Scania DI12. Marine engine. Operator’s manual — part 1
Industrial & Marine Engines
IMPORTANT INFORMATION
When working on the engine, e.g. when adjusting the belts, changing oil or adjusting the clutch it is
important that the engine does not start. The engine may be damaged but above all 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 it is
especially important to consider the risk of injury.
Operator’s Manual
DI12
Marine engine
opm99-12m en
1 588 649
START-UP REPORT - WARRANTY
When the start-up report has been filled in and sent to Scania there is a 1 year warranty starting from
the start-up date. Also enter the below information since this will facilitate contacts with e.g. service
workshops.
Engine number
Start-up date
User's name and address
Signature
Engine type
Variant
Engine type and variant are indicated on the engine type plate
FOREWORD
This operator’s manual describes the operation and maintenance of the
Scania DI12 marine engines. The instructions apply to engines in program
99, starting with engine number 5 997 161.
The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder in
line diesel type. They are supercharged and equipped with a charge air cooler
which is coolant-cooled. See also page 14.
The engines may have two different cooling systems, a heat exchanger which
is cooled by sea water or keel cooling which has cooling coils on the keel in
which the engine coolant is cooled.
Common areas of usage include propulsion engines in boats like patrol boats
and fishing boats, larger pleasure craft or propulsion engines or aggregate
engines on board ships.
The engines can have different output and speed settings and are classified in
different class categories (classed engines must be used in certain marine
installations).
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. Regarding special equipment, refer to the instructions of
the relevant manufacturer.
In order to obtain the best value and service life from your engine, there are a
few points to bear in mind:
- Read the manual before starting to use the engine. You will find new
information in this Operator’s Manual even if you have previous
experience of Scania engines.
- Follow the maintenance instructions. Proper maintenance is essential to
keep the engine operating correctly and to increase engine life.
- Pay special attention to the safety information beginning on page 6.
- Get to know your engine so that you know what it can do and how it
works.
- Whenever necessary, always contact an authorised Scania workshop.
During the warranty period,
They have special tools, genuine Scania parts and trained staff with
only use genuine Scania parts in
practical experience of Scania engines.
service and repair for the
Note: Always use genuine Scania parts in service and repair to keep the
warranty to be valid.
engine operating correctly.
The information in this manual was correct at the time of going to press.
However, we reserve the right to make changes at any time, without prior
notice.
Scania CV AB
Industrial and Marine Engines
S-151 87 Södertälje
2
TABLE OF CONTENTS
FOREWORD
2
AIR CLEANER
42
ENVIRONMENTAL RESPONSIBILITY
4
CHECKING THE VACUUM INDICATOR . . . 42
CERTIFIED ENGINES
5
CLEANING THE AIR CLEANER COARSE
CLEANER
42
SCANIA INDUSTRIAL AND MARINE ENGINE
WARRANTY FOR MARINE ENGINES
6
CLEANING OR CHANGING THE
FILTER ELEMENT
42
SAFETY DETAILS
10
RENEWING THE SAFETY CARTRIDGE
44
Safety precautions for operation
11
Safety precautions for handling materials
12
FUEL SYSTEM
45
Safety precautions for care and maintenance .12
CHECKING THE FUEL LEVEL
45
RENEWING THE FUEL FILTER
45
TYPE DESIGNATIONS
14
CHECKING THE INJECTORS
46
DEC2 CONTROL SYSTEM
16
ELECTRICAL SYSTEM
47
STARTING AND RUNNING
22
CHECKING THE ELECTROLYTE LEVEL
AT FIRST START
22
IN BATTERIES
47
CHECKS BEFORE RUNNING
23
CHECKING THE STATE OF CHARGE
IN BATTERIES
47
STARTING THE ENGINE
23
CLEANING THE BATTERIES
47
At temperatures below 0 В°C:
24
CHECKING THE COOLANT LEVEL
RUNNING
25
MONITOR
48
Engine speed
25
CHECKING THE TEMPERATURE
Coolant temperature
25
MONITOR
49
Oil pressure
26
CHECKING THE TEMPERATURE SENSOR . 49
STOPPING THE ENGINE
26
CHECKING THE OIL PRESSURE
Clutch
27
SENSOR/MONITOR
50
CHECKS AFTER RUNNING
27
CHECKING THE OIL PRESSURE MONITOR
FOR DEC 2
50
MAINTENANCE
28
RENEWING THE BATTERY
51
ENGINES WITH FEW HOURS
OF OPERATION
28
MISCELLANEOUS
51
MAINTENANCE SCHEDULE
29
CHECKING THE DRIVE BELT
51
CHECKING FOR LEAKAGE, RECTIFY
LUBRICATING OIL SYSTEM
30
AS NECESSARY
52
OIL GRADE
30
CHECKING/ADJUSTING VALVE
Oil analysis
30
CLEARANCE
53
CHECKING THE OIL LEVEL
31
CHANGING (OR CLEANING) THE CLOSED
Checking oil level during operation
31
CRANKCASE VENTILATION VALVE
54
OIL CHANGE
31
LONG-TERM STORAGE
55
Maximum angles of inclination
Preservative fuel
55
during operation
31
Preservative oil
56
CLEANING THE OIL CLEANER
32
Preparations for storage
56
RENEWING THE OIL FILTER
34
Batteries
57
COOLING SYSTEM
34
Storage
57
CHECKING THE COOLANT LEVEL
34
Taking out of storage
57
CHECKING CORROSION BARS
35
TECHNICAL DATA
58
CHECKING THE SEA WATER PUMP
IMPELLER
35
FUEL
60
CHECKING THE COOLANT
36
ALPHABETICAL INDEX
62
Checking the corrosion inhibitor
38
Changing the coolant
38
CLEANING THE COOLING SYSTEM
39
Internal cleaning
41
3
ENVIRONMENTAL RESPONSIBILITY
Scania has always been at the forefront in the development and production of
environmentally safe engines.
We have made great progress in reducing harmful exhaust emissions to be
able to meet the stringent emission standards that are mandatory for almost
all markets.
We have done this without compromising the high quality of Scania
industrial and marine engines in terms of performance and cost effective
operation.
To maintain these superior properties throughout the life of the engine it is
important that the operator/owner follows the instructions of this manual as
regards operation, maintenance and choice of fuel and lubricants.
To further contribute to protecting the environment in service, maintenance
and repair, ensure that harmful waste (oil, fuel, coolant, filters, batteries etc.)
is disposed of and destroyed according to applicable local regulations.
This operator’s manual contains highlighted text urging you to protect the
environment in different service and maintenance operations.
Always use suitable containers
to avoid spillage when bleeding
Refer to example
systems or renewing
components.
4
CERTIFIED ENGINES
An emission certified engine has been approved according to a specific
certification standard. The certified engines delivered by Scania meet the
most compelling emission standards in the European (EU) and non-European
(USA) markets.
Scania guarantees that all engines of a certified engine type that are delivered,
correspond to the engine approved for certification.
The engine is fitted with a certification plate, stating according to which
certification rules (standard) the engine has been approved. Refer to page.
The following is required for the engine to meet the emission standards after
being commissioned:
- Service and maintenance must be performed according to this
Operator’s Manual.
- Only genuine Scania parts or equivalent must be used.
- Service work on the injection equipment must be performed by an
authorized workshop.
- The engine must not be modified with equipment not approved by
Scania.
- Seals and setting data may only be broken/modified by an authorised
workshop.
- Changes affecting the exhaust system and intake system must be
approved by Scania.
Otherwise, follow the instructions in this manual for operation, care and
maintenance of the engine. Also observe the safety precautions described in
the following four pages.
Important! If service and maintenance are not performed as stated
above, Scania cannot guarantee that the engine corresponds
to the certified configuration and will not assume liability for
any damage occurring.
For products used in the U.S.A., see next pages for special warranty
regulations.
5
SCANIA INDUSTRIAL AND MARINE
ENGINE WARRANTY FOR MARINE
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") marine diesel engine were designed, built and tested using genuine
parts, and the engine is 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 marine diesel engine that the emission
control system of your 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
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.
6
Warranty Period
This warranty shall apply for one of the following periods, whichever occurs
first:
• A period of operating hours equal to at least 50 percent of the engine's
useful life in operating hours, or
• A period of years equal to at least 50 percent of the engine's useful life
in years;
• Except that the warranty period shall apply for a period not less than
any mechanical warranties provided by Scania to the owner.
The warranty period shall begin:
• "On the date the marine vessel is delivered to the first retail purchaser,
or
• "If the marine vessel 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 a part of the Emission Control
Systems and is covered by the Emission Warranty for engines which were
built to conform to applicable U.S. Environmental Protection Agency
regulations:
1. Fuel injection system
2. Air intake system
a. Intake manifold
b. Turbocharger system
c. Charge air cooler system
3. Exhaust manifold
4. Combustion chamber
a. Piston
b. 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.
7
General Warranty Limitations
To retain the dependability of the exhaust emission control originally built
into your Scania marine 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 or repairs on your new Scania marine diesel engine. Scania may
deny a warranty claim if your failure to perform maintenance resulted in the
failure of the warranted part (listed under Section C 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 marine vessel 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
8
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. Damage resulting from accidents, acts of nature or other events beyond
the control of Scania.
3. 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.
4. Replacement items which are not genuine Scania parts or not authorized
by Scania.
5. Inconvenience, loss of use of the marine vessel or commercial loss.
6. Any marine vessel on which the actual use cannot be accurately
determined.
7. Any marine vessel 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
9
SAFETY DETAILS
General
This Operator’s Manual contains safety information that must be observed in
order to avoid personal injuries and damage to the product or property. Refer
to page 1.
The text boxes to the right on the pages provide information that is important
Only use Scania genuine fuel
for the proper operation of the engine and to avoid damage to the engine.
filter.
Failure to follow these instructions may void the warranty.
Refer to example.
Corresponding texts may also appear in the text column, headed Caution! or
Important
The warning text in text boxes to the right on the pages provided with a
warning triangle and headed WARNING is extremely important and warns
Immobilise the starting device
of serious defects to the engine or improper handling that may lead to
when working on the engine.
personal injury.
If the engine starts out of
control, there is a
Refer to example
SERIOUS RISK
OF INJURY.
The safety precautions that must be observed in the operation and
maintenance of Scania engines are compiled on the following three pages.
The corresponding text is also often stated next to the maintenance step
concerned, shown with different degrees of significance as described above.
All items are marked with a ! to highlight the importance of reading each
item in the section.
A general safety rule is that no smoking is allowed:
• Near the engine and the engine bay
• When refuelling and near the filling station
• When work is performed on the fuel system
• Near flammable or explosive materials (fuel, oils, batteries, chemicals
etc.)
10
Safety precautions for operation
Daily inspection
Starter lock
Always perform visual inspection of the engine
If the control panel is not fitted with a key
and engine bay before the engine is started and
switch, the engine bay should be fitted with a
when the engine has been stopped after oper-
lock to prevent unauthorized starting of the en-
ation.
gine.
This will make it easy to detect any leakage of
Alternatively, a lockable main switch or battery
fuel, oil or coolant or any other abnormal condi-
master switch may be used.
tion that may require remedial action.
Starting spray
Refuelling
Never use starting spray or similar as a starting
When refuelling, there is a risk of fire and explo-
aid. An explosion may occur in the intake pipe,
sion. The engine must be stopped and smoking
which could cause personal injury.
is not allowed.
Do not overfill the tank, since the fuel may ex-
Operation
pand, and close the fuel filler cap properly.
The engine should not be operated in environ-
Only use fuel recommended in the service
ments with surrounding explosive materials
literature. Fuel of an incorrect grade may cause
since electrical or mechanical components of
malfunctions or stoppage by interfering with the
the engine may emit sparks.
operation of the fuel injection pump and the in-
jectors.
It is always a safety hazard to be near an en-
gine that is running. Body parts or clothing, or a
This could cause engine damage and possibly
dropped tool may get stuck in rotating parts,
personal injury.
such as the fan, causing bodily injury.
Always cover rotating parts and hot surfaces as
Harmful gases
much as possible to ensure personal safety.
Only start the engine in a properly ventilated ar-
ea. The exhaust emissions contain carbon
monoxide and nitrogen oxides that are toxic.
When operating the engine in an enclosed ar-
ea, an effective extraction device for exhaust
gases and crankcase gases must be used.
11
Safety precautions for handling
Safety precautions for care and
materials
maintenance
Fuel and lubrication oil
Stop the engine
All fuels and lubricants as well as many chemi-
Always stop the engine before any mainte-
cals are flammable. Always follow the instruc-
nance and service work unless otherwise
tions stated on the container.
stated.
All work on the fuel system must be performed
Prevent unauthorized starting by removing the
when the engine is cold. Fuel leakage and spill-
starter key and turning off the power by the
age on hot surfaces may cause fire.
main switch or the battery disconnect switch,
locking it in the off position. Also attach a warn-
Store drenched rags and other flammable ma-
ing tag, stating that work on the engine is in
terials in a safe way to avoid spontaneous com-
progress, at a suitable location.
bustion.
It is always a safety hazard to work on an en-
gine that is running. Parts of your body or cloth-
Batteries
ing, or a dropped tool may get stuck in rotating
parts, causing bodily injury.
Batteries, particularly when being recharged,
emit highly flammable fumes that can explode.
Do not smoke or let open flame or sparks come
Hot surfaces and fluids
near the batteries or the battery compartment.
A hot engine always presents a risk of scalding.
Incorrect connection of a battery cable or jump
Always take care not to touch the exhaust
start cable may cause a spark, which in tun
manifold, turbocharger, oil pan, hot coolant and
may cause the battery to explode.
oil in pipes and hoses.
Chemicals
Lifting the engine
Most chemicals, such as glycol, corrosion in-
Use the engine lifting eyes when lifting the
hibitors, preservation oils, degreasers etc. are
engine. First check that the lifting equipment is
hazardous. Always follow the safety precau-
in proper condition and has sufficient lift capac-
tions stated on the container.
ity rating.
Some chemicals, e.g. preservative oil, are
Auxiliary equipment fitted to the engine may
flammable.
cause the centre of gravity to be displaced.
Always store chemicals and other hazardous
Thus, additional lift devices may be required in
materials in approved and distinctly marked
order to provide proper balance and a safe lift.
containers and out of reach of unauthorized
Never work below a suspended engine!
persons. Always dispose of superfluous or
used chemicals through an authorized waste
disposal contractor.
Batteries
Batteries contain a highly corrosive electrolyte
(sulphuric acid). Always take care to protect
your eyes, skin and clothing when charging and
handling batteries. Wear protective gloves and
goggles.
If electrolyte splashes on the skin, wash the
affected part of the body with soap and plenty
of water. If electrolyte splashes into the eyes,
rinse eyes immediately with plenty of water and
seek medical attention.
Dispose of used batteries through an author-
ized waste disposal contractor.
12
Electrical system
Cooling system
Before work is performed on the electrical sys-
Never open the coolant filler cap while the en-
tem, turn off the power by the main switch or
gine is hot. Steam and hot coolant can come
the battery disconnect switch.
out forcefully and cause scalding.
Also disconnect any external power supply to
If the cooling system must still opened or disas-
auxiliary equipment on the engine.
sembled while the engine is hot, open the filler
cap very cautiously and slowly to release the
pressure before the cap is removed. Use
Arc Welding
gloves since the coolant is still very hot.
Before welding near or on the engine, remove
Dispose of used coolant through an authorized
the battery and alternator cables. Also remove
waste disposal contractor.
the control unit connector.
Connect the weld clamp to the component to be
Fuel system
welded, close to the weld location. Never con-
nect it to the engine or in such a way that the
Always use gloves when checking for leaks in
current can pass through a bearing.
or performing other work on the fuel system. Al-
ways wear eye protection when testing injec-
After the welding is completed, connect the ca-
tors.
bles to the alternator and the control unit before
connecting the batteries.
Fuel escaping under high pressure can pene-
trate body tissue and cause serious injury.
Never use non-genuine parts in the fuel system
Lubrication system
and the electrical system. Genuine parts are
Hot oil may cause scalding and skin irritation.
designed and manufactured to minimize fire
Avoid skin contact with hot oil.
and explosion hazard.
Make sure that the pressure in the lubrication
system is relieved before work is carried out.
Before starting
Never start or operate the engine with the oil fill-
er cap removed since oil will be ejected force-
Install any guards that have been removed be-
fully.
fore the engine is started. Check to ensure that
no tools or other objects have been left on the
Dispose of used oil through an authorized
engine.
waste disposal contractor.
Never start the engine unless the air filter is in-
stalled. Otherwise there is a risk of objects en-
tering the compressor wheel or a risk of
personal injury from contact with it.
13
TYPE DESIGNATIONS
The engine designation indicates, in the form of a code, the type of engine,
its size and intended use, etc.
The type designation and engine serial number are indicated on a type plate
affixed to the right-hand side of the flywheel. The engine serial number is
also stamped into the cylinder block on the right-hand side. See arrow in the
illustration.
Engines that are certified regarding smoke and emissions are fitted with a
certification plate specifying the documents they conform to.
DI 12 41 M 01 E LR
Type
DI Supercharged diesel engine with liquid-cooled charge air cooler
Displacement in whole dm3
Performance and certification code
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
M For marine use
Variant 01-99
Type of governor
E
Electronically controlled governor (DEC2)
Classification society (applies to classed engines)
ABS American Bureau of Shipping
BV Bureau Veritas
GL Germanischer Lloyd
LRS Lloyd's Register of Shipping
DNV Det Norske Veritas
Rina Registro Italiano Navale
SjöV Sjöfartsverket
14
23
2
1, 4
5
6
13
12
3
11
7
10
8
9
21
14
20
15
19
16
17
18
The illustrations show a typical DI12 engine configuration.
Your engine may have different equipment from the one shown.
1. Expansion tank
10. Oil dipstick
19. Oil pressure sensor
2. Oil top up
11. Heat exchanger
20. Fuel filter
3. Type plate
12. Sea water outlet
21. Charge air cooler
4. Engine number, stamped
13. Sea water pump
22. Sea water intlet
on the engine block
14. Fuel shut-off valve
23. Filler cap, coolant
5. Coolant pump
15. Turbocharger
6. Draining, coolant
16. Injection pump
7. Oil filter
17. Starter motor
8. Centrifugal cleaner
18. Alternator
9. Draining, engine oil
15
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