Scania OC16 Operator's Manual
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Scania OC16 Operator's Manual

Gas industrial engine
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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.
Therefore, block the starting device and switch off the manual fuel cock when 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
OC16 Gas Industrial engine
en-GB 2 831 273
Issue 3.0

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Summary of Contents for Scania OC16

  • Page 1 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 OC16 Gas Industrial engine en-GB 2 831 273 Issue 3.0...

  • Page 2: Table Of Contents

    Checks after running ....19 Scania Assistance ..... . .71 Maintenance .

  • 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

    • Always contact an authorised Scania work- shop for maintenance and repairs. The information in this Operator's manual was correct at the time of going to press. Scania re- serves the right to make alterations without prior notice. Note: Always use spare parts that are approved by Sca- nia for maintenance and repairs.

  • 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

    WARNING! Methane is not toxic, but in a mixture of 50 per cent or more with air, the oxygen content will be so low that the risk of suffocation increases. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 8: Scania Cv Ab 2019, Sweden

    The exhaust gases contain carbon monoxide and nitrogen oxides, which are toxic. When the engine is run in an enclosed space, there must be effective devices to extract gas and exhaust gases. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 9: Scania Cv Ab 2019, Sweden

    There must be no smoking, naked flames or sparks near the batteries or the battery compart- ment. Incorrect connection of a battery cable or jump lead can cause a spark, which can cause the battery to explode. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 10: Scania Cv Ab 2019, 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 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 11: Scania Cv Ab 2019, Sweden

    Wear protective gog- explosive atmosphere. gles and gloves when handling coolant. Always use Scania spare parts for the fuel and Ethylene glycol can be fatal if ingested. electrical systems. Scania spare parts are de- signed to minimise the risk of fire and explosion.

  • Page 12: Scania Cv Ab 2019, Sweden

    External power supplies to extra equipment in the engine must also be disconnected. Always use Scania spare parts for the fuel and electrical systems. Scania spare parts are de- signed to minimise the risk of fire and explosion.

  • Page 13: Scania Cv Ab 2019, Sweden

    If sulphuric acid comes in contact with the skin: Wash with soap and plenty of water. If it gets in your eyes: Rinse immediately with plenty of wa- ter and seek medical attention. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 14: Engine Data Plate

    Output . 372-426 1800 r pm . tion code, the normal gross engine output. Code for application. A means for general industrial use. Example of an engine data plate. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 15: Component Identification

    Filling coolant Centrifugal oil cleaner Throttle at gas mixer Oil dipstick Oil plug Oil filler Nipple to drain and fill coolant (behind the coolant manifold, one on each side). Oil filter OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 16: Scania Cv Ab 2019, Sweden

    Component identification Engine data plate and engine serial number Air cleaner Spark plug Lambda sensor Flame arrestor Throttle at flame arrestor OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 17: Starting And Running

    Take the local environmental requirements into account. Use the engine heater to avoid starting difficulties. Scania recommends that an engine Carry out daily maintenance as described in the heater should be used if the engine will be used maintenance schedule prior to operation.

  • Page 18: Running

    High oil pressure (above 6 bar/87 psi) is normal if the engine is cold when started. • Alarm at the lowest limit value and engine shutdown at the highest limit value. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 19: Engine Shutdown

    Check that the manual fuel cock is turned off. Engine shutdown Check that the power supply has been cut. Check that the cooling system contains enough glycol according to the Scania in- IMPORTANT! structions. See the section Coolant. If the temperature is below 0°C (32°F): Pre-...

  • Page 20: Maintenance

    Maintenance Maintenance IMPORTANT! The maintenance programme covers a number of On delivery a Scania engine is optimised for its points that are divided into the following sec- tions: application. However, regular maintenance is necessary to • Lubrication system. • prevent unplanned stops •...

  • Page 21: Maintenance Interval

    Checking deposits in the combustion chamber Electrical system Renewing the spark plugs Other Checking the drive belt Checking for leaks Checking and adjusting the valve clearance OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 22: Lubrication System

    Lubrication system Lubrication system If Scania Oil LDF-4 is not used, the oil must be of a viscosity class suitable for the outdoor tem- perature in the area where the engine is used. Oil grade Scania LDF stands for the Scania Long Drain Viscosity Outdoor temperature in °C...

  • Page 23: Scania Cv Ab 2019, Sweden

    Replace the label if it is missing. If the oil grades below are used, it is possible to order labels for the oil filler cap from Scania. Product Colour Part No.

  • Page 24: Oil Analysis

    Lubrication system Oil analysis To be able to extend the oil change intervals us- ing an oil analysis, Scania LDF-4 oils must be used. Certain laboratories offer engine oil analy- sis. The following conditions must remain fulfilled when the oil is changed: •...

  • Page 25: Checking The Oil Level

    For information on the correct oil grade, see the Oil filler section grade. Maximum angles of inclina- tion during operation The illustration shows the maximum permissible angles of inclination during operation. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 26: Changing The Oil

    Renew the gasket on the oil plug. Refit the oil plug. Fill with the amount of oil specified for the oil sump. Wait at least seven minutes. Check the level on the oil dipstick. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 27: Cleaning The Centrifugal Oil Cleaner

    Let the oil run out from the rotor. x 1.5 Lift out the rotor. Wipe off the outside. Loosen the rotor nut and unscrew it about 1.5 turns. Note: Take care not to damage the rotor shaft. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • 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 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 29 Renew any damaged nozzles. Check that the bearings are undamaged. Renew damaged bearings. Fold and fit a new paper insert on the inside of the rotor cover as illustrated. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 30 Screw the rotor nut back on by hand. Check that the shaft is not damaged or loose. Contact a Scania workshop if the rotor shaft needs renewing. Note: Take care not to damage the rotor shaft.

  • Page 31: Operational Testing Of The Centrifugal Oil Cleaner

    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 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 32: Renewing The Oil Filter

    Make sure the oil filter drain has emptied the Gasket 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 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 33: Air Cleaner

    Renew the O-ring if it is damaged or hard. Assemble the air cleaner. Ensure that the O-ring is not outside the edg- Reset the vacuum indicator by pressing in the button marked in the illustration. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 34: Cooling System

    The coolant should be changed when the cooling functioning antifreeze and corrosion protection system is cleaned: every 6,000 hours or at least may be used in Scania engines. Products not ful- every five years. See Changing the coolant and filling the demands in this section may lead to cleaning the cooling system.

  • Page 35: Scania Cv Ab 2019, Sweden

    There is no risk of damage by freezing if the content of Scania antifreeze and corrosion inhibitor, or an equiva- lent mixture of a similar product, is at least 35% by volume.

  • Page 36: Scania Cv Ab 2019, Sweden

    In order to retain the corrosion protection and the Scania Ready Mix 50/50 higher boiling point, it is essential to use coolant Scania Ready Mix 50/50 is a ready-mixed cool- consisting of water mixed with antifreeze and ant containing 50% antifreeze (ethylene glycol) corrosion inhibitor (ethylene glycol).

  • Page 37: Scania Cv Ab 2019, Sweden

    Cooling system Antifreeze and corrosion protection dosing 35% by volume of Scania antifreeze provides sufficient protection against corrosion. The low- er the temperature, the higher the anti-freeze content required. In the tables below, you can see how much antifreeze is required in litres and US gallons at different temperatures.

  • Page 38: Checking Coolant Level

    Only pour pre-mixed coolant into the cooling system. IMPORTANT! The following instructions apply to Scania ex- pansion tanks. For other types of expansion Use only pure fresh water that is free of particles, tanks, follow the manufacturer's instructions.
  • Page 39 Make sure that the drainage starts. If the drainage does not start: Change the position of the cable terminals. Repeat the procedure on the lowest draining point of the cooling system (2). OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 40: Scania Cv Ab 2019, Sweden

    There is no need to clean the whole cooling system again. Run the engine until it has reached operating temperature and then drain the cooling sys- tem following the previous description. Remove the thermostat. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 41: Scania Cv Ab 2019, Sweden

    Carefully scrape away any deposits from the radiator cooling fins. Use a paraffin-based engine cleaner if necessary. Carefully straighten bent cooling fins using a steel brush or the like. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 42: Scania Cv Ab 2019, Sweden

    Filling via the ex- pansion tank leads to air locks in the cooling sys- tem which can lead to e.g. damage to the coolant pump shaft seal. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 43 Air pockets may still be left in the cooling system. These will disappear after the engine has been operated for a period of time. Therefore, the coolant may need topping up at a later stage. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 44: Fuel System

    This procedure applies only if pure biogas is used as fuel. IMPORTANT! Read the safety precautions before starting work. Detach the harness-to-component connector from the throttle. Remove the screws securing the throttle bracket to the flame arrestor. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 45: Scania Cv Ab 2019, Sweden

    Remove the flame arrestor. Clean the insert with degreasing agent. Re- move dirt with a soft brush. Rinse the insert with hot water. Blow out any remaining water with com- pressed air. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 46: Scania Cv Ab 2019, Sweden

    Renew the gasket. Fit the throttle to the flame arrestor housing. Check the O-rings. Renew them if necessary. Fit the flame arrestor housing and the throt- tle. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 47: Scania Cv Ab 2019, Sweden

    Fit the screws and the bracket. Fit the screws securing the throttle bracket. Fit the throttle harness-to-component con- nector. Check the fuel system is not leaking. See Leak testing after maintenance of the fuel circuit. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 48: Cleaning The Throttle At The Gas Mixer

    Fit the gas mixer housing. Renew the gaskets. Fit the throttle and gas connection. Check the fuel system is not leaking. See the following section. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 49: Leak Testing After Maintenance Of The Fuel Circuit

    2 541 520 Pressure testing kit Calibration of the pressure testing equipment Connect pressure regulator 2 301 551 to the compressed air. Block the connection nipple and open the pressure regulator valve. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 50 Undo the hose clamps. Turn the charge air pipe downwards. Close the nipple on pressure cap 2 655 714 and fit the cover to the hose spigot. Tighten the hose clamps. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 51 Fit pressure cap 2 541 521 in the hose spigot on the gas mixer. Detach the crankcase ventilation connection. Fit cover 2 655 695. Connect pressure regulator 2 301 851 to cov- er 2 655 695. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 52 Open the valve on pressure regulator 2 301 851. Monitor the pressure on pressure cap 2 541 521. The manometer should indicate a pressure below 0.3 bar. Greater pressure may damage the engine. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 53 2 284 630. Fit adapter 2 541 522 and the pressure testing equipment and plug the pneumatic connection with cover 2 655 696. Fit the pressure testing equipment with adapter. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 54 2 284 630. The manometer should indicate a pressure below 0.3 bar. Greater pressure may damage the engine. IMPORTANT! The pressure must not exceed 0.3 bar. A higher pressure may damage the turbocharger. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 55 The exhaust system up to the turbocharger outlet is pressurised, but does not need to be checked. If you discover a leak, rectify the leakage and repeat the leak tracing. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 56: Checking Deposits In The Combustion Chamber

    – the deposit protrudes at least 5 mm from the valves. The cleaning procedure is described in the Workshop Manual, which can be ordered from a Scania dealer or directly from Scania. Repeat steps 1-3 on the other cylinders. OPM 320 en-GB ©...

  • Page 57: Electrical System

    Renewing the spark plugs Tools Designation Illustration Spark plug socket IMPORTANT! Read the safety precautions before starting work. Disconnect the ignition coil harness-to-com- ponent connector. Twist off the spark plug connector arm later- ally. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 58: Scania Cv Ab 2019, Sweden

    Always place the spark plug in the spark plug socket be- fore fitting. The correct gap between the spark plug electrodes is 0.25 mm. Fit the spark plug connector. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 59: Other

    Example of a minor crack in the drive belt. The drive The drive belt has deep cracks and must be renewed. belt can be refitted. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 60: Checking For Leaks

    Checking for leaks WARNING! If there is leakage in the fuel system, contact your nearest Scania workshop immediately. IMPORTANT! If there is a major oil or coolant leak, contact your nearest Scania workshop. Start the engine.

  • Page 61: 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 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 62 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°) Order of cylinders. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 63 Mark the rocker arm with the felt-tip pen and then continue with the next cylinder accord- ing to the table. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 64: Quality Requirements For Fuel

    407/426 kW Natural gas 26.5 360/360 kW Pure biogas 21.5 330/350 kW Natural gas 23.5 320/320 Pure biogas 21.5 Lower calorific value at the reference state of 15°C (59°F) and 101.325 kPa. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 65: Other Quality Requirements

    0.5% Ch4/30 s ic value 1. The values also apply at full load. Lower values may be permitted if they have first been approved by Scania. If lower values are used, the maximum output is reduced. With normal cubic metres (Nm...

  • Page 66: Preparing The Engine For Storage

    Top up with preservative coolant. The oil should have as few other additives as possible and must not contain PTFE or silicone. An example of a good product to use is CRC Mo- tor Protect. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 67 Clearly mark the engine with the storage Throttle at the gas mixer. preparation date, and state that the engine must not be started or cranked. OPM 320 en-GB © Scania CV AB 2019, Sweden...
  • Page 68 Renew the spark plugs. stored indoors in a dry location at room temper- ature. The engine must be packed in packaging made of VCI plastic to protect against dust, dirt and moisture. OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 69: Technical Data

    Interval between oil changes (h) Oil pressure (bar/psi) Normal with the engine at operating temperature, operating speed 3-6/44-87 Minimum permitted at idling speed 0.65/9 Crankcase pressure with closed crankcase ventilation (mbar) -5.4 to 2.0 OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 70: Fuel System

    Permissible pressure drop in the intake system with blocked (dirty) fil- 65/0.9 ter (mbar/psi) Electrical system Type 1-pin, 24 V, DC Starter motor, standard equipment 1-pin, 24 V, 7.0 kW Alternator, standard equipment 1-pin, 28 V, 100 A OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 71: 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...

  • Page 72: Hexagon Screws, Hexagon Socket Screws, Torx Screws, Hexagon Nuts

    Metric thread. Strength class 8.8/8. Tightening torque Thread Lb-ft Flange screws with hexago- nal head and hexagonal flange nuts Metric thread. Strength class 8.8/8. Tightening torque Thread Lb-ft 10.2 OPM 320 en-GB © Scania CV AB 2019, Sweden...

  • Page 73: Hose Clamps

    A = width Tightening torque (mm) Lb-ft 7.5-9 The maximum tightening torque for a new unfitted hose clamp is 1 Nm (0.7 lb-ft). A = width Tightening torque (mm) Lb-ft OPM 320 en-GB © Scania CV AB 2019, Sweden...

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