Scania D11, DI11. Marine engine. Operator’s manual — part 2
17
- Wash all parts in diesel fuel oil.
- Place the O-ring in position in the rotor bowl. This must not be
damaged.
Change if necessary.
- Assemble the rotor
- Tighten the rotor nut hard by hand
- Refit the rotor.
- Check that it turns easily.
- Check that the O-ring in the bowl is not damaged.
A hardened or damaged O-ring should be replaced.
- Screw down the bowl hard by hand
If the nut is tightened using a tool, the rotor shaft, nut or bowl may be
damaged.
Operational test
The rotor turns very quickly and should continue to rotate when the engine
has stopped.
- Stop the engine when it is warm.
- Listen for the whirring from the rotor or feel whether the cleaner hous-
ing is vibrating.
The rotor normally rotates 30 - 60 seconds after the engine has stopped.
If not: Dismantle and check.
18
4. Every 400 hours:
CHANGING THE TURBO FILTER
(at the same time as the oil change)
- Remove the old filter and discard it according to environmental require-
ments.
- Oil the rubber gasket a fit a new Scania genuine filter.
- Tighten the filter by hand.
Never use tools as the filter may sustain damage, interfering with cir-
culation.
- Start the engine and check for leaks.
If the deposits in the centrifugal cleaner exceed 20 mm, the turbo filter
must be changed more often, at the same time as cleaning the centrifugal
filter and changing the oil.
COOLING SYSTEM
5. Daily:
CHECKING COOLANT LEVEL
- Open the expansion tank cap and check coolant level.
- Correct level: (integrated expansion tank in heat exchanger)
- Cold engine: Coolant level should be between 10 - 20 mm below
the expansion tank’s inner upper part.
- Warm engine: Coolant level reach the expansion tank’s
inner upper part.
- Other types of expansion tank according to the installer’s instructions.
- Top up coolant as necessary, see point 6.
Note
When filling large amounts of coolant:
Never pour cold coolant into a warm engine.
This could crack the cylinder block and head.
Always top up using pre-
mixed coolant.
WARNING
Open the cover carefully.
water and steam can
spray out.
!
19
6. Every 400 hours:
CHECKING CORROSION PROTECTION
RODS
(Only engines with heat exchanger)
- Drain the seawater circuit and check the corrosion protection rods
(sacrificial anodes). Location as per drawing on page 5.
- Scrape away all loose material from the anode.
- Change if less than half the rod remains.
New rods are 55 mm long, diameter 17 mm.
If the corrosion protection rods are highly eroded, they should be checked
more often, e.g. every 200 hours.
7. Every 400 hours:
CHECKING SEAWATER PUMP
IMPELLER
(Only engines with heat exchanger)
- Close the bottom valve if the seawater pump is below the water line.
- Drain the seawater circuit.
- Remove the cover from the seawater pump.
- Check that the impeller vanes are not worn or damaged.
If the impeller often requires changing, it is necessary to improve
the purity of the seawater.
Changing the impeller
- Extract the impeller using extractor 98 482 (Scania special tool).
- Fit new impeller and the cover. Check that the cover seal is not hard or
damaged.
Note
A spare impeller should be carried onboard.
- The impeller can become deformed after long periods of standstill.
Change before starting or remove the impeller before long periods of
disuse. Also see “Mothballing”.
20
8. Every 2,400 hours:
CHECKING COOLANT
Coolant should be checked as follows:
a)
Check the appearance of the coolant.
b)
Coolant with glycol: Check the glycol content.
c)
Coolant with Scania Anti-corrosive:
Check the protection against corrosion.
The composition of the coolant is also described under
“Starting and running”
a)
Checking the appearance of the coolant
- Take a little coolant in a vessel and check that it is clean and clear.
- If the coolant is contaminated or cloudy: Consider changing the coolant
- The water for the coolant should be free of dirt.
- Use drinking water with a pH of 6 - 9.
b)
Checking glycol content
If there is a danger of freezing, use only glycol as protection against corrosion
in the coolant.
- Cooling systems with glycol must contain at least 30% glycol by
volume to offer sufficient protection against corrosion.
- 30% glycol by volume provides anti-freeze protection down to -18 В°C.
If more protection is required, see the table on the next page for calcula-
ting the necessary amount of glycol.
We recommend only nitrite-free glycol anti-freeze with the following supp-
lier designations:
BASF G48 or BASF D542
- Always top up the anti-freeze if the content drops below 30% by
volume. A glycol content above 60% by volume will not improve the
protection against corrosion.
- The table shows the temperature at which ice (slush) starts to form. The
engine freezes and breaks at significantly lower temperatures, see graph.
- Ice forming in the coolant often causes malfunction without any risk of
damage. The engine must not be loaded hard when ice is forming.
Note
The coolant should be changed when the cooling system is clea-
ned: Every 4,800 hours or at least every 5th year.
Important
If a coolant filter is used in the cooling system, it must not con-
tain an inhibitor.
Coolant composition:
If there is a danger of freezing:
at least 30% glycol by volume,
max. 60% glycol by volume
If there is no danger of
freezing:
7-12% by volume
Scania Anti-corrosive
The coolant should be mixed
before it is poured into the
cooling system.
Never top up with only water
or only glycol.
WARNING
Ethylene glycol is
toxic if ingested.
Avoid contact with the skin.
!
The recommended glycols
must not be mixed with glycol
which has nitrite-based anti-
corrosive.
This could cause sludging and
reduced cooling capacity.
21
A
A= Range to be avoided. Only for calculation of glycol mix.
Freezing point of coolant when ice slush starts to form at different glycol mixes
% Glycol
by volume
15
20
25
30
35
40
45
50
Cooling
system
capacity,
dm
3
Ice slush starts
to form at В°C
-7 -10
-14
-18
-24
-30
-38
-40
Glycol dm
3
(litres)
5
6
8
9
11
12
14
15
30
6
8
10
12
14
16
18
20
40
8
10 13
15
18
20
23
25
50
9
12 15
18
21
24
27
30
60
11
14 18
21
25
28
32
35
70
12
16 20
24
28
32
36
40
80
14
18 23
27
32
36
41
45
90
15
20 25
30
35
40
45
50
100
17
22 28
33
39
44
50
55
110
18
24 30
36
42
48
54
60
120
20
26 33
39
46
52
59
65
130
21
28 35
42
49
56
63
70
140
23
30 38
45
53
60
68
75
150
24
32 40
48
56
64
72
80
160
26
34 43
51
60
68
77
85
170
27
36 45
54
63
72
81
90
180
29
38 48
57
67
76
86
95
190
30
40 50
60
70
80
90 100
200
% Glycol by volume
Cold characteristics of glycol:
- Example with 30% glycol by volume
- Ice slush starts to form at -18 В°C.
- At -30 В°C there is a risk of malfunction
- The engine cannot be damaged if there is at
least 30% glycol by volume
Line A:
Ice starts to form (slush)
Line B:
Temperature at which engine freezes
and breaks
1. Safe range
2. Malfunction can arise (ice slush)
3. Coolant frozen
22
c)
Checking Protection against corrosion
There must always be sufficient anti-corrosive (inhibitor) in the coolant to
protect the cooling system against corrosion.
If there is no danger of freezing use only Scania Anti-corrosive.
The inhibitor in Scania Anti-corrosive is nitrite-free.
The correct level of anti-corrosive is 7-12% by volume.
- Fill with Scania Anti-corrosive as indicated on the packaging.
- Topping up with 1.0% by volume of Scania Anti-corrosive should be
done after every 2,400 operating hours.
- Never top up with water only or anti-corrosive only. Lost fluid should
always be replaced with pre-mixed coolant:
water + 10% Scania Anti-corrosive by volume.
Note
The coolant should be changed when the cooling system is clea-
ned: every 4,800 hours or at least every 5th year.
Changing coolant
1.
Remove the filler cap from the expansion tank.
2.
The coolant is drained at two points:
- the ”lowest point” of the engine block, see drawing
- the ”lowest point” of the cooling system.
3.
Close the valves.
4.
Fill coolant through the expansion tank filler hole.
Mix coolant as described on page 20.
Scania Anti-corrosive must not
be mixed with glycol.
Mixing or over concentration
can cause sludging and
reduced cooling capacity.
Any coolant filter must not
contain inhibitor.
23
9.
Every 4,800 hours:
CLEANING COOLING SYSTEM
Note
If necessary, the cooling system should be cleaned more often.
External cleaning
Heat exchanger
1.
Drain the coolant from the engine, see “Changing coolant”.
2.
Drain the seawater circuit.
3.
Detach the heat exchanger hose and pipe connections.
4.
Dismantle the heat exchanger as illustrated.
5.
Clean the outside of the element. Use a paraffin-based engine cleaner.
6.
Any deposit on the inside of the pipes is removed mechanically using a
round file.
7.
Assemble the heat exchanger. Change damaged and hardened O-rings.
8.
Refit hose and pipe connections.
9.
Fill the system with coolant as described in the specifications on
page 20.
1.
Heat exchanger
housing
5.
Cover
6.
Gasket
7.
Screw
8.
Cooling element
9.
O-ring
10.
Gasket
11.
O-ring
(DS only)
12.
Cover
13.
Gasket
14.
Screw
15.
Washer
16.
Cover
17.
O-ring
18.
Screw
19.
Washer
20.
O-ring
21.
Protective anode
(4 pcs)
22.
Plug
23.
Gasket
24.
Pressure cap
28.
Cover (DS only)
29.
Gasket
(DS only)
30.
Screw (DS only)
The cooling system must not
be cleaned using caustic soda.
Risk of damaging
aluminium parts.
Note
There is a spring and a
retainer in the heat exchanger,
between the housing and the
element, which are not
illustrated.
24
Charge air cooler (DSI engine)
1.
Drain the coolant from the engine, see “Changing coolant”.
2.
Detach the upper part of the intake manifold.
3.
Detach the charge air cooler hose and pipe connections.
4.
Dismantle the charge air cooler as illustrated.
Take care not to damage the element’s water connections.
5.
Clean the outside of the element. Use a paraffin-based engine cleaner.
6.
Assemble the charge air cooler. Change all seals and gaskets.
7.
Refit hose and pipe connections.
8.
Fill coolant as described on page 20.
9.
Connect the intake manifold from the turbo.
1.
Intake manifold, lower
part
2.
Gasket
3.
Radiator element
4.
Gasket
5.
Intake manifold, upper
part
6.
V-ring seal
Engines without heat exchanger (keel-cooling)
1.
Check cooling elements/cooling pipes on the inside and outside of the
keel.
2.
Clean as necessary using a paraffin-based engine cleaner or carefully
scrape off deposits from external pipes.
Take care - do not damage cooling elements or cooling pipes.
The cooling system must not
be cleaned using caustic soda.
Risk of damaging aluminium
parts.
25
Internal cleaning
Removing oils and greases
- If possible, run the engine until it is warm and then drain the cooling
system.
- Remove the thermostat(s).
- Fill the system with clean, hot water mixed with liquid dishwasher
detergent designed for household machines.
Mix 1% (0.1/10 l).
- Run the engine until warm (about 20 or 30 minutes). Do not forget any
cab heating system.
- Drain the cooling system.
- Fill the system again using clean, hot water and run the engine for about
20-30 minutes.
- Drain the water from the system.
- Refit the thermostat(s).
- Fill the system with coolant as described in the specifications on
page 20.
Removing deposits
- If possible, run the engine until it is warm and then drain the cooling
system.
- Remove the thermostat(s).
- Fill the system with clean, hot water mixed with one of the commerci-
ally available radiator cleaners based on sulphamin acid and containing
dispersing agents. Follow the manufacturer’s instructions for mix ratios
and cleaning times.
- Run the engine for the for the specified time and then drain the cooling
system.
- Fill the system again with hot water and run the engine for about 20 or
30 minutes.
- Drain the water from the system.
- Refit the thermostat(s).
- Fill the system with coolant as described in the specifications on
page 20.
WARNING
When handling cleaners for
the cooling system:
Study the warning on the
packaging.
!
26
AIR CLEANER
10. Daily:
TEST READING
LOW PRESSURE INDICATOR
If the indicator’s red plunger is fully visible, change or clean the air cleaner
filter insert, point 12.
11. Every 200 hours:
CLEANING THE AIR CLEANER
COARSE CLEANER
1.
Detach the eccentric catch and remove the coarse cleaner.
2.
Remove the plastic cover from the coarse cleaner and clean the parts.
3.
Check that the plastic cover is intact and that it makes a seal against the
air cleaner housing during assembly.
4.
Assemble the air cleaner
12. Every 1,200 hours:
CLEANING OR CHANGING
FILTER INSERT
Note
Earlier if low pressure indicator shows red
Dismantling
1.
Remove and clean the coarse cleaner, see point 11.
2.
Undo the nut securing the filter insert and remove it.
3.
Change or clean the insert.
Note
Cleaning the insert always means a risk of damage. The insert
may only be cleaned no more than four times. After cleaning, it
has a lower dust capacity than a new insert.
4.
Mark the filter when it has been cleaned.
Cleaning insert
- Carefully blow the filter insert clean using dry compressed air from the
inside.
Note
This insert must not be washed using water.
Use only Scania genuine
air filter.
Change damaged filter
inserts.
Major risk of engine
damage if the filter insert is
damaged.
1.
Pre-filter with cover
2.
Filter insert
3.
Low pressure indicator
4.
Safety cartridge
The coarse cleaner should
be fitted with the marking
“TOP” facing up.
27
Checking
- Insert a flashlamp into the insert and check from the outside that there
are no holes or cracks in the filter paper.
- Change the filter insert if there is any damage at all. Danger of engine
damage.
Assembly
1.
Assemble the air cleaner in reverse order.
2.
Reset the red plunger in the low pressure indicator by pressing in the
button
Filters with non-replaceable insert (unit cleaner)
Cleaning
- The filter must be cleaned no more than 3 times. Make a mark on it each
time it is cleaned.
- Use a solution of water and 1% mild detergent
1.
Pour the washing solution into the filter intake while turning the filter so
that the solution runs out of it in the direction of air flow.
2.
Leave the filter in the washing solution for 5 minutes and then lift it to
drain off the solution
3.
Rinse the filter with about 30 litres of clean water at 30 - 40 В°C. Pour the
rinse water into the filter in the same way as the washing solution.
4.
Lift the filter and allow the rinse water to drain.
5.
Repeat this procedure until the rinse water runs clear.
6.
Leave the filter to dry in a warm place for several days.
Note
The filter must not be blown dry using compressed air.
28
13. Every 2,400 hours:
CHANGING SAFETY CARTRIDGE
1.
Remove and clean the coarse cleaner, see point 11.
2.
Undo the nut securing the filter insert and remove it.
3.
Change or clean the filter insert, see point 12.
4.
Undo the nut securing the safety cartridge and remove it.
5.
Fit a new Scania genuine safety cartridge.
6.
Assemble the air cleaner.
Never clean the safety
cartridge.
Do not remove the safety
cartridge unnecessarily.
1.
Pre-filter
with cover
2.
Filter insert
3.
Low pressure indicator
4.
Safety cartridge
29
FUEL SYSTEM
14. Daily:
CHECKING FUEL LEVEL
- Top up fuel if necessary.
- If the tank is run dry, bleed the fuel system, see point 15.
Be extremely careful with
cleanliness when working on
the fuel system.
Malfunctions
can easily arise and the
injection equipment
can be damaged.
15.
Every 1,200 hours:
CHANGING THE FUEL FILTER
Fuel tanks
- Drain any water from the fuel tanks.
Main filter
The filter consists of two parallel coupled filter units.
- Wash the outside of the filters and unscrew them. Dispose of the filters
according to environmental regulations.
- Do up the new filter by hand.
Never use tools. The filters may be damaged, inhibiting circulation.
- Bleed the fuel system as below.
- Start the engine and check for leaks.
Bleeding the fuel system
- Open the bleed screw 1 on the main filter.
- Pump the hand pump 2 until air-free fuel flows out at the maim bleed
screw.
- Close the bleed screw. Pump a few times using the hand pump.
If the engine is difficult to start after bleeding . . . . .
- Slacken the injection pump overflow valve 3 one half turn
and try starting again. On the 8000 pump, the overflow valve is located
on the fuel shut-off valve.
If the engine still won’t start . . . . . . .
- Pump the hand pump until bubble-free fuel flows from the overflow
valve.
Tighten the overflow valve when the engine has started.
Use only Scania genuine
fuel filter
1
2
3
30
16. Every 2,400 hours:
CHECKING INJECTORS
Injectors should be inspected by trained personnel with access to the required
equipment, at least once every year or every 2,400 hours.
Removal
1.
Clean around the injectors and connections including the clamps and
brackets.
2.
Detach the delivery pipe bundle and the leak-off fuel lines.
3.
Unscrew the injector.
4.
Place protective plugs on the injector and delivery pipe.
5.
Lift the seal from the bottom of the injector seat if it does not come out
together with the injector.
6.
Place a seal plug in the injector seat in the cylinder head.
7.
Clean the injectors and check/adjust in an injector tester.
Correct opening pressure, see Technical data, page 43.
Fitting
1.
Check that there is no old seal in place and fit a new seal in the bottom
of the injector seat.
2.
Fit a new O-ring in the socket nut and a new seal under it.
3.
Fit the injector.
4.
Tighten the socket nut to 70 Nm (7.0 kpm).
5.
Fit the delivery pipe and tighten the cap nuts to 20 Nm
(2.0 kpm). Fit clamps and brackets.
Take care to fit the delivery pipe without tension and make sure that
the cone on the delivery pipe is correctly positioned in the connector.
6.
Fit the leak-off fuel line. Tighten the bolts to 11 Nm (1.1 kpm).
1.
Delivery pipes
2.
Cap nut
3.
Washer
4.
Cone
5.
Connector on injector or
injection pump
Delivery pipe connection
1.
Socket nut
2.
O-ring
3.
O-ring
4.
Stop ring
5.
Guide pin
6.
Seal
The delivery pipes must not
be bent.
All clamps must be refitted.
31
ELECTRICAL SYSTEM
17. Every 200 hours:
CHECKING ELECTROLYTE LEVEL
IN BATTERIES
1.
Undo the plugs and check the electrolyte level in all cells.
2.
Top up using distilled water until the level is 10-15 mm above the plates.
18. Every 200 hours:
CHECKING CHARGE STATE
IN THE BATTERIES
Note
Every 200 hours applies to gensets and the like. Other installa-
tions every 1,200 hours.
- Check specific gravity using a battery electrolyte tester.
In a fully charged battery it should be:
1,280 at +20В°C
1,294 at 0В°
1,308 at -20В°C
- If the specific gravity is below 1.20, the battery must be charged.
A discharged battery freezes at -5 В°C.
Avoid boost charging. This will damage the battery in the long term.
19. Every 200 hours:
CLEANING BATTERIES
Note
Every 200 hours applies to gensets and the like.Other installa-
tions every 1,200 hours.
1.
Clean batteries, cables and cable terminals.
2.
Check that all cable terminals are well tightened.
3.
Grease posts and cable terminals using petroleum jelly.
32
20. Every 1,200 hours:
CHECKING COOLANT
LEVEL MONITOR
(optional equipment)
1.
Start the engine.
2.
Check the level monitor by turning the ”TEST” knob to the right.
3.
Automatic stop in case of fault: Engine stops, warning lamp lights and
buzzer sounds if there is no fault in the level monitor.
4.
No automatic stop in case of fault: Warning lamp lights, buzzer sounds
if there is no fault in the level monitor.
C = Common connection
NC =Connection NC - C breaks at
low coolant level
NO =Connection NC - C closes at
low coolant level
2-pole level monitor
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