Scania DC11 User manual

©Scania CV AB 2011, Sweden
1 585 592
01:03-02
Issue 9 en-GB
11 and 12 litre engines
Work description
106 351
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Contents
Engine assembly General information.................................................. 4
Removing the engine................................................ 6
Fitting the engine.................................................... 14
Mounting the engine in an engine stand................. 20
Measuring the compression pressure...................... 22
Cylinder head ................................................................................ 25
Removing the cylinder head................................... 26
Fitting the cylinder head......................................... 32
Checking and adjusting the valve clearance........... 36
Removing valves .................................................... 38
Fitting valves .......................................................... 38
Checking and machining valves............................. 39
Renewing the valve stem seal................................. 40
Renewing the valve seats........................................ 41
Machining the cylinder head .................................. 43
Renewing the valve guides..................................... 48
Renewing the injector sleeves ................................ 49
Renewing the unit injector sleeves......................... 51
Cylinder block Reconditioning ....................................................... 54
Removing the cylinder liners.................................. 55
Fitting the cylinder liners........................................ 56
Measuring and machining the cylinder liner
height ...................................................................... 57
Renewing the rear crankshaft seal.......................... 63
Renewing camshaft bearings.................................. 65
Flywheel housing ................................................................................ 71
Removing the flywheel housing............................. 72
Fitting the flywheel housing................................... 72
Fan coupling Removing the fan coupling .................................... 76
Fitting the fan coupling .......................................... 76
Renewing the bearing in the fan coupling.............. 77
Renewing the front crankshaft seal ........................ 80
Closed crankcase ventilation Troubleshooting...................................................... 83
Renewing the diaphragm........................................ 85
Crank mechanism ................................................................................ 86
Removing a piston.................................................. 87
Fitting a piston........................................................ 89
Renewing a piston .................................................. 91
Checking the connecting rod.................................. 94
Bearing bush in connecting rod.............................. 96
Flywheel Removing the flywheel........................................... 98
Fitting the flywheel................................................. 99
Support bearing .................................................... 101
External ring gear ................................................. 102
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Crankshaft Removing the crankshaft...................................... 103
Fitting the crankshaft............................................ 104
Machining crankshafts.......................................... 105
Timing gear .............................................................................. 108
Removing the intermediate gear........................... 110
Fitting the intermediate gear................................. 112
Renewing the bearing in the intermediate gear
for the compressor ................................................ 113
Renewing the bearing in the intermediate gear
for the camshaft .................................................... 114
Removing the camshaft gear ................................ 115
Fitting the camshaft gear ...................................... 116
Removing the crankshaft gear.............................. 117
Fitting the crankshaft gear.................................... 118
Removing the camshaft ........................................ 119
Fitting the camshaft .............................................. 120
Checking the camshaft setting.............................. 123
Lubrication system General ................................................................. 124
Measuring the oil pressure.................................... 125
Oil filter ................................................................ 127
Oil cooler.............................................................. 128
Oil filter unit......................................................... 130
Oil pump............................................................... 135
Turbocharger .............................................................................. 136
Measuring radial and axial clearance ................... 138
Checks after breakdown ....................................... 140
Belt transmission .............................................................................. 141
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Engine assembly
General information
1 Smoke values.
2 Instruction plate.
3 A Engine type, Engine serial number (on engines built before November 2000).
3 B Engine type (on engines built from November 2000 onwards).
4 Engine serial number, stamp.
DC11 DC12
Cylinder diameter 127.0 mm 127.0 mm
Piston stroke 140.0 mm 154.0 mm
Cubic capacity 10.64 dm311.7 dm3
No. of main bearings 7 7
Firing sequence 1-5-3-6-2-4 1-5-3-6-2-4
3B
A
Typ/Type DSC 12 01
Variant
Motor/Engine No
Made by
Valve clearance cold engine
Inlet
Outlet
Pump timing
:
mm
:
mm
0.45
0.70
15
:
o
AB
: DSC 1201
: 0.75
123 45XX
before T.D.C.
1 2
3
4
Variant
Made by
Type DSC 12 01
119 867
Engine assembly
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01:03-02 ©Scania CV AB 2011, Sweden 5
Lubrication
Engine oil must be applied to all moving parts
before fitting unless otherwise stated.
Compression ratio 18:1 18.5:1
Direction of rotation (engine viewed from the rear) Anticlockwise Anticlockwise
Engine speed, low idling 500 rpm 500 rpm
Engine speed, high idling 2,400 rpm 2,400 rpm
Oil capacity 28-35 litres 28-35 litres
Oil grade refer to booklet
00:03-09
refer to booklet
00:03-09
Total weight without oil and water 1,010-1,030 kg 1,020-1,040 kg
DC11 DC12
Engine assembly
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Removing the engine
Comments
1Drain Oil and coolant.
2Remove The battery cover and detach the
negative cable.
3Remove The protective casing.
4Remove Connectors 13 (C2) and 14 (C188). Connector 14 (C188) is only fitted
on vehicles without a coordinator.
5Disconnect The positive and negative cables.
6Remove The clamps to release electrical cables
13 and 14.
7Tilt the cab according to instructions, refer to Group 18.
8Remove The mudguards.
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01:03-02 ©Scania CV AB 2011, Sweden 7
120232
4
5
3
6
Engine assembly
120231
8
82
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8©Scania CV AB 2011, Sweden 01:03-02
Right-hand side:
Comments
9Pull through the detached cable harnesses and place them on the engine.
10 Remove The turbocharger induction pipe. The compressor air pipe and the
crankcase ventilation hose must be
detached from the induction pipe.
11 Cover the air filter.
12 Detach The radiator water hoses. The number of hoses varies
depending on the design. Only one
hose is illustrated.
13 Detach The flexible hose for the charge air pipe.
14 Lift off The poly-V-belt. Only on vehicles with air
conditioning.
15 Detach The air hose for the exhaust brake
cylinder.
16 Remove The exhaust pipe.
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01:03-02 ©Scania CV AB 2011, Sweden 9
120234
12
9
13
10
16
15
11
14
Engine assembly
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Left-hand side:
Note: When removing the gearbox, engine
support 99 318 must be used to support the
engine.
Comments
17 Detach The flexible hose for the charge air pipe.
18 Detach The AC compressor and move it aside. 4 bolts.
19 Detach The compressor feed pipe.
20 Detach The water heater hose. Only on vehicles equipped with a
water heater.
21 Detach The ground connection.
22 Detach The fuel pipes.
23 Detach The oil filler hose.
24 Detach The oil dipstick.
25 Detach The starter motor ground connection.
26 Detach The pressure regulator pipe. Detach at the compressor.
27 Detach The positive starter motor cable.
28 Detach The hydraulic pump and move it aside. 5 bolts in the flange.
29 Remove The gearbox. Refer to Group 5.
100329
99 318
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01:03-02 ©Scania CV AB 2011, Sweden 11
120235
17
18
21
22
25
18
19
23 24 26 27 28
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12 ©Scania CV AB 2011, Sweden 01:03-02
IMPORTANT! The lifting eyes on the engine are
not designed to lift the whole vehicle and
therefore must not be used for this purpose. All
three lifting eyes must be used when lifting the
engine.
On vehicles built from May 2000 onwards, the
rear lifting eyes have been removed. They may be
ordered as a spare part, part number 1 360 442.
30 Fasten lifting chain 98 094 to the rear
lifting eyes.
01_1397
98 094
31 Fasten ratchet lever hoist 587 308 to the
front lifting eye.
01 1398
587 308
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01:03-02 ©Scania CV AB 2011, Sweden 13
IMPORTANT! The lifting eyes are designed to
cope with a maximum inclination angle of 30°,
when lifting an engine with the gearbox removed.
For engines without the gearbox removed, the
maximum angle is 20°.
Engine assembly
32 Remove the bolts in the engine brackets
and lift out the engine.
01_1399
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Fitting the engine
Tightening torques
Left-hand side:
Engine bracket bolts M14: 47 Nm
M16: 130 Nm+90°
V-clamp for the charge air cooler 8 Nm
1 Lift the engine so that the engine brackets are approx. 10 mm over the engine cushions.
2 Position the bolts and lower the engine so that it rests on the engine cushions and engine
supports 99 318. Tightening torques: M14 bolts, 47 Nm and M16 bolts, 130 Nm+90°.
3Fit the gearbox. Refer to Group 5.
Comments
4Fit The hydraulic pump. Fit a new gasket.
5Fit The positive starter motor cable.
6Fit The pressure regulator pipe. At the compressor.
7Fit The starter motor ground connection.
8Fit The oil dipstick.
9Fit The oil filler hose.
10 Fit The fuel pipes. RV= upper, RA= lower.
11 Fit The ground connection. At the compressor.
12 Fit The water heater hose.
13 Fit The compressor feed pipe.
14 Fit The AC compressor.
15 Fit The flexible hose for the charge air pipe. Tightening torque, 8 Nm.
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01:03-02 ©Scania CV AB 2011, Sweden 15
120545
15
14
11
10
7
12
13
98654
Engine assembly
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16 ©Scania CV AB 2011, Sweden 01:03-02
Right-hand side:
Comments
16 Fit The exhaust pipe.
17 Fit The air hose for the exhaust brake
cylinder.
18 Fit The radiator water hoses. Only one hose is illustrated.
19 Fit The flexible hose for the charge air
cooler.
Tightening torque, 8 Nm.
20 Fit The turbocharger induction pipe. Tightening torque, 10 Nm, must
be applied at max. 100 rpm.
21 Fit The compressor air pipe and the
crankcase ventilation hose on the
induction pipe.
22 Fit The poly-V-belt.
23 Route Cables 13 and 14 to the front of the cab.
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01:03-02 ©Scania CV AB 2011, Sweden 17
120544
18 23
19
20
16
17
22
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Comments
24 Fit The mudguards.
25 Tilt the cab back to the driving position.
26 Fit The positive and negative cables.
27 Fit Connectors 13(C2) and 14(C188) Connector 14 (C188) is only fitted
on vehicles without a coordinator.
28 Fit All cables with clamps.
29 Fit The plastic cover over the central
electric unit.
30 Fit The negative cable on the battery and
the battery cover.
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01:03-02 ©Scania CV AB 2011, Sweden 19
120542
30
24
24
120543
27
26
29
28
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20 ©Scania CV AB 2011, Sweden 01:03-02
Mounting the engine in an engine stand
Engines with injection pump
Remove: Pos.
Fuel filter A
Injection pump F
Bracket E
Starter motor D
Required brackets
Engines with PDE unit injectors
Remove: Pos.
Fuel filter A
Control unit B
Compressor C
Starter motor D
Required brackets
Engines with HPI unit injectors
Securely bolt the engine to the engine stand as
illustrated. Use tool 99 331.
Remove: Pos.
Fuel filter A
Control unit B
Compressor C
Starter motor D
Feed pump G
Engine assembly
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