Scania DI12, DC12. Industrial engine. Operator’s manual - part 4

2001-05:1

Alternative 2

- Position No. 1 cylinder at TDC by turning the crankshaft in its normal

direction of rotation until all four valves are closed.

- Adjust all valves for No. 1 cylinder. Correct valve clearances are

indicated on the instruction plate on one of the rocker covers.

- Proceed in the same way for the remaining cylinders in the sequence

5 - 3 - 6 - 2 - 4 (firing order) by turning the crankshaft 1/3 of a
revolution in its normal direction of rotation after each adjustment.

Note:

Readings can be taken from the

flywheel through covers in the

flywheel housing either from

above or underneath depending

on access when fitting.

It says up and down respectively

on the flywheel

Both covers are fitted with a

cover at delivery.

Covers for reading

on the flywheel housing

24. Every 2400 hours:

CHANGING (or CLEANING) THE
CLOSED CRANKCASE VENTILATION
VALVE.

Alternative 1:

Change the valve at the specified interval.

Alternative 2:

- Remove the valve after the specified interval.

- Clean the valve by placing it in a bath of diesel oil overnight. Then rinse

it several times in diesel oil and allow it to drip dry.

- Refit the valve.

- The valve may be reused (cleaned), maximum twice after the initial

2400 hours of operation. Take care to mark the valve after cleaning it.

LONG-TERM STORAGE

If the engine is not to be used for a lengthy period of time, special measures
should be taken to protect the cooling system, fuel system and combustion
chamber from corrosion and the exterior from rusting.

The engine can normally stand idle for up to six months. If it remains unused
for longer than this the following measures, which provide protection for
about four years, should be adopted. An alternative to preparing the engine
for long-term storage is to start the engine and warm it up every 6 months.

Preparing the engine for long-term storage means:

- Thoroughly cleaning the engine

- To run the engine for a period of time with preservative fuel,

preservative oil and preservative coolant.

- Otherwise preparing the engine for storage (filter changes, lubrication,

etc.).

Preservative coolant

If the engine is to be stored with a full cooling system, use coolant containing
50% glycol by volume. Glycol without nitrite-based inhibitor must be used.
E.g. BASF G48 or BASF D542.

Preservative fuel

- Use diesel fuel mixed with Lubrizol 560A or equal.

- Mix 1 cm

(ml) of Lubrizol 560A with 10 dm

(l) of fuel.

HANDLING LUBRIZOL 560A

Hazardous!

Contains aromatic hydrocarbons

Use spot extractors where there is a danger of vapour build-up.

Wear protective gloves and goggles when handling Lubrizol. Do not use contaminated clothing.

In case of splashes in the eye: Rinse with moderate water spray (for min. 15 minutes). Seek medical attention.

In case of skin contact:

Wash affected areas with soap and water.

If you inhale it:

Fresh air, rest and warmth

Flammable:

Fire class 2A. Flash point + 27°.
In case of fire: Extinguish using carbonic acid, powder or foam

Storage:

In properly sealed container in a dry, cool place. Keep out of reach of children.

Ethylene glycol, if swallowed

can be fatal.

Avoid contact with the skin.

Preservative oil

Suitable preservative oil can be supplied by most petroleum companies.

E.g. Dinitrol 40 or the equivalent.

Preparations for storage

- Drain and flush the cooling system. Top up with preservative coolant.

- Warm up the engine on regular fuel. Stop the engine and drain the oil.

- Change the fuel filter and turbo filter.

- Fill the engine with preservative oil up to the minimum level on the

dipstick.

- Mix preservative fuel in a can. Detach the fuel pipe at the feed pump

suction line and connect a hose from the can.

- Detach the fuel pipe at the overflow valve and connect a return hose to

the can.

- Start the engine and run it at approximately 1000 rpm (not single-speed

engines) for 20-25 minutes.

- Stop the engine, remove the hoses and connect the normal fuel lines.

- Oil the valve mechanism generously with preservative oil.

- Remove the injectors and spray preservative oil into each cylinder,

maximum 30 cm

(ml).

Turn the engine over a few revolutions using the starter motor. Spray an
additional small amount of oil into each cylinder.
After this the engine must not be cranked. Refit the injectors.

- Drain the preservative oil from the engine. Fresh engine oil can be filled

directly or when the engine is taken out of storage.

- Drain the coolant if the engine is not to be stored with a full cooling

system. Plug and tape over all coolant connections (if the cooling system
is not completely assembled).

- Air cleaner: Clean or renew the filter element.

- Cover air intakes and exhaust pipes.

- Alternator and starter motor:

- Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or equal.

- Spray the outside of bright metal engine parts, first with penetrating

preservative oil such as Dinitrol 25B and then with Dinitrol 112 or
equal.

Always use suitable containers

to avoid spillage when

draining oil and coolant.

Dispose of used oil and coolant

through an authorized waste

disposal contractor.

2001-05:1

- Attach a label to the engine showing the date of preservation and

clearly stating that it must not be started or cranked.

Batteries

Remove the batteries for trickle charging at a charging station. (Does not
apply to batteries, which the manufacturer specifies to be maintenance free).
The same is applicable for short-term storage if the engine has not been
prepared for storage as above.

Storage

After the preparations, the engine should be stored in a dry and warm place
(room temperature).

Taking out of storage

(Procedure when the engine is to be put into operation)

- Remove plugs and tape from coolant connections, air intakes and

exhaust pipes.

- Fill the cooling system with coolant, refer to page 19.

- Check the oil level in the engine or fill up with fresh motor oil.

- Turn the engine over a few times with the injectors removed, at the same

time copiously oiling the valve mechanism with pushrods and tappets.

Important

The engine must be cranked with the injectors removed so that
surplus preservative oil will be pressed out of the cylinders.

- Fit the injectors.

- Empty the fuel system’s main filter of preservative oil.

- Bleed the fuel system, refer to page 40.

- Wash off any externally applied preservative oil, using white spirit.

STORED ENGINE

Date . . . . . . . . . . .

Do not start or crank!

Wear gloves and eye protection

when charging and handling

batteries.

Batteries contain a highly

corrosive acid.

2001-05:1

TECHNICAL DATA

GENERAL

DC12

DI12

Number of cylinders

6 in line

Bore

127

Stroke

154

Displacement

(litres)

11.70

No. of main bearings

Firing order

1 - 5 - 3 - 6 - 2 - 4

Compression ratio

15:1(DC12 40=17:1)

17:1

Engine direction of rotation viewed from rear

Anti-clockwise

Fan direction of rotation viewed from front

Clockwise

Cooling

Liquid

Valve clearances, cold engine

intake valve

outlet valve

0.45

0.70

Weight, without coolant and oil

*With charge air cooler, radiator, expansion tank and

pipes

1065*

995

Power

refer to, "Engine record card"

LUBRICATION SYSTEM

Max. oil pressure

(warm engine at engine speed
exceeding 800 rpm)

bar (kp/cm

)

Normal oil pressure

(warm engine at operating speed)

bar (kp/cm

)

3 - 6

Min. oil pressure

(warm engine 800 rpm)

bar (kp/cm

)

0.7

Oil capacity, refer to page 29

Crankcase pressure with closed crankcase

ventilation

mm H2O

-55 - +20

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FUEL SYSTEM

DC12

DI12

Pump setting BTDC

See plate on rocker cover

Injectors, opening pressure

bar (kp/cm

)

300

Low idle speed

rpm

700

Maximum full load speed

See engine card

Fuel

Diesel fuel

Tightening torques:

Socket nut for injectors

Union nut for delivery pipe

Leak-off connection

refer to page 56

COOLING SYSTEM

Number of thermostats

1 (dual thermostat)

Thermostat, opening temperature

Coolant temperature:

System with ambient pressure

System with overpressure

70 - 93

70 - approx. 100

Capacity, including radiator, engine and expansions tank

and, for DI12, charge air cooler
with 0.75 m

radiator

(litres)

with 1.0 m

radiator

(litres)

with 1.2 m

radiator

(litres)

ELECTRICAL SYSTEM

System voltage

Alternator, charging current

65 or 90

Starter motor output

kW (hp)

6.7 (9.1)

Monitors, alarm values:

oil pressure monitor

bar (kp/cm

)

temperature monitor

°C

0.7

0.15

Stamped on hexagonal part of monitor

2001-05:1

FUEL

Diesel fuel

The composition of the diesel fuel is vitally important to the operation and
life of the engine and the fuel injection pump. The engine power output and
the exhaust emissions are also dependent on the fuel quality.

The requirements and the test standards for the most important properties are
described in the workshop manual in sections that can be ordered from your
Scania dealer or directly from Scania. The address of Scania is printed on the
cover.

The diesel fuel shall comply with the following standard:
EN 590 (European standard).

The table below shows the requirements for some of the most important
properties:

Environmentally favourable fuels (low sulphur fuels)

There are three different grades of so called environmentally favorable fuels
(SS15 54 35). Grade 1 is sulphur-free and grade 2 is low in sulphur.
Compared with class 3 (normal fuel), these fuels are less dense and this
reduces engine power output. Only class 1 fuel should be used with a
catalytic converter.

Short term use of fuel with a higher sulphur content than 0.05% by weight
will not cause permanent damage to the catalytic converter.

The catalytic converter may, however, require fuel with low sulphur content
for some time after this to regain its normal efficiency.

Property

Requirement

Viscosity at 40

2.0 - 4.5 mm

/s (cSt)

Density at 15

0.82 - 0.86 kg/dm

Sulphur (concentration by mass)

max. 0.3%

Ignitability (CET rating)

min. 49

Flashpoint

56°C

2001-05:1

Temperature dependence of diesel fuel

At temperatures lower than those specified for the diesel fuel, paraffin wax
may precipitate from the fuel and block filters and pipes. The engine can then
loose power or stop.

The diesel fuel is adapted for use in the specific climate of each country.
If a vehicle or an engine is to be operated in a temperature zone with lower
temperature than normal, first identify the temperature properties of the
fuel concerned.

The properties of the fuel when cold can be improved by adopting one of the
following measures before the temperature drops:

- If the fuel concerned is not intended for the expected temperature and no

diesel fuel with the correct temperature properties is available, we
recommend that an electric fuel heater be installed as a preventative
measure.

- The low temperature properties of diesel fuel may be improved by

adding kerosene as a preventative measure. A maximum of 20% may
be added. When refuelling, the kerosene should be added first, so that it
mixes thoroughly with the diesel fuel.

Note:

It is prohibited to use kerosene in engine fuel in some countries.

- To prevent water in the fuel from freezing and forming ice, maximum

0.5-2% alcohol (isopropanol) may be added.

Drain fuel tanks and drain or renew fuel filters at regular intervals.

It is not permitted to mix

kerosene with diesel fuel that is

already adapted for the climate

concerned. The injection pump

may be damaged. All use of

paraffin other than kerosene is

forbidden, as it causes