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Fuel system

OPM 320 en-GB

49

©

Scania CV AB 2019, Sweden

Leak testing after mainte-

nance of the fuel circuit

This procedure applies only if pure biogas is

used as fuel.

Special tool

Calibration of the pressure testing

equipment

1.

Connect pressure regulator 2 301 551 to the

compressed air.

2.

Block the connection nipple and open the

pressure regulator valve.

Number

Designation

2 541 520

Pressure testing kit

389 393

38

9 392

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Содержание OC16

Страница 1: ...to start the engine The engine could be damaged but more importantly there is a serious risk of injury Therefore block the starting device and switch off the manual fuel cock when working on the engi...

Страница 2: ...el 38 Checking the coolant s antifreeze and corrosion protection 38 Changing the coolant and cleaning the cooling system 39 Fuel system 44 Cleaning the flame arrestor and throttle at the flame lock 44...

Страница 3: ...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 bel...

Страница 4: ...acturers 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...

Страница 5: ...overload 110 for one hour per 12 hour period This power class applies to single speed engines COP Continuous power Intended for continual use with a non varying load and an unlimited number of operati...

Страница 6: ...pages contain a summary of the safety precautions to be complied with when op erating and maintaining Scania engines The equivalent text can also be found under the rele vant maintenance item To preve...

Страница 7: ...e is not toxic but in a mixture of 50 per cent or more with air the oxygen content will be so low that the risk of suffocation increases IMPORTANT Comply with applicable local laws and regula tions wh...

Страница 8: ...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 effective devices to extra...

Страница 9: ...ly explosive There must be no smoking naked flames or sparks near the batteries or the battery compart ment Incorrect connection of a battery cable or jump lead can cause a spark which can cause the b...

Страница 10: ...attery master switch and lock them 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...

Страница 11: ...WARNING Natural gas and pure biogas are extremely flam mable and can even be ignited by static electric ity from a person Natural gas and pure biogas are lighter than air and therefore rise in the ev...

Страница 12: ...e where open handling of gas takes place i e handling which may give rise to an explosive atmosphere Never attempt to put out a burning gas flame Try to stop the flow of gas instead Move material that...

Страница 13: ...es 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 wit...

Страница 14: ...ol unit The engine seri al number is stamped onto the top of the cylinder block at the front right Example OC16 071A OC Supercharged gas engine with air cooled charge air cooler 16 Displacement in who...

Страница 15: ...9 Sweden Component identification 2 3 4 5 6 7 8 1 368 360 1 Filling coolant 2 Centrifugal oil cleaner 3 Throttle at gas mixer 4 Oil dipstick 5 Oil plug 6 Oil filler 7 Nipple to drain and fill coolant...

Страница 16: ...ification OPM 320 en GB 16 Scania CV AB 2019 Sweden 368 361 9 10 11 12 13 14 9 Engine data plate and engine serial number 10 Air cleaner 11 Spark plug 12 Lambda sensor 13 Flame arrestor 14 Throttle at...

Страница 17: ...ted area When the engine is run in an enclosed space there must be effective devices to extract gas and exhaust gases IMPORTANT The starter motor must only be cranked twice for 30 seconds at a time Af...

Страница 18: ...owest limit value Alarm at the lowest limit value and engine shutdown at the highest limit value The engine is designed and optimised for contin uous operation at 100 load To ensure opera tional relia...

Страница 19: ...off with out cooling The power must not be switched off before the engine has stopped 1 Run the engine without load for 3 minutes at the nominal engine speed 2 Switch off the engine via the coordinato...

Страница 20: ...oil in pipes and hoses The maintenance programme includes the fol lowing R maintenance One event when taken into service S maintenance Minimum basic maintenance M maintenance More extensive mainte na...

Страница 21: ...lement X X X Renewing the safety car tridge X X X Cooling system Checking coolant level X X X X X X X X Checking the coolant s anti freeze and corrosion protec tion X X X X Changing the coolant and cl...

Страница 22: ...suitable for the outdoor tem perature in the area where the engine is used For operation at extremely low outdoor tempera tures Consult your nearest Scania representative on how to avoid starting diff...

Страница 23: ...he filled oil grade However there are only labels for oils from Scania and oil grade ACEA E9 Stick on a new label if the oil type or oil grade is changed in favour of any of the oil types above Replac...

Страница 24: ...ysis the oil s TBN Total Base Num ber TAN Total Acid Number fuel dilution water content and viscosity are measured as well as the quantity of particles in the oil The result of a series of analyses is...

Страница 25: ...correct level is between the mini mum and maximum marks on the oil dip stick 2 Top up with more oil via the oil filler if the oil level is at or below the minimum mark For information on the correct...

Страница 26: ...1 1 in Renew the oil filter and clean the centrifugal oil cleaner when changing oil Environment Use a suitable container Used oil must be dis posed of as specified in national and internation al laws...

Страница 27: ...e dirt deposits on the paper in the rotor cover If the paper is clean the equipment is not working as it should If this is the case in vestigate the cause of this Renew the paper more frequently if th...

Страница 28: ...ion the screw head at the bottom of the rotor 11 Position a ring spanner on the lower nut and turn the rotor 1 5 turns anti clockwise IMPORTANT Do not attach the rotor directly to the vice Never strik...

Страница 29: ...m 1 1 in the centrifugal oil cleaner must be cleaned more often 16 Wash the parts according to the applicable industrial method 17 Inspect the 2 nozzles on the rotor Ensure that they are not blocked o...

Страница 30: ...Refit the rotor cover Ensure that the O ring is not outside the edges but is in the groove 23 Screw the rotor nut back on by hand 24 Check that the shaft is not damaged or loose Contact a Scania works...

Страница 31: ...al testing need only be carried out if it is suspected that the centrifugal oil cleaner is malfunctioning For example if there are unusu ally few deposits given the distance driven 1 Run the engine un...

Страница 32: ...The filter housing will drain automat ically once the filter has been removed 3 Undo the old filter from the cover by careful ly bending it to one side 4 Fit a new O ring on the cover Lubricate the O...

Страница 33: ...er element will be dam aged when it is cleaned Reading the vacuum indicator If the vacuum indicator s red plunger is fully vis ible renew the air cleaner filter element in ac cordance with the followi...

Страница 34: ...nia coolant or another product with functioning antifreeze and corrosion protection may be used in Scania engines Products not ful filling the demands in this section may lead to faults and damage occ...

Страница 35: ...gine has been started The chart depicts coolant properties at different percents of antifreeze and corrosion inhibitor concentration by volume The following example shows coolant properties with 30 pe...

Страница 36: ...t and dust Note Within the coolant change interval coolant may only be reused if it has been cleaned of dirt sludge and particles If the coolant is contaminat ed with oil or fuel it must not be reused...

Страница 37: ...uired in the cooling system Since there are already 25 litres in the cooling system fill another 7 litres of ethylene glycol 32 25 7 litres Ethylene glycol con tent 35 40 45 50 60 Ice slush forms C 21...

Страница 38: ...e lower edge of the filler neck The right coolant level on a hot engine is approximately 25 mm 1 in over the low er edge of the filler neck 2 Top up with coolant as necessary Checking the coolant s an...

Страница 39: ...h the skin Environment Use a suitable container Used coolant must be disposed of as specified in national and interna tional laws and regulations 1 Open the expansion tank cap 2 Position the hose from...

Страница 40: ...mostat and a new cover to the expansion tank after cleaning as the oil in the cooling system destroys the seals If the engine is equipped with a coolant filter also renew this fil ter It may be necess...

Страница 41: ...e whether it it is necessary to carry out another full cleaning or whether only rinsing or cleaning of the expansion tank will suffice Internal cleaning Removing deposits in the cooling system Environ...

Страница 42: ...can cause irrita tion if it comes in contact with the skin Hot cool ant can also cause scalding IMPORTANT Mix the coolant as specified in the section head ed Coolant It is not permissible to top up l...

Страница 43: ...lock 1 3 Connect the pump s 2 cable terminals to the battery s negative and positive terminal Make sure that the filling starts If the filling does not start Change the position of the ca ble terminal...

Страница 44: ...d throttle at the flame lock This procedure applies only if pure biogas is used as fuel IMPORTANT Read the safety precautions before starting work 1 Detach the harness to component connector from the...

Страница 45: ...and screws 4 Remove the upper part of the flame arrestor housing and the throttle 5 Remove the flame arrestor 6 Clean the insert with degreasing agent Re move dirt with a soft brush 7 Rinse the inser...

Страница 46: ...gents can damage the throttle 12 Rinse the throttle with hot water 13 Dry off the water 14 Spray the outside of the throttle with water repellent anti corrosive oil for example LPS1 or equivalent Make...

Страница 47: ...19 Fit the screws and the bracket 20 Fit the screws securing the throttle bracket 21 Fit the throttle harness to component con nector 22 Check the fuel system is not leaking See Leak testing after ma...

Страница 48: ...4 Clean the throttle with soap and water Use a soft brush to remove stubborn dirt IMPORTANT Only use soap and water Solvents and degreas ing agents can damage the throttle 5 Rinse the throttle with h...

Страница 49: ...s procedure applies only if pure biogas is used as fuel Special tool Calibration of the pressure testing equipment 1 Connect pressure regulator 2 301 551 to the compressed air 2 Block the connection n...

Страница 50: ...sure regulator adjustment rota ry control and close the valve Leak testing the intake system up stream of the throttle 1 Undo the hose clamps 2 Turn the charge air pipe downwards 3 Close the nipple on...

Страница 51: ...air pipe between the air cleaner and the gas mixer 6 Fit pressure cap 2 541 521 in the hose spigot on the gas mixer 7 Detach the crankcase ventilation connection 8 Fit cover 2 655 695 9 Connect pressu...

Страница 52: ...nia CV AB 2019 Sweden 10 Open the valve on pressure regulator 2 301 851 11 Monitor the pressure on pressure cap 2 541 521 The manometer should indicate a pressure below 0 3 bar Greater pressure may da...

Страница 53: ...has been cut 13 If you discover a leak rectify the leakage and repeat the leak tracing Leak testing the intake system down stream of the throttle 1 Remove the V clamp and move the exhaust pipe to one...

Страница 54: ...and connect it to pressure cap 2 655 714 6 Fit the hose spigot and pressure cap 2 655 714 at the throttle housing 7 Open the valve on pressure regulator 2 301 851 8 Monitor the pressure on pressure te...

Страница 55: ...ak bubbles form upon application of leak detection spray Be careful with areas where work has been carried out or where a joint has been cut The exhaust system up to the turbocharger outlet is pressur...

Страница 56: ...ug See the section Renewing the spark plugs 2 Check if there are any deposits in the com bustion chamber using an endoscope 3 Check the amount of deposits on the top of the piston The cylinder piston...

Страница 57: ...system Renewing the spark plugs Tools IMPORTANT Read the safety precautions before starting work 1 Disconnect the ignition coil harness to com ponent connector 2 Twist off the spark plug connector arm...

Страница 58: ...PORTANT Do not touch the spark plug insulator with your fingers If this occurs clean the insulator with al cohol 6 Place the new spark plug in the spark plug socket and tighten the spark plug Tighteni...

Страница 59: ...lt if deep cracks have formed Note Small and shallow cracks are normal and form after only a few hours of operation They do not mean that the drive belt needs to be renewed If there are many deep crac...

Страница 60: ...orkshop 1 Start the engine 2 Check for oil coolant fuel air or exhaust leaks 3 Tighten or renew leaking connections Check the overflow holes which show whether the O rings between the cylinder liners...

Страница 61: ...out the working without pausing so that no step is overlooked Carry out a check and adjustment of the valve clearances one more time after the first 500 hours of operation After this adjustment accor...

Страница 62: ...e flywheel in the lower or the upper window Start adjustment at the top of the table Valve clearance specifications Intake valve 0 45 mm 0 018 in Exhaust valve 0 80 mm 0 032 in Tightening torque Lock...

Страница 63: ...wed from the back of the en gine During a valve transition the exhaust valve the long arm is closing at the same time as the intake valve is opening The UP TDC engraving on the flywheel is now visible...

Страница 64: ...MWN method in EN 16726 2015 Use the calculator on the Euromot website The calorific value is calculated according to standard ISO 6976 Use Natural gas calorific value calculator on the Unitrove websi...

Страница 65: ...0 3 0 5 psi 20 35 mbar 0 3 0 5 psi Fuel temperature 10 40 C 50 104 F Max water content A maximum of 60 per cent relative humidity at the lowest fuel temperature There is no water other visible impurit...

Страница 66: ...engine oil that meets the require ments in the Oil grade section Preservative oil for combustion chambers Suitable preservative oils are supplied by most oil companies Use a preservative oil based on...

Страница 67: ...ine is to be stored without coolant in the cooling system 12 Renew the filter elements in the air cleaner 13 Cover the air intake and exhaust pipe 14 Spray the outside of the alternator and starter mo...

Страница 68: ...a dry location at room temper ature The engine must be packed in packaging made of VCI plastic to protect against dust dirt and moisture When the engine is to be taken into operation again 1 Remove pl...

Страница 69: ...t Valve clearances cold engine Intake valve mm in 0 45 0 017 Exhaust valve mm in 0 80 0 031 Number of teeth on the flywheel 158 Low idling speed rpm 1 000 Operating speed rpm 1 500 1 800 Fuel Natural...

Страница 70: ...radiator dm3 US gallons 68 18 Coolant temperature C F 90 95 194 203 Number of thermostats 1 Thermostat opening temperature C F 80 176 and 87 189 Permissible pressure drop in the intake system with cl...

Страница 71: ...BR 0800 019 42 24 NA 27 11 226 5005 BW 27 11 226 5005 NL 31 76 52 54 111 CA 1 800 2 SCANIA NO 47 223 217 00 CH 41 800 55 24 00 PE 0800 51 727 CL 188 800 722 642 PL 48 22 331 22 33 CZ 420 225 020 225...

Страница 72: ...thread Strength class 8 8 8 Flange screws with hexago nal head and hexagonal flange nuts Metric thread Strength class 8 8 8 Thread Tightening torque Nm Lb ft M4 2 9 21 M5 6 4 M6 9 5 7 M8 24 18 M10 47...

Страница 73: ...Specifications in the tables show tightening torque when tightening by hand A width mm Tightening torque Nm Lb ft 7 5 9 1 5 1 12 5 4 A width mm Tightening torque Nm Lb ft 20 10 7 25 20 15 327 162 D A...

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