Scania Marine engine. DI16 EMS with S6/PDE. Operator’s manual - part 2
Troubleshooting using flash codes for
the EMS coordinator
• 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 coordinator, it is stored in the
EEPROM fault code memory and the diagnostics lamp on the
instrument panel(s) comes on.
• Even if the lamp has gone off and the fault is no longer active, the code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 coordinator fault codes
1. Switch on the 15-supply.
2. Activate the diagnostics switch to the right for 1 second to view the flash
codes for the coordinator (COO).
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.
16
Overview of flash codes for the EMS coordinator
Flash code
Fault description
111)
Incorrect signal from the fine adjustment for the nominal engine speed signal.
112)
Incorrect signals from the accelerator pedal sensor.
121)
Incorrect signal from the resistor module for governor setting.
122)
Incorrect signal from the resistor module for idle and fixed speed setting.
13
No communication (EMS) with the engine.
14
Short circuit in the tachometer signal cable.
15
Faulty atmospheric pressure sensor.
17
Short circuit in the coolant temperature gauge signal cable.
18
Short circuit in the oil pressure gauge signal cable.
19
Short circuit in the oil pressure lamp signal cable.
21
Different versions of the communications protocol between the coordinator and EMS.
22
Faulty start switch or short circuit.
23
The supply voltage is too high.
24
The supply voltage is too low.
25
Check value from End of Line (EOL) is incorrect.
26
Road speed sensor signal missing or incorrect.
27
The signals from the RCB (Remote Control Box) switches are implausible.
28
Incorrect signals from the droop setting switches.
29
Faulty remote start switch or short circuit.
31
No communication from the slave coordinator or the master coordinator.
32
Short circuit in the signal cable to the coolant temperature warning lamp.
33
Short circuit in the signal cable to the charge warning lamp.
34
Incorrect signal from the Fixed speed switches.
35
Fault in CAN communication.
1) Single-speed engine
2) All-speed engine
17
Starting and running
First start
When the engine is started for the first time, the inspection points listed under
Coolant composition:
"First start" in the inspection schedule should be followed, see page 25.
If there is a danger of freezing:
Since the points are important for satisfactory operation of the engine right
from the outset, they are also listed below.
min 30% glycol by volume
max 60% glycol by volume
1. Checking the oil level, see page 27.
If there is no danger of freezing:
8. Checking the coolant, see page 33.
8-12% by volume
The coolant must contain corrosion inhibitor to protect the cooling
Scania Corrosion Inhibitor
system from corrosion.
(no glycol)
If there is a danger of freezing:
- Only antifreeze glycol should be used in the coolant as protection
against corrosion. Scania recommends only nitrite-free antifreeze
!
glycols with the following supplier designations:
WARNING
BASF G48 or BASF D542
- The concentration of glycol should be 30-60% by volume depending on
Ethylene glycol and corrosion
the ambient temperature. 30% glycol by volume provides anti-freeze
inhibitor can be fatal if
protection down to -16°C. See page 33.
ingested.
- Never top up with water alone or glycol alone! Fluid losses must always
Avoid contact with the skin.
be replaced with pre-mixed coolant having the same glycol
concentration as that in the engine. If the glycol content drops, both
antifreeze protection and protection against corrosion are impaired.
Note: A glycol concentration below 30% by volume will not provide
!
sufficient protection against corrosion. Glycol concentrations
Important
higher than 60% do not improve antifreeze protection and have
an adverse effect on engine cooling capacity.
The recommended glycols must
If there is no danger of freezing:
not be mixed with glycol
containing nitrite-based
- Only Scania Corrosion Inhibitor should be used in the coolant as
corrosion inhibitor.
protection against corrosion. The correct concentration of corrosion
inhibitor is 8-12% by volume, and this must never drop below 8% by
volume. The inhibitor in Scania Corrosion Inhibitor is free of nitrites.
- First filling: Fill up the system with water +10% by volume Scania
Corrosion Inhibitor. Use drinking water with a pH of 6-9.
!
- Never top up with water alone or corrosion inhibitor alone!
WARNING
Fluid losses must always be replaced with pre-mixed coolant:
water + 10% Scania Corrosion Inhibitor by volume.
Overdosing with Scania
Corrosion Inhibitor and mixing
with glycol can cause sludge to
Coolant filter (not standard equipment)
be formed.
Only coolant filters without inhibitor may be used. The use of coolant filters
increases the life of the coolant and reduces the risk of deposit corrosion.
!
WARNING
If a coolant filter has been fitted
it must not contain inhibitor.
18
12. Checking the fuel level, see page 42.
14. Checking the electrolyte level in batteries, see page 44.
15. Checking the state of charge in batteries, see page 44.
18. Checking the drive belt tension, see page 46.
!
WARNING
Block the starting device when
working on the engine.
If the engine starts
unexpectedly, there is a
Checks before running
SERIOUS RISK OF INJURY.
Before running, "Daily maintenance" as described in the inspection schedule
should be carried out, see page 25.
!
WARNING
Starting the engine
Only start the engine in a well
If the fuel tank has been run dry or if the engine has not been used for a long
time, bleed the fuel system.
ventilated area.
If it is run in an enclosed space,
Out of consideration for our common environment, your Scania engine has
been designed to use less fuel when starting. Using unnecessarily large
there should be an effective
amounts of fuel when starting the engine always results in emissions of
device to draw off exhaust gases
unburnt fuel.
and crankcase gases.
- Open the inlet valve for the sea water system (if fitted).
- Open the fuel cock if fitted.
- Disengage the engine.
- Engines with battery master switch: Switch on the power by means of
!
the battery master switch.
WARNING
- Start the engine with the key in the control panel (SCP) or the start
Never use starter spray or
button (only from RCB).
similar agents to help start the
- S6: The diagnostics lamp should go out after approximately 2 seconds
engine.
when starting.
An explosion may occur in the
intake manifold with a risk of
personal injury.
19
Starting at low temperatures
Local environmental requirements must be complied with. Starting aids,
engine heaters should be used to avoid starting problems and white smoke.
To limit white smoke, the engine should be run at low speed and under
moderate load. A moderate load on a cold engine gives better combustion and
!
faster heating than warming up with no load.
WARNING
Avoid running it longer than necessary at idling speed.
At temperatures below 0°C:
The starter motor may only be
cranked for a maximum of
Note: Only use starting aids recommended by Scania.
30 seconds. There is a risk of
- The starter motor must only be cranked for 30 seconds at a time. After
overheating. Let the starter
that it must rest for 30 seconds before the next attempt to start it.
motor rest for 30 seconds
Max. 5 start attempts are permitted. After that the starter motor must rest
between each attempt to start
for 15 minutes before the procedure can be repeated.
the engine.
Note: If the engine is equipped with an INTERLOCK switch, this
switch should be depressed and held down until the oil pressure
has reached a sufficiently high level.
Running
Check instruments and warning lamps at regular intervals.
Engine speed
The Scania tachometer is divided into different coloured sectors as follows.
0-500 rpm
red area:
prohibited engine speed,
passed through when stopping
and starting.
500-700 rpm
yellow area:
slow idle. Engine idling is
controlled by the EMS/S6
control system. Fixed raised
idling speed with a cold
engine. See page 20.
700-2,200 rpm
green area:
normal operating speed
The engine operating speed
range is controlled by the
EMS/S6 control system.
2,200-2,600 rpm
yellow/green
unsuitable operating speed.
striped area:
May occur when switching
off.
2,600-3,000 rpm
red area:
prohibited engine speed.
20
Limp home mode
If there is a fault on the normal accelerator pedal or if CAN communication is
interrupted, the following limp-home option is available:
CAN fault or accelerator pedal fault (both signal and idling switch):
- The accelerator pedal value is 0 % and the engine is running at normal
idling speed.
- The accelerator pedal value is 0% and the engine is running at fixed
raised idling speed (750 rpm) if this function is activated.
Accelerator pedal malfunction but the idling switch is working:
- The accelerator pedal value can be increased slowly between 0% and
50% by using the idling switch.
CAN fault:
- The engine is switched off if the shutdown function is activated.
Coolant temperature
Normal coolant temperature when the engine is running should be 70-90°C.
The EMS/S6 control system has the following alarm levels for elevated
coolant temperatures:
The basic values are 95°C for the lower level and 105°C for the higher level.
- If the temperature is over 95°C for a certain period (1 second), S6 will
send a CAN message which switches on the warning lamp and
diagnostics lamp via the coordinator.
- If the temperature exceeds 95°C and torque reduction is activated, the
warning lamp and the diagnostics lamp will come on and the amount of
fuel will be reduced to 70%. A fault code is generated in the control unit.
- At temperatures exceeding 105°C and with engine shutdown activated,
the warning lamp and diagnostics lamp come on and the engine is
switched off. If override is activated, only torque reduction works. A
fault code is generated in the control unit.
After an alarm, approved values should be registered for more than 2 seconds
to reset the alarm.
Excessively high coolant temperature can damage the engine.
If run for extended periods under an extremely light load, the engine may
have difficulty in maintaining normal operating temperature. However, the
temperature will rise to a normal level again when the load on the engine is
increased.
21
Oil pressure
Max. oil pressure:
warm engine running at a speed above 800 rpm
6 bar
Normal oil pressure:
High lubricating oil pressure
warm engine at operating speed
3-6 bar
(above 6 bar) is normal when
Min. oil pressure:
starting a cold engine.
warm engine running at 1,000 rpm
2.3 bar
The control system has the following alarm levels:
- at a speed of less than 1,000 rpm and an oil pressure of less than 1.0 bar
- at a speed of more than 1,000 rpm and an oil pressure of less than
2.3 bar for longer than 5 seconds.
The following functions are available if there is an alarm:
- Alarm which only switches on the warning lamp and diagnostics lamp.
- Alarm which switches on the warning lamp and diagnostics lamp as
well as torque reduction if this function is activated (70% of fuel
quantity).
A fault code is generated in the control unit.
- Alarm which switches on the warning lamp and diagnostics lamp. The
engine is switched off if engine shutdown is activated. If the override
function is activated, only torque reduction takes place when this
function is activated.
A fault code is generated in the control unit.
After an alarm, approved values should be registered for more than 1 second
to reset the alarm.
22
Charging indicator lamp
If the lamp comes on during operation:
- Check and adjust the alternator drive belt as described under the
inspection point; see page 46.
- If the charging indicator lamp is still on, this could be due to an
alternator fault or a fault in the electrical system.
!
Important
Stopping the engine
There is danger of turbocharger
1. Run the engine without a load for a few minutes if it has been run
damage and post boiling if the
continuously with a heavy load.
engine is stopped without
2. Stop the engine with the stop button or the starter key (depending on
cooling.
version). Keep the stop button depressed until the engine has stopped
completely.
3. Before disconnecting the power, check that the control system
!
diagnostics lamp is not on. See page 14 for troubleshooting.
Important
4. Set the control switch to the "0" position.
The power must not be switched
5. Engines with battery master switch: Switch off the power using the
off before the engine has
battery master switch.
stopped.
Note: If the engine is stopped improperly 10 times, torque reduction
will be activated (70% fuel volume). To reset the engine, shut it
down once in the specified manner.
!
WARNING
Checks after running
- Check that the power is cut from the battery master switch and that the
Block the starting device when
control switch is in the 0 position.
working on the engine.
If the engine starts
- Fill the fuel tank. Make sure that the filler cap and the area round the
filler opening are clean to avoid contamination of the fuel.
unexpectedly, there is a
SERIOUS RISK OF
- If there is a risk of freezing, the cooling system must contain enough
INJURY.
glycol. See pages 18 and 33.
- Switch off inlet valve for the sea water system (if fitted).
- If there is danger of freezing the sea water system must be emptied.
- At temperatures below 0°C: prepare for the next start by connecting the
!
engine heater (if fitted).
WARNING
Coolant should be topped up
when the engine is stopped after
the first start.
23
Maintenance
The maintenance programme covers 21 points, divided into the following
main groups:
Lubrication system
page 26
!
Cooling system
page 31
Air cleaner
page 40
WARNING
Fuel system
page 42
Electrical system, batteries, etc
page 44
Block the starting device when
Miscellaneous
page 46
working on the engine.
If the engine starts
The inspection points are divided into intervals as follows:
unexpectedly, there is a
SERIOUS RISK OF
Daily maintenance
INJURY.
Maintenance before the first start
Maintenance after the first 400 hours of operation
Periodic maintenance every 200 hours of operation. Carried out at 200, 400,
600, 800 etc. hours.
Periodic maintenance every 400 hours of operation. Carried out at 400, 800,
1,200, 1,600 etc. hours.
Periodic maintenance every 1,200 hours of operation. Carried out at 1,200,
2,400, 3,600 etc. hours.
Periodic maintenance every 2,400 hours of operation. Carried out at 2,400,
4,800 etc. hours.
Periodic maintenance every 4,800 hours of operation. Carried out at 4,800,
9,600 etc. hours.
Annual maintenance.
Maintenance every 5 years.
Engines with few hours of operation
Emergency generator sets etc., that are not used regularly should be test run
and checked in accordance with the generator set manufacturer's instructions.
!
Run the engine until it reaches operating temperature and then carry out the
inspection points below:
Important
1. Checking oil level.
For engines with few
5. Checking coolant level.
operating hours that do not
receive periodic maintenance
10. Checking vacuum indicator.
according to the inspection
12. Checking fuel level.
schedule on page 25,
14. Checking electrolyte level in batteries.
maintenance should be carried
out in accordance with the
15. Checking state of charge in batteries.
schedule:
16. Cleaning batteries.
"Annually"
19. Check for leaks, rectify as necessary.
"Every 5 years"
24
Inspection schedule
First
Interval
At least
time at
Lubrication system, page 26
z
z
1. Checking the oil level
2. Oil change
z
1
z
3. Cleaning the centrifugal oil cleaner
z
1
z
4. Renewing the oil filter and closed crankcase ventilation
z
1
z
filter
Cooling system, page 31
z
5. Checking coolant level
6. Checking sacrificial anodes 4)
z
5
z
7. Checking the sea water pump impeller 4)
z
5
z
8. Checking the coolant
z
6
z6
9. Cleaning the cooling system
z
1
z
Air cleaner, page 40
z
10. Checking the read-out from the vacuum indicator
11. Cleaning or renewing the filter element
z
3
z
Fuel system, page 42
z
z
12. Checking fuel level
13. Renewing the main filter and water separating filter
z
1
z
Electrical system, page 44
z
2
z
z
14. Checking the electrolyte level in batteries
15. Checking the state of charge in batteries
z
2
z
z
16. Cleaning batteries
z
2
z
17. Checking the coolant level monitor
z
Miscellaneous, page 46
z
z
18. Checking the drive belt
19. Check for leaks, rectify as necessary
z
20. Checking and adjusting the valve clearance
z
21. Checking and adjusting PDE injector rocker arms
z
1. More often if required.
2. For engines with few operating hours, see page 24.
3. Earlier if the vacuum indicator shows red.
4. Only applies to marine engines with sea water pump and heat exchanger.
5. Guideline value. Varies depending on the composition of the sea water.
6. If inhibitor has not been topped up for 5 years, the coolant should be changed.
25
Lubrication system
Oil grade
The engine oil must at least meet the requirements for one of the following oil
classifications:
-ACEA E3, E4 or E5
- The Total Base Number (TBN) should be at least 12-13 (ASTM 2896).
!
- Check with your oil supplier that the oil meets these requirements.
Important
- Specified oil change intervals apply provided that the sulphur content of
Additives must not be used.
the fuel does not exceed 0.3% by weight. If the sulphur content is
The oil should be suitable for all
greater than 0.3% but no more than 1.0%, the oil change interval must
temperature variations until the
be halved (200 hours).
next oil change.
- Viscosities are shown in the figure below.
- For operation at extremely low outdoor temperatures: Consult your
nearest Scania distributor on how to avoid starting difficulties.
Oil analysis
Some oil companies can offer analysis of the engine oil. Such analysis
measures the oil's TBN (Total Base Number), TAN (Total Acid Number),
fuel dilution, water content, viscosity and the quantity of particles and soot in
the oil.
The result of a series of analyses is used as the basis for establishing a
suitable oil change interval.
If the conditions change, a new oil analysis programme must be carried out to
establish the new change interval.
-40
-30
-20
-10
0
10
20
30
40
°C
SAE 20W-30
SAE 30
SAE 40
SAE 50
SAE 5W-30
SAE 10W-30
SAE 15W-40
26
1. Daily:
Checking the oil level
Note: Before checking the oil level: leave the engine switched off for at
least 1 minute.
- The correct level is between the marks on the oil dipstick. Top up when
the oil level is at the lower mark on the dipstick.
- Refer to page 26 for correct oil grade.
Checking the oil level during operation
On some engines the oil level can be checked during operation.
- Remove the oil filler cap to release the pressure in the crankcase.
- Check the level on the dipstick. Correct oil level: 10 mm below the Max.
mark.
Max.
2. Every 400 hours:
Min.
Oil change
Note: If the engine is used for especially demanding operations,
particularly in a dusty environment or if the deposits in the
centrifugal oil cleaner are thicker than 20 mm: change the oil
more frequently.
- Unscrew the oil plug and drain the oil when the engine is hot.
- In certain engines the oil is pumped out by means of a bilge pump.
- Clean the magnet on the oil plug.
- Refit the oil plug.
- Top up with oil.
Max. 40 dm3
- Check the level on the oil dipstick.
Min. 35 dm3
Max. 33 dm3
Min. 25 dm3
1 dm3 = 1 litre
!
Help protect our
WARNING
environment!
The oil may be hot.
Use a container to avoid spills
when changing the oil. Dispose
Wear protective gloves and
of used oil through an
goggles.
authorised waste disposal
contractor.
27
Maximum angles of inclination during operation
Maximum permissible angles during operation vary, depending on the type of
oil sump, see illustration.
Note: The specified angles may only occur periodically.
24°
15°
26°
15°
30°
30°
3. Every 400 hours:
!
Cleaning the centrifugal oil cleaner
WARNING
(At the same time as an oil change)
Open the cover carefully. The
- Clean the cover. Unscrew the nut and remove the cover.
oil may be hot.
- Lift out the rotor and loosen the nut on the rotor cover 3 turns.
- If the nut is jammed:
Clamp the nut, but never the rotor, in a vice and turn the rotor 3 turns by
hand or with a screwdriver.
- Tap the nut lightly with your hand or a plastic hammer, to detach the
rotor cover from the bottom plate.
28
- Unscrew the nut and remove the rotor cover.
- Remove the strainer located on the rotor. If the strainer is stuck, you can
prise its bottom edge carefully until it comes loose from the bottom
plate.
- Scrape off the deposits from the inside of the rotor cover. If there are no
deposits, this indicates that the cleaner is not working properly.
- If the deposits are thicker than 20 mm: clean more often.
- Wash all parts in diesel.
- Make sure the nozzles on the rotor are not blocked or damaged.
- Check that the bearings are not damaged.
- Fit the O-ring in the rotor cover. The O-ring must not be damaged.
Renew if necessary.
- Assemble the rotor.
- Tighten the rotor nut firmly by hand.
- Check that the shaft is not loose. If it is loose, use thread-locking fluid
561 200 and torque tighten to 34 Nm.
- Refit the rotor.
- Check that it rotates easily by rotating it manually.
29
- Check that the O-ring in the cover is not damaged.
15 Nm
Renew hardened or damaged O-rings.
- Screw on the cover and tighten the lock nut to 15 Nm.
Tighten the nut carefully so as not to damage the rotor shaft, nut or cover.
Operational testing
The rotor rotates very fast and should continue to rotate when the engine has
stopped.
- Stop the engine when it is warm.
- Listen for a whirring sound from the rotor or feel whether the oil cleaner
housing is vibrating.
The rotor normally continues spinning for 30-60 seconds after the engine has
stopped.
If not: dismantle and check.
4. Every 400 hours:
Renewing the oil filter
(in connection with oil change)
- Unscrew the filter cover with a closed tool with hexagon driver,
e.g. socket 587 637, so as not to damage the filter cover.
- Lift out the filter housing cover with filter element. The filter housing
will drain automatically once the filter has been removed.
- Undo the old filter from the cover by carefully bending it to one side.
- Lubricate a new O-ring with engine oil and place it in the cover.
- Press a new filter element into the snap fastener in the cover.
- Make sure the oil filter drain has emptied the oil from the filter housing.
- Screw the cover into place with a closed tool with hexagon driver, e.g.
socket 587 637. Tightening torque 25 Nm.
- Start the engine and check for leaks.
Important! If the deposits in the centrifugal oil cleaner are more than
Help protect our
20 mm thick, the oil filter must be renewed more often. The
environment!
same is true for cleaning the centrifugal filter and changing
Use a container to avoid spills
the oil.
when renewing the filter.
Dispose of used filters through
an authorised waste disposal
contractor.
30
Renewing the closed crankcase
ventilation filter
In the case of engines with closed crankcase ventilation, the filter element
must be renewed at the same time as the main oil filter as described below:
- Remove the drainage line at the filter base.
- Release clamps (1) holding the container to the filter head.
- Remove the container (2). There may be oil in the bottom.
- Remove and renew the filter element.
- Replace the O-ring at the base of the head, and check that there is an
O-ring on top of the new filter element.
- Fit the new filter and press it into the centre of the filter head.
3
- Refit the container and lock firmly.
- If the indicator (3) on top of the filter showed red, remove the plastic
cover and press the indicator button.
- Refit the drainage line.
1
2
Cooling system
5. Daily:
Checking the coolant level
- Open the expansion tank filler cap and check the coolant level.
- Correct level:
- Cold engine: The coolant level must be approximately 50 mm below
the full line.
!
- Hot engine: The coolant level must be approximately 25 mm below
WARNING
the full line.
- Other types of expansion tank according to the instructions of the fitter.
Open the cover carefully.
Water and steam may spray
- Top up the coolant as necessary, see point 8.
out.
Note: When filling large amounts of coolant:
Never pour cold coolant into a hot engine.
This could crack the cylinder block and cylinder head.
!
Important
Always top up with pre-mixed
coolant.
31