Scania DC16 XPI. Industrial engine. Operator’s manual - part 2
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.
16
Environment and safety
Chemicals
REQUIREMENT!
WARNING!
Use only reductant which fulfils the require-
ments in the Reductant for SCR section.
Most chemicals such as glycol, anti-corrosive
agents, preservative oils and degreasing agents,
are hazardous to health. Some chemicals are also
Safety precautions for maintenance
flammable: preservative oil, for example. Al-
ways follow the safety precautions on the pack-
Switch off the engine
aging.
Store chemicals and other materials which are
WARNING!
hazardous to health in approved and clearly
marked containers, where they are inaccessible
Working with a running engine always poses a
to unauthorised persons.
safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts and cause
injury.
Environment
Always switch off the engine before carrying out
Excess and used chemicals must be disposed of
maintenance, unless otherwise indicated.
as specified in national and international laws
and regulations.
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
Reductant
them.
Reductant (AdBlue®, DEF, ARLA 32 eller
Fix a warning plate somewhere appropriate,
AUS 32) is used in the reductant tank on engines
showing that work is being carried out on the en-
equipped with an SCR system.
gine.
The reductant is not toxic, but it is still important
Hot surfaces and fluids
to observe the following when working on the re-
ductant circuit:
WARNING!
• If reductant comes in contact with the skin:
Wash with soap and plenty of water.
There is always a risk of sustaining burns when
• If reductant splashes in the eyes: Rinse imme-
an engine is hot. Particularly hot parts are engine
diately using an eye bath and then seek med-
manifolds, turbochargers, oil sumps, as well as
ical attention.
hot coolant and oil in pipes and hoses.
• Change out of clothes which have spills on.
17
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.
SCR system
Cooling system
IMPORTANT!
WARNING!
Cleanliness is very important when working on
the reductant circuit. Clean thoroughly around
Never open the coolant filler cap when the en-
all parts to be dismantled to prevent dirt from en-
gine is hot. Hot coolant and steam may spray out
tering the system.
and cause burns. If the cap has to be opened do it
slowly to release the pressure before removing
When working on the SCR system, the reductant
the cap. Wear protective gloves as the coolant is
connections may only be lubricated with soapy
still very hot.
water or with distilled water with a 3% urea mix-
ture. Any other types of lubricants may block
Avoid skin contact with coolant as this may
and damage the components in the SCR system.
cause irritation to the skin. Wear protective gog-
gles and gloves when handling coolant.
Reductant causes certain metals to corrode. Al-
ways rinse away reductant spillage on connec-
Ethylene glycol can be fatal if ingested.
tions and other parts with lukewarm water to
prevent corrosion. If reductant seeps into electri-
cal connections or electrical cables, these must
be renewed.
Environment
Used coolant must be disposed of as specified in
national and international laws and regulations.
18
Environment and safety
Electrical system
Batteries
WARNING!
WARNING!
Switch off the engine and switch off the power
The batteries contain highly corrosive sulphuric
by disconnecting the electrical cables to the bat-
acid. Take care to protect your eyes, skin and
tery. External power supplies to extra equipment
clothes when charging or handling batteries.
on the engine must also be disconnected.
Wear protective gloves and goggles.
Always use Scania spare parts for the fuel and
If sulphuric acid comes in contact with the skin:
electrical systems. Scania spare parts are de-
Wash with soap and plenty of water. If it gets in
signed to minimise the risk of fire and explosion.
your eyes: Rinse immediately with plenty of wa-
ter and seek medical attention.
Electric welding
Environment
WARNING!
Used batteries must be disposed of as specified
When carrying out welding work on and near the
in national and international laws and regula-
engine, disconnect the battery and alternator
tions.
leads. Pull out the multi-pin connector for the en-
gine control unit as well.
Before starting
Connect the welding clamp close to the compo-
nent to be welded. The welding clamp must not
WARNING!
be connected to the engine, or so that the current
can cross a bearing.
Ensure that all guards are in place before starting
the engine. Ensure that no tools or other objects
When welding is finished:
have been left on the engine.
1. Connect the alternator and engine control
The air filter must be fitted before starting the en-
unit cables.
gine. Otherwise there is a risk of objects being
2. Connect the batteries.
sucked into the compressor impeller or of injury
if you come into contact with the air filter.
19
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.
Made b y
Example: DC16 084A
DC Supercharged diesel engine with air-
Type
DC16 084A
cooled charge air cooler.
Engine No
6950106
16
Displacement in whole dm3
Output.
405-493
kW
2100
r pm.
084
Performance and certification code. The
code indicates, together with the applica-
tion code, the normal gross engine out-
put.
Example of an engine data plate.
A
Code for application. A means for gen-
eral industrial use.
20
Component identification
Component identification
Engine
1
2
7
8
6
5
4
3
2
9
The illustration shows a normal version of a DC16 engine. The engine ordered may have different equipment.
1. Centrifugal oil cleaner
2. Oil filler
3. Oil dipstick
4. Nipples for draining and filling coolant (1 on each side)
5. Fuel filter
6. Oil filter
7. Engine control unit
8. Engine data plate and engine serial number, stamped into the cylinder block
9. Oil plug
Note: The water separating prefilter for the fuel is located between the fuel tank and engine.
21
Component identification
SCR system
The illustration provides an overview of SCR
system components.
6
2
1
3
5
4
7
12
13
8
10
11
9
1. Evaporator or hydrolysis catalytic converter
8. Reductant pump and control unit
2. Pressure line for reductant
9. Coolant hose, return from tank and pump heating
3. Coolant hose for tank and pump heating
10. Exhaust gas temperature sensor
4. NOx sensor with control unit1
11. SCR catalytic converter
5. Coolant valve
12. NOx sensor with control unit
6. Reductant return line
7. Reductant tank
1. DC16 084A/384A/085A/385A only.
22
Starting and running
Starting and running
1
Checks before first start
Before the engine is started for the first time, car-
ry out the maintenance items listed under First
start in the maintenance schedule. Check the fol-
lowing:
• Oil level.
• Coolant.
• Fuel level.
2
• Fluid level in batteries.
• State of battery charge.
• Condition of the drive belt.
• Level in the reductant tank, if the engine is
equipped with an SCR system.
See also Maintenance intervals.
IMPORTANT!
Running the engine without reductant in the re-
3
ductant tank violates emissions legislation and
will damage the SCR system.
Reductant tank
Reductant tanks come in 5 different sizes. The
volumes indicated for each tank are filling vol-
umes.
1. 38 litres (10 US gallons).
4
2. 60 litres (15.8 US gallons).
3. 45 litres (11.9 US gallons).
4. 63 litres (16.6 US gallons).
5. 70 litres (18.5 US gallons).
A filler filter with magnet is fitted in the reduct-
ant tank to prevent the reductant from becoming
contaminated when topping up. It is used when
refuelling at a filling station. A filler filter with-
out a magnet is also supplied for use when filling
manually.
5
23
Starting and running
Reductant pump
When the reductant pump is new, the check
valves may need to be slackened.
IMPORTANT!
Blow the reductant pump suction nipple with
compressed air (approx. 6 bar/87 psi) for at least
3 seconds before starting the engine for the first
time.
Start the reductant pump immediately after the
reductant tank has been filled for the first time.
Reductant pump suction nipple.
Checks before running
Carry out daily maintenance as described in the
maintenance schedule prior to operation. See
Maintenance intervals.
24
Starting and running
Starting the engine
Starting at low temperatures and at
high altitudes
Take the local environmental requirements into
WARNING!
account. Use a fuel heater and engine heater to
avoid starting problems and white smoke.
Never use starter gas or similar agents to help
start the engine. This can cause an explosion in
Scania recommends that an engine heater should
the intake manifold and possible injury.
be used if the engine will be used at temperatures
below -10°C (14°F) or at an altitude of more than
Only start the engine in a well ventilated area.
2,000 metres.
When the engine is run in an enclosed space,
there must be effective devices to extract exhaust
A low engine speed and a moderate load on a
gases and crankcase gases.
cold engine limits white smoke, gives better
combustion and warms up the engine more
quickly than warming it up with no load.
IMPORTANT!
Avoid running it longer than necessary at idling
speed.
The starter motor must only be cranked twice for
30 seconds at a time. After that, it must rest for at
Running
least 5 minutes before the next attempt to start it.
Check instruments and warning lamps at regular
intervals.
For environmental reasons the Scania engine has
been developed to be started with a low fuel feed.
Engine speed range
Using unnecessarily large amounts of fuel when
The engine operating speed range is between low
starting the engine always results in emissions of
idling and the nominal engine speed. The nomi-
unburnt fuel.
nal engine speed is indicated on the engine data
plate. Low idling can be set between 500 and 975
1. Open the fuel cock if fitted.
rpm.
2. Disengage the engine.
A slightly higher engine speed than the nominal
3. If the engine has a battery master switch:
engine speed may occur at low or negative load.
Switch on the power by means of the battery
master switch.
Driving at high altitude
4. Start the engine.
When driving at high altitudes engine power is
If the fuel tank has been run dry or if the engine
reduced automatically due to the lower oxygen
has not been used for a long time, bleed the fuel
content in the air. It is then not possible to run the
system. See the section Bleeding the fuel system.
engine at maximum power.
Note:
Driving at an altitude higher than 4,000 metres
above sea level is only permitted if it has first
been approved by Scania.
25
Starting and running
Emission control
The system provides a warning if there are faults
on the SCR system or if the level of reductant in
the reductant tank is too low. In the case of some
faults, for example if doser cooling is not work-
ing, the torque is reduced.
Reaction at low reductant level
Reductant
Warning
Torque reduction1
level
lamp
20%
Constant
light
10%
Flashing
Torque is reduced by
1% per minute to
70% of the highest
torque
0%
Flashing rap-
Torque is reduced to
Symbol for low reductant level.
idly
0% (low idling)
within 2-10 minutes
1. Applies only to engines that are certified according to
Tier 4.
The engine resumes normal torque after reduct-
ant has been filled to a level of at least 20%.
Reaction to fault in SCR system
Time
Warning
Torque reduction1
lamp
Fault detect-
Constant
ed
light
After 30
Flashing
Torque is reduced by
minutes
1% per minute to
70% of the highest
torque
After 4 hours
Flashing rap-
Torque is reduced to
Symbol for fault in SCR system.
idly
0% (low idling)
within 2-10 minutes
1. Applies only to engines that are certified according to
Tier 4.
26
Starting and running
Once the fault has been remedied and the engine
control unit has received an indication that it is
working, torque returns to the normal level.
If a new fault occurs within 40 hours of opera-
tion since the first fault, the warning lamp will
come on. After 30 minutes of operation, the
warning lamp will flash rapidly and torque will
be reduced to 0% (low idling) within 30 minutes.
IMPORTANT!
If the torque has been reduced to 0% (low
idling), the control unit does not detect that the
SCR system is functioning again. A service tech-
nician must then reset the system so that the
torque returns to the normal level.
Note:
The torque reduction applies only to engines that
are certified according to Tier 4.
Some emergency vehicles do not have torque re-
duction.
27
Starting and running
Coolant temperature
Oil pressure
Normal oil pressure during operation is 3-6 bar
IMPORTANT!
(43.5-87 psi). The lowest permitted oil pressure
when idling is 0.7 bar (10.2 psi).
An excessive coolant temperature can cause en-
The engine management system issues an alarm
gine damage.
at the following levels:
• At an engine speed below 1,000 rpm and an
Normal coolant temperature during operation is
oil pressure below 0.7 bar (10.2 psi).
90 to 95°C (194 to 203°F).
• At an engine speed above 1,000 rpm and an
The alarm levels are set in the engine control
oil pressure below 2.5 bar (36.3 psi) for
unit. The default setting for the lowest and high-
longer than 3 seconds.
est limit values for high coolant temperature are
95 °C (203 °F) and 105°C (221°F) respectively.
The following function is standard as alarm for
The following function is standard as alarm for
incorrect oil pressure:
high coolant temperature:
• Alarm and torque reduction by 30%.
• Alarm and torque reduction at the lowest lim-
Depending on the engine configuration, the fol-
it value.
lowing alarm functions may also be available:
Depending on the engine configuration, the fol-
• Alarm only.
lowing alarm functions may also be available:
• Alarm and engine shutdown.
• Alarm only.
• Alarm and engine shutdown override control.
• Alarm and engine shutdown at the highest
limit value.
Note:
• Alarm, torque reduction at the lowest limit
High oil pressure (above 6 bar/87 psi) is normal
value and engine shutdown at the highest lim-
if the engine is cold when started.
it value.
• Alarm and engine shutdown at the highest
limit value with the possibility of engine shut-
Charging indicator lamp
down override control.
If the lamp comes on during operation: Check
• Alarm, torque reduction at the lowest limit
and adjust the alternator drive belt according to
value and engine shutdown at the highest lim-
the instructions in the section Checking the drive
it value, with the possibility of engine shut-
belt.
down override control.
If the charging indicator lamp is still on, this
If run for extended periods under an extremely
could be due to an alternator fault or a fault in the
light load, the engine may have difficulty in
electrical system.
maintaining the coolant temperature. At an in-
creased load the coolant temperature rises to the
normal value.
28
Starting and running
Belt transmission
When the belt transmission is new, it may make
a squeaking noise when running. This noise is
normal and disappears after 50-100 hours of op-
eration. The noise does not affect the service life
of the belt transmission.
Raised idling speed on engines with
SCR and EGR system
If the engine is run without load for an extended
period of time, the SCR system needs to be heat-
ed by raising the idling speed. The function is
called periodic hydrocarbon evaporation and is
used to avoid damaging the SCR catalytic con-
verter.
Periodic hydrocarbon evaporation functions dif-
ferently depending on how the engine is
equipped. A warning is output for all engines if
the engine needs to be warmed up. The warning
is output after approx. eight hours if the engine is
idling without load and the outdoor temperature
is 20°C (68°F). The time is reduced as the out-
door temperature becomes colder.
For some engines, a request for automatic raising
of the idling speed is also output after the warn-
ing. If the request is confirmed, the idling speed
is raised automatically. The function is active for
45 minutes or less and is deactivated automati-
cally. If the request is not confirmed, the engine
is switched off after approx. 45 minutes, if the
engine has been configured with engine shut-
down.
29
Starting and running
Engine shutdown
IMPORTANT!
There is risk of post boiling and of damage to the
turbocharger if the engine is switched off with-
out cooling. The power must not be switched off
before the engine has stopped.
If the engine is equipped with a battery master
switch and an SCR system, the SCR system must
run for a while after the engine has been switched
off to allow it to cool down. During this period
the power must not be cut using the battery mas-
ter switch.
Note:
The battery voltage must remain on for a few
seconds after the 15 voltage is switched off so
that the control units can store the values and
switch to standby mode.
10 prohibited engine shutdowns will cause a
torque reduction (70% of fuel quantity). Reset
the engine by switching it off correctly once.
1. Run the engine without a load for a few min-
utes if it has been run continuously with a
heavy load.
2. Switch off the engine.
30
Starting and running
Checks after running
WARNING!
Block the starting device when working on the
engine. If the engine starts unexpectedly, there is
a serious risk of injury.
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.
IMPORTANT!
Check the coolant level following the first start.
Top up with coolant as necessary.
1. Check that the power supply has been cut.
2. Top up the fuel tank. Make sure that the filler
cap and the area round the filler opening are
clean to avoid contamination of the fuel.
3. If the engine is equipped with an SCR sys-
tem: Top up the reductant tank. Make sure
that the filler cap and the area round the filler
opening are clean to avoid contamination of
the reductant.
4. If there is a risk of freezing, the cooling sys-
tem must contain enough glycol. See the sec-
tion Risk of freezing.
5. If the temperature is below 0°C (32°F): Pre-
pare for the next start by connecting the en-
gine heater (if fitted).
31