Scania DI16, DI13, DI09 Service Manual

Name: Scania DI16
Brand: Scania
SKU: 4535339
Rating: 5 (1 reviews)

5 (1)

INSTALLATION

MANUAL

Engine

Marine engines

DI09, DI13, DI16

02:01 Issue 6.0 en-GB

INSTALLATION MANUAL

Engine suspension....................................................................................................	3
Design requirements............................................................................................	3
Flexible engine suspension..................................................................................	4
Rigid engine suspension......................................................................................	6
Suspension of reverse gear..................................................................................	7
Permissible installation and operating angles .....................................................	8
Flywheel housings...............................................................................................	9
Lifting the engine ..............................................................................................	10
Engine bed.........................................................................................................	10
Accessibility for maintenance and repairs ..........................................................	11
Installation requirements ...................................................................................	11
Clearances .........................................................................................................	13
Engine alignment...................................................................................................	14
Flexible coupling...............................................................................................	15
Aligning engine and shafts................................................................................	16
Power transmission ...............................................................................................	21
Flexible coupling...............................................................................................	21
Friction clutch ...................................................................................................	22
Transmission types ................................................................................................	23
Mechanical transmissions .................................................................................	23
Belt transmissions .............................................................................................	23
Power take-offs ......................................................................................................	25
Front-mounted power take-offs.........................................................................	25
Side-mounted power take-offs ..........................................................................	27
Connection of sensors for external monitoring systems ....................................	34
DI09 and DI13...................................................................................................	35
DI16...................................................................................................................	37

Torsional oscillations ............................................................................................	39
Data for torsional oscillation calculation..........................................................	39
Torsional oscillation calculations from Scania.................................................	40
General tightening torques for screw joints .......................................................	42
Specification of normal tightening torques.......................................................	42
Tightening torques ............................................................................................	43

02:01 Issue 6.0 en-GB

INSTALLATION

MANUAL

Engine suspension

Design requirements

The type of engine suspension that is appropriate varies for different engine installations. In general, the following applies:

•The engine suspension should be designed for the forces it is exposed to, both continuously and momentarily during operation. Such forces are reaction forces from the transmitted torque and in some cases longitudinal acceleration, retardation and reaction forces in the engine.

•For engines with marine transmission, Scania recommends a 6-point suspension or common rear suspension for pipes, transmission and engine.

•Both the engine suspension and the engine bed should be designed so that there are no resonant oscillations within the engine speed range. They should also be designed so that annoying vibrations from the engine are not transmitted to the surroundings.

•The engine suspension and engine bed should be designed in a manner which allows access for maintenance and repair work.

•The engine bed location and the engine suspension must be designed so that the permissible angles of inclination for the engine are not exceeded. See the table Permissible installation and operating angles.

IMPORTANT!

If the angles of inclination are exceeded, lubrication system performance will deteriorate, which can cause damage to the engine or reduce its service life.

There are two standard engine suspension designs:

•flexible engine suspension

•rigid engine suspension.

02:01 Issue 6.0 en-GB

Engine suspension

INSTALLATION

MANUAL

Engine suspension

Flexible engine suspension

Flexible engine suspension dampens vibrations more effectively than rigid engine suspension. It prevents extreme movement between engine and engine bed during violent ship movement. Flexible engine suspension can also absorb some level of reaction force from the propeller. Flexible engine suspension does not require such careful alignment of the engine as rigid engine suspension.

However, flexible engine suspension does not absorb longitudinal and lateral forces in the engine to the same extent as rigid engine suspension.

327 968

Examples of flexible engine suspension

02:01 Issue 6.0 en-GB

INSTALLATION

MANUAL

Insulators

Cushyfloat insulators with hardness 55 or 65 Shore can be ordered as option.

max 1° 407310

The engine bracket and frame or engine bed should be parallel.

310 408

0°

Vertical centre lines should coincide laterally.

02:01 Issue 6.0 en-GB

Engine suspension

160±10 Nm

310 404

Tightening torque

310 405

55 alt. 65

Hardness marking

	0°
55	406
	310

Upper and lower parts of the insulators should be parallel longitudinally.

INSTALLATION

MANUAL

Rigid engine suspension

A rigid engine suspension can absorb greater forces in all directions than flexible engine suspension. It requires highly accurate alignment of the engine in relation to the driven unit. On the other hand, it requires no special flexibility in the hoses, pipes and controls connected to the engine.

A rigid engine suspension can be used in engine installations where vibration causes no significant problems and where other characteristics make it desirable.

Even with a rigid engine suspension, the transmission of vibration to the engine bed can be kept low if the masses of the engine bed and connected parts are large in relation to the mass of the engine.

It is also possible to construct flexible engine suspension between the frame and the engine bed to reduce the transmission of vibration to the engine bed.

02:01 Issue 6.0 en-GB

Engine suspension

327 967

Examples of rigid engine suspension

328 053

Example of rigid engine suspension for single-speed engines

INSTALLATION

MANUAL

Engine suspension

Suspension of reverse gear

Built-on reverse gear can either have separate brackets or suspension attachments which are integrated with the engine.

Contact Scania or the supplier of the reverse gear about approved type of suspension for reverse gear.

327 753

Example of suspension of a reverse gear

02:01 Issue 6.0 en-GB

INSTALLATION

MANUAL

Engine suspension

Permissible installation and operating angles

Maximum permissible installation angle means maximum permissible installation angle for an engine relative to the horizontal plane. The angle indicates the limit for engine inclination during continuous operation.

Maximum operating angle means maximum permissible angle of inclination for an engine in operation and with minimum oil level. The angle may only be used for short periods. The maximum forward or rearward operating angles are not applicable to their full extent if the engine is inclined laterally at the same time.

Engine type	Type of oil sump	Max. installation angle		Max. operating angle		Oil capacity (litres)
		Inclination rear-	Inclination lat-	Inclination rear-	Inclination lat-	Min.	Max.
		wards and for-	erally	wards and for-	erally
		wards		wards
DI09	Standard oil sump	12°	12°	30°	30°	32	38
DI09	Low oil sump	12°	12°	20°	30°	25	32

DI13	Standard oil sump with ladder frame	12°	12°	30°	30°	39	45
DI13	Standard oil sump without ladder frame	12°	12°	30°	30°	36	30
DI13	Low oil sump	12°	12°	25°	30°	28	34

DI13	Extra low oil sump	12°	12°	25°	30°	25	30
DI16	Standard oil sump	12°	10°	25°	30°	40	48
DI16	Low oil sump	12°	10°	25°	30°	29	37

02:01 Issue 6.0 en-GB

INSTALLATION

MANUAL

Flywheel housings

Silumin housings are supplied as standard on most marine engines, except on certain 16 litre engines. The maximum permissible bending torque for a silumin housing is 10,000 Nm. This presumes that there are no axial loads from, for example, the propeller shaft, abnormal G forces or vibration.

However, nodular iron flywheel housing can also be chosen. Nodular iron housings can dampen vibrations at certain engine speeds but increase vibrations at other engine speeds. Nodular iron is stronger than silumin and can therefore tolerate greater bending and torsional forces. Certain 16 litre engines have nodular iron casing as standard.

The stronger nodular iron housings are recommended in installations where the flywheel housing is exposed to serious stress, e.g. with high reverse gear ratios and when heavy components without support are attached to the rear of the engine (e.g. hydraulic pump). Nodular iron housings are also recommended for generator sets with high outputs.

The propeller installation without separate thrust bearing can be approved if the following requirements are met:

•Max. pressure load from the propeller must not exceed 40,000 N.

•Reverse gear ratio must not exceed 2:1.

•The suspension must be on the front engine bracket and the common bracket for the rear edge of the engine and the reverse gear.

•The displacement between the input and output shaft of the reverse gear must not exceed 250 mm.

•Most of the propeller force must be taken up by the rear suspension.

•The support points of the brackets must be aligned with the propeller shaft as much as possible.

02:01 Issue 6.0 en-GB

Engine suspension

INSTALLATION

MANUAL

Note:

The suspension must be dimensioned for the appropriate pressure load.

For the installation to be approved in a propeller installation with a reverse gear ratio greater than 2:1, the pressure forces must be fully taken up in the reverse gear suspension.

Contact Scania if it is difficult to determine the size and type of load.

Lifting the engine

WARNING!

The engine lifting eyes are dimensioned for lifting the engine only, not the engine together with connected equipment or frame!

Engine bed

The engine bed should be made as robust and rigid as possible. The attachment to the hull should be as widely distributed as possible.

The engine bed should have welded support plates for engine and reverse gear. The brackets should be as low as possible. Accessibility underneath the engine must be good so that the oil sump can be removed for example.

There must be space for spacers with a thickness of 5-10 mm between the engine brackets and the engine bed brackets for accurate alignment.

02:01 Issue 6.0 en-GB

Engine suspension

INSTALLATION

MANUAL

Accessibility for maintenance and repairs

Installation requirements

The installer is responsible for ensuring that accessibility is ensured for maintenance and repairs.

Note:

There must be sufficient space at installation so that standard times for maintenance and repairs can be attained.

The following requirements for accessibility must be met:

•Canopies and connected components must be designed so that the engine can be removed and fitted without time being lost due to obstructive structures.

•In the case of static engine installations, there should be permanent securing points for lifting devices above the unit.

•The fuel system must be easily accessible for maintenance and bleeding.

•It should be possible to read the graduations on the flywheel when adjusting valves and unit injectors.

•It should be possible to remove and fit the cylinder head, rocker covers and pushrods while leaving the engine in place.

•It must be possible to remove the oil sump in order to renew cylinder liners or pistons with the engine in place.

•It should be easy to fill and drain oil. In addition, the oil dipstick must be easily accessible.

•Centrifugal oil cleaners and oil filters must be easy to access for maintenance and renewal.

•It should be easy to fill and drain coolant.

•Engine air filters must be located so that they are easy to access for the renewal of filter elements.

02:01 Issue 6.0 en-GB

INSTALLATION

MANUAL

Accessibility for maintenance and repairs

It must also be easy to carry out maintenance on the following components:

•Turbocharger

•Starter motor

•Generator

•Coolant pump

•Seawater pump and seawater filter

•Heat exchanger

•Sacrificial anodes

•Clutch

•Batteries

02:01 Issue 6.0 en-GB

INSTALLATION

MANUAL

Accessibility for maintenance and repairs

Clearances

The most important clearances are shown in the table and illustrations below. The specified measurements apply to the largest standard equipment.

Measurement

Clearance (mm)

For maintenance or renewal of

DI09, DI13

DI16

150

900

Cylinder liner, cylinder head etc.

250

300

Oil sump

400

Various units

150

Seawater pump impeller

Clearances for DI09 and DI13

Clearances for DI16

02:01 Issue 6.0 en-GB

INSTALLATION

MANUAL

Engine alignment

The alignment of the engine in relation to the driven unit is very important in order to prevent malfunctions.

Otherwise there is a risk of vibration and serious stress to the crankshaft, engine brackets, drive shaft and coupling, causing damage which is costly to repair.

For propeller installations, a first alignment is made before the ship is launched. Alignment must then be checked after the ship is launched and has been placed under load. The ship should also be laden and equipped with filled tanks.

Since there can be some settling in the hull after the first hours of operation, further checks on the alignment should be made after a period in service.

Alignment should be checked regularly on certain vibration-sensitive engine installations.

If flexible engine suspension is part of the system, this should be placed under load before alignment. Otherwise, it will quickly settle by several millimeters.

Poor alignment between engine and propeller shaft can cause damaging vibration in the hull, damage to the reverse gear and accelerated wear of the shaft and propeller bearings.

02:01 Issue 6.0 en-GB

Engine alignment

+ 32 hidden pages