Scania DC16 EMS with S6/PDE. Industrial engine. Operator’s manual — part 4
19. Daily:
Check for leaks, rectify as necessary
- Start the engine.
- Check for oil, coolant, fuel, air and exhaust leaks.
- Tighten or renew leaking connections. Check the overflow holes (1) in
the block which show whether the O-rings between the cylinder liners
and crankcase are leaking, see figure.
a) If coolant is running out, the O-ring is leaking.
b) If lubricating oil is running out, the liner shelf is leaking.
- Check that there are no leaks from the coolant pump (2). If there is
leakage, change the pump seal or the complete coolant pump.
- A small amount of leakage from the overflow holes during the engine
running-in period is normal. (Sealing rings and O-rings are lubricated
with soap or oil when fitted.)
- This leakage normally stops after a time.
Take care to ensure that any
leaks do not cause pollution.
If serious leakage occurs,
contact your nearest Scania
workshop.
Important
!
Help protect our
environment!
50
20. Every 2,400 hours:
Check and adjust valve clearance
Note:
Checking and adjusting valve clearances should also be done
after the first 400 hours of operation.
Valve clearances should be adjusted when the engine is cold, at least
30 minutes after running.
The rocker cover gaskets should be renewed as necessary. Tightening torque:
26 Nm.
Intake valve clearance: 0.45 mm.
Exhaust valve clearance: 0.70 mm.
Tightening torque for lock nut: 35 Nm.
Order of adjustment
- Turn the flywheel so that the marks on the flywheel can be seen in the
lower opening in the flywheel casing.
- Measure the valve clearance with a feeler gauge and adjust the valves as
per the order of adjustment in the table below. Correct valve clearances
are also given on the instruction plate on one of the rocker covers.
Mark on flywheel
Valve
overlap on
cylinder
Adjust
intake
valves on
cylinder
Adjust
exhaust
valves on
cylinder
TDC Down (0В°)
6
7 and 8
4 and 5
TDC Up (180В°)
7
1 and 5
2 and 6
TDC Down (360В°)
1
2 and 4
3 and 7
TDC Up (540В°)
4
3 and 6
1 and 8
21. Every 2,400 hours
Checking and adjusting the unit
injector rocker arms
Note:
Checking and adjusting of the unit injector rocker arms should
also be done together with the valve clearance check and
adjustment after the first 400 hours of operation.
Block the starting device when
working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK OF INJURY.
7
4
3
2
1
8
Cylinder numbering
FLYWHEEL
5
6
Measurement A =
PDE31: 66.9 В±0.1 mm
PDE32: 69.9 В±0.1 mm
Measurement B =
PDE31: 36.5 mm
PDE32: 38.8 mm
WARNING
!
PDE31:
1.
First, measure the distance (A) between plane (a) and the top edge of the
valve spring collar on the unit injector using a digital sliding caliper. See
figure.
2.
Dimension (A) should be 66.9 mm for PDE31 (dimension B=36.5 mm).
3.
The dimension is adjusted by undoing the lock nut and screwing the
rocker arm adjusting screw (1) to the correct measurement.
WARNING! Take care when carrying out the adjustment if the
dimension is well outside the adjustment dimension. The
spring is pre-tensioned and can cause personal injury if it is
released.
4.
Position setting tool 99 414 with the metal plate around the injector
spring.
5.
Finely adjust dimension (A) by simultaneously using a finger to sense
that the small piston (2) is level with the flat upper surface of the tool. It
is possible to feel differences of less than a tenth of a millimetre.
6.
If the setting tool is not available, a digital sliding calliper can also be
used for fine adjustment. The rocker arm position is adjusted using the
adjusting screw to 66.9 +/-0.1 mm as stated above.
7.
Tighten the adjusting screw lock nut to 39 Nm and remove the tool.
8.
The order in which the injector rockers are to be checked and adjusted is
shown in the table below.
Note:
No further checking and adjustment of the unit injector, such as
checking the opening pressure, must be done. Faulty injectors
must always be replaced completely.
Order of adjustment:
- Turn the flywheel so that the marks on the flywheel can be seen in the
lower opening in the flywheel casing.
Mark on flywheel
Valve
overlap on
cylinder
Adjust injector
rocker arm on
cylinder
TDC Down (0В°)
6
4 and 5
TDC Up (180В°)
7
2 and 6
TDC Down (360В°)
1
3 and 7
TDC Up (540В°)
4
1 and 8
Piston above or below the flat
surface. Adjustment necessary
Piston level with the flat surface.
The adjustment is correct
66.9
99 414
52
PDE32:
1.
First, measure the distance (A) between plane (a) and the top edge of the
valve spring collar on the unit injector using a digital sliding caliper. See
figure.
2.
Dimension (A) should be 69.9 mm for PDE32 (dimension B=38.8 mm).
3.
The dimension is adjusted by undoing the lock nut and screwing the
rocker arm adjusting screw (1) to the correct measurement.
WARNING! Take care when carrying out the adjustment if the
dimension is well outside the adjustment dimension. The
spring is pre-tensioned and can cause personal injury if it is
released.
4.
Position setting tool 99 442 with the metal plate around the injector
spring.
5.
Finely adjust dimension (A) by simultaneously using a finger to sense
that the small piston (2) is level with the flat upper surface of the tool. It
is possible to feel differences of less than a tenth of a millimetre.
6.
If the setting tool is not available, a digital sliding calliper can also be
used for fine adjustment. The rocker arm position is adjusted using the
adjusting screw to 69.9 +/-0.1 mm as stated above.
7.
Tighten the adjusting screw lock nut to 39 Nm and remove the tool.
8.
The order in which the injector rockers are to be checked/adjusted is
shown in the table below.
Note:
No further checking and adjustment of the unit injector, such as
checking the opening pressure, must be done. Faulty injectors
must always be replaced completely.
Order of adjustment:
- Turn the flywheel so that the marks on the flywheel can be seen in the
lower opening in the flywheel casing.
Mark on flywheel
Valve
overlap on
cylinder
Adjust injector
rocker arm on
cylinder
TDC Down (0В°)
6
4 and 5
TDC Up (180В°)
7
2 and 6
TDC Down (360В°)
1
3 and 7
TDC Up (540В°)
4
1 and 8
Piston above or below the flat
surface. Adjustment necessary
Piston level with the flat surface.
The adjustment is correct
69.9
99 442
Long-term storage
If the engine is not to be used for a lengthy period of time, special measures
should be taken to protect the cooling system, fuel system and combustion
chamber from corrosion and the exterior from rusting.
The engine can normally stand idle for up to six months. If it remains unused
for longer than this the following measures, which provide protection for
about four years, should be adopted. An alternative to preparing the engine
for long-term storage is to start the engine and warm it up every 6 months.
Preparing for storage means:
- Thoroughly cleaning the engine.
- Running the engine for a certain time using special preservative fuel, oil
and coolant.
- Otherwise preparing the engine for storage (filter renewal, lubrication,
etc.).
Preservative coolant
If the engine is stored with coolant in the system, the coolant should contain
50% glycol by volume. Use glycol without nitrite-based inhibitors, such as
BASF G48 or BASF D542.
Preservative fuel
- Use diesel mixed with Lubrizol 560H or equivalent.
- Mix 1 cm
3
(ml) Lubrizol 560H in 10 dm
3
(l) of fuel.
Ethylene glycol is highly
dangerous if imbibed and can
prove fatal.
Avoid contact with the skin.
HANDLING LUBRIZOL 560H
Hazardous!
Contains aromatic hydrocarbons
Use spot extractors where there is a danger of vapour build-up.
Wear protective gloves and goggles when handling Lubrizol. Do not use contaminated clothing.
If it gets in your eyes:
Rinse with a gentle stream of water (at least 15 minutes). Seek medical attention.
If it gets on your skin:
Wash the affected area with soap and water.
If inhaled:
Fresh air, rest and warmth.
Flammable:
Fire class 2A. Flashpoint +27В°.
In the event of fire: Extinguish with carbon dioxide, powder or foam.
Storage:
In well-sealed receptacle in a dry, cool place. Keep out of reach of children.
!
WARNING
!
54
Preservative oil
Suitable preservative oils are supplied by most oil suppliers.
For example, Dinitrol 40 or equivalent.
Preparations for storage
- Drain and flush the cooling system. Top up with preservative coolant.
- Warm up the engine on normal fuel. Stop the engine and drain the oil.
- Renew the fuel filter.
- Fill the engine with preservative oil up to the minimum level on the
dipstick.
- Mix preservative fuel in a can. Detach the fuel pipe at the feed pump
suction line and connect a hose from the can.
- Detach the fuel pipe at the overflow valve and connect a return hose to
the can.
- Start the engine and run it at about 1,000 rpm (not single-speed engines)
for 20-25 minutes.
- Stop the engine, remove the hoses and connect the normal fuel lines.
- Remove the rocker covers and lubricate the valve mechanisms and unit
injector mechanisms with preservative oil. Refit the rocker covers.
Note:
The unit injectors must not be removed.
- Drain the preservative oil from the engine. Fresh engine oil can be filled
directly or when the engine is taken out of storage.
- Drain the coolant if the engine is not to be stored with coolant in the
system. Plug and tape over all coolant connections (if the cooling system
is not completely assembled).
- Air cleaner: Clean or renew the filter element.
- Cover air intakes and exhaust pipes.
- Alternator and starter motor:
- Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or the
equivalent.
- Spray the outside of bright engine parts with penetrating preservative
oil, for example Dinitrol 25B, and then with Dinitrol 112 or equivalent.
Use a container to avoid spills
when draining the oil and
coolant.
Dispose of used oil and coolant
through an authorised waste
disposal contractor.
Help protect our
environment!
- Attach a label to the engine, clearly stating the storage preparation
date and that the engine must not be started or cranked.
Batteries
Remove the batteries for trickle charging at the battery charging station.
(Does not apply to batteries which according to the manufacturer do not
require any maintenance.) The same applies to short-term storage, even if
the engine has not been prepared for storage as above.
Storage
After the preparations, the engine should be stored in a dry and warm place
(room temperature).
Taking out of storage
(Procedure for taking the engine into operation)
- Remove plugs and tape from coolant connections, air intakes and
exhaust pipes.
- Fill the system with coolant, see page 22.
- Check the oil level in the engine or fill up with fresh engine oil.
- Lubricate the valve mechanisms and their pushrods and valve tappets as
well as the PDE injector mechanisms.
- Drain the preservative fuel from the fuel manifolds and fuel filter.
- Connect and bleed the fuel system, see page 45.
- Wash off any externally applied preservative oil, using white spirit.
ENGINE PREPARED FOR
LONG-TERM STORAGE
Date . . . . . . . . . . . .
Do not start or crank!
Wear gloves and protective
goggles when charging and
handling batteries.
The batteries contain a highly
corrosive acid.
WARNING
!
56
Technical data
General
DC16
Number of cylinders
8 (V8, 90В°)
Cylinder diameter
mm
127
Piston stroke
mm
154
Displacement
dm
3
(litres)
15.60
No. of main bearings
5
Firing order
1 - 5 - 4 - 2 - 6 - 3 - 7 - 8
Compression ratio
18:1 DC16 44:16:1
Engine direction of rotation viewed from rear
Counterclockwise
Fan direction of rotation viewed from front
Clockwise
Cooling
Liquid
Valve clearances, cold engine
intake valve
mm
outlet valve
mm
0.45
0.70
Weight with fan, without coolant or oil
kg
1,346
Power
see "Engine record card"
Lubrication system
Max. oil pressure
hot engine at a speed above 1,000 rpm
bar (kp/cm
2
)
6
Normal oil pressure
hot engine at operating speed
bar (kp/cm
2
)
3-6
Min. oil pressure
hot engine 1,000 rpm
bar (kp/cm
2
)
3.0
Min. oil pressure
hot engine, idling
bar (kp/cm
2
)
1.4
Oil capacity, see page 31
Crankcase pressure with closed crankcase
ventilation
mm VP
-55 - +20
Fuel system
DC16
Low idling
rpm
700 (adjustable 500-800)
Maximum full-load speed
See engine card
Fuel
Diesel
1
1
see page 58
Cooling system
Number of thermostats
1 (dual thermostat)
Thermostat, opening temperature
В°C
79
Coolant temperature:
system at atmospheric pressure
В°C
system at overpressure
В°C
70-93
70 - approximately 100
Capacity, including radiator, engine and expansion tank
with 0.8 m
2
radiator
dm
3
(litres)
with 1.3 m
2
radiator
dm
3
(litres)
85
95
Electrical systems
System voltage
V
24
Alternator, current
A
65 or 90
Starter motor output
kW (hp)
6.7 (9.1)
Monitors, threshold values:
oil pressure monitor
bar (kp/cm
2
)
temperature monitor
В°C
1.0
В±
0.15
Stamped on hexagonal part of monitor
58
Fuel
Diesel
The composition of the diesel has a great influence on the functioning and the
service life of the engine and the injection system. The engine output and
exhaust emissions are also dependent on the fuel quality. The requirements
and testing standards for the most important properties are described in the
workshop manual in sections which can be ordered from Scania dealers or
directly from Scania. Scania’s address is printed on the cover.
Diesel must comply with the following standard: EN 590 (European
standard).
The table below shows the requirements for some of the most important
properties.
Environmentally friendly fuels (low sulphur fuels)
There are three classes of environmentally friendly fuels (SS15 54 35).
Class 1 is sulphur-free and class 2 is low in sulphur. Compared with class 3
(normal fuel), these fuels are less dense and this reduces engine power output.
Only class 1 fuel should be used with a catalytic converter.
Short term use of fuel with a higher sulphur content than 0.05% by weight
will not cause permanent damage to the catalytic converter.
The catalytic converter may, however, require fuel with low sulphur content
for some time after this to regain its normal efficiency.
Property
Requirements
Viscosity at 40В°C
2.0-4.5 mm
2
/s (cSt)
Density at 15В°C
0.82-0.86 kg/dm
3
Sulphur (concentration by mass)
max. 0.3%
Ignitability (CET rating)
min. 49
Flashpoint
56В°C
Temperature dependence of diesel
At temperatures lower than those specified for the diesel, paraffin wax may
precipitate from the fuel and block filters and pipes. The engine can then lose
power or stop.
The diesel is adapted for use in the specific climate of each country. If a
vehicle or an engine is to be operated in a temperature zone with lower
temperature than normal, first identify the temperature properties of the fuel
concerned.
The properties of the fuel when cold can be improved by adopting one of the
following measures before the temperature drops:
- If the fuel concerned cannot cope with the expected temperatures, and
diesel is not available with the correct temperature properties, we
recommend that an electric fuel heater is installed as a preventative
measure.
- The low temperature properties of diesel may be improved by adding
kerosene as a preventive measure. A maximum of 20% may be added.
When refuelling, the kerosene should be added first, so that it mixes
thoroughly with the diesel.
Note:
It is prohibited to use kerosene in engine fuel in some countries.
- To prevent water in the fuel from freezing and forming ice, a maximum
of 0.5-2% alcohol (isopropanol) may be added.
Drain fuel tanks and drain or renew fuel filters regularly.
It is not permitted to mix
kerosene with diesel fuel that is
already adapted for the climate
concerned, it can damage the
unit injectors. All use of
paraffin other than kerosene is
forbidden, as it causes engine
damage.
It is not permissible to mix
petrol with diesel. Petrol may
cause wear to the unit injectors
and it may also cause damage to
the engine.
Important
!
WARNING
!
60
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Air cleaner, prefilter . . . . . . . . . . . . . . . . . . . . 42
Air cleaner, safety cartridge . . . . . . . . . . . . . . 43
Air cleaner, vacuum indicator . . . . . . . . . . . . . 42
Air filter, element . . . . . . . . . . . . . . . . . . . . . . 42
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Battery, renewing . . . . . . . . . . . . . . . . . . . . . . 47
Bleeding, fuel system . . . . . . . . . . . . . . . . . . . 45
Certified engines . . . . . . . . . . . . . . . . . . . . . . . . 5
Checks after running . . . . . . . . . . . . . . . . . . . . 27
Checks before running. . . . . . . . . . . . . . . . . . . 23
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Coolant level monitor . . . . . . . . . . . . . . . . . . . 47
Coolant temperature . . . . . . . . . . . . . . . . . . . . 25
Coolant, changing . . . . . . . . . . . . . . . . . . . . . . 39
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 36
Cooling system, cleaning . . . . . . . . . . . . . . . . 40
Corrosion protection . . . . . . . . . . . . . . . . . . . . 39
Drive belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Electrical system . . . . . . . . . . . . . . . . . . . . . . . 46
EMS sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Environmental responsibility . . . . . . . . . . . . . . 4
Filter, air cleaner . . . . . . . . . . . . . . . . . . . . . . . 42
Filter, closed crankcase ventilation . . . . . . . . . 35
Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
First start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Flash codes, control unit . . . . . . . . . . . . . . . . . 19
Flash codes, coordinator . . . . . . . . . . . . . . . . . 21
Fuel filter, renewing . . . . . . . . . . . . . . . . . . . . 44
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuel specifications . . . . . . . . . . . . . . . . . . . . . . 58
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuel system, bleeding . . . . . . . . . . . . . . . . . . . 45
Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Lubricating oil pressure. . . . . . . . . . . . . . . . . . 26
Lubricating oil system . . . . . . . . . . . . . . . . . . . 30
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Maintenance schedule . . . . . . . . . . . . . . . . . . . 29
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Oil filter unit . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Prefilter, air cleaner . . . . . . . . . . . . . . . . . . . . . 42
Preparations for storage . . . . . . . . . . . . . . . . . . 53
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Safety cartridge, air cleaner . . . . . . . . . . . . . . . 43
Safety information . . . . . . . . . . . . . . . . . . . . . . 10
Safety instructions for care and maintenance . 12
Safety instructions for materials handling . . . . 12
Safety precautions for running the engine. . . . 13
Starting the engine . . . . . . . . . . . . . . . . . . . . . . 23
Stopping the engine . . . . . . . . . . . . . . . . . . . . . 27
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Taking out of storage. . . . . . . . . . . . . . . . . . . . 55
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 56
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 20
Troubleshooting, control unit . . . . . . . . . . . . . 18
Troubleshooting, coordinator . . . . . . . . . . . . . 20
Type designations . . . . . . . . . . . . . . . . . . . . . . 14
Unit injector. . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Vacuum indicator . . . . . . . . . . . . . . . . . . . . . . 42
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . 50
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Scania Assistance
Always call the contact for your country.
Other countries: +46 8 52 24 24 24
Note:
Calls will be recorded for training purposes.
AR
0800 999 722 642
IE
+353 71 9634000
AT
+43 1 256 44 11
IT
+39 0461 996 222
AU
1300 SCANIA
KR
+82 1588 6575
1300 722642
LU
+32 226 400 000
BE
+32 2 264 00 00
MA
+34 91 678 92 13
BG
+359 886 660001
MX
01 800 4SCANIA
BR
0800 019 42 24
NL
+31 70 4182666
CH
+41 800 55 24 00
NO
+47 223 217 00
CL
188 800 722 642
PL
+48 602 622 465
CZ
+420 225 020 225
PT
+351 91 678 9247
DE
+49 261 887 8888
RO
+40 723 27 27 26
DK
+45 333 270 44
SE
+46 42 100 100
ES
+34 91 678 80 58
SK
+421 903 722 048
FI
+358 10 555 24
TR
+90 212 335 04 40
FR
+33 2 414 132 32
TZ
+255 78 472 2642
GB
0 800 800 660
UY
0800 8351
+44 1274 301260
ZA
0800 005 798
GR
+30 6944 420 410
+27 11 661 9823
HU
+36 209 727 197
62
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