Scania DC16 EMS with S6/PDE. Industrial engine. Operator’s manual - part 4

 

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Scania DC16 EMS with S6/PDE. Industrial engine. Operator’s manual - part 4

 

 

19. Daily:
Check for leaks, rectify as necessary

- Start the engine.
- Check for oil, coolant, fuel, air and exhaust leaks.
- Tighten or renew leaking connections. Check the overflow holes (1) in 

the block which show whether the O-rings between the cylinder liners 

and crankcase are leaking, see figure.
a) If coolant is running out, the O-ring is leaking.

b) If lubricating oil is running out, the liner shelf is leaking.

- Check that there are no leaks from the coolant pump (2). If there is 

leakage, change the pump seal or the complete coolant pump.

- A small amount of leakage from the overflow holes during the engine 

running-in period is normal. (Sealing rings and O-rings are lubricated 

with soap or oil when fitted.)

- This leakage normally stops after a time.

Take care to ensure that any 

leaks do not cause pollution.

If serious leakage occurs, 

contact your nearest Scania 

workshop.

Important

!

Help protect our 

environment!

50

20. Every 2,400 hours:
Check and adjust valve clearance

Note:

Checking and adjusting valve clearances should also be done 

after the first 400 hours of operation.

Valve clearances should be adjusted when the engine is cold, at least 

30 minutes after running.
The rocker cover gaskets should be renewed as necessary. Tightening torque: 

26 Nm.
Intake valve clearance: 0.45 mm.

Exhaust valve clearance: 0.70 mm.
Tightening torque for lock nut: 35 Nm.

Order of adjustment

- Turn the flywheel so that the marks on the flywheel can be seen in the 

lower opening in the flywheel casing. 

- Measure the valve clearance with a feeler gauge and adjust the valves as 

per the order of adjustment in the table below. Correct valve clearances 

are also given on the instruction plate on one of the rocker covers.

Mark on flywheel

Valve 

overlap on 

cylinder

Adjust 

intake 

valves on 

cylinder

Adjust 

exhaust 

valves on 

cylinder

TDC Down (0°)

6

7 and 8

4 and 5

TDC Up (180°)

7

1 and 5

2 and 6

TDC Down (360°)

1

2 and 4

3 and 7

TDC Up (540°)

4

3 and 6

1 and 8

21. Every 2,400 hours
Checking and adjusting the unit 

injector rocker arms

Note:

Checking and adjusting of the unit injector rocker arms should 

also be done together with the valve clearance check and 

adjustment after the first 400 hours of operation.

Block the starting device when 

working on the engine.

If the engine starts out of 

control, there is a

SERIOUS RISK OF INJURY.

7

4

3

2

1

8

Cylinder numbering

FLYWHEEL

5

6

Measurement A =

PDE31: 66.9 ±0.1 mm

PDE32: 69.9 ±0.1 mm

Measurement B =

PDE31: 36.5 mm

PDE32: 38.8 mm

WARNING

!

PDE31:

1.

First, measure the distance (A) between plane (a) and the top edge of the 

valve spring collar on the unit injector using a digital sliding caliper. See 

figure.

2.

Dimension (A) should be 66.9 mm for PDE31 (dimension B=36.5 mm).

3.

The dimension is adjusted by undoing the lock nut and screwing the 

rocker arm adjusting screw (1) to the correct measurement.

WARNING! Take care when carrying out the adjustment if the 

dimension is well outside the adjustment dimension. The 

spring is pre-tensioned and can cause personal injury if it is 

released.

4.

Position setting tool 99 414 with the metal plate around the injector 

spring.

5.

Finely adjust dimension (A) by simultaneously using a finger to sense 

that the small piston (2) is level with the flat upper surface of the tool. It 

is possible to feel differences of less than a tenth of a millimetre.

6.

If the setting tool is not available, a digital sliding calliper can also be 

used for fine adjustment. The rocker arm position is adjusted using the 

adjusting screw to 66.9 +/-0.1 mm as stated above.

7.

Tighten the adjusting screw lock nut to 39 Nm and remove the tool.

8.

The order in which the injector rockers are to be checked and adjusted is 

shown in the table below.

Note:

No further checking and adjustment of the unit injector, such as 

checking the opening pressure, must be done. Faulty injectors 

must always be replaced completely.

Order of adjustment:

- Turn the flywheel so that the marks on the flywheel can be seen in the 

lower opening in the flywheel casing.

Mark on flywheel

Valve 

overlap on 

cylinder

Adjust injector 

rocker arm on 

cylinder

TDC Down (0°)

6

4 and 5

TDC Up (180°)

7

2 and 6

TDC Down (360°)

1

3 and 7

TDC Up (540°)

4

1 and 8

Piston above or below the flat 

surface. Adjustment necessary

Piston level with the flat surface. 

The adjustment is correct

66.9

99 414

52

PDE32:

1.

First, measure the distance (A) between plane (a) and the top edge of the 

valve spring collar on the unit injector using a digital sliding caliper. See 

figure.

2.

Dimension (A) should be 69.9 mm for PDE32 (dimension B=38.8 mm).

3.

The dimension is adjusted by undoing the lock nut and screwing the 

rocker arm adjusting screw (1) to the correct measurement.

WARNING! Take care when carrying out the adjustment if the 

dimension is well outside the adjustment dimension. The 

spring is pre-tensioned and can cause personal injury if it is 

released.

4.

Position setting tool 99 442 with the metal plate around the injector 

spring.

5.

Finely adjust dimension (A) by simultaneously using a finger to sense 

that the small piston (2) is level with the flat upper surface of the tool. It 

is possible to feel differences of less than a tenth of a millimetre.

6.

If the setting tool is not available, a digital sliding calliper can also be 

used for fine adjustment. The rocker arm position is adjusted using the 

adjusting screw to 69.9 +/-0.1 mm as stated above.

7.

Tighten the adjusting screw lock nut to 39 Nm and remove the tool.

8.

The order in which the injector rockers are to be checked/adjusted is 

shown in the table below.

Note:

No further checking and adjustment of the unit injector, such as 

checking the opening pressure, must be done. Faulty injectors 

must always be replaced completely.

Order of adjustment:

- Turn the flywheel so that the marks on the flywheel can be seen in the 

lower opening in the flywheel casing.

Mark on flywheel

Valve 

overlap on 

cylinder

Adjust injector 

rocker arm on 

cylinder

TDC Down (0°)

6

4 and 5

TDC Up (180°)

7

2 and 6

TDC Down (360°)

1

3 and 7

TDC Up (540°)

4

1 and 8

Piston above or below the flat 

surface. Adjustment necessary

Piston level with the flat surface. 

The adjustment is correct

69.9

99 442

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 for storage means:

- Thoroughly cleaning the engine.
- Running the engine for a certain time using special preservative fuel, oil 

and coolant.

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

etc.).

Preservative coolant

If the engine is stored with coolant in the system, the coolant should contain 

50% glycol by volume. Use glycol without nitrite-based inhibitors, such as 

BASF G48 or BASF D542.

Preservative fuel

- Use diesel mixed with Lubrizol 560H or equivalent.
- Mix  1  cm

3

 (ml) Lubrizol 560H in 10 dm

3

 (l) of fuel.

Ethylene glycol is highly 

dangerous if imbibed and can 

prove fatal.

Avoid contact with the skin.

HANDLING LUBRIZOL 560H

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.

If it gets in your eyes:

Rinse with a gentle stream of water (at least 15 minutes). Seek medical attention.

If it gets on your skin:

Wash the affected area with soap and water.

If inhaled:

Fresh air, rest and warmth.

Flammable:

Fire class 2A. Flashpoint +27°.

In the event of fire: Extinguish with carbon dioxide, powder or foam.

Storage:

In well-sealed receptacle in a dry, cool place. Keep out of reach of children.

!

WARNING

!

54

Preservative oil

Suitable preservative oils are supplied by most oil suppliers.
For example, Dinitrol 40 or equivalent.

Preparations for storage

- Drain and flush the cooling system. Top up with preservative coolant.
- Warm up the engine on normal fuel. Stop the engine and drain the oil.
- Renew the fuel 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 about 1,000 rpm (not single-speed engines) 

for 20-25 minutes.

- Stop the engine, remove the hoses and connect the normal fuel lines.
- Remove the rocker covers and lubricate the valve mechanisms and unit 

injector mechanisms with preservative oil. Refit the rocker covers.

Note:

The unit injectors must not be removed.

- 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 coolant in the 

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 the 

equivalent.

- Spray the outside of bright engine parts with penetrating preservative 

oil, for example Dinitrol 25B, and then with Dinitrol 112 or equivalent.

Use a container to avoid spills 

when draining the oil and 

coolant.

Dispose of used oil and coolant 

through an authorised waste 

disposal contractor.

Help protect our 

environment!

- Attach a label to the engine, clearly stating the storage preparation 

date and that the engine must not be started or cranked.

Batteries

Remove the batteries for trickle charging at the battery charging station. 

(Does not apply to batteries which according to the manufacturer do not 

require any maintenance.) The same applies to short-term storage, even 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 for taking the engine into operation)

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

exhaust pipes.

- Fill the system with coolant, see page 22.
- Check the oil level in the engine or fill up with fresh engine oil.
- Lubricate the valve mechanisms and their pushrods and valve tappets as 

well as the PDE injector mechanisms.

- Drain the preservative fuel from the fuel manifolds and fuel filter.
- Connect and bleed the fuel system, see page 45.
- Wash off any externally applied preservative oil, using white spirit.

ENGINE PREPARED FOR 

LONG-TERM STORAGE

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

Do not start or crank!

Wear gloves and protective 

goggles when charging and 

handling batteries.

The batteries contain a highly 

corrosive acid.

WARNING

!

56

Technical data 

General

DC16

Number of cylinders

8 (V8, 90°)

Cylinder diameter

mm

127

Piston stroke

mm

154

Displacement

dm

3

 (litres)

15.60

No. of main bearings

5

Firing order

1 - 5 - 4 - 2 - 6 - 3 - 7 - 8

Compression ratio

18:1 DC16 44:16:1

Engine direction of rotation viewed from rear

Counterclockwise

Fan direction of rotation viewed from front

Clockwise

Cooling

Liquid

Valve clearances, cold engine

intake valve

mm

outlet valve

mm

0.45

0.70

Weight with fan, without coolant or oil

kg

1,346

Power

see "Engine record card"

Lubrication system

Max. oil pressure

hot engine at a speed above 1,000 rpm

bar (kp/cm

2

)

6

Normal oil pressure

hot engine at operating speed

bar (kp/cm

2

)

3-6

Min. oil pressure

hot engine 1,000 rpm

bar (kp/cm

2

)

3.0

Min. oil pressure

hot engine, idling

bar (kp/cm

2

)

1.4

Oil capacity, see page 31

Crankcase pressure with closed crankcase 

ventilation

mm VP

-55 - +20

Fuel system

DC16

Low idling

rpm

700 (adjustable 500-800)

Maximum full-load speed

See engine card

Fuel

Diesel

1

1

 see page 58

Cooling system

Number of thermostats

1 (dual thermostat)

Thermostat, opening temperature

°C

79

Coolant temperature:

system at atmospheric pressure

°C

system at overpressure

°C

70-93

70 - approximately 100

Capacity, including radiator, engine and expansion tank

with 0.8 m

2

 radiator

dm

3

 (litres)

with 1.3 m

2

 radiator

dm

3

 (litres)

85

95

Electrical systems

System voltage

V

24

Alternator, current

A

65 or 90

Starter motor output

kW (hp)

6.7 (9.1)

Monitors, threshold values:

oil pressure monitor

bar (kp/cm

2

)

temperature monitor

°C

1.0 

± 

0.15

Stamped on hexagonal part of monitor

58

Fuel

Diesel

The composition of the diesel has a great influence on the functioning and the 

service life of the engine and the injection system. The engine output and 

exhaust emissions are also dependent on the fuel quality. The requirements 

and testing standards for the most important properties are described in the 

workshop manual in sections which can be ordered from Scania dealers or 

directly from Scania. Scania’s address is printed on the cover.
Diesel must comply with the following standard: EN 590 (European 

standard).
The table below shows the requirements for some of the most important

properties.

Environmentally friendly fuels (low sulphur fuels)

There are three classes of environmentally friendly fuels (SS15 54 35).

Class 1 is sulphur-free and class 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

Requirements

Viscosity at 40°C

2.0-4.5 mm

2

/s (cSt)

Density at 15°C

0.82-0.86 kg/dm

3

Sulphur (concentration by mass)

max. 0.3%

Ignitability (CET rating)

min. 49

Flashpoint

56°C

Temperature dependence of diesel

At temperatures lower than those specified for the diesel, paraffin wax may 

precipitate from the fuel and block filters and pipes. The engine can then lose 

power or stop.
The diesel 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 cannot cope with the expected temperatures, and 

diesel is not available with the correct temperature properties, we 

recommend that an electric fuel heater is installed as a preventative 

measure.

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

kerosene as a preventive measure. A maximum of 20% may be added. 

When refuelling, the kerosene should be added first, so that it mixes 

thoroughly with the diesel.

Note:

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

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

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

Drain fuel tanks and drain or renew fuel filters regularly.

It is not permitted to mix 

kerosene with diesel fuel that is 

already adapted for the climate 

concerned, it can damage the 

unit injectors. All use of 

paraffin other than kerosene is 

forbidden, as it causes engine 

damage.

It is not permissible to mix 

petrol with diesel. Petrol may 

cause wear to the unit injectors 

and it may also cause damage to 

the engine.

Important

!

WARNING

!

60

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . .  42
Air cleaner, prefilter  . . . . . . . . . . . . . . . . . . . .  42
Air cleaner, safety cartridge  . . . . . . . . . . . . . .  43
Air cleaner, vacuum indicator . . . . . . . . . . . . .  42
Air filter, element  . . . . . . . . . . . . . . . . . . . . . .  42

Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  46
Battery, renewing  . . . . . . . . . . . . . . . . . . . . . .  47
Bleeding, fuel system  . . . . . . . . . . . . . . . . . . .  45

Certified engines . . . . . . . . . . . . . . . . . . . . . . . .  5
Checks after running . . . . . . . . . . . . . . . . . . . .  27
Checks before running. . . . . . . . . . . . . . . . . . .  23
Coolant  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  37
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . .  36
Coolant level monitor  . . . . . . . . . . . . . . . . . . .  47
Coolant temperature  . . . . . . . . . . . . . . . . . . . .  25
Coolant, changing . . . . . . . . . . . . . . . . . . . . . .  39
Cooling system  . . . . . . . . . . . . . . . . . . . . . . . .  36
Cooling system, cleaning  . . . . . . . . . . . . . . . .  40
Corrosion protection . . . . . . . . . . . . . . . . . . . .  39

Drive belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . .  48

Electrical system . . . . . . . . . . . . . . . . . . . . . . .  46
EMS sensors  . . . . . . . . . . . . . . . . . . . . . . . . . .  17
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . .  24
Environmental responsibility  . . . . . . . . . . . . . .  4

Filter, air cleaner . . . . . . . . . . . . . . . . . . . . . . .  42
Filter, closed crankcase ventilation . . . . . . . . .  35
Filter, fuel  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  44
First start . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  22
Flash codes, control unit . . . . . . . . . . . . . . . . .  19
Flash codes, coordinator . . . . . . . . . . . . . . . . .  21
Fuel filter, renewing  . . . . . . . . . . . . . . . . . . . .  44
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  44
Fuel specifications . . . . . . . . . . . . . . . . . . . . . .  58
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . .  44
Fuel system, bleeding  . . . . . . . . . . . . . . . . . . .  45

Glycol  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  37

Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  49
Lubricating oil pressure. . . . . . . . . . . . . . . . . .  26
Lubricating oil system . . . . . . . . . . . . . . . . . . .  30

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . .  28
Maintenance schedule . . . . . . . . . . . . . . . . . . .  29

Oil analysis  . . . . . . . . . . . . . . . . . . . . . . . . . . .  30
Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . .  31
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . .  31
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  35
Oil filter unit  . . . . . . . . . . . . . . . . . . . . . . . . . .  33
Oil grade  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30
Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  31
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .  26

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2
Prefilter, air cleaner . . . . . . . . . . . . . . . . . . . . .  42
Preparations for storage . . . . . . . . . . . . . . . . . .  53

Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  24

Safety cartridge, air cleaner . . . . . . . . . . . . . . .  43
Safety information . . . . . . . . . . . . . . . . . . . . . .  10
Safety instructions for care and maintenance  .  12
Safety instructions for materials handling . . . .  12
Safety precautions for running the engine. . . .  13
Starting the engine . . . . . . . . . . . . . . . . . . . . . .  23
Stopping the engine . . . . . . . . . . . . . . . . . . . . .  27
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  55

Taking out of storage. . . . . . . . . . . . . . . . . . . .  55
Technical data . . . . . . . . . . . . . . . . . . . . . . . . .  56
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . .  20
Troubleshooting, control unit  . . . . . . . . . . . . .  18
Troubleshooting, coordinator  . . . . . . . . . . . . .  20
Type designations  . . . . . . . . . . . . . . . . . . . . . .  14

Unit injector. . . . . . . . . . . . . . . . . . . . . . . . . . .  50

Vacuum indicator  . . . . . . . . . . . . . . . . . . . . . .  42
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . .  50

Warranty  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1

Scania Assistance

Always call the contact for your country.

Other countries: +46 8 52 24 24 24

Note:

Calls will be recorded for training purposes.

AR

0800 999 722 642

IE

+353 71 9634000

AT

+43 1 256 44 11

IT

+39 0461 996 222

AU

1300 SCANIA

KR

+82 1588 6575

1300 722642

LU

+32 226 400 000

BE

+32 2 264 00 00

MA

+34 91 678 92 13

BG

+359 886 660001

MX

01 800 4SCANIA

BR

0800 019 42 24

NL

+31 70 4182666

CH

+41 800 55 24 00

NO

+47 223 217 00

CL

188 800 722 642

PL

+48 602 622 465

CZ

+420 225 020 225

PT

+351 91 678 9247

DE

+49 261 887 8888

RO

+40 723 27 27 26

DK

+45 333 270 44

SE

+46 42 100 100

ES

+34 91 678 80 58

SK

+421 903 722 048

FI

+358 10 555 24

TR

+90 212 335 04 40

FR

+33 2 414 132 32

TZ

+255 78 472 2642

GB

0 800 800 660

UY

0800 8351

+44 1274 301260

ZA

0800 005 798

GR

+30 6944 420 410

+27 11 661 9823

HU

+36 209 727 197

62

 

 

 

 

 

 

 

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