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

 

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

 

 

Component identification
9
10
11
14
13
12
9. Engine data plate and engine serial number
10. Air cleaner
11. Spark plug
12. Lambda sensor
13. Flame arrestor
14. Throttle at flame arrestor
16
Starting and running
Starting and running
Starting the engine
Checks before first start
WARNING!
Before the engine is started for the first time, car-
Only start the engine in a well-ventilated area.
ry out the maintenance items listed under First
When the engine is run in an enclosed space,
start in the maintenance schedule. Check the fol-
there must be effective devices to extract gas and
lowing:
exhaust gases.
• Oil level.
• Coolant.
• Fluid level in batteries.
IMPORTANT!
• State of battery charge.
The starter motor must only be cranked twice for
• Condition of the drive belt.
30 seconds at a time. After that, it must rest for at
least 5 minutes before the next attempt to start it.
See also Maintenance interval.
1. Open the manual fuel cock.
2. Disconnect the engine from any load.
3. If the engine has a battery master switch:
Checks before running
Connect the power using the battery master
switch.
WARNING!
4. Start the engine.
5. The engine will rev up. Let the engine run
Block the starting device and switch off the man-
without load for 2 minutes.
ual fuel cock when working on the engine. If the
engine starts unexpectedly, there is a serious risk
Starting at low temperatures
of injury.
Take the local environmental requirements into
account. Use the engine heater to avoid starting
difficulties. Scania recommends that an engine
Carry out daily maintenance as described in the
heater should be used if the engine will be used
maintenance schedule prior to operation. See
at temperatures below -10°C.
Maintenance interval.
A low engine speed and moderate load on a cold
engine gives better combustion and faster heat-
ing than warming up with no load.
Avoid running it longer than necessary at idling
speed.
17
Starting and running
Running
The engine is designed and optimised for contin-
uous operation at 100% load. To ensure opera-
Check instruments and warning lamps at regular
tional reliability and to extend the maintenance
intervals.
intervals, the following limitations for load and
operating time apply:
Engine speed range
The engine operating speed range is between low
Output at 100% PRP
Max. operating time
idling and the nominal engine speed. The nomi-
0-25% load
30 minutes
nal engine speed is 1,500 or 1,800 rpm. Low
idling is normally 1,000 rpm.
25-40% load
120 minutes
More than 40% load
No restrictions.
Driving at high altitude
When driving at high altitudes engine power is
The accumulated total engine operating time at
reduced automatically due to the lower oxygen
less than 25% load should be < 5%.
content in the air. It is then not possible to run the
The accumulated total engine operating time of
engine at maximum power.
the engine at less than 40% load should be
< 15%.
Note:
Driving at a height higher than 2,000 metres
Oil pressure
above sea level is only permitted if it has first
For information on the normal oil pressure and
been approved by Scania.
lowest permitted oil pressure, see the Technical
data section.
Coolant temperature
The engine management system activates an
alarm for high or low oil pressure at engine
IMPORTANT!
speeds above 650 rpm. The values below are for
overpressure, not absolute pressure.
An excessive coolant temperature can cause en-
• An alarm for high oil pressure is activated
gine damage.
when the pressure exceeds 7.9 bar (115 psi).
• An alarm for low oil pressure is activated
Normal coolant temperature during operation is
when the oil pressure drops below 0.65 bar
90-95°C (194-203°F).
(9 psi).
Alarm levels are set in the engine control unit.
The incorrect oil pressure alarm has the follow-
The default setting for the lowest and highest
ing functions:
limit values for high coolant temperature are
• Alarm only.
98°C (208°F) and 105°C (221°F) respectively.
• Alarm and engine shutdown.
The high coolant temperature alarm has the fol-
lowing functions:
Note:
• Alarm at the lowest limit value.
High oil pressure (above 6 bar/87 psi) is normal
if the engine is cold when started.
• Alarm at the lowest limit value and engine
shutdown at the highest limit value.
18
Starting and running
Charge air temperature
Checks after running
The engine management system has the follow-
ing alarm levels for high charge air temperature.
WARNING!
• Alarm at 70 C (158°F).
Block the starting device and switch off the man-
• Alarm or engine shutdown at 80°C (176°F).
ual fuel cock when working on the engine. If the
engine starts unexpectedly, there is a serious risk
Charging indicator lamp
of injury.
If the lamp comes on during operation: Check
There is always a risk of sustaining burns when
and adjust the alternator drive belt according to
an engine is hot. Particularly hot parts are turbo-
the section Checking the drive belt.
chargers, oil sumps, hot coolant and oil in pipes
If the charging indicator lamp is still on, this
and hoses.
could be due to an alternator fault or a fault in the
electrical system.
Belt transmission
IMPORTANT!
When the belt transmission is new, it may make
Check the coolant level following the first start.
a squeaking noise when running. This noise is
Top up with coolant as necessary.
normal and disappears after 50-100 hours of op-
eration. The noise does not affect the service life
of the belt transmission.
1. Check that the manual fuel cock is turned off.
2. Check that the power supply has been cut.
Engine shutdown
3. Check that the cooling system contains
enough glycol according to the Scania in-
IMPORTANT!
structions. See the section Coolant.
4. If the temperature is below 0°C (32°F): Pre-
There is risk of post boiling and of damage to the
pare for the next start by connecting the en-
turbocharger if the engine is switched off with-
gine heater (if fitted).
out cooling. The power must not be switched off
before the engine has stopped.
1. Run the engine without load for 3 minutes at
the nominal engine speed.
2. Switch off the engine via the coordinator and
allow the engine to run until the gas has run
out and the engine stops.
3. Close the manual fuel cock.
19
Maintenance
Maintenance
IMPORTANT!
The maintenance programme covers a number of
points that are divided into the following sec-
On delivery a Scania engine is optimised for its
tions:
application. However, regular maintenance is
necessary to
• Lubrication system.
prevent unplanned stops
• Air cleaner.
extend the service life of the engine
• Cooling system.
maximise the long-term emission perfor-
• Fuel system.
mance of the engine
• Electrical system.
give the best possible operating economy.
• Miscellaneous.
WARNING!
Block the starting device and switch off the man-
ual fuel cock 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 turbo-
chargers, oil sumps, hot coolant and oil in pipes
and hoses.
The maintenance programme includes the fol-
lowing:
• R maintenance: One event when taken into
service.
• S maintenance: Minimum basic maintenance.
• M maintenance: More extensive mainte-
nance.
• L maintenance: Includes nearly all mainte-
nance items in the form.
• XL maintenance: Includes all maintenance
items in the form.
During a period, the sequence is S-M-S-L-S-M-
S-L-S-M-S-XL.
XL
L
L
M
M
M
S
S
S
S
S
S
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
20
Maintenance
Maintenance interval
Daily
First time at
Interval (hours)
Minimum
first start
500
500
1,000
1,500
2,000
6,000
an-
every
nual-
5
R
S
M
L
XL
SP
ly
years
Lubrication system
Checking the oil level
X
X
Changing the oil
X
X
X
X
X
X
X
Cleaning the centrifugal oil
X
X
X
X
X
cleaner
Renewing the oil filter
X
X
X
X
X
X
X
Air cleaner
Reading the vacuum indica-
X
X
X
X
X
X
X
tor
Renewing the filter element
X
X
X
Renewing the safety car-
X
X
X
tridge
Cooling system
Checking coolant level
X
X
X
X
X
X
X
X
Checking the coolant's anti-
freeze and corrosion protec-
X
X
X
X
tion
Changing the coolant and
X
X
cleaning the cooling system
Fuel system, only when using pure biogas
Cleaning the flame arrestor
and throttle at the flame
X
lock
Cleaning the throttle at the
X
gas mixer
Leak testing after mainte-
X
nance of the fuel circuit
Checking deposits in the
X
X
combustion chamber
Electrical system
Renewing the spark plugs
X
X
Other
Checking the drive belt
X
X
X
X
X
Checking for leaks
X
X
X
X
X
X
Checking and adjusting the
X
X
X
valve clearance
21
Lubrication system
If Scania Oil LDF-4 is not used, the oil must be
Lubrication system
of a viscosity class suitable for the outdoor tem-
perature in the area where the engine is used.
Oil grade
Scania LDF stands for the Scania Long Drain
Viscosity
Outdoor temperature in °C
Field test standard. Scania LDF oils have been
class
carefully selected after extensive testing. The ap-
SAE 20W-30
-15°C
-
+30°C
proval is only granted to the highest quality en-
gine oils available on the market.
SAE 30
-10°C
-
+30°C
SAE 40
-5°C
-
+45°C
Recommended oil: Scania Oil LDF-4.
SAE 50
0°C
-
+45°C
The engine oil must fulfil the following quality
SAE 5W-30
< -40°C
-
+30°C
requirements:
SAE 10W-30
-25°C
-
+30°C
• ACEA E6.
SAE 15W-40
-20°C
-
+45°C
• ACEA E9
• API CJ4.
Viscosity
Outdoor temperature in °F
Check with your oil supplier that the oil meets
class
these requirements.
SAE 20W-30
5°F
-
86°F
SAE 30
14°F
-
86°F
SAE 40
23°F
-
113°F
SAE 50
32°F
-
113°F
SAE 5W-30
< -40°F
-
86°F
SAE 10W-30
-13°F
-
86°F
SAE 15W-40
-4°F
-
113°F
For operation at extremely low outdoor tempera-
tures: Consult your nearest Scania representative
on how to avoid starting difficulties.
If the engine is used in areas of the world where
engine oil with ACEA or API classification is
not available, the oil grade must be measured in
actual operation. In this case contact the nearest
Scania workshop.
22
Lubrication system
Filled engine oil grade label
When changing oil it is important to use the cor-
rect engine oil grade. The oil filler cap must be
clearly marked with a label showing the filled oil
grade. However, there are only labels for oils
from Scania and oil grade ACEA E9.
Stick on a new label if the oil type or oil grade is
changed in favour of any of the oil types above.
Replace the label if it is missing.
If the oil grades below are used, it is possible to
order labels for the oil filler cap from Scania.
Product
Colour
Part No.
Scania Oil LDF-4
Blue
2 602 886
ACEA E9
-
2 132 429
Oil filler label.
23
Lubrication system
Oil analysis
To be able to extend the oil change intervals us-
ing an oil analysis, Scania LDF-4 oils must be
used. Certain laboratories offer engine oil analy-
sis.
The following conditions must remain fulfilled
when the oil is changed:
• Viscosity at 100°C (212°F): max. ±20% of
the original value of the fresh oil.
• TBN (in accordance with ASTM D4739):
>3.5
• TBN (in accordance with ASTM D4739):
>TAN (in accordance with ASTM D664).
• Oil oxidation (in accordance with
DIN 51453) > 10.
During analysis, the oil’s TBN (Total Base Num-
ber), TAN (Total Acid Number), fuel dilution,
water content and viscosity are measured, as well
as the quantity of particles in the oil.
The result of a series of analyses is used as the
basis for establishing a suitable oil change inter-
val.
If the conditions are changed, a new oil analysis
programme must be carried out to establish new
oil change intervals. Work out the new oil
change interval for the engine in conjunction
with the workshop.
Note:
Only Scania LDF-4 oils may be used in conjunc-
tion with oil analysis and a possible extended oil
change interval.
Depending on the market, the warranty condi-
tions may also change if the oil change intervals
differ from the recommended Scania timetable.
24
Lubrication system
Checking the oil level
Note:
1
Leave the engine off for at least 7 minutes before
you check the oil level.
2
1. Remove the oil dipstick and check the oil
level. The correct level is between the mini-
mum and maximum marks on the oil dip-
stick.
2. Top up with more oil via the oil filler if the
oil level is at or below the minimum mark.
1. Oil dipstick
For information on the correct oil grade, see the
2. Oil filler
section Oil grade.
Maximum angles of inclina-
tion during operation
The illustration shows the maximum permissible
angles of inclination during operation.
25
Lubrication system
Changing the oil
WARNING!
Hot oil can cause burns and skin irritation. Wear
protective gloves and eye protection when
changing hot oil. Make sure that there is no pres-
sure in the lubrication system before changing
the oil. The oil filler cap must always be in place
when starting and running the engine to prevent
oil being ejected.
Note:
Change oil more often if the engine is subjected
to particularly demanding operation, such as a
dusty environment, or if deposits in the centrifu-
gal oil cleaner are thicker than 28 mm (1.1 in).
Renew the oil filter and clean the centrifugal oil
cleaner when changing oil.
Environment
Use a suitable container. Used oil must be dis-
posed of as specified in national and internation-
Oil volume:
al laws and regulations.
Min. 40 litres (10.5 US gallons).
Max. 48 litres (12.6 US gallons).
1. Unscrew the oil plug and drain the oil when
the engine is hot. In certain engine types the
oil is pumped out by means of a bilge pump.
If the engine is drained via the valve, the oil
should be hot. Alternatively, use a pump.
This so that draining occurs more quickly.
2. Wipe off the magnet on the oil plug.
3. Renew the gasket on the oil plug.
4. Refit the oil plug.
5. Fill with the amount of oil specified for the
oil sump.
6. Wait at least seven minutes.
7. Check the level on the oil dipstick.
26
Lubrication system
Cleaning the centrifugal oil
cleaner
WARNING!
The oil may be hot. Carefully remove the cover
from the centrifugal oil cleaner.
Use eye protection and protective gloves when
working on the centrifugal oil cleaner.
When the centrifugal oil cleaner is cleaned, there
should be some dirt deposits on the paper in the
rotor cover. If the paper is clean, the equipment
is not working as it should. If this is the case, in-
vestigate the cause of this.
Renew the paper more frequently if the dirt de-
posits are thicker than 28 mm (1.1 inches) during
a scheduled oil change.
1. Clean the cover.
2. Unscrew the nut securing the outer cover.
3. Let the oil run out from the rotor.
x 1.5
4. Lift out the rotor. Wipe off the outside.
5. Loosen the rotor nut and unscrew it about
1.5 turns.
Note:
Take care not to damage the rotor shaft.
27
Lubrication system
6. If the rotor nut is jammed: Turn the rotor up-
side down and fasten the rotor nut in a vice.
See illustration.
7. Use protective jaws so as not to damage the
M20
grooves of the rotor nut.
8. Turn the rotor 1.5 turns anti-clockwise by
hand.
9. If this does not work: Screw two nuts togeth-
er with an M20 screw.
10. Position the screw head at the bottom of the
x 1.5
rotor.
11. Position a ring spanner on the lower nut and
turn the rotor 1.5 turns anti-clockwise.
IMPORTANT!
Do not attach the rotor directly to the vice. Never
strike the rotor cover.
12. Remove the rotor cover by holding the rotor
in both hands and tapping the rotor nut
against the table. Never strike the rotor di-
rectly as this may damage its bearings.
13. Remove the strainer from the rotor cover. If
the strainer is stuck, insert a screwdriver be-
tween the rotor cover and strainer and care-
fully prise them apart.
28
Lubrication system
14. Remove the paper insert.
15. Scrape off any remaining dirt deposits from
the inside of the rotor cover. If the deposits
on the paper are thicker than 28 mm (1.1 in),
the centrifugal oil cleaner must be cleaned
more often.
16. Wash the parts according to the applicable
industrial method.
17. Inspect the 2 nozzles on the rotor. Ensure that
they are not blocked or damaged.
Renew any damaged nozzles.
18. Check that the bearings are undamaged.
Renew damaged bearings.
1
19. Fold and fit a new paper insert on the inside
of the rotor cover as illustrated.
2
3
4
29
Lubrication system
20. Fit the strainer onto the rotor.
21. Fit a new O-ring to the foot of the centrifugal
oil cleaner.
22. Refit the rotor cover. Ensure that the O-ring
is not outside the edges, but is in the groove.
23. Screw the rotor nut back on by hand.
24. Check that the shaft is not damaged or loose.
Contact a Scania workshop if the rotor shaft
needs renewing.
Note:
Take care not to damage the rotor shaft.
25. Refit the rotor and rotate it by hand to make
sure it rotates easily.
30
Lubrication system
26. Fit a new O-ring in the cover.
27. Refit the cover and tighten the lock nut.
Tightening torque 20 Nm (15 lb-ft).
IMPORTANT!
To reduce the risk of oil leakage it is important to
tighten the cover to the correct tightening torque.
Operational testing of the
centrifugal oil cleaner
Operational testing need only be carried out if it
is suspected that the centrifugal oil cleaner is
malfunctioning. For example, if there are unusu-
ally few deposits given the distance driven.
1. Run the engine until it reaches normal oper-
ating temperature.
2. Switch off the engine and listen for the sound
from the rotor. It should continue rotating for
a time, even when the engine has stopped.
3. Use your hand to feel if the filter housing is
vibrating.
4. If the filter housing is not vibrating, disman-
tle and check the centrifugal oil cleaner.
31

 

 

 

 

 

 

 

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