . . . . . 8
RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Coolant temperature . . . . . . . . . . . . . . . . . . . . . 9
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STOPPING THE ENGINE . . . . . . . . . . . . . . . . . 10
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . 10
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CHECKS AFTER RUNNING . . . . . . . . . . . . . . 11
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 12
ENGINES WITH FEW HOURS OF
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MAINTENANCE SCHEDULE . . . . . . . . . . . . . 13
LUBRICATION OIL SYSTEM . . . . . . . . . 14
OIL GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . . 15
Checking oil level during operation . . . . . . . . 15
OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CLEANING THE OIL CLEANER . . . . . . . . . . 16
CHANGING THE TURBO FILTER . . . . . . . 18
COOLING SYSTEM . . . . . . . . . . . . . . . . . . 18
CHECKING COOLANT LEVEL . . . . . . . . . . . 18
CHECKING COOLANT . . . . . . . . . . . . . . . . . . 19
CLEANING COOLING SYSTEM . . . . . . . . . . . 22
Internal cleaning . . . . . . . . . . . . . . . . . . . . . . . 23
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 24
TEST READING
LOW PRESSURE INDICATOR . . . . . . . . . . . . 24
CLEANING THE AIR CLEANER
COARSE CLEANER . . . . . . . . . . . . . . . . . . . . . 24
CLEANING OR CHANGING
FILTER INSERT . . . . . . . . . . . . . . . . . . . . . . . . 24
CHANGING THE SAFETY CARTRIDGE . . . . 25
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 26
CHECKING FUEL LEVEL . . . . . . . . . . . . . . . . 26
CHANGING THE FUEL FILTER . . . . . . . . . . . 26
CHECKING INJECTORS . . . . . . . . . . . . . . . . . 27
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 28
CHECKING ELECTROLYTE LEVEL
IN BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . 28
CHECKING CHARGE
STATE IN THE BATTERIES . . . . . . . . . . . . . . 28
CLEANING BATTERIES . . . . . . . . . . . . . . . . . 28
CHECKING COOLANT
LEVEL MONITOR . . . . . . . . . . . . . . . . . . . . . . 29
CHECKING TEMPERATURE MONITOR . . . 30
CHECKING TEMPERATURE SENSOR . . . . . 30
CHECKING THE OIL PRESSURE MONITOR 31
CHECKING OIL PRESSURE SENSOR . . . . . . 31
CHECKING THE STOP FEATURE . . . . . . . . . 31
CHANGING BATTERY . . . . . . . . . . . . . . 33
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 33
CHECK/TENSION
V-BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
LOOK FOR LEAKAGE,
REMEDY AS NECESSARY . . . . . . . . . . . . . . 34
CHECK/ADJUST
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . 35
CHANGING (
FOR CLOSED CRANKCASE VENTILATION 36
LONG-TERM STORAGE . . . . . . . . . . . . . . 37
Preservative fuel . . . . . . . . . . . . . . . . . . . . . . . 37
Preservative oil . . . . . . . . . . . . . . . . . . . . . . . . 38
Preparations for storage . . . . . . . . . . . . . . . . . 38
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Taking out of storage . . . . . . . . . . . . . . . . . . . 39
TECHNICAL DATA . . . . . . . . . . . . . . . . . . 40
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ALHPABETIC INDEX . . . . . . . . . . . . . . . . 44
LIST OF CONTENTS
4
TYPE DESIGNATIONS
The engine designation indicates, in the form of a code: Engine type, size,
application etc.
The type designation and engine number are indicated on a type plate located
on the right-hand front side of the engine. The engine number is also stamped
in the engine block above the type plate.
Engines which are certified for smoke and emissions are equipped with a
plate which indicates which documents they are certified to. This plate is
located on the forward rocker cover behind the oil filler.
Certification plate
DI 11 71 A 31 S
Type
D
Supercharged diesel engine (with turbo)
DC
like D but with air-cooled charge air cooler
DI
like D but with fluid-cooled charge air cooler
Stroke 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
Governor type
D
Electronically controlled auxiliary governor
S
RSV, all-speed and single-speed governor
T
RQ, single-speed governor
1.
Typskylt
2.
Engine number,
stamped in engine block
3.
Oil cooler
4.
Oil dipstick
5.
Oil cleaner
6.
Turbo 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.
Fan belt, adjutstment
16.
Draining, coolant
17.
Oil filling
The drawings illustrate a common type of DI 11 engine.
Your engine may have other equipment not shown here.
3
5
13
6
4
1, 2
12
14
15
8
17
7
11
10
9
16
6
STARTING AND RUNNING
AT FIRST START
When the engine is started for the first time, the maintenance points listed
under ”First start” in the maintenance schedule should be followed,
see page 13.
Since these points are important for the engine to work satisfactorily right
from the start, they are also listed below.
1. Checking oil level (see page 15).
6. Checking coolant (see page 19).
The coolant should contain anti-corrosive to protect the cooling system
from corrosion.
If there is a danger of freezing:
- Only glycol anti-freeze should be used in the coolant as protection
against corrosion. We recommend only nitrite-free glycol anti-freeze
with the following supplier designations:
BASF G48 or BASF D542
- The concentration of glycol should be 30 - 60% by volume depending
on ambient temperature. 30% by volume offers protection down to
-18 °C. See page 19.
- Never top up with water only or glycol only. Lost fluid should always
be replaced with pre-mixed coolant with the same glycol content as the
coolant in the engine. If the concentration of glycol drops, both anti-
freeze and corrosion protection will suffer.
Note!
A glycol concentration below 30% by volume will not provide suf-
ficient protection against corrosion. A glycol concentration
greater than 60% will not increase anti-freeze protection and
reduces engine cooling capacity.
If there is no danger of freezing:
- Only Scania Anti-corrosive should be used in the coolant to protect
against corrosion. The correct level of anti-corrosive is 7-12% by vol-
ume and this must never drop below 7% by volume. The inhibitor in
Scania Anti-corrosive is nitrate-free.
- First fill: Fill with Scania Anti-corrosive as indicated on the packaging.
- Never top up with water only or anti-corrosive only. Lost fluid should
always be replaced with pre-mixed coolant:
water + 10% Scania Anti-corrosive by volume.
- Only coolant filter without inhibitor may be used. The use of a coolant
filter increases the life of the coolant and reduces the risk of deposit cor-
rosion.
Coolant should be topped up
when the engine is stopped
after the first start
The recommended glycols
may not be mixed with glycol
which has a nitrite-based
anti-corrosive or with
Scania Anti-corrosive
Scania Anti-corrosive must not
be mixed with glycol.
Mixing or over concentration
can cause sludging
Coolant composition:
If there is a danger of freezing:
at least 30% glycol by volume
Max. 60% glycol by volume
If there is no danger of
freezing:
7-12% by volume
Scania Anti-corrosive
12. Checking fuel level (see page 26).
15. Checking electrolyte level in batteries (see page 28).
16. Checking battery charge (see page 28)
18. Checking coolant level monitor (see page 29).
19. Checking temperature monitor (see page 30).
20. Checking oil pressure monitor (see page 31).
21. Checking stop feature (see page 31).
22. Checking v-belt tension (see page 33).
CHECKS BEFORE RUNNING
Before running, ”Daily maintenance” as described in the maintenance sched-
ule should be carried out, see page 13.
STARTING THE ENGINE
If the fuel tank has been run dry or if the engine has not been used for a long
time, bleed the fuel system, see page 26.
Out of consideration to our common environment, your new Scania engine
has been designed to be started with less fuel. Unnecessarily large fuel supply
at start will always result in the release of uncombusted fuel.
- Engines with mechanical stop control: Set the stop control to operating
position.
- Open fuel valve (if fitted).
- Declutch the engine (does not apply to engines with a fixed clutch, e.g.
gensets).
- Engines with battery master switch: Switch on the power using the bat-
tery master switch.
- Set the speed control to raised idling. (Does not apply to gensets)
- Start the engine.
Important!
A maximum of 3 start attempts per minute may be made when
the stop solenoid is activated at start. The timer module can be
damaged resulting in the loss of the stop feature.
Starting at low temperatures
Local environmental requirements should be complied with. Start aids,
engine heater and/or flame start should be used to avoid starting problems
and white smoke.
WARNING
Block the starter device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK OF
INJURY
!
8
At temperatures below 0 °C:
Note!
Use only start aids recommended by Scania.
- The starter motor may only be used for 30 seconds, after which it must
rest for 2 minutes.
If the engine has flame start:
- Operating flame start without timer relay: Press the control button
which also acts as a pre-glow button (max. 20 s). The glow plug contin-
ues to glow as long as the button is held down after the engine is started.
Max. time is 5 minutes.
- Operating flame start with timer relay: Press the pre-glow button (max.
20 s). Release the pre-glow button after the engine starts. The timer
relay keeps the glow plug working for 5 minutes. If a shorter on-time is
required, press the release button. The key must be set to 0 of the start
attempt fails.
Note!
If the engine is equipped with an INTERLOCK switch, this
should be held depressed until sufficient oil pressure has been
achieved. If the INTERLOCK switch is released too early, the
engine will stop.
- Gensets should be placed under load directly after start to avoid the risk
of white smoke. This applies especially to engines which are installed
without heating aids or addition of base load.
- Set the appropriate idle speed before the engine reaches 1,000 rpm (does
not apply to gensets).
- Run the engine until warm with a light load. A light load on a cold
engine gives better combustion and faster heating than warming up with
no load.
RUNNING
Check instruments and warning lamps at regular intervals.
Speed
The Scania tachometer is divided into different coloured sections as follows.
0 - 500 rpm
red area:
prohibited speed, passed when
starting and stopping.
500 - 700 rpm
yellow area:
low idle.
700 - 2200 rpm
green area:
normal operating speed.
Highest torque and lowest
fuel consumption at
1400 - 1600 rpm.
Low operating speed gives less
engine
wear.
2200 - 2600 rpm
yellow/green
striped:
unsuitable operating speed. Can
arise when switching off and
when using engine brake downhill.
2600 - 3000 rpm
red area:
prohibited speed.
Coolant temperature
Correct coolant temperature during operation:
70 - 93 °C for system at atmospheric pressure.
70 - about 100 °C for system with positive pressure.
High coolant temperature leads to engine damage. Reduce the load on the
engine in order to lower the temperature. If the temperature does not drop,
stop the engine and look for the fault.
During long periods of operation with very low power take-off, the engine
may have difficulty in reaching 70 °C. However, if the load is increased, tem-
perature will rise.
Cooling systems with a
Scania radiator and plastic
expansion tank must not
have positive pressure in
the system, i.e. a pressure
cap must not be used on
the expansion tank.
10
Oil pressure
Max. oil pressure:
warm engine at speed above 800 rpm
6 bar
Normal oil pressure:
warm engine at operating speed
3 - 6 bar
Min. oil pressure:
warm engine at 800 rpm
0.7 bar
At speeds below 800 rpm, the gauge may show low oil pressure without there
being a fault.
Oil pressure below 0.7 bar at speeds above 800 rpm will cause engine dam-
age. The engine must be stopped immediately.
Charge test lamp
If the lamp lights during operation:
- Check/adjust the alternator drive belts as described under maintenance
point See page 33.
- If the charge test lamp is still lit, there may be a fault in the alternator or
in the electrical system.
STOPPING THE ENGINE
1.
Allow the engine to run without load for a few minutes if it has been run
with a high continuous load.
2.
Stop the engine using the stop control. Engines with a stop solenoid are
stopped using the stop button. Hold the stop button depressed until the
engine has fully stopped.
3.
Engines with battery master switch: Cut the power using the battery
master switch. (Does not apply to emergency power back-up units).
4.
Set the control switch to 0. (Does not apply to emergency power back-
up units).
Emergency stop
The stop solenoid linkage system has a knob marked ”STOP”. Pull the link-
age system to the stop position using this knob if it is not possible to stop the
engine using the stop solenoid.
Danger of turbo damage or
boiling over if the engine is
stopped without cooling off.
The power must not be cut
until the engine has stopped.
High lubrication oil pressure
(above 6 bar) is normal when
starting a cold engine.
Clutch
- See the manufacturer’s instructions for handling and operating the
clutch.
WARNING!
If the clutch output shaft is rotating (e.g. in multiple
engine installations where other engines are running) the
clutch can, under its own power, be drawn to engaged posi-
tion.
THIS CAN CAUSE INJURY and engine damage. Always
secure the clutch in disengaged position if there is a risk of
the output shaft starting to rotate.
CHECKS AFTER RUNNING
- Check that the power is cut from the battery master switch and that the
control switch is set to ”0”.
- Fill the fuel tank. Make sure that the cap and the area around the filler
opening are clean to avoid contamination of the fuel.
- If there is a risk of freezing, the cooling system must be drained if it
does not contain sufficient anti-freeze, see page 19.
- At temperatures below 0 °C: Prepare for the next start by connecting the
engine heater (if fitted).
WARNING
Always secure the clutch in
disengaged position if there is
a risk of the output shaft
starting to rotate.
If the engine is started
during e.g. service work,
there is a
SERIOUS RISK OF
INJURY
!
12
MAINTENANCE
The maintenance programme covers 25 points, divided into the following
main groups:
Lubrication oil system . . . . . . . . . . . . . . . . . page 14
Cooling system . . . . . . . . . . . . . . . . . . . . . . . page 18
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . page 26
Electrical system, monitors, batteries etc. . . page 28
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . page 33
The maintenance points are divided into intervals as follows:
Daily maintenance
Maintenance before first start
Maintenance after the first 400 hours of operation
Periodic maintenance every 200 hours of operation (carried out after 200,
400, 600, 800 etc. hours)
Periodic maintenance after every 400 hours of operation (carried out after
400, 800, 1200, 1600 etc. hours)
Periodic maintenance after every 1,200 hours of operation (carried out after
1,200, 2,400, 3,600 etc. hours)
Periodic maintenance after every 2,400 hours of operation (carried out after
2,400, 4,800 etc. hours)
Periodic maintenance after every 4,800 hours of operation (carried out after
4,800, 9,600 etc. hours)
Maintenance every year
Maintenance every 5th year
ENGINES WITH FEW HOURS OF
OPERATION
Emergency back-up power units and the like which are not used regularly
should be test run and checked according to the unit manufacturer’s instruc-
tions.
The engine is run to operating temperature and the maintenance points below
should be carried out:
1. Checking oil level.
5. Checking coolant level.
8. Checking low pressure indicator.
12. Checking fuel level.
15. Checking electrolyte level in batteries.
16. Checking battery charge.
17. Cleaning batteries.
23. Look for leaks. Remedy as necessary
For engines with few operating
hours which do not receive
periodic maintenance
according to the maintenance
schedule on page 13,
maintenance should be carried
out according to the schedules
for:
“Every year”
“Every 5th year”
MAINTENANCE SCHEDULE
1.
More often if required
2.
For engines with few operating hours, see page 12.
3.
Earlier if low pressure indicator shows red.
4.
If inhibitor has not been topped up for five years, coolant should be changed.
Dail
y
First
time at
Interval At
least
A
t fi
rs
t s
ta
rt
400 h
200 h
400 h
1200
h
2400
h
4800
h
Ever
y ye
ar
Ever
y 5t
h ye
ar
LUBRICATION OIL SYSTEM, page 14
1. Checking oil level
l
l
2. Oil change
l1
l
3. Cleaning the lubrication oil cleaner
l1
l
4. Changing the turbo filter
l1
l
COOLING SYSTEM, page 18
5. Checking coolant level
l
6. Checking coolant
l
l4
l
7. Cleaning cooling system
l1
l
AIR CLEANER, page 24
8. Test reading low pressure indicator
l
9. Cleaning coarse cleaner
l1
l
10. Cleaning or changing filter insert
l3
l
11. Changing safety cartridge
l
l
FUEL SYSTEM, page 26
12. Checking fuel level
l
l
13. Changing main filter
l1
l
14. Checking injectors
l
l
ELECTRICAL SYSTEM, page 28
15. Checking electrolyte level in batteries
l
l2
l
16. Checking charge state of batteries
l
l2
l
17. Cleaning batteries
l2
l
18. Checking level monitor
l
l
l
19. Checking temperature monitor
l
l
l
20. Checking oil pressure monitor
l
l
l
21. Checking stop function
l
l
l
MISCELLANEOUS, page 33
22. Checking v-belts
l
l
l
23. Look for leakage. Remedy as necessary
l
24. Checking/adjusting valve clearance
l
l
25. Changing (or cleaning) valve for closed crankcase
ventilation
l
14
LUBRICATION OIL SYSTEM
OIL GRADE
The engine oil should at least meet the requirements for one of the following
oil classifications:
-Service CE or CF as per API
-CMC - D5
-Acea E3-96
- Check with your oil supplier if the oil meets these requirements.
- Specified oil change intervals apply under the provision that the sulphur
content of the fuel does not exceed 0.3% by weight.
- Viscosities as illustrated.
- At very low outside temperatures: Consult your nearest Scania repre-
sentative to avoid difficulties.
Oil analysis
Some oil companies can offer analysis of the engine oil. This analysis meas-
ures the oil’s total base number (TBN), total acid number (TAN), fuel dilu-
tion, water content, viscosity and the content of wear particles and soot in the
oil.
The result of a series of analyses forms the basis of establishing a suitable oil
change interval.
If the conditions are changed, a new oil analysis program must be undertaken
to establish a new change interval.
-40 -30 -20 -10 0 10 20 30 40
°C
SAE 10W-30
SAE 20W-30
SAE 30
SAE 40
SAE 50
SAE 5W-30
SAE 15W-40
Additives must not be used.
The oil should be able to cope
with all temperature
variations up until the next
oil change.
1.
Daily:
CHECKING OIL LEVEL
Before checking oil level: Let the engine remain stationary for at
least 1 minute.
- The correct level is between the marks on the dipstick. Top up when the
level is at the lower mark.
- Correct type, see ”Oil grade”, page 14.
Checking oil level during operation
On some engines, oil level can be checked during operation.
- Remove the oil filler cap to release the pressure in the crankcase.
- Check the level on the dipstick. Correct oil level: 10 mm below Min. or
Max. mark.
2. Every 400 hours:
OIL CHANGE
If the engine is used for particularly demanding operation,
especially in a dusty environment or if the deposits in the
centrifugal cleaner are thicker than 20 mm: Change the oil more
often.
- Unscrew the plug and drain the oil when the engine is warm.
- In certain engines, the oil is pumped out using a bilge pump.
- Clean the magnet on the plug.
- Refit the plug.
- Fill with oil.
- Check the level on the dipstick.
1 dm
3
= 1 litre
Maximum angle of inclination during operation
Maximum permitted angles during operation vary depending on the type of
oil sump, see drawing.
Note!
Given angles may only be used intermittently.
30°
20°
35°
30°
15° (or 20°)
30°
WARNING
The oil may be hot.
Wear protective gloves
and eye protection
!
10 mm
10 mm
16
3. Every 400 hours:
CLEANING THE OIL CLEANER
(at same time as oil change)
- Unscrew the nut and remove the cover.
- Lift out the rotor and slacken the nut for the rotor cover three turns.
- If the nut is stuck:
Secure the nut, absolutely not the rotor, in a vice and turn the rotor three
turns by hand or using a screwdriver.
- Gently tap the nut using your hand or a plastic hammer so that the rotor
bowl becomes detached from the bottom plate.
- Undo the nut and remove the rotor bowl.
- Carefully prise the strainer loose from the bottom plate.
- Scrape away deposits from the inside of the rotor bowl. If there are no
deposits, this shows that the cleaner is not working.
- If the deposits are thicker than 20 mm: Clean more often.
WARNING
Open the bowl with care.
The oil may be hot.
!
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