Scania DI16 Operator's Manual

Scania DI16 Operator's Manual

Ems with s6/pde
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When working on the engine, for example adjusting drive belts, changing the oil or adjusting the
clutch, it is important not to start the engine. The engine may be damaged and there is a
!
For this reason, always secure the starting device or disconnect a
This is especially important if the engine has a remote starter or automatic starting.
This warning symbol and text is reproduced beside those inspection points where the risk of injury
When the start-up report has been filled in and sent to Scania, you have a 1-year warranty from the date of
entry into service.
Also fill in the particulars below as this can make things easier if you need to contact a workshop for example.
Engine serial number
Date of entry into service
Power class, see page 5
User's name and address
Signature
Engine type
Variant
Engine type and variant are indicated on the engine type plate

IMPORTANT INFORMATION

SERIOUS RISK OF INJURY
battery cable before working on the engine.
is particularly great.
Operator's Manual
EMS with S6/PDE
Marine engine
opm_d16mar_en-GB 2 291 675
COMMISSIONING REPORT - WARRANTY
DI16

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Summary of Contents for Scania DI16

  • Page 1: Important Information

    2 291 675 COMMISSIONING REPORT - WARRANTY When the start-up report has been filled in and sent to Scania, you have a 1-year warranty from the date of entry into service. Also fill in the particulars below as this can make things easier if you need to contact a workshop for example.
  • Page 2: Preface

    In order to obtain the best value and service life from your engine, there are several points you should bear in mind: - Read the Operator's Manual before starting to use the engine. Even though you may have experience of Scania engines you may find new information in this Operator's Manual. Help protect our environment! - Follow the maintenance instructions.
  • Page 3: Table Of Contents

    Location of sensors for EMS with S6 on DI16 ......13 Renewing the fuel filter ........42 Troubleshooting using flash codes for the Electrical system .
  • Page 4: Environmental Responsibility

    Environmental responsibility Scania has always been very much at the leading edge when it comes to developing and producing engines which are as environmentally friendly as possible. Major progress has been made on reducing harmful exhaust emissions in order to comply with the stringent environmental requirements in force on almost all markets.
  • Page 5: Power Classes

    4 pages must also be observed. Important! If inspection and maintenance are not carried out as specified above, Scania can no longer guarantee that the engine will comply with the certified design, nor can it take responsibility for any damage that occurs.
  • Page 6: Safety Information

    INJURY. A list of the safety precautions to be followed when running and maintaining Scania engines can be found on the next 3 pages. Similar text can often be found at the relevant maintenance points, and here different levels of importance are attached to such text in accordance with the above description.
  • Page 7: Daily Inspection

    Only start the engine in a well ventilated area. The exhaust gases contain carbon monoxide and nitrogen oxides, which are toxic. If it is run in an enclosed space, there should be an effective device to extract exhaust gases and crankcase gases. © Scania CV 2011...
  • Page 8: Stop The Engine

    If the acid splashes on your skin, wash it off with soap and copious amounts of water. If acid splashes in your eyes, flush them immediately with copious amounts of water and contact a doctor. Dispose of used batteries through an authorised waste disposal contractor. © Scania CV 2011...
  • Page 9 There is a risk of objects being sucked into the Dispose of used oil through an authorised waste compressor impeller or of injury if you come into disposal contractor. contact with it. © Scania CV 2011...
  • Page 10: Type Designations

    Supercharged diesel engine with liquid-cooled charge air cooler dm³ Displacement in whole Performance and certificate 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 For marine use © Scania CV 2011...
  • Page 11 The illustrations show a normal version of a DI16 engine. Your engine may have different equipment from the one illustrated Type plate Heat exchanger (main Starter motor circuit) Engine serial number, Control unit Sea water outlet stamped into the cylinder...
  • Page 12: Ems Engine Management System

    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 instrumentation. If the torque reduction function is activated, the amount of fuel and the engine power are reduced to 70%, and if engine shutdown is activated, the engine is switched off at programmed alarm levels.
  • Page 13: Location Of Sensors For Ems With S6 On Di16

    Location of sensors for EMS with S6 on DI16 Oil pressure sensor Coolant temperature sensor Charge air temperature and pressure sensor Engine speed sensor (2) © Scania CV 2011...
  • Page 14: Troubleshooting Using Flash Codes For The Ems Control Unit

    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. When a fault has been rectified the fault code can be cleared as described below.
  • Page 15: Overview Of Flash Codes For The Ems Control Unit

    Incorrect voltage supply to one of the sensors. tor. PDE in cylinder 1: The solenoid valve is not work- Internal hardware fault in the processor (TPU). ing properly. PDE in cylinder 2: The solenoid valve is not work- ing properly. © Scania CV 2011...
  • Page 16: Troubleshooting Using Flash Codes For The Ems

    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. When a fault has been rectified the fault code can be cleared as described below.
  • Page 17: Overview Of Flash Codes For The Ems Coordinator

    Short circuit in the signal cable to the coolant temperature warning lamp. Short circuit in the signal cable to the charge warning lamp. Incorrect signal from the Fixed speed switches. Fault in CAN communication. 1) Single-speed engine 2) All-speed engine © Scania CV 2011...
  • Page 18: Starting And Running

    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.
  • Page 19: Checks Before Running

    If it is run in an enclosed space, Out of consideration for our common environment, your Scania engine has there should be an effective been designed to use less fuel when starting. Using unnecessarily large...
  • Page 20: Running

    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.
  • Page 21: Coolant Temperature

    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. © Scania CV 2011...
  • Page 22: Oil Pressure

    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. © Scania CV 2011...
  • Page 23: Stopping The Engine

    - If there is danger of freezing the sea water system must be emptied. - At temperatures below 0°C: prepare for the next start by connecting the engine heater (if fitted). WARNING Coolant should be topped up when the engine is stopped after the first start. © Scania CV 2011...
  • Page 24: Maintenance

    14. Checking electrolyte level in batteries. maintenance should be carried out in accordance with the 15. Checking state of charge in batteries. schedule: 16. Cleaning batteries. "Annually" 19. Check for leaks, rectify as necessary. "Every 5 years" © Scania CV 2011...
  • Page 25: Inspection Schedule

    Only applies to marine engines with sea water pump and heat exchanger. Guideline value. Varies depending on the composition of the sea water. If inhibitor has not been topped up for 5 years, the coolant should be changed. © Scania CV 2011...
  • Page 26: Lubrication System

    - Viscosities are shown in the figure below. - For operation at extremely low outdoor temperatures: Consult your nearest Scania distributor on how to avoid starting difficulties. Oil analysis Some oil companies can offer analysis of the engine oil. Such analysis...
  • Page 27: Checking The Oil Level

    = 1 litre Help protect our WARNING environment! Use a container to avoid spills The oil may be hot. when changing the oil. Dispose Wear protective gloves and of used oil through an goggles. authorised waste disposal contractor. © Scania CV 2011...
  • Page 28: Cleaning The Centrifugal Oil Cleaner

    Clamp the nut, but never the rotor, in a vice and turn the rotor 3 turns by hand or with a screwdriver. - Tap the nut lightly with your hand or a plastic hammer, to detach the rotor cover from the bottom plate. © Scania CV 2011...
  • Page 29 - Check that the shaft is not loose. If it is loose, use thread-locking fluid 561 200 and torque tighten to 34 Nm. - Refit the rotor. - Check that it rotates easily by rotating it manually. © Scania CV 2011...
  • Page 30: Renewing The Oil Filter

    20 mm thick, the oil filter must be renewed more often. The same is true for cleaning the centrifugal filter and changing Use a container to avoid spills the oil. when renewing the filter. Dispose of used filters through an authorised waste disposal contractor. © Scania CV 2011...
  • Page 31: Renewing The Closed Crankcase Ventilation Filter

    - Top up the coolant as necessary, see point 8. out. Note: When filling large amounts of coolant: Never pour cold coolant into a hot engine. This could crack the cylinder block and cylinder head. Important Always top up with pre-mixed coolant. © Scania CV 2011...
  • Page 32: Checking The Sacrificial Anodes

    If the impeller must be renewed frequently, the cleaning of the sea water needs to be improved. Renewing the impeller - Pull out the impeller with puller 98 482 (Scania special tools). - Fit a new impeller and cap. Check that the cap seal is not hard or damaged.
  • Page 33: Checking The Coolant

    The coolant should be page to help you calculate how much glycol you need. pre-mixed when it is poured Scania recommends only nitrite-free antifreeze glycols with the following into the cooling system. supplier designations: Never top up with only water or BASF G48 or BASF D542 only glycol.
  • Page 34 Ice slush starts to -12 -16 -21 -24 -30 -37 form at °C Ethylene glycol (litre) A= Area to be avoided. Only for calculating glycol mix. Coolant freezing point, when ice starts to form, for different glycol mixes © Scania CV 2011...
  • Page 35: Changing The Coolant

    Corrosion inhibitor can be fatal if ingested. If there is no danger of freezing, only Scania Corrosion Inhibitor should be used in the coolant. Avoid contact with the skin. The inhibitor in Scania Corrosion Inhibitor is free of nitrites.
  • Page 36: Cleaning The Cooling System

    Tighten the flange nuts to 26 Nm. Fit the complete heat exchanger to the engine and tighten the screws to 92 Nm. Connect the sea water pipes and the radiator where fitted. Connect the pipes to the engine and charge air coolers. © Scania CV 2011...
  • Page 37 Heat exchanger housing, main Core, main section section Rear cover O-ring O-ring Flange Core, charge air section O-ring Heat exchanger housing, charge Front cover air section Seal O-ring Sacrificial anodes Flange O-ring Housing, intermediate section O-ring O-ring © Scania CV 2011...
  • Page 38 Refit the air pipes from the turbochargers and the pipe between the charge air coolers. Refit the expansion tank, catwalk and belt guard. Intake manifold, upper part Core V-ring seal O-ring Pipe connection Gasket Intake manifold, lower part © Scania CV 2011...
  • Page 39: Internal Cleaning

    - Refill the system with hot water and run the engine for about 20-30 minutes. - Drain the water from the system. - Refit the thermostats. - Top up the system with new coolant according to the specification on page 33. © Scania CV 2011...
  • Page 40: Air Cleaner

    11. This is especially important if the engine is run with a heavy load or high engine speed. 11. Every 1,200 hours: Important Cleaning or renewing the filter element Only use genuine Scania air Note: Earlier if the vacuum indicator shows red. filters. Dismantling...
  • Page 41 Take out the element and allow the rinsing water to drain off. Repeat this procedure until the rinsing water is clean. Leave the element to dry in a warm place for approximately 24 hours. The filter must not be dried with compressed air. © Scania CV 2011...
  • Page 42: Fuel System

    13. Every 1,200 hours: Renewing the fuel filter Important Fuel tanks Use only genuine Scania fuel - Drain any water from the fuel tanks. filters. Main filter The filter consists of a filter unit. - Wash the outside of the filter and unscrew it.
  • Page 43: Bleeding The Fuel System

    If the engine fails to start after bleeding: - Open the bleed nipples again and pump the hand pump until fuel without air bubbles flows out. - Tighten the bleed nipples. Start the engine and check for leaks. © Scania CV 2011...
  • Page 44: Electrical System

    Clean batteries, electrical cables and cable terminals. to the electrical system. Check that all cable terminals are firmly tightened. If the terminals are shorted, Grease the battery terminals and cable terminals with Vaseline. sparking will occur. © Scania CV 2011...
  • Page 45: Renewing The Battery

    (if fitted) sounds if there is no fault in the level monitor. Top up coolant to the correct level, see page 31. Help protect our environment! Use a container to avoid spills when draining the coolant. Dispose of used coolant through an authorised waste disposal contractor. © Scania CV 2011...
  • Page 46: Miscellaneous

    - If the drive belt (1), which is a poly-V belt, is worn or damaged it must be renewed. - Also check that the automatic belt tensioner (2) is in proper working order and keeps the drive belt correctly tensioned. © Scania CV 2011...
  • Page 47: Check For Leaks, Rectify As Necessary

    - 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. If serious leakage occurs, contact your nearest Scania - This leakage normally stops after a time. workshop. © Scania CV 2011...
  • Page 48: Checking And Adjusting The Valve

    This adjustment is essential as a fault in the position of the Dimension A=PDE31: 66.9 ± 0.1 mm unit injector can result in poor performance and possible breakdown. PDE32: 69.9 ± 0.1 mm Dimension B=PDE31: 36.5 mm PDE32: 38.8 mm © Scania CV 2011...
  • Page 49 TDC Down (0°) 4 and 5 surface. Adjustment necessary TDC Up (180°) 2 and 6 TDC Down (360°) 3 and 7 TDC Up (540°) 1 and 8 Piston level with the flat surface. The adjustment is correct © Scania CV 2011...
  • Page 50 TDC Down (0°) 4 and 5 surface. Adjustment necessary TDC Up (180°) 2 and 6 TDC Down (360°) 3 and 7 TDC Up (540°) 1 and 8 Piston level with the flat surface. The adjustment is correct © Scania CV 2011...
  • Page 51: Preparing The Engine For Storage

    Fresh air, rest and warmth Flammable: Fire class 2A. Flashpoint +27°C. In the event of fire: Extinguish with carbon dioxide, powder or foam Storage: In a well-sealed receptacle in a dry, cool place. Keep out of reach of children. © Scania CV 2011...
  • Page 52: Preservative Oil

    - Spray the outside of bright engine parts, first with penetrating preservative oil such as Dinitrol 25B and then with Dinitrol 112 or the equivalent. Winter storage - To reduce the risk of condensation in the fuel tank during winter storage, fill the tank with fuel. © Scania CV 2011...
  • Page 53 PDE injector mechanisms. - Drain the preservative fuel from the fuel manifolds and fuel filter. - Connect and bleed the fuel system, see page 43. - Wash off any externally applied preservative oil using white spirit. © Scania CV 2011...
  • Page 54: Technical Data

    (kp/cm Min. oil pressure warm engine 1,000 rpm bar (kp/cm Min. oil pressure warm engine, idling bar (kp/cm Oil capacity, see page 27 -55 - +20 Crankcase pressure with closed crankcase ventilationmm water column © Scania CV 2011...
  • Page 55 Volume including heat exchanger and expansion tank Electrical system System voltage Alternator, current 6.7 (9.1) Starter motor output kW (hp) Monitors, threshold values: 0.15 oil pressure monitor bar (kp/cm ± Stamped on hexagonal part of monitor temperature monitor °C © Scania CV 2011...
  • Page 56: Fuel

    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.
  • Page 57 - If the fuel concerned cannot cope with the expected temperatures, and diesel is not available with the correct temperature properties, Scania causes engine damage. recommends that an electric fuel heater is installed as a preventive measure.
  • Page 58: Ec Declaration Of Conformity

    EC declaration of conformity The following declaration of conformity applies to the DI16 45M with an engine output of 662 kW. The declaration guarantees that the engine is classified as suitable for recreational craft according to directive 94/25/EC. © Scania CV 2011...
  • Page 59: Alphabetical Index

    Lubricating oil pressure ........ 22 Lubrication system ........26 Maintenance ..........24 Oil analysis ............ 26 Oil capacity ........... 27 Oil change ............. 27 Oil filter ............28 Oil filter ............30 Oil grade ............26 © Scania CV 2011...
  • Page 60: Scania Assistance

    Wherever you are, you can always get assistance from the Scania service organisation, Scania Assistance, all day, every day of the year. Using Scania Assistance is free, but the cost of repairs, spare parts and help from mechanics will be debited.

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