Scania DI14 69, Operator'S Manual

Page 1: ...ng symbol and text is reproduced beside those maintenance points where it is especially important to consider the risk of injury START UP 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 start up Also fill in the information below as this can make things easier if you need to contact a service workshop or the like Operator s...

Page 2: ...tandard components are described in the instruction manual For special equipment we would refer you to the appro priate manufacturer s instructions In order to obtain the best value and service life from your engine there are several points to bear in mind Read through the Instruction Manual before starting to use your engine Even those experienced with Scania engines may find new information in t...

Page 3: ...STEM 30 CHECKING COOLANT LEVEL 30 CHECKING CORROSION PROTECTION RODS 31 CHECKING SEAWATER PUMP IMPELLER 31 CHECKING COOLANT 32 Checking glycol content 32 Checking Protection against corrosion 34 Changing the coolant 34 CLEANING THE COOLING SYSTEM 35 External cleaning 35 Internal cleaning 38 Preventive replacement of coolant pump gear 38 AIR CLEANER 39 TEST READING LOW PRESSURE INDICATOR 39 CLEANIN...

Page 4: ...n To maintain these superior properties throughout the life of the engine it is important that the operator owner follows the instructions of this manual as regards operation maintenance and choice of fuel and lubricants To further contribute to protecting the environment in service maintenance and repair ensure that harmful waste oil fuel coolant filters batteries etc is disposed of and destroyed...

Page 5: ...vice and maintenance must be performed according to this Operator s Manual Only genuine Scania parts must be used Service work on the injection equipment must be performed by an authorized Scania workshop The engine must not be modified with equipment not approved by Scania Seals and setting data may only be broken modified after approval by Scania Södertälje Changes should only be made by qualifi...

Page 6: ... serious defects to the engine or improper handling that may lead to personal injury Refer to example The safety precautions that must be observed in the operation and maintenance of Scania engines are compiled on the following three pages The corresponding text is also often stated next to the maintenance step concerned shown with different degrees of significance as described above All items are...

Page 7: ...he engine in a properly ventilated ar ea The exhaust emissions contain carbon monoxide and nitrogen oxides that are toxic When operating the engine in an enclosed ar ea an effective extraction device for exhaust gases and crankcase gases must be used Starter lock If the control panel is not fitted with a key switch the engine bay should be fitted with a lock to prevent unauthorized starting of the...

Page 8: ...and service work unless otherwise stated Prevent unauthorized starting by removing the starter key and turning off the power by the main switch or the battery disconnect switch locking it in the off position Also attach a warn ing tag stating that work on the engine is in progress at a suitable location It is always a safety hazard to work on an en gine that is running Parts of your body or cloth ...

Page 9: ...h an authorized waste disposal contractor Cooling system Never open the coolant filler cap while the en gine is hot Steam and hot coolant can come out forcefully and cause scalding If the cooling system must still opened or disas sembled while the engine is hot open the filler cap very cautiously and slowly to release the pressure before the cap is removed Use gloves since the coolant is still ver...

Page 10: ... that are certified regarding smoke and emissions are fitted with a cer tification plate specifying the documents they conform to The plate is fitted to rocker cover number four from the front on the right hand side DI 14 69 M 48 E Type DI Supercharged diesel engine with liquid cooled charge air cooler Swept volume in whole dm3 Performance and certification code Indicates together with the applica...

Page 11: ... Charge air cooler engine coolant cooled 10 Turbocharger 11 Injection pump 12 Fuel filter 13 Starter motor 14 Alternator 15 Fan belt adjuster 16 Coolant pipes to turbo 17 Inspection holes engine block 18 Drain cock coolant 19 Oil filler cap 20 Seawater pump 21 Heat exchanger 22 Sacrificial anodes 23 Expansion tank with pres sure cap 24 Oil pressure monitor 25 Charge air cooler seawa ter cooled 26 ...

Page 12: ...supply box and the instrument panel will illuminate If a fault has been indicated on the main indicator lamp the operator can determine the cause of the fault with the help of the LEDs on the control unit and the troubleshooting schedule on page 17 and carry out the required investigation and remedy Depending on the nature of the fault the control system will take different actions to protect the ...

Page 13: ...ne Engines 13 Location of sensors for DEC2 1 Connection of lead to charge air temperature sensor 2 Charge air temperature sensor 3 Coolant temperature sensor 4 Engine speed sensors 5 Oil pressure monitor 6 Connector panel 1 5 2 6 3 4 ...

Page 14: ...l unit detects that the engine has received the maximum permissible quantity of injected fuel according to its power curve This means 100 power output at the current rpm If the load increases engine rpm will decrease BOOST LIMIT The LED comes on when the control unit smoke limiter restricts the maximum fuel quantity Operation of the smoke limiter is dependent on the charge air pressure POWER The L...

Page 15: ...could cause damage to the engine if operation continues The control unit automatically reduces engine power output to a predefined level if the corresponding function has been selected Action Reduce engine speed to idle if possible and conduct troubleshooting according to instructions on page 16 and the chart on page 17 SHUTDOWN The LED comes on and the engine is switched off automatically in case...

Page 16: ... equipment the main indicator lamp is located in this switch on the main supply box All LEDs will then come on for 2 seconds to indicate that they are intact and in working order This also applies to the main indicator lamp in the main supply box and the instrument panel Make a note of any LED that is defective All LEDs will then be out for approximately 4 seconds Following this a fault code will ...

Page 17: ...ative Check the wiring and connector Renew the engine speed sensor Control rack position sensor inoperative Check connectors and cables to governor The intake air temperature has reached the threshold level or the charge air temperature sensor is inoperative Check the intake system Check the temperature sensor and cable routing DEC2 detects no charge air pressure The charge air pressure sensor is ...

Page 18: ...by volume will not provide suf ficient protection against corrosion A glycol concentration greater than 50 will not increase anti freeze protection and reduces engine cooling capacity If there is no danger of freezing Only Scania Anti corrosive should be used in the coolant to protect against corrosion The correct level of anti corrosive is 7 12 by vol ume and this must never drop below 7 by volum...

Page 19: ...Switch on the power using the bat tery master switch DEC2 If the main indicator lamp comes on or flashes when the power is turned on this indicates the presence of a fault in the control system or engine which must be found and rectified before the engine is started See page 16 Start the engine by means of the starter button or ignition key Starting at low temperatures Local environmental requirem...

Page 20: ...ress the pre glow button max 20 s Release the pre glow button after the engine starts The timer relay keeps the glow plug working for 5 minutes If a shorter on time is required press the release button The key must be set to 0 if the start attempt fails 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 suffici...

Page 21: ...erature If the temperature continues to rise the engine will be stopped automatically Shutdown at 103 C 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 0 500...

Page 22: ... still lit there may be a fault in the alternator or in the electrical system STOPPING THE ENGINE 1 Allow the engine to run without load for a few minutes if it has been run with a high continuous load 2 Stop the engine with the stop button Keep the stop button depressed until the engine is completely stationary 3 DEC2 Before switching off check that the control system s main indi cator lamp is no...

Page 23: ...ng the cooling system must be drained if it does not contain sufficient anti freeze see page 32 Close intake valve for seawater if fitted If there is a danger of freezing the seawater must also be drained At temperatures below 0 C Prepare for the next start by connecting the engine heater if fitted Top up engine coolant when the engine has been stopped after being started for the first time Immobi...

Page 24: ...hours Periodic maintenance after every 1 200 hours of operation carried out after 1 200 2 400 3 600 etc hours Maintenance every year Maintenance every 3rd year ENGINES WITH FEW HOURS OF OPERATION The engine is run to operating temperature and the maintenance points below should be carried out 1 Checking oil level 5 Checking coolant level 10 Checking low pressure indicator 12 Checking fuel level 15...

Page 25: ...er l1 l COOLING SYSTEM page 30 5 Checking coolant level l 6 Checking corrosion protection rods 4 l4 l 7 Checking seawater pump impeller 4 l4 l 8 Checking coolant l l5 l5 9 Cleaning cooling system l1 l AIR CLEANER page 39 10 Test reading low pressure indicator l 11 Cleaning or changing filter insert l3 l FUEL SYSTEM page 41 12 Checking fuel level l l 13 Changing main filter l1 l 14 Checking injecto...

Page 26: ...rest Scania repre sentative to avoid starting difficulties Oil analysis Some oil companies can offer analysis of the engine oil This analysis meas ures the oil s total base number TBN total acid number TAN fuel dilu tion water content viscosity and the content of wear particles and soot in the oil The result of a series of analyses forms the basis of establishing a suitable oil change interval If ...

Page 27: ...hange the oil more often Pump out the oil using the oil bilge pump when the engine is warm Fill with new oil Check the level on the dipstick Note Observe the applicable environment protection regulations when disposing of the old oil Maximum oil sump angles of inclination when in operation Maximum permissible angles for operation vary according to the type of oil sump see figure Note Given angles ...

Page 28: ...and turn the rotor three turns by hand or using a screwdriver Gently tap the nut using your hand or a plastic hammer so that the rotor bowl becomes detached from the bottom plate Undo the nut and remove the rotor bowl Carefully prise the strainer loose from the bottom plate Scrape away deposits from the inside of the rotor bowl If there are no deposits this shows that the cleaner is not working If...

Page 29: ...owl is not damaged A hardened or damaged O ring should be replaced Screw down the bowl hard by hand If the nut is tightened using a tool the rotor shaft nut or bowl may be damaged Operational test The rotor turns very quickly and should continue to rotate when the engine has stopped Stop the engine when it is warm Listen for the whirring from the rotor or feel whether the cleaner hous ing is vibra...

Page 30: ...G SYSTEM 5 Daily CHECKING COOLANT LEVEL Open the expansion tank cap and check the coolant level Correct level Scania expansion tank Cold engine The coolant should reach up to the bottom of the filler pipe Warm engine The coolant should be 10 20 mm above the bottom of the filler pipe Other types of expansion tank according to the installer s instructions Top up coolant as necessary see point 6 Note...

Page 31: ...WATER PUMP IMPELLER Close the bottom valve if the seawater pump is below the water line Drain the seawater circuit Remove the cover from the seawater pump Check that the impeller vanes are not worn or damaged If the impeller often requires changing it is necessary to improve the purity of the seawater Changing the impeller Extract the impeller using extractor 98 482 Scania special tool Fit a new i...

Page 32: ... glycol anti freeze with the following sup plier designations BASF G48 or BASF D542 Top up with glycol if the glycol content is less than 30 by volume A glycol content greater than 50 by volume will not provide more anti freeze protection The table shows the temperature at which ice slush starts to form The engine freezes and breaks at significantly lower temperatures see graph Ice forming in the ...

Page 33: ... 35 40 45 50 60 100 17 22 28 33 39 44 50 55 66 110 18 24 30 36 42 48 54 60 72 120 20 26 33 39 46 52 59 65 78 130 21 28 35 42 49 56 63 70 84 140 23 30 38 45 53 60 68 75 90 150 24 32 40 48 56 64 72 80 96 160 26 34 43 51 60 68 77 85 102 170 27 36 45 54 63 72 81 90 108 180 29 38 48 57 67 76 86 95 114 190 30 40 50 60 70 80 90 100 120 200 Properties of glycol at low temperatures Example with 30 glycol b...

Page 34: ... Anti corrosive by volume Note The coolant should be changed when the cooling system is cleaned every 1 200 hours or at least every 3rd year Changing the coolant 1 Remove the filler cap from the expansion tank 2 The coolant is drained at two points the lowest point of the engine block see drawing the lowest point of the cooling system 3 Close the drain cocks 4 Fill coolant through the expansion ta...

Page 35: ... round file 7 Assemble the heat exchanger Change damaged and hardened O rings 8 Make sure that the thermostats are in place and fit the heat exchanger back in place on the engine Reconnect the pipes to the charge air cool ers and oil cooler and also the return line from the block 9 Fill the system with coolant as described in the specifications on page 32 1 Housing 2 Spiral pin 3 Element 4 O ring ...

Page 36: ...ssembly the charge air cooler Change any damaged and hard O rings 6 Refit the charge air cooler assembly after the seawater cooled charge air coolers have been cleaned and assembled Tighten bolt 8 to 9 2 Nm Note On assembly silicone 816 064 should be applied to both sides of new gaskets 13 7 Refit the pipe connections for air and seawater 1 Housing 2 Element 3 Spiral pin 4 Spacer 5 O ring 6 Cover ...

Page 37: ...alant silicone 816 064 in a uniform bead approximately 2 3 mm on both sealing surfaces of the element 9 Fit new V ring seals on the connections of the element 10 Assemble the charge air cooler within 15 minutes of applying the sea lant Torque tighten the bolts to 50 Nm 11 Reconnect the inlet and outlet pipe connections and refit the delivery pipe fuel filter and other parts that have been removed ...

Page 38: ...is therefore advisable to do this in connection with cleaning the heat exchanger Fill the system with clean hot water mixed with one of the commer cially available radiator cleaners based on sulphamic acid and contain ing dispersing agents Follow the manufacturer s instructions for mix ratios and cleaning times Run the engine for the specified time and then drain the cooling system Fill the system...

Page 39: ...t always entails a risk of damage The insert may be cleaned no more than four times After cleaning it has a lower dust capacity than a new insert 3 Mark the filter when it has been cleaned Cleaning insert Carefully blow the filter insert clean using dry compressed air from the inside Note This insert must not be washed using water 1 2 3 1 Cover 2 Filter insert 3 Filter housing Only use Scania genu...

Page 40: ...ime it is cleaned Use a washing solution consisting of water mixed with about 1 mild detergent 1 Pour the washing solution into the filter outlet while turning the filter so that the solution runs out of it opposite to the direction of air flow 2 Leave the filter in the washing solution for 5 minutes and then lift it to drain off the solution 3 Rinse the filter with about 30 litres of clean water ...

Page 41: ...ne and check for leaks Bleeding the fuel system Open bleed screw 1 on the main filter Pump hand pump 2 until air free fuel flows out at the main bleed screw Close the bleed screw Pump a few times using the hand pump If the engine is difficult to start after bleeding Slacken injection pump overflow valve 3 half a turn and make a fresh attempt to start If the engine still won t start Pump the hand p...

Page 42: ...ssure see Technical data page 52 Fitting 1 Check that there is no old seal in place and fit a new seal in the bottom of the injector seat 2 Fit a new O ring in the socket nut and a new seal under it 3 Fit the injector 4 Tighten the socket nut to 70 Nm 7 0 kgfm 5 Fit the delivery pipe and tighten the cap nuts to 20 Nm 2 0 kgfm Fit clamps and brackets Take care to fit the delivery pipe without tensi...

Page 43: ...tery freezes at 5 C Trickle charging is recommended during the winter if the engine is not used Avoid boost charging This will damage the battery in the long term 17 Every 200 hours CLEANING BATTERIES 1 Clean batteries cables and cable terminals 2 Check that all cable terminals are well tightened 3 Grease posts and cable terminals using petroleum jelly Wear gloves and eye protection when charging ...

Page 44: ...coolant on your skin 3 Plug in the monitor s connector and set the control switch to ON 4 Check that the indicator lamp remains on and that the buzzer sounds 5 Submerse the monitor in liquid in a metal receptacle steel It is impor tant to ensure that the body of the monitor is in contact with the metal 6 The indicator lamp should go out after about 2 seconds 7 Remove the monitor from the liquid In...

Page 45: ...etach the securing screws 2 Set the correct tension using the adjusting screw Do not overtighten the belts Measurement using a Krikit belt tension gauge Part No 587 495 1 Zero the gauge by pressing the measuring arm 2 Place the gauge on the V belt at an equal distance from two pulleys 3 Press until the gauge clicks 4 Read the gauge The recommended tension of genuine Scania belts when tested is 300...

Page 46: ...at the drain hole 2 on the coolant pump is not blocked see drawing If there is leakage change the pump seal Check that the drain for the V behind the injection pump is open all the way through the block and drain pipe so that no fluid can collect in the V See drawing A small amount of leakage from the overflow holes when running in the engine is normal Seals and O rings are fitted lubricated with ...

Page 47: ...eft side Cyl 5 In and ex 7 In 8 In Turn the crankshaft one revolution in its direction of rotation to the mark The piston in cylinder No 1 will then be 30 after TDC on the induction stroke Adjust the following valves Right side Cyl 2 In 3 In and ex 4 In Left side Cyl 6 In and ex 7 Ex 8 Ex Covers for reading on flywheel casing Important On silumin housings reading is possible only from underneath O...

Page 48: ...er by turning the engine 1 4 revolution in its direction of rotation between each adjustment 22 Every 1 200 hours CHANGING or CLEANING VALVES FOR CLOSED CRANKCASE VENTILATION Alternative 1 Change the valves at the specified interval Alternative 2 Remove the valves at the specified interval Clean the valves by placing them in a bath of diesel oil overnight Then rinse them several times in diesel oi...

Page 49: ...ation etc Preservative coolant If the engine is to be stored with a full cooling system use coolant containing 50 glycol by volume Glycol without nitrite based inhibitor must be used E g BASF G48 or BASF D542 Preservative fuel Use diesel fuel mixed with Lubrizol 560A or equal Mix 1 cm3 ml of Lubrizol 560A with 10 dm3 l of fuel HANDLING LUBRIZOL 560A Hazardous Contains aromatic hydrocarbons Use spo...

Page 50: ...il Remove the injectors and spray preservative oil into each cylinder max 30 cm3 ml Crank the engine several revolutions using the starter motor Spray a small amount into each cylinder The engine must not then be cranked Refit the injectors Drain the preservative oil from the engine New engine oil can be filled directly or when taken out of preservative Drain the coolant if the engine is not to be...

Page 51: ...tions air intakes and exhaust pipes Fill the cooling system with coolant see page 18 Check the oil level in the engine and top up with new oil Crank the engine several revolutions with the injectors removed oiling the valve mechanism pushrods and tappets with plenty of oil Important The engine must be cranked with the injectors removed so that excess preservative oil can be forced out of the cylin...

Page 52: ...5 1 Engine direction of rotation viewed from rear Anticlockwise Cooling Fluid Valve clearance cold engine intake valve mm exhaust valve mm 0 45 0 80 Weight without coolant and oil kg 1350 Power see Engine record card LUBRICATION SYSTEM Max oil pressure warm engine at speed above 800 rpm bar kgf cm2 6 Normal oil pressure warm engine at operating speed bar kp cm2 3 6 Min oil pressure warm engine 800...

Page 53: ... Nm Oil leakage connection Nm 70 20 11 1 see page 54 COOLING SYSTEM Number of thermostats 2 Thermostat opening temperature C 79 2 Thermostat in charge air circuit opening temperature C 50 2 Coolant temperature system with overpressure C 70 about 100 Volume dm3 litres about 95 ELECTRICAL SYSTEM System voltage V 24 Alternator current A 65 or 120 or 2x65 Starter motor power kW hp 6 7 9 1 Monitors set...

Page 54: ... the most important properties Environmentally favourable fuels low sulphur fuels There are three different grades of so called environmentally favorable fuels SS15 54 35 Grade 1 is sulphur free and grade 2 is low in sulphur Compared with class 3 normal fuel these fuels are less dense and this reduces engine power output Only class 1 fuel should be used with a catalytic converter Short term use of...

Page 55: ...2 16 Filter air cleaner 39 Filter fuel 41 First start 18 Foreword 2 Fuel filter changing 41 Fuel level 41 Fuel specifications 54 Fuel system 41 Fuel system bleeding 41 Glycol 32 Injectors 42 Leakage 46 LED functions 14 Long term storage 49 Low pressure indicator 39 Lubrication oil pressure 22 Lubrication oil system 26 Maintenance 24 Maintenance schedule 25 Oil analysis 26 Oil capacity 27 Oil chang...