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Scania DI12, DC12. Industrial engine. Operator’s manual - part 1

Operator’s Manual

DI12 DC12

Industrial engine

opm96-12a en

1 588 546

2001-05:1

Industrial & Marine Engines

IMPORTANT INFORMATION

When working on the engine, e.g. when adjusting the belts, changing oil or adjusting the clutch it is

important that the engine does not start. The engine may be damaged but above all there is -

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.

This warning symbol and text is reproduced beside those maintenance points where it is

especially important to consider the risk of injury.

START-UP REPORT - WARRANTY

When the start-up report has been filled in and sent to Scania there is a 1 year warranty starting from
the start-up date. Also enter the below information since this will facilitate contacts with e.g. service
workshops.

Engine number

Start-up date

User’s name and address

Signature

Engine type

Variant

Engine type and variant are indicated on the engine type plate

2001-05:1

FOREWORD

This operator’s manual describes the operation and maintenance of Scania
DC12 and DI12 Industrial Engines. The instructions apply to engines
in programme 96 from engine serial number 5 997 001 onwards.

The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder
inline diesel type. The engines are equipped with turbocharger and charge air
cooler, refer to page 10.

The engines are typically used in earthmoving equipment, generator sets,
agricultural, railway and forestry machinery as well as power units in
irrigation systems.

The engines are available with different power output and engine speed
settings.

The normal output setting of the engine (performance code) is indicated on
the type plate, see page 10.

Note:

Only standard components are described in the operator’s
manual. Regarding special equipment, refer to the instructions of
the relevant manufacturer.

In order to obtain the best value and service life from your engine, there are a
few points to bear in mind:

- Read the manual before starting to use the engine. You will find new

information in this Operator’s Manual even if you have previous
experience of Scania engines.

- Follow the maintenance instructions. Proper maintenance is essential to

keep the engine operating correctly and to increase engine life.

- Pay special attention to the safety information beginning on page 6.

- Get to know your engine so that you know what it can do and how it

works.

- Whenever necessary, always contact an authorised Scania workshop.

They have special tools, genuine Scania parts and trained staff with
practical experience of Scania engines.

Note:

Always use genuine Scania parts in service and repair to keep the
engine operating correctly.

The information in this manual was correct at the time of going to press.
However, we reserve the right to make changes at any time, without prior
notice.

Scania CV AB
Industrial and Marine Engines

S-151 87 Södertälje, Sweden

During the warranty period,

only use genuine Scania parts in

service and repair for the

warranty to be valid.

2001-05:1

TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ENVIRONMENTAL RESPONSIBILITY  . . . . . . 4
CERTIFIED ENGINES   . . . . . . . . . . . . . . . . . . . . 5
SAFETY DETAILS   . . . . . . . . . . . . . . . . . . . . . . . 6

Safety precautions for operation . . . . . . . . . . . . 7
Safety precautions for handling materials . . . . . 8
Safety precautions for care and maintenance . . 8

TYPE DESIGNATIONS . . . . . . . . . . . . . . . 10

DEC2 CONTROL SYSTEM . . . . . . . . . . . . 12

STARTING AND RUNNING . . . . . . . . . . . 19

AT FIRST START   . . . . . . . . . . . . . . . . . . . . . . . 19
CHECKS BEFORE RUNNING  . . . . . . . . . . . . . 21
STARTING THE ENGINE   . . . . . . . . . . . . . . . . 21

At temperatures below 0 °C: . . . . . . . . . . . . . . 22

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Engine speed  . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Coolant temperature  . . . . . . . . . . . . . . . . . . . . 23
Oil pressure  . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

STOPPING THE ENGINE . . . . . . . . . . . . . . . . . 24

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

CHECKS AFTER RUNNING . . . . . . . . . . . . . . 25

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 26

ENGINES WITH FEW HOURS OF
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MAINTENANCE SCHEDULE . . . . . . . . . . . . . 27

LUBRICATING OIL SYSTEM . . . . . . . . . 28

OIL GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

CHECKING THE OIL LEVEL . . . . . . . . . . . . . 29

Checking oil level during operation . . . . . . . . 29

OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Maximum angles of inclination during
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

CLEANING THE OIL CLEANER . . . . . . . . . . 30
RENEWING THE OIL FILTER . . . . . . . . . . . . 32

COOLING SYSTEM . . . . . . . . . . . . . . . . . . 32

CHECKING THE COOLANT LEVEL . . . . . . . 32
CHECKING THE COOLANT . . . . . . . . . . . . . . 33

Checking the corrosion inhibitor . . . . . . . . . . 35
Changing the coolant . . . . . . . . . . . . . . . . . . . 35

CLEANING THE COOLING SYSTEM . . . . . . 36

Internal cleaning . . . . . . . . . . . . . . . . . . . . . . . 37

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 38

CHECKING THE VACUUM INDICATOR . . . 38
CLEANING THE AIR CLEANER COARSE
CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

CLEANING OR CHANGING THE
FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . 38
RENEWING THE SAFETY CARTRIDGE . . . . 39

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 40

CHECKING THE FUEL LEVEL . . . . . . . . . . . . 40
RENEWING THE FUEL FILTER . . . . . . . . . . . 40
CHECKING THE INJECTORS . . . . . . . . . . . . . 41

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 42

RENEWING THE BATTERY . . . . . . . . . . 46

MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 46

CHECKING THE DRIVE BELT . . . . . . . . . . . . 46
CHECKING FOR LEAKAGE, RECTIFY AS
NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CHECKING/ADJUSTING VALVE
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CHANGING (

CLEANING) THE CLOSED

CRANKCASE VENTILATION VALVE. . . . . . 50

LONG-TERM STORAGE . . . . . . . . . . . . . . 51

Preservative fuel  . . . . . . . . . . . . . . . . . . . . . . . 51
Preservative oil  . . . . . . . . . . . . . . . . . . . . . . . . 52
Preparations for storage   . . . . . . . . . . . . . . . . . 52
Batteries   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Storage   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Taking out of storage   . . . . . . . . . . . . . . . . . . . 53

TECHNICAL DATA . . . . . . . . . . . . . . . . . . 54

FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

ALPHABETICAL INDEX . . . . . . . . . . . . . . 58

2001-05:1

ENVIRONMENTAL RESPONSIBILITY

Scania has always been at the forefront in the development and production of
environmentally safe engines.

We have made great progress in reducing harmful exhaust emissions to be
able to meet the stringent emission standards that are mandatory for almost
all markets.

We have done this without compromising the high quality of Scania
industrial and marine engines in terms of performance and cost effective
operation.

To maintain these superior properties throughout the life of the engine it is
important that the operator/owner follows the instructions of this manual as
regards operation, maintenance and choice of fuel and lubricants.

To further contribute to protecting the environment in service, maintenance
and repair, ensure that harmful waste (oil, fuel, coolant, filters, batteries etc.)
is disposed of and destroyed according to applicable local regulations.

This operator’s manual contains highlighted text urging you to protect the
environment in different service and maintenance operations.

Refer to example

Always use suitable containers

to avoid spillage when bleeding

systems or renewing

components.

2001-05:1

CERTIFIED ENGINES

An emission certified engine has been approved according to a specific
certification standard. The certified engines delivered by Scania meet the
most compelling emission standards in the European (EU) and non-European
(USA) markets.

Scania guarantees that all engines of a certified engine type that are delivered,
correspond to the engine approved for certification.

The engine is fitted with a certification plate, stating according to which
certification rules (standard) the engine has been approved. Refer to page 10.

The following is required for the engine to meet the emission standards after
being commissioned:

- Service and maintenance must be performed according to this

Operator’s Manual.

- Only genuine Scania parts must be used.

- Service work on the injection equipment must be performed by an

authorized Scania workshop.

- The engine must not be modified with equipment not approved by

Scania.

- Seals and setting data may only be broken/modified after approval by

Scania, Södertälje. Changes should only be made by qualified
personnel.

- Changes affecting the exhaust system and intake system must be

approved by Scania.

Otherwise, follow the instructions in this manual for operation, care and
maintenance of the engine. Also observe the safety precautions described in
the following four pages.

Important!

If service and maintenance are not performed as stated
above, Scania cannot guarantee that the engine corresponds
to the certified configuration and will not assume liability for
any damage occurring.

2001-05:1

SAFETY DETAILS

General

This Operator’s Manual contains safety information that must be observed in
order to avoid personal injuries and damage to the product or property. Refer
to page 1.

The text boxes to the right on the pages provide information that is important
for the proper operation of the engine and to avoid damage to the engine.
Failure to follow these instructions may void the warranty.

Refer to example.

Corresponding texts may also appear in the text column, headed

Note

Important

The warning text in text boxes to the right on the pages provided with a
warning triangle and headed WARNING is extremely important and warns
of serious defects to the engine or improper handling that may lead to
personal injury.

Refer to example

The safety precautions that must be observed in the operation and
maintenance of Scania engines are compiled on the following three pages.
The corresponding text is also often stated next to the maintenance step
concerned, shown with different degrees of significance as described above.

All items are marked with a

to highlight the importance of reading each

item in the section.

A general safety rule is that no smoking is allowed:

•

Near the engine and the engine bay

•

When refuelling and near the filling station

•

When work is performed on the fuel system

•

Near flammable or explosive materials (fuel, oils, batteries, chemicals
etc.)

Immobilise the starting device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK

OF INJURY.

Only use Scania genuine fuel

filter.

2001-05:1

Safety precautions for operation

Daily inspection

Always perform visual inspection of the engine

and engine bay before the engine is started and

when the engine has been stopped after oper-

ation.
This will make it easy to detect any leakage of

fuel, oil or coolant or any other abnormal condi-

tion that may require remedial action.

Refuelling

When refuelling, there is a risk of fire and explo-

sion. The engine must be stopped and smoking

is not allowed.
Do not overfill the tank, since the fuel may ex-

pand, and close the fuel filler cap properly.
Only use fuel recommended in the service

literature. Fuel of an incorrect grade may cause

malfunctions or stoppage by interfering with the

operation of the fuel injection pump and the in-

jectors.
This could cause engine damage and possibly

personal injury.

Harmful gases

Only start the engine in a properly ventilated

area. The exhaust emissions contain carbon

monoxide and nitrogen oxides that are toxic.
When operating the engine in an enclosed

area, an effective extraction device for exhaust

gases and crankcase gases must be used.

Starter lock

If the control panel is not fitted with a key

switch, the engine bay should be fitted with a

lock to prevent unauthorized starting of the en-

gine.
Alternatively, a lockable main switch or battery

master switch may be used.

Starting spray

Never use starting spray or similar as a starting

aid. An explosion may occur in the intake pipe,

which could cause personal injury.

Operation

The engine should not be operated in environ-

ments with surrounding explosive materials

since electrical or mechanical components of

the engine may emit sparks.
It is always a safety hazard to be near an en-

gine that is running. Body parts or clothing, or a

dropped tool may get stuck in rotating parts,

such as the fan, causing bodily injury.
Always cover rotating parts and hot surfaces as

much as possible to ensure personal safety.

2001-05:1

Safety precautions for handling
materials

Fuel and lubrication oil

All fuels and lubricants as well as many chemi-

cals are flammable. Always follow the instruc-

tions stated on the container.
All work on the fuel system must be performed

when the engine is cold. Fuel leakage and spill-

age on hot surfaces may cause fire.
Store drenched rags and other flammable ma-

terials in a safe way to avoid spontaneous com-

bustion.

Batteries

Batteries, particularly when being recharged,

emit highly flammable fumes that can explode.

Do not smoke or let open flame or sparks come

near the batteries or the battery compartment.
Incorrect connection of a battery cable or jump

start cable may cause a spark, which in tun may

cause the battery to explode.

Chemicals

Most chemicals, such as glycol, corrosion in-

hibitors, preservation oils, degreasers etc. are

hazardous. Always follow the safety precau-

tions stated on the container.
Some chemicals, e.g. preservative oil, are

flammable.
Always store chemicals and other hazardous

materials in approved and distinctly marked

containers and out of reach of unauthorized

persons. Always dispose of superfluous or

used chemicals through an authorized waste

disposal contractor.

Safety precautions for care and
maintenance

Stop the engine

Always stop the engine before any mainte-

nance and service work unless otherwise

stated.
Prevent unauthorized starting by removing the

starter key and turning off the power by the

main switch or the battery disconnect switch,

locking it in the off position. Also attach a warn-

ing tag, stating that work on the engine is in

progress, at a suitable location.
It is always a safety hazard to work on an en-

gine that is running. Parts of your body or cloth-

ing, or a dropped tool may get stuck in rotating

parts, causing bodily injury.

Hot surfaces and fluids

A hot engine always presents a risk of scalding.

Always take care not to touch the exhaust

manifold, turbocharger, oil pan, hot coolant and

oil in pipes and hoses.

Lifting the engine

Use the engine lifting eyes when lifting the

engine. First check that the lifting equipment is

in proper condition and has sufficient lift capac-

ity rating.
Auxiliary equipment fitted to the engine may

cause the centre of gravity to be displaced.

Thus, additional lift devices may be required in

order to provide proper balance and a safe lift.

Never work below a suspended engine!

Batteries

Batteries contain a highly corrosive electrolyte

(sulphuric acid). Always take care to protect

your eyes, skin and clothing when charging and

handling batteries. Wear protective gloves and

goggles.
If electrolyte splashes on the skin, wash the

affected part of the body with soap and plenty

of water. If electrolyte splashes into the eyes,

rinse eyes immediately with plenty of water and

seek medical attention.
Dispose of used batteries through an author-

ized waste disposal contractor.

2001-05:1

Electrical system

Before work is performed on the electrical sys-

tem, turn off the power by the main switch or the

battery disconnect switch.
Also disconnect any external power supply to

auxiliary equipment on the engine.

Arc Welding

Before welding near or on the engine, remove

the battery and alternator cables. Also remove

the control unit connector.
Connect the weld clamp to the component to be

welded, close to the weld location. Never con-

nect it to the engine or in such a way that the

current can pass through a bearing.
After the welding is completed, connect the ca-

bles to the alternator and the control unit before

connecting the batteries.

Lubrication system

Hot oil may cause scalding and skin irritation.

Avoid skin contact with hot oil.
Make sure that the pressure in the lubrication

system is relieved before work is carried out.

Never start or operate the engine with the oil fill-

er cap removed since oil will be ejected force-

fully.
Dispose of used oil through an authorized

waste disposal contractor.

Cooling system

Never open the coolant filler cap while the en-

gine is hot. Steam and hot coolant can come

out forcefully and cause scalding.
If the cooling system must still opened or disas-

sembled while the engine is hot, open the filler

cap very cautiously and slowly to release the

pressure before the cap is removed. Use

gloves since the coolant is still very hot.
Dispose of used coolant through an authorized

waste disposal contractor.

Fuel system

Always use gloves when checking for leaks in

or performing other work on the fuel system. Al-

ways wear eye protection when testing injec-

tors.
Fuel escaping under high pressure can pene-

trate body tissue and cause serious injury.
Never use non-genuine parts in the fuel system

and the electrical system. Genuine parts are

designed and manufactured to minimize fire

and explosion hazard.

Before starting

Install any guards that have been removed be-

fore the engine is started. Check to ensure that

no tools or other objects have been left on the

engine.
Never start the engine unless the air filter is in-

stalled. Otherwise there is a risk of objects en-

tering the compressor wheel or a risk of

personal injury from contact with it.

TYPE DESIGNATIONS

The engine designation indicates, in the form of a code, the type of engine, its
size and intended use, etc.

The type designation and engine serial number are indicated on a type plate
affixed to the right-hand side of the flywheel housing. The engine serial
number is also stamped into the cylinder block on the right hand side.
See arrow in the illustration.

Engines that are certified regarding smoke and emissions are fitted with a
certification plate specifying the documents they conform to.

DI 12 40 A 01 E

Type

Supercharged diesel engine with air-cooled charge air cooler

Supercharged diesel engine with liquid-cooled charge air cooler

Displacement in whole dm

Performance and certification code

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

Variant 01-99

Type of governor

Electronically controlled governor (DEC2)

RQ, single-speed governor and electronically controlled auxiliary
governor (GAC)

RQ, single-speed governor

2001-05:1

The illustrations show a typical DI12 engine configuration.

Your engine may have different equipment from the one shown.

Type plate

Engine serial number,
stamped into the cylinder
block

Oil cooler

Oil dipstick

Oil cleaner

Oil filter

Draining, engine oil

Coolant pump

Charge air cooler

10.

Turbocharger

11.

Injection pump

12.

Fuel filter

13.

Starter motor

14.

Alternator

15.

Automatic belt tensioner

16.

Draining, coolant

17.

Oil top up

1, 2

2001-05:1

DEC2 CONTROL SYSTEM

This engine has an injection pump with an electromagnetic actuator which
adjusts the control rack to give the correct amount of fuel.

The system which controls the pump is called DEC2 (Digital Engine Control,
generation 2).

The control unit (DEC2) continuously receives signals from sensors for
engine speed, charge air temperature and pressure, coolant temperature, oil
pressure, throttle position and control rack travel in the injection pump. Using
this input data and a control program, the correct amount of fuel for the
current operating conditions can be calculated.

The system’s sensors may be used only for DEC2, not for other instruments
or other monitoring purposes.

The control unit contains monitoring functions to protect the engine in the
event of a fault which would otherwise damage it. Faults and the more
important monitoring functions are indicated on the control unit in the form
of light emitting diodes. See illustration on page 15 for a description.

In case of a fault, the Power - or Shutdown indicator on the DEC2 control
unit as well as the main indicator lamp on the main supply box and the
instrument panel will illuminate.

If a fault has been indicated on the main indicator lamp the operator can
determine the cause of the fault with the help of the LEDs on the control unit
and the troubleshooting schedule on page 18, and carry out the required
investigation and remedy.

Depending on the nature of the fault, the control system will take different
actions to protect the engine such as reducing the power output, keeping the
engine running at a constant low speed or, in case of a function impairing
fault, shutting down the engine (Shutdown).

To enable readout of LED fault codes there is a lamp test/fault code switch
located in the main supply box near the control unit.

A PC based program is also available to help service personnel to detect and
rectify faults and to adjust certain parameters in the operating program.

Diagnostics and changes to programs must only be performed by
authorized personnel.

The locations of the sensors and monitors that send signals to the control unit
are shown in the illustrations on pages 13 an d 14.

There is a description of the functions of the LEDs during normal operation
on page 15.

On page 16 there is a description of the functions of the LEDs in case of a
fault and actions in case of Power- and Shutdown indication.

Troubleshooting and fault code reading are described on pages 17 and 18.

2001-05:1

Location of sensors for DEC2 on DI12

Connection of lead to charge air
temperature sensor

Charge air temperature sensor

Oil pressure monitor

Connector panel

Coolant temperature sensor

Engine speed sensors

2001-05:1

Location of sensors for DEC2 on DC12

Connection of lead to charge air
temperature sensor

Charge air temperature sensor

Oil pressure monitor

Connector panel

Coolant temperature sensor

Engine speed sensors

2001-05:1

LED functions during normal operation

Note:

The lamp test/fault code switch should not be
depressed. All LEDs come on briefly when
the control unit is powered up.

CONTROL STATUS

✹

The LED flashes continuously when the control
unit is supplied with current, regardless of
whether the engine is running or not.

SHUTDOWN

❍

The LED is out.

STARTING

✹

The LED lights up as soon as the engine turns
over on cranking and follows the programmed
starting sequence until it has been completed
and then goes out.

RUNNING

✹

The LED comes on when the engine has started
and the "Starting" LED goes out. It remains on
until the engine is stopped.

TORQUE LIMIT

✹

The LED comes on when the control unit
detects that the engine has received the
maximum permissible quantity of injected fuel
according to its power curve. This means 100%
power output at the current rpm. If the load
increases, engine rpm will decrease.

BOOST LIMIT

✹

The LED comes on when the control unit smoke
limiter restricts the maximum fuel quantity.
Operation of the smoke limiter is dependent on
the charge air pressure.

POWER

❍

The LED remains out during normal operation
as long as no fault is detected by the control
unit. See next page for the procedure to be
adopted in the event of a fault.

POWER

✹

If the control unit is programmed to allow the
engine to be operated according to more than
one power/torque curve (map), the following
applies.

The LED comes on when the engine is run at
more than 100% power output (MAP 2). It goes
out when the engine returns to the 100% power
output curve (MAP 1) or when the power output
required is less than 100%.

2001-05:1

Action in case of a fault

LED indications in case of a fault

Note:

The main indicator lamp in the main supply
box and at the instrument panel has
indicated a fault. The lamp test/fault code
switch should not be depressed.

CONTROL STATUS

✹

The LED will continue to flash even in case of a
fault as long as voltage is supplied to the control
unit.

POWER

✹

If the LED comes on, the control unit has
detected a defect that could cause damage to the
engine if operation continues.

The control unit automatically reduces engine
power output to a predefined level if the
corresponding function has been selected.

Action: Reduce engine speed to idle if possible
and conduct troubleshooting according to
instructions on page 17 and the chart on page 18

SHUTDOWN

✹

The LED comes on and the engine is switched
off automatically in case of a severe fault that
could cause damage to the engine if operation
continues.

Action: Conduct troubleshooting according to
instructions on page 17 and the chart on page 18

If the engine has not stopped, reduce engine
speed to idle and conduct troubleshooting.

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