Scania DI12, DC12. Industrial engine. Operator’s manual — part 2
17
Changing functions using the DIP
switches in the control unit
There are 8 DIP switches in the control unit under the
round black rubber cover.
These switches shall be in the ON position to obtain
normal functions according to the operating program.
However, for single-speed engines, the normal
position of DIP switches 6, 7, and 8 may also be OFF
Shutdown at threshold values for low oil pressure and
high coolant temperature can be selected by setting
DIP switch 4 to OFF
With DIP switch 4 in position ON, Power- indication
is obtained for these threshold values. Engine output
reduction (LOP) can be selected to prevent damage to
the engine. Changes to the program must only be
performed by authorized personnel.
Note:
Do not operate the engine with a Power-
indication except for in emergencies.
Readout of fault codes
Note:
If the engine has stopped or lost power but
the main indicator lamp is out and neither
POWER- nor SHUTDOWN are on, the fault
is outside the control unit detection range.
Probable causes: fuel shortage, temporary
overload, mechanical fault.
- Activate the lamp test/fault code switch. In
Scania electrical equipment the main indicator
lamp is located in this switch on the main supply
box.
- All LEDs will then come on for 2 seconds to
indicate that they are intact and in working order.
This also applies to the main indicator lamp in the
main supply box and the instrument panel
.
Make
a note of any LED that is defective.
- All LEDs will then be out for approximately 4
seconds.
- Following this, a fault code will be indicated on
one of the LEDs for 2 seconds. Note which LED
it is.
- The control unit then resumes the operating mode
automatically.
- After having made a note of the fault code, reset
the lamp test/fault code switch and reset the
control unit by turning off its power supply
momentarily.
- The most probable cause of the fault can then be
found in the trouble shooting schedule on the next
page.
- When the fault or faults have been rectified the
engine can be restarted.
- If the control system continues to indicate a fault
by way of the main indicator lamp, further faults
may have been recorded. The fault code readout
must then be repeated as per above since the
system can only display one fault code at a time.
- The fault(s) will be stored in a special memory in
the control unit along with information about the
operating time when it(they) occurred. Stored
faults can be accessed and erased by authorised
service personnel.
18
READOUT OF
F
A
UL
T
CODES
LE
D INDI
CA
TION WHE
N
THE
LAMP T
E
S
T
/F
AUL
T CODE SWITCH IS AC
TIV
A
TED
CON
TROL ST
AT
US
SHUTDOWN
STA
RT
ING
RUNNING
TO
RQUE LIM
IT
BOOS
T LIMIT
POWER -
POWER +
Pr
obabl
e ca
use
A
ct
io
n
вњ№
DEC2 ha
s de
te
ct
ed a
n
in
te
rna
l f
aul
t
in t
h
e con
tr
o
l u
n
it
.
Send
in t
he
cont
rol u
nit
f
or r
e
p
a
ir
as
soo
n as
poss
ib
le.
вњ№
The
engi
ne
te
m
p
era
tu
re h
as
rea
che
d t
h
e t
h
resho
ld
lev
el
or
th
e t
e
mper
at
ure
se
nsor
i
s i
nope
rat
ive.
Check
th
e co
oli
ng s
yst
em. Che
c
k
the
te
m
p
era
tu
re
se
ns
o
r a
n
d c
a
bl
e
r
o
ut
in
g
.
вњ№
The
engi
ne
has
re
ach
ed t
he o
ver
re
vvi
ng l
imi
t or
t
he
eng
ine
sp
eed
sen
sor
is
in
oper
a
ti
v
e
.
Check
th
e wir
ing an
d co
nnec
tor
.
Renew t
he
engi
ne
spe
e
d s
e
ns
or.
вњ№
Cont
ro
l r
ack
pos
it
ion
se
nsor
i
nope
rat
iv
e
.
C
heck
con
nect
or
s a
nd c
a
bl
es t
o g
over
nor
.
вњ№
The
int
ak
e ai
r
tem
p
er
at
ur
e h
as r
ea
che
d th
e t
h
re
sho
ld
le
vel
or
th
e c
h
ar
ge a
ir
te
mper
at
ure
se
nsor
i
s i
nope
rat
iv
e.
Check
th
e i
nta
ke s
yst
em. Che
c
k t
he
te
m
p
era
tu
re
se
ns
o
r a
n
d c
a
bl
e
r
o
ut
in
g
.
вњ№
DEC2 de
te
cts
no
char
ge
ai
r pr
es
sur
e
.
The
cha
rge
ai
r pr
es
sur
e s
ens
or
is
ino
p
er
at
ive
.
Check
th
e ch
arg
e
ai
r pre
ssu
re
hos
e. Se
nd i
n t
he
cont
ro
l u
n
it
fo
r r
epa
ir
if
t
h
e c
onne
ct
ion
is
damag
ed.
вњ№
Engi
ne
spe
e
d po
te
nti
omet
e
r or
the
id
li
ng s
a
fe
ty
swi
tch
is
in
ope
rat
iv
e.
Check
th
e ca
ble
ro
uti
ng,
conn
ect
or
s an
d ca
bl
es.
вњ№
The
oil
pr
es
sur
e
ha
s dr
opp
ed t
o t
he t
hr
e
sh
old
le
vel
or
th
e oi
l
pre
ssu
re
m
o
nit
o
r is
in
oper
at
iv
e.
Check
oi
l l
e
ve
l, c
onne
ct
or
and c
a
bl
e.
Renew t
he
oil
pr
es
sur
e
moni
to
r.
вњ№
=
LED on
19
STARTING AND RUNNING
AT FIRST START
When the engine is started for the first time, follow the maintenance points
listed under "First start" in the maintenance schedule, see page 27.
Since the points are important for satisfactory operation of the engine right
from the outset, they are also listed below.
1. Checking the oil level (refer to page 29).
6. Checking the coolant (refer to page 33).
The coolant should contain anti-corrosive to protect the cooling system
from corrosion.
If there is a danger of freezing:
- Only anti-freeze glycol should be used in the coolant as protection
against corrosion. We recommend only nitrite-free anti-freeze glycols
with the following supplier designations:
BASF G48 or BASF D542
- The concentration of glycol should be 30 - 60% by volume depending
on the ambient temperature. A content of 30 % by volume provides
protection down to -16 В°C. Refer to page 33.
- Never top up with only water or only glycol. Fluid losses must always
be replaced with pre-mixed coolant having the same glycol
concentration as that in the engine. If the glycol content drops, both
anti-freeze protection and protection against corrosion are impaired.
Note:
A glycol concentration below 30% by volume will not provide
sufficient protection against corrosion. Glycol concentrations
higher than 60 % do not improve anti-freeze protection and have
a negative effect on engine cooling capacity.
Coolant composition:
If there is a danger of freezing:
minimum 30% glycol by volume
maximum 60 % glycol by volume
If there is no danger of freezing:
7-12% by volume
Scania Corrosion Inhibitor
(no glycol)
The recommended glycol must
not be mixed with glycol having
nitrite-based anti-corrosive.
Ethylene glycol and corrosion
inhibitor, if swallowed can be
fatal.
Avoid contact with the skin.
20
If there is no danger of freezing:
- Only Scania Corrosion Inhibitor should be used in the coolant as
protection against corrosion. The correct corrosion inhibitor content is
7-12% by volume and must never be less than 7% by volume. The
inhibitor in Scania Corrosion Inhibitor is free of nitrite.
- First filling: Fill the cooling system with water + 10% by volume of
Scania Corrosion Inhibitor. Use drinkable water with a pH value of
6 - 9.
- Never top up with only water or only anti-corrosive! Fluid losses
must always be replaced with premixed coolant:
water + 10 % by volume of Scania Corrosion Inhibitor.
Coolant filter (not standard equipment)
Only coolant filter without inhibitor may be used. The use of coolant filters
increases the life of the coolant and reduces the risk of deposition corrosion.
12. Checking the fuel level (refer to page 40).
15. Checking the electrolyte level in batteries (refer to page 42).
16. Checking the state of charge in batteries refer to page 42).
18. Checking the coolant level monitor (if fitted) (refer to page 43).
19. Checking the temperature monitor (refer to page 44).
20. Checking the oil pressure monitor (refer to page 45).
21. Checking the tension of drive belts (refer to page 46).
Ethylene glycol and corrosion
inhibitor, if swallowed
can be fatal.
Avoid contact with the skin.
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK
OF INJURY.
The use of too much Scania
Corrosion Inhibitor as mixed
with glycol may cause deposits.
If a coolant filter has been fitted
it must not contain inhibitor.
21
CHECKS BEFORE RUNNING
Before running, "Daily maintenance" as described in the maintenance
schedule should be carried out, see page 27.
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 40).
For environmental reasons, your new Scania engine has been designed to use
a smaller amount of fuel when starting. Using unnecessarily large amounts of
fuel when starting the engine always results in the discharge of unburnt fuel.
- Open the fuel cock, if fitted.
- Declutch the engine (not engines with fixed clutch, e.g. generator sets).
- Engines with battery master switch: Switch on the power by means of
the battery master switch.
- DEC2: If the main indicator lamp comes on or flashes when the power is
turned on, this indicates the presence of a fault in the control system or
engine which must be found and rectified before the engine is started.
Refer to page16.
- Start the engine by means of the starter button or starter key.
Starting at low temperatures
Local environmental requirements must be complied with. Starting aids,
engine heaters and/or flame start devices should be used to avoid starting
problems and white smoke.
To limit white smoke, the engine should be run at low speed and under
moderate load. Avoid running it longer than necessary at idling speed.
Only start the engine in a
properly ventilated area.
When operating the engine in
an enclosed area, an effective
extraction device for exhaust
gases and crankcase gases
must be used.
Never use starting spray or
similar as a starting aid.
An explosion may occur in the
intake pipe, which could cause
personal injury.
22
At temperatures below 0 В°C:
Note:
Only use starting aids recommended by Scania.
- The starter motor may only be used for 30 seconds at a time. After that
time it must cool 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 seconds). The glow plug
continues to glow as long as this button is depressed after the engine has
started. Maximum time is 5 minutes.
- Operating flame start with timer relay: Press the pre-glow button (a
maximum of 20 seconds). Release it when the engine starts. The timer
relay keeps the glow plug glowing for 5 minutes. If a shorter glow time
is required, press the release button. The key must be turned to the 0
position if the start attempt fails.
Note:
If the engine is equipped with an INTERLOCK switch, this
switch should be depressed and held until the oil pressure has
reached a sufficiently high level.
- Generator sets should be operated under load immediately after starting
to avoid the risk of white smoke. This applies in particular to engines
that have been installed without aids for heating or applying a basic
load.
- Warm up the engine with a light load. A light load on a cold engine
gives better combustion and faster heating than warming up with no
load.
Maximum starter engagement
time is 30 seconds. Risk of
overheating. Allow starter to
cool for 2 minutes after a
starting attempt before
cranking again.
23
OPERATION
Check instruments and warning lamps at regular intervals.
Engine speed
The Scania tachometer is divided into sectors of different colours, as follows:
Coolant temperature
Normal coolant temperature when the engine is running should be 70 - 90В°C.
DEC2: If the temperature is high, 98В°C or above, you can select for the
control system to reduce power output (Power -) in order to bring down the
temperature. Refer to the DEC section on page 17.
If the temperature continues to rise, the engine will be shut down
automatically (Shutdown) at 103В°C. Refer to the DEC section on page 17.
Excessively high coolant temperature can damage the engine.
If run for extended periods under an extremely light load, the engine may
have difficulty in maintaining normal operating temperature. However, the
temperature will rise to a normal level again when the load on the engine is
increased.
0-500 rpm
red area:
prohibited engine speed,
passed when stopping and
starting.
500-700 rpm
yellow area:
low idle.
700-2200 rpm
green area:
normal operating speed.
The engine’s operating
speed range is controlled by
the DEC2 control system.
2200-2600 rpm
yellow/green
striped:
unsuitable operating speed.
May occur when switching
off and during downhill
engine braking
2600-3000 rpm
red area:
prohibited engine speed
WARNING!
When driving a vehicle down a steep descent
or in other installations, where the engine may be pro-
pelled by the vehicle motion, DEC2 will set the fuel
feed to zero to protect against engine overspeed and
shut down the engine. The clutch must not be released
in such a situation since this may cause vital functions
such as steering and brake system to become inopera-
tive when the engine stops.
!
Overpressure is not allowed in
cooling systems with Scania
radiators and expansion tanks
made of plastic, i.e. the
expansion tank must not be
fitted with a pressure cap.
24
Oil pressure
Max. oil pressure:
hot engine at engine speed exceeding 800 rpm
6 bar
Normal oil pressure:
hot engine at operating speed
3 - 6 bar
Min. oil pressure:
hot engine at 800 rpm
0.7 bar
At engine speeds below 800 rpm the gauge may indicate low oil pressure
although no fault is present.
Oil pressures below 0.7 bar at engine speeds above 800 rpm will cause
engine damage. The engine must be stopped immediately.
DEC2: The engine is shut down automatically if this function has been
selected. Refer to the DEC section on page 17.
Charging indicator lamp
If the lamp comes on during operation:
- Check/adjust the alternator drive belts as described in the maintenance
step. Refer to page 46.
- If the charging indicator lamp is still on, this could be due to an alter-
nator fault or a fault in the electrical system.
STOPPING THE ENGINE
1.
Run the engine without a load for a few minutes if it has been run
continuously with a heavy load.
2.
Stop the engine with the stop button. Keep the stop button depressed
until the engine is completely stationary.
3.
DEC2: Before switching off, check that the control system’s main
indicator lamp is not on or flashing.
Refer to page 16 for troubleshooting.
4.
Engines with battery master switch: Switch the power off with the
battery master switch. (Does not apply to emergency generator sets).
5.
Set the control switch to "0". (Does not apply to emergency generator
sets).
High lubricating oil pressure
(above 6 bar) is normal when
starting a cold engine.
High lubricating oil pressure
(above 6 bar) is normal when
starting a cold engine.
There is danger of turbo damage
and post boiling if the engine is
stopped without cooling.
The power must not be switched
off before the engine has
stopped.
25
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 the engaged position.
THIS MAY CAUSE PERSONAL INJURY and engine damage.
For this reason, always secure the clutch in the disengaged posi-
tion 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 in the "0" position.
- Fill the fuel tank. Make sure that the filler cap and the area round 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 a sufficient amount of glycol, refer to page 33
- At temperatures below 0 В°C: Prepare for the next start by switching on
the engine heater (if fitted).
Top up engine coolant when the
engine has been stopped after
being started for the first time.
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK
OF INJURY.
26
MAINTENANCE
The maintenance programme covers 24 points, divided into the following
main groups:
Lubricating oil system . . . . . . . . . . . . . . . . . page 28
Cooling system . . . . . . . . . . . . . . . . . . . . . . . page 32
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . page 40
Electrical system, monitors, batteries etc. . . page 42
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . page 46
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 every 400 hours of operation (carried out after 400,
800, 1200, 1600, etc. hours)
Periodic maintenance every 1200 hours of operation (carried out after 1200,
2400, 3600, etc. hours)
Periodic maintenance every 2400 hours of operation (carried out after 2400,
4800 etc. hours)
Periodic maintenance every 4800 hours of operation (carried out after 4800,
9600, etc. hours)
Annual Maintenance
Maintenance every 5th year
ENGINES WITH FEW HOURS OF
OPERATION
Emergency generator sets and the like that are not used regularly should be
run on test and checked in accordance with the generator set manufacturer’s
instructions.
Run the engine until it reaches operating temperature and then carry out the
maintenance points below:
1. Checking the oil level.
5. Checking the coolant level.
8. Checking the vacuum sensor.
12. Checking the fuel level.
15. Checking the electrolyte level in batteries.
16. Checking the state of charge in batteries.
17. Cleaning the batteries.
22. Checking for leakage, rectify as necessary
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK
OF INJURY
For engines with few operating
hours that are not subject to
periodic maintenance according
to the maintenance schedule on
page 27, maintenance should be
carried out in accordance with
the schedule:
"Every year"
"Every 5 years"
27
MAINTENANCE SCHEDULE
1.
More often if required
2.
For engines with few operating hours, see page 26.
3.
Earlier if vacuum indicator shows red.
4.
If inhibitor has not been topped up for five years, the coolant should be changed.
Dail
y
First
time at
Interval
At least
Firs
t sta
rt
400 h
200 h
400 h
1200
h
2400
h
4800
h
Annual
ly
Ever
y 5t
h ye
ar
LUBRICATING OIL SYSTEM, page 28
1. Checking the oil level
l
l
2. Oil change
l1
l
3. Cleaning the oil cleaner
l1
l
4. Renewing the oil filter
l1
l
COOLING SYSTEM, page 32
5. Checking the coolant level
l
6. Checking the coolant
l
l4
l
7. Cleaning the cooling system
l1
l
AIR CLEANER, page 38
8. Checking the vacuum sensor
l
9. Cleaning the coarse cleaner
l1
l
10. Cleaning or renewing filter element
l3
l
11. Renewing the safety cartridge
l
l
FUEL SYSTEM, page 40
12. Checking the fuel level
l
l
13. Renewing the main filter
l1
l
14. Checking the injectors
l
l
ELECTRICAL SYSTEM, page 42
15. Checking the electrolyte level in batteries
l
l2
l
16. Checking the state of charge in batteries
l
l2
l
17. Cleaning the batteries
l2
l
18. Checking the level monitor
l
l
l
19. Checking the temperature monitor
l
l
l
20. Checking the oil pressure monitor
l
l
l
MISCELLANEOUS, page 46
21. Checking the drive belt
l
l
l
22. Checking for leakage, rectify as necessary
l
23. Checking/adjusting valve clearance
l
l
24. Renewing (or cleaning) the valve for closed crankcase
ventilation
l
28
LUBRICATING OIL SYSTEM
OIL GRADE
The engine oil must at least meet the requirements for one of the following
oil classifications:
-ACEA E3, E4 or E5
- The Total Base Number (TBN) should be minimum 12-13
(ASTM 2896).
- Check with your oil supplier that the oil meets these requirements.
- The specified oil change intervals apply provided that the fuel sulphur
content does not exceed 0.3% by weight. If the sulphur content exceeds
0.3 % but is maximum 1.0%, the oil change intervals must be halved
(200 h).
- Viscosities as illustrated below.
- For operation at extremely low ambient temperature: Consult your
nearest Scania representative on how to avoid starting difficulties.
Oil analysis
Some oil companies can offer analysis of the engine oil. Such analysis
measures the oil TBN (Total Base Number), TAN (Total Acid Number), fuel
dilution, water content, viscosity and the quantity of friction particles and
soot in the oil.
The result of a series of analyses is used as the basis for establishing a
suitable oil change interval.
If the conditions are changed, a new oil analysis programme must be carried
out to establish the new change interval.
Additives must not be used.
The oil should be suitable for all
temperature variations until the
next oil change.
-40
-30
-20
-10
0
10
20
30
40 В°C
SAE 10W-30
SAE 20W-30
SAE 30
SAE 40
SAE 50
SAE 5W-30
SAE 15W-40
29
1. Daily:
CHECKING THE OIL LEVEL
Note
Before checking oil level: Allow the engine to remain stopped 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" on page 28.
Checking oil level during operation
On some engines the 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 the
minimum and the maximum mark
2. Every 400 hours:
OIL CHANGE
Note
Under extremely severe operating conditions, especially in dusty
environment or if the deposits in the centrifugal cleaner are
thicker than 20 mm: change oil more frequently.
- Unscrew the plug and drain the oil when the engine is hot.
- In certain engines the oil is pumped out by means of a bilge pump.
- Clean the magnet on the plug.
- Refit the plug.
- Fill up with oil.
- Check the level on the dipstick.
Max. 33 dm
3
Min. 28 dm
3
1 dm
3
= 1 litre
Maximum angles of inclination during operation
Maximum permissible angles during operation vary, depending on the type
of oil sump, see illustration.
Note:
Specified angles may only occur intermittently.
35В°
25В°
25В°
35В°
10 mm
10 mm
WARNING
The oil may be hot.
Wear protective gloves and
goggles
Always use a suitable container
to avoid spillage when
changing oil.
Dispose of used oil through an
authorized waste disposal
contractor.
30
3. Every 400 hours:
CLEANING THE OIL CLEANER
(at same time as an oil change)
- Unscrew the nut and remove the cover.
- Lift out the rotor and loosen the nut on the rotor bowl three turns.
- If the nut is jammed:
Clamp the nut, not the rotor, in a vise and turn the rotor three
revolutions by hand or using a screwdriver.
- Tap the nut lightly with your hand or a plastic hammer, to detach the
rotor bowl from the bottom plate.
- Unscrew the nut and remove the rotor bowl.
- Prize carefully to detach the strainer from the bottom plate.
- Scrape off the deposits from the inside of the rotor bowl. If there are no
deposits, this indicates that the cleaner is not working properly.
- If the deposits are thicker than 20 mm: clean more frequently.
Open the cap carefully. The
oil may be hot.
- Rinse all parts in diesel fuel.
- Fit the O-ring in the rotor bowl. Make sure it is not damaged.
Renew parts if necessary.
- Assemble the rotor.
- Tighten the rotor nut firmly by hand
- Refit the rotor.
- Make sure that it spins easily.
- Check that the O-ring in the bowl is undamaged.
Renew the O-ring if hard or damaged.
- Secure the bowl firmly, tightening the nut
If the nut is tightened with a tool, the rotor shaft, nut or bowl may be
damaged.
Operational test
The rotor rotates very fast and should continue to turn when the engine has
stopped.
- Stop the engine when it is warm.
- Listen for a whirring sound from the rotor or feel whether the cleaner
housing is vibrating.
The rotor normally continues spinning for 30 - 60 seconds after the engine
has stopped.
If not: dismantle and inspect.
32
4. Every 400 hours:
RENEWING THE OIL FILTER
(at same time as an oil change)
- Remove the old filter.
- Oil the rubber gasket and fit a new genuine Scania filter.
- Tighten the filter by hand.
Never use a tool for tightening. The filter could be damaged,
obstructing circulation.
- Start the engine and check for leaks.
Important
If the deposits in the centrifugal cleaner are thicker than 20
mm the oil filter should be renewed more frequently. This
includes cleaning the centrifugal filter and changing oil.
COOLING SYSTEM
5. Daily:
CHECKING THE COOLANT LEVEL
- Open the expansion tank filler cap and check the coolant level.
- Correct level: (Scania plastic expansion tank)
- Cold engine: The coolant should be level with the lower edge of the
filler neck.
- Hot engine:
The coolant should be approximately 25 mm above the
lower edge of the filler neck.
- Other types of expansion tank according to the instructions of the fitter.
- Top up the coolant as necessary, see point 6.
Note:
When filling large amounts of coolant:
Never pour cold coolant into a hot engine.
This could cause cracks in the cylinder block and the cylinder
head.
Always top up with ready mixed
coolant.
Carefully open the cap.
Hot water and steam
may blow out.
Always collect oil in a suitable
container to avoid spillage when
renewing the oil filter.
Dispose of used filters through
an authorized waste disposal
contractor.
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