Scania DI16 XPI series Operator's Manual

Marine engine en-GB 2 587 322 Issue 2.0 DI16 Operator's manual XPI 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 important to bear in mind the risk of injury. Downloaded from www.Manualslib.com manuals search engine

OPM 360 en-GB 2 © Scania CV AB 2017, Sweden Start of warranty . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Power classes . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Environment and safety . . . . . . . . . . . . . . . . . . 6 Environmental responsibility . . . . . . . . . . . . . 6 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Warnings and advisories . . . . . . . . . . . . . . . . . 7 Engine data plate . . . . . . . . . . . . . . . . . . . . . . . 12 Component identification . . . . . . . . . . . . . . . . 13 Starting and running . . . . . . . . . . . . . . . . . . . . 15 Checks before first start . . . . . . . . . . . . . . . . 15 Checks before running . . . . . . . . . . . . . . . . . 15 Starting the engine . . . . . . . . . . . . . . . . . . . . 15 Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine shutdown . . . . . . . . . . . . . . . . . . . . . . 18 Checks after running . . . . . . . . . . . . . . . . . . . 18 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Maintenance intervals . . . . . . . . . . . . . . . . . . 21 Lubrication system . . . . . . . . . . . . . . . . . . . . . 22 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Checking oil level . . . . . . . . . . . . . . . . . . . . . 24 Changing the oil . . . . . . . . . . . . . . . . . . . . . . 25 Maximum angles of inclination during operation 26 Cleaning the centrifugal oil cleaner . . . . . . . 27 Operational testing of the centrifugal oil cleaner 31 Renewing the oil filter. . . . . . . . . . . . . . . . . . 32 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Reading the vacuum indicator. . . . . . . . . . . . 33 Renewing the filter element . . . . . . . . . . . . . 33 Renewing the safety cartridge . . . . . . . . . . . . 34 Renewing an air filter with a non-renewable element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 35 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Checking coolant level . . . . . . . . . . . . . . . . . 38 Checking coolant antifreeze and corrosion pro- tection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Checking sacrificial anodes . . . . . . . . . . . . . 40 Checking the sea water pump impeller . . . . . 40 Changing the coolant and cleaning the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Cleanliness requirements . . . . . . . . . . . . . . . 58 Checking fuel level . . . . . . . . . . . . . . . . . . . . 58 Draining and renewing the water separating prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Draining and renewing the single water separating prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Draining the commutative water separating prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Renewing the commutative, water separating prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Renewing the fuel filter . . . . . . . . . . . . . . . . .65 Bleeding the fuel system . . . . . . . . . . . . . . . .66 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . .68 Checking the drive belt . . . . . . . . . . . . . . . . .68 Checking for leaks . . . . . . . . . . . . . . . . . . . . .70 Checking and adjusting the valve clearance .71 Quality requirements for fuel . . . . . . . . . . . . .74 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Biodiesel (FAME) . . . . . . . . . . . . . . . . . . . . .76 Preparing the engine for storage . . . . . . . . . . .77 Preservative products . . . . . . . . . . . . . . . . . . .77 Preparations for storage . . . . . . . . . . . . . . . . .78 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . .80 General data . . . . . . . . . . . . . . . . . . . . . . . . . .80 Lubrication system . . . . . . . . . . . . . . . . . . . . .80 Intake system . . . . . . . . . . . . . . . . . . . . . . . . .81 Cooling system . . . . . . . . . . . . . . . . . . . . . . . .81 Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . .81 Electrical system . . . . . . . . . . . . . . . . . . . . . .81 Material content . . . . . . . . . . . . . . . . . . . . . . .82 Scania Assistance . . . . . . . . . . . . . . . . . . . . . . .83 Downloaded from www.Manualslib.com manuals search engine

Start of warranty OPM 360 en-GB 3 © Scania CV AB 2017, Sweden 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 warranty 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. Country 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 Postcode Town/City State/County Downloaded from www.Manualslib.com manuals search engine

OPM 360 en-GB 4 © Scania CV AB 2017, Sweden Introduction Introduction This Operator's manual describes the operation and maintenance of Scania marine engines. The engines are direct-injection, liquid-cooled, four-stroke turbocharged diesel engines. The engines are available with different output and engine speed settings. The engine power of the engine ordered is indicated on the engine data plate. Note: Only standard components are described in the operator's manual. Information about special equipment is contained in instructions from the various manufacturers. To ensure the maximum performance and the longest service life for the engine remember the following: • Read through the Operator's manual before starting to use the engine. Even regular users of Scania engines will get new information from the Operator's manual. • Always follow the maintenance instructions. • Read the section on safety carefully. • Get to know your engine so that you know what it can do and how it works. • Always contact an authorised Scania workshop for maintenance and repairs. The information in this Operator's manual was correct at the time of going to press. Scania re- serves the right to make alterations without prior notice. Note: Always use Scania spare parts for maintenance and repair. Certification IMPORTANT! For Scania to guarantee that the engine corre- sponds to its certified configuration, and take responsibility for any damage and injuries that occur, maintenance must be carried out in accordance with the instructions in this Operator's manual. An emissions certified engine fulfils the emissions requirements for a particular range of application. On each emissions certified engine there is a la- bel which shows which requirements the engine fulfils. Scania guarantees that each such engine fulfils the emissions requirements for the range of application for which it is certified. The following are required for the certified engine to fulfil the emissions requirements once it has been taken into service: • Maintenance is to be carried out in accordance with the instructions in this Operator's manual. • Maintenance and repairs of injection equipment are to be carried out by an authorised Scania workshop. • The engine may only be modified with equipment that has been approved by Scania. • Seals may be broken and setting data edited only once approval has been granted by Sca- nia. Modifications may be made by authorised personnel only. • Modifications affecting the exhaust and intake systems must be approved by Scania. Otherwise, the instructions in the Operator's manual for the running and maintenance of the engine shall apply. Follow the safety precautions on the following pages. Downloaded from www.Manualslib.com manuals search engine

Power classes OPM 360 en-GB 5 © Scania CV AB 2017, Sweden 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, www.scania.com. Engine serial number: Engine type: Engine power: kW at rpm IFN, Intermittent service Patrol craft long Patrol craft short Downloaded from www.Manualslib.com manuals search engine

OPM 360 en-GB 6 © Scania CV AB 2017, Sweden Environment and safety Environment and safety Environmental responsibility Scania develops and produces engines that are as environmentally-friendly as possible. Scania has made major investments in the reduction of harmful exhaust emissions in order to fulfil the environmental requirements in force in almost every market. At the same time, we have been able to maintain a high level of performance and operating econ- omy for Scania engines. To maintain these throughout the entire service life of the engine, it is important for the user to follow the instructions on running, maintenance and fuel and lubricating oil as outlined in the Operator's manual. Other green initiatives taken include ensuring that, following maintenance and repair, waste that is harmful to the environment (for example oil, fuel, coolant, filters and batteries) is disposed of accordance with the applicable environmental requirements. Safety The following pages contain a summary of the safety precautions to be complied with when operating and maintaining Scania engines. The equivalent text can also be found under the relevant maintenance item. To prevent damage to the engine and to ensure that it runs optimally, follow the instructions in the warnings and advisories. If the instructions are not followed, the warranty can cease to apply. Different types of advisory Warning! All advisories preceded by Warning! are very important. They warn of serious faults and incorrect operation that could lead to personal injury. Example: WARNING! Block the starting device when working on the engine. If the engine starts unexpectedly, there is a serious risk of injury. Important! Advisories preceded by Important! warn of faults and incorrect operation that could lead to equipment being damaged. Example: IMPORTANT! An excessive coolant temperature can cause engine damage. Note: Advisories preceded by Note: refer to information important to ensure the best possible operation and functionality. Example: Note: Leave the engine off for at least 7 minutes before you check the oil level. Downloaded from www.Manualslib.com manuals search engine

OPM 360 en-GB 7 © Scania CV AB 2017, Sweden Environment and safety Environment This Operator’s Manual contains specially high- lighted text with instructions to help protect the environment during maintenance. Example: Environment Use a suitable container. The fuel collected must be disposed of as specified in national and international laws and regulations. Warnings and advisories Smoking WARNING! Smoking is prohibited • in the vicinity of flammable or explosive material, e.g. fuel, oils, batteries, chemicals • when refuelling and in the vicinity of the fill- ing station • when working on the fuel system Safety precautions for running the engine Daily maintenance Always carry out a visual inspection of the engine and engine compartment before starting the engine or when the engine has been switched off after operation. This inspection should be done to detect fuel, oil or coolant leaks, or anything else that may re- quire corrective action. Fuel WARNING! The wrong fuel grade can cause breakdowns or stoppages by causing the injection system to malfunction. This can cause damage to the engine and, possibly, personal injury. REQUIREMENT! Use only fuel which fulfils the requirements in the Quality requirements for fuel section. Refuelling WARNING! During refuelling there is a risk of fire and explosion. The engine must be switched off and smoking is prohibited. Never overfill the tank as the fuel needs space to expand. Make sure that the filler cap is fully closed. Hazardous gases WARNING! Only start the engine in a well-ventilated area. 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 exhaust gases and crankcase gases. Downloaded from www.Manualslib.com manuals search engine

OPM 360 en-GB 8 © Scania CV AB 2017, Sweden Environment and safety Starter lock IMPORTANT! If the instrument panel is not fitted with a starter lock, the engine compartment should be locked to prevent unauthorised personnel from starting the engine. Alternatively, a lockable master switch or battery master switch can be used. Starter gas WARNING! Never use starter gas or similar agents to help start the engine. This can cause an explosion in the intake manifold and possible injury. Running WARNING! The engine must not be run in environments where there is a risk of explosion, as all of the electrical or mechanical components can gener- ate sparks. Approaching a running engine always poses a 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 rotating parts and hot surfaces must be fitted with guards. Safety precautions for handling materials Fuel and lubricating oil WARNING! All fuels and lubricants as well as many chemicals are flammable. Always follow the instructions on the relevant packaging. The work must be carried out on a cold engine. Fuel leaks and spillage on hot surfaces can cause fire. Store used rags and other flammable materials safely so as to avoid spontaneous combustion. Batteries WARNING! The batteries contain and form oxyhydrogen gas, particularly during charging. Oxyhydrogen gas is flammable and highly explosive. There must be no smoking, naked flames or sparks near the batteries or the battery compartment. Incorrect connection of a battery cable or jump lead can cause a spark, which can cause the battery to explode. Downloaded from www.Manualslib.com manuals search engine

OPM 360 en-GB 9 © Scania CV AB 2017, Sweden Environment and safety Chemicals WARNING! Most chemicals such as glycol, anti-corrosive agents, preservative oils and degreasing agents, are hazardous to health. Some chemicals are also flammable: preservative oil, for example. Al- ways follow the safety precautions on the packaging. Store chemicals and other materials which are hazardous to health in approved and clearly marked containers, where they are inaccessible to unauthorised persons. Environment Excess and used chemicals must be disposed of as specified in national and international laws and regulations. Safety precautions for maintenance Switch off the engine WARNING! 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. Always switch off the engine before carrying out maintenance, unless otherwise indicated. 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 them. Fix a warning plate somewhere appropriate, showing that work is being carried out on the engine. 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. Downloaded from www.Manualslib.com manuals search engine

OPM 360 en-GB 10 © Scania CV AB 2017, Sweden Environment and safety Lubrication system WARNING! Hot oil can cause burns and skin irritation. Wear protective gloves and goggles when changing hot oil. Make sure that there is no pressure in the lubrication system before starting work on it. Make sure that the oil filler cover is fitted when starting and running in order to avoid oil escap- ing. Environment Used oil must be disposed of as specified in national and international laws and regulations. Cooling system WARNING! Never open the coolant filler cap when the engine is hot. Hot coolant and steam may spray out and cause burns. If the cap has to be opened do it slowly to release the pressure before removing the cap. Wear protective gloves as the coolant is still very hot. Environment Used coolant must be disposed of as specified in national and international laws and regulations. Fuel system WARNING! Maintenance and repairs of injection equipment are to be carried out by an authorised Scania workshop. Always use Scania spare parts for the fuel and electrical systems. Scania spare parts are de- signed to minimise the risk of fire and explosion. Environment Use a suitable container. The fuel collected must be disposed of as specified in national and international laws and regulations. Electrical system WARNING! Switch off the engine and switch off the power by disconnecting the electrical cables to the battery. External power supplies to extra equipment on the engine must also be disconnected. Always use Scania spare parts for the fuel and electrical systems. Scania spare parts are de- signed to minimise the risk of fire and explosion. Downloaded from www.Manualslib.com manuals search engine

Scania DI16 XPI series Operator's Manual

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