Scania D11, DI11. Marine engine. Operator’s manual

IMPORTANT INFORMATION

When working on the engine, for example adjusting drive belts, oil change or adjusting the clutch,

it is important not to start the engine. The engine may be damaged and 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, you have a 1-year warranty from the date of
start-up. Also fill in the particulars below as this can make things easier if you need to contact for example a
service workshop.

Operator’s Manual

D11 DI11

Marine engine

opm96-11m en

1 588 296

1997-11:2

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

Industrial & Marine Engines

1997-11:2

FOREWORD

This instruction manual describes the operation and maintenance of the Sca-
nia D11 and DI11 Marine Engines. The instructions apply to engines in
program 96 from engine number 5 364 870.

The engines are direct injection, fluid-cooled, four-stroke diesel engines with
6 cylinders in line. The engines are available with or without charge air coo-
ler, see page 4.

The engines may be equipped with two different cooling systems; heat
exchangers which are cooled by seawater or keel-cooling which means that
there are cooling pipes on the keel through which the engine’s internal coo-
lant is cooled.

Common applications are propulsion engines in small boats such as fishing
boats and ferries and in large recreational boats or as engines for driving
equipment onboard ships.

The engines can have different output and speed settings and may be classed
by different classification societies (classified engines are required for certain
marine installations).

The normal output setting of the engine (performance code) is indicated on
the type plate, see page 4.

Note

Only standard components are described in the instruction
manual. For special equipment, refer to the instructions issued by
the manufacturer.

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

- Read through the Instruction Manual before starting to use your engine.

Even those experienced with Scania engines may find new information
in this manual.

- Follow the maintenance instructions. Maintenance according to the ins-

tructions forms the basis of good function and service life.

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

works.

- When necessary, always turn to an authorised Scania workshop. These

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

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.

Scania CV AB
Industrial and Marine Engines

S-151 87 Södertälje

1997-11:2

TYPE DESIGNATIONS

The engine designation indicates, in the form of a code: Engine type, size,
application etc.

The type designation and engine number are indicated on a type plate which
is located on the right-hand, front side of the engine. The engine number is
also stamped in the block beside the type plate.

DI 11 73 M 31 S LR

Type

Supercharged diesel engine (with turbo)

like D but with fluid-cooled charge air cooler

Stroke 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 marine use

Variant 01-99

Governor type

Electronically controlled auxiliary governor

RSV, all-speed and single-speed governor

RQ, single-speed governor

RQV-K, all-speed governor

Classification society (for classified engines)

ABS American Bureau of Shipping
BV

Bureau Veritas

Germanischer Lloyd

Lloyd’s Register of Shipping

DNV Dwt Norske Veritas
RINA Registro Italiano Navale
SjöV Sjöfartsverket

1997-11:2

Type plate

Engine number,
stamped in engine block

Oil cooler

Oil dipstick

Oil cleaner

Turbo filter

Draining, engine oil

Coolant pump

Turbocharger

10.

Injection pump

11.

Fuel filter

12.

Stop solenoid

13.

Starter motor

14.

Alternator

15.

Fan belt, adjustment

16.

Draining, coolant

17.

Oil filling

18.

Seawater pump

19.

Heat exchanger with expan-
sion tank

20.

Sacrificial anodes

21.

Charge air cooler

22.

Oil pressure monitor

The drawings illustrate a common type of DI11 engine.

Your engine may have other equipment not shown here.

1, 2

1997-11:2

STARTING AND RUNNING

AT FIRST START

When the engine is started for the first time, the maintenance points listed
under ”First start” in the maintenance schedule should be followed, see
page 13.

Since these points are important for the engine to work satisfactorily right
from the start, they are also listed below.

1. Checking oil level (see page 15).

8. Checking coolant (see page 20).

The coolant should contain anti-corrosive to protect the cooling system
from corrosion.

If there is a danger of freezing:

- Only glycol anti-freeze should be used in the coolant as protection

against corrosion. We recommend only nitrite-free glycol anti-freeze
with the following supplier designations:

BASF G48 or BASF D542

- The concentration of glycol should be 30 - 60% by volume depending

on ambient temperature. 30% by volume offers protection down to
-18 °C. See page 20.

- Never top up with water only or glycol only. Lost fluid should always

be replaced with pre-mixed coolant with the same glycol content as the
coolant in the engine. If the concentration of glycol drops, both anti-
freeze and corrosion protection will suffer.

Note

A glycol concentration below 30% by volume will not provide suf-
ficient protection against corrosion. A glycol concentration grea-
ter than 60% will not increase anti-freeze protection and reduces
engine cooling capacity.

If there is no danger of freezing:

- Only Scania Anti-corrosive should be used in the coolant to protect

against corrosion. The correct level of anti-corrosive is 7-12% by
volume and this must never drop below 7% by volume. The inhibitor in
Scania Anti-corrosive is nitrate-free.

- First fill: Fill with Scania Anti-corrosive as indicated on the packaging.

- Never top up with water only or anti-corrosive only. Lost fluid should

always be replaced with pre-mixed coolant:
water + 10% Scania Anti-corrosive by volume.

- Only coolant filter without inhibitor may be used. The use of a coolant

filter increases the life of the coolant and reduces the risk of deposit cor-
rosion.

Coolant should be topped up

when the engine is stopped

after the first start

The recommended glycols

may not be mixed with

glycol which has a nitrite-

based anti-corrosive or with

Scania Anti-corrosive

Scania Anti-corrosive must not

be mixed with glycol.

Mixing or over concentration

can cause sludging

Coolant composition:

If there is a danger of freezing:

at least 30% glycol by volume

Max. 60% glycol by volume

If there is no danger of

freezing:

7-12% by volume

Scania Anti-corrosive

1997-11:2

14. Checking fuel level (see page 29).

17. Checking electrolyte level in batteries (see page 31).

18. Checking battery charge (see page 31).

20. Checking coolant level monitor (see page 32).

21. Checking temperature monitor (see page 33).

22. Checking oil pressure monitor (see page 34).

23. Checking stop feature (see page 34).

24. Checking v-belt tension (see page 36).

CHECKS BEFORE RUNNING

Before running, ”Daily maintenance” as described in the maintenance sche-
dule should be carried out, see page 13.

STARTING THE ENGINE

If the fuel tank has been run dry or if the engine has not been used for a long
time, bleed the fuel system, see page 29.

Out of consideration to our common environment, your new Scania engine
has been designed to be started with less fuel. Unnecessarily large fuel supply
at start will always result in the release of uncombusted fuel.

- Engines with mechanical stop control: Set the stop control to operating

position.

- Open fuel valve (if fitted).

- Declutch the engine (does not apply to engines with a fixed clutch, e.g.

gensets).

- Engines with battery master switch: Switch on the power using the bat-

tery master switch.

- Set the speed control to raised idling. (Does not apply to gensets)

- Start the engine.

Important

A maximum of 3 start attempts per minute may be made when
the stop solenoid is activated at start. The timer module can be
damaged resulting in the loss of the stop feature.

Starting at low temperatures

Local environmental requirements should be complied with. Start aids, eng-
ine heater and/or flame start should be used to avoid starting problems and
white smoke.

WARNING

Block the starter device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK OF

INJURY

1997-11:2

At temperatures below 0 °C:

Note

Use only start aids recommended by Scania.

- The starter motor may only be used for 30 seconds, after which it must

rest for 2 minutes.

If the engine has flame start:

- Operating flame start without timer relay: Press the control button

which also acts as a pre-glow button (max. 20 s). The glow plug conti-
nues to glow as long as the button is held down after the engine is star-
ted. Max. time is 5 minutes.

- Operating flame start with timer relay: Press the pre-glow button (max.

20 s). Release the pre-glow button after the engine starts. The timer
relay keeps the glow plug working for 5 minutes. If a shorter on-time is
required, press the release button. The key must be set to 0 of the start
attempt fails.

Note

If the engine is equipped with an INTERLOCK switch, this
should be held depressed until sufficient oil pressure has been
achieved. If the INTERLOCK switch is released too early, the
engine will stop.

- Gensets should be placed under load directly after start to avoid the risk

of white smoke. This applies especially to engines which are installed
without heating aids or addition of base load.

- Set the appropriate idle speed before the engine reaches 1,000 rpm (does

not apply to gensets).

- Run the engine until warm with a light load. A light load on a cold eng-

ine gives better combustion and faster heating than warming up with no
load.

1997-11:2

RUNNING

Check instruments and warning lamps at regular intervals.

Speed

The Scania tachometer is divided into different coloured sections as follows.

0 - 500 rpm

red area:

prohibited speed, passed when
starting and stopping.

500 - 700 rpm

yellow area:

low idle.

700 - 2200 rpm

green area:

normal operating speed.

Highest torque and lowest

fuel consumption at

1400 - 1600 rpm.

Low operating speed gives less

engine

wear.

2200 - 2600 rpm

yellow/green
striped:

unsuitable operating speed.

2600 - 3000 rpm

red area:

prohibited speed.

Coolant temperature

Correct coolant temperature during operation:

70 - 93 °C for system at atmospheric pressure.

70 - about 100 °C for system with positive pressure.

High coolant temperature leads to engine damage. Reduce the load on the
engine in order to lower the temperature. If the temperature does not drop,
stop the engine and look for the fault.

During long periods of operation with very low power take-off, the engine
may have difficulty in reaching 70 °C. However, if the load is increased, tem-
perature will rise.

1997-11:2

Oil pressure

Max. oil pressure:

warm engine at speed above 800 rpm

6 bar

Normal oil pressure:

warm engine at operating speed

3 - 6 bar

Min. oil pressure:

warm engine at 800 rpm

0.7 bar

At speeds below 800 rpm, the gauge may show low oil pressure without there
being a fault.

Oil pressure below 0.7 bar at speeds above 800 rpm will cause engine
damage. The engine must be stopped immediately.

Charge test lamp

If the lamp lights during operation:

- Check/adjust the alternator drive belts as described under maintenance

point. See page 36.

- If the charge test lamp is still lit, there may be a fault in the alternator or

in the electrical system.

STOPPING THE ENGINE

Allow the engine to run without load for a few minutes if it has been run
with a high continuous load.

Stop the engine using the stop control. Engines with a stop solenoid and
fuel shut-off valve are stopped using the stop button. Hold the stop but-
ton depressed until the engine has fully stopped.

Engines with battery master switch: Cut the power using the battery
master switch. (Does not apply to emergency power back-up units).

Set the control switch to 0. (Does not apply to emergency power back-
up units).

Emergency stop

The stop solenoid linkage system has a knob marked ”STOP”. Pull the lin-
kage system to the stop position using this knob if it is not possible to stop the
engine using the stop solenoid.

Danger of turbo damage or

boiling over if the engine is

stopped without cooling off.

The power must not be cut

until the engine has stopped.

High lubrication oil pressure

(above 6 bar) is normal when

starting a cold engine.

1997-11:2

Clutch

- See the manufacturer’s instructions for handling and operating the

clutch.

WARNING

If the clutch output shaft is rotating (e.g. in multiple eng-

ine installations where other engines are running) the clutch can,
under its own power, be drawn to engaged position.
THIS CAN CAUSE INJURY and engine damage. Always secure
the clutch in disengaged position if there is a risk of the output
shaft starting to rotate.

CHECKS AFTER RUNNING

- Check that the power is cut from the battery master switch and that the

control switch is set to ”0”.

- Fill the fuel tank. Make sure that the cap and the area around the filler

opening are clean to avoid contamination of the fuel.

- If there is a risk of freezing, the cooling system must be drained if it

does not contain sufficient anti-freeze, see page 20

- Close intake valve for seawater (if fitted).

- If there is a danger of freezing, the seawater must also be drained.

- At temperatures below 0 °C: Prepare for the next start by connecting the

engine heater (if fitted).

WARNING

Always secure the clutch in

disengaged position if there is

a risk of the output shaft

starting to rotate.

If the engine is started

during e.g. service work,

there is a

SERIOUS RISK OF

INJURY

1997-11:2

MAINTENANCE

The maintenance programme covers 27 points, divided into the following
main groups:

Lubrication oil system  . . . . . . . . . . . . . . . . . page 14
Cooling system . . . . . . . . . . . . . . . . . . . . . . . page 18
Air cleaner  . . . . . . . . . . . . . . . . . . . . . . . . . . page 26
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . page 29
Electrical system, monitors, batteries etc.  . . page 31
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . page 36

The maintenance points are divided into intervals as follows:

Daily maintenance

Maintenance before first start

Maintenance after the first 400 hours of operation

Periodic maintenance every 200 hours of operation (carried out after 200,
400, 600, 800 etc. hours)

Periodic maintenance after every 400 hours of operation (carried out after
400, 800, 1200, 1600 etc. hours)

Periodic maintenance after every 1,200 hours of operation (carried out after
1,200, 2,400, 3,600 etc. hours)

Periodic maintenance after every 2,400 hours of operation (carried out after
2,400, 4,800 etc. hours)

Periodic maintenance after every 4,800 hours of operation (carried out after
4,800, 9,600 etc. hours)

Maintenance every year

Maintenance every 5th year

ENGINES WITH FEW HOURS
OF OPERATION

Emergency back-up power units and the like which are not used regularly
should be test run and checked according to the unit manufacturer’s instruc-
tions.

The engine is run to operating temperature and the maintenance points below
should be carried out:

1. Checking oil level.

5. Checking coolant level.

10. Checking low pressure indicator.

14. Checking fuel level.

17. Checking electrolyte level in batteries.

18. Checking battery charge.

19. Cleaning batteries.

25. Look for leaks. Remedy as necessary

For engines with few

operating hours which do not

receive periodic maintenance

according to the maintenance

schedule on page 13 ,

maintenance should be

carried out according to the

schedules for:

“Every year”

“Every 5th year”

1997-11:2

MAINTENANCE SCHEDULE

More often if required

For engines with few operating hours, see page 12.

Earlier if low pressure indicator shows red.

Applies only to M engines with seawater pump.

Guidline values. Vary according to composition of seawater.

If inhibitor has not been topped up for five years, coolant should be changed.

Dail

First

time at

Interval At

least

t fi

t s

400 h

200 h

400 h

1200

2400

4800

Ever

y ye

Ever

y 5t

h ye

LUBRICATION OIL SYSTEM, page 14

1. Checking oil level

2. Oil change

3. Cleaning the lubrication oil cleaner

4. Changing the turbo filter

COOLING SYSTEM, page 18

5. Checking coolant level

6. Checking corrosion protection rods 4)

7. Checking seawater pump impeller 4)

8. Checking coolant

l 6

9. Cleaning cooling system

AIR CLEANER, page 26

10. Test reading low pressure indicator

11. Cleaning coarse cleaner

l 1

12. Cleaning or changing filter insert

13. Changing safety cartridge

FUEL SYSTEM, page 29

14. Checking fuel level

15. Changing main filter

16. Checking injectors

ELECTRICAL SYSTEM, page 31

17. Checking electrolyte level in batteries

l 2

18. Checking charge state of batteries

l 2

19. Cleaning batteries

20. Checking level monitor

21. Checking temperature monitor

22. Checking oil pressure monitor

23. Checking stop function

MISCELLANEOUS, page 36

24. Checking V-belts

25. Look for leaks. Remedy as necessary

26. Checking/adjusting valve clearance.

27. Changing (or cleaning) valve for closed crankcase

ventilation

1997-11:2

LUBRICATION OIL SYSTEM

OIL GRADE

The engine oil should at least meet the requirements for one of the following
oil classifications:

-Service CE or CF as per API

-CCMC - D5

-Acea E3-96

- Check with your oil supplier if the oil meets these requirements.

- Specified oil change intervals apply under the provision that the sulphur

content of the fuel does not exceed 0.3% by weight.

- Viscosities as illustrated.

- At very low outside temperatures: Consult your nearest Scania represen-

tative to avoid difficulties.

Oil analysis

Some oil companies can offer analysis of the engine oil. This analysis measu-
res the oil’s total base number (TBN), total acid number (TAN), fuel dilution,
water content, viscosity and the content of wear particles and soot in the oil.

The result of a series of analyses forms the basis of establishing a suitable oil
change interval.

If the conditions are changed, a new oil analysis program must be undertaken
to establish a new change interval.

-40 -30 -20 -10 0 10 20 30 40

°C

SAE 10W-30

SAE 20W-30

SAE 30

SAE 40

SAE 50

SAE 5W-30

SAE 15W-40

Additives must not be used.

The oil should be able to cope

with all temperature

variations up until the next

oil change.

1997-11:2

Daily:

CHECKING OIL LEVEL

Before checking oil level: Let the engine remain stationary for at
least 1 minute.

- The correct level is between the marks on the dipstick. Top up when the

level is at the lower mark.

- Correct type, see ”Oil grade”, page 14.

Checking oil level during operation

On some engines, oil level can be checked during operation.

- Remove the oil filler cap to release the pressure in the crankcase.

- Check the level on the dipstick. Correct oil level: 10 mm below

Min. or Max. mark.

1 dm

= 1 litre

10 mm

2. Every 400 hours:

OIL CHANGE

If the engine is used for particularly demanding operation,
especially in a dusty environment or if the deposits in the
centrifugal cleaner are thicker than 20 mm: Change the oil
more often.

- Pump out the oil using the oil bilge pump when the engine is warm.

- Fill with new oil.

- Check the level on the dipstick.

Maximum angle of inclination during operation

Maximum permitted angles during operation vary depending
on the type of oil sump, see drawing.

Note

Given angles may only be used intermittently.

30°

20°

35°

30°

15° (Alt 20°)

30°

WARNING

The oil may be hot.

Wear protective gloves

and eye protection

1997-11:2

3. Every 400 hours:

CLEANING THE OIL CLEANER

(at same time as oil change)

- Unscrew the nut and remove the cover.

- Lift out the rotor and slacken the nut for the rotor cover three turns.

- If the nut is stuck:

Secure the nut, absolutely not the rotor, in a vice and turn the rotor three
turns by hand or using a screwdriver.

- Gently tap the nut using your hand or a plastic hammer so that the rotor

bowl becomes detached from the bottom plate.

- Undo the nut and remove the rotor bowl.

- Carefully prise the strainer loose from the bottom plate.

- Scrape away deposits from the inside of the rotor bowl. If there are no

deposits, this shows that the cleaner is not working.

- If the deposits are thicker than 20 mm: Clean more often.

WARNING

Open the bowl with care.

The oil may be hot.

Scania D11, DI11. Marine engine. Operator’s manual - part 1