Scania DI16 PDE. Marine engine en-GB 2 805 697. 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
DI16 PDE Marine engine
en-GB 2 805 697
Issue 9
Start of warranty
3
Cleanliness requirements
69
Introduction
4
Checking the fuel level
70
Certification
4
Draining and renewing the single water separat-
Power classes
5
ing prefilter (option)
71
Environment and safety
6
Draining the commutative water separating pre-
Environmental responsibility
6
filter (option)
72
Safety
6
Renewing the commutative water separating
Warnings and advisories
7
prefilter (option)
74
Scania Engines engine warranty for marine en-
Renewing the fuel filter
76
gines
13
Renewing and bleeding commutative fuel filters
Emission control systems warranty
13
(option)
77
Emission control system warranty statement 13
Bleeding the fuel system
78
Engine data plate
16
Miscellaneous
80
Component identification
17
Checking the drive belt
80
Engine
17
Checking for leaks
81
SCR system
19
Checking and adjusting the valve clearance and
Starting and running
20
unit injectors
82
Checks before first start
20
Renewing the reductant filters
87
Checks before running
22
Quality requirements for fuel
90
Starting the engine
22
Diesel
90
Running
23
Biodiesel (FAME)
93
Engine shutdown
27
Reductant for SCR
95
Checks after running
27
32.5% by weight of urea
96
Maintenance
28
40% by weight of urea
96
Maintenance interval
29
Preparing the engine for storage
97
Lubrication system
30
Preservative products
97
Oil grade
30
Preparations for storage
99
Oil analysis
32
Technical data
101
Checking the oil level
33
General data
101
Maximum angles of inclination during operation
Lubrication system
102
33
Intake system
102
Changing the oil
34
Cooling system
102
Cleaning the centrifugal oil cleaner
35
Injection system
103
Operational testing of the centrifugal oil cleaner
Electrical system
103
39
Material content
103
Renewing the oil filter
40
Scania Assistance
104
Renewing the commutative oil filter
41
General tightening torques for screw joints .105
Air cleaner
42
Hexagon screws, hexagon socket screws, Torx
Reading the vacuum indicator
42
screws, hexagon nuts
105
Renewing the air cleaner filter element and safe-
Flange screws with hexagonal head and hexago-
ty cartridge
43
nal flange nuts
105
Renewing an air filter with a non-renewable ele-
Hose clamps
106
ment
43
Cooling system
44
Coolant
44
Checking the coolant level
49
Checking coolant antifreeze and corrosion pro-
tection
50
Checking sacrificial anodes
51
Checking the sea water pump impeller
52
Changing the coolant and cleaning the cooling
system
53
Fuel system
69
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 make things easier when
contacting the workshop for example. The engine serial number is indicated on the engine data plate and is
also stamped 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
Postcode
Postal town
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,
For Scania to guarantee that the engine corre-
four-stroke turbocharged diesel engines. Certain
sponds to its certified configuration, and take re-
engines are also equipped with an SCR system
sponsibility for any damage and injuries that
for emission control.
occur, maintenance must be carried out in ac-
cordance with the instructions in this Operator's
The engines are available with different output
manual.
and engine speed settings. The engine power of
the engine ordered is indicated on the engine data
plate.
An emissions certified engine fulfils the emis-
sions requirements for a particular range of ap-
Note:
plication.
Only standard components are described in the
operator's manual. Information about special
On each emissions certified engine there is a la-
equipment is contained in instructions from the
bel which shows which requirements the engine
various manufacturers.
fulfils. Scania guarantees that each such engine
fulfils the emissions requirements for the range
of application for which it is certified.
To ensure the maximum performance and the
The following are required for the certified en-
longest service life for the engine remember the
gine to fulfil the emissions requirements once it
following:
has been taken into service:
• Read through the Operator's manual before
• Maintenance is to be carried out in accord-
starting to use the engine. Even regular users
ance with the instructions in this Operator's
of Scania engines will get new information
manual.
from the Operator's manual.
• Maintenance and repairs of injection equip-
• Always follow the maintenance instructions.
ment are to be carried out by an authorised
• Read the section on safety carefully.
Scania workshop.
• Get to know your engine so that you know
• The engine may only be modified with equip-
what it can do and how it works.
ment that has been approved by Scania.
• Always contact an authorised Scania work-
• Seals may be broken and setting data edited
shop for maintenance and repairs.
only once approval has been granted by Sca-
nia. Modifications may be made by author-
The information in this Operator's manual was
ised personnel only.
correct at the time of going to press. Scania re-
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
manual for the running and maintenance of the
Always use Scania spare parts for maintenance
engine shall apply. Follow the safety precautions
and repair.
on the following pages.
4
Power classes
Power classes
Scania supplies engines in 5 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.
PRP, Prime power: Intended for continual use and an unlimited number of operational hours with varying
loads. The average load factor must not exceed 70% of the rated power in a 24-hour period. Total overload
110% for one hour per 12-hour period. This power class applies to single-speed engines.
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
PRP, Prime power
5
Environment and safety
Environment and safety
Safety
The following pages contain a summary of the
Environmental responsibility
safety precautions to be complied with when op-
erating and maintaining Scania engines. The
Scania develops and produces engines that are as
equivalent text can also be found under the rele-
environmentally-friendly as possible. Scania has
vant maintenance item.
made major investments in the reduction of
harmful exhaust emissions in order to fulfil the
To prevent damage to the engine and to ensure
environmental requirements in force in almost
that it runs optimally, follow the instructions in
every market.
the warnings and advisories.
At the same time, we have been able to maintain
If the instructions are not followed, the warranty
a high level of performance and operating econ-
can cease to apply.
omy for Scania engines. To maintain these
throughout the entire service life of the engine, it
Different types of advisory
is important for the user to follow the instruc-
tions on running, maintenance and fuel, lubricat-
Warning!
ing oil and coolant as outlined in the Operator's
All advisories preceded by Warning! are very
manual.
important. They warn of serious faults and incor-
rect operation that could lead to personal injury.
Other green initiatives taken include ensuring
Example:
that, following maintenance and repair, waste
that is harmful to the environment (for example
oil, fuel, coolant, filters and batteries) is disposed
WARNING!
of accordance with the applicable environmental
requirements.
Secure the starting device or disconnect a battery
cable before working on the engine. If the engine
starts unexpectedly, there is a serious risk of in-
jury.
6
Environment and safety
Important!
Warnings and advisories
Advisories preceded by Important! warn of
faults and incorrect operation that could lead to
Smoking
equipment being damaged. Example:
WARNING!
IMPORTANT!
Smoking is prohibited
An excessive coolant temperature can cause en-
• in the vicinity of flammable or explosive ma-
gine damage.
terial, e.g. fuel, oils, batteries, chemicals
• when refuelling and in the vicinity of the fill-
ing station
Note:
• when working on the fuel system
Advisories preceded by Note: refer to informa-
tion important to ensure the best possible opera-
tion and functionality. Example:
Safety precautions for running the
engine
Note:
Leave the engine off for at least 7 minutes before
Daily maintenance
you check the oil level.
Always carry out a visual inspection of the en-
gine and engine compartment before starting the
engine or when the engine has been switched off
Environment
after operation.
This Operator’s Manual contains specially high-
This inspection should be done to detect fuel, oil
lighted text with instructions to help protect the
or coolant leaks, or anything else that may re-
environment during maintenance. Example:
quire corrective action.
Environment
Use a suitable container. The fuel collected must
be disposed of as specified in national and inter-
national laws and regulations.
7
Environment and safety
Fuel
Starter lock
WARNING!
IMPORTANT!
The wrong fuel grade can cause breakdowns or
If the instrument panel is not fitted with a starter
stoppages by causing the injection system to
lock, the engine compartment should be locked
malfunction. This can cause damage to the en-
to prevent unauthorised personnel from starting
gine and, possibly, personal injury.
the engine. Alternatively, a lockable master
switch or battery master switch can be used.
REQUIREMENT!
Starter gas
Use only fuel which fulfils the requirements in
WARNING!
the Quality requirements for fuel section.
Never use starter gas or similar agents to help
start the engine. This can cause an explosion in
Refuelling
the intake manifold and possible injury.
WARNING!
Running
During refuelling there is a risk of fire and explo-
sion. The engine must be switched off and smok-
WARNING!
ing is prohibited.
Never overfill the tank as the fuel needs space to
The engine must not be run in environments
expand. Make sure that the filler cap is fully
where there is a risk of explosion, as all of the
closed.
electrical or mechanical components can gener-
ate sparks.
Approaching a running engine always poses a
Hazardous gases
safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts such as the
WARNING!
fan and cause injury. For personal safety all ro-
tating parts and hot surfaces must be fitted with
Only start the engine in a well-ventilated area.
guards.
The exhaust gases contain carbon monoxide and
nitrogen oxides, which are toxic.
When the engine is run in an enclosed space,
there must be an effective device to extract ex-
haust gases and crankcase gases.
8
Environment and safety
Safety precautions for handling ma-
Chemicals
terials
WARNING!
Fuel and lubricating oil
Most chemicals such as glycol, anti-corrosive
WARNING!
agents, preservative oils and degreasing agents,
are hazardous to health. Some chemicals are also
All fuels and lubricants as well as many chemi-
flammable: preservative oil, for example. Al-
cals are flammable. Always follow the instruc-
ways follow the safety precautions on the pack-
tions on the relevant packaging.
aging.
The work must be carried out on a cold engine.
Store chemicals and other materials which are
Fuel leaks and spillage on hot surfaces can cause
hazardous to health in approved and clearly
fire.
marked containers, where they are inaccessible
to unauthorised persons.
Store used rags and other flammable materials
safely so as to avoid spontaneous combustion.
Environment
Batteries
Excess and used chemicals must be disposed of
as specified in national and international laws
WARNING!
and regulations.
The batteries contain and form oxyhydrogen gas,
particularly during charging. Oxyhydrogen gas
is flammable and highly explosive.
Reductant
Reductant (AdBlue®, DEF, ARLA 32 eller
There must be no smoking, naked flames or
AUS 32/AUS 40) is used in the reductant tank
sparks near the batteries or the battery compart-
on engines equipped with an SCR system.
ment. Incorrect connection of a battery cable or
jump lead can cause a spark, which can cause the
The reductant is not toxic, but it is still important
battery to explode.
to observe the following when working on the re-
ductant circuit:
• If reductant comes in contact with the skin:
Wash with soap and plenty of water.
• If reductant splashes in the eyes: Rinse imme-
diately using an eye bath and then seek med-
ical attention.
• Change clothes if they have been spilled on.
9
Environment and safety
Lubrication system
REQUIREMENT!
WARNING!
Use only reductant which fulfils the require-
ments in the Reductant for SCR section.
Hot oil can cause burns and skin irritation. Wear
protective gloves and goggles when changing
hot oil.
Safety precautions for maintenance
Make sure that there is no pressure in the lubri-
Switch off the engine
cation system before starting work on it.
Make sure that the oil filler cover is fitted when
WARNING!
starting and running in order to avoid oil escap-
ing.
Working with a running engine always poses a
safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts and cause
injury.
Environment
Used oil must be disposed of as specified in na-
Always switch off the engine before carrying out
tional and international laws and regulations.
maintenance, unless otherwise indicated.
Make it impossible to start the engine: Remove
Cooling system
any starter key, or cut the power using the main
power switch or battery master switch and lock
them.
WARNING!
Fix a warning plate somewhere appropriate,
Never open the coolant filler cap when the en-
showing that work is being carried out on the en-
gine is hot. Hot coolant and steam may spray out
gine.
and cause burns. If the cap has to be opened do it
slowly to release the pressure before removing
Hot surfaces and fluids
the cap. Wear protective gloves as the coolant is
still very hot.
WARNING!
Avoid skin contact with coolant as this may
cause irritation to the skin. Wear protective gog-
There is always a risk of sustaining burns when
gles and gloves when handling coolant.
an engine is hot. Particularly hot parts are engine
manifolds, turbochargers, oil sumps, as well as
Ethylene glycol can be fatal if ingested.
hot coolant and oil in pipes and hoses.
Environment
Used coolant must be disposed of as specified in
national and international laws and regulations.
10
Environment and safety
Fuel system
SCR system
WARNING!
IMPORTANT!
Maintenance and repairs of injection equipment
Cleanliness is very important when working on
are to be carried out by an authorised Scania
the reductant circuit. Clean thoroughly around
workshop.
all parts to be dismantled to prevent dirt from en-
tering the system.
Always use Scania spare parts for the fuel and
electrical systems. Scania spare parts are de-
When working on the SCR system, the reductant
signed to minimise the risk of fire and explosion.
connections may only be lubricated with soapy
water or with distilled water with a 3% urea mix-
ture. Any other types of lubricants may block
and damage the components in the SCR system.
Environment
Reductant causes certain metals to corrode. Al-
ways rinse away reductant spillage on connec-
Use a suitable container. The fuel collected must
tions and other parts with lukewarm water to
be disposed of as specified in national and inter-
prevent corrosion. If reductant seeps into electri-
national laws and regulations.
cal connections or electrical cables, these must
be renewed.
11
Environment and safety
Electrical system
Batteries
WARNING!
WARNING!
Switch off the engine and switch off the power
The batteries contain highly corrosive sulphuric
by disconnecting the electrical cables to the bat-
acid. Take care to protect your eyes, skin and
tery. External power supplies to extra equipment
clothes when charging or handling batteries.
on the engine must also be disconnected.
Wear protective gloves and goggles.
Always use Scania spare parts for the fuel and
If sulphuric acid comes in contact with the skin:
electrical systems. Scania spare parts are de-
Wash with soap and plenty of water. If it gets in
signed to minimise the risk of fire and explosion.
your eyes: Rinse immediately with plenty of wa-
ter and seek medical attention.
Electric welding
Environment
WARNING!
Used batteries must be disposed of as specified
When carrying out welding work on and near the
in national and international laws and regula-
engine, disconnect the battery and alternator
tions.
leads. Pull out the multi-pin connector for the en-
gine control unit as well.
Before starting
Connect the welding clamp close to the compo-
nent to be welded. The welding clamp must not
WARNING!
be connected to the engine, or so that the current
can cross a bearing.
Ensure that all guards are in place before starting
the engine. Ensure that no tools or other objects
When welding is finished:
have been left on the engine.
1. Connect the alternator and engine control
The air filter must be fitted before starting the en-
unit cables.
gine. Otherwise there is a risk of objects being
2. Connect the batteries.
sucked into the compressor impeller or of injury
if you come into contact with the air filter.
12
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
13
fail to conform to applicable regulations for
its warranty period.
Warranty period
13
Parts covered by the Warranty
14
Warranty period
General warranty limitations
14
This warranty shall apply for one of the follow-
Specific warranty exclusions
15
ing periods, whichever occurs first:
Customer support
15
• 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.
13
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
7. Electronic control unit
or individual without invalidating the Warranty.
8. Components used in the above mentioned
The use of other than Scania replacement parts
systems
also does not invalidate the warranty on other
components unless such parts cause damage to
IMPORTANT!
warranted parts. However, the cost of such ser-
vices or parts will not be covered by the Warran-
ty.
This list does not include all expendable mainte-
nance parts. Expendable emission related parts
requiring scheduled maintenance are warranted
WARNING!
until their first scheduled replacement point. See
Specific warranty exclusions below.
Use of replacement parts which are not of equiv-
alent quality may impair the effectiveness of
emission control systems. Accordingly, it is rec-
ommended that only Scania repair or replace-
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.
14
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 1002,
stallation, that is not completed in
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.
15