Scania DI12 EMS with S6/PDE. Marine engine. Operator’s manual - part 4

 

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Scania DI12 EMS with S6/PDE. Marine engine. Operator’s manual - part 4

 

 

22. Every 2,400 hours:
Checking and adjusting the valve
!
clearance
WARNING
Note: Checking and adjusting valve clearances should also be done
after the first 400 hours of operation.
Block the starting device when
working on the engine.
Valve clearances should be adjusted when the engine is cold, at least
30 minutes after running.
If the engine starts
The rocker cover gaskets should be renewed as necessary. Tightening torque:
unexpectedly, there is a
26 Nm.
SERIOUS RISK OF INJURY.
Intake valve clearance: 0.45 mm.
Exhaust valve clearance: 0.70 mm.
Tightening torque for lock nut: 35 Nm
Location of read-off openings on the flywheel housing.
48
Order of adjustment
- Turn the flywheel counterclockwise so that the marks on the flywheel
1
can be seen in the lower opening in the flywheel housing (depending on
which opening the reading is to be taken from). See table.
- Measure the valve clearance with a feeler gauge and adjust the valves as
2
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.
3
- Checking and adjustment of the rocker arms for the unit injectors should
be done together with the valve clearance check/adjustment. See point
4
21.
- Readings can be taken from the flywheel through openings in the
5
flywheel housing either from above or underneath depending on access
when fitting. Up or down is shown on the flywheel. Both openings are
fitted with a blanking piece at delivery.
6
- If it is not possible to take a reading in one of the openings, observe the
valve transition, turn the flywheel counterclockwise 120° (1/3 turn) at a
FLYWHEEL
time and adjust the valves according to the table below and the unit
Cylinder numbering
injectors as described on the next page.
Mark on flywheel (reading
Valve transition Adjust valves on
taken through lower
on cylinder
cylinder
window)
TDC Down (0°)
1
6
120º
5
2
240º
3
4
TDC Down (0°)
6
1
120º
2
5
240º
4
3
Mark on flywheel (reading
Valve transition Adjust valves on
taken through upper
on cylinder
cylinder
window)
TDC Up (0º)
1
6
300º
5
2
60º
3
4
TDC Up (360º)
6
1
300º
2
5
60º
4
3
49
23. Every 2,400 hours:
Checking and adjusting the unit
injector rocker arms
Note: Checking/adjusting the rocker arms for the unit injectors should
also be done together with the valve clearance check/adjustment
after the first 400 hours of operation.
Important! The PDE31 unit injector is adjusted using setting tool
99 414 or a digital sliding calliper. The PDE32 unit injector
is adjusted using setting tool 99 442 or a digital sliding
Measurement A=
caliper. This adjustment is essential as a fault in the position
PDE31: 66.9 ± 0.1 mm
of the unit injector can result in poor performance and
PDE32: 69.9 ± 0.1 mm
possible breakdown.
Measurement B=
PDE31: 36.5 mm
PDE32: 38.8 mm
Readings can be taken from the flywheel through openings in the flywheel
housing either from above or underneath depending on access when fitting.
Both openings are fitted with a blanking piece on delivery; see illustration on
page 48.
50
Order of adjustment
Turn the flywheel counterclockwise so that the marks on the flywheel can be
seen in the lower or upper opening in the flywheel housing (depending on
which opening the reading is to be taken through). Refer to table.
Mark on flywheel (reading
Adjust injector
Valve transition
taken through lower
rocker arm on
on cylinder
window)
cylinder
TDC Down (0°)
1
2
120º
5
4
240º
3
1
TDC Down (360º)
6
5
120º
2
3
240º
4
6
Mark on flywheel (reading
Adjust injector
Valve transition
taken through upper
rocker arm on
on cylinder
window)
cylinder
TDC Up (0º)
1
2
300º
5
4
60º
3
1
TDC Up (360º)
6
5
300º
2
3
60º
4
6
51
PDE31:
1. Firstly, measure the distance (A) between plane (a) and the top edge of
the valve spring washer on the unit injector using a digital sliding
calliper. 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.
Note: No further checking or adjustment of the unit injectors, such as
checking the opening pressure, is to be carried out. If the unit
injector is faulty, the entire unit injector must be renewed.
66.9
99 414
Piston above or below the flat
surface. Adjustment necessary.
Piston level with the flat surface.
Adjustment is correct.
52
PDE32:
1. Firstly, measure the distance (A) between plane (a) and the top edge of
the valve spring washer on the unit injector using a digital sliding
calliper. 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.
Note: No further checking or adjustment of the unit injectors, such as
checking the opening pressure, is to be carried out. Faulty
injectors must always be replaced completely.
69.9
99 442
Piston above or below the flat
surface. Adjustment necessary.
Piston level with the flat surface.
Adjustment is correct.
53
Preparing the engine for
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,
WARNING
etc.).
Ethylene glycol is highly
dangerous if imbibed.
Preservative coolant
Avoid contact with the skin.
If the engine is being stored with coolant in the system, the coolant should
contain 50% glycol by volume. Glycol without nitrite-based inhibitor should
be used. For example BASF G48 or BASF D542.
Preservative fuel
- Use diesel mixed with Lubrizol 560H or equivalent.
- Mix 1 cm3 (ml) Lubrizol 560H in 10 dm3 (l) of fuel.
!
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 you inhale it: Fresh air, rest and warmth.
Flammable: Fire class 2A. Flashpoint + 27º.
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.
54
Preservative oil
Suitable preservative oils are supplied by most oil suppliers.
E.g. Dinitrol 40 or the equivalent.
Preparations for storage
Help protect our
- Drain and flush the cooling system. Top up with preservative coolant.
environment!
- Warm up the engine on normal fuel. Stop the engine and drain the oil.
Use a container to avoid spills
- Renew the fuel filter.
when draining the oil and
- Fill the engine with preservative oil up to the minimum level on the
coolant.
dipstick.
Dispose of used oil and coolant
- Mix preservative fuel in a can. Detach the fuel pipe at the feed pump
through an authorised waste
suction line and connect a hose from the can.
disposal contractor.
- 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 PDE
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).
- Drain the sea water system.
- 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.
Winter storage
- To reduce the risk of condensation in the fuel tank during winter storage,
fill the tank with fuel.
55
Attach a label to the engine, clearly stating the storage preparation date and
that the engine must not be started or cranked.
ENGINE PREPARED FOR
LONG-TERM STORAGE
Date
!
WARNING
Batteries
Remove the batteries for trickle charging at the battery charging station.
Wear gloves and protective
(Does not apply to batteries which according to the manufacturer do not
goggles when charging and
require any maintenance). The same applies to short-term storage, even if the
handling batteries.
engine has not been prepared for storage as above.
The batteries contain a highly
corrosive acid.
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 cooling system with coolant.
- Connect the sea water system.
- 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 unit injector mechanisms.
- Drain the preservative fuel from the fuel manifolds and fuel filter.
- Connect and bleed the fuel system, see page 44.
Wash off any externally applied preservative oil, using white spirit.
56
Technical data
General
DI12
Number of cylinders
6 in line
Cylinder diameter
mm
127
Piston stroke
mm
154
Displacement
dm3 (litres)
11.70
No. of main bearings
7
Firing order
1 - 5 - 3 - 6 - 2 - 4
Compression ratio
16:1
Engine direction of rotation viewed from rear
Anticlockwise
Cooling
Liquid
Valve clearances, cold engine
intake valve
mm
0.45
outlet valve
mm
0.70
Weight, without coolant or oil
engine with heat exchanger
kg
1,130
engine without heat exchanger
1,070
(keel cooling engine)
kg
Power
See "Engine record card"
Lubrication system
Max. oil pressure
hot engine at engine speeds above
6
1,000 rpm
bar (kp/cm2)
Normal oil pressure
hot engine at operating speed
bar (kp/cm2)
3-6
Min. oil pressure
hot engine, 1,000 rpm
bar (kp/cm2)
3.0
Min. oil pressure
hot engine, idling
bar (kp/cm2)
1.4
Oil capacity, see page 27
Crankcase pressure with closed crankcase ventilation mm
-55 - +20
water column
57
Fuel
Fuel system
DI12
Low idling
rpm
700 (adjustable 500-800)
Maximum full load speed
See engine card
Fuel
Diesel1
1 see page 59
Cooling system
Number of thermostats
1 (dual thermostat)
Thermostat, opening temperature
°C
83
Coolant temperature:
system at atmospheric pressure
°C
70-93
system at overpressure
°C
70 - approx. 100
Volume
with heat exchanger
dm3 (litres)
approx. 42
without heat exchanger
approx. 24
(keel cooling engine)
dm3 (litres)
Electrical system
System voltage
V
24
Alternator, current
A
65 or 2x65
Starter motor output
kW (hp)
6.7
(9.1)
Monitors, threshold values:
oil pressure sensor
bar (kp/cm2)
1.0 ± 0.15
temperature monitor
°C
Stamped on hexagonal part of monitor
58
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.
Property
Requirements
Viscosity at 40°C
2.0-4.5 mm2/s (cSt)
Density at 15°C
0.82-0.86 kg/dm3
Sulphur (concentration by mass)
max. 0.3%
Ignitability (CET rating)
min 49
Flashpoint
56°C
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. 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 a low sulphur content
for some time after this to regain its normal efficiency.
59
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
WARNING
power or stop.
The diesel is adapted for use in the specific climate of each country. If a
It is not permitted to mix
vehicle or an engine is to be operated in a temperature zone with lower
kerosene with diesel that is
temperature than normal, first identify the temperature properties of the fuel
already adapted for the climate
concerned.
concerned, it can damage the
The properties of the fuel when cold can be improved by adopting one of the
unit injectors. All use of
following measures before the temperature drops:
paraffin other than kerosene is
- If the fuel concerned cannot cope with the expected temperatures, and
forbidden, as it causes engine
diesel is not available with the correct temperature properties, we
damage.
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.
Important
- To prevent water in the fuel from freezing and forming ice, a maximum
of 0.5-2% alcohol (isopropanol) may be added.
It is not permissible to mix
Drain fuel tanks and drain or renew fuel filters regularly.
petrol with diesel. Petrol may
cause wear to the unit injectors
and it may also cause damage to
the engine.
60
Alphabetical index
Taking out of storage
56
Air cleaner, safety cartridge
42
Air cleaner, vacuum indicator
41
Battery, renewing
46
Leakage
47
Batteries
45
Flash codes, coordinator
17
Environmental responsibility
4
Flash codes, control unit
15
Fuel filter, renewing
43
Oil analysis
26
Fuel level
43
Oil change
27
Fuel specifications
59
Oil filter
30
Fuel system
43
Oil grade
26
Fuel system, bleeding
44
Oil level
27
Oil filter unit
28
Certified engines
5
Oil pressure
22
Oil capacity
27
Drive belt
47
Electrical system
45
Maintenance
24
Unit injector
50
Maintenance schedule
25
Sea water-cooled charge air cooler
36
Troubleshooting, coordinator
16
Lubricating oil system
26
Troubleshooting, control unit
14
Lubricating oil pressure
22
Filter, fuel
43
Starting the engine
19
Filter, air cleaner
41
Stopping the engine
23
Prefilter, air cleaner
41
Preface
2
Safety precautions for running the engine
7
First start
18
Safety instructions for materials handling
8
Safety instructions for care and maintenance . . 8
Warranty
1
Safety information
6
EMS sensors
13
Safety cartridge, air cleaner
42
Glycol
33
Technical data
57
Preparations for storage
54
Type designations
10
Checks after running
23
Checks before running
19
Vacuum indicator
41
Corrosion inhibitor
35
Cooling system
31
Engine speed
20
Cooling system, cleaning
36
Valve clearance
48
Coolant
33
Coolant, changing
35
Coolant level
31
Coolant level monitor
46
Coolant temperature
21
Running
20
Storage
56
Air filter, element
41
Bleeding, fuel system
44
Air cleaner
41
Air cleaner, prefilter
41
61
Scania Assistance
Wherever you are you can always get assistance from our service
organisation, Scania Assistance. All day, every day of the year. Using Scania
Assistance is free, but the cost of repairs, spare parts and help from
mechanics will be debited.
Always call the contact for your country.
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
+48 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
Other countries: +46 8 52 24 24 24
Note: Calls will be recorded for training purposes.
62

 

 

 

 

 

 

 

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