Scania Marine engine. DI13 XPI. 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.
Secure the starting device or disconnect a battery cable before working on the engine. This is especially im-
portant 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
DI13 XPI Marine engine
en-GB 2 784563
Issue 3.0
Start of warranty
3
Renewing the fuel filter
67
Introduction
4
Draining and renewing an engine-mounted water
Certification
4
separating prefilter
68
Power classes
5
Draining and renewing the single water separat-
Environment and safety
6
ing prefilter (option)
69
Environmental responsibility
6
Draining the commutative water separating pre-
Safety
6
filter (option)
70
Warnings and advisories
7
Renewing the commutative water separating
Scania Engines engine warranty for marine en-
prefilter (option)
72
gines
12
Bleeding the fuel system
74
Emission control systems warranty
12
Other
77
Emission control system warranty statement 12
Checking the drive belt
77
Engine data plate
15
Checking for leaks
78
Component identification
16
Checking and adjusting the valve clearance .79
Starting and running
17
Quality requirements for fuel
82
Checks before first start
17
Diesel
82
Checks before running
17
Biodiesel (FAME)
83
Starting the engine
17
Preparing the engine for storage
84
Running
18
Preservative products
84
Engine shutdown
22
Preparations for storage
85
Checks after running
23
Technical data
87
Maintenance
24
General data
87
Cleaning the engine
26
Lubrication system
87
Maintenance intervals
27
Intake system
88
Lubrication system
28
Cooling system
88
Oil grade
28
Fuel system
88
Oil analysis
31
Electrical system
88
Checking the oil level
32
Material content
89
Maximum angles of inclination during operation
Scania Assistance
90
32
General tightening torques for screw joints . .91
Changing the oil
33
Hexagon screws, hexagon socket screws, Torx
Cleaning the centrifugal oil cleaner
34
screws, hexagon nuts
91
Operational testing of the centrifugal oil cleaner
Flange screws with hexagonal head and hexago-
38
nal flange nuts
91
Renewing the oil filter
39
Hose clamps
92
Air cleaner
40
Reading the vacuum indicator
40
Renewing the air cleaner filter element and safe-
ty cartridge
41
Renewing an air filter with a non-renewable ele-
ment
41
Cooling system
42
Coolant
42
Checking coolant level
48
Checking coolant antifreeze and corrosion pro-
tection
49
Checking sacrificial anodes
50
Checking the sea water pump impeller
51
Changing the coolant and cleaning the cooling
system
52
Fuel system
65
Cleanliness requirements
65
Checking the fuel level
66
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
Town/City
State/County
Country
3
Introduction
Introduction
Certification
This Operator's manual describes the operation
IMPORTANT!
and maintenance of Scania marine engines. The
engines are direct-injection, liquid-cooled, four-
stroke turbocharged diesel engines.
For Scania to guarantee that the engine corre-
sponds to its certified configuration, and take re-
The engines are available with different output
sponsibility for any damage and injuries that
and engine speed settings. The engine power of
occur, maintenance must be carried out in ac-
the engine ordered is indicated on the engine data
cordance with the instructions in this Operator's
plate.
manual.
Note:
Only standard components are described in the
An emissions certified engine fulfils the emis-
operator's manual. Information about special
sions requirements for a particular range of ap-
equipment is contained in instructions from the
plication.
various manufacturers.
On each emissions certified engine there is a la-
bel which shows which requirements the engine
fulfils. Scania guarantees that each such engine
To ensure the maximum performance and the
fulfils the emissions requirements for the range
longest service life for the engine remember the
of application for which it is certified.
following:
The following are required for the certified en-
• Read through the Operator's manual before
gine to fulfil the emissions requirements once it
starting to use the engine. Even regular users
has been taken into service:
of Scania engines will get new information
from the Operator's manual.
• Maintenance is to be carried out in accord-
• Always follow the maintenance instructions.
ance with the instructions in this Operator's
manual.
• Read the section on safety carefully.
• The maintenance and repair of injection
• Get to know your engine so that you know
equipment are to be carried out by a work-
what it can do and how it works.
shop with qualified personnel.
• Always contact a workshop with qualified
• Seals may be broken and setting data edited
personnel for maintenance and repair.
only once approval has been granted by Sca-
The information in this Operator's manual was
nia. Modifications may be made by author-
correct at the time of going to press. Scania re-
ised personnel only.
serves the right to make alterations without prior
• Modifications affecting the exhaust and in-
notice.
take systems must be approved by Scania.
Note:
Otherwise, the instructions in the Operator's
Scania recommends that Scania spare parts are
manual for the running and maintenance of the
used for maintenance and repairs.
engine shall apply. Follow the safety precautions
on the following pages.
4
Power classes
Power classes
Scania supplies engines in 4 different power classes:
ICFN, Continuous service: Intended for continual use and an unlimited number of operational hours per
year at a total load factor of 100%.
IFN, Intermittent service: Intended for periodic use, where the rated power is available for one hour per
three-hour period. The total load factor must not exceed 80% of the rated power. Unlimited number of op-
erational hours per year.
Patrol craft long: Intended for periodic use, where the rated power is available for one hour per six-hour
period. 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 total operating time must not exceed 2,000 hours per year.
Patrol craft short: Intended for periodic use, where the rated power is available for one hour per 12-hour
period. 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 total operating time must not exceed 1,200 hours per year.
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
ICFN, Continuous service
IFN, Intermittent service
Patrol craft long
Patrol craft short
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
Secure the starting device or disconnect a battery
a high level of performance and operating econ-
cable before working on the engine. If the engine
omy for Scania engines. To maintain these
starts unexpectedly, there is a serious risk of in-
throughout the entire service life of the engine, it
jury.
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, fuel, coolant, filters and batteries) is disposed
IMPORTANT!
of 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 to ensure
Leave the engine off for at least 7 minutes before
that it runs optimally, follow the instructions in
you check the oil level.
the warnings and advisories.
If the instructions are not followed, the warranty
can cease to apply.
6
Environment and safety
Environment
Fuel
This Operator’s manual contains specially high-
lighted text with instructions to help protect the
WARNING!
environment during maintenance. Example:
The wrong fuel grade can cause breakdowns or
stoppages by causing the injection system to
Environment
malfunction. This can cause damage to the en-
gine and, possibly, personal injury.
Use a suitable container. The fuel collected must
be disposed of as specified in national and inter-
national laws and regulations.
REQUIREMENT!
Use only fuel which fulfils the requirements in
the Quality requirements for fuel section.
Warnings and advisories
Smoking
Refuelling
WARNING!
WARNING!
Smoking is prohibited
During refuelling there is a risk of fire and explo-
• in the vicinity of flammable or explosive ma-
sion. The engine must be switched off and smok-
terial, e.g. fuel, oils, batteries, chemicals
ing is prohibited.
• when refuelling and in the vicinity of the fill-
Never overfill the tank as the fuel needs space to
ing station
expand. Make sure that the filler cap is fully
• when working on the fuel system
closed.
Safety precautions for running the
Hazardous gases
engine
WARNING!
Daily maintenance
Always carry out a visual inspection of the en-
Only start the engine in a well-ventilated area.
gine and engine compartment before starting the
The exhaust gases contain carbon monoxide and
engine or when the engine has been switched off
nitrogen oxides, which are toxic.
after operation.
When the engine is run in an enclosed space,
This inspection should be done to detect fuel, oil
there must be an effective device to extract ex-
or coolant leaks, or anything else that may re-
haust gases and crankcase gases.
quire corrective action.
7
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.
8
Environment and safety
Chemicals
Safety precautions for maintenance
Switch off the engine
WARNING!
Most chemicals such as glycol, anti-corrosive
WARNING!
agents, preservative oils and degreasing agents,
are hazardous to health. Some chemicals are also
Working with a running engine always poses a
flammable: preservative oil, for example. Al-
safety risk. Parts of the body, clothes or dropped
ways follow the safety precautions on the pack-
tools can get caught in rotating parts and cause
aging.
injury.
Store chemicals and other materials which are
hazardous to health in approved and clearly
Always switch off the engine before carrying out
marked containers, where they are inaccessible
maintenance, unless otherwise indicated.
to unauthorised persons.
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
Environment
them.
Fix a warning plate somewhere appropriate,
Excess and used chemicals must be disposed of
showing that work is being carried out on the en-
as specified in national and international laws
gine.
and regulations.
Hot surfaces and fluids
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.
9
Environment and safety
Lubrication system
Fuel system
WARNING!
WARNING!
Hot oil can cause burns and skin irritation. Wear
The maintenance and repair of injection equip-
protective gloves and goggles when changing
ment are to be carried out by a workshop with
hot oil.
qualified personnel.
Make sure that there is no pressure in the lubri-
Scania recommends that Scania spare parts are
cation system before starting work on it.
used for the fuel and electrical systems. Scania
spare parts are designed to minimise the risk of
Make sure that the oil filler cover is fitted when
fire and explosion.
starting and running in order to avoid oil escap-
ing.
Environment
Environment
Use a suitable container. The fuel collected must
be disposed of as specified in national and inter-
Used oil must be disposed of as specified in na-
national laws and regulations.
tional and international laws and regulations.
Electrical system
Cooling system
WARNING!
WARNING!
Switch off the engine and switch off the power
Never open the coolant filler cap when the en-
by disconnecting the electrical cables to the bat-
gine is hot. Hot coolant and steam may spray out
tery. External power supplies to extra equipment
and cause burns.
on the engine must also be disconnected.
If the cap has to be opened do it slowly to release
Scania recommends that Scania spare parts are
the pressure before removing the cap. Wear pro-
used for the fuel and electrical systems. Scania
tective gloves as the coolant is still very hot.
spare parts are designed to minimise the risk of
fire and explosion.
Environment
Used coolant must be disposed of as specified in
national and international laws and regulations.
10
Environment and safety
Electric welding
Before starting
WARNING!
WARNING!
When carrying out welding work on and near the
Ensure that all guards are in place before starting
engine, disconnect the battery and alternator
the engine. Ensure that no tools or other objects
leads. Pull out the multi-pin connector for the en-
have been left on the engine.
gine control unit as well.
The air filter must be fitted before starting the en-
gine. Otherwise there is a risk of objects being
Connect the welding clamp close to the compo-
sucked into the compressor impeller or of injury
nent to be welded. The welding clamp must not
if you come into contact with the air filter.
be connected to the engine, or so that the current
can cross a bearing.
When welding is finished:
1. Connect the alternator and engine control
unit cables.
2. Connect the batteries.
Batteries
WARNING!
The batteries contain highly corrosive sulphuric
acid. Take care to protect your eyes, skin and
clothes when charging or handling batteries.
Wear protective gloves and goggles.
If sulphuric acid comes in contact with the skin:
Wash with soap and plenty of water. If it gets in
your eyes: Rinse immediately with plenty of wa-
ter and seek medical attention.
Environment
Used batteries must be disposed of as specified
in national and international laws and regula-
tions.
11
Scania Engines engine warranty for marine engines
Scania Engines engine war-
Emission control system war-
ranty for marine engines
ranty statement
General warranty provisions
Emission control systems
The emission control systems of your new Scan-
warranty
ia Engines (“Scania”) marine diesel engine were
designed, built and tested using genuine parts,
IMPORTANT!
and were certified as being in conformity with
federal emission control regulations. Scania war-
This section is only applicable to engines used in
rants to the original owner, and to each subse-
the U.S.A, and to engines without exhaust gas af-
quent owner, of a new Scania marine diesel
tertreatment system (SCR system).
engine (“You”) that the emission control system
of your engine:
This section is not applicable to incorrectly in-
stalled or non-Scania low pressure fuel system
1. Was designed, built and equipped so as to
components.
conform at the time of sale with all applica-
ble regulations under Section 213 of the
Clean Air Act, 42 U.S.C. § 7547, and
2. Is free from defects in material and work-
Table of Contents
manship which would cause such engine to
General warranty provisions
12
fail to conform to applicable regulations for
its warranty period.
Warranty period
12
Parts covered by the Warranty
13
Warranty period
General warranty limitations
13
This warranty shall apply for one of the follow-
Specific warranty exclusions
14
ing periods, whichever occurs first:
Customer support
14
• A period of operating hours equal to at least
50 percent of the engine's useful life in oper-
ating hours, or
• A period of years equal to at least 50 percent
of the engine's useful life in years;
• Except that the warranty period shall apply
for a period not less than any mechanical war-
ranties provided by Scania to the owner.
The warranty period shall begin:
• On the date the marine vessel is delivered to
the first retail purchaser, or
• If the marine vessel is placed in service for
demonstration purposes prior to sale at retail,
on the date the engine is first placed in ser-
vice.
12
Scania Engines engine warranty for marine engines
Parts covered by the Warranty
General warranty limitations
The following is a list of parts considered a part
To retain the dependability of the exhaust emis-
of the Emission Control Systems and is covered
sion control originally built into your Scania ma-
by the Emission Warranty for engines which
rine diesel engine, it is essential that the engine is
were built to conform to applicable U.S. Envi-
installed according to Scania installation instruc-
ronmental Protection Agency regulations:
tions and emission certificates.
1. Fuel system
In addition, You are responsible for the perfor-
mance of all scheduled maintenance or repairs
2. Air-induction system
on your new Scania marine diesel engine. Scania
a) Intake manifold
may deny a warranty claim if your failure to per-
b) Turbocharger system
form maintenance resulted in the failure of the
c) Charge air cooler system
warranted part.
3. Exhaust manifold
Receipts covering the performance of regular
4. Combustion chamber
maintenance should be retained in the event
a) Piston
questions arise concerning maintenance. The re-
b) Cylinder head
ceipts should be transferred to each subsequent
owner of the marine vessel with the emission
5. Crankcase ventilation
warranted engine.
6. Sensors
The Warranty covers the cost of repair and re-
a) Engine speed sensors
placement parts and services of warranted com-
b) Oil pressure sensor
ponents and systems performed by an authorized
c) Coolant temperature sensor
Scania distributor or dealer using genuine Scania
d) Coolant level sensor
parts. You may elect to have maintenance, re-
e) Charge air pressure sensor
placement or repair of these components and
f) Charge air temperature sensor
systems performed by any repair establishment
g) Ambient air pressure sensor
or individual without invalidating the Warranty.
h) Ambient air temperature sensor
i) Common rail pressure sensor
The use of other than Scania replacement parts
j) Common rail temperature sensor
also does not invalidate the warranty on other
7. Electronic control unit
components unless such parts cause damage to
warranted parts. However, the cost of such ser-
8. Components used in the above mentioned
vices or parts will not be covered by the Warran-
systems
ty.
IMPORTANT!
WARNING!
This list does not include all expendable mainte-
Use of replacement parts which are not of equiv-
nance parts. Expendable emission related parts
alent quality may impair the effectiveness of
requiring scheduled maintenance are warranted
emission control systems. Accordingly, it is rec-
until their first scheduled replacement point. See
ommended that only Scania repair or replace-
Specific warranty exclusions below.
ment parts be used for maintenance, repair or
replacement of emission control systems.
If other than Scania parts are used for mainte-
nance, repair or replacement, the owner should
obtain assurance that such parts are warranted by
their manufacturer to be equivalent to genuine
Scania parts.
13
Scania Engines engine warranty for marine engines
Specific warranty exclusions
Customer support
This warranty does not cover:
In the event that You do not receive the warranty
service to which You believe You are entitled
1. Malfunctions in any part caused by any of
under the Warranty, or if You need additional
the following: misuse, abuse, improper ad-
support or information concerning the Warranty,
justments, modifications, alteration, tamper-
please contact:
ing, disconnection, improper or inadequate
maintenance, or use of fuels not recommend-
Scania USA, Inc.
ed for the engine as described in the Opera-
Address: 121 Interpark Blvd, suite 1002, 78216,
tor's Manual.
San Antonio, Texas
2. Engine installation, including cooling sys-
tem, intake system and exhaust system in-
Mailing address: 121 Interpark Blvd, suite
stallation, that is not completed in
1002, 78216, San Antonio, Texas
accordance with the Scania installation in-
Telephone:+1 210 403 0007
structions and emissions certificate for this
engine type, unless engine installation is the
Fax:+1 210 403 0211
engine manufacturer's fault or responsibility.
E-mail: na.contact@scania.com
3. Damage resulting from accidents, acts of na-
ture or other events beyond the control of
Scania.
4. The replacement of expendable maintenance
items such as filters, hoses, belts, oil, ther-
mostat, exhaust system and coolant made in
connection with scheduled maintenance ser-
vices once these parts have been replaced.
5. Replacement items which are not genuine
Scania parts or not authorized by Scania as of
equal quality to the original parts.
6. Inconvenience, loss of use of the marine ves-
sel or commercial loss.
7. Any marine vessel on which the actual use
cannot be accurately determined.
8. Any marine vessel operating outside the
United States.
14
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 power and the nominal
engine speed. The engine EU type approval for
exhaust emissions is indicated under Output,
where applicable.
The engine serial number is stamped onto the top
of the cylinder block at the front right.
Example: DI13 076M
Made by
DI Supercharged diesel engine with water-
cooled charge air cooler.
DI13 076M
Type.
Engine No
1234567
13
Displacement in whole dm3.
Output.
680
kW
2300
rpm.
076
Performance and certification code. The
Output.
kW
rpm.
code indicates, together with the applica-
Type approval No:
tion code, the normal gross engine output.
e5*97/68VC*2012/46*1234*00
M Code for application. M means for marine
use.
Example of an engine data plate.
15