Scania DI12, DC12 EMS with S6/PDE. Industrial engine. Operator’s manual — part 4

п»ї

49

19. Daily:
Look for leakage, 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)

(below the side covers) 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 the coolant pump drain hole (2) is not clogged, see figure. If

there is a leak, renew 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

torques: 26 Nm.
Intake valve clearance: 0.45 mm.

Exhaust valve clearance: 0.70 mm.
Tightening torque for lock nut: 35 Nm.

Block the starting device when

working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK OF INJURY.

Openings for reading

on the flywheel housing

Readings can be taken from the flywheel through covers in the flywheel

housing either from above or underneath depending on access when fitting.

Up or down is shown on the flywheel. Both openings are fitted with a cover at

delivery.

WARNING

!

51

Order of adjustment

- Turn the flywheel counterclockwise so that the marks on the flywheel

can be seen in the lower opening in the flywheel housing (depending on

which opening the reading is to be taken from). Refer to table.

- 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.

- Checking and adjustment of the rocker arms for the PDE injectors

should be done together with the valve clearance check/adjustment. See

step 21.

- If it is not possible to take a reading in one of the covers, observe the

valve overlap, turn the flywheel counterclockwise 120

В° (1/3 turn) at a

time and adjust the valves according to the table below and the unit

injectors as described on the next page.

Mark on flywheel

(reading taken through the

lower opening)

Valve overlap on

cylinder

Adjust the valves

on cylinder

TDC Down (0В°)

1

6

120В°

5

2

240В°

3

4

TDC Down (360В°)

6

1

120В°

2

5

240В°

4

3

Mark on flywheel

(reading taken through the

upper opening)

Valve overlap on

cylinder

Adjust the valves

on cylinder

TDC Up (0В°)

1

6

300В°

5

2

60В°

3

4

TDC Up (360В°)

6

1

300В° 2

5

60В°

4

3

5

4

3

2

1

6

FLYWHEEL

Cylinder numbering

52

21. Every 2,400 hours
Checking and adjusting the unit

injector rocker arms

Note:

Checking/adjusting the rocker arms for the PDE injectors

should also be done together with the valve clearance

check/adjustment after the first 400 hours of operation.

Important!

The PDE 31 unit injector is adjusted using setting tool

99 414 or a digital sliding calliper.

The PDE32 unit injector is adjusted using setting tool

99 442 or a digital sliding calliper.

This adjustment is essential as a fault in the position of the

unit injector can result in poor performance and possible

breakdown.

Readings can be taken from the flywheel through covers in the flywheel

housing either from above or underneath depending on access when fitting.

Up or down is shown on the flywheel. Both openings are fitted with a

blanking piece on delivery; see illustration on page 46.

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

53

Order of adjustment

Turn the flywheel counterclockwise so that the marks on the flywheel can be

seen in the lower opening in the flywheel housing (depending on which

opening the reading is to be taken from). Refer to table.

Mark on flywheel

(reading taken through the

lower opening)

Valve overlap on

cylinder

Adjust injector

rocker arm on

cylinder

TDC Down (0В°)

1

2

120В°

5

4

240В°

3

1

TDC Down (360В°)

6

5

120В°

2

3

240В°

4

6

Mark on flywheel

(reading taken through the

upper opening)

Valve overlap on

cylinder

Adjust injector

rocker arm on

cylinder

TDC Up (0В°)

1

2

300В°

5

4

60В°

3

1

TDC Up (360В°)

6

5

300В°

2

3

60В°

4

6

54

PDE31:

1.

Firstly, measure the distance (A) between plane (a) and the top edge of

the valve spring washer on the unit injector using a digital sliding

calliper. 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 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.

Note:

No further checking or adjustment of the unit injector, such as

checking the opening pressure, must be done. If an injector is

defective, the whole injector must be replaced.

Piston level with the flat surface.

Adjustment is correct.

Piston above or below the flat

surface. Adjustment necessary.

66.9

99 414

55

PDE32:

1.

Firstly, measure the distance (A) between plane (a) and the top edge of

the valve spring washer on the PDE injector using a digital sliding

calliper. 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 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.

Note:

No further checking or adjustment of the unit injectors, such as

checking the opening pressure, must be done. If an injector is

defective, the whole injector must be replaced.

Piston above or below the flat

surface. Adjustment necessary.

Piston level with the flat surface.

Adjustment is correct.

69.9

99 442

56

22. Every 2,400 hours:
Renewing (or cleaning) the closed

crankcase ventilation valve

Alternative 1:

Renew the valve at the specified interval.

Alternative 2:

- Dismantle the valve after the specified interval.
- Clean the valve by placing it in a bath of diesel fuel 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), but not more than twice after the

first 2,400 hours of use. Take care to mark the valve after cleaning it.

57

Preparing the engine for

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 being stored with coolant in the system, the coolant should

contain 50% glycol by volume. Glycol without nitrite-based inhibitor should

be used. For example BASF G48 or BASF D542.

Preservative fuel

- Use diesel fuel oil 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°C.

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

!

58

Preservative oil

Suitable preservative oils are available from most oil companies.
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 pipes.
- Remove the rocker covers and lubricate the valve mechanisms and unit

injector mechanisms with preservative oil. Refit the rocker covers.

Note:

The unit injectors are not to 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!

59

- 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 24.
- Check the oil level in the engine or fill up with fresh motor oil.
- Lubricate the valve mechanisms and their pushrods and valve tappets as

well as the unit injector mechanisms.

- Drain the preservative fuel from the fuel manifold and fuel filter.
- Connect and bleed the fuel system, see page 44.
- 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

!

60

Technical data

General

DC12

DI12

Number of cylinders

6 in line

Cylinder diameter

mm

127

Piston stroke

mm

154

Displacement

dm

3

(litres)

11.70

No. of main bearings

7

Firing order

1 - 5 - 3 - 6 - 2 - 4

Compression ratio

18:1

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, without coolant or oil

kg

*With charge air cooler, radiator, expansion tank and

pipes

1,065*

В§

995

Power

see "Engine record card"

Lubrication system

Maximum oil pressure

(warm 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

Minimum oil pressure

(hot engine 1,000 rpm

bar (kp/cm

2

)

1.0

Oil capacity, see page 33

Crankcase pressure with closed crankcase

ventilation

mm VP

-55 - +20

61

Fuel system

DC12

DI12

Pump setting BTDC

See plate on rocker cover

Low idling

rpm

700 (adjustable 500-800)

Maximum full load speed

See engine card

Fuel

Diesel fuel oil

1

1

see page 62

Cooling system

Number of thermostats

1 (dual thermostat)

Thermostat, opening temperature

В°C

75

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

and, for DI12, also 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, current

A

65 or 100

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

62

Fuel

Diesel fuel oil

The composition of the diesel fuel oil 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 fuel 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

63

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

lose 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 cannot cope with the expected temperatures, and

diesel fuel 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 fuel may be improved by

adding kerosene as a preventative measure. Maximum 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, 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. The unit injectors

can fail. All use of paraffin

other than kerosene is

forbidden, as it causes engine

damage.

It is not permissible to mix

petrol with diesel fuel. In the

long term, petrol may cause

wear to the unit injectors and at

worst it may also cause damage

to the engine.

Important

!

WARNING

!

64

Alphabetical index

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Air cleaner, prefilter . . . . . . . . . . . . . . . . . . . . 42
Air cleaner, safety cartridge . . . . . . . . . . . . . . 43
Air cleaner, vacuum indicator . . . . . . . . . . . . 43
Air filter, element . . . . . . . . . . . . . . . . . . . . . . 42

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Battery, renewing . . . . . . . . . . . . . . . . . . . . . . 47
Bleeding, fuel system . . . . . . . . . . . . . . . . . . . 45

Certified engines . . . . . . . . . . . . . . . . . . . . . . . . 5
Checks after running . . . . . . . . . . . . . . . . . . . 29
Checks before running . . . . . . . . . . . . . . . . . . 25
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Coolant, changing . . . . . . . . . . . . . . . . . . . . . . 39
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Coolant level monitor . . . . . . . . . . . . . . . . . . . 47
Coolant temperature . . . . . . . . . . . . . . . . . . . . 27
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 36
Cooling system, cleaning . . . . . . . . . . . . . . . . 40
Corrosion protection . . . . . . . . . . . . . . . . . . . . 39

Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Electrical system . . . . . . . . . . . . . . . . . . . . . . . 46
EMS engine management system . . . . . . . . . . 20
EMS sensors . . . . . . . . . . . . . . . . . . . . . . . 19, 20
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Environmental responsibility . . . . . . . . . . . . . . 4

Filter, air cleaner . . . . . . . . . . . . . . . . . . . . . . . 42
Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
First start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Flash codes, control unit . . . . . . . . . . . . . . . . . 21
Flash codes, coordinator . . . . . . . . . . . . . . . . . 23
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel filter, renewing . . . . . . . . . . . . . . . . . . . . 44
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuel specifications . . . . . . . . . . . . . . . . . . . . . 62
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuel system, bleeding . . . . . . . . . . . . . . . . . . . 45

Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Lubricating oil pressure . . . . . . . . . . . . . . . . . 28
Lubricating oil system . . . . . . . . . . . . . . . . . . 32

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maintenance schedule . . . . . . . . . . . . . . . . . . . 31

Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil filter unit . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Prefilter, air cleaner . . . . . . . . . . . . . . . . . . . . 42
Preparations for storage . . . . . . . . . . . . . . . . . 57

Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Safety cartridge, air cleaner . . . . . . . . . . . . . . 43
Safety information . . . . . . . . . . . . . . . . . . . . . . 6
Safety precautions for care and maintenance . 10
Safety precautions for handling materials . . . 12
Safety precautions for running the engine . . . 11
Starting the engine . . . . . . . . . . . . . . . . . . . . . 25
Stopping the engine . . . . . . . . . . . . . . . . . . . . . 29
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Taking out of storage . . . . . . . . . . . . . . . . . . . 59
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 60
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 20
Troubleshooting, control unit . . . . . . . . . . . . . 20
Troubleshooting, coordinator . . . . . . . . . . . . . 22
Type designations . . . . . . . . . . . . . . . . . . . . . . 14

Unit injector. . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Vacuum indicator . . . . . . . . . . . . . . . . . . . . . . 42
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . 50

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Политика конфиденциальности