Scania DC16 EMS with S6/PDE. Industrial engine. Operator’s manual — part 1
Operator’s Manual
DC16
EMS with S6/PDE
Industrial engine
opm_d16ind_en-GB01 1 920 792
IMPORTANT INFORMATION
When working on the engine, for example adjusting drive belts, changing the oil 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 the risk of
injury is particularly great.
!
COMMISSIONING REPORT - WARRANTY
When the commissioning report has been filled in and sent to Scania, you have a 1-year warranty from the date
of commissioning.
Also fill in the particulars below as this can make things easier if you need to contact, for example, a service
workshop.
Engine number
Date of commissioning
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 handling and maintenance of Scania
DC16 Industrial Engines with EMS S6/PDE injection systems.
The four stroke V8 diesel engines have direct-injection and are liquid-cooled.
These engines have turbochargers and charge air coolers; see page 14.
Common applications are as power units in construction machines, generator
sets, earth-moving, railway and forestry machines as well as in irrigation
systems.
The engines can have different output and speed settings.
The normal output setting of the engine (performance code) is indicated on
the type plate, see page 14.
Note:
Only standard components are described in the Operator’s
Manual. Please see the manufacturer’s instructions regarding
special equipment.
In order to obtain the best value and service life from your engine, there are
several points you should bear in mind:
- Read the manual before starting to use the engine. Even though you may
have experience of Scania engines, you may find new information in
this Operator’s Manual.
- Follow the maintenance instructions. Good working order and service
life are ensured if maintenance is carried out according to the
instructions.
- In particular, read the safety information starting on page 10.
- Get to know your engine so that you know what it can do and how it
works.
- If necessary, contact an authorised Scania workshop. They have special
tools, genuine Scania parts and staff with training and practical
experience of Scania engines.
Note:
Always use genuine Scania parts during service and repair so as
to keep your engine in the best possible working order.
The information in this manual was correct at the time of going to press.
However, we reserve the right to make alterations without prior notice.
During the warranty period,
only genuine Scania parts may
be used during service and
repair; otherwise the warranty
will be invalidated.
Important
!
Table of contents
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Contents . . . . . . . . . . . . . . ..3
Environmental responsibility . . . . . . .4
Certified engines . . . . . . . . . . . 5
Scania industrial and marine engine warranty
for industrial engines. . . . . . . . . ...6
Safety information . . . . . . . . . . 10
Type designations . . . . . . . . . . . . . . . . . . . . . 14
Engine management system (EMS) . . . . . . . 16
Troubleshooting using flash codes for the
EMS control unit . . . . . . . . . . . . . . . . . . . . . . .18
Overview of flash codes for the EMS
Starting and driving . . . . . . . . . . . . . . . . . . . 22
Starting at low temperatures . . . . . . . . . . . . . .24
Running . . . . . . . . . . . . . . 24
Stopping the engine . . . . . . . . . ..27
Checks after running . . . . . . . . . 27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engines with few hours of operation . . ...28
Maintenance schedule . . . . . . . . ...29
Lubricating oil system . . . . . . . . . . . . . . . . . 30
Oil grade . . . . . . . . . . . . . ...30
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Checking the oil level . . . . . . . . ...31
Oil change . . . . . . . . . . . . . 31
Maximum angles of inclination during
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
filter . . . . . . . . . . . . . . . ..35
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 36
Checking coolant level . . . . . . . . .36
Checking coolant . . . . . . . . . . ..37
Cleaning the cooling system . . . . . . .40
Internal cleaning . . . . . . . . . . . . . . . . . . . . . . .41
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Checking the fuel level . . . . . . . . .44
Changing the fuel filter . . . . . . . . .44
Bleeding the fuel system . . . . . . . . . . . . . . . . .45
Electrical system . . . . . . . . . . . . . . . . . . . . . . 46
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . 48
rocker arms . . . . . . . . . . . . ...50
Preparing the engine for storage . . . . . . . . . 53
Technical data . . . . . . . . . . . . . . . . . . . . . . . . 56
Fuel . . . . . . . . . . . . . . . ...58
Alphabetical index . . . . . . . . . . . . . . . . . . . . . 60
Scania Assistance . . . . . . . . . . . . . . . . . . . . . . 61
4
Environmental responsibility
Scania has always been very much at the leading edge when it comes to
developing and producing engines which are as environmentally friendly as
possible.
Major progress has been made on reducing harmful exhaust emissions as
required to be able to meet the stringent environmental standards stipulated
on almost all markets.
At the same time, we have been able to maintain high quality in terms of
performance and operating economy for Scania Industrial and Marine
Engines.
To preserve these qualities throughout the entire service life of the engine, it
is important for the operator/owner to follow the instructions on running,
maintenance and the choice of fuel and oil as outlined in the manual.
Other efforts to preserve the environment we all share are possible by
ensuring that the person carrying out servicing and maintenance always
makes sure that environmentally hazardous waste after servicing and repairs
(oil, fuel, coolant, filters, batteries, etc.) is dealt with and disposed of in
accordance with applicable environmental standards.
On a number of pages, this Operator’s Manual contains specially highlighted
text with instructions to help protect our environment during certain servicing
and maintenance work.
See example
Use a container to avoid spillage
when bleeding and renewing
components.
Help protect our
environment!
Certified engines
Emissions-certified engines have been approved in accordance with a special
certification standard. The certified engines supplied by Scania meet the most
stringent emissions standards which apply on European (EU) and non-
European (USA) markets.
Scania guarantees that all the engines it supplies of a certified type are
equivalent to the engine approved for certification.
The engine comes with a special certification plate which indicates the
certification rules (standard) to which the engine has been approved. See
page 14.
The following is required for the certified engine to meet emissions standards
once it has been commissioned:
- Servicing and maintenance must be carried out in accordance with the
instructions in this manual.
- Only genuine Scania parts are to be used.
- Injection equipment is to be serviced by an authorised Scania workshop.
- The engine must not be modified with equipment not approved by
Scania.
- Seals may be broken and setting data edited only once approval has been
granted by Scania in Södertälje. Changes may be made by authorised
personnel only.
- Changes which affect the exhaust system and intake system must be
approved by Scania.
Otherwise, the instructions in the manual in respect of running, care and
maintenance of the engine shall apply. The safety precautions described over
the next four pages must also be observed.
Important!
If servicing and maintenance are not carried out as specified
above, Scania can no longer guarantee that the engine will
comply with the certified design, nor can it take responsibility
for any damage that occurs.
6
Scania industrial and marine
engine warranty for industrial
engines
Emission Control Systems Warranty
Important!
Only applicable to engines used in the U.S.A.
Table of contents
General Warranty Provisions . . . . . . . 6
Warranty Period . . . . . . . . . . . . 7
Parts covered by the Warranty . . . . . ... 7
General Warranty Limitations . . . . . ... 8
Specific Warranty Exclusions . . . . . ... 9
Customer Support . . . . . . . . . . ... 9
Emission Control System Warranty
Statement
General warranty provisions
The emission control systems of your new Scania Industrial and Marine
("Scania") industrial diesel engine were designed, built and tested using
genuine parts, and were certified as being in conformity with federal emission
control regulations. Scania warrants to the original owner, and to each
subsequent owner, of a new Scania industrial diesel engine that the engine:
1.
Was designed, built and equipped so as to conform at the time of sale
with all applicable regulations under Section 213 of the Clean Air Act
42 U.S.C. В§ 7547, and all applicable regulations under Chapter 1 and 2,
Part 5, Division 26 of Health and Safety Code, and;
2.
Is free from defects in material and workmanship which would cause
such engine to fail to conform to applicable regulations for its warranty
period.
Warranty Period
This warranty shall apply for one of the following periods, whichever occurs
first:
• 3,000 hours of operation, or
• Five years of use
The warranty period shall begin:
• "On the date the engine is delivered to the first retail purchaser, or
• "If the engine is placed in service for demonstration purposes prior to
sale at retail, on the date the engine is first placed in service.
Parts covered by the Warranty
The following is a list of parts considered to be part of the Emission Control
Systems covered by the Emission Warranty for Scania industrial engines
which were built to conform to federal emission control regulations:
1.
Fuel injection system
2.
Air intake system
• Intake manifold
• Turbocharger system
• Charge air cooler system
3.
Exhaust manifold
4.
Combustion chamber
• Piston
• Cylinder head
5.
Components used in the above mentioned systems
Important!
This list does not include all expendable maintenance parts.
Expendable emission related parts requiring scheduled
maintenance are warranted until their first scheduled
replacement point. See Specific Warranty Exclusions
below.
8
General Warranty Limitations
To retain the dependability of the exhaust emission control originally built
into your Scania industrial diesel engine, it is essential that the engine is
installed according to Scania installation instructions and emission
certificates.
In addition, you are responsible for the performance of all scheduled
maintenance and necessary repairs on your new Scania industrial diesel
engine. Scania may deny a warranty claim if your failure to perform
maintenance resulted in the failure of the warranted part, listed under Parts
covered by the Warranty above.
Receipts covering the performance of regular maintenance should be retained
in the event questions arise concerning maintenance. The receipts should be
transferred to each subsequent owner of the engine with the emission
warranted engine.
The Warranty covers the cost of repair and replacement parts and services of
warranted components and systems performed by an authorized Scania
distributor or dealer using genuine Scania parts. You may elect to have
maintenance, replacement or repair of these components and systems
performed by any repair establishment or individual without invalidating the
Warranty.
The use of other than Scania replacement parts also does not invalidate the
warranty on other components unless such parts cause damage to warranted
parts. However, the cost of such services or parts will not be covered by the
Warranty.
WARNING!Use of replacement parts which are not of equivalent
quality may impair the effectiveness of emission control
systems. Accordingly, it is recommended that only Scania
repair or replacement parts be used for maintenance, repair
or replacement of emission control systems. If other than
Scania parts are used for maintenance, repair or
replacement, the owner should obtain assurance that such
parts are warranted by their manufacturer to be equivalent
to genuine Scania parts
Specific Warranty Exclusions
This warranty does not cover:
1.
Malfunctions in any part caused by any of the following: misuse, abuse,
improper adjustments, modifications, alteration, tampering,
disconnection, improper or inadequate maintenance, or use of fuels not
recommended for the engine as described in the Operator's Manual.
2.
Engine installation, including cooling system, intake system and exhaust
system installation, that is not completed in accordance with the Scania
installation instructions and emissions certificate for this engine type.
3.
Damage resulting from accidents, acts of nature or other events beyond
the control of Scania.
4.
The replacement of expendable maintenance items such as filters, hoses,
belts, oil, thermostat, exhaust system and coolant made in connection
with scheduled maintenance services once these parts have been
replaced.
5.
Replacement items which are not genuine Scania parts or not authorized
by Scania.
6.
Inconvenience, loss of use of the engine or commercial loss.
7.
Any engine on which the actual use cannot be accurately determined.
8.
Any engine operating outside the United States.
Customer Support
In the event that you do not receive the warranty service to which you believe
you are entitled under the Warranty, or if you need additional support or
information concerning the Warranty, please contact:
Scania USA, Inc
Address: 121 Interpark Blvd, suite 601, 78216, San Antonio, Texas
Mailing address: 121 Interpark Blvd, suite 601, 78216, San Antonio,
Texas
Telephone: +1 210 403 0007
Fax: +1 210 403 0211
E-mail: contact@scaniausainc.com
10
Safety information
General
This Operator’s Manual contains safety information which is important so as
to avoid both personal injury and damage to the product or other property.
See also page 1.
The text highlighted in text boxes on the right of a number of pages is
important for engine function and in order to avoid damage to the engine.
If these instructions are not followed, your warranty may be invalidated.
See example.
Similar text may also appear in the text column, and in this instance it will be
marked
Note:
or
Important!
.
The warning text found in text boxes on the right of a number of pages which
is marked with a warning triangle and starts with
WARNING
is extremely
important and warns you of serious engine faults or incorrect handling which
may lead to injury.
See example.
A list of the safety precautions to be followed when running and maintaining
Scania engines can be found on the next three pages. Similar text can often be
found at the relevant maintenance points, and here different levels of
importance are attached to such text in accordance with the above
description.
All points are marked
!
, so as to indicate how important it is to read through
each point in this section.
For safety reasons, smoking is not allowed:
• In the vicinity of the engine and in the engine room
• When fuelling and close to the filling station
• When working on the fuel system
• In the vicinity of flammable or explosive material (fuel, oils, batteries,
chemicals, etc.)
Block the starting device when
working on the engine.
If the engine starts accidentally,
there is a
SERIOUS RISK OF INJURY.
Only use genuine Scania fuel
filters.
WARNING
!
Important
!
Safety precautions for running the engine
Daily inspection
Always carry out a visual check of the engine and
engine room before starting the engine and once you
have stopped the engine after running.
This will enable you to easily detect fuel, oil or
coolant leaks, or any other abnormalities which may
require rectification.
Filling with fuel
There is a risk of fire and explosion when refuelling.
The engine must be stopped and smoking is not
allowed.
Do not overfill the tank due to a risk of expansion,
and close the filler cap properly.
Use only fuel recommended in the service
literature. Fuel of the wrong quality can cause the
engine to malfunction or stop by preventing the
injection pump and injectors from operating as they
should.
This can cause damage to the engine and, possibly,
injury.
Hazardous gases
Only start the engine in a well ventilated area. The
exhaust fumes contain carbon monoxide and
nitrogen oxides, which are toxic.
If it is run in a enclosed space, there should be an
effective device to extract exhaust gases and
crankcase gases.
Starter lock
If the control panel is not fitted with a key operated
switch, there should be a lock on the engine room to
prevent unauthorised starting of the engine.
Alternatively, a lockable on/off master switch or
battery master switch can be used.
Starter spray
Never use starter spray or similar agents to help start
the engine. This can cause an explosion in the intake
manifold and possible injury.
Running
The engine must not be run in environments where
there is a risk of explosion as all of the electrical or
mechanical components can generate sparks.
Approaching a running engine always poses a safety
risk. Parts of the body, clothes or dropped tools can
get caught in rotating parts such as the fan and cause
injury.
For personal safety all rotating parts and hot
surfaces must therefore be shielded as much as
possible.
12
materials
Fuel and oil
All fuels and lubricants and many chemicals are
flammable. Always follow the instructions on the
relevant packaging.
All work on the fuel system must be done with the
engine cold. Fuel leaks and spillage on hot surfaces
can cause fire.
Store soaked rags and other flammable materials
safely so as to avoid spontaneous combustion.
Batteries
The batteries contain and emit oxyhydrogen gas,
particularly during charging, and this gas is
flammable and highly explosive. There must be no
smoking, naked flames or sparks near the batteries
or the battery compartment.
Incorrect connection of a battery cable or jump lead
can cause a spark, which in turn can cause the
battery to explode.
Chemicals
Most chemicals such as glycol, corrosion inhibitors,
preservative oils, degreasing agents, etc. are
hazardous to health. Always follow the safety
precautions on the relevant packaging.
Some chemicals, such as preservative oil, are also
flammable.
Store chemicals and other materials which are
hazardous to health in approved containers, marking
them clearly and storing them where they are
inaccessible to unauthorised persons. Always hand
in leftover or used chemicals to an authorised waste
disposal contractor.
Safety precautions for care and
maintenance
Stop the engine
Always stop the engine before maintenance and
servicing unless stated otherwise.
Prevent unwanted starting by taking out the starter
key where applicable and disconnecting the power
using the master switch or battery master switch and
locking them. Also put up a warning sign
somewhere appropriate, indicating that work is in
progress on the engine.
Working with a running engine always poses a
safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts and cause
injury.
Hot surfaces and fluids
There is always a risk of sustaining burns when an
engine is hot. Therefore, take care not to come into
contact with manifolds, the turbocharger, the sump,
hot coolant and oil in pipes and hoses.
Lifting the engine
The engine lifting eyes must be used when lifting
the engine. Check first that your lifting devices are
in good condition and of the correct size to lift the
weight.
Extra equipment on the engine can alter the centre of
gravity, which is why you may need additional
lifting devices to balance the engine correctly and
lift it safely.
Never work underneath a suspended engine!
Batteries
The batteries contain a highly corrosive electrolyte
(sulphuric acid). Take care to protect your eyes, skin
and clothes when charging or handling batteries.
Wear protective gloves and goggles.
If the acid splashes on your skin, wash it off with
soap and copious amounts of water. If acid splashes
in your eyes, flush them immediately with copious
amounts of water and contact a doctor.
Dispose of used batteries through an authorised
waste disposal contractor.
Electrical systems
The engine must be stopped and the power
disconnected using the master switch or battery
master switch before working on the electrical
system.
External power supplies to extra equipment on the
engine must also be disconnected.
Electric welding
When carrying out welding work close to and on the
engine, remove the battery leads and the cables to
the alternator. Also remove the multi-pin connector
to the control unit.
Connect the weld clamp to the component to be
welded and close to the welding point, never to the
engine or in such a manner that the current can pass
over to a mounting.
When you have finished welding, connect the cables
to the alternator and control unit before connecting
the batteries.
Lubrication system
Hot oil can cause burns and skin irritation.
Therefore, avoid skin contact with hot oil.
Make sure that there is no pressure in the lubrication
system before starting work on it. Never start or run
the engine with the oil filler cap removed, as this
may cause oil to be thrown out.
Dispose of used oil through an authorised waste
disposal contractor.
Cooling system
Never open the coolant filler cap if the engine is hot.
Hot coolant or steam may spray out and cause burns.
If you have to open or remove a cooling system
component when the engine is hot, open the cap
very carefully and slowly to relieve the system
pressure before removing the cap. Wear gloves as
the coolant is still very hot.
Dispose of used coolant through an authorised
waste disposal contractor.
Fuel system
Always wear gloves when looking for leaks or
carrying out any other work on the fuel system. Also
wear protective goggles when testing injectors.
Fuel escaping at high pressure can penetrate tissues
and cause serious injury.
Never use non-genuine parts in the fuel and
electrical systems as genuine parts are designed and
manufactured to minimise the risk of fire and
explosion.
Before starting
Fit all removed shields before starting the engine
again. Check that you have not left any tools or other
objects on the engine.
Never start the engine without the air filter fitted.
There is a risk of objects being sucked into the
compressor impeller or of injury if you come into
contact with it.
14
1023558
308 775
Type designations
The engine type designation indicates, in the form of a code, the type of
engine, its size and applications.
The engine number is stamped on the right-hand side of the engine in front of
cylinder head 1. See illustration.
Engines which hold certification in respect of smoke and emissions are fitted
with a plate which indicates the documents in accordance with which they are
certified.
DC 16 40 A
Version
DC
Supercharged diesel engine with air-cooled charge air cooler
Displacement in whole dm
3
Performance and certificate
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
Made by
Type
Engine No
Output.
Output
kW
kW
rpm.
rpm.
DC16 40A
1023558
308 776
1.
Type number, stamped into
the cylinder block
2.
Engine serial number,
stamped into the cylinder
block
3.
Outlet to radiator
4.
Inlet from radiator
5.
Draining, engine oil
6.
Draining, coolant
7.
Rotation speed sensor
8.
Cylinder head ventilation
9.
Charge air sensor
10.
Fuel filter
11.
S6 control unit
12.
Oil filter unit
13.
Turbocharger
14.
Oil filler
15.
Oil dipstick
16.
Draining, coolant
17.
Starter motor
18.
Automatic belt tensioner
19.
Alternator
20.
Oil filter
21.
Fuel pump with hand pump
22.
Oil pressure sensor
23.
Coolant temperature sensor
6
4
3
11
18
1, 2
20
22
10
19
12
8
5
13
21
23
15
16 17
7
9
The illustrations show a normal version of a DC16 engine.
Your engine may have different equipment from that illustrated.
14
16
EMS engine management
system
This engine has an electronic management system, EMS (Engine
Management System), with unit injectors (PDE) which provide each cylinder
with the right amount of fuel, at the right time, in all operating situations.
The EMS system consists of a control unit (S6) and sensors for speed, charge
air temperature and pressure, coolant temperature, oil pressure, accelerator
pedal/throttle actuation which constantly emit signals to the control unit.
With the aid of this input data and the programmed control software, the
correct amount of fuel and the correct injection time are calculated for each
unit injector under the specific operating conditions.
The EMS system sensors can also be used to emit signals to the instruments
in the instrument panel.
The control unit constantly checks the sensors to make sure they are
operational.
The control unit contains monitoring functions to protect the engine in the
event of a fault which would otherwise damage it. In the event of a fault, for
example, alarm level for low oil pressure or high coolant temperature, the S6
control unit sends a CAN message to a coordinator.
The main task of the coordinator is to pass on data by means of CAN
communication from the engine control unit to other control units and signals
to gauges and lamps in the instrument panel. The coordinator also has
monitoring functions.
When the EMS control unit or the coordinator detects a fault, the diagnostics
lamp on the instrument panel(s) comes on, and it stays on as long as the fault
is active. At the same time, a fault code is generated which can be read off via
the coordinator on the diagnostics lamp in the form of a flash code when the
diagnostics switch is activated. A flash code may consist of a number of
different fault codes.
Diagnosis and troubleshooting using Scania EMS Display is described in the
Operator’s Manual for Scania EMS Instrumentation.
If the torque reduction function is activated, the amount of fuel and the engine
power output are reduced to 70%, and if the engine shutdown function is
activated, the engine is switched off at programmed alarm levels.
A separate PC-based diagnostics program is used to read off the contents of
the flash codes. For an in-depth analysis of fault codes, contact an authorised
Scania dealer.
Reading off the fault codes, and descriptions of these, are also covered in a
separate document in the workshop manual, Engine Management System
EMS-S6: Troubleshooting.
Only authorised personnel are allowed to carry out diagnostic procedures
and program changes.
The positions of the sensors which emit signals to the control unit are shown
in the illustrations on page 17.
See pages 18 and 20 for a description of how to read off flash codes.
See pages 19 and 21 for a list of flash codes for the control unit and
coordinator.
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