Scania DI12, DC12. Industrial engine. Operator’s manual — part 4
49
Alternative 2
- Position No. 1 cylinder at TDC by turning the crankshaft in its normal
direction of rotation until all four valves are closed.
- Adjust all valves for No. 1 cylinder. Correct valve clearances are
indicated on the instruction plate on one of the rocker covers.
- Proceed in the same way for the remaining cylinders in the sequence
5 - 3 - 6 - 2 - 4 (firing order) by turning the crankshaft 1/3 of a
revolution in its normal direction of rotation after each adjustment.
Note:
Readings can be taken from the
flywheel through covers in the
flywheel housing either from
above or underneath depending
on access when fitting.
It says up and down respectively
on the flywheel
Both covers are fitted with a
cover at delivery.
Covers for reading
on the flywheel housing
50
24. Every 2400 hours:
CHANGING (or CLEANING) THE
CLOSED CRANKCASE VENTILATION
VALVE.
Alternative 1:
Change the valve at the specified interval.
Alternative 2:
- Remove the valve after the specified interval.
- Clean the valve by placing it in a bath of diesel oil overnight. Then rinse
it several times in diesel oil and allow it to drip dry.
- Refit the valve.
- The valve may be reused (cleaned), maximum twice after the initial
2400 hours of operation. Take care to mark the valve after cleaning it.
51
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 the engine for long-term storage means:
- Thoroughly cleaning the engine
- To run the engine for a period of time with preservative fuel,
preservative oil and preservative coolant.
- Otherwise preparing the engine for storage (filter changes, lubrication,
etc.).
Preservative coolant
If the engine is to be stored with a full cooling system, use coolant containing
50% glycol by volume. Glycol without nitrite-based inhibitor must be used.
E.g. BASF G48 or BASF D542.
Preservative fuel
- Use diesel fuel mixed with Lubrizol 560A or equal.
- Mix 1 cm
3
(ml) of Lubrizol 560A with 10 dm
3
(l) of fuel.
HANDLING LUBRIZOL 560A
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.
In case of splashes in the eye: Rinse with moderate water spray (for min. 15 minutes). Seek medical attention.
In case of skin contact:
Wash affected areas with soap and water.
If you inhale it:
Fresh air, rest and warmth
Flammable:
Fire class 2A. Flash point + 27В°.
In case of fire: Extinguish using carbonic acid, powder or foam
Storage:
In properly sealed container in a dry, cool place. Keep out of reach of children.
!
Ethylene glycol, if swallowed
can be fatal.
Avoid contact with the skin.
52
Preservative oil
Suitable preservative oil can be supplied by most petroleum companies.
E.g. Dinitrol 40 or the equivalent.
Preparations for storage
- Drain and flush the cooling system. Top up with preservative coolant.
- Warm up the engine on regular fuel. Stop the engine and drain the oil.
- Change the fuel filter and turbo 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 approximately 1000 rpm (not single-speed
engines) for 20-25 minutes.
- Stop the engine, remove the hoses and connect the normal fuel lines.
- Oil the valve mechanism generously with preservative oil.
- Remove the injectors and spray preservative oil into each cylinder,
maximum 30 cm
3
(ml).
Turn the engine over a few revolutions using the starter motor. Spray an
additional small amount of oil into each cylinder.
After this the engine must not be cranked. Refit the injectors.
- 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 a full cooling
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 equal.
- Spray the outside of bright metal engine parts, first with penetrating
preservative oil such as Dinitrol 25B and then with Dinitrol 112 or
equal.
Always use suitable containers
to avoid spillage when
draining oil and coolant.
Dispose of used oil and coolant
through an authorized waste
disposal contractor.
53
- Attach a label to the engine showing the date of preservation and
clearly stating that it must not be started or cranked.
Batteries
Remove the batteries for trickle charging at a charging station. (Does not
apply to batteries, which the manufacturer specifies to be maintenance free).
The same is applicable for short-term storage 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 when the engine is to be put into operation)
- Remove plugs and tape from coolant connections, air intakes and
exhaust pipes.
- Fill the cooling system with coolant, refer to page 19.
- Check the oil level in the engine or fill up with fresh motor oil.
- Turn the engine over a few times with the injectors removed, at the same
time copiously oiling the valve mechanism with pushrods and tappets.
Important
The engine must be cranked with the injectors removed so that
surplus preservative oil will be pressed out of the cylinders.
- Fit the injectors.
- Empty the fuel system’s main filter of preservative oil.
- Bleed the fuel system, refer to page 40.
- Wash off any externally applied preservative oil, using white spirit.
STORED ENGINE
Date . . . . . . . . . . .
Do not start or crank!
Wear gloves and eye protection
when charging and handling
batteries.
Batteries contain a highly
corrosive acid.
54
TECHNICAL DATA
GENERAL
DC12
DI12
Number of cylinders
6 in line
Bore
mm
127
Stroke
mm
154
Displacement
dm
3
(litres)
11.70
No. of main bearings
7
Firing order
1 - 5 - 3 - 6 - 2 - 4
Compression ratio
15:1(DC12 40=17:1)
17:1
Engine direction of rotation viewed from rear
Anti-clockwise
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, without coolant and oil
kg
*With charge air cooler, radiator, expansion tank and
pipes
1065*
995
Power
refer to, "Engine record card"
LUBRICATION SYSTEM
Max. oil pressure
(warm engine at engine speed
exceeding 800 rpm)
bar (kp/cm
2
)
6
Normal oil pressure
(warm engine at operating speed)
bar (kp/cm
2
)
3 - 6
Min. oil pressure
(warm engine 800 rpm)
bar (kp/cm
2
)
0.7
Oil capacity, refer to page 29
Crankcase pressure with closed crankcase
ventilation
mm H2O
-55 - +20
FUEL SYSTEM
DC12
DI12
Pump setting BTDC
See plate on rocker cover
Injectors, opening pressure
bar (kp/cm
2
)
300
Low idle speed
rpm
700
Maximum full load speed
See engine card
Fuel
Diesel fuel
1
Tightening torques:
Socket nut for injectors
Nm
Union nut for delivery pipe
Nm
Leak-off connection
Nm
70
20
11
1
refer to page 56
COOLING SYSTEM
Number of thermostats
1 (dual thermostat)
Thermostat, opening temperature
В°
C
83
Coolant temperature:
System with ambient pressure
В°
C
System with overpressure
В°
C
70 - 93
70 - approx. 100
Capacity, including radiator, engine and expansions tank
and, for DI12, charge air cooler
with 0.75 m
2
radiator
dm
3
(litres)
with 1.0 m
2
radiator
dm
3
(litres)
with 1.2 m
2
radiator
dm
3
(litres)
54
56
59
61
63
65
ELECTRICAL SYSTEM
System voltage
V
24
Alternator, charging current
A
65 or 90
Starter motor output
kW (hp)
6.7 (9.1)
Monitors, alarm values:
oil pressure monitor
bar (kp/cm
2
)
temperature monitor
В°C
0.7
В±
0.15
Stamped on hexagonal part of monitor
56
FUEL
Diesel fuel
The composition of the diesel fuel is vitally important to the operation and
life of the engine and the fuel injection pump. The engine power output and
the exhaust emissions are also dependent on the fuel quality.
The requirements and the test standards for the most important properties are
described in the workshop manual in sections that can be ordered from your
Scania dealer or directly from Scania. The address of Scania is printed on the
cover.
The diesel fuel shall comply with the following standard:
EN 590 (European standard).
The table below shows the requirements for some of the most important
properties:
Environmentally favourable fuels (low sulphur fuels)
There are three different grades of so called environmentally favorable fuels
(SS15 54 35). Grade 1 is sulphur-free and grade 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
Requirement
Viscosity at 40
В°
C
2.0 - 4.5 mm
2
/s (cSt)
Density at 15
В°
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 fuel
At temperatures lower than those specified for the diesel fuel, paraffin wax
may precipitate from the fuel and block filters and pipes. The engine can then
loose power or stop.
The diesel fuel 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 is not intended for the expected temperature and no
diesel fuel with the correct temperature properties is available, we
recommend that an electric fuel heater be installed as a preventative
measure.
- The low temperature properties of diesel fuel may be improved by
adding kerosene as a preventative measure. A maximum of 20% may
be added. When refuelling, the kerosene should be added first, so that it
mixes thoroughly with the diesel fuel.
Note:
It is prohibited to use kerosene in engine fuel in some countries.
- To prevent water in the fuel from freezing and forming ice, maximum
0.5-2% alcohol (isopropanol) may be added.
Drain fuel tanks and drain or renew fuel filters at regular intervals.
It is not permitted to mix
kerosene with diesel fuel that is
already adapted for the climate
concerned. The injection pump
may be damaged. All use of
paraffin other than kerosene is
forbidden, as it causes
engine damage.
It is not permissible to mix
petrol with diesel fuel. Petrol
may cause wear to the fuel
injection pump and it may also
cause damage to the engine.
58
ALPHABETICAL INDEX
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Air cleaner, prefilter . . . . . . . . . . . . . . . . . . . . 38
Air cleaner, safety cartridge . . . . . . . . . . . . . . 39
Air filter, element . . . . . . . . . . . . . . . . . . . . . . 38
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Battery, renewing . . . . . . . . . . . . . . . . . . . . . . 46
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Bleeding, fuel system . . . . . . . . . . . . . . . . . . . 40
Certified engines . . . . . . . . . . . . . . . . . . . . . . . . 5
Checks after running . . . . . . . . . . . . . . . . . . . 25
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Coolant level monitor . . . . . . . . . . . . . . . . . . . 43
Coolant temperature . . . . . . . . . . . . . . . . . . . . 23
Coolant temperature monitor . . . . . . . . . . . . . 44
Coolant temperature sensor . . . . . . . . . . . . . . 44
Coolant, changing . . . . . . . . . . . . . . . . . . . . . . 35
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 32
Cooling system, cleaning . . . . . . . . . . . . . . . . 36
Corrosion inhibitor . . . . . . . . . . . . . . . . . . . . . 35
DEC2 Control system . . . . . . . . . . . . . . . . . . . 12
Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Electrical system . . . . . . . . . . . . . . . . . . . . . . . 42
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Environmental responsibility . . . . . . . . . . . . . . 4
Fault codes DEC2 . . . . . . . . . . . . . . . . . . . . . . 17
Filter, air cleaner . . . . . . . . . . . . . . . . . . . . . . . 38
Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel filter, renewing . . . . . . . . . . . . . . . . . . . . 40
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuel specifications . . . . . . . . . . . . . . . . . . . . . 56
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuel system, bleeding . . . . . . . . . . . . . . . . . . . 40
Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
LED functions . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lubricating oil pressure sensor/monitor . . . . . 45
Lubricating oil system . . . . . . . . . . . . . . . . . . 28
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Maintenance schedule . . . . . . . . . . . . . . . . . . . 27
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Oil pressure monitor, DEC2 . . . . . . . . . . . . . . 45
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Prefilter, air cleaner . . . . . . . . . . . . . . . . . . . . 38
Pre-operation checks . . . . . . . . . . . . . . . . . . . . 21
Preparations for storage . . . . . . . . . . . . . . . . . 51
Safety cartridge, air cleaner . . . . . . . . . . . . . . 39
Safety details . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety precautions for care and maintenance . . 8
Safety precautions for handling materials . . . . 8
Safety precautions for operation . . . . . . . . . . . . 7
Sensors for DEC2 . . . . . . . . . . . . . . . . . . . . . . 13
Starting the engine . . . . . . . . . . . . . . . . . . . . . 21
Stopping the engine . . . . . . . . . . . . . . . . . . . . 24
Taking out of storage . . . . . . . . . . . . . . . . . . . 53
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 54
Temperature monitor . . . . . . . . . . . . . . . . . . . 44
Troubleshooting DEC2 . . . . . . . . . . . . . . . . . . 16
Type designations . . . . . . . . . . . . . . . . . . . . . . 10
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . 48
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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