Scania Marine engine. DI16 EMS with S6/PDE. Operator’s manual - part 1
IMPORTANT INFORMATION
When working on the engine, for example adjusting drive belts, changing the oil or adjusting the
clutch, it is important not to start the engine. The engine may be damaged and 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.
This warning symbol and text is reproduced beside those inspection points where the risk of injury
is particularly great.
Operator's Manual
DI16
EMS with S6/PDE
Marine engine
opm_d16mar_en-GB 2 291 675
COMMISSIONING REPORT - WARRANTY
When the start-up report has been filled in and sent to Scania, you have a 1-year warranty from the date of
entry into service.
Also fill in the particulars below as this can make things easier if you need to contact a workshop for example.
Engine serial number
Date of entry into service
Power class, see page 5
User's name and address
Signature
Engine type
Variant
Engine type and variant are indicated on the engine type plate
Preface
This Operator's Manual describes the handling and maintenance of Scania
DI16 marine engines with EMS S6/PDE injection system.
The four stroke V8 diesel engines have direct-injection and are liquid-cooled.
The engines are turbocharged and equipped with a charge air cooler which is
coolant-cooled.
The engines can have 2 different cooling systems: a heat exchanger which is
cooled by sea water, or keel cooling which has cooling coils on the hull in
which the engine coolant is cooled.
Common areas of usage include forward propulsion engines in small boats
like fishing boats and ferries, and in larger pleasure crafts, or as auxiliary
engines on-board ships.
!
The engines can have different output and speed settings and are classified
Important
into different categories by classification societies (classified engines must be
used in certain marine installations).
See page 5 for information
The normal output setting of the engine (performance code) is indicated on
the type plate, see page 10.
about the power classification.
Note: Only standard components are described in the operator's
manual. Scania recommends that you consult the manufacturer's
instructions with regard to special equipment.
In order to obtain the best value and service life from your engine, there are
several points you should bear in mind:
- Read the Operator's Manual before starting to use the engine. Even
though you may have experience of Scania engines you may find new
information in this Operator's Manual.
Help protect our
- Follow the maintenance instructions. Good working order and service
environment!
life are ensured if maintenance is carried out according to the
instructions.
During the warranty period,
only genuine Scania parts may
- In particular, read the safety information starting on page 6.
be used during inspection and
- Get to know your engine so that you know what it can do and how it
repair; otherwise the warranty
works.
will be invalidated.
- If necessary, contact an authorised Scania workshop. They have special
tools, genuine Scania parts and staff with training and practical
experience of Scania engines.
Note: Always use genuine Scania parts during inspection and repair so
as to keep your engine in the best possible working order.
The information in this manual was correct at the time of going to press.
However, Scania reserves the right to make alterations without prior notice.
2
Contents
Preface
2
Checking the sea water pump impeller
32
Contents
3
Checking the coolant
33
Environmental responsibility
4
Cleaning the cooling system
36
Certified engines
4
Air cleaner
40
Power classes
5
Checking the read-out from the vacuum
Safety information
6
indicator
40
Cleaning or renewing the filter element
40
Type designations
10
Fuel system
42
EMS engine management system
12
Location of sensors for EMS with S6
Checking the fuel level
42
on DI16
13
Renewing the fuel filter
42
Troubleshooting using flash codes for the
EMS control unit
14
Electrical system
44
Reading off control unit fault codes
14
Checking the electrolyte level in batteries ...44
Clearing fault codes
14
Checking the state of charge in batteries
44
Overview of flash codes for the EMS control
Cleaning the batteries
44
unit
15
Renewing the battery
45
Troubleshooting using flash codes for the EMS
Checking the coolant level monitor
45
coordinator
16
Reading off coordinator fault codes
16
Miscellaneous
46
Clearing fault codes
16
Checking the drive belt
46
Overview of flash codes for the EMS
Check for leaks, rectify as necessary
47
coordinator
17
Checking and adjusting the valve
Starting and running
18
clearance
48
First start
18
Checking and adjusting the unit injector
Checks before running
19
rocker arms
48
Starting the engine
19
Preparing the engine for storage
51
Running
20
Stopping the engine
23
Technical data
54
Checks after running
23
Fuel
56
Maintenance
24
EC declaration of conformity
58
Engines with few hours of operation
24
Alphabetical index
59
Inspection schedule
25
Scania Assistance
60
Lubrication system
26
Oil grade
26
Checking the oil level
27
Oil change
27
Cleaning the centrifugal oil cleaner
28
Renewing the oil filter
30
Renewing the closed crankcase ventilation
filter
31
Cooling system
31
Checking the coolant level
31
Checking the sacrificial anodes
32
3
Environmental responsibility
Scania has always been very much at the leading edge when it comes to
developing and producing engines which are as environmentally friendly as
possible.
Major progress has been made on reducing harmful exhaust emissions in
order to comply with the stringent environmental requirements in force on
almost all markets.
At the same time, we have been able to maintain high quality in terms of
performance and operating economy for Scania Industrial and Marine
Engines.
To preserve this quality level throughout the entire service life of the engine,
it is important for the operator/owner to follow the instructions on running,
maintenance and the choice of fuel and lubricating oil as outlined in the
Operator's Manual.
Other efforts to preserve the environment we all share are possible by
ensuring that the person carrying out inspection and maintenance always
makes sure that environmentally hazardous waste after inspection and repairs
Help protect our
(oil, fuel, coolant, filters, batteries, etc.) is dealt with and disposed of in
environment!
accordance with applicable environmental requirements.
Use a container to avoid spills
On a number of pages, this Operator's Manual contains specially highlighted
when bleeding and renewing
text with instructions to help protect our environment during certain
inspection and maintenance work.
components.
See example
Certified engines
Emissions-certified engines have been approved in accordance with a special
certification standard. The certified engines supplied by Scania meet the most
stringent emissions requirements which apply on European (EU) and
non-European (USA) markets.
Scania guarantees that all the engines it supplies of a certified type are
equivalent to the engine approved for certification.
The engine comes with a special certification plate which indicates the
certification rules (standard) to which the engine has been approved. See
page 10.
The following are required for the certified engine to fulfil the emissions
requirements once it has been taken into service:
- Inspection and maintenance must be carried out in accordance with the
instructions in this Operator's Manual.
- Only genuine Scania parts are to be used.
- The inspection of injection equipment must be carried out by an
authorised Scania workshop.
- The engine may only be modified with equipment that has been
approved by Scania.
- Seals may be broken and setting data edited only once approval has been
granted by Scania in Södertälje. Modifications may be made by
authorised personnel only.
4
- Changes which affect the exhaust system and intake system must be
approved by Scania.
Otherwise, the instructions in the Operator's Manual in respect of running,
care and maintenance of the engine shall apply. The safety precautions
described over the next 4 pages must also be observed.
Important! If inspection and maintenance are not carried out as specified
above, Scania can no longer guarantee that the engine will
comply with the certified design, nor can it take responsibility
for any damage that occurs.
Power classes
Scania supplies engines in 4 different power classes:
ICFN - Continuous operation: Unlimited number of operational hours per
year at a total load factor of 100%.
IFN - Periodic operation: Intended for periodic operation where full power
is available 1h/3h. The accumulated load factor must not exceed 80% of the
calculated load. Unlimited number of hours per year.
Patrol craft - long: Intended for periodic operation where full power is
available 1h/6h. In between periods of operation at full load, the engine speed
must be reduced by at least 10% of the maximum engine speed attained. The
maximum accumulated operating time must be 2,000 hours per year.
Patrol craft - short: Intended for periodic operation where the calculated
power is available 1h/12h. In between periods of operation at full load, the
engine speed must be reduced by at least 10% of the maximum engine speed
attained. The maximum accumulated operating time must be 1,200 hours per
year.
Below is a list of engine serial numbers and power classes for the engines that
are used in this installation:
Engine serial number:
Engine type:
Engine power:
kW, at
rpm
Indicate below the type of operation, and enter it on page 1.
(
) ICFN - Continuous operation
(
) IFN - Periodic operation:
(
) Patrol craft - long
(
) Patrol craft - short
5
Safety information
General
This Operator's Manual contains safety information which is important so as
!
to avoid both personal injury and damage to the product/other property. See
Important
also page 1.
The text highlighted in text boxes on the right of a number of pages is
Use only genuine Scania fuel
important for engine function and in order to avoid damage to the engine. If
filters.
these instructions are not followed, the warranty may be invalidated.
See example.
Similar text may also appear in the text column, and in this instance it will be
marked Note: or Important.
!
The warning text found in text boxes on the right of a number of pages which
WARNING
is marked with a warning triangle and starts with WARNING is extremely
important and warns you of serious engine faults or incorrect handling which
Block the starting device when
may lead to injury.
working on the engine.
If the engine starts
See example
unexpectedly, there is a
SERIOUS RISK OF
INJURY.
A list of the safety precautions to be followed when running and maintaining
Scania engines can be found on the next 3 pages. Similar text can often be
found at the relevant maintenance points, and here different levels of
importance are attached to such text in accordance with the above
description.
All points are marked !, so as to indicate how important it is to read through
each point in this section.
For safety reasons, smoking is prohibited:
• In the vicinity of the engine and in the engine compartment
• When refuelling and in the vicinity of the filling station
• When working on the fuel system
• In the vicinity of flammable or explosive material (fuel, oils, batteries,
chemicals, etc.).
6
Safety precautions for running the engine
Daily inspection
Starter lock
Always visually inspect the engine and engine
If the control panel is not fitted with a key operated
compartment before starting the engine and once
switch, there should be a lock on the engine
you have stopped the engine after running.
compartment to prevent unauthorised starting of the
engine.
This will enable you to easily detect fuel, oil or
coolant leaks, or any other abnormalities which may
Alternatively, a lockable on/off master switch or
require rectification.
battery master switch can be used.
Refuelling
Starter spray
There is a risk of fire and explosion when refuelling.
Never use starter spray or similar agents to help start
The engine must be stopped and smoking is
the engine. This can cause an explosion in the intake
prohibited.
manifold and possible injury.
Do not overfill the tank due to a risk of expansion,
and close the filler cap properly.
Running
Use only fuel recommended in the workshop
The engine must not be run in environments where
literature. Fuel of the wrong grade could cause the
there is a risk of explosion as all of the electrical or
engine to malfunction or stop by preventing the
mechanical components can generate sparks.
injection pump and injectors from operating as they
should.
Approaching a running engine always poses a safety
risk. Parts of the body, clothes or dropped tools can
This can cause damage to the engine and, possibly,
get caught in rotating parts such as the fan and cause
injury.
injury.
For personal safety all rotating parts and hot
Hazardous gases
surfaces must therefore be shielded as much as
possible.
Only start the engine in a well ventilated area.
The exhaust gases contain carbon monoxide and
nitrogen oxides, which are toxic.
If it is run in an enclosed space, there should be an
effective device to extract exhaust gases and
crankcase gases.
7
Safety precautions for handling
Safety precautions for care and
materials
maintenance
Fuel and lubricating oil
Stop the engine
All fuels and lubricants and many chemicals are
Always stop the engine before carrying out
flammable. Always follow the instructions on the
maintenance and repair work unless stated
relevant packaging.
otherwise.
All work on the fuel system must be done with the
Prevent unwanted starting by taking out the starter
engine cold. Fuel leaks and spillage on hot surfaces
key where applicable and disconnecting the power
can cause fire.
using the master switch or battery master switch and
locking them. Also put up a warning sign
Store soaked rags and other flammable materials
somewhere appropriate, indicating that work is in
safely so as to avoid spontaneous combustion.
progress on the engine.
Working with a running engine always poses a
Batteries
safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts and cause
The batteries contain and emit oxyhydrogen gas,
injury.
particularly during charging, and this gas is
flammable and highly explosive. There must be no
smoking, naked flames or sparks near the batteries
Hot surfaces and fluids
or the battery compartment.
There is always a risk of sustaining burns when an
Incorrect connection of a battery cable or jump lead
engine is hot. Therefore, take care not to come into
can cause a spark, which in turn can cause the
contact with manifolds, the turbocharger, oil sump,
battery to explode.
hot coolant and oil in pipes and hoses.
Chemicals
Lifting the engine
Most chemicals such as glycol, corrosion inhibitors,
The engine lifting eyes must be used when lifting
preservative oils, degreasing agents, etc. are
the engine. Check first that your lifting tools are in
hazardous to health. Always follow the safety
good condition and of the correct size to lift the
precautions on the relevant packaging.
weight.
Some chemicals, such as preservative oil, are also
Extra equipment on the engine can alter the centre of
flammable.
gravity, which is why you may need additional
Store chemicals and other materials which are
lifting devices to balance the engine correctly and
hazardous to health in approved containers, marking
lift it safely.
them clearly and storing them where they are
Never work underneath a suspended engine!
inaccessible to unauthorised persons. Always hand
in leftover or used chemicals to an authorised waste
disposal contractor.
Batteries
The batteries contain a highly corrosive electrolyte
(sulphuric acid). Take care to protect your eyes, skin
and clothes when charging or handling batteries.
Wear protective gloves and goggles.
If the acid splashes on your skin, wash it off with
soap and copious amounts of water. If acid splashes
in your eyes, flush them immediately with copious
amounts of water and contact a doctor.
Dispose of used batteries through an authorised
waste disposal contractor.
8
Electrical system
Cooling system
The engine must be stopped and the power
Never open the coolant filler cap if the engine is hot.
disconnected using the master switch or battery
Hot coolant or steam may spray out and cause burns.
master switch before working on the electrical
If you have to open or remove a cooling system
system.
component when the engine is hot, open the cap
External power supplies to extra equipment on the
very carefully and slowly to relieve the system
engine must also be disconnected.
pressure before removing the cap. Wear gloves as
the coolant is still very hot.
Dispose of used coolant through an authorised
Electric welding
waste disposal contractor.
When carrying out welding work close to and on the
engine, remove the electrical cables to the battery
and the cables to the alternator. Also remove the
Fuel system
multi-pin connector to the control unit.
Always wear gloves when looking for leaks or
Connect the weld clamp to the component to be
carrying out any other work on the fuel system. Also
welded and close to the welding point, never to the
wear protective goggles when testing injectors.
engine or in such a manner that the current can pass
Fuel escaping at high pressure can penetrate tissues
over to a mounting.
and cause serious injury.
When you have finished welding, connect the cables
Never use non-genuine parts in the fuel and
to the alternator and control unit before connecting
electrical systems as genuine parts are designed and
the batteries.
manufactured to minimise the risk of fire and
explosion.
Lubrication system
Hot oil can cause burns and skin irritation.
Before starting
Therefore, avoid skin contact with hot oil.
Fit all removed shields before starting the engine
Make sure that there is no pressure in the lubricating
again. Check that you have not left any tools or other
system before starting work on it. Never start or run
objects on the engine.
the engine with the oil filler cap removed, as this
Do not start the engine until the air filter is fitted.
may cause oil to be thrown out.
There is a risk of objects being sucked into the
Dispose of used oil through an authorised waste
compressor impeller or of injury if you come into
disposal contractor.
contact with it.
9
Type designations
The engine type designation indicates, in the form of a code, the engine
type, its size and applications.
The type designation and engine serial number are shown on a type plate
located on the block on the rear of the engine above the sea water pump. The
engine serial number is also stamped on the front right-hand side of the
cylinder block, in front of
cylinder head 1. See illustration.
Engines which hold certification in respect of smoke and emissions are
fitted with a plate which indicates the documents in accordance with which
they are certified.
DI 16 42 M
Version
DI Supercharged diesel engine with liquid-cooled charge air cooler
Displacement in whole dm³
Performance and certificate
Indicates, together with the application code, the normal gross engine
output.
The actual output setting of the engine is indicated on the engine card.
Application
M For marine use
10
11
21
21
20
19
18
23
10
17
7
22
15
16
2
13
14
12
1
3
11
10
4
9
8
7
5
6
The illustrations show a normal version of a DI16 engine.
Your engine may have different equipment from the one illustrated
1. Type plate
7. Heat exchanger (main
15. Starter motor
circuit)
2. Engine serial number,
16. Control unit
8. Sea water outlet
stamped into the cylinder
17. Fuel filter
block
9. Heat exchanger (charge air
18. Oil dipstick
circuit)
3. Thermostat housing with
19. Fuel pump with hand pump
10. Sea water intake
thermostat (double)
20. Oil filter
11. Expansion tank
4. Outlet from engine
21. Turbocharger
12. Filler, coolant
5. Outlet from heat exchanger
22. Sacrificial anodes (2)
13. Alternator
6. Drain, engine oil
23. Sea water pump
14. Catwalk
11
EMS engine management
system
This engine has an electronic management system, EMS (Engine
Management System), with unit injectors (PDE) which provide each cylinder
with the right amount of fuel at the right time in all operating situations.
The EMS system consists of a control unit (S6) and sensors for speed, charge
air temperature and pressure, coolant temperature, oil pressure, accelerator
pedal/throttle actuation which constantly emit signals to the control unit.
With the aid of this input data and the set control program, the correct amount
of fuel and the correct injection time are calculated for each unit injector
(PDE) under the specific operating conditions.
The EMS system sensors can also be used to emit signals to the instruments
in the instrument panel.
The control unit constantly monitors the sensors to make sure they are
operational.
The control unit contains monitoring functions to protect the engine in the
event of a fault which would otherwise damage it. In the event of a fault, e.g.
alarm level for low oil pressure or high coolant temperature, the S6 control
unit sends a CAN message to a coordinator.
The main task of the coordinator is to pass on data by means of CAN
communication from the engine control unit to other control units and signals
to gauges and lamps in the instrument panel. The coordinator also has
monitoring functions.
When the EMS control unit or the coordinator detects a fault, the diagnostics
lamp on the instrument panel(s) comes on, and it stays on as long as the fault
is active. At the same time, a fault code is generated which can be read off via
the coordinator on the diagnostics lamp in the form of a flash code when the
diagnostics switch is activated. A flash code may consist of a number of
different fault codes.
Diagnosis and troubleshooting using Scania EMS display is described in the
Operator's Manual for Scania instrumentation.
If the torque reduction function is activated, the amount of fuel and the engine
power are reduced to 70%, and if engine shutdown is activated, the engine is
switched off at programmed alarm levels.
A separate PC-based diagnostics program is used to read off the contents of
the flash codes. For an in-depth analysis of fault codes, contact an authorised
Scania dealer.
Reading off the fault codes, and descriptions of these, are also covered in a
separate document in the Workshop Manual, Engine Management System
EMS-S6: Troubleshooting.
Only authorised personnel are allowed to carry out diagnostic procedures and
program changes.
The positions of the sensors which emit signals to the control unit are shown
in the illustrations on page 13.
See pages 14 and 16 for a description of how to read off flash codes.
See pages 15 and 17 for a list of flash codes for the control unit and
coordinator.
12
Location of sensors for EMS with S6 on DI16
1. Oil pressure sensor
2. Coolant temperature sensor
3. Charge air temperature and pressure
sensor
4. Engine speed sensor (2)
13
Troubleshooting using flash codes for
the EMS control unit
• The diagnostics lamp on the instrument panel(s) always comes on for
2 seconds when the system is powered up.
• As soon as a fault is detected by the control unit, it is stored in the
EEPROM fault code memory and the diagnostics lamp on the
instrument panel(s) comes on.
• The diagnostic lamp will stay on for as long as a fault is active. Even if
the lamp has gone off and the fault is no longer active, the code can
generally be read off by following the instructions below.
Reading off control unit fault codes
1. Switch on the 15-supply.
2. Activate the diagnostics switch to the left to view the flash codes for the
control unit (EMS).
3. A fault code will then flash on the diagnostic lamp. This flash code
consists of long flashes (approximately 1 second long) and short flashes
(0.3 seconds long). Long flashes are equivalent to units of 10, and short
flashes are equivalent to
units of 1.
Example: long - short - short = fault code 12.
4. Repeat this procedure until the first flash code is repeated. This means
that the entire fault code memory has been flashed out. If the fault code
memory is empty, only one long flash approx. 4 seconds long will be
given.
5. See the flash code table on the next page for a description and to locate
the fault.
6. In order to obtain further information about the fault code, the PC-based
diagnostics tool or Scania EMS display must be used. Contact an
authorised Scania workshop.
7. When a fault has been rectified the fault code can be cleared as
described below.
Clearing fault codes
1. Switch off the 15-supply. If dual instrumentation has been fitted, the
15 voltage must be switched off on both panels.
2. Activate the diagnostics switch in the same direction as the flash codes
indicate, i.e. to the right for the coordinator (COO) or to the left for
EMS.
3. Switch on the 15 voltage and at the same time keep the diagnostics
switch activated, to the right (COO) or to the left (EMS), for 3 seconds.
4. This will erase passive fault codes which can be read via flash codes for
the relevant system. The rest of the fault codes will remain in the
EEPROM and can only be deleted using the PC tool.
14
Overview of flash codes for the EMS control unit
Code
Description
Code
Description
PDE in cylinder 3: The solenoid valve is not work-
0
No fault detected.
53
ing properly.
Engine overspeed. One or both engine speed sen-
PDE in cylinder 4: The solenoid valve is not work-
11
sors are indicating engine speeds in excess of
54
ing properly.
3,000 rpm.
Rotational speed sensor 1 faulty, or incorrect sig-
PDE in cylinder 5: The solenoid valve is not work-
12
55
nal.
ing properly.
PDE in cylinder 6: The solenoid valve is not work-
13
Engine speed sensor 2 faulty, or incorrect signal.
56
ing properly.
Coolant temperature sensor faulty, or incorrect sig-
PDE in cylinder 7: The solenoid valve is not work-
14
57
nal.
ing properly.
Charge air temperature sensor faulty, or incorrect
PDE in cylinder 8: The solenoid valve is not work-
15
58
signal.
ing properly.
Charge air pressure sensor faulty, or incorrect sig-
16
59
Incorrect signal in extra analogue input.
nal.
17
Oil temperature sensor faulty, or incorrect signal.
61
Incorrect control unit shutdown.
18
Oil pressure sensor faulty, or incorrect signal.
66
Shutdown due to coolant level.
21
Coolant level sensor faulty.
68
Alternator charging incorrectly
23
Internal fault code in the coordinator.
69
Starter motor function interrupted or not activated.
Accelerator pedal/brake. If the accelerator and
24
82
Engine speed above ref. engine speed at start
brake pedals have been operated simultaneously.
Accelerator pedal sensor/idling switch
Fault in memory circuit (EEPROM) in control
25
83
Accelerator pedal sensor/kickdown switch
unit.
Data transfer to the control unit memory
27
Engine shutdown bypassed.
84
(EEPROM) has been interrupted.
28
Shutdown due to oil pressure.
85
Incorrect internal temperature in the control unit.
Internal fault in the control unit: Fault in hardware
31
Torque limitation due to oil pressure
86
control.
32
Incorrect parameters for limp home function.
87
Fault in control unit RAM.
33
Battery voltage incorrect or no signal.
88
Internal control unit fault: Memory fault
Emergency stop switch activated in accordance
37
89
Defective seal: Prohibited changes in software.
with CAN message from coordinator.
CAN communication circuit faulty in the control
43
93
Engine speed sensors faulty or not connected.
unit.
Shutdown due to high coolant
47
Immobiliser function. Starter key code incorrect.
94
temperature.
CAN message from the coordinator incorrect or
Torque limitation due to high
48
96
missing.
coolant temperature.
Incorrect CAN version in control unit or coordina-
49
98
Incorrect voltage supply to one of the sensors.
tor.
PDE in cylinder 1: The solenoid valve is not work-
51
99
Internal hardware fault in the processor (TPU).
ing properly.
PDE in cylinder 2: The solenoid valve is not work-
52
ing properly.
15