Table of Contents
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When work is being carried out on the engine such as adjusting drive belts, changing oil or
adjusting the clutch, it is important not to start the engine. The engine may be damaged and
!
For this reason, always secure the starting device or disconnect a battery cable before working on
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 the risk of
When the commissioning report has been filled in and sent to Scania, you have a 1-year warranty from the date
of commissioning.
Also fill in the particulars below as this can make things easier if you need to contact for example a service
workshop.
Engine number
Date of commissioning
User's name and address
Signature
Engine type
Variant
Engine type and variant are indicated on the engine type plate
IMPORTANT INFORMATION
A SERIOUS RISK OF INJURY
injury is particularly great.
Operator's Manual
DI12, DC12
EMS with S6/PDE
Industrial engine
opm_d12ind_en-GB01
COMMISSIONING REPORT - WARRANTY
there is
the engine.
1 920 785
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Table of Contents
Troubleshooting
Related Manuals for Scania DC12
Summary of Contents for Scania DC12
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Page 1: Important Information
1 920 785 COMMISSIONING REPORT - WARRANTY When the commissioning report has been filled in and sent to Scania, you have a 1-year warranty from the date of commissioning. Also fill in the particulars below as this can make things easier if you need to contact for example a service workshop. -
Page 2: Preface
- Read the 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. - Follow the maintenance instructions. Good working order and service life are ensured if maintenance is carried out according to the instructions. -
Page 3: Table Of Contents
......33 Scania Assistance ..... . 65 Cleaning the oil filter unit ......34... -
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 as required to be able to meet the stringent environmental standards stipulated on almost all markets. -
Page 5: Certified Engines
European (EU) and non- European (USA) markets. Scania guarantees that all the engines it supplies of a certified type are equivalent to the engine approved for certification. The engine comes with a special certification plate which indicates the certification rules (standard) to which the engine has been approved. -
Page 6: Scania Industrial And Marine Engine Warranty For Industrial Engines
Scania warrants to the original owner, and to each subsequent owner, of a new Scania industrial diesel engine that the engine: 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. -
Page 7: Warranty Period
Parts covered by the Warranty The following is a list of parts considered to be part of the Emission Control Systems covered by the Emission Warranty for Scania industrial engines which were built to conform to federal emission control regulations:... -
Page 8: General Warranty Limitations
General Warranty Limitations To retain the dependability of the exhaust emission control originally built into your Scania industrial 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 and necessary repairs on your new Scania industrial diesel engine. -
Page 9: Specific Warranty Exclusions
Operator's Manual. Engine installation, including cooling system, intake system and exhaust system installation, that is not completed in accordance with the Scania installation instructions and emissions certificate for this engine type. Damage resulting from accidents, acts of nature or other events beyond the control of Scania. -
Page 10: Safety Information
SERIOUS RISK OF INJURY. A list of the safety precautions to be followed when running and maintaining Scania engines can be found on the next three 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 11: Safety Precautions Before Running
Only start the engine in a well ventilated area. The exhaust fumes contain carbon monoxide and nitric oxides, which are toxic. If it is run in a enclosed space, there should be an effective device to extract exhaust gases and crankcase gases. © Scania CV 2009... -
Page 12: Safety Precautions For Materials Handling
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 2009... - Page 13 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 2009...
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Page 14: Type Designations
Displacement in whole dm 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 general industrial use © Scania CV 2009... - Page 15 Engine number, stamped Oil dipstick Starter motor into the cylinder block Draining, engine oil S6 control unit Coolant pump Oil cooler Fuel filter Automatic belt tensioner Turbocharger Charge air cooler Draining, coolant Oil filler Oil filter Hydraulic pump © Scania CV 2009...
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Page 16: Engine Management System, Ems
The main task of the coordinator is to pass on data by means of CAN communication from the engine control unit to other control units and signals to gauges and lamps in the instrument panel. The coordinator also has monitoring functions. © Scania CV 2009... - Page 17 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.
- Page 18 Positions of sensors for EMS with S6 on DI12 Oil pressure sensor Charge air temperature and pressure sensor Coolant temperature sensor Engine speed sensor (2) © Scania CV 2009...
- Page 19 Location of sensors for EMS with S6 on DC12 Oil pressure sensor Charge air temperature and pressure sensor Coolant temperature sensor Engine speed sensor (2) © Scania CV 2009...
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Page 20: Troubleshooting Using Flash Codes For The Ems Control Unit
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. When a fault has been rectified the fault code can be erased as described below. -
Page 21: Overview Of Flash Codes For The Ems Control Unit
Incorrect voltage supply to one of the sensors. coordinator. PDE in cylinder 1: The solenoid valve is not Internal hardware fault in the processor (TPU). working properly. PDE in cylinder 2: The solenoid valve is not working properly. © Scania CV 2009... -
Page 22: Troubleshooting Using Flash Codes For The Ems Coordinator
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 erased as described below. -
Page 23: 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 2009... -
Page 24: Starting And Driving
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 25: Checks Before Running
45. Only start the engine in a well ventilated area. Out of consideration for our common environment, your Scania engine has been designed to use less fuel when starting. Using unnecessarily large If it is run in a enclosed space,... -
Page 26: Starting At Low Temperatures
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 27: Limp Home Mode
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 2009... -
Page 28: 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 2009... -
Page 29: Stopping The Engine
- At temperatures below 0°C: prepare for the next start by connecting the Important engine heater (if fitted). Coolant should be topped up when the engine is stopped after the first start. WARNING The system is pressurised. Major risk of burns. © Scania CV 2009... -
Page 30: Maintenance
8. Checking the vacuum indicator. "Annually" 12. Checking the fuel level. "Every 5th year" 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. © Scania CV 2009... -
Page 31: Maintenance Schedule
21. Checking and adjusting the unit injector rocker arms 22. Renewing (or cleaning) the closed crankcase ventilation valve More often if required. Earlier if the vacuum indicator shows red. If inhibitor has not been topped up for five years, the coolant should be changed. © Scania CV 2009... -
Page 32: Lubricating Oil System
- 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),... -
Page 33: Checking The Oil Level
Maximum permissible angles during operation vary, depending on the type of authorised waste disposal oil sump, see illustration. contractor. Note: The specified angles may only occur intermittently. 25° 25° 35° 35° © Scania CV 2009... -
Page 34: Cleaning The Oil Filter Unit
- Scrape off the deposits from the inside of the rotor cover. If there are no deposits, this indicates that the cleaner is not working properly. - If the deposits are thicker than 28 mm: clean more often. © Scania CV 2009... - Page 35 - Stop the engine when it is warm. - Listen for a whirring sound from the rotor or feel whether the cleaner housing is vibrating. The rotor normally continues spinning for 30-60 seconds after the engine has stopped. If not: dismantle and check. © Scania CV 2009...
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Page 36: Renewing The Oil Filter
(in connection with oil change) - Remove the old filter. - Fit a new Scania genuine filter. Oil the seal on the filter before fitting. - Tighten the filter by hand. Never use tools for this. The filter could sustain damage, obstructing circulation. -
Page 37: Checking Coolant
Coolant should be checked as follows: Check the appearance of the coolant. Coolant with glycol only: Check the glycol content. Coolant composition: Coolant containing only Scania Corrosion Inhibitor: check the corrosion inhibitor content If there is a danger of freezing: minimum 30% glycol by... - Page 38 -12 -16 -22 -27 -36 -46 -55 form at °C Glycol dm (litres) 100 120 A = Area to be avoided. Only for calculating glycol mix. Coolant freezing point (when ice starts to form) for different glycol mixes © Scania CV 2009...
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Page 39: Checking The Corrosion Protection
There must always be sufficient corrosion protection (inhibitor) in the coolant to protect the cooling system against corrosion. Corrosion inhibitor is highly If there is no danger of freezing, only Scania Corrosion Inhibitor should be dangerous if ingested and can used in the coolant. -
Page 40: Cleaning The Cooling System
Fill up with coolant according to the specification on page 35. Important! Let the sealing compound harden for at least 24 hours before the engine is used again. Charge air cooler element O-ring Sealant 816 064 Intake manifold © Scania CV 2009... -
Page 41: 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 coolant according to the specification on page 35. © Scania CV 2009... -
Page 42: Air Cleaner
Renew or clean the filter element. Note: There is always a risk that the filter element will be damaged Only use genuine Scania air during cleaning. The filter element can only be cleaned a filters. maximum of four times. After cleaning, it has poorer dust Renew the filter element if it is capacity than a new filter element. -
Page 43: Renewing The Safety Cartridge
Remove the cover from the air cleaner. Remove the filter element. Remove the safety cartridge. Fit a new genuine Scania safety cartridge. Renew or clean the filter element, see point 10. Assemble the air cleaner. 1. Safety cartridge... -
Page 44: Fuel System
- Fit the new filter and tighten it by hand. Important Never use tools for this. The filter could sustain damage, obstructing Use only genuine Scania fuel circulation. filters. - Bleed the fuel system as described below. -
Page 45: Bleeding The Fuel System
If the engine fails to start after bleeding: - Open the bleed nipple again and pump the hand pump until fuel without air bubbles flows out. - Tighten the bleed nipple. Start the engine and check for leaks. © Scania CV 2009... -
Page 46: Electrical System
Clean batteries, cables and cable terminals. This can cause serious damage Check that all cable terminals are firmly tightened. to the electrical system. Grease the battery terminal posts and cable terminals with Vaseline. If the terminals are shorted, sparking will occur. © Scania CV 2009... -
Page 47: Renewing The Battery
(if fitted) sounds if there is no fault in the level monitor. Top up coolant to the correct level, see page 36. 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 2009... -
Page 48: Miscellaneous
- On installations with dual belt circuits, the second belt circuit has two drive belts with one manual belt tensioner. These drive belts should be tensioned to 20 Nm ±2 Nm as illustrated. © Scania CV 2009... -
Page 49: Look For Leakage, Rectify As Necessary
A small amount of leakage from the overflow holes during the engine If serious leakage occurs, running-in period is normal. (Sealing rings and O-rings are lubricated contact your nearest Scania with soap or oil when fitted). workshop. - This leakage normally stops after a time. -
Page 50: Check And Adjust Valve Clearance
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. Openings for reading on the flywheel housing © Scania CV 2009... - Page 51 TDC Down (0°) 120° 240° TDC Down (360°) 120° 240° Mark on flywheel Valve overlap on Adjust the valves (reading taken through the cylinder on cylinder upper opening) TDC Up (0°) 300° 60° TDC Up (360°) 300° 60° © Scania CV 2009...
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Page 52: Checking And Adjusting The Unit Injector Rocker Arms
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. © Scania CV 2009... - Page 53 120° 240° TDC Down (360°) 120° 240° Mark on flywheel Adjust injector Valve overlap on (reading taken through the rocker arm on cylinder upper opening) cylinder TDC Up (0°) 300° 60° TDC Up (360°) 300° 60° © Scania CV 2009...
- Page 54 If an injector is defective, the whole injector must be replaced. 66.9 99 414 Piston above or below the flat surface. Adjustment necessary. Piston level with the flat surface. Adjustment is correct. © Scania CV 2009...
- Page 55 If an injector is defective, the whole injector must be replaced. 69.9 99 442 Piston above or below the flat surface. Adjustment necessary. Piston level with the flat surface. Adjustment is correct. © Scania CV 2009...
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Page 56: Renewing (Or Cleaning) The Closed Crankcase Ventilation Valve
- 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. © Scania CV 2009... -
Page 57: 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 well-sealed receptacle in a dry, cool place. Keep out of reach of children. © Scania CV 2009... -
Page 58: Preservative Oil
- 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. © Scania CV 2009... -
Page 59: Batteries
- 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. © Scania CV 2009... -
Page 60: Technical Data
(kp/cm Normal oil pressure (hot engine at operating speed) bar (kp/cm Minimum oil pressure (hot engine 1,000 rpm bar (kp/cm Oil capacity, see page 33 Crankcase pressure with closed crankcase ventilation mm VP -55 - +20 © Scania CV 2009... - Page 61 (litres) Electrical system System voltage Alternator, current 65 or 100 Starter motor output kW (hp) 6.7 (9.1) Monitors, threshold values: oil pressure monitor bar (kp/cm 0.15 ± temperature monitor °C Stamped on hexagonal part of monitor © Scania CV 2009...
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Page 62: Fuel
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). - Page 63 In the long term, petrol may cause Drain fuel tanks and drain or renew fuel filters regularly. wear to the unit injectors and at worst it may also cause damage to the engine. © Scania CV 2009...
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Page 64: Alphabetical Index
Glycol ....... 37 Warranty ......1 © Scania CV 2009... -
Page 65: Scania Assistance
Scania Assistance Wherever you are you can always get assistance from our service organization, 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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