Scania DI16 XPI. Marine engine en-GB 2 741 685. 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.
For this reason, always secure the starting device or disconnect a battery cable before working on the engine.
This is especially important if the engine has a remote starter or automatic starting.
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 XPI Marine engine
en-GB 2 741 685
Issue 4.0
Start of warranty
3
filter
63
Introduction
4
Renewing the commutative, water separating
Certification
4
prefilter
65
Power classes
5
Renewing the reversible fuel filter, 16 litre ma-
Environment and safety
6
rine engine with XPI
67
Environmental responsibility
6
Renewing the fuel filter
68
Safety
6
Bleeding the fuel system
69
Warnings and advisories
7
Bleeding the fuel system using a hand pump, 16
Engine data plate
12
litre marine engine, XPI
71
Component identification
13
Other
73
Starting and running
15
Checking the drive belt
73
Checks before first start
15
Checking for leaks
75
Checks before running
15
Checking and adjusting the valve clearance .76
Starting the engine
15
Quality requirements for fuel
79
Running
16
Diesel
79
Engine shutdown
18
Biodiesel (FAME)
81
Checks after running
18
Preparing the engine for storage
83
Maintenance
19
Preservative products
83
Maintenance intervals
20
Preparations for storage
85
Lubrication system
21
Technical data
89
Oil grade
21
General data
89
Oil analysis
23
Lubrication system
89
Checking the oil level
23
Intake system
90
Changing the oil
24
Cooling system
90
Maximum angles of inclination during operation
Fuel system
90
25
Electrical system
90
Cleaning the centrifugal oil cleaner
26
Material content
91
Operational testing of the centrifugal oil cleaner
Scania Assistance
92
30
General tightening torques for screw joints . .93
Renewing the oil filter
31
Hexagon screws, hexagon socket screws, Torx
Air cleaner
32
screws, hexagon nuts
93
Reading the vacuum indicator
32
Flange screws with hexagonal head and hexago-
Renewing the filter element
32
nal flange nuts
93
Renewing the safety cartridge
33
Hose clamps
94
Renewing an air filter with a non-renewable ele-
ment
33
Cooling system
34
Coolant
34
Checking coolant level
39
Checking the coolant's antifreeze and corrosion
protection
40
Checking sacrificial anodes
41
Checking the sea water pump impeller
41
Changing the coolant and cleaning the cooling
system
43
Fuel system
60
Cleanliness requirements
60
Checking the fuel level
60
Draining and renewing the water separating pre-
filter
61
Draining and renewing the single water separat-
ing prefilter
62
Draining the commutative water separating pre-
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)
Fartygsidentifikationsnummer (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,
For Scania to guarantee that the engine corre-
four-stroke turbocharged diesel engines.
sponds to its certified configuration, and take re-
sponsibility for any damage and injuries that
The engines are available with different output
occur, maintenance must be carried out in ac-
and engine speed settings. The engine power of
cordance with the instructions in this Operator's
the engine ordered is indicated on the engine data
manual.
plate.
Note:
An emissions certified engine fulfils the emis-
Only standard components are described in the
sions requirements for a particular range of ap-
operator's manual. Information about special
plication.
equipment is contained in instructions from the
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
• Maintenance is to be carried out in accord-
from the Operator's manual.
ance with the instructions in this Operator's
• Always follow the maintenance instructions.
manual.
• Read the section on safety carefully.
• Maintenance and repairs of injection equip-
• Get to know your engine so that you know
ment are to be carried out by an authorised
what it can do and how it works.
Scania workshop.
• Always contact an authorised Scania work-
• The engine may only be modified with equip-
shop for maintenance and repairs.
ment that has been approved by Scania.
• Seals may be broken and setting data edited
The information in this Operator's manual was
only once approval has been granted by Sca-
correct at the time of going to press. Scania re-
nia. Modifications may be made by author-
serves the right to make alterations without prior
ised personnel only.
notice.
• Modifications affecting the exhaust and in-
Note:
take systems must be approved by Scania.
Always use Scania spare parts for maintenance
Otherwise, the instructions in the Operator's
and repair.
manual for the running and maintenance of the
engine shall apply. Follow the safety precautions
on the following pages.
4
Power classes
Power classes
Scania supplies engines in 3 different power classes:
IFN, Intermittent service: Intended for periodic use, where the rated power is available for one hour per
three-hour period. The accumulated load factor must not exceed 80% of the rated power. Unlimited number
of operational 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 accumulated 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 accumulated 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
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
Block the starting device when working on the
a high level of performance and operating econ-
engine. If the engine starts unexpectedly, there is
omy for Scania engines. To maintain these
a serious risk of injury.
throughout the entire service life of the engine, it
is important for the user to follow the instruc-
tions on running, maintenance and fuel, lubricat-
Important!
ing oil and coolant as outlined in the Operator's
Advisories preceded by Important! warn of
manual.
faults and incorrect operation that could lead to
Other green initiatives taken include ensuring
equipment being damaged. Example:
that, following maintenance and repair, waste
that is harmful to the environment (for example
IMPORTANT!
oil, fuel, coolant, filters and batteries) is disposed
of accordance with the applicable environmental
An excessive coolant temperature can cause en-
requirements.
gine damage.
Safety
Note:
The following pages contain a summary of the
Advisories preceded by Note: refer to informa-
safety precautions to be complied with when op-
tion important to ensure the best possible opera-
erating and maintaining Scania engines. The
tion and functionality. Example:
equivalent text can also be found under the rele-
vant maintenance item.
Note:
Leave the engine off for at least 7 minutes before
To prevent damage to the engine and to ensure
you check the oil level.
that it runs optimally, follow the instructions in
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
Maintenance and repairs of injection equipment
protective gloves and goggles when changing
are to be carried out by an authorised Scania
hot oil.
workshop.
Make sure that there is no pressure in the lubri-
Always use Scania spare parts for the fuel and
cation system before starting work on it.
electrical systems. Scania spare parts are de-
signed to minimise the risk of fire and explosion.
Make sure that the oil filler cover is fitted when
starting and running in order to avoid oil escap-
ing.
Environment
Use a suitable container. The fuel collected must
Environment
be disposed of as specified in national and inter-
national laws and regulations.
Used oil must be disposed of as specified in na-
tional and international laws and regulations.
Electrical system
Cooling system
WARNING!
WARNING!
Switch off the engine and switch off the power
by disconnecting the electrical cables to the bat-
Never open the coolant filler cap when the en-
tery. External power supplies to extra equipment
gine is hot. Hot coolant and steam may spray out
on the engine must also be disconnected.
and cause burns. If the cap has to be opened do it
slowly to release the pressure before removing
Always use Scania spare parts for the fuel and
the cap. Wear protective gloves as the coolant is
electrical systems. Scania spare parts are de-
still very hot.
signed to minimise the risk of fire and explosion.
Avoid skin contact with coolant as this may
cause irritation to the skin. Wear protective gog-
gles and gloves when handling coolant.
Ethylene glycol can be fatal if ingested.
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
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.
The engine serial number is stamped onto the top
of the cylinder block at the front right.
Example: DI16 076M
DI
Supercharged diesel engine with water-
cooled charge air cooler.
16
Displacement in whole dm3.
076
Performance and certification code. The
code indicates, together with the applica-
tion code, the normal gross engine out-
put.
M Code for application. M means for
marine use.
Made by
Type
DI16 076M
Engine No
123456 7
Outp ut .
809
kW
2300
rpm.
Outp ut .
kW
rpm.
Type approval No:
e5*97/68VC*2012/46*0182*00
Example of an engine data plate.
12
Component identification
Component identification
1
2
3
12
4
11
5
10
6
3
9
8
7
17
18
19
16
15
14
13
20
23
22
21
13
Component identification
1. Oil filler.
2. Air filter.
3. Sacrificial anodes (6).
4. Sea water pump.
5. Sea water intake.
6. Sea water outlet (1 on each side)
7. Valve for draining and filling coolant (1 on
each side behind the heat exchanger).
8. Oil plug.
9. Heat exchanger (1 on each side).
10. Fuel filter.
11. Hand pump for fuel.
12. Oil filter.
13. Expansion tank.
14. Level glass for checking coolant level.
15. Filling coolant.
16. Engine number, stamped into the cylinder
block.
17. Engine data plate.
18. Fuel manifold bleed nipple.
19. Bleed nipple on high pressure pump.
20. Charge air cooler.
21. Holes for draining condensation in charge air
cooler (2 off on the underside).
22. Oil dipstick.
23. Centrifugal oil cleaner.
Note:
The two water separating prefilters for the fuel
are located between the fuel tank and engine.
14
Starting and running
Starting and running
Starting the engine
Checks before first start
WARNING!
Before the engine is started for the first time, car-
Never use starter gas or similar agents to help
ry out the maintenance items listed under First
start the engine. This can cause an explosion in
start in the maintenance schedule. Check the fol-
the intake manifold and possible injury.
lowing (also see Maintenance intervals):
Only start the engine in a well ventilated area.
• Oil level.
When the engine is run in an enclosed space,
• Coolant.
there must be effective devices to extract exhaust
• Fuel level.
gases and crankcase gases.
• Fluid level in batteries.
• State of battery charge.
IMPORTANT!
• Condition of the drive belt.
The starter motor must only be cranked twice for
30 seconds at a time. After that, it must rest for at
least 5 minutes before the next attempt to start it.
Checks before running
For environmental reasons the Scania engine has
Carry out daily maintenance as described in the
been developed to be started with a low fuel feed.
maintenance schedule prior to operation. See
Using unnecessarily large amounts of fuel when
Maintenance intervals.
starting the engine always results in emissions of
unburnt fuel.
1. Open the fuel cock if fitted.
2. Disengage the engine.
3. If the engine has a battery master switch:
Switch on the power by means of the battery
master switch.
4. Start the engine.
If the fuel tank has been run dry or if the engine
has not been used for a long time, bleed the fuel
system. Refer to the Bleeding the fuel system
section.
15