Scania Helper

NORDHAVN A/S

Montør hjælper 1 SCANIA SERVICE

Nordhavn A/S 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Service info DI 9 Service info DI 11 Service info DI 12 Service info DEC 2 Service info DI 14 Service info DI 16 Service info EMS blink koder Service info olie cyklon/centrifuge Service info Kølevand/ Etylen glycol Service info Dyser / indsprøjtnings tidspunkt

DI 9

LUBRICATION OIL SYSTEM, page 20 1. Checking oil level 2. Oil change 3. Cleaning the lubrication oil cleaner 4. Changing the turbo filter COOLING SYSTEM, page 24 5. Checking coolant level 6. Checking corrosion protection rods 4) 7. Checking seawater pump impeller 4) 8. Checking coolant 9. Cleaning cooling system AIR CLEANER, page 32 10. Test reading low pressure indicator 11. Cleaning coarse cleaner 12. Cleaning or changing filter insert 13. Changing safety cartridge FUEL SYSTEM, page 35 14. Checking fuel level 15. Changing main filter 16. Checking injectors ELECTRICAL SYSTEM, page 37 17. Checking electrolyte level in batteries 18. Checking charge state of batteries 19. Cleaning batteries 20. Checking level monitor 21. Checking temperature monitor 22. Checking oil pressure monitor 23. Checking stop function MISCELLANEOUS, page 42 24. Checking transmission belt 25. Look for leaks. Remedy as necessary 26. Checking/adjusting valve clearance. 27. Changing (or cleaning) valve for closed crankcase ventilation

1. 2. 3. 4. 5. 6.

l

Every 5th year

Annually

At least

4800 h

2400 h

400 h

Interval

200 h

400 h

At first start

Daily

First time at

1200 h

MAINTENANCE SCHEDULE

l l1

l

l1

l

l1

l

l5

l

l5

l

l

l

l6

l6 l1

l

l l1

l l3

l l

l

l

l l1

l l

l

l

l2

l

l

l2

l

l2

l

l

l

l

l

l

l

l

l

l

l

l

l

l l

l

l l

l l

More often if required. For engines with few operating hours, see page 18. Earlier if low pressure indicator shows red. Applies only to M engines with sea water pump. Reference value. Varies depending on the composition of the sea water. If inhibitor has not been topped up for five years, the coolant should be changed.

2001-05:1

© Scania Industrial & Marine Engines

19

Program 96

Specifications General information Cylinder configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swept volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. weight, incl. alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation (engine viewed from rear) . . . . . . . . . . . . . . . . Compression ratio Output Engine speed Torque Oil capacity Oil grade

In-line engine 6 115 mm 144 mm 8.97 dm3 7 1-5-3-6-2-4 Direct 4 stroke Liquid 805 kg anticlockwise

See Operator’s Manual.

Locking compound, lubricants, sealing compounds T Activator for faster curing of locking compound 561 200. . . . . . . Locking compount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant for exhaust pipe bolts and joints . . . . . . . . . . . . . . . . . . . . Sealant for cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread-locking adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

561 045 561 200 561 205 584 010 561 019

Cylinder head Minimum cylinder head height after machining, page 17. . . . . . . . . 114.4 mm Distance “B” between cylinder head surface and valve head, page 11 With new parts, min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.78 mm With machined parts, max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm Intake valve Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm Head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.4°-19.6° Minimum dimension A for machined valve, page 10 . . . . . . . . . . . . 3.0 mm

01:01-02

© Scania CV AB 1997

65

Program 96 Exhaust valve Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm Head angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.4°-44.6° Minimum dimension A for machined valve, page 10. . . . . . . . . . . . . 1.7 mm

Intake valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.0° Contact surface width A, page 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 - 2.8 mm Valve seat ring OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.066 - 53.079 mm Position for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . 53.000 - 53.019 mm Position for valve seat ring, depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25 - 11.35 mm

Exhaust valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0° Contact surface width A, page 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 - 2.6 mm Valve seat ring OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.081 - 49.092 mm Position for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . 49.000 - 49.016 mm Position for valve seat ring, depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25 - 11.35 mm

Valve guides Length, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.2 mm exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.2 mm Height above surface for valve guide: intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7 mm exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7 mm

Rocker arm mechanism Rocker arm bushing, ID (pressed in and machined). . . . . . . . . . . . . . 30.007 - 30.028 mm Surface quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 Ra Oil hole diameter drilled to same diameter as in rocker arm.

66

© Scania CV AB 1997

01:01-02

Program 96 Tightening torques Cylinder head bolts: First tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm Second tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Nm + 90° Injector nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for adjusting screw on rocker arm . . . . . . . . . . . . . . . . . . . . . . . Rocker cover bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker arm mechanism bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 Nm 40 Nm 20 Nm 50 Nm 150 Nm

Turbocharger Wear limits Radial shaft clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.329-0.501 mm Axial shaft clearance (after running in). . . . . . . . . . . . . . . . . . . . . . . 0.038-0.093 mm

Tightening torques Bolts, turbocharger - exhaust pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm Hose clip, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm

Pistons and cylinder liners Cylinder liner Shims for cylinder liner, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20, 0.25, 0.30, 0.40, 0.50, 0.75 mm Cylinder liner height above cylinder block . . . . . . . . . . . . . . . . . . . . 0.27 - 0.33 mm Maximum permitted height difference on individual liner between measurements read at two diametrically opposite points across the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035 mm

01:01-02

© Scania CV AB 1997

67

Program 96 Pistons Fitted with arrow on piston crown facing forwards.

Piston rings Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gap: 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 - 0.75 mm 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.6 mm Clearance in groove max 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm Rings marked “TOP” should be turned with the marking facing upwards. Number of oil scraper rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 - 0.55 mm Clearance in groove max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm

Connecting rods Connecting rods and caps marked 1 to 6. Fitted with marking facing inwards.

Tightening torques Bolts for tension lugs when pressing down cylinder liner . . . . . . . . . 50 Nm Oil sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm Connecting rod bolts (oiled threads). . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90°

Flywheel and flywheel housing Flywheel Maximum machining of contact surface for plate: See group 4, Clutch

Ring gear Heated to 100 - 150 °C before fitting.

68

© Scania CV AB 1997

01:01-02

Program 96

Flywheel housing Seal in flywheel housing: Dimension B, page 43 . . . . . . . . . . . . . . . 7 mm

Tightening torques Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm Bolts for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm

Timing gear Camshaft gear Heated to 100 °C before fitting. Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.18 mm

Injection pump gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.16 mm

Intermediate gear Axial clearance max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.23 mm

Power take-off gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.18 mm

Camshaft Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 - 0.30 mm

01:01-02

© Scania CV AB 1997

69

Program 96 Crankshaft Main bearing races . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter: Standard Undersize 1 Undersize 2 Undersize 3 Undersize 4 Undersize 5 Undersize 6

95.000 - 94.978 mm 94.750 - 94.728 mm 94.500 - 94.478 mm 94.250 - 94.228 mm 94.000 - 93.978 mm 93.750 - 93.728 mm 93.500 - 93.228 mm

Fillet radius

4.75 - 4.85 mm

Surface quality

0.25 Ra

Width, max

46.78 mm

Bearing clearance 0.054 - 0.116 mm

Big-end bearing journals. . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter: Standard Undersize 1 Undersize 2 Undersize 3 Undersize 4 Undersize 5 Undersize 6

80.000 - 79.981 mm 79.750 - 79.731 mm 79.500 - 79.481 mm 79.250 - 79.231 mm 79.000 - 79.981 mm 78.750 - 78.731 mm 78.500 - 78.481 mm

Fillet radius

4.8 - 5.2 mm

Surface quality

0.25 Ra

Width, max

53.10 mm

Bearing clearance 0.050 - 0.112 mm

Thrust bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness:

70

© Scania CV AB 1997

Standard Oversize 1 Oversize 2 Oversize 3 Oversize 4 Oversize 5

3.38 - 3.43 mm 3.46 - 3.51 mm 3.51 - 3.56 mm 3.64 - 3.69 mm 3.89 - 3.94 mm 4.27 - 4.32 mm

Axial clearance

0.14 - 0.37 mm

01:01-02

Program 96 Tightening torques Tightening torques Nut for camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for compressor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for intermediate gear shaft journal . . . . . . . . . . . . . . . . . . . . . . Main bearing bolts: Stage I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stage II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 Nm 200 Nm 49 Nm 70-90 Nm 290 Nm 180 Nm 300 Nm+60° 30 Nm

Lubrication system Oil pump Backlash: Crankshaft gear - intermediate gear on oil pump . . . . . . . . . . . . . . . 0.03 - 0.36 mm Intermediate gear - crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.16 mm

Oil pressure valve (Note: not safety valve) Oil pressure: With hot engine at 2000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 bar With hot engine at 800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min. 1.5 bar Free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 mm

Oil cleaner Permitted thickness of deposits on wall of bowl . . . . . . . . . . . . . . . . 20 mm

Oil filter Use only genuine Scania filters (screwed on by hand).

01:01-02

© Scania CV AB 1997

71

Program 96 Tightening torques

Oil pump: Bolts for oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm Bolts, oil pump - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm Lock bolt (left-hand thread) for intermediate gear . . . . . . . . . . . . . . . 40 Nm

Oil cleaner: Locknut for oil cleaner housing cover . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm Nut for rotor bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten by hand Rotor shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm

Oil nozzle for piston cooling: Banjo bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm

72

© Scania CV AB 1997

01:01-02

Program 96

Valve clearance Checking and adjusting Check valve clearance. The clearance for intake valves should be 0.45 mm and the clearance for exhaust valves should be 0.80 mm when the engine is cold.

Adjustment can be carried out in one of the following ways: A. Adjust both valves in each cylinder starting with No. 1 cylinder at TDC after compression. Turn the crankshaft 1/3 turn at a time and adjust valves in injection sequence: 1-5-3-6-2-4

B. Set No. 1 cylinder at precisely TDC after compression. The following valves can now be adjusted: cylinder 1 intake and exhaust cylinder 2

intake

cylinder 3

exhaust

cylinder 4

intake

cylinder 5

exhaust

Turn the crankshaft precisely one revolution so that TDC for No. 6 cylinder is set. The remaining valves can now be adjusted: cylinder 2 exhaust cylinder 3 intake

Intake valve Exhaust valve

cylinder 4 exhaust cylinder 5 intake cylinder 6 exhaust and intake

01:01-02

© Scania CV AB 1997-05:2

5

DI 11

LUBRICATION OIL SYSTEM, page 14 1. Checking oil level 2. Oil change 3. Cleaning the lubrication oil cleaner 4. Changing the turbo filter COOLING SYSTEM, page 18 5. Checking coolant level 6. Checking corrosion protection rods 4) 7. Checking seawater pump impeller 4) 8. Checking coolant 9. Cleaning cooling system AIR CLEANER, page 26 10. Test reading low pressure indicator 11. Cleaning coarse cleaner 12. Cleaning or changing filter insert 13. Changing safety cartridge FUEL SYSTEM, page 29 14. Checking fuel level 15. Changing main filter 16. Checking injectors ELECTRICAL SYSTEM, page 31 17. Checking electrolyte level in batteries 18. Checking charge state of batteries 19. Cleaning batteries 20. Checking level monitor 21. Checking temperature monitor 22. Checking oil pressure monitor 23. Checking stop function MISCELLANEOUS, page 36 24. Checking V-belts 25. Look for leaks. Remedy as necessary 26. Checking/adjusting valve clearance. 27. Changing (or cleaning) valve for closed crankcase ventilation

1. 2. 3. 4. 5. 6.

l

Every 5th year

Every year

At least

4800 h

2400 h

400 h

Interval

200 h

400 h

At first start

Daily

First time at

1200 h

MAINTENANCE SCHEDULE

l l1

l

l1

l

l1

l

l l5

l

l5

l

l

l6

l6 l1

l

l l1

l l3

l l

l

l

l l1

l l

l

l

l2

l

l

l2

l

l2

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l l

l l

More often if required For engines with few operating hours, see page 12. Earlier if low pressure indicator shows red. Applies only to M engines with seawater pump. Guidline values. Vary according to composition of seawater. If inhibitor has not been topped up for five years, coolant should be changed.

1997-11:2

© Scania Industrial & Marine Engines

13

Program 96

Specifications General information Cylinder configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line engine Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 mm Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.02 dm3 Number of main bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Firing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4 Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Principle of operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 stroke Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Weight including alternator approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . 990 kg Direction of rotation (engine viewed from rear) . . . . . . . . . . . . . . . . . . Anti-clockwise Compression ratio Output Engine speed Torque Oil capacity Oil grade

See Operator’s Manual or Engine Card

Locking compound, lubricants, sealing compounds Activator T for faster curing of locking compound 561 200 . . . . . . . . . 561 045 Locking fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561 200 Lubricant for exhaust pipe bolts and joints . . . . . . . . . . . . . . . . . . . . . . 561 205 Hydraulic sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561 019

Cylinder head Minimum cylinder head height after machining, page 17 . . . . . . . . . . . 124.4 mm Distance ”B” between the surface of the cylinder head and valve disc, page 11 With new parts min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.72 mm With machined parts max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm Intake valve Clearance (cold engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm Head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.4°- 19.6° Minimum dimension A for ground valve, page 10 . . . . . . . . . . . . . . . . 3.0 mm

01:02-02

© Scania CV AB 1998

65

Program 96

Exhaust valve Clearance (cold engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.80 mm Disc angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.4°- 44.5° Minimum dimension A for machined valve, page 10 . . . . . . . . . . . . . . 1.7 mm

Intake valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width A of contact surface, page 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat ring outer diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20.0°- 20.5° 2.3 - 2.8 mm 56.0 mm 55.934 - 55.953 mm 11.25 - 11.35 mm

Valve seat ring in oversize: Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.2 mm Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.134 - 56.153 mm Cooling temperature when fitting valve seat ring . . . . . . . . . . . . . . . . . approx. -80 °C

Exhaust valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width A of contact surface, page 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat ring, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat ring, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45.0°- 45.5° 1.9 - 2.6 mm 52.0 mm 51.914 - 51.933 mm 11.25 - 11.35 mm

Valve seat ring in oversize: Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.2 mm Seat for valve seat ring, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.114 - 52.133 mm Cooling temperature when fitting valve seat ring . . . . . . . . . . . . . . . . . approx. -80 °C

Valve guides Height above surface for valve spring washer: Without valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.75 - 24.25 mm With valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.95 - 9.45 mm

Rocker arm mechanism Rocker arm bushing, inside diameter (pressed in and machined) . . . . . 25.00 - 25.02 mm Surface quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 Ra Diameter of oil holes (2 holes) drilled to same diameter as in rocker arm.

66

© Scania CV AB 1998

01:02-02

Program 96

Tightening torques Cylinder head bolts: First time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm Second time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Nm + 90° Nut for injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm Nut for rocker arm adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm Bolt for rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Nm Bolts for exhaust manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Nm

Turbocharger Wear limits Shaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.198-0.564 mm Shaft axial clearance (after running in) . . . . . . . . . . . . . . . . . . . . . . . . . 0.025-0.106 mm

Tightening torques Bolts, turbocharger - exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm Bolts against turbine housing (exhaust line) . . . . . . . . . . . . . . . . . . . . . 24 Nm

Pistons and cylinder liners Cylinder liner Shims for cylinder liner, thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 , 0.25 , 0.30 , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 , 0.50 , 0.75 mm Cylinder liner height above cylinder block . . . . . . . . . . . . . . . . . . . . . . 0.22 - 0.28 mm

Maximum permitted height difference on individual liner between measurements read at two diametrically opposed points across the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 mm Max. permissible difference in height under same cylinder head . . . . . 0.03 mm

01:02-02

© Scania CV AB 1998

67

Program 96

Pistons Fitted with arrow on piston crown towards the front of the engine

Piston rings Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gap: 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. clearance in groove, 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 0.60 - 0.80 mm 0.50 - 0.70 mm 0.25 mm

Rings marked ”TOP” should be turned with the mark upwards Number of oil scraper rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 - 0.80 mm Clearance in groove max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm Connecting rods Connecting rod and cap marked 1 to 6. Fitted with marking in.

Tightening torques Bolts for tension lugs when pressing down cylinder liner . . . . . . . . . . 60 Nm Bolts, oil sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90°

Flywheel and flywheel housing Flywheel Maximum machining of contact surface for disc: 2.0 mm

Ring gear Heated to 100 - 150 °C before fitting.

68

© Scania CV AB 1998

01:02-02

Program 96

Flywheel housing Seal in flywheel housing: Dimension B, page 46 . . . . . . . . . . . . . . . . . 7 mm

Tightening torques Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm Bolts for flywheel housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm

Timing gear Camshaft gear Heated to 100 °C before fitting. Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm

Injection pump gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm

Intermediate gear Axial clearance max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.238 mm

Bushing for power take-off gear Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.009 - 45.034 mm

Camshaft Axial clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm

01:02-02

© Scania CV AB 1998

69

Program 96 Crankshaft Main bearing journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter: Standard Undersize 1 Undersize 2 Undersize 3 Undersize 4 Undersize 5 Undersize 6

101.598 - 101.620 mm 101.348 - 101.370 mm 101.098 - 101.120 mm 100.848 - 100.870 mm 100.598 - 100.620 mm 100.348 - 100.370 mm 100.098 - 100.120 mm

Fillet radius

4.8 - 5.2 mm

Surface quality 0.25 Ra Width, max.

51.28 mm

Radial clearance

0.054 - 0.116 mm

Big-end bearing journals . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter: Standard Undersize 1 Undersize 2 Undersize 3 Undersize 4 Undersize 5 Undersize 6

84.233 - 84.255 mm 83.983 - 84.005 mm 83.733 - 83.755 mm 83.483 - 83.505 mm 83.233 - 83.255 mm 82.983 - 83.005 mm 82.733 - 82.755 mm

Fillet radius

4.8 - 5.2 mm

Surface quality

0.25 Ra

Width, max.

59.10 mm

Radial clearance 0.050 - 0.112 mm

Thrust bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness: Standard Undersize 1 Undersize 2 Undersize 3 Undersize 4 Undersize 5

3.378 - 3.429 mm 3.454 - 3.505 mm 3.505 - 3.556 mm 3.632 - 3.683 mm 3.886 - 3.937 mm 4.267 - 4.318 mm

Axial clearance 0.14 - 0.37 mm

70

© Scania CV AB 1998

01:02-02

Program 96 Tightening torques Nut for camshaft gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 Nm Nut for compressor gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm Bolts for intermediate gear shaft journal . . . . . . . . . . . . . . . . . . . . . . . . 39 Nm Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90° Main bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm + 90° Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm Crankshaft bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Nm+60° Bolts for crankshaft damper and pulley . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm Fan bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm

Lubrication system Oil pump Radial clearance: pump gear - pump housing . . . . . . . . . . . . . . . . . . . . 0.130 - 0.179 mm Axial clearance: pump gear - pump housing cover (without gasket). . . 0.07 - 0.10 mm

Oil pressure valve (Note: not safety valve) Oil pressure: With warm engine at 2,000 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 - 6 bar With warm engine at 800 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 bar Free spring length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.4 mm

Oil cleaner Permitted thickness of deposits on wall of bowl . . . . . . . . . . . . . . . . . . 20 mm

Oil filter Use only genuine Scania filters.

01:02-02

© Scania CV AB 1998

71

Program 96

Tightening torques Oil pump: Bolts for oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm Bolts oil pump - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Nm Valve sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm

Oil cleaner: Lock nut for oil cleaner housing cover . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm Nut for rotor bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten by hand Rotor shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Nm

Oil nozzle for piston cooling: Banjo bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm M8 Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm

72

© Scania CV AB 1998

01:02-02

Program 96

Valve clearance Checking and adjusting Check valve clearance. The clearance for intake valves should be 0.45 mm and the clearance for exhaust valves should be 0.80 mm when the engine is cold. Adjustment can be carried out in one of the following ways:

A. Adjust both valves in each cylinder starting with No.1 cylinder at TDC after compression. Turn the crankshaft 1/3 turn at a time and adjust valves in injection sequence: 1-5-3-6-2-4

B. Set No.1 cylinder at precisely TDC after compression. The following valves can now be adjusted: cyl. 1 cyl. 2 cyl. 3 cyl. 4 cyl. 5

intake and exhaust intake exhaust intake exhaust

Turn the crankshaft precisely one revolution so that TDC for No.6 cylinder is set. The remaining valves can now be adjusted: cyl 2 cyl 3 cyl 4 cyl 5 cyl 6

01:02-02

2

1

exhaust intake exhaust intake exhaust and intake

1

2

3

3

5

4

4

5

6

6

Intake valve Exhaust valve

© Scania CV AB 1998

5

Program 96

Compression Measuring The compression tester is used to quickly and simply check wear and damage to primarily the cylinder head valves, but also to cylinder liners and piston rings.

Measurements are only intended for comparison between cylinders. Lower compression in one or several cylinders is a sign of abnormal wear or damage.

By using various accessories, the compression tester can be used for several engine types.

1. Switch off the fuel supply. 2. Clean around injectors. Detach delivery pipes and leak-off pipes from all injectors. Note Place protective caps on the pressure valve holders in the injection pump and on the injectors in order to protect them from dirt.

1. Pressure gauge 2. Zeroing valve 3. Flexible metal hose 4. Test rod 5. End sleeve, diameter 21 mm 6. Spacing sleeve with guide lug 7. Spacing sleeve with collar 8. Spacing sleeve, length 6 mm 9. Spacing sleeve, length 19 mm 10. Spacing sleeve, length 25 mm 11. Spacing sleeve, length 38 mm 12. Cap nut 13. Threaded socket nut 14. Large yoke 15. Small yoke Compression tester 98 249

3. Undo and remove the injectors and copper washers. 4. Turn the engine several times using the starter motor to remove any loose soot in the cylinders.

6

© Scania CV AB 1998

01:02-02

Noter

DI 12

1. 2. 3. 4. 5. 6.

z1

z

z1

z

z1

z

z5

z

Every 5th year

Annually

At least

4800 h

2400 h

400 h

z

Interval

200 h

z

400 h

First start

LUBRICATING OIL SYSTEM, page 30 1. Checking the oil level 2. Oil change 3. Cleaning the oil cleaner 4. Renewing the oil filter COOLING SYSTEM, page 34 5. Checking the coolant level 6. Checking the corrosion bars 4) 7. Checking the marine water pump impeller 4) 8. Checking the coolant 9. Cleaning the cooling system AIR CLEANER, page 42 10. Checking the vacuum sensor 11. Cleaning the coarse cleaner 12. Cleaning or renewing filter element 13. Renewing the safety cartridge FUEL SYSTEM, page 45 14. Checking the fuel level 15. Renewing the main filter 16. Checking the injectors ELECTRICAL SYSTEM, page 47 17. Checking the electrolyte level in batteries 18. Checking the state of charge in batteries 19. Cleaning the batteries 20. Checking the level monitor 21. Checking the temperature monitor 22. Checking the oil pressure monitor MISCELLANEOUS, page 51 23. Checking the drive belt 24. Checking for leakage, rectify as necessary 25. Checking/adjusting valve clearance 26. Renewing (or cleaning) the valve for closed crankcase ventilation

Daily

First time at

1200 h

MAINTENANCE SCHEDULE

z z5

z

z

z6

z6 z1

z

z z1

z z3

z z

z

z

z z1

z z

z

z

z2

z

z

z2

z

z2

z

z

z

z

z

z

z

z

z

z

z

z

z

z z

z z

More often if required. For engines with few operating hours, see page 28. Earlier if low pressure indicator shows red. Only applies to M engines with sea water pump. Reference value. Varies depending on the composition of the sea water. If inhibitor has not been topped up for five years, the coolant should be changed.

2005-03:1

© Scania Industrial & Marine Engines

29

Specifications General information Cylinder configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swept volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approx. weight, including alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation (engine viewed from rear) . . . . . . . . . . . . . . . . . .

Compression ratio Output Engine speed Torque Oil capacity Oil grade

In-line engine 6 127 mm 154 mm 11.7 dm3 7 1-5-3-6-2-4 Direct 4-stroke Liquid 990 kg Anti-clockwise

See Operator's Manual or Service Card for the particular engine

Locking compound, lubricants, sealing compound Activator T for faster hardening of locking compound 561 200 . . . . . . Locking compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant for exhaust pipe bolts and joints . . . . . . . . . . . . . . . . . . . . . . Thread sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing compound for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . .

561 045 561 200 561 205 561 019 816 064

General tightening torques The following tightening torques apply in general unless otherwise specified: Thread M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thread M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01:03-02

©

Scania CV AB, Sweden, 2003-05:6

6.7 Nm 10.2 Nm 26 Nm 50 Nm 92 Nm 149 Nm

91

Cylinder head Intake valve Valve head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5 Minimum dimension A for ground valve . . . . . . . . . . . . . . . . . . . . . . . 2.6 mm Distance between the surface of the cylinder head and the valve head. 0.75-1.8 mm Exhaust valve Valve head angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.5 Minimum dimension A for ground valve . . . . . . . . . . . . . . . . . . . . . . . 1.8 mm Distance between the surface of the cylinder head and the valve head. 0.66-1.8 mm - Check dimension A for each valve. - Grind the valves in a valve grinding machine

Minimum dimension A for ground valve

Intake valve seat Seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of contact surface A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat insert, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat insert, depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20.0°-20.5° 1.9 - 2.6 mm 46.054 - 46.065 mm 46.000 - 46.016 mm 11.25 - 11.35 mm

Oversized valve seat insert: Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.254 - 46.265 mm Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.200 - 46.216 mm Cooling temperature when fitting valve seat insert. . . . . . . . . . . . . . . . approx. -80°C

92

©

Scania CV AB, Sweden, 2003-05:6

01:03-02

Exhaust valve seat Seat angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of contact surface A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat insert, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat for valve seat insert, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45.0°-45.5° 1.8 - 2.6 mm 44.081 - 44.092 mm 44.000 - 44.016 mm 11.25 - 11.35 mm

Oversized valve seat insert: Outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.281 - 44.292 mm Seat for valve seat insert, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.200 - 44.216 mm Cooling temperature when fitting valve seat insert . . . . . . . . . . . . . . . . approx. -80°C

Tightening torques Cylinder head bolts: First tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Second tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Third tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fourth tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for shaft with rocker arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nut for adjusting screw on rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . Bolt for rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for exhaust manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for support bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 Nm 150 Nm 250 Nm 90° 70 Nm 105 Nm 40 Nm 26 Nm 59 Nm 50 Nm 105 Nm

Valve clearances and unit injectors Valve clearance, intake valve (cold engine) . . . . . . . . . . . . . . . . . . . . . Valve clearance, exhaust valve (cold engine) . . . . . . . . . . . . . . . . . . . . Dimension for PDE31 unit injector (cold engine) . . . . . . . . . . . . . . . . . Dimension for PDE32 unit injector (cold engine) . . . . . . . . . . . . . . . . .

0.45 mm 0.70 mm 66.9 +/- 0.1 mm 69.9 +/- 0.1 mm

Tightening torques Adjusting screw lock nut on rocker arm for unit injector . . . . . . . . . . . Adjusting screw lock nut on rocker arm for valves . . . . . . . . . . . . . . . . Bolt for upper rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolt for lower rocker cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support bracket and rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . Cable connection, unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01:03-02

©

Scania CV AB, Sweden, 2003-05:6

39 Nm 35 Nm 26 Nm 26 Nm 105 Nm 2 +/- 0,2 Nm

93

Turbocharger Wear limits Shaft radial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.198-0.564 mm Shaft axial clearance (after running in) . . . . . . . . . . . . . . . . . . . . . . . . . 0.025-0.106 mm

Tightening torques Bolts, turbocharger - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . 63 Nm Bolts in turbine housing (exhaust pipe). . . . . . . . . . . . . . . . . . . . . . . . . 24 Nm V-clamps, exhaust and intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Nm

Pistons and cylinder liners Cylinder liner Shims for cylinder liner, thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20, 0.25, 0.30, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40, 0.50, 0.75 mm Height of cylinder liner above cylinder block. . . . . . . . . . . . . . . . . . . . 0.20 - 0.30 mm Maximum permitted height difference on one liner between dimensions measured at two diametrically opposite points . . . . . . . . . 0.02 mm

Pistons Fitted with arrow on piston crown facing forward.

Piston rings Number of compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gap: 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum clearance in groove, 2nd ring. . . . . . . . . . . . . . . . . . . . . . . .

2 0.35 - 0.60 mm 0.45 - 0.65 mm 0.25 mm

Rings marked "TOP" should be turned with the marking up. Number of oil scraper rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 - 0.65 mm Max. clearance in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm

94

©

Scania CV AB, Sweden, 2003-05:6

01:03-02

Connecting rods Connecting rod and bearing cap marked 1 to 6. Fitted with marking in. Tightening torques Oil sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm + 90°

Flywheel and flywheel housing Flywheel Maximum machining allowance for disc pressure surface: 2.0 mm

Ring gear Heated to 100 - 150°C before fitting.

Tightening torques Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Nm + 90° Bolts for flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M10: 50 Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M12 : 90 Nm

01:03-02

©

Scania CV AB, Sweden, 2003-05:6

95

Timing gear Camshaft gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm

Injection pump gear Backlash against intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 - 0.15 mm

Intermediate gear Max. axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.238 mm

Camshaft Axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 - 0.25 mm

Tightening torques Bolts for camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for intermediate gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for compressor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearing bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bolts for crankshaft damper and pulley. . . . . . . . . . . . . . . . . . . . . . . . . Flange bolts and banjo bolts for valve tappets . . . . . . . . . . . . . . . . . . . Bolts for timing gear plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96

©

Scania CV AB, Sweden, 2003-05:6

63 Nm 50 Nm + 60° 105 Nm 20 Nm + 90° 50 Nm + 90° 135 Nm 110 Nm 32 Nm 63 Nm

01:03-02

Lubrication system Oil cleaner Permitted thickness of deposits on wall of cover . . . . . . . . . . . . . . . . . max. 20 mm

Oil pressure valve (Note: not safety valve) Oil pressure: Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With warm engine running at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . With warm engine running at 2,000 rpm . . . . . . . . . . . . . . . . . . . . . . . . Free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 bar 2.5 bar 4.5 - 6.0 bar 61.4 mm

Oil filter Only use original Scania filters.

Tightening torques Oil pump: Bolts for oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm Bolts, oil pump - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm Oil cleaner: Lock nut for oil cleaner housing cover . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm Nut for rotor bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightened by hand Rotor shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm Oil nozzle for piston cooling: Banjo bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm Oil cooler: Bolts for oil cooler insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Nm

01:03-02

©

Scania CV AB, Sweden, 2003-05:6

97

Valve clearances (engines with injection pump) Checks and adjustments Check the valve clearance. The clearance for intake valves should be 0.45 mm and the clearance for exhaust valves should be 0.70 mm when the engine is cold. The following alternative methods of adjustment are possible: I. Adjust all four valves for each cylinder when at TDC after compression. Start with cylinder No. 1 and turn the crankshaft 1/3 turn at a time using tool 99 309 in the following injection order: 1-5-3-6-2-4

J. Put cylinder 1 at exact TDC after the compression stroke. The following valves can now be adjusted: cyl. 1 cyl. 2 cyl. 3 cyl. 4 cyl. 5

intake and exhaust intake exhaust intake exhaust

O Intake valve ⊗ Exhaust valve

Turn the crankshaft precisely one revolution so that TDC for No. 6 cylinder is set. The remaining valves can now be adjusted: cyl. 2 exhaust cyl. 3 intake cyl. 4 exhaust cyl. 5 intake cyl. 6 exhaust and intake

01:03-02

©

Scania CV AB, Sweden, 2003-05:6

O Intake valve ⊗ Exhaust valve

9

Adjusting the valve clearance and unit injectors (engines with PDE unit injector) Note: Check and adjust the valve clearance and unit injectors at the same time and with the engine cold. Checking and adjusting the valve clearance 1. Turn the flywheel (counterclockwise) with tool 99 309 so that the marks on the flywheel can be seen in the lower opening in the flywheel casing. See table on next page for order of adjustment. 2. Check the valve clearance using a feeler gauge and, if necessary, use the adjusting screw on the rocker arm to set the correct clearance. The clearance for intake valves should be 0.45 mm and the clearance for exhaust valves should be 0.70 mm when the engine is cold. The intake valves are actuated by the short rocker arms and the exhaust valves by the long rocker arms. Make sure the valve bridge is resting correctly against the valves. 3. Adjust the unit injectors in accordance with adjustment order in the table and Adjusting unit injectors. 4. If reading cannot be performed from underneath but only in the upper opening: Start with the TDC Up position and turn the flywheel counterclockwise 120° (1/3 turn) at a time, observe the valve change and adjust in accordance with the table. Important The flywheel marking is only correct if the reading is taken through the lower opening.

10

©

Scania CV AB, Sweden, 2003-05:6

01:03-02

Order of adjustment:

Mark on flywheel (reading from underneath)

Valve change on cylinder

Adjust valves on cylinder

Adjust injector rocker arm on cylinder

TDC Down (0°)

1

6

2

120°

5

2

4

240°

3

4

1

TDC Down (0°)

6

1

5

480°

2

5

3

600°

4

3

6

Adjusting unit injectors, PDE31 and PDE32 Important! The PDE31 unit injector is adjusted using setting tool 99 414 or a digital sliding caliper. The PDE32 unit injector is adjusted using setting tool 99 442 or a digital sliding caliper. This adjustment is important because an incorrectly positioned unit injector may result in poor performance and possible breakdown. Screw on the rocker arm adjusting screw 1 while measuring the distance between plane a and the top of the valve spring collar using a digital sliding caliper. The dimension should be 66.9 mm for PDE31 and 69.9 mm for PDE32. See dimension B in the figure for identifying the injector.

Dimension A = PDE31: 66.9 +/- 0.1 mm PDE32: 69.9 +/- 0.1 mm Dimension B = PDE31: 36.5 mm PDE32: 38.8 mm

01:03-02

©

Scania CV AB, Sweden, 2003-05:6

11

!

WARNING!

Take care when carrying out the adjustment if the dimension is well outside the adjustment dimension. The spring is pre-tensioned and can cause personal injury if it is released. PDE31 1. Position setting tool 99 414 with the metal plate around the injector spring. 2. Finely adjust dimension A by simultaneously using a finger to sense that the small piston 2 is level with the flat upper surface of the tool. It is possible to sense differences of less than a tenth of a millimetre. 3. If tool 99 414 is not available: Measure the distance between plane a and the top of the valve spring collar using a digital sliding caliper. Adjust the rocker position by means of the adjusting screw until the dimension is 66.9 +/- 0.1 mm. 4. Tighten the lock nut to 39 Nm. 5. See Order of adjustment on page 6 for checking/adjusting the injector rockers.

Piston above or below the flat surface. Adjustment necessary.

Piston level with the flat surface. Adjustment is correct. 12

©

Scania CV AB, Sweden, 2003-05:6

01:03-02

PDE32 1. Position setting tool 99 442 with the metal plate around the injector spring. 2. Finely adjust dimension A by simultaneously using a finger to sense that the small piston 2 is level with the flat upper surface of the tool. It is possible to sense differences of less than a tenth of a millimetre. 3. If tool 99 442 is not available: Measure the distance between plane a and the top of the valve spring collar using a digital sliding caliper. Adjust the rocker position by means of the adjusting screw until the dimension is 69.9 +/- 0.1 mm. 4. Tighten the lock nut to 39 Nm. 5. See Order of adjustment on page 6 for checking/adjusting the injector rockers.

Piston above or below the flat surface. Adjustment necessary.

Piston level with the flat surface. Adjustment is correct.

01:03-02

©

Scania CV AB, Sweden, 2003-05:6

13

Location of sensors for DEC2 on DI12

1. Connection of lead to charge air 2. 3. 4. 5. 6.

2005-03:1

temperature sensor Charge air temperature sensor Oil pressure monitor Connector panel Coolant temperature sensor Engine speed sensorse

© Scania Industrial & Marine Engines

17

LED functions during normal operation POWER-

Note: The lamp test/fault code switch should not be depressed. All LEDs come on briefly when the control unit is powered up.

P The LED remains out during normal operation as long as no fault is detected by the control unit. See next page for the procedure to be adopted in the event of a fault.

CONTROL STATUS

<

The LED flashes continuously when the control unit is supplied with current, regardless of whether the engine is running or not.

SHUTDOWN P The LED is out. STARTING

<

The LED lights up as soon as the engine turns over on cranking and follows the programmed starting sequence until it has been completed and then goes out.

POWER+

<

If the control unit is programmed to allow the engine to be operated according to more than one power/torque curve (map), the following applies. The LED comes on when the engine is run at more than 100% power output (MAP 2). It goes out when the engine returns to the 100% power output curve (MAP 1) or when the power output required is less than 100%.

RUNNING

<

The LED comes on when the engine has started and the "Starting" LED goes out. It remains on until the engine is stopped.

TORQUE LIMIT

<

The LED comes on when the control 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

<

18

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.

© Scania Industrial & Marine Engines

2005-03:1

Action in case of a fault LED indications in case of a fault Note The main indicator lamp in the main supply box and at the instrument panel has indicated a fault. The lamp test/fault code switch should not be depressed.

CONTROL STATUS

<

The LED will continue to flash even in case of a fault as long as voltage is supplied to the control unit.

POWER -

<

If the LED comes on, the control unit has detected a defect that 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 20 and the chart on page 21

SHUTDOWN

<

The LED comes on and the engine is switched off automatically in case of a severe fault that could cause damage to the engine if operation continues. Action: Conduct troubleshooting according to instructions on page 20 and the chart on page 21 If the engine has not stopped, reduce engine speed to idle and conduct troubleshooting.

2005-03:1

© Scania Industrial & Marine Engines

19

Changing functions using the DIP switches in the control unit There are 8 DIP switches in the control unit under the round black rubber cover. These switches shall be in the ON position to obtain normal functions according to the operating program. However, for single-speed engines, the normal position of DIP switches 6, 7, and 8 may also be OFF

Readout of fault codes Note If the engine has stopped or lost power but the main indicator lamp is out and neither POWER- nor SHUTDOWN are on, the fault is outside the control unit detection range. Probable causes: fuel shortage, temporary overload, mechanical fault.

Shutdown at threshold values for low oil pressure and high coolant temperature can be selected by setting DIP switch 4 to OFF

- Activate the lamp test/fault code switch. In Scania electrical equipment the main indicator lamp is located in this switch on the main supply box.

With DIP switch 4 in position ON, Power- indication is obtained for these threshold values. Engine output reduction (LOP) can be selected to prevent damage to the engine. Changes to the program must only be performed by authorized personnel.

- 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.

Note Do not operate the engine with a Power-

- All LEDs will then be out for approximately 4 seconds.

indication except for in emergencies.

- Following this, a fault code will be indicated on one of the LEDs for 2 seconds. Note which LED it is. - The control unit then resumes the operating mode automatically. - After having made a note of the fault code, reset the lamp test/fault code switch and reset the control unit by turning off its power supply momentarily. - The most probable cause of the fault can then be found in the trouble shooting schedule on the next page. - When the fault or faults have been rectified the engine can be restarted. - If the control system continues to indicate a fault by way of the main indicator lamp, further faults may have been recorded. The fault code readout must then be repeated as per above since the system can only display one fault code at a time. - The fault(s) will be stored in a special memory in the control unit along with information about the operating time when it(they) occurred. Stored faults can be accessed and erased by authorised service personnel. The DIP switches are showed in ON position

20

© Scania Industrial & Marine Engines

2005-03:1

POWER +

POWER -

BOOST LIMIT

TORQUE LIMIT

RUNNING

STARTING

SHUTDOWN

LED INDICATION WHEN THE LAMP TEST/FAULT CODE SWITCH IS ACTIVATED CONTROL STATUS

2005-03:1

READOUT OF FAULT CODES

© Scania Industrial & Marine Engines

< < < < < < < <