Scania DI12. Marine engine. Operator’s manual - part 2
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 18 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 21, 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 17.
There is a description of the functions of the LEDs during normal operation
on page 18.
On page 19 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 20 and 21.
16
Location of sensors for DEC2 on DI12
1. Connection of lead to charge air
temperature sensor
2. Charge air temperature sensor
3. Oil pressure monitor
4. Connector panel
5. Coolant temperature sensor
6. Engine speed sensorse
17
LED functions during normal operation
Note: The lamp test/fault code switch should not be
POWER-
depressed. All LEDs come on briefly when
P The LED remains out during normal operation
the control unit is powered up.
as long as no fault is detected by the control
unit. See next page for the procedure to be
CONTROL STATUS
adopted in the event of a fault.
< The LED flashes continuously when the control
unit is supplied with current, regardless of
POWER+
whether the engine is running or not.
< If the control unit is programmed to allow the
engine to be operated according to more than
SHUTDOWN
one power/torque curve (map), the following
P The LED is out.
applies.
The LED comes on when the engine is run at
STARTING
more than 100% power output (MAP 2). It goes
< The LED lights up as soon as the engine turns
out when the engine returns to the 100% power
over on cranking and follows the programmed
output curve (MAP 1) or when the power output
starting sequence until it has been completed
required is less than 100%.
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.
18
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 20 and the chart on page 21
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 20 and the chart on page 21
If the engine has not stopped, reduce engine
speed to idle and conduct troubleshooting.
19
Changing functions using the DIP
Readout of fault codes
switches in the control unit
Note If the engine has stopped or lost power but
There are 8 DIP switches in the control unit under the
the main indicator lamp is out and neither
round black rubber cover.
POWER- nor SHUTDOWN are on, the
fault is outside the control unit detection
These switches shall be in the ON position to obtain
range. Probable causes: fuel shortage,
normal functions according to the operating program.
temporary overload, mechanical fault.
However, for single-speed engines, the normal
position of DIP switches 6, 7, and 8 may also be OFF
-
Activate the lamp test/fault code switch. In
Scania electrical equipment the main indicator
Shutdown at threshold values for low oil pressure and
lamp is located in this switch on the main supply
high coolant temperature can be selected by setting
box.
DIP switch 4 to OFF
-
All LEDs will then come on for 2 seconds to
With DIP switch 4 in position ON, Power- indication
indicate that they are intact and in working order.
is obtained for these threshold values. Engine output
This also applies to the main indicator lamp in the
reduction (LOP) can be selected to prevent damage to
main supply box and the instrument panel. Make
the engine. Changes to the program must only be
a note of any LED that is defective.
performed by authorized personnel.
-
All LEDs will then be out for approximately 4
Note
Do not operate the engine with a Power-
seconds.
indication except for in emergencies.
-
Following this, a fault code will be indicated on
one of the LEDs for 2 seconds. Note which LED
it is.
-
The control unit then resumes the operating mode
automatically.
-
After having made a note of the fault code, reset
the lamp test/fault code switch and reset the
control unit by turning off its power supply
momentarily.
-
The most probable cause of the fault can then be
found in the trouble shooting schedule on the next
page.
-
When the fault or faults have been rectified the
engine can be restarted.
-
If the control system continues to indicate a fault
by way of the main indicator lamp, further faults
may have been recorded. The fault code readout
must then be repeated as per above since the
system can only display one fault code at a time.
-
The fault(s) will be stored in a special memory in
the control unit along with information about the
operating time when it(they) occurred. Stored
faults can be accessed and erased by authorised
service personnel.
The DIP switches are showed in ON position
20
READOUT OF FAULT CODES
LED INDICATION WHEN THE LAMP TEST/FAULT CODE SWITCH IS ACTIVATED
Probable cause
Action
Send in the control unit for repair as soon as
<
DEC2 has detected an internal fault in the control unit.
possible.
The engine temperature has reached the threshold level
Check the cooling system. Check the temperature
<
or the temperature sensor is inoperative.
sensor and cable routing.
The engine has reached the overrevving limit or the
Check the wiring and connector.
<
engine speed sensor is inoperative.
Renew the engine speed sensor.
<
Control rack position sensor inoperative.
Check connectors and cables to governor.
The intake air temperature has reached the threshold
Check the intake system. Check the temperature
<
level or the charge air temperature sensor is inoperative.
sensor and cable routing.
DEC2 detects no charge air pressure.
Check the charge air pressure hose. Send in the
<
The charge air pressure sensor is inoperative.
control unit for repair if the connection is damaged.
Engine speed potentiometer or the idling safety switch
Check the cable routing, connectors and cables.
<
is inoperative.
The oil pressure has dropped to the threshold level or
Check oil level, connector and cable.
<
the oil pressure monitor is inoperative.
Renew the oil pressure monitor.
<=LED on
STARTING AND RUNNING
AT FIRST START
Coolant composition:
When the engine is started for the first time, follow the maintenance points
listed under "First start" in the maintenance schedule, see page 29.
If there is a danger of freezing:
Since the points are important for satisfactory operation of the engine right
minimum 30% glycol by volume
from the outset, they are also listed below.
maximum 60 % glycol by volume
1. Checking the oil level (refer to page 31).
8. Checking the coolant (refer to page 36).
If there is no danger of freezing:
The coolant should contain corrosion inhibitor to protect the cooling
7-12% by volume
system from corrosion.
Scania Anti-corrosive
If there is a danger of freezing:
(no glycol)
- Only anti-freeze glycol should be used in the coolant as protection
against corrosion. We recommend only nitrite-free anti-freeze glycols
with the following supplier designations:
BASF G48 or BASF D542
- The concentration of glycol should be 30 - 60% by volume depending
Ethylene glycol and corrosion
on the ambient temperature. A content of 30 % by volume provides
inhibitor, if swallowed can be
protection down to -16 °C. Refer to page 36.
fatal.
- Never top up with only water or only glycol. Fluid losses must always
Avoid contact with the skin.
be replaced with pre-mixed coolant having the same glycol
concentration as that in the engine. If the glycol content drops, both
anti-freeze protection and protection against corrosion are impaired.
Note A glycol concentration below 30% by volume will not provide suf-
ficient protection against corrosion. Glycol concentrations higher
The recommended glycol must
than 60 % do not improve anti-freeze protection and have a nega-
not be mixed with glycol having
tive effect on engine cooling capacity.
nitrite-based anti-corrosive.
If there is no danger of freezing:
- Only Scania Anti-corrosive should be used in the coolant as protection
against corrosion. The correct corrosion inhibitor content is 7-12% by
volume and must never be less than 7% by volume. The inhibitor in
Scania Anti-corrosive is free of nitrite.
The use of too much Scania
- First filling: Fill the cooling system with water + 10% by volume of
Anti-corrosive as mixed with
Scania Anti-corrosive. Use drinkable water with a pH value of 6 - 9.
glycol may cause deposits.
- Never top up with only water or only anti-corrosive! Fluid losses
must always be replaced with premixed coolant:
water + 10 % by volume of Scania Anti-corrosive.
Coolant filter (not standard equipment)
Only coolant filter without inhibitor may be used. The use of coolant filters
If a coolant filter has been fitted
increases the life of the coolant and reduces the risk of deposition corrosion.
it must not contain inhibitor.
22
14. Checking the fuel level (refer to page 45).
17. Checking the electrolyte level in batteries (refer to page 47).
18. Checking the state of charge in batteries refer to page 47).
20. Checking the coolant level monitor (if fitted) (refer to page 48).
Immobilise the starting device
21. Checking the temperature monitor (refer to page 49).
when working on the engine.
If the engine starts out of
22. Checking the oil pressure monitor (refer to page 50).
control, there is a
23. Checking the tension of drive belts (refer to page 51).
SERIOUS RISK
OF INJURY.
CHECKS BEFORE RUNNING
Before running, "Daily maintenance" as described in the maintenance sche-
dule should be carried out, see page 29.
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 45).
For environmental reasons, your new Scania engine has been designed to use
a smaller amount of fuel when starting. Using unnecessarily large amounts of
Only start the engine in a
fuel when starting the engine always results in the discharge of unburnt fuel.
properly ventilated area.
- Open the fuel cock, if fitted.
When operating the engine in
- Declutch the engine (not engines with fixed clutch, e.g. generator sets).
an enclosed area, an effective
extraction device for exhaust
- Engines with battery master switch: Switch on the power by means of
gases and crankcase gases
the battery master switch.
must be used.
- DEC2: If the main indicator lamp comes on or flashes when the power is
turned on, this indicates the presence of a fault in the control system or
engine which must be found and rectified before the engine is started.
Refer to page19.
- Start the engine by means of the starter button or starter key.
Starting at low temperatures
Never use starting spray or
Local environmental requirements must be complied with. Starting aids,
similar as a starting aid.
engine heaters and/or flame start devices should be used to avoid starting
problems and white smoke.
An explosion may occur in the
intake pipe, which could cause
To limit white smoke, the engine should be run at low speed and under mode-
rate load. Avoid running it longer than necessary at idling speed.
personal injury.
23
At temperatures below 0 °C:
Note Only use starting aids recommended by Scania.
- The starter motor may only be used for 30 seconds at a time. After that
time it must cool 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 seconds). The glow plug
Maximum starter engagement
continues to glow as long as this button is depressed after the engine has
time is 30 seconds. Risk of
started. Maximum time is 5 minutes.
overheating. Allow starter to
- Operating flame start with timer relay: Press the pre-glow button (a
cool for 2 minutes after a
maximum of 20 seconds). Release it when the engine starts. The timer
starting attempt before
relay keeps the glow plug glowing for 5 minutes. If a shorter glow time
cranking again.
is required, press the release button. The key must be turned to the 0
position if the start attempt fails.
Note If the engine is equipped with an INTERLOCK switch, this
switch should be depressed and held until the oil pressure has
reached a sufficiently high level.
- Generator sets should be operated under load immediately after starting
to avoid the risk of white smoke. This applies in particular to engines
that have been installed without aids for heating or applying a basic
load.
- Warm up the engine with a light load. A light load on a cold engine
gives better combustion and faster heating than warming up with no
load.
24
Running
Check instruments and warning lamps at regular intervals.
Engine speed
The Scania tachometer is divided into sectors of different colours, as follows:
0-500 rpm
red area:
prohibited engine speed,
passed when stopping and
starting.
500-700 rpm
yellow area:
low idle.
700-2200 rpm
green area:
normal operating speed.
The engine's operating
speed range is controlled by
the DEC2 control system.
2200-2600 rpm
yellow/green
unsuitable operating speed.
striped:
May occur when switching
off.
2600-3000 rpm
red area:
prohibited engine speed
Coolant temperature
Normal coolant temperature when the engine is running should be 70 - 90°C.
DEC2: If the temperature is high, 98°C or above, you can select for the
control system to reduce power output (Power -) in order to bring down the
temperature. Refer to the DEC section on page 20.
If the temperature continues to rise, the engine will be shut down
automatically (Shutdown) at 103°C. Refer to the DEC section on page 20.
Excessively high coolant temperature can damage the engine.
If run for extended periods under an extremely light load, the engine may
have difficulty in maintaining normal operating temperature. However, the
temperature will rise to a normal level again when the load on the engine is
increased.
25
Oil pressure
Max. oil pressure:
hot engine at engine speed exceeding 800 rpm
6 bar
Normal oil pressure:
hot engine at operating speed
3 - 6 bar
High lubricating oil pressure
Min. oil pressure:
(above 6 bar) is normal when
hot engine at 800 rpm
0.7 bar
starting a cold engine.
At engine speeds below 800 rpm the gauge may indicate low oil pressure
although no fault is present.
Oil pressures below 0.7 bar at engine speeds above 800 rpm will cause
engine damage. The engine must be stopped immediately.
DEC2: The engine is shut down automatically if this function has been
selected. Refer to the DEC section on page 20.
Charging indicator lamp
If the lamp comes on during operation:
- Check/adjust the alternator drive belts as described in the maintenance
step. Refer to page 51.
- If the charging indicator lamp is still on, this could be due to an alter-
nator fault or a fault in the electrical system.
STOPPING THE ENGINE
1. Run the engine without a load for a few minutes if it has been run
continuously with a heavy load.
There is danger of turbo damage
2. Stop the engine with the stop button. Keep the stop button depressed
and post boiling if the engine is
until the engine is completely stationary.
stopped without cooling.
3. DEC2: Before switching off, check that the control system's main
indicator lamp is not on or flashing.
Refer to page 19 for troubleshooting.
4. Engines with battery master switch: Switch the power off with the
The power must not be switched
battery master switch.
off before the engine has
stopped.
5. Set the control switch to "0".
26
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 the engaged position.
THIS MAY CAUSE PERSONAL INJURY and engine damage.
For this reason, always secure the clutch in the disengaged posi-
tion 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 in the "0" position.
Immobilise the starting device
when working on the engine.
- Fill the fuel tank. Make sure that the filler cap and the area round the
filler opening are clean to avoid contamination of the fuel.
If the engine starts out of
control, there is a
- If there is a risk of freezing, the cooling system must be drained if it
SERIOUS RISK
does not contain a sufficient amount of glycol, refer to page 36.
OF INJURY.
- Close inlet valve for the sea water system (if fitted).
- If there is danger of freezing, the sea water system must be emptied.
- At temperatures below 0 °C: Prepare for the next start by switching on
the engine heater (if fitted).
Top up engine coolant when the
engine has been stopped after
being started for the first time.
27
MAINTENANCE
The maintenance programme covers 26 points, divided into the following
main groups:
Lubricating oil system
page 30
Cooling system
page 34
Immobilise the starting device
Air cleaner
page 42
Fuel system
page 45
when working on the engine.
Electrical system, monitors, batteries etc. . . page 47
If the engine starts out of
Miscellaneous
page 51
control, there is a
SERIOUS RISK
OF INJURY
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 every 400 hours of operation (carried out after 400,
800, 1200, 1600, etc. hours)
Periodic maintenance every 1200 hours of operation (carried out after 1200,
2400, 3600, etc. hours)
Periodic maintenance every 2400 hours of operation (carried out after 2400,
4800 etc. hours)
Periodic maintenance every 4800 hours of operation (carried out after 4800,
9600, etc. hours)
Annual Maintenance
Maintenance every 5th year
ENGINES WITH FEW HOURS OF
OPERATION
Run the engine until it reaches operating temperature and then carry out the
For engines with few operating
maintenance points below:
hours that are not subject to
1. Checking the oil level.
periodic maintenance according
to the maintenance schedule on
5. Checking the coolant level.
page 29, maintenance should be
10. Checking the vacuum sensor.
carried out in accordance with
14. Checking the fuel level.
the schedule:
17. Checking the electrolyte level in batteries.
"Every year"
"Every 5 years"
18. Checking the state of charge in batteries.
19. Cleaning the batteries.
24. Checking for leakage, rectify as necessary
28
MAINTENANCE SCHEDULE
First
Interval
At least
time at
LUBRICATING OIL SYSTEM, page 30
z
z
1. Checking the oil level
2. Oil change
z
1
z
3. Cleaning the oil cleaner
z
1
z
4. Renewing the oil filter
z
1
z
COOLING SYSTEM, page 34
z
5. Checking the coolant level
6. Checking the corrosion bars 4)
z
5
z
7. Checking the marine water pump impeller 4)
z
5
z
8. Checking the coolant
z
6
z6
9. Cleaning the cooling system
z
1
z
AIR CLEANER, page 42
z
10. Checking the vacuum sensor
11. Cleaning the coarse cleaner
z
1
z
12. Cleaning or renewing filter element
z
3
z
13. Renewing the safety cartridge
z
FUEL SYSTEM, page 45
z
z
14. Checking the fuel level
15. Renewing the main filter
z
1
z
16. Checking the injectors
z
ELECTRICAL SYSTEM, page 47
z
2
z
z
17. Checking the electrolyte level in batteries
18. Checking the state of charge in batteries
z
2
z
z
19. Cleaning the batteries
z
2
z
20. Checking the level monitor
z
21. Checking the temperature monitor
z
22. Checking the oil pressure monitor
z
MISCELLANEOUS, page 51
z
23. Checking the drive belt
24. Checking for leakage, rectify as necessary
z
25. Checking/adjusting valve clearance
z
26. Renewing (or cleaning) the valve for closed crankcase
z
ventilation
1. More often if required.
2. For engines with few operating hours, see page 28.
3. Earlier if low pressure indicator shows red.
4. Only applies to M engines with sea water pump.
5. Reference value. Varies depending on the composition of the sea water.
6. If inhibitor has not been topped up for five years, the coolant should be changed.
29
LUBRICATING OIL SYSTEM
OIL GRADE
The engine oil must at least meet the requirements for one of the following
oil classifications:
-ACEA E3, E4 or E5
- The Total Base Number (TBN) should be minimum 12-13
(ASTM 2896).
- Check with your oil supplier that the oil meets these requirements.
Additives must not be used.
- The specified oil change intervals apply provided that the fuel sulphur
content does not exceed 0.3% by weight. If the sulphur content exceeds
The oil should be suitable for all
0.3 % but is maximum 1.0%, the oil change intervals must be halved
temperature variations until the
(200 h).
next oil change.
- Viscosities as illustrated below.
- For operation at extremely low ambient temperature: Consult your
nearest Scania representative on how to avoid starting difficulties.
Oil analysis
Some oil companies can offer analysis of the engine oil. Such analysis
measures the oil TBN (Total Base Number), TAN (Total Acid Number), fuel
dilution, water content, viscosity and the quantity of friction particles and
soot in the oil.
The result of a series of analyses is used as the basis for establishing a
suitable oil change interval.
If the conditions are changed, a new oil analysis programme must be carried
out to establish the new change interval.
-40
-30
-20
-10
0
10
20
30
40
°C
SAE 20W-30
SAE 30
SAE 40
SAE 50
SAE 5W-30
SAE 10W-30
SAE 15W-40
30
1. Daily:
CHECKING THE OIL LEVEL
Note Before checking oil level: Allow the engine to remain stopped 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" on page 30.
Checking oil level during operation
On some engines the 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 the mini-
mum and the maximum mark.
10 mm
10 mm
2. Every 400 hours:
OIL CHANGE
Note Under extremely severe operating conditions, especially in dusty
environment or if the deposits in the centrifugal cleaner are
thicker than 20 mm: change oil more frequently.
- Pump out the oil with the oil bilge pump when the engine is warm.
- Fill up with new oil.
- Check the level on the dipstick.
3
Max 33 dm
Min 28 dm3
Always use a suitable container
to avoid spillage when
changing oil.
The oil may be hot.
Dispose of used oil through an
Wear protective gloves and
authorized waste disposal
goggles
contractor.
Max 28 dm3
Min 20 dm3
Maximum angles of inclination during operation
1 dm3 = 1 liter
Maximum permissible angles during operation vary, depending on the type
of oil sump, see illustration..
Note Specified angles may only occur intermittently.
25°
25°
25°
35°
25°
3
5°
35°
31