Table of Contents
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Important information
Serious risk of injury
When working on the engine, for example when adjusting drive belts and the clutch, or when changing the
oil, it is important not to start the engine. The engine could be damaged, but more importantly there is a
serious risk of injury.
For this reason, always secure the starting device or disconnect a battery cable before working on the engine.
This is especially important if the engine has a remote starter or automatic starting.
WARNING!
This warning symbol and text can be found next to those maintenance items where it is particularly impor-
tant to bear in mind the risk of injury.
Operator's manual
DI16
XPI
Marine engine
en-GB 2 587 322
Issue 2.0
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Table of Contents
Related Manuals for Scania DI16 XPI series
Summary of Contents for Scania DI16 XPI series
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Page 1: Important Information
Important information Serious risk of injury When working on the engine, for example when adjusting drive belts and the clutch, or when changing the oil, it is important not to start the engine. The engine could be damaged, but more importantly there is a serious risk of injury. -
Page 2: Table Of Contents
Changing the oil ..... . 25 Scania Assistance ..... . .83 Maximum angles of inclination during operation Cleaning the centrifugal oil cleaner . -
Page 3: Start Of Warranty
The more we know about you, your company and your equipment, the more effectively we can adapt our services to you. If you have started to use a new Scania engine, it is very important that you send in the war- ranty start report to us immediately. -
Page 4: Introduction
The information in this Operator's manual was only once approval has been granted by Sca- correct at the time of going to press. Scania re- nia. Modifications may be made by author- serves the right to make alterations without prior ised personnel only. -
Page 5: Power Classes
The engine serial numbers and power classes for the engines that are used in this installation should be listed below: You can find the power class of your engine in the engine type data sheet on the Scania website, www.scania.com. -
Page 6: Environment And Safety
Warning! Environmental responsibility All advisories preceded by Warning! are very important. They warn of serious faults and incor- Scania develops and produces engines that are as rect operation that could lead to personal injury. environmentally-friendly as possible. Scania has Example:... -
Page 7: Warnings And Advisories
This inspection should be done to detect fuel, oil there must be an effective device to extract ex- or coolant leaks, or anything else that may re- haust gases and crankcase gases. quire corrective action. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 8: Scania Cv Ab 2017, Sweden
Parts of the body, clothes or dropped tools can get caught in rotating parts such as the fan and cause injury. For personal safety all ro- tating parts and hot surfaces must be fitted with guards. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 9: Scania Cv Ab 2017, Sweden
There is always a risk of sustaining burns when an engine is hot. Particularly hot parts are engine manifolds, turbochargers, oil sumps, as well as hot coolant and oil in pipes and hoses. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 10: Scania Cv Ab 2017, Sweden
Hot oil can cause burns and skin irritation. Wear Maintenance and repairs of injection equipment protective gloves and goggles when changing are to be carried out by an authorised Scania hot oil. workshop. Make sure that there is no pressure in the lubri- Always use Scania spare parts for the fuel and cation system before starting work on it. -
Page 11: Scania Cv Ab 2017, Sweden
Wash with soap and plenty of water. If it gets in your eyes: Rinse immediately with plenty of wa- ter and seek medical attention. Environment Used batteries must be disposed of as specified in national and international laws and regula- tions. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 12: Engine Data Plate
Made b y DI16 076M T ype 123456 7 Engine N o Outp u t . rpm. 2300 Outp u t . rpm. Type approval No: e5*97/68VC*2012/46*0182*00 Example of an engine data plate. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 13: Component Identification
Component identification Component identification OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 14: Scania Cv Ab 2017, Sweden
Holes for draining condensation in charge air cooler (2 off on the underside). Oil dipstick. Centrifugal oil cleaner. Note: The two water separating prefilters for the fuel are located between the fuel tank and engine. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 15: Starting And Running
30 seconds at a time. After that, it must rest for at least 5 minutes before the next attempt to start it. Checks before running For environmental reasons the Scania engine has Carry out daily maintenance as described in the been developed to be started with a low fuel feed. -
Page 16: Running
It is then not possible to run the engine at maximum power. The engine must not be run at an altitude of more than 1,000 metres. Contact Scania if the operat- ing conditions deviate from these. OPM 360 en-GB ©... -
Page 17: Scania Cv Ab 2017, Sweden
The noise is normal value. normal and disappears after 50-100 hours of op- eration. The noise does not affect the service life of the belt transmission. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 18: Engine Shutdown
See the sec- tion Coolant resistance to cold. If the temperature is below 0°C (32°F): Pre- pare for the next start by connecting the en- gine heater (if fitted). OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 19: Maintenance
• L maintenance: Almost all maintenance items. • XL maintenance: All maintenance items. During a period, the sequence is S-M-S-L-S-M- S-L-S-M-S-XL. 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 20: Scania Cv Ab 2017, Sweden
Maintenance IMPORTANT! On delivery a Scania engine is optimised for its application. However, regular maintenance is necessary to: • prevent unplanned stops • extend the service life of the engine • maximise the long-term emission perfor- mance of the engine •... -
Page 21: Maintenance Intervals
Fuel system Checking fuel level Draining the water separating prefilter Renewing the fuel filters Miscellaneous Checking the drive belt Checking for leaks Checking and adjusting the valve clearance OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 22: Lubrication System
Lubrication system Lubrication system Oil grade Scania LDF stands for the Scania Long Drain Field test standard. Scania LDF oils have been carefully selected after extensive testing. The ap- proval is only granted to the highest quality en- gine oils available on the market. -
Page 23: Scania Cv Ab 2017, Sweden
2 296 071 ACEA E7 White 2 296 065 Scania Low Ash Green 2 296 067 Scania Bioethanol Black 2 296 068 Scania BEO-2 Orange 2 296 070 ACEA E9 2 296 069 OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 24: Oil Analysis
Lubrication system Oil analysis To be able to extend the oil change intervals us- ing an oil analysis, Scania LDF-2 and LDF-3 oils must be used. Most oil companies offer analysis of the engine oil. The following conditions must remain ful- filled when the oil is changed: •... -
Page 25: Changing The Oil
Min. 29 litres (7.6 US gallons). Clean the magnet on the oil plug. Max. 37 litres (9.7 US gallons). Refit the oil plug. Fill with oil. Check the level on the oil dipstick. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 26: Maximum Angles Of Inclination During Operation
Maximum angles of inclina- tion during operation Maximum permissible angles of inclination dur- ing operation vary, depending on the type of oil 25° sump. See illustration. 25° 30° 30° 25° 25° 30° 30° OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 27: Cleaning The Centrifugal Oil Cleaner
The oil may be hot. Carefully remove the cover from the centrifugal oil cleaner. Note: Always use genuine Scania parts during mainte- nance of the centrifugal oil cleaner. This will en- sure that the centrifugal oil cleaner continues to function. - Page 28 Remove the strainer from the rotor cover. If the strainer is stuck, insert a screwdriver be- tween the rotor cover and strainer and care- fully prise them apart. OPM 360 en-GB © Scania CV AB 2017, Sweden...
- Page 29 Inspect the 2 nozzles on the rotor. Ensure that they are not blocked or damaged. Renew any damaged nozzles. Check that the bearings are undamaged. Re- new damaged bearings. Fit a new paper insert inside the rotor cover. OPM 360 en-GB © Scania CV AB 2017, Sweden...
- Page 30 If the rotor shaft needs renewing, the renewal procedure is described in the Workshop Manual, which can be ordered from a Scania dealer or directly from Scania. Refit the rotor and rotate it by hand to check that it rotates easily.
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Page 31: Operational Testing Of The Centrifugal Oil Cleaner
Turn off the engine and listen for the sound from the rotor. Use your hand to feel if the filter housing is vibrating. If the filter housing is not vibrating, disman- tle and check the centrifugal oil cleaner. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 32: Renewing The Oil Filter
Make sure the oil filter drain has emptied the oil from the filter housing. Screw on the filter cover firmly with the socket. Start the engine and inspect the filter housing for leaks. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 33: Air Cleaner
Insert a torch into the element and check from the outside that there are no holes or cracks in the filter paper. Assemble the air cleaner. Reset the vacuum indicator by pressing the button. Resetting the vacuum indicator. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 34: Renewing The Safety Cartridge
Remove the cover from the air cleaner. Remove the filter element. Air cleaner. Remove the safety cartridge. Cover. Fit a new safety cartridge from Scania. Filter element. Renew or clean the filter element. Safety cartridge. Check the condition of the O-ring. Renew O-ring. -
Page 35: Cooling System
• Corrosion inhibitor. • Antifreeze. °C • Increases the boiling point. Scania recommends that the coolant used is a mixture of water with antifreeze and corrosion inhibitor (ethylene glycol). The coolant should The chart depicts coolant properties at different always contain 35-55% by volume of antifreeze... -
Page 36: Scania Cv Ab 2017, Sweden
Cooling system Antifreeze and corrosion protection con- centration table, litres 35% by volume of Scania antifreeze provides sufficient protection against corrosion. Example: • The total volume of the cooling system is 40 litres. • The measured concentration of ethylene gly- col is 35% by volume (freezing point -21°C). -
Page 37: Scania Cv Ab 2017, Sweden
Cooling system Antifreeze and corrosion protection con- centration table, US gallons 35% by volume of Scania antifreeze provides sufficient protection against corrosion. Example: • The total volume of the cooling system is 10.6 US gallons. • The measured concentration of ethylene gly- col is 35% by volume (freezing point -6 °F). -
Page 38: Checking Coolant Level
Products that do not satisfy the require- sion tank if the engine is hot. Hot coolant and ments for use in a Scania engine can result in steam may spray out and cause burns. faults in and damage to the cooling system. This... -
Page 39: Checking Coolant Antifreeze And Corrosion Pro
• If ice forms in the coolant, there are disrup- tions initially, but there is no immediate risk of damage. The engine should not be subject- ed to heavy loads when ice starts to form. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 40: Checking Sacrificial Anodes
Drain the sea water circuit. See the section Draining the sea water circuit. Check that the vanes of the impeller are not heavily splintered or damaged. Sea water pump cover. OPM 360 en-GB © Scania CV AB 2017, Sweden... - Page 41 Lubricate the impeller with pump grease and then fit it using a rubber mallet. Fit the sea water pump cover. Tightening torque 7.5 Nm (5.5 lb/ft). Sea water pump cover. OPM 360 en-GB © Scania CV AB 2017, Sweden...
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Page 42: Changing The Coolant And Cleaning The Cooling
Repeat the procedure at the cooling system's Drain nipple in the cylinder block (behind the heat lowest drainage point. The location of the lowest drainage point on the engine may dif- exchanger). fer depending on engine application. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 43: Scania Cv Ab 2017, Sweden
Make sure that the cooling system is com- pletely drained as described in the previous section. Unscrew and remove the catwalk, protective plate and the protective casing. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 44: Scania Cv Ab 2017, Sweden
Use a screwdriver to pull out the lock. Loosen and remove the hose clamps for the charge air pipe. Remove all sea water pipes to and from the charge air cooler. OPM 360 en-GB © Scania CV AB 2017, Sweden... - Page 45 Left-hand turbocharger: Remove the V- clamp and carefully turn the charge air pipe during removal. Remove the screws securing the charge air cooler. Lift out the charge air cooler. OPM 360 en-GB © Scania CV AB 2017, Sweden...
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Page 46: Scania Cv Ab 2017, Sweden
Spacer. Charge air cooler housing. Cooler core. Renew damaged or hard O-rings (2). Assemble the charge air cooler. Tighten the M8 screws on the cover to 15 Nm (11 lb-ft). OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 47: Scania Cv Ab 2017, Sweden
If the engine has a water-cooled exhaust pipe bend: Remove the sea water pipe between the heat exchanger and the exhaust pipe bend. Remove the coolant pipe with the thermostat housing cover. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 48: Scania Cv Ab 2017, Sweden
2 upper screws on the exhaust mani- fold bracket. Remove the heat exchanger by holding it in the bracket, moving the heat exchanger slightly to the side and removing it. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 49: Scania Cv Ab 2017, Sweden
Do not use caustic soda as this could damage the aluminium. Cooler core. Renew damaged or hard O-rings (3). Assemble the heat exchanger. Tighten the M8 screws on the cover to 15 Nm (11 lb-ft). OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 50: Scania Cv Ab 2017, Sweden
Tightening torque 50 Nm (37 lb/ft). Lubricate and fit the coolant pipe from the heat exchanger. Angle the pipe from the ther- mostat housing inwards and push it onto the connection. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 51: Scania Cv Ab 2017, Sweden
Fit the sea water pipe between the charge air cooler and heat exchanger. If the engine has a water-cooled exhaust pipe bend: Fit the sea water pipe between the heat exchanger and the exhaust pipe bend. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 52: Scania Cv Ab 2017, Sweden
Fit the sea water pipe from the sea water pump, first to the charge air cooler (the inner pipe) and then from the charge air cooler to the heat exchanger (the outer pipe). OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 53: Scania Cv Ab 2017, Sweden
– Fit the protective casing. Tighten the screws later. – Fit the catwalk with screws. – Tighten all screws. The protective plate and protective casing must be tightened to a tightening torque of 15 Nm (11 lb-ft). OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 54: Scania Cv Ab 2017, Sweden
Remember to switch on the cab heating system, if one is installed. Drain the cooling system. Fill the cooling system with clean, hot water and run the engine for about 20-30 minutes. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 55: Scania Cv Ab 2017, Sweden
20-30 minutes. Drain the water from the cooling system. Refit the thermostats. Fill the cooling system with new coolant as described in the next section. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 56: Scania Cv Ab 2017, Sweden
Do not start the engine until the correct coolant level has been obtained. If the engine is started with an insufficient coolant level, it can damage the coolant pump shaft seal, which leads to cool- ant leakage. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 57: Scania Cv Ab 2017, Sweden
Open the bottom valve on the sea water inlet. Start the engine and check that no leakage occurs. Check the coolant level and top up the cool- ant via the expansion tank if necessary. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 58: Fuel System
Be extra careful and always use clean, lint-free and dust-free clothes and gloves when working on the fuel system. Scania recommends using Tegera 848 gloves. Clean tools before they are used and do not use any worn or chrome-plated tools. Material and flakes of chrome may come off. -
Page 59: Draining And Renewing The Water Separating Pre
Connect the sensor cable to the contact hous- ings on the filters. Bleed the fuel system according to the in- structions in the Bleeding the fuel system section. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 60: Draining And Renewing The Single Water Separat- Ing Prefilter
Screw the sensor cable in the contact housing onto the filter bracket. Bleed the fuel system according to the in- structions in the Bleeding the fuel system section. OPM 360 en-GB © Scania CV AB 2017, Sweden... - Page 61 A closed position can result in the engine stopping. In marine applications, the engine stopping rep- resents a safety hazard. Remove the cover from the filter housing. OPM 360 en-GB © Scania CV AB 2017, Sweden...
- Page 62 Fuel system Undo the drain plug. Tighten the drain plug when all the water has emptied. Fill the filter housing with clean fuel. Fit the cover. Tighten the cover screw by hand. OPM 360 en-GB © Scania CV AB 2017, Sweden...
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Page 63: Renewing The Commutative, Water Separating
In marine applications, the engine stopping rep- resents a safety hazard. Clean the filter housing externally with a cloth. Remove the cover from the filter housing. OPM 360 en-GB © Scania CV AB 2017, Sweden... - Page 64 Remove the filter and fit the new filter. Renew the O-rings in the cover. Lubricate the O-rings with engine oil. Fill the filter housing with clean fuel. Fit the cover. Tighten the cover screw by hand. OPM 360 en-GB © Scania CV AB 2017, Sweden...
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Page 65: Renewing The Fuel Filter
Screw the filter into place by hand until it makes contact. Screw a further half turn by hand. Bleed the fuel system according to the in- structions in the following section. Fuel filter. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 66: Bleeding The Fuel System
Close the bleed nipple on the high pressure pump and screw down the hand pump han- dle. Start the engine. The engine should be easy to start. Bleed nipple on high pressure pump. OPM 360 en-GB © Scania CV AB 2017, Sweden... - Page 67 Close the bleed nipple on the high pressure pump. Remove the hose and suction tool. Start the engine and check that no leakage occurs. Bleed nipple on high pressure pump. OPM 360 en-GB © Scania CV AB 2017, Sweden...
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Page 68: Miscellaneous
However, if there are many, deep cracks, the drive belt must be renewed. See the illustrations. Example of a minor crack in the drive belt. The drive belt can be refitted. OPM 360 en-GB © Scania CV AB 2017, Sweden... - Page 69 See the illustrations. The drive belt is starting to become worn, but can be refitted. The belt is worn down to the cord. The drive belt must be renewed. OPM 360 en-GB © Scania CV AB 2017, Sweden...
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Page 70: Checking For Leaks
Check for leaks in the lubrication, intake, cooling, fuel, or exhaust system. Tighten or renew leaking connections. Check the overflow holes which show whether the O-rings between the cylinder liners and crankcase are leaking. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 71: Checking And Adjusting The Valve Clearance
Carry out a check and adjustment of the valve clearances one more time after the first 500 hours of operation. After this, adjustment according to the regular interval takes place, which is every 2,000 operational hours. OPM 360 en-GB © Scania CV AB 2017, Sweden... - Page 72 1 and 5 2 and 6 DOWN TDC (0°) DOWN TDC (360°) 2 and 4 3 and 7 UP TDC (540°) UP TDC (540°) 3 and 6 1 and 8 DOWN TDC (360°) OPM 360 en-GB © Scania CV AB 2017, Sweden...
- Page 73 Mark the rocker arm with the felt-tip pen and then continue with the next cylinder accord- ing to the table. Adjusting screw. Lock nut. Rocker arm. Valve bridge. Feeler gauge. OPM 360 en-GB © Scania CV AB 2017, Sweden...
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Page 74: Quality Requirements For Fuel
Quality requirements and testing standards for the most important properties of different types of fuel are described in the Workshop Manual. This can be ordered from Scania dealers or di- rectly from Scania. Diesel Properties The quality of the diesel is very important for the operation and service life of the engine and the fuel system, and also for the engine performance. - Page 75 To the user, HVO is reminiscent of diesel in accordance with EN590, apart from HVO having a somewhat lower density. Scania approves the use of up to 100% HVO for all engines in accordance with the European standard EN 15940.
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Page 76: Biodiesel (Fame)
Biodiesel (FAME) Storage of biodiesel Use of biodiesel IMPORTANT! Scania uses the term biodiesel to refer to a re- Biodiesel must not be stored for more than 6 newable diesel made from greases or oils and months. methanol. The biodiesel should conform to the requirements of European standard EN 14214 or Brazilian standard ANP-45. -
Page 77: Preparing The Engine For Storage
Use a normal engine oil that meets the require- • Max. sulphur content 50 ppm. ments in the Oil grade section. • Max. water content 200 ppm. • The fuel must contain additives to stop the growth of micro-organisms. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 78: Preparations For Storage
Dinitrol 25B and then with Dinitrol 112 or connect a hose from the can. the equivalent. Clearly mark the engine with the storage preparation date, and state that the engine must not be started or cranked. OPM 360 en-GB © Scania CV AB 2017, Sweden... - Page 79 Wash off any preservative oil on the outside ature. The engine must be packed in packaging using white spirit. made of VCI plastic to protect against dust, dirt and moisture. OPM 360 en-GB © Scania CV AB 2017, Sweden...
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Page 80: Technical Data
Total Base Number (TBN) > 12 (ASTM D2896) Oil pressure (bar/psi) Normal with hot engine and nominal engine speed 3-6/43.5-87 Minimum permitted at idling speed 0.7/10.2 Crankcase pressure (mbar/psi) -5.4 to 2.0/-0.08 to 0.03 OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 81: Intake System
Scania polymer filter Water separating prefilter Scania polymer filter Electrical system Type 2-pin, 24 V, DC Starter motor, standard equipment 2-pin, 24 V, 7.0 kW Alternator, standard equipment 2-pin, 28 V, 100 A OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 82: Material Content
Re-use if possible; otherwise hand in to an authorised waste disposal contrac- tor. Fuel filter and oil filter Hand in to an authorised waste disposal contractor. Paint No known recycling methods. Electronics Hand in to an authorised waste disposal contractor. OPM 360 en-GB © Scania CV AB 2017, Sweden... -
Page 83: Scania Assistance
Scania Assistance Scania Assistance Wherever you are, you can always get assistance from the Scania service organisation, Scania As- sistance, all day, every day of the year. Always call the contact for your country. 0800 999 722 642 +32 226 400 000...
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