Scania DI12, DC12 EMS with S6/PDE. Industrial engine. Operator’s manual - part 1

 

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Scania DI12, DC12 EMS with S6/PDE. Industrial engine. Operator’s manual - part 1

 

 

 

Operator’s Manual

DI12, DC12

EMS with S6/PDE

Industrial engine

opm_d12ind_en-GB01 1 920 785

IMPORTANT INFORMATION

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 

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.

This warning symbol and text is reproduced beside those maintenance points where the risk of 

injury is particularly great.

!

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.

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

2

Foreword

This Operator’s Manual describes the handling and maintenance of Scania 

DC12 and DI12 Industrial Engines with EMS S6/PDE injection systems.
The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder in-

line diesel type. These engines have turbochargers and charge air coolers; see 

page 14.
Common applications are as power units in construction machines, generator 

sets, earth-moving, railway and forestry machines as well as in irrigation 

systems.
The engines can have different output and speed settings.
The normal output setting of the engine (performance code) is indicated on 

the type plate, see page 14.

Note:

Only standard components are described in the Operator’s 

Manual. Please see the manufacturer’s instructions regarding 

special equipment.

In order to obtain the best value and service life from your engine, there are 

several points you should bear in mind:

- 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.

- In particular, read the safety information starting on page 6.
- Get to know your engine so that you know what it can do and how it 

works.

- If necessary, contact an authorised Scania workshop. They have special 

tools, genuine Scania parts and staff with training and practical 

experience of Scania engines. 

Note:

Always use genuine Scania parts during service and repair so as 

to keep your engine in the best possible working order.

The information in this manual was correct at the time of going to press. 

However, we reserve the right to make alterations without prior notice.

During the warranty period, 

only genuine Scania parts may 

be used during service and 

repair; otherwise the warranty 

will be invalidated. 

Important

!

3

Contents

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Environmental responsibility  .........................4
Certified engines  ............................................5
Scania industrial and marine engine warranty 

for industrial engines.......................................6
Safety information ........................................10

Safety precautions before running   . . . . . . . . .11
Safety precautions for materials handling . . . .12
Safety precautions for care and maintenance  .12

Type designations  . . . . . . . . . . . . . . . . . . . . . 14

Engine management system, EMS   . . . . . . . 16

Troubleshooting using flash codes for the 

EMS control unit . . . . . . . . . . . . . . . . . . . . . . .20
Overview of flash codes for the EMS 

control unit   . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Troubleshooting using flash codes for the 

EMS coordinator  . . . . . . . . . . . . . . . . . . . . . . .22
Overview of flash codes for the EMS 

coordinator   . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Starting and driving  . . . . . . . . . . . . . . . . . . . 24

First start .......................................................24
Checks before running  .................................25
Starting the engine ........................................25

Starting at low temperatures  . . . . . . . . . . . . . .26

Running ........................................................26

Engine speed  . . . . . . . . . . . . . . . . . . . . . . . . . .26
Limp home mode . . . . . . . . . . . . . . . . . . . . . . .27
Coolant temperature  . . . . . . . . . . . . . . . . . . . .27
Oil pressure  . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Stopping the engine ......................................29
Checks after running  ....................................29

Maintenance   . . . . . . . . . . . . . . . . . . . . . . . . . 30

Engines with few hours of operation  ...........30
Maintenance schedule  ..................................31

Lubricating oil system   . . . . . . . . . . . . . . . . . 32

Oil grade .......................................................32

Oil analysis  . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Checking the oil level ...................................33

Checking oil level during operation  . . . . . . . .33

Oil change  ....................................................33

Maximum angles of inclination during 

operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Cleaning the oil filter unit  ............................34
Renewing the oil filter ..................................36

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 36

Checking coolant level  .................................36
Checking coolant ..........................................37

Checking the corrosion protection   . . . . . . . . .39
Changing the coolant   . . . . . . . . . . . . . . . . . . .39

Cleaning the cooling system .........................40

Internal cleaning  . . . . . . . . . . . . . . . . . . . . . . .41

Air cleaner  . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Test reading of vacuum indicator .................42
Cleaning the air cleaner coarse cleaner  ........42
Cleaning or changing filter element  .............42
Renewing the safety cartridge  ......................43

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Checking the fuel level .................................44
Changing the fuel filter .................................44

Electrical system  . . . . . . . . . . . . . . . . . . . . . . 46

Checking the electrolyte level in batteries  ...46
Checking the state of charge in batteries ......46
Cleaning batteries  .........................................46
Renewing the battery ....................................47
Checking coolant level monitor  ...................47

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . 48

Checking the drive belt .................................48
Look for leakage, rectify as necessary  .........49
Check and adjust valve clearance .................50 
Checking and adjusting the unit injector 

rocker arms  ...................................................52
Renewing (or cleaning) the closed 

crankcase ventilation valve  ..........................56

Preparing the engine for storage  . . . . . . . . . 57

Preservative fuel  . . . . . . . . . . . . . . . . . . . . . . .57
Preservative oil  . . . . . . . . . . . . . . . . . . . . . . . .58
Preparation for storage  . . . . . . . . . . . . . . . . . .58
Batteries   . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Storage   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Taking out of storage   . . . . . . . . . . . . . . . . . . .59

Technical data  . . . . . . . . . . . . . . . . . . . . . . . . 60

Fuel ...............................................................62

Alphabetical index . . . . . . . . . . . . . . . . . . . . . 64

Scania Assistance . . . . . . . . . . . . . . . . . . . . . . 65

4

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.
At the same time, we have been able to maintain high quality in terms of 

performance and operating economy for Scania Industrial and Marine 

Engines.
To preserve these qualities throughout the entire service life of the engine, it 

is important for the operator/owner to follow the instructions on running, 

maintenance and the choice of fuel and oil as outlined in the manual. 
Other efforts to preserve the environment we all share are possible by 

ensuring that the person carrying out servicing and maintenance always 

makes sure that environmentally hazardous waste after servicing and repairs 

(oil, fuel, coolant, filters, batteries, etc.) is dealt with and disposed of in 

accordance with applicable environmental standards.
On a number of pages, this Operator’s Manual contains specially highlighted 

text with instructions to help protect our environment during certain servicing 

and maintenance work.

See example

Use a container to avoid spillage 

when bleeding and changing 

components.

Help protect our 

environment!

5

Certified engines

Emissions-certified engines have been approved in accordance with a special 

certification standard. The certified engines supplied by Scania meet the most 

stringent emissions standards which apply on 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. See 

page 14.
The following is required for the certified engine to meet emissions standards 

once it has been commissioned:

- Servicing and maintenance must be carried out in accordance with the 

instructions in this manual.

- Only genuine Scania parts are to be used.
- Injection equipment is to be serviced by an authorised Scania workshop.
- The engine must not be modified with equipment not approved by 

Scania.

- Seals may be broken and setting data edited only once approval has been 

granted by Scania in Södertälje. Changes may be made by authorised 

personnel only.

- Changes which affect the exhaust system and intake system must be 

approved by Scania.

Otherwise, the instructions in the manual in respect of running, care and 

maintenance of the engine shall apply. The safety precautions described over 

the next four pages must also be observed.

Important!

If servicing and maintenance are not carried out as 

specified above, Scania can no longer guarantee that the 

engine will comply with the certified design, nor can it take 

responsibility for any damage that occurs.

6

Scania industrial and marine 

engine warranty for industrial 

engines

Emission Control Systems Warranty

Important!

Only applicable to engines used in the U.S.A.

Table of contents

General Warranty Provisions ......................... 6
Warranty Period ............................................. 7
Parts covered by the Warranty ....................... 7
General Warranty Limitations  ....................... 8
Specific Warranty Exclusions  ....................... 9
Customer Support ........................................... 9

Emission Control System Warranty 

Statement

General warranty provisions

The emission control systems of your new Scania Industrial and Marine 

("Scania") industrial diesel engine were designed, built and tested using 

genuine parts, and were certified as being in conformity with federal emission 

control regulations. Scania warrants to the original owner, and to each 

subsequent owner, of a new Scania industrial diesel engine that the engine:

1.

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. § 7547, and all applicable regulations under Chapter 1 and 2, 

Part 5, Division 26 of Health and Safety Code, and;

2.

Is free from defects in material and workmanship which would cause 

such engine to fail to conform to applicable regulations for its warranty 

period.

7

Warranty Period

This warranty shall apply for one of the following periods, whichever occurs 

first:

• 3,000 hours of operation, or

• Five years of use

The warranty period shall begin:

• "On the date the engine is delivered to the first retail purchaser, or

• "If the engine is placed in service for demonstration purposes prior to 

sale at retail, on the date the engine is first placed in service.

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:

1.

Fuel injection system

2.

Air intake system

• Intake manifold

• Turbocharger system

• Charge air cooler system

3.

Exhaust manifold

4.

Combustion chamber

• Piston

• Cylinder head

5.

Components used in the above mentioned systems

Important!

This list does not include all expendable maintenance parts. 

Expendable emission related parts requiring scheduled 

maintenance are warranted until their first scheduled 

replacement point. See Specific Warranty Exclusions 

below.

8

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. Scania may deny a warranty claim if your failure to perform 

maintenance resulted in the failure of the warranted part, listed under Parts 

covered by the Warranty above.
Receipts covering the performance of regular maintenance should be retained 

in the event questions arise concerning maintenance. The receipts should be 

transferred to each subsequent owner of the engine with the emission 

warranted engine.
The Warranty covers the cost of repair and replacement parts and services of 

warranted components and systems performed by an authorized Scania 

distributor or dealer using genuine Scania parts. You may elect to have 

maintenance, replacement or repair of these components and systems 

performed by any repair establishment or individual without invalidating the 

Warranty.
The use of other than Scania replacement parts also does not invalidate the 

warranty on other components unless such parts cause damage to warranted 

parts. However, the cost of such services or parts will not be covered by the 

Warranty.

WARNING!Use of replacement parts which are not of equivalent 

quality may impair the effectiveness of emission control 

systems. Accordingly, it is recommended that only Scania 

repair or replacement parts be used for maintenance, repair 

or replacement of emission control systems. If other than 

Scania parts are used for maintenance, repair or 

replacement, the owner should obtain assurance that such 

parts are warranted by their manufacturer to be equivalent 

to genuine Scania parts

9

Specific Warranty Exclusions

This warranty does not cover:

1.

Malfunctions in any part caused by any of the following: misuse, abuse, 

improper adjustments, modifications, alteration, tampering, 

disconnection, improper or inadequate maintenance, or use of fuels not 

recommended for the engine as described in the Operator's Manual.

2.

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.

3.

Damage resulting from accidents, acts of nature or other events beyond 

the control of Scania.

4.

The replacement of expendable maintenance items such as filters, hoses, 

belts, oil, thermostat, exhaust system and coolant made in connection 

with scheduled maintenance services once these parts have been 

replaced.

5.

Replacement items which are not genuine Scania parts or not authorized 

by Scania.

6.

Inconvenience, loss of use of the engine or commercial loss.

7.

Any engine on which the actual use cannot be accurately determined.

8.

Any engine operating outside the United States.

Customer Support

In the event that you do not receive the warranty service to which you believe 

you are entitled under the Warranty, or if you need additional support or 

information concerning the Warranty, please contact:

Scania USA, Inc

Address: 121 Interpark Blvd, suite 601, 78216, San Antonio, Texas

Mailing address: 121 Interpark Blvd, suite 601, 78216, San Antonio, 
Texas

Telephone: +1 210 403 0007

Fax: +1 210 403 0211
E-mail: contact@scaniausainc.com

10

Safety information

General

This Operator’s Manual contains safety information which is important so as 

to avoid both personal injury and damage to the product/other property. See 

also page 1.
The text highlighted in text boxes on the right of a number of pages is 

important for engine function and in order to avoid damage to the engine. If 

these instructions are not followed, your warranty may be invalidated.

See example

Similar text may also appear in the text column, and in this instance it will be 

marked 

Note:

 or 

Important!

.

The warning text found in text boxes on the right of a number of pages which 

is marked with a warning triangle and starts with 

WARNING

 is extremely 

important and warns you of serious engine faults or incorrect handling which 

may lead to injury.

See example

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.
All points are marked 

!

, so as to indicate how important it is to read through 

each point in this section.

For safety reasons, smoking is not allowed:

• In the vicinity of the engine and in the engine room

• When fuelling and close to the filling station

• When working on the fuel system

• In the vicinity of inflammable or explosive material (fuel, oils, 

batteries, chemicals, etc.)

Block the starting device when 

working on the engine.

If the engine starts accidentally, 

there is a

SERIOUS RISK OF INJURY.

Only use genuine Scania fuel 

filters.

Important

!

WARNING

!

11

Safety precautions for running the engine

Daily inspection

Always visually inspect the engine and engine 
compartment before starting the engine and once 
you have stopped the engine after running.
This will enable you to easily detect fuel, oil or 
coolant leaks, or any other abnormalities which may 
require rectification.

Refuelling

There is a risk of fire and explosion when refuelling. 
The engine must be stopped and smoking is not 
allowed.
Do not overfill the tank due to a risk of expansion, 
and close the filler cap properly. 
Use only fuel recommended in the service 
literature. Fuel of the wrong quality can cause the 
engine to malfunction or stop by preventing the 
injection pump and injectors from operating as they 
should.
This can cause damage to the engine and, possibly, 
injury.

Hazardous gases

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.

Starter lock

If the control panel is not fitted with a key operated 
switch, there should be a lock on the engine room to 
prevent unauthorised starting of the engine.
Alternatively, a lockable on/off master switch or 
battery master switch can be used.

 

Starter spray

Never use starting spray or similar as a starting aid. 
This can cause an explosion in the intake manifold 
and possible injury

.

Running

The engine must not be run in environments where 
there is a risk for explosion as all of the electrical or 
mechanical components can generate sparks.
Approaching a running engine always poses a safety 
risk. 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 rotating parts and hot 
surfaces must therefore be shielded as much as 
possible.

12

Safety precautions for handling 

materials

Fuel and lubricating oil

All fuels and lubricants and many chemicals are 
flammable. Always follow the instructions on the 
relevant packaging.
All work on the fuel system must be done with the 
engine cold. Fuel leaks and spillage on hot surfaces 
can cause fire.
Store soaked rags and other flammable materials 
safely so as to avoid spontaneous combustion.

Batteries

The batteries contain and emit oxyhydrogen gas, 
particularly during charging, and this gas is 
flammable and highly explosive. There must be no 
smoking, naked flames or sparks near the batteries 
or the battery compartment.
Incorrect connection of a battery cable or jump lead 
can cause a spark, which in turn can cause the 
battery to explode.

Chemicals

Most chemicals such as glycol, corrosion inhibitors, 
preservative oils, degreasing agents, etc. are 
hazardous to health. Always follow the safety 
precautions on the relevant packaging.
Some chemicals, such as preservative oil, are also 
flammable.
Store chemicals and other materials which are 
hazardous to health in approved containers, marking 
them clearly and storing them where they are 
inaccessible to unauthorised persons. Always hand 
in leftover or used chemicals to an authorised waste 
disposal contractor.

Safety precautions for care and 

maintenance

Stop the engine

Always stop the engine before maintenance and 
servicing unless stated otherwise.
Prevent unwanted starting by taking out the ignition 
key where applicable and disconnecting the power 
using the master switch or battery master switch and 
locking them. Also put up a warning sign 
somewhere appropriate, indicating that work is in 
progress on the engine.
Working with a running engine always poses a 
safety risk. Parts of the body, clothes or dropped 
tools can get caught in rotating parts and cause 
injury.

Hot surfaces and fluids

There is always a risk of sustaining burns when an 
engine is hot. Therefore, take care not to come into 
contact with manifolds, the turbocharger, the sump, 
hot coolant and oil in pipes and hoses.

Lifting the engine

The engine lifting eyes must be used when lifting 
the engine. Check first that your lifting devices are 
in good condition and of the correct size to lift the 
weight.
Extra equipment on the engine can alter the centre of 
gravity, which is why you may need additional 
lifting devices to balance the engine correctly and 
lift it safely.
Never work underneath a suspended engine!

Batteries

The batteries contain a highly corrosive electrolyte 
(sulphuric acid). Take care to protect your eyes, skin 
and clothes when charging or handling batteries. 
Wear protective gloves and goggles.
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.

13

Electrical system

The engine must be stopped and the power 
disconnected using the master switch or battery 
master switch before working on the electrical 
system.
External power supplies to extra equipment on the 
engine must also be disconnected.

Electric welding

When carrying out welding work close to and on the 
engine, remove the battery leads and the cables to 
the alternator. Also remove the multi-pin connector 
to the control unit.
Connect the weld clamp to the component to be 
welded and close to the welding point, never to the 
engine or in such a manner that the current can pass 
over to a mounting.
When you have finished welding, connect the cables 
to the alternator and control unit before connecting 
the batteries

.

Lubrication system

Hot oil can cause burns and skin irritation. 
Therefore, avoid skin contact with hot oil. 
Make sure that there is no pressure in the lubricating 
system before starting work on it. Never start or run 
the engine with the oil filler cap removed, as this 
may cause oil to be thrown out. 
Dispose of used oil through an authorised waste 
disposal contractor.

Cooling system

Never open the coolant filler cap if the engine is hot. 
Hot coolant or steam may spray out and cause burns.
If you have to open or remove a cooling system 
component when the engine is hot, open the cap 
very carefully and slowly to relieve the system 
pressure before removing the cap. Wear gloves as 
the coolant is still very hot.
Dispose of used coolant through an authorised 
waste disposal contractor.

Fuel system

Always wear gloves when looking for leaks or 
carrying out any other work on the fuel system. Also 
wear protective goggles when testing injectors.
Fuel escaping at high pressure can penetrate tissues 
and cause serious injury.
Never use non-genuine parts in the fuel and 
electrical systems as genuine parts are designed and 
manufactured to minimise the risk of fire and 
explosion.

Before starting

Fit all removed shields before starting the engine 
again. Check that you have not left any tools or other 
objects on the engine.
Never start the engine without the air filter fitted. 
There is a risk of objects being sucked into the 
compressor impeller or of injury if you come into 
contact with it.

14

Type designations 

The engine type designation indicates engine type, size and applications in 

code form.
The type designation and engine serial number are specified on a type plate 

affixed to the right-hand side of the flywheel housing. The engine number is 

also stamped on the right-hand side of the cylinder block. See the arrow in 

illustration.

Version

DC

Supercharged diesel engine with air-cooled charge air cooler

DI

Supercharged diesel engine with liquid-cooled charge air cooler

Displacement in whole dm

3

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

A

For general industrial use

Made by

Type
Engine No
Output.
Output

kW
kW

rpm.
rpm.

DI12 54A
6521399

2200

331

308 664

DI 12 54 A

15

10

8

1, 2

4

3

12

9

11

5

7 6

15

17

13

18

16

14

1.

Type plate

2.

Engine number, stamped 

into the cylinder block

3.

Coolant pump

4.

Automatic belt tensioner

5.

Draining, coolant

6.

Oil filter

7.

Oil filter unit

8.

Oil dipstick

9.

Draining, engine oil

10.

Oil cooler

11.

Turbocharger

12.

Oil filler

13.

Hydraulic pump

14.

Fuel pump with hand pump

15.

Starter motor

16.

S6 control unit

17.

Fuel filter

18.

Charge air cooler

The illustrations show a normal version of a DI12-engine.

Your engine may have different equipment from that illustrated.

16

EMS engine management 

system

This engine has an electronic management system, EMS (Engine 

Management System) with unit injectors (PDE) which provide each cylinder 

with the right amount of fuel at the right time in all operating situations.
The EMS system consists of a control unit (S6) and sensors for speed, charge 

air temperature and pressure, coolant temperature, oil pressure, accelerator 

pedal/throttle actuation which constantly emit signals to the control unit. 

With the aid of this input data and the programmed control software, the 

correct fuel amount and correct injection time are calculated for each unit 

injector under the specific operating conditions.
The EMS system sensors can also be used to emit signals to the instruments 

in the instrument panel.
The control unit constantly checks the sensors to make sure they are 

operational.
The control unit contains monitoring functions to protect the engine in the 

event of a fault which would otherwise damage it. In the event of a fault, for 

example alarm level for low oil pressure or high coolant temperature, the S6 

control unit sends a CAN message to a coordinator.
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.

 

 

 

 

 

 

 

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