Scania D11, DC11, DI11. Industrial engine. Instruction — part 2
- Wash all parts in diesel.
- Place the O-ring in position in the rotor bowl. This must not be
damaged.
Change if necessary.
- Assemble the rotor
- Tighten the rotor nut hard by hand.
- Refit the rotor.
- Check that it turns easily.
- Check that the O-ring in the bowl is not damaged.
A hardened or damaged O-ring should be replaced.
- Screw down the bowl hard by hand.
If the nut is tightened using a tool, the rotor shaft, nut or bowl may be
damaged.
Operational test
The rotor turns very quickly and should continue to rotate when the engine
has stopped.
- Stop the engine when it is warm.
- Listen for the whirring from the rotor or feel whether the cleaner hous-
ing is vibrating.
The rotor normally rotates 30 - 60 seconds after the engine has stopped.
If not: Dismantle and check.
18
4. Every 400 hours:
CHANGING THE TURBO FILTER
(at the same time as the oil change)
- Remove the old filter and discard it according to environmental require-
ments.
- Oil the rubber gasket a fit a new Scania genuine filter.
- Tighten the filter by hand.
Never use tools as the filter may sustain damage, interfering with cir-
culation.
- Start the engine and check for leaks.
If the deposits in the centrifugal cleaner exceed 20 mm, the turbo filter
must be changed more often, at the same time as cleaning the centrifugal
filter and changing the oil.
COOLING SYSTEM
5. Daily:
CHECKING COOLANT LEVEL
- Open the expansion tank cap and check coolant level.
- Correct level: (Scania plastic expansion tank).
- Cold engine: The coolant level should be level with the lower edge
of the filler neck.
- Warm engine:The coolant level should be about 25 mm above the
lower edge of the filler hole.
- Other types of expansion tank according to the installer’s instructions.
- Top up coolant as necessary, see point 6.
Note!
When filling large amounts of coolant:
Never pour cold coolant into a warm engine.
This could crack the cylinder block and head.
Always top up using pre-
mixed coolant.
WARNING
Open the cover carefully.
water and steam can
spray out.
!
6. Every 2,400 hours:
CHECKING COOLANT
Coolant should be checked as follows:
a)
Check the appearance of the coolant.
b)
Coolant with glycol only: Check the glycol content.
c)
Coolant with only Scania Anti-corrosive:
Check the protection against corrosion.
The composition of the coolant is described in more detail under
“Starting and running”
a)
Checking the appearance of the coolant
- Take a little coolant in a vessel and check that it is clean and clear.
- If the coolant is contaminated or cloudy: Consider changing the coolant
- The water for the coolant should be free of dirt.
- Use drinking water with a pH of 6 - 9.
b)
Checking glycol content
If there is a danger of freezing, use only glycol as protection against corrosion
in the coolant.
- Cooling systems with glycol must contain at least 30% glycol by vol-
ume to offer sufficient protection against corrosion.
- 30% glycol by volume provides anti-freeze protection down to -18 °C.
If more protection is required, see the table on the next page for calculat-
ing the necessary amount of glycol.
We recommend only nitrite-free glycol anti-freeze with the following sup-
plier designations:
BASF G48 or BASF D542
- Always top up the anti-freeze if the content drops below 30% by vol-
ume. A glycol content above 60% by volume will not improve the pro-
tection against corrosion.
- The table below shows the temperature at which ice starts to form. The
engine freezes and breaks at significantly lower temperatures, see graph.
- Ice forming in the coolant often causes malfunction without any risk of
damage. The engine must not be loaded hard when ice is forming.
Note!
The coolant should be changed when the cooling system is
cleaned: Every 4,800 hours or at least every 5th year.
Important!
If a coolant filter is used in the cooling system, it must not
contain an inhibitor.
The coolant should be mixed
before it is poured into the
cooling system.
Never top up with only water
or only glycol.
WARNING
Ethylene glycol is
toxic if ingested.
Avoid contact with the skin.
!
The recommended glycols
must not be mixed with glycol
which has nitrite-based anti-
corrosive.
This could cause sludging and
reduced cooling capacity.
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
20
A
A= Range to be avoided. Only for calculation of glycol mix.
Freezing point of coolant when ice slush starts to form at different glycol mixes
% Glycol by
volume
15
20
25
30
35
40
45
50
Cooling
system
capacity, dm
3
Ice slush starts
to form at °C
-7
-10
-14
-18
-24
-30
-38
-40
Glycol dm
3
(litres)
5
6
8
9
11
12
14
15
30
6
8
10
12
14
16
18
20
40
8
10
13
15
18
20
23
25
50
9
12
15
18
21
24
27
30
60
11
14
18
21
25
28
32
35
70
12
16
20
24
28
32
36
40
80
14
18
23
27
32
36
41
45
90
15
20
25
30
35
40
45
50
100
17
22
28
33
39
44
50
55
110
18
24
30
36
42
48
54
60
120
20
26
33
39
46
52
59
65
130
21
28
35
42
49
56
63
70
140
23
30
38
45
53
60
68
75
150
24
32
40
48
56
64
72
80
160
26
34
43
51
60
68
77
85
170
27
36
45
54
63
72
81
90
180
29
38
48
57
67
76
86
95
190
30
40
50
60
70
80
90 100
200
Line A:
Ice starts to form (slush)
Line B:
Temperature at which engine freezes and breaks
1. Safe range
2. Malfunction can arise (ice slush)
3. Coolant frozen
Cold characteristics of glycol:
- Example with 30% glycol by volume
- Ice slush starts to form at -18 °C.
- At -30 °C there is a risk of malfunction
- The engine cannot be damaged if there is at
least 30% glycol by volume
% glycol by volume
c)
Checking protection against corrosion
There must always be sufficient anti-corrosive (inhibitor) in the coolant to
protect the cooling system against corrosion.
If there is no danger of freezing use only Scania Anti-corrosive.
The inhibitor in Scania Anti-corrosive is nitrite-free.
The correct level of anti-corrosive is 7-12% by volume.
- Fill with Scania Anti-corrosive as indicated on the packaging.
- Topping up with 1.0% by volume of Scania Anti-corrosive should be
done after every 2,400 operating hours.
- 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.
Note!
The coolant should be changed when the cooling system is
cleaned: every 4,800 hours or at least every 5th year.
Changing 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 drawing
- the ”lowest point” of the cooling system.
3.
Close the valves.
4.
Fill coolant through the expansion tank filler hole.
Mix coolant as described on page 19.
Scania Anti-corrosive must not
be mixed with glycol.
Mixing or over concentration
can cause sludging and
reduced cooling capacity.
Any coolant filter must not
contain inhibitor.
22
7. Every 4,800 hours:
CLEANING COOLING SYSTEM
Note!
If necessary, the cooling system should be cleaned more often.
External cleaning
Radiator
- Check that the radiator is not blocked on the air side and that the fins are
not damaged.
- Carefully scrape the deposit away from the radiator fins. If necessary a
paraffin-based engine cleaner may be used.
- Bent fins can be carefully straightened, e.g. using a steel wire brush.
Charge air cooler (DSI engine)
1.
Drain the coolant from the engine, see “Changing coolant”.
2.
Detach the upper part of the intake manifold.
3.
Detach the charge air cooler hose and pipe connections.
4.
Dismantle the charge air cooler as illustrated.
Take care not to damage the element’s 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.
Assemble the charge air cooler. Change all seals and gaskets.
7.
Refit hose and pipe connections.
8.
Fill coolant as described on page 19.
9.
Connect the intake manifold from the turbo.
1.
Intake manifold, lower
part
2.
Gasket
3.
Radiator element
4.
Gasket
5.
Intake manifold, upper
part
The cooling system must not
be cleaned using caustic soda.
Risk of damaging
aluminium parts.
Internal cleaning
Removing oils and greases
- If possible, run the engine until it is warm and then drain the cooling
system.
- Remove the thermostats.
- Fill the system with clean, hot water mixed with liquid dishwasher
detergent designed for household machines.
Mix 1% (0.1/10 l).
- Run the engine until warm (about 20 or 30 minutes). Do not forget any
cab heating system.
- 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.
- Fill the system with coolant as described in the specifications on
page 19.
Removing deposits
- If possible, run the engine until it is warm and then drain the cooling
system.
- Remove the thermostats.
- Fill the system with clean, hot water mixed with one of the commer-
cially available radiator cleaners based on sulphamin acid and contain-
ing dispersing agents. Follow the manufacturer’s instructions for mix
ratios and cleaning times.
- Run the engine for the for the specified time and then drain the cooling
system.
- Fill the system again with hot water and run the engine for about 20 or
30 minutes.
- Drain the water from the system.
- Refit the thermostats.
- Fill the system with coolant as described in the specifications on
page 19.
WARNING
When handling cleaners for
the cooling system:
Study the warning on the
packaging.
!
24
AIR CLEANER
8. Daily:
TEST READING
LOW PRESSURE INDICATOR
If the indicator’s red plunger is fully visible, change or clean the air cleaner
filter insert, point 10.
9. Every 200 hours:
CLEANING THE AIR CLEANER
COARSE CLEANER
1.
Detach the eccentric catch and remove the coarse cleaner.
2.
Remove the plastic cover from the coarse cleaner and clean the parts.
3.
Check that the plastic cover is intact and that it makes a seal against the
air cleaner housing during assembly.
4.
Assemble the air cleaner.
1.
Pre-filter with cover
2.
Filter insert
3.
Low pressure indicator
4.
Safety cartridge
Air cleaner with pre-filter
The coarse cleaner should be
fitted with the marking
”TOP” facing up.
10. Every 1,200 hours
CLEANING OR CHANGING
FILTER INSERT
Note!
Earlier if low pressure indicator shows red
Dismantling
1.
Remove and clean the coarse cleaner, see point 9.
2.
Undo the nut securing the filter insert and remove it.
3.
Change or clean the insert.
Note!
Cleaning the insert always means a risk of damage. The insert
may only be cleaned no more than four times. After cleaning, it
has a lower dust capacity than a new insert.
4.
Mark the filter when it has been cleaned.
Cleaning insert
- Carefully blow the filter insert clean using dry compressed air from the
inside.
Note!
This insert must not be washed using water.
Use only Scania genuine
air filter.
Change damaged filter
inserts.
Major risk of engine
damage if the filter insert is
damaged.
Test
- Insert a flashlamp into the insert and check from the outside that there
are no holes or cracks in the filter paper.
- Change the filter insert if there is any damage at all. Danger of engine
damage.
Assembly
1.
Assemble the air cleaner in reverse order.
2.
Reset the red plunger in the low pressure indicator by pressing in the
button.
11. Every 2,400 hours:
CHANGING THE SAFETY CARTRIDGE
1.
Remove and clean the coarse cleaner, see point 9.
2.
Undo the nut securing the filter insert and remove it.
3.
Change or clean the filter insert, see point 10.
4.
Undo the nut securing the safety cartridge and remove it.
5.
Fit a new Scania genuine safety cartridge.
6.
Assemble the air cleaner.
1.
Pre-filter with cover
2.
Filter insert
3.
Low pressure indicator
4.
Safety cartridge
Air cleaner with pre-filter
Never clean the safety
cartridge.
Do not remove the safety
cartridge unnecessarily.
26
FUEL SYSTEM
12. Daily:
CHECKING FUEL LEVEL
- Top up fuel if necessary.
- If the tank is run dry, bleed the fuel system, see point 13.
13. Every 1,200 hours:
CHANGING 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. Discard the filter
according the environmental requirements.
- Do up the new filter by hand.
Never use tools. The filters may be damaged, inhibiting circulation.
- Bleed the fuel system as below.
- Start the engine and check for leaks.
Bleeding the fuel system
- Open the bleed screw 1 on the main filter.
- Pump the hand pump 2 until air-free fuel flows out at the maim
bleed screw.
- Close the bleed screw. Pump a few times using the hand pump.
If the engine is difficult to start after bleeding . . . . .
- Slacken the injection pump overflow valve 3 one half turn
and try starting again. On the 8000 pump, the overflow valve is
located on the fuel shut-off valve.
If the engine still won’t start . . . . . . .
- Pump the hand pump until bubble-free fuel flows from the overflow
valve.
Tighten the overflow valve when the engine has started.
Use only Scania genuine
fuel filter.
1
2
3
Be extremely careful with
cleanliness when working on
the fuel system.
Malfunctions
can easily arise and the
injection equipment
can be damaged.
14. Every 2,400 hours:
CHECKING INJECTORS
Injectors should be inspected by trained personnel with access to the required
equipment, at least once every year or every 2,400 hours.
Removal
1.
Clean around the injectors and connections including the clamps and
brackets.
2.
Detach the delivery pipe bundle and the leak-off fuel lines.
3.
Unscrew the injector.
4.
Place protective plugs on the injector and delivery pipe.
5.
Lift the seal from the bottom of the injector seat if it does not come out
together with the injector.
6.
Place a seal plug in the injector seat in the cylinder head.
7.
Clean the injectors and check/adjust in an injector tester.
Correct opening pressure, see Technical data, page 40.
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 it.
3.
Fit the injector.
4.
Tighten the socket nut to 70 Nm (7.0 kpm).
5.
Fit the delivery pipe and tighten the cap nuts to 20 Nm
(2.0 kpm). Fit clamps and brackets.
Take care to fit the delivery pipe without tension and make sure that
the cone on the delivery pipe is correctly positioned in the connector.
6.
Fit the leak-off fuel line. Tighten the bolts to 11 Nm (1.1 kpm).
1.
Delivery pipes
2.
Cap nut
3.
Washer
4.
Cone
5.
Connector on injector or
injection pump
Delivery pipe connection
1.
Socket nut
2.
O-ring
3.
O-ring
4.
Stop ring
5.
Guide pin
6.
Seal
The delivery pipes must not
be bent.
All clamps must be refitted.
28
ELECTRICAL SYSTEM
15. Every 200 hours:
CHECKING ELECTROLYTE LEVEL
IN BATTERIES
1.
Undo the plugs and check the electrolyte level in all cells.
2.
Top up using distilled water until the level is 10-15 mm above the plates.
16. Every 200 hours:
CHECKING CHARGE
STATE IN THE BATTERIES
Note!
Every 200 hours applies to gensets and the like.
Other installations every 1,200 hours.
- Check specific gravity using a battery electrolyte 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 specific gravity is below 1.20, the battery must be charged.
A discharged battery freezes at -5 °C.
Avoid boost charging. This will damage the battery in the long term.
17. Every 200 hours:
CLEANING BATTERIES
Note!
Every 200 hours applies to gensets and the like.Other installa-
tions every 1,200 hours.
1.
Clean batteries, cables and cable terminals.
2.
Check that all cable terminals are well tightened.
3.
Grease posts and cable terminals using petroleum jelly.
18. Every 1,200 hours:
CHECKING 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: Engine stops, warning lamp lights and
buzzer sounds if there is no fault in the level monitor.
4.
No automatic stop in case of fault: Warning lamp lights, buzzer sounds
if there is no fault in the level monitor.
5.
Top up coolant to correct level, see page 18.
2-pole level monitor installed in
expansion tank for radiator deliv-
ered by Scania
30
19. Every 1,200 hours:
CHECKING TEMPERATURE MONITOR
1.
Drain sufficient coolant for 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.
Dip the monitor sensor in water. Slowly heat the water (about 1° per
minute) using e.g. an immersion heater.
6.
Set the control switch to ”ON”. Use a thermometer to check that the
warning lamp lights when the alarm is given at the correct temperature.
Correct temperature is stamped on the monitor’s hexagon.
Tolerance is
±
3° for the monitor.
CHECKING TEMPERATURE SENSOR
1.
Drain sufficient coolant for 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.
Dip the sensor body into water. Slowly heat the water (about 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
Resist-
ance
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
stamped temperature
2 = Connection C -2 opens at
stamped temperature
2-pole temperature monitor
20. Every 1,200 hours:
CHECKING THE OIL PRESSURE
MONITOR
Alternative 1
Connect an ohmmeter to the oil pressure monitor and check that the monitor
opens/closes at the correct pressure when the engine is started and stopped.
Alternative 2
Monitor coupled for automatic stop in case of fault:
1.
Start the engine.
2.
Check on the oil pressure gauge that oil pressure rises.
3.
Stop the engine manually (using the emergency stop).
4.
Check on the oil pressure gauge at what pressure the stop solenoid oper-
ates and the monitor opens. Correct pressure: 0.7
±
0.15 bar.
Monitor coupled to buzzer:
1.
Main switch in operate position, check that buzzer sounds.
2.
With the engine running, check that the buzzer stops sounding when oil
pressure is above 1.1
±
0.15 bar and the monitor closes.
CHECKING OIL PRESSURE SENSOR
- Connect an ohmmeter to the oil pressure sensor and check the resist-
ance.
- The sensor should give the following readings:
0 bar - 10
±
3
Ω
2 bar - 56
±
6
Ω
4 bar - 88
±
6
Ω
6 bar - 124
±
6
Ω
7 bar - 140
±
6
Ω
21. Every 400 hours:
CHECKING THE STOP FEATURE
Check that the stop solenoid is activated and stops the engine when the stop
signal is given by the button, temperature monitor, coolant level monitor and
oil pressure monitor if these are coupled for automatic stop in the case of
fault.
Important!
Stop solenoids with a timer module may be activated for start
and stop a maximum of 3 times per minute. Otherwise, the
timer module may be damaged and the stop feature cease.
2-pole oil pressure sensor
2-pole oil pressure monitor
32
CHECKING STOP SOLENOID STOP POSITION
When changing the stop solenoid, or if the stop feature is not satisfactory, the
following should be done (the figures show the stop control with the engine
in stop position):
The stop position at “Pull to stop”.
- Check and/or set the length of the link rod so that the distance between
the locknuts (nut height 5.2 mm) is 21.0
±
0.1 mm when the nuts are
tightened.
- Fit the stop solenoid in the bracket as in the figure.
- Connect the stop solenoid electrically, red to
+
and black to
-
, and acti-
vate so that it is fully drawn. Note: The timer module is damaged if
the poles are reversed.
- Screw the clevis onto the stop lever using the link pin and check, in stop
position, that there is a small clearance (0.2-0.3 mm) between the stop
lever and the operating point on the governor
- Check the stop feature by starting the engine and then stopping it by
activating the stop solenoid.
Important!
The stop solenoid must not be activated more than 3 times per
minute as the timer module can be damaged.
Stop position at “Pulled during operation”.
- Check and/or set the length of the link rod so that the distance between
the locknuts (nut height 5.2 mm) is 26.0
±
0.1 mm when the nuts are
tightened.
- Fit the stop solenoid in the bracket as in the figure.
- Connect the stop solenoid electrically, red to
+
and black to
-
and acti-
vate it so that it is fully pulled. Note: The timer module is damaged if
the poles are reversed.
- Turn the stop lever to operating position and screw the clevis onto the
stop lever using the link pin and check, in operating position, that there
is a small clearance (0.2-0.3 mm) between the stop lever and the operat-
ing point on the governor
- Activete the stop solenoid and start the engine. Stop the engine by cut-
ting the power to the stop solenoid.
Important!
The stop solenoid must not be activated more than 3 times per
minute as the timer module can be damaged.
Installation “Pull to stop”
Installation “Pulled during
operation”
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