Scania DC16 PDE. Industrial engine. Operator’s manual - part 1
Important information
Serious risk of injury
When working on the engine, for example when adjusting drive belts and the clutch, or when changing the
oil, it is important not to start the engine. The engine could be damaged, but more importantly 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.
WARNING!
This warning symbol and text can be found next to those maintenance items where it is particularly impor-
tant to bear in mind the risk of injury.
Operator's manual
DC16 PDE Industrial engine
en-GB 2 587 274
Issue 5.0
Start of warranty
3
Quality requirements for fuel
62
Introduction
4
Diesel
62
Certification
4
Use of fuel oil in stand-by generator sets
64
Power classes
5
Biodiesel (FAME)
64
Environment and safety
6
Preparing the engine for storage
65
Environmental responsibility
6
Preservative products
65
Safety
6
Preparations for storage
66
Warnings and advisories
7
Technical data
67
Engine data plate
12
General data
67
Component identification
13
Lubrication system
67
Starting and running
14
Intake system
68
Checks before first start
14
Cooling system
68
Checks before running
14
Fuel system
68
Starting the engine
14
Electrical system
68
Running
15
Scania Assistance
69
Engine shutdown
17
General tightening torques for screw joints . .70
Checks after running
17
Hexagon screws, hexagon socket screws, Torx
Maintenance
18
screws, hexagon nuts
70
Engines with few hours of operation
19
Flange screws with hexagonal head and hexago-
Maintenance intervals
20
nal flange nuts
70
Lubrication system
21
Hose clamps
71
Oil grade
21
Oil analysis
23
Checking the oil level
24
Maximum angles of inclination during operation
24
Changing the oil
25
Cleaning the centrifugal oil cleaner
26
Operational testing of the centrifugal oil cleaner
30
Renewing the oil filter
31
Air cleaner
32
Reading the vacuum indicator
32
Renewing the air cleaner filter element and safe-
ty cartridge
33
Cooling system
34
Coolant
34
Checking coolant level
39
Checking coolant antifreeze and corrosion pro-
tection
40
Changing the coolant and cleaning the cooling
system
41
Fuel system
48
Cleanliness requirements
48
Checking the fuel level
48
Renewing the water separating prefilter
49
Renewing the fuel filter
50
Bleeding the fuel system
52
Other
55
Checking the drive belt
55
Checking for leaks
56
Checking and adjusting the valve clearance and
unit injectors
57
2
Start of warranty
Start of warranty
The more we know about you, your company and your equipment, the more effectively we can adapt our
services to you. If you have started to use a new Scania engine, it is very important that you send in the war-
ranty start report to us immediately. Quite simply, we need to register all the details on engine ownership
etc., so we can monitor it for you.
You can report the start of the warranty on the Scania website: www.scania.com.
Note:
If you do not send in the warranty report, the engine is not covered by the accompanying Scania warranty.
Also fill in below the details you enter in the warranty report. These details can facilitate contact with a
workshop, for example. The engine serial number is on the engine data plate and is also engraved on the
cylinder block.
Engine serial number (e.g. 1111111)
Ship ID (for example MMSI 111111111 or IMO 1111111)
Start date (yyyy-mm-dd)
Company name
Contact person
Telephone number
E-mail address
Address
Post code
Postal town
State/County
Country
3
Introduction
Introduction
Certification
This Operator's manual describes the operation
IMPORTANT!
and maintenance of Scania industrial engines.
The engines are direct-injection, liquid-cooled,
For Scania to guarantee that the engine corre-
four-stroke turbocharged diesel engines.
sponds to its certified configuration, and take re-
sponsibility for any damage and injuries that
The engines are available with different output
occur, maintenance must be carried out in ac-
and engine speed settings. Engine power for the
cordance with the instructions in this Operator's
engine ordered is indicated on a plate located on
manual.
the engine control unit.
Note:
An emissions certified engine fulfils the emis-
Only standard components are described in the
sions requirements for a particular range of ap-
operator's manual. Information about special
plication.
equipment is contained in instructions from the
various manufacturers.
On each emissions certified engine there is a la-
bel which shows which requirements the engine
fulfils. Scania guarantees that each such engine
To ensure the maximum performance and the
fulfils the emissions requirements for the range
longest service life for the engine remember the
of application for which it is certified.
following:
The following are required for the certified en-
• Read through the Operator's manual before
gine to fulfil the emissions requirements once it
starting to use the engine. Even regular users
has been taken into service:
of Scania engines will get new information
• Maintenance is to be carried out in accord-
from the Operator's manual.
ance with the instructions in this Operator's
• Always follow the maintenance instructions.
manual.
• Read the section on safety carefully.
• Maintenance and repairs of injection equip-
• Get to know your engine so that you know
ment are to be carried out by an authorised
what it can do and how it works.
Scania workshop.
• Always contact an authorised Scania work-
• The engine may only be modified with equip-
shop for maintenance and repairs.
ment that has been approved by Scania.
• Seals may be broken and setting data edited
The information in this manual was correct at the
only once approval has been granted by Sca-
time of going to press. Scania reserves the right
nia. Modifications may be made by author-
to make alterations without prior notice.
ised personnel only.
Note:
• Modifications affecting the exhaust and in-
take systems must be approved by Scania.
Always use Scania spare parts for maintenance
and repair.
Otherwise, the instructions in the Operator's
manual for the running and maintenance of the
engine shall apply. Follow the safety precautions
on the following pages.
4
Power classes
Power classes
Scania supplies engines in 5 different power classes:
ICFN, Continuous Service: Intended for continual use and an unlimited number of operational hours per
year at a total load factor of 100%.
IFN, Intermittent Service: Intended for periodic use, where the rated power is available for one hour per
three-hour period. The total load factor must not exceed 80% of the rated power. Unlimited number of op-
erational hours per year.
PRP, Prime Power: Intended for continual use and an unlimited number of operational hours with varying
loads. The average load factor must not exceed 70% of the rated power in a 24-hour period. Accumulated
overload 110% for one hour per 12-hour period. This power class applies to single-speed engines.
COP, Continuous Power: Intended for continual use with a non-varying load and an unlimited number of
operational hours.
ESP, Emergency Standby Power: Intended for use with varying loads for a maximum of 200 hours per
year. Cannot be overloaded. The average load factor must not exceed 70% of the rated power in a 24-hour
period. ESP engines are intended as back-up power supplies in the efficient electrical networks in Europe,
North and South America, Australia, New Zealand, Japan and Taiwan. In other areas, PRP is recommended
for back-up power supply.
The engine serial numbers and power classes for the engines that are used in this installation should be listed
below: You can find the power class of your engine in the engine type data sheet on the Scania website,
Engine serial num-
ber:
Engine type:
Engine power:
kW at
rpm
ICFN, Continuous service
IFN, Intermittent service
PRP, Prime power
COP, Continuous Power
ESP, Maximum stand-by power
5
Environment and safety
Different types of advisory
Environment and safety
Warning!
Environmental responsibility
All advisories preceded by Warning! are very
Scania develops and produces engines that are as
important. They warn of serious faults and incor-
environmentally-friendly as possible. Scania has
rect operation that could lead to personal injury.
made major investments in the reduction of
Example:
harmful exhaust emissions in order to fulfil the
environmental requirements in force in almost
WARNING!
every market.
At the same time, we have been able to maintain
Block the starting device when working on the
a high level of performance and operating econ-
engine. If the engine starts unexpectedly, there is
omy for Scania engines. To maintain these
a serious risk of injury.
throughout the entire service life of the engine, it
is important for the user to follow the instruc-
tions on running, maintenance and fuel, lubricat-
Important!
ing oil and coolant as outlined in the Operator's
manual.
Advisories preceded by Important! warn of
faults and incorrect operation that could lead to
Other green initiatives taken include ensuring
equipment being damaged. Example:
that, following maintenance and repair, waste
that is harmful to the environment (for example
IMPORTANT!
oil, fuel, coolant, filters and batteries) is disposed
of accordance with the applicable environmental
requirements.
An excessive coolant temperature can cause en-
gine damage.
Safety
Note:
The following pages contain a summary of the
Advisories preceded by Note: refer to informa-
safety precautions to be complied with when op-
tion important to ensure the best possible opera-
erating and maintaining Scania engines. The
tion and functionality. Example:
equivalent text can also be found under the rele-
vant maintenance item.
Note:
To prevent damage to the engine and to ensure
Leave the engine off for at least 7 minutes before
that it runs optimally, follow the instructions in
you check the oil level.
the warnings and advisories.
If the instructions are not followed, the warranty
can cease to apply.
6
Environment and safety
Environment
Fuel
This Operator’s manual contains specially high-
lighted text with instructions to help protect the
WARNING!
environment during maintenance. Example:
The wrong fuel grade can cause breakdowns or
stoppages by causing the injection system to
Environment
malfunction. This can cause damage to the en-
gine and, possibly, personal injury.
Use a suitable container. The fuel collected must
be disposed of as specified in national and inter-
national laws and regulations.
REQUIREMENT!
Use only fuel which fulfils the requirements in
the Quality requirements for fuel section.
Warnings and advisories
Smoking
Refuelling
WARNING!
WARNING!
Smoking is prohibited
During refuelling there is a risk of fire and explo-
• in the vicinity of flammable or explosive ma-
sion. The engine must be switched off and smok-
terial, e.g. fuel, oils, batteries, chemicals
ing is prohibited.
• when refuelling and in the vicinity of the fill-
Never overfill the tank as the fuel needs space to
ing station
expand. Make sure that the filler cap is fully
• when working on the fuel system
closed.
Safety precautions for running the
Hazardous gases
engine
Daily maintenance
WARNING!
Always carry out a visual inspection of the en-
Only start the engine in a well-ventilated area.
gine and engine compartment before starting the
The exhaust gases contain carbon monoxide and
engine or when the engine has been switched off
nitrogen oxides, which are toxic.
after operation.
When the engine is run in an enclosed space,
This inspection should be done to detect fuel, oil
there must be an effective device to extract ex-
or coolant leaks, or anything else that may re-
haust gases and crankcase gases.
quire corrective action.
7
Environment and safety
Starter lock
Safety precautions for handling ma-
terials
IMPORTANT!
Fuel and lubricating oil
If the instrument panel is not fitted with a starter
lock, the engine compartment should be locked
WARNING!
to prevent unauthorised personnel from starting
the engine. Alternatively, a lockable master
All fuels and lubricants as well as many chemi-
switch or battery master switch can be used.
cals are flammable. Always follow the instruc-
tions on the relevant packaging.
The work must be carried out on a cold engine.
Starter gas
Fuel leaks and spillage on hot surfaces can cause
fire.
WARNING!
Store used rags and other flammable materials
safely so as to avoid spontaneous combustion.
Never use starter gas or similar agents to help
start the engine. This can cause an explosion in
the intake manifold and possible injury.
Batteries
Running
WARNING!
The batteries contain and form oxyhydrogen gas,
WARNING!
particularly during charging. Oxyhydrogen gas
is flammable and highly explosive.
The engine must not be run in environments
where there is a risk of explosion, as all of the
There must be no smoking, naked flames or
electrical or mechanical components can gener-
sparks near the batteries or the battery compart-
ate sparks.
ment. Incorrect connection of a battery cable or
jump lead can cause a spark, which can cause the
Approaching a running engine always poses a
battery to explode.
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 ro-
tating parts and hot surfaces must be fitted with
guards.
8
Environment and safety
Chemicals
Safety precautions for maintenance
Switch off the engine
WARNING!
WARNING!
Most chemicals such as glycol, anti-corrosive
agents, preservative oils and degreasing agents,
are hazardous to health. Some chemicals are also
Working with a running engine always poses a
flammable: preservative oil, for example. Al-
safety risk. Parts of the body, clothes or dropped
ways follow the safety precautions on the pack-
tools can get caught in rotating parts and cause
aging.
injury.
Store chemicals and other materials which are
hazardous to health in approved and clearly
Always switch off the engine before carrying out
marked containers, where they are inaccessible
maintenance, unless otherwise indicated.
to unauthorised persons.
Make it impossible to start the engine: Remove
any starter key, or cut the power using the main
power switch or battery master switch and lock
Environment
them.
Fix a warning plate somewhere appropriate,
Excess and used chemicals must be disposed of
showing that work is being carried out on the en-
as specified in national and international laws
gine.
and regulations.
Hot surfaces and fluids
WARNING!
There is always a risk of sustaining burns when
an engine is hot. Particularly hot parts are engine
manifolds, turbochargers, oil sumps, as well as
hot coolant and oil in pipes and hoses.
9
Environment and safety
Lubrication system
Fuel system
WARNING!
WARNING!
Hot oil can cause burns and skin irritation. Wear
Maintenance and repairs of injection equipment
protective gloves and goggles when changing
are to be carried out by an authorised Scania
hot oil.
workshop.
Make sure that there is no pressure in the lubri-
Always use Scania spare parts for the fuel and
cation system before starting work on it.
electrical systems. Scania spare parts are de-
signed to minimise the risk of fire and explosion.
Make sure that the oil filler cover is fitted when
starting and running in order to avoid oil escap-
ing.
Environment
Use a suitable container. The fuel collected must
Environment
be disposed of as specified in national and inter-
national laws and regulations.
Used oil must be disposed of as specified in na-
tional and international laws and regulations.
Electrical system
Cooling system
WARNING!
WARNING!
Switch off the engine and switch off the power
by disconnecting the electrical cables to the bat-
Never open the coolant filler cap when the en-
tery. External power supplies to extra equipment
gine is hot. Hot coolant and steam may spray out
on the engine must also be disconnected.
and cause burns. If the cap has to be opened do it
slowly to release the pressure before removing
Always use Scania spare parts for the fuel and
the cap. Wear protective gloves as the coolant is
electrical systems. Scania spare parts are de-
still very hot.
signed to minimise the risk of fire and explosion.
Avoid skin contact with coolant as this may
cause irritation to the skin. Wear protective gog-
gles and gloves when handling coolant.
Ethylene glycol can be fatal if ingested.
Environment
Used coolant must be disposed of as specified in
national and international laws and regulations.
10
Environment and safety
Electric welding
Before starting
WARNING!
WARNING!
When carrying out welding work on and near the
Ensure that all guards are in place before starting
engine, disconnect the battery and alternator
the engine. Ensure that no tools or other objects
leads. Pull out the multi-pin connector for the en-
have been left on the engine.
gine control unit as well.
The air filter must be fitted before starting the en-
gine. Otherwise there is a risk of objects being
sucked into the compressor impeller or of injury
Connect the welding clamp close to the compo-
if you come into contact with the air filter.
nent to be welded. The welding clamp must not
be connected to the engine, or so that the current
can cross a bearing.
When welding is finished:
1. Connect the alternator and engine control
unit cables.
2. Connect the batteries.
Batteries
WARNING!
The batteries contain highly corrosive sulphuric
acid. Take care to protect your eyes, skin and
clothes when charging or handling batteries.
Wear protective gloves and goggles.
If sulphuric acid comes in contact with the skin:
Wash with soap and plenty of water. If it gets in
your eyes: Rinse immediately with plenty of wa-
ter and seek medical attention.
Environment
Used batteries must be disposed of as specified
in national and international laws and regula-
tions.
11
Engine data plate
Engine data plate
The engine data plate indicates, in the form of a
code, the engine type, its size and applications. It
also indicates the engine type power range and
the nominal engine speed. The engine EU type
approval for exhaust emissions is indicated un-
der Output, where applicable.
The engine power is stated on a plate which is lo-
cated on the engine control unit. The engine seri-
al number is stamped onto the top of the cylinder
block at the front right.
Example: DC16 071A
DC Supercharged diesel engine with air-cooled
charge air cooler.
16
Displacement in whole dm3
071
Performance and certification code. The
code indicates, together with the application
code, the normal gross engine output.
A Code for application. A means for general
industrial use.
Made by
Type
DC16 074A
Engine No
1234567
Output .
405-515
kW
2100
r pm .
Output .
kW
r pm .
Example of an engine data plate
12
Component identification
Component identification
5
6
4
3
7
2
1
10
4
9
8
The illustrations show a normal version of a DC16 engine. The engine ordered may have different equipment.
1. Hand pump for fuel.
2. Fuel filter.
3. Oil filter.
4. Oil filler.
5. Engine control unit.
6. Centrifugal oil cleaner.
7. Engine data plate and engine serial number, stamped into the cylinder block.
8. Oil plug.
9. Oil dipstick.
10. Nipples for draining and filling coolant (1 on each side).
Note: The water separating prefilter for the fuel is located between the fuel tank and engine.
13
Starting and running
For environmental reasons the Scania engine has
Starting and running
been developed to be started with a low fuel feed.
Using unnecessarily large amounts of fuel when
Checks before first start
starting the engine always results in emissions of
unburnt fuel.
Before the engine is started for the first time, car-
ry out the maintenance items listed under First
1. Open the fuel cock if fitted.
start in the maintenance schedule. Check the fol-
2. Disengage the engine.
lowing (also see Maintenance intervals):
3. If the engine has a battery master switch:
• Oil level.
Switch on the power by means of the battery
• Coolant.
master switch.
• Fuel level.
4. Start the engine.
• Fluid level in batteries.
If the fuel tank has been run dry or if the engine
• State of battery charge.
has not been used for a long time, bleed the fuel
system. See the section Bleeding the fuel system.
• Condition of the drive belt.
Starting at low temperatures and at
Checks before running
high altitudes
Carry out daily maintenance as described in the
Take the local environmental requirements into
maintenance schedule prior to operation. See
account. Use a fuel heater and engine heater to
Maintenance intervals.
avoid starting problems and white smoke.
Scania recommends that an engine heater should
Starting the engine
be used if the engine will be used at temperatures
below -10°C (14°F) or at an altitude of more than
2,000 metres.
WARNING!
A low engine speed and a moderate load on a
Never use starter gas or similar agents to help
cold engine limits white smoke, gives better
start the engine. This can cause an explosion in
combustion and warms up the engine more
the intake manifold and possible injury.
quickly than warming it up with no load.
Only start the engine in a well ventilated area.
Avoid running it longer than necessary at idling
When the engine is run in an enclosed space,
speed.
there must be effective devices to extract exhaust
gases and crankcase gases.
IMPORTANT!
The starter motor must only be cranked twice for
30 seconds at a time. After that, it must rest for at
least 5 minutes before the next attempt to start it.
14
Starting and running
Running
Driving at high altitude
When driving at high altitudes engine power is
Check instruments and warning lamps at regular
reduced automatically due to the lower oxygen
intervals.
content in the air. It is then not possible to run the
engine at maximum power.
Engine speed range
The engine operating speed range is between low
Note:
idling and the nominal engine speed. The nomi-
Driving at a higher height than 4,000 metres
nal engine speed is indicated on the engine data
above sea level is only permitted if it has first
plate. Low idling can be set between 500 and 975
been approved by Scania.
rpm.
A slightly higher engine speed than the nominal
engine speed may occur at low or negative load.
Coolant temperature
Limp home mode
IMPORTANT!
If there is a fault in the normal throttle opening or
if CAN communication is interrupted, the fol-
An excessive coolant temperature can cause en-
lowing emergency operation option is provided:
gine damage.
A CAN fault or throttle opening fault in an all-
speed engine (both signal and idling switch):
Normal coolant temperature during operation is
90 to 95°C (194 to 203°F).
• The throttle opening value is 0% and the en-
gine is running at normal idling speed.
The alarm levels are set in the engine control
unit. The default setting for the lowest and high-
• The throttle opening value is 0% and the en-
est limit values for high coolant temperature are
gine is running at raised idling speed (750
95 °C (203 °F) and 105°C (221°F) respectively.
rpm) if this function is activated.
The following function is standard as alarm for
CAN fault:
high coolant temperature:
• The engine is switched off if the shutdown
• Alarm and torque reduction at the lowest lim-
function is activated.
it value.
15