Jcb Engines Scania 12 Engine (1588557) Workshop Manual

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Work Description - 12 Engine Industrial and Marine Engines

Part no.

1 588 557

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Use a container to avoid spills when draining the coolant and oil.

Dispose of used coolant and oil through an authorised waste disposal contractor.

Contents Complete engine . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removing the engine . . . . . . . . . . . . . . . . . . . . 4 Fitting the engine . . . . . . . . . . . . . . . . . . . . . . . 5 Mounting the engine in a universal stand . . . . 6 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valve clearances (engines with injection pump)9 Adjusting the valve clearance and unit injectors (engines with PDE unit injector) . . . . . . . . . . 10 Compression . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removing the cylinder head (engines with injection pump) . . . . . . . . . . . . . . . . . . . . . . . 16 Removing the cylinder head (engines with PDE unit injector) . . . . . . . . . . . . . . . . . . . . . 17 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Renewing the valve stem seal . . . . . . . . . . . . 21 Renewing the valve seats . . . . . . . . . . . . . . . . 22 Machining the valve seat insert . . . . . . . . . . . 23 Renewing the valve guides . . . . . . . . . . . . . . 25 Renewing injector sleeves (engines with injection pump) . . . . . . . . . . . . . . . . . . . . . . . 26 Renewing PDE unit injector sleeves . . . . . . . 28 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Fitting (all engines) . . . . . . . . . . . . . . . . . . . . 29 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . 32 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Measuring the radial and axial clearance. . . . 35 If the turbocharger does not work . . . . . . . . . 36 Renewing the turbocharger . . . . . . . . . . . . . . 37 Pistons and cylinder liners . . . . . . . . . . . . . . . . 38 Removing the scraper ring in the liner (engines with injection pump) . . . . . . . . . . . . 40 Removing and dismantling connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Checking connecting rods . . . . . . . . . . . . . . . 42 Renewal of bearing bushing in connecting rod43 Assembling the piston and connecting rod . . 45 Removing the cylinder liners . . . . . . . . . . . . . 46 Measuring the cylinder liner height . . . . . . . . 47 2

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Machining cylinder liner height. . . . . . . . . . .

Fitting the cylinder liners . . . . . . . . . . . . . . . .

Fitting the piston and connecting rod. . . . . . .

Flywheel and flywheel housing . . . . . . . . . . . .

Removing the flywheel . . . . . . . . . . . . . . . . .

Removing the flywheel housing . . . . . . . . . .

Fitting the flywheel housing . . . . . . . . . . . . .

Fitting the flywheel . . . . . . . . . . . . . . . . . . . .

Timing gear. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearwheel timing gear . . . . . . . . . . . . . . . . . . .

Intermediate gear . . . . . . . . . . . . . . . . . . . . . .

Camshaft gear . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft gear . . . . . . . . . . . . . . . . . . . . . . .

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Renewing the camshaft bearing . . . . . . . . . . .

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder block . . . . . . . . . . . . . . . . . . . . . . . .

Belt transmission. . . . . . . . . . . . . . . . . . . . . . . .

Renewing the seal in the front cover . . . . . . . .

Lubrication system . . . . . . . . . . . . . . . . . . . . . .

Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .

General information . . . . . . . . . . . . . . . . . . . .

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . .

Valve clearances and unit injectors . . . . . . . .

Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . .

Pistons and cylinder liners . . . . . . . . . . . . . . .

Flywheel and flywheel housing . . . . . . . . . . .

Timing gear . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication system. . . . . . . . . . . . . . . . . . . . .

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . .

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48 52 53 55 56 58 59 61 62 64 64 67 68 69 70 78 79 82 83 84 84 86 90 91 91 92 93 94 94 95 96 97 98

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Complete engine General DI, DC12 engine with injection pump

DI, DC12 engine with EMS

1

1 2

3 3 1. Instruction plate: Valve clearance 2. Type plate: Engine type, Engine number

3. Engine number, stamped

Special tool Number 99 318 98 094

Designation Engine support Lifting chain

587 308

Lever block

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Illustration

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Tool board

3

Removing the engine 1. Drain the oil and coolant.

2. Remove the air filter and the inlet pipe between the turbocharger and the air filter.

Cover the turbo inlet.

3. Undo the connections for coolant, charge air pipes between engine and charge air cooler, and ventilation line to the expansion tank.

4. Remove the cables with cable clamps.

Note The engine lifting eyes are sized for lifting the engine only, not the engine together with connected equipment (high-current generator, gearbox, reverse gear, etc.) or frame. All three lifting eyes must be used.

5. Fasten the lifting chain 98 094 to the rear lifting eyes.

6. Fasten the lever block 587 308 to the front lifting eye.

Note The lifting eyes are dimensioned for a maximum inclination angle of 20° when lifting the engine.

7. Undo all the engine brackets and lift away/out the engine.

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Fitting the engine Note The engine lifting eyes are sized for lifting the engine only, not the engine together with connected equipment (high-current generator, gearbox, reverse gear, etc.) or frame. All three lifting eyes must be used.

Note The lifting eyes are dimensioned for a maximum inclination angle of 20° when lifting the engine.

1. Fasten the lifting chain 98 094 to the rear lifting eyes.

2. Fasten the lever block 587 308 to the front lifting eye.

3. Lift the engine in position and bolt it to the front engine suspension.

4. Connect the wiring with clamps.

5. Fit the connections for coolant, charge air pipes between engine and charge air cooler, and ventilation line to the expansion tank.

6. Fit the air filter and the inlet pipe between the turbocharger and the air filter.

7. Fill with oil and coolant as directed in booklet 00:03-01.

8. Test run the engine to check that no leakage occurs. Top up with coolant if necessary.

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Mounting the engine in a universal stand Special tools Number Designation 99 331 Fixture

587 692

Illustration

Tool board

Universal stand

Engines with injection pump Remove: - Fuel filter - Injection pump - Starter motor - Brackets as necessary

Engines with unit injectors PDE Remove: - Fuel filter - Control unit - Compressor - Starter motor - Brackets as necessary

Attach the engine to the universal stand in accordance with the picture with tool 99 331.

6

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1. Screw M10x30 (8 st), Torque 47 Nm. 2. Nut M16 (4 st), Torque 180 Nm. 3. Screw M16x50 (4 st).

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Cylinder head

1. Valve bridge 2. Pin 3. Bolt 4. Collet 5. Valve spring collar 6. Valve spring 7. Valve spring 8. Valve stem seal 9. Valve guide 10. Socket 11. Collet 12. Valve spring collar 13. Valve spring 14. Rivet plug 15. Tight-fit screw

16. Shaft 17. Bearing bracket 18. Rocker arm for unit injector 19. Adjusting screw 20. Hexagon nut 21. Rocker arm 22. Spacing sleeve (injection pump) 23. Adjusting screw 24. Hexagon nut 25. Rocker arm 26. Core plug 27. Unit injector 28. Cylinder head

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29. Pin 30. Rivet plug 31. Gasket 32. Exhaust valve 33. Valve seat insert 34. Intake valve 35. Flange bolt 36. Flange bolt 37. Rocker cover, upper section 38. Rocker cover gasket 39. Rocker cover, lower section 40. Rocker cover gasket

7

Special tools

87 596 98 249 99 074 99 079 99 308 99 309 99 310 99 322 99 323

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Slide hammer Compression tester Impact drift Extractor for injectors Sleeve for injectors Tool for turning flywheel Socket Press drift Assembly drift

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99 381 99 382 99 383 99 384 99 385 99 394 99 414 99 442 587 277 588 221

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Drift Drift Drift Drift Handle Guide Setting tool Setting tool Valve seat cutter Pilot tap

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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

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O Intake valve ⊗ Exhaust valve

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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.

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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

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!

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.

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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.

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13

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DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL