Scania DI12, DC12 EMS with S6/PDE. Industrial engine. Operator’s manual — part 2
17
When the EMS control unit or the coordinator detects a fault, the diagnostics
lamp on the instrument panels(s) comes on, and it stays on as long as the fault
is active. At the same time, a fault code is generated which can be read off via
the coordinator on the diagnostics lamp in the form of a flash code when the
diagnostics switch is activated. A flash code may consist of a number of
different fault codes.
Diagnosis and troubleshooting using Scania EMS Display is described in the
Operator’s Manual for Scania EMS Instrumentation.
If the torque reduction function is activated, the amount of fuel and the engine
power output are reduced to 70%, and if the engine shutdown function is
activated, the engine is switched off at programmed alarm levels.
A separate PC-based diagnostics program is used to read off the contents of
the flash codes. For an in-depth analysis of fault codes, contact an authorised
Scania dealer.
Reading off the fault codes, and descriptions of these, are also covered in a
separate document in the workshop manual, Engine Management System
EMS-S6: Troubleshooting.
Only authorised personnel are allowed to carry out diagnostic procedures
and program changes.
The positions of the sensors which emit signals to the control unit are shown
in the illustrations on page 16.
See pages 20 and 22 for a description of how to read off flash codes.
See pages 21and 23 for a list of flash codes for the control unit and
coordinator.
18
Positions of sensors for EMS with S6 on DI12
3
4
2
1
1.
Oil pressure sensor
2.
Charge air temperature and pressure sensor
3.
Coolant temperature sensor
4.
Engine speed sensor (2)
19
Location of sensors for EMS with S6 on DC12
2
3
4
1
1.
Oil pressure sensor
2.
Charge air temperature and pressure sensor
3.
Coolant temperature sensor
4.
Engine speed sensor (2)
20
Troubleshooting using flash codes for the EMS
control unit
• The diagnostics lamp on the instrument panel(s) always comes on for
two seconds when the system is powered up.
• As soon as a fault is detected by the control unit, it is stored in the
EEPROM fault code memory and the diagnostics lamp on the
instrument panel(s) comes on.
• The diagnostic lamp will stay on for as long as a fault is active. Even if
the lamp has gone off and the fault is no longer active, the code can
generally be read off by following the instructions below.
Reading off control unit fault codes
1.
Turn on the ignition.
2.
Activate the diagnostics switch to the left to view the flash codes for the
control unit (EMS).
3.
A fault code will then flash on the diagnostics lamp. This flash code
consists of long flashes (approximately 1 second long) and short flashes
(0.3 seconds long). Long flashes are equivalent to tens and short flashes
to units.
Example: long - short - short = fault code 12.
4.
Repeat this procedure until the first flash code is repeated. This means
that the entire fault code memory has been flashed out. If the fault code
memory is empty, only one long flash approximately 4 seconds long
will be given.
5.
See the flash code table on the next page for a description and to locate
the fault.
6.
In order to obtain further information on the fault code, the PC-based
diagnostics tool or Scania EMS Display must be used. Contact an
authorised Scania workshop.
7.
When a fault has been rectified the fault code can be erased as described
below.
Clearing fault codes
1.
Switch off the ignition. If there is dual instrumentation the ignition must
be switched off on both panels.
2.
Activate the diagnostics switch in the same direction as the flash codes
indicate, i.e. to the right for the coordinator (COO) or to the left for
EMS.
3.
Switch on the ignition and at the same time keep the diagnostics switch
activated, to the right (COO) or to the left (EMS), for 3 seconds.
4.
This will erase passive fault codes which can be read off via flash code
for the relevant system. The rest of the fault codes will remain in the
EEPROM and can only be deleted using the PC tool.
21
Overview of flash codes for the EMS control unit
Code
Description
Code
Description
0
No fault detected.
53
PDE in cylinder 3: The solenoid valve is not
working properly.
11
Overrevving. One or both engine speed sensors
displays a speed in excess of 3,000 rpm.
54
PDE in cylinder 4: The solenoid valve is not
working properly.
12
Engine speed sensor 1 faulty, or incorrect signal.
55
PDE in cylinder 5: The solenoid valve is not
working properly.
13
Rotation speed sensor 2 faulty, or incorrect signal.
56
PDE in cylinder 6: The solenoid valve is not
working properly.
14
Coolant temperature sensor faulty, or incorrect
signal.
57
PDE in cylinder 7: The solenoid valve is not
working properly.
15
Charge air temperature sensor faulty, or incorrect
signal.
58
PDE in cylinder 8: The solenoid valve is not
working properly.
16
Charge air pressure sensor faulty, or incorrect
signal.
59
Incorrect signal in extra analogue input.
17
Oil temperature sensor faulty, or incorrect signal.
61
Incorrect control unit shutdown.
18
Oil pressure sensor faulty, or incorrect signal.
66
Shutdown due to coolant level.
21
Coolant level sensor faulty.
68
Alternator charging incorrectly.
23
Internal fault code in the coordinator.
69
Starter motor function interrupted or not activated.
24
Accelerator pedal / brake. If the accelerator and
brake pedals have been operated simultaneously.
82
Rotation speed above ref.speed at start.
25
Accelerator pedal sensor / idling switch
Accelerator pedal sensor / kickdown switch
83
Fault in memory circuit (EEPROM) in control unit.
27
Engine shutdown bypassed.
84
Data transfer to the control unit memory
(EEPROM) has been interrupted.
28
Shutdown due to oil pressure.
85
Incorrect internal temperature in the control unit.
31
Torque limitation due to oil pressure.
86
Internal fault in the control unit: Fault in hardware
control.
32
Incorrect parameters for limp home function.
87
Fault in control unit RAM.
33
Battery voltage incorrect or no signal.
88
Internal control unit fault: Memory fault.
37
Emergency shutdown switch activated in
accordance with CAN message from coordinator.
89
Defective seal: Illegal editing of software.
43
CAN circuit faulty in the control unit.
93
Rotation speed sensors faulty or not connected.
47
Immobiliser function. Starter key code incorrect.
94
Shutdown due to high coolant temperature.
48
CAN message from the coordinator incorrect or
missing.
96
Torque limitation due to high coolant temperature.
49
Incorrect CAN version in control unit or
coordinator.
98
Incorrect voltage supply to one of the sensors.
51
PDE in cylinder 1: The solenoid valve is not
working properly.
99
Internal hardware fault in the processor (TPU).
52
PDE in cylinder 2: The solenoid valve is not
working properly.
22
Troubleshooting using flash codes for the EMS
co-coordinator
• The diagnostics lamp on the instrument panel(s) always comes on for
two seconds when the system is powered up.
• As soon as a fault is detected by the coordinator, it is stored in the
EEPROM fault code memory and the diagnostics lamp on the
instrument panel(s) comes on.
• Even if the lamp has gone off and the fault is no longer active, the code
can generally be read off by following the instructions below.
Reading off coordinator fault codes
1.
Turn on the ignition.
2.
Activate the diagnostics switch to the right for 1 second to view the flash
codes for the coordinator (COO).
3.
A fault code will then flash on the diagnostics lamp. This flash code
consists of long flashes (approximately 1 second long) and short flashes
(0.3 seconds long). Long flashes are equivalent to tens and short flashes
to units.
Example: long - short - short = fault code 12.
4.
Repeat this procedure until the first flash code is repeated. This means
that the entire fault code memory has been flashed out. If the fault code
memory is empty, only one long flash (approximately 4 seconds long)
will be given.
5.
See the flash code table on the next page for a description and to locate
the fault.
6.
In order to obtain further information about the fault code, the PC-based
diagnostics tool or Scania EMS Display must be used. Contact an
authorised Scania workshop.
7.
When a fault has been rectified the fault code can be erased as described
below.
Clearing fault codes
1.
Switch off the ignition. If there is dual instrumentation the ignition must
be switched off on both panels.
2.
Activate the diagnostics switch in the same direction as the flash codes
indicate, i.e. to the right for the coordinator (COO) or to the left for
EMS.
3.
Switch on the ignition and at the same time keep the diagnostics switch
activated, to the right (COO) or to the left (EMS), for 3 seconds.
4.
This will erase passive fault codes which can be read off via flash code
for the relevant system. The rest of the fault codes will remain in the
EEPROM and can only be deleted using the PC tool.
23
Overview of flash codes for the EMS co-coordinator
1) Single speed engine
2) All-speed engine
Flash code
Fault description
11
1)
Incorrect signal from the fine adjustment for the nominal engine speed signal.
11
2)
Incorrect signals from the accelerator pedal sensor.
12
1)
Incorrect signal from the resistor module for governor setting.
12
2)
Incorrect signal from the resistor module for idle and fixed speed setting.
13
No communication (EMS) with the engine.
14
Short circuit in the tachometer signal cable.
15
Faulty atmospheric pressure sensor.
17
Short circuit in the coolant temperature gauge signal cable.
18
Short circuit in the oil pressure gauge signal cable.
19
Short circuit in the oil pressure lamp signal cable.
21
Different versions of the communications protocol in the coordinator and EMS.
22
Faulty start switch or short circuit.
23
The supply voltage is too high.
24
The supply voltage is too low.
25
Check value from End of line (EOL) is incorrect.
26
Road speed sensor signal missing or incorrect.
27
The signals from the RCB (Remote Control Box) switches are implausible.
28
Incorrect signals from the droop setting switches.
29
Faulty remote start switch or short circuit.
31
No communication from the slave coordinator or the master coordinator.
32
Short circuit in the signal cable to the coolant temperature warning lamp.
33
Short circuit in the signal cable to the charge warning lamp.
34
Incorrect signal from the Fixed speed switches.
35
Fault in CAN communication.
24
Starting and driving
First start
When the engine is started for the first time, carry out the maintenance points
listed under "First start" in the maintenance schedule; see page 31.
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; see page 33.
6. Checking the coolant; see page 34.
The coolant must contain corrosion inhibitor to protect the cooling
system from corrosion.
If there is a danger of freezing:
- Only antifreeze glycol should be used in the coolant as protection
against corrosion. We recommend only nitrite-free antifreeze 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. 30% glycol by volume provides anti-freeze
protection down to -16В°C. See page 37.
- Never top up with water alone or glycol alone! 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.
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
8-12% by volume, and this must never drop below 8% by volume. The
inhibitor in Scania Corrosion Inhibitor is free of nitrites.
- First filling: Fill up the system with water + 10% by volume Scania
Corrosion Inhibitor. Use drinking water with a pH of 6-9.
- Never top up with water alone or corrosion inhibitor alone!
Fluid losses must always be replaced with pre-mixed coolant: water
+ 10% Scania Corrosion Inhibitor by volume.
Coolant filter (not standard equipment)
Only coolant without inhibitor may be used. The use of coolant filters
increases the life of the coolant and reduces the risk of deposit corrosion.
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:
8-12% by volume
Scania Corrosion Inhibitor
(no glycol)
The recommended glycols must
not be mixed with glycol
containing nitrite-based
corrosion inhibitor.
Ethylene glycol and corrosion
inhibitor can be fatal if
imbibed.
Avoid contact with the skin.
Overdosing with Scania
Corrosion Protection and mixing
with glycol can cause sludge to
form.
If a coolant filter has been fitted
it must not contain inhibitor.
Important
!
Important
!
Important
!
WARNING
!
25
12. Checking the fuel level; see page 44.
14. Checking the electrolyte level in batteries; see page 46.
15. Checking the state of charge in batteries; see page 46.
18. Checking the drive belt tension; see page 48.
Checks before running
Before running, carry out "Daily maintenance" as described in the
maintenance schedule, see page 31.
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 45.
Out of consideration for our common environment, your Scania engine has
been designed to use less fuel when starting. Using unnecessarily large
amounts of fuel when starting the engine always results in emissions of
unburnt fuel.
- Open the fuel cock, if fitted.
- Disengage the engine.
- Engines with battery master switch: Switch on the power by means of
the battery master switch.
- Start the engine with the key on the control panel (SCP).
- S6: All lamps should go out after approximately 2 seconds when starting
the engine.
Block the starting device when
working on the engine.
If the engine starts accidentally,
there is a
SERIOUS RISK OF INJURY.
Only start the engine in a well
ventilated area.
If it is run in a enclosed space,
there should be an effective
device to draw off exhaust gases
and crankcase gases.
Never use starter spray or
similar agents to help start the
engine.
An explosion may occur in the
intake manifold with a risk of
personal injury.
WARNING
!
WARNING
!
WARNING
!
26
Starting at low temperatures
Local environmental requirements must be complied with. Starting aids,
engine heaters 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. A moderate load on a cold engine gives better combustion and
faster heating than warming up with no load.
Avoid running it longer than necessary at idling speed.
At temperatures below 0В°C:
Note:
Only use starting aids recommended by Scania.
- The starter motor may only be used for 30 seconds at a time. After that it
must rest for 30 seconds before attempting to start it again. Only 5
attempts may be made to start the engine. After that the starter motor
must rest for 15 minutes before the procedure can be repeated.
Note:
If the engine is equipped with an INTERLOCK switch, this
switch should be depressed and held down until the oil pressure
has reached a sufficiently high level.
RUNNING
Check instruments and warning lamps at regular intervals.
Engine speed
The Scania tachometer is divided into different coloured sectors, as follows:
0-500 rpm
red area:
prohibited engine speed, passed
through when stopping and
starting.
500-700 rpm
yellow area:
slow idle. Engine idling is
controlled by the S6 control
system. Raised idling speed
with a cold engine.
See page 26.
700-2,200 rpm
green area:
normal operating speed.
The engine operating speed
range is controlled by the S6
control system.
2,200-2,600 rpm
yellow/green
striped:
unsuitable operating speed.
May occur when switching off.
2,600-3,000 rpm
red area:
prohibited engine speed
The starter motor may only be
cranked for a maximum of
30 seconds. There is risk of
overheating. Let the starter
motor rest for 30 seconds
between each start attempt.
Important
!
27
Limp home mode
If there is a fault on the normal accelerator pedal or if CAN communication is
interrupted, the following limp-home option is provided:
CAN outage or accelerator pedal malfunction (both signal and idling switch):
- The accelerator pedal value is 0% and the engine is running at normal
idling speed.
- The accelerator pedal value is 0% and the engine is running at raised
idling speed (750 rpm) if this function is activated.
Accelerator pedal malfunction but the idling switch is working:
- The accelerator pedal value can be increased slowly between 0% and
50% by using the idling switch.
CAN outage:
- The engine is switched off if the shutdown function is activated.
Coolant temperature
Normal coolant temperature when the engine is running should be 70-90В°C.
The S6 control system has the following alarm levels:
- If the temperature is high, 98В°C-103В°C, for a certain period (1 second),
S6 will send a CAN message which switches on the warning lamp and
diagnostics lamp via the coordinator.
- If the temperature exceeds 103В°C, the warning lamp and diagnostics
lamps will come on. If torque reduction is activated, the control system
will reduce the fuel quantity to 70%. A fault code is generated in the
control unit.
- At temperatures exceeding 103В°C and with engine shutdown activated,
the warning lamp and diagnostics lamp come on and the engine is
switched off. If the override function is activated, only torque reduction
takes place when this function is activated. A fault code is generated in
the control unit.
After an alarm, approved values should be registered for more than 2 seconds
to reset the alarm.
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.
28
Oil pressure
Maximum oil pressure:
warm engine running at a speed above 800 rpm
6 bar
Normal oil pressure:
warm engine at operating speed
3-6 bar
Minimum oil pressure:
warm engine running at a speed of 1,000 rpm
2.3 bar
The control system has the following alarm levels:
- at a speed of less than 1,000 rpm and an oil pressure of less than 1.0 bar
- at a speed of more than 1,000 rpm and an oil pressure of less than 2.3 bar
for longer than 5 seconds.
The following functions are available if there is an alarm:
- Alarm which only switches on the warning lamp and diagnostics lamp.
- Alarm which switches on the warning lamp and diagnostics lamp as
well as torque reduction if this function is activated (70% of fuel
quantity).
A fault code is generated in the control unit.
- Alarm which switches on the warning lamp and diagnostics lamp. The
engine is switched off if engine shutdown is activated. If the override
function is activated, only torque reduction takes place when this
function is activated.
A fault code is generated in the control unit.
After an alarm, approved values should be registered for more than
1 second to reset the alarm.
High lubricating oil pressure
(above 6 bar) is normal when
starting a cold engine.
29
Charging indicator lamp
If the lamp comes on during operation:
- Check and adjust the alternator drive belts as described under the
maintenance point. See page 48.
- If the charging indicator lamp is still on, this could be due to an
alternator 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 or the starter key (depending on
version). Keep the stop button depressed until the engine has stopped
completely.
3.
Set the control switch to the "0" position.
4.
Engines with battery master switch: Switch the power off with the
battery master switch.
Note:
10 prohibited engine stops will cause torque reduction (70% of
fuel quantity). To reset the engine, switch off the engine once in
the prescribed manner.
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 contain enough
glycol. See pages 24 and 37.
- At temperatures below 0В°C: prepare for the next start by connecting the
engine heater (if fitted).
There is danger of turbocharger
damage and post boiling if the
engine is stopped without
cooling.
Coolant should be topped up
when the engine is stopped after
the first start.
Block the starting device when
working on the engine.
If the engine starts accidentally,
there is a
SERIOUS RISK OF INJURY.
The power must not be switched
off before the engine has
stopped.
The system is pressurised.
Major risk of burns.
Important
!
Important
!
Important
!
WARNING
!
WARNING
!
30
Maintenance
The maintenance programme covers 20 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, batteries, etc. . . . . . . . . . . page 42
Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . page 44
The maintenance points are divided into intervals as follows:
Daily maintenance
Maintenance before the first start
Maintenance after the first 400 hours of operation
Periodic maintenance every 200 hours of operation (carried out at 200, 400,
600, 800, etc. hours)
Periodic maintenance every 400 hours of operation (carried out at 400, 800,
1,200, 1,600, etc. hours)
Periodic maintenance every 1,200 hours of operation (carried out at 1,200,
2,400, 3,600, etc. hours)
Periodic maintenance every 2,400 hours of operation (carried out at 2,400,
4,800, etc. hours)
Periodic maintenance every 4,800 hours of operation (carried out at 4,800,
9,600 etc. hours)
Annual maintenance
Maintenance every 5 years
Engines with few hours of operation
Emergency generator sets and the like that are not used regularly should be
test run 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 indicator.
12. Checking the fuel level.
14. Checking the electrolyte level in batteries.
15. Checking the state of charge in batteries.
16. Cleaning the batteries.
19. Check for leaks, rectify as necessary.
Block the starting device when
working on the engine.
If the engine starts accidentally,
there is a
SERIOUS RISK OF INJURY.
For engines with few operating
hours that do not receive
periodic maintenance according
to the maintenance schedule on
page 29, maintenance should be
carried out in accordance with
the schedule:
"Annually"
"Every 5th year"
Important
!
WARNING
!
31
Maintenance schedule
1.
More often if required.
2.
Earlier if the vacuum indicator shows red.
3.
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
1,200
h
2,400
h
4,800
h
Annual
ly
Ever
y 5 y
ear
s
Lubricating oil system, page 28
1. Checking the oil level
z
z
2. Oil change
z1
z
3. Cleaning the lubricating oil cleaner.
z1
z
4. Renewing the oil filter
z1
z
Cooling system, page 32
5. Checking the coolant level
z
6. Checking the coolant
z
z3
z
7. Cleaning the cooling system
z1
z
Air cleaner, page 38
8. Test reading of vacuum indicator
z
9. Cleaning the coarse cleaner
z1
z
10. Cleaning or renewing the filter element
z2
z
11. Renewing the safety cartridge
z
z
Fuel system, page 40
12. Checking the fuel level
z
z
13. Changing the main filter and water separating filter
z1
z
Electrical system, page 42
14. Checking the electrolyte level in batteries
z
z
z
15. Checking the state of charge in batteries
z
z
z
16. Cleaning the batteries
z
z
17. Checking the coolant level monitor
z
z
Miscellaneous, page 44
18. Checking the drive belt
z
z
z
19. Check for leaks, rectify as necessary
z
20. Checking and adjusting valve clearances
z
z
21. Checking and adjusting the unit injector rocker arms
z
z
22. Renewing (or cleaning) the closed crankcase ventilation
valve
z
32
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.
- Specified oil change intervals apply provided that the sulphur content of
the fuel does not exceed 0.3% by weight. If the sulphur content is
greater than 0.3% but no more than 1.0%, the oil change interval must
be halved (200 h).
- Viscosities are shown in the figure 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’s TBN (Total Base Number), TAN (Total Acid Number),
fuel dilution, water content, viscosity and the quantity of wear 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
Important
!
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