Scania OC16 Gas. Industrial engine en-GB 2 831 273. Operator’s manual - part 1

 

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Scania OC16 Gas. Industrial engine en-GB 2 831 273. 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.
Therefore, block the starting device and switch off the manual fuel cock when 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
OC16 Gas Industrial engine
en-GB 2 831 273
Issue 3.0
Start of warranty
3
Checking and adjusting the valve clearance .61
Introduction
4
Quality requirements for fuel
64
Power classes
5
Methane amount and calorific value per power
Environment and safety
6
level
64
Environmental responsibility
6
Other quality requirements
65
Safety
6
Preparing the engine for storage
66
Warnings and advisories
7
Preservative products
66
Engine data plate
14
Preparations for storage
66
Component identification
15
Technical data
69
Starting and running
17
General data
69
Checks before first start
17
Lubrication system
69
Checks before running
17
Fuel system
70
Starting the engine
17
Cooling system
70
Running
18
Intake system
70
Engine shutdown
19
Electrical system
70
Checks after running
19
Scania Assistance
71
Maintenance
20
General tightening torques for screw joints . .72
Maintenance interval
21
Hexagon screws, hexagon socket screws, Torx
Lubrication system
22
screws, hexagon nuts
72
Oil grade
22
Flange screws with hexagonal head and hexago-
Oil analysis
24
nal flange nuts
72
Checking the oil level
25
Hose clamps
73
Maximum angles of inclination during operation
25
Changing the oil
26
Cleaning the centrifugal oil cleaner
27
Operational testing of the centrifugal oil cleaner
31
Renewing the oil filter
32
Air cleaner
33
Reading the vacuum indicator
33
Renewing the filter element and safety cartridge
33
Cooling system
34
Coolant
34
Checking coolant level
38
Checking the coolant's antifreeze and corrosion
protection
38
Changing the coolant and cleaning the cooling
system
39
Fuel system
44
Cleaning the flame arrestor and throttle at the
flame lock
44
Cleaning the throttle at the gas mixer
48
Leak testing after maintenance of the fuel circuit
49
Checking deposits in the combustion chamber.
56
Electrical system
57
Renewing the spark plugs
57
Other
59
Checking the drive belt
59
Checking for leaks
60
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
This Operator's manual describes the operation
and maintenance of Scania industrial engines.
The engines are liquid-cooled Otto gas engines
with turbochargers.
The engines are available with different power
settings. Engine power for the engine ordered is
indicated on a plate located on the engine control
unit.
Note:
Only standard components are described in the
operator's manual. Information about special
equipment is contained in instructions from the
various manufacturers.
To ensure the maximum performance and the
longest service life for the engine remember the
following:
• Read through the Operator's manual before
starting to use the engine. Even regular users
of Scania engines will get new information
from the Operator's manual.
• Always follow the maintenance instructions.
• Read the section on safety carefully.
• Get to know your engine so that you know
what it can do and how it works.
• Always contact an authorised Scania work-
shop for maintenance and repairs.
The information in this Operator's manual was
correct at the time of going to press. Scania re-
serves the right to make alterations without prior
notice.
Note:
Always use spare parts that are approved by Sca-
nia for maintenance and repairs.
4
Power classes
Power classes
Scania supplies engines in two different power classes:
PRP, Prime power: Intended for continuous use and an unlimited number of operational hours with vary-
ing loads. The average load factor must not exceed 70% of the rated power in a 24-hour period. Accumu-
lated 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.
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 no.:
Engine type:
Engine power:
kW at
rpm
PRP, Prime power
COP, Continuous 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 and switch off the man-
a high level of performance and operating econ-
ual fuel cock when working on the engine. If the
omy for Scania engines. To maintain these
engine starts unexpectedly, there is a serious risk
throughout the entire service life of the engine, it
of injury.
is important for the user to follow the instruc-
tions on running, maintenance and fuel, lubricat-
ing oil and coolant as outlined in the Operator's
Important!
manual.
Advisories preceded by Important! warn of
Other green initiatives taken include ensuring
faults and incorrect operation that could lead to
that, following maintenance and repair, waste
equipment being damaged. Example:
that is harmful to the environment (for example
oil, coolant, filters and batteries) is disposed of
IMPORTANT!
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
safety precautions to be complied with when op-
Advisories preceded by Note: refer to informa-
erating and maintaining Scania engines. The
tion important to ensure the best possible opera-
equivalent text can also be found under the rele-
tion and functionality. Example:
vant maintenance item.
Note:
To prevent damage to the engine and personal in-
Leave the engine off for at least 7 minutes before
jury, and to ensure that it runs optimally, follow
you check the oil level.
the instructions in the warnings and advisories.
If the instructions are not followed, the warranty
can cease to apply.
6
Environment and safety
Environment
IMPORTANT!
This Operator’s manual contains specially high-
lighted text with instructions to help protect the
Comply with applicable local laws and regula-
environment during maintenance. Example:
tions when handling natural gas and pure biogas.
Environment
Methane is a highly flammable gas which is
flammable when present in a 5-16% mixture in
Use a suitable container. Used coolant must be
the air.
disposed of as specified in national and interna-
tional laws and regulations.
Methane can even be ignited by static electricity
from a person.
Methane ignites when in contact with hot surfac-
es at approx. 580°C.
Warnings and advisories
Methane burns with an almost invisible flame.
Therefore, take extra care.
Fuel
The engine is designed and optimised to be run
Methane is lighter than air and therefore rises in
on either natural gas or pure biogas.
the event of leakage. Bear this in mind if leaks do
occur in enclosed spaces such as indoors or in a
tunnel. In those cases the gas can cause suffoca-
WARNING!
tion and an explosive atmosphere.
Natural gas and pure biogas mainly consist of
Smoking
methane, and may have a methane content of up
to 97%. Methane is flammable and must be han-
WARNING!
dled with great care.
Smoking is prohibited in the vicinity of gas en-
gines.
WARNING!
Methane is not toxic, but in a mixture of 50 per
cent or more with air, the oxygen content will be
so low that the risk of suffocation increases.
7
Environment and safety
Safety precautions for running the
Starter lock
engine
IMPORTANT!
Daily maintenance
Always carry out a visual inspection of the en-
If the instrument panel is not fitted with a starter
gine and engine compartment before starting the
lock, the engine compartment should be locked
engine or when the engine has been switched off
to prevent unauthorised personnel from starting
after operation.
the engine. Alternatively, a lockable master
switch or battery master switch can be used.
This inspection should be done to detect fuel, oil
or coolant leaks, or anything else that may re-
quire corrective action.
Fuel
WARNING!
Running
Fuel of the wrong quality can cause malfunctions
or cause the engine to stop. This can cause dam-
WARNING!
age to the engine and, possibly, personal injury.
The engine must not be run in environments
where there is a risk of explosion, as all of the
electrical or mechanical components can gener-
REQUIREMENT!
ate sparks.
Use only fuel which fulfils the requirements in
Approaching a running engine always poses a
the Quality requirements for fuel section.
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
Hazardous gases
guards.
WARNING!
Only start the engine in a well-ventilated area.
The exhaust gases contain carbon monoxide and
nitrogen oxides, which are toxic.
When the engine is run in an enclosed space,
there must be effective devices to extract gas and
exhaust gases.
8
Environment and safety
Safety precautions for handling ma-
Chemicals
terials
WARNING!
Lubricating oil
Most chemicals such as glycol, anti-corrosive
WARNING!
agents, preservative oils and degreasing agents,
are hazardous to health. Some chemicals, such as
All lubricants and many chemicals are flamma-
preservative oil, are also flammable. Always fol-
ble. Always follow the instructions on the rele-
low the safety precautions on the packaging.
vant packaging.
Store chemicals and other materials which are
The work must be carried out on a cold engine.
hazardous to health in approved and clearly
Spillage on hot surfaces can cause fires.
marked containers, where they are inaccessible
to unauthorised persons.
Store used rags and other flammable materials
safely so as to avoid spontaneous combustion.
Environment
Batteries
Excess and used chemicals must be disposed of
as specified in national and international laws
WARNING!
and regulations.
The batteries contain and form oxyhydrogen gas,
particularly during charging. Oxyhydrogen gas
is flammable and highly explosive.
There must be no smoking, naked flames or
sparks near the batteries or the battery compart-
ment. Incorrect connection of a battery cable or
jump lead can cause a spark, which can cause the
battery to explode.
9
Environment and safety
Safety precautions for maintenance
Lubrication system
Switch off the engine
WARNING!
WARNING!
Hot oil can cause burns and skin irritation. Wear
protective gloves and goggles when changing
Working on a running engine always poses a
hot oil.
safety risk. Parts of the body, clothes or dropped
Make sure that there is no pressure in the lubri-
tools can get caught in rotating parts and cause
cation system before starting work on it.
injury.
Make sure that the oil filler cover is fitted when
starting and running in order to avoid oil escap-
Always switch off the engine before carrying out
ing.
maintenance, unless otherwise indicated.
Make it impossible to start the engine: Remove
any starter key, or cut the power using the main
Environment
power switch or battery master switch and lock
them.
Used oil must be disposed of as specified in na-
Hot surfaces and fluids
tional and international laws and regulations.
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.
10
Environment and safety
Cooling system
Fuel system
WARNING!
WARNING!
Never open the coolant filler cap when the en-
Natural gas and pure biogas are extremely flam-
gine is hot. Hot coolant and steam may spray out
mable and can even be ignited by static electric-
and cause burns. If the cap has to be opened do it
ity from a person.
slowly to release the pressure before removing
Natural gas and pure biogas are lighter than air
the cap. Wear protective gloves as the coolant is
and therefore rise in the event of leakage. Be
still very hot.
aware of if there is a leak in a confined space. In
Avoid skin contact with coolant as this may
those cases the gas can cause suffocation and an
cause irritation to the skin. Wear protective gog-
explosive atmosphere.
gles and gloves when handling coolant.
Always use Scania spare parts for the fuel and
Ethylene glycol can be fatal if ingested.
electrical systems. Scania spare parts are de-
signed to minimise the risk of fire and explosion.
Environment
IMPORTANT!
Used coolant must be disposed of as specified in
national and international laws and regulations.
Work on the engine may only be carried out by
personnel who are aware of the risks and have
sufficient knowledge of natural gas and pure bi-
ogas.
Comply with applicable local laws and regula-
tions when handling natural gas and pure biogas.
The operator is responsible for using the correct
type of gas to ensure that local laws are complied
with.
11
Environment and safety
Before working on the engine, ensure that the
gas content of the air is below 10% of the lower
explosive limit (LEL). Also check the permitted
gas content with reference to local laws and reg-
ulations.
When working on the engine, use warning plates
indicating that work with flammable fuel is in
progress. Warning signs should be written in the
local language. Comply with local regulations on
the design of warning signs. An example of the
design of a warning sign is shown in the illustra-
tion.
Inform all personnel of the basic risks of natural
gas and pure biogas.
Check the grounding of the engine where open
handling of gas takes place, i.e. handling which
may give rise to an explosive atmosphere.
Display signs such as this when working on a gas
engine.
Never attempt to put out a burning gas flame. Try
to stop the flow of gas instead. Move material
that could be ignited by the flame.
Electrical system
WARNING!
Before working on the electrical system, ensure
that the gas content of the air is below 10% of the
lower explosive limit (LEL). Also check the per-
mitted gas content with reference to local laws
and regulations.
Switch off the engine and switch off the power
by disconnecting the electrical cables to the bat-
tery. External power supplies to extra equipment
in the engine must also be disconnected.
Always use Scania spare parts for the fuel and
electrical systems. Scania spare parts are de-
signed to minimise the risk of fire and explosion.
12
Environment and safety
Electric welding
WARNING!
WARNING!
Cut the power by disconnecting the electrical ca-
bles to the battery and not to the engine, as there
Before welding, ensure that the gas content of
is a risk of sparks building up.
the air is below 10% of the lower explosive limit
(LEL). Also check the permitted gas content
with reference to local laws and regulations.
Environment
When carrying out welding work on and near the
engine, disconnect the battery and alternator
electrical cables. Pull out the multi-pin connector
Used batteries must be disposed of as specified
for the engine control unit as well.
in national and international laws and regula-
tions.
Connect the welding clamp close to the compo-
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 control unit ca-
bles.
2. Connect the batteries.
Before starting
Batteries
WARNING!
WARNING!
Ensure that all guards are in place before starting
the engine. Ensure that no tools or other objects
The batteries contain highly corrosive sulphuric
have been left on the engine.
acid. Take care to protect your eyes, skin and
The air filter must be fitted before starting the en-
clothes when charging or handling batteries.
gine. Otherwise there is a risk of objects being
Wear protective gloves and goggles.
sucked into the compressor impeller or of injury
If sulphuric acid comes in contact with the skin:
if you come into contact with the air filter.
Wash with soap and plenty of water. If it gets in
your eyes: Rinse immediately with plenty of wa-
ter and seek medical attention.
13
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 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: OC16 071A
Made by
OC Supercharged gas engine with air-cooled
charge air cooler.
OC16 071A
16
Displacement in whole dm3.
Type
Engine No
1234567
071
Performance and certification code. The
Output .
333-407
kW
1500
r pm .
code indicates, together with the applica-
Output .
372-426
kW
1800
r pm .
tion code, the normal gross engine output.
A Code for application. A means for general
industrial use.
Example of an engine data plate.
14
Component identification
Component identification
1
2
3
4
8
7
6
5
1. Filling coolant
2. Centrifugal oil cleaner
3. Throttle at gas mixer
4. Oil dipstick
5. Oil plug
6. Oil filler
7. Nipple to drain and fill coolant (behind the coolant manifold, one on each side).
8. Oil filter
15

 

 

 

 

 

 

 

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