Shanghai Diesel Engine E Series Manuale utente
Caution
Be sure to read this instruction manual carefully and strictly observe the safety and
operation instructions herein, especially the warnings and cautions, so as to redXce the
possibilities of personnel injury, property loss, engine performance deterioration,
premature wear or damage.
Warnings in this manual muVt be observed strictly. Failure to do so can cause burns,
amputation, mutilation, asphyxiation, other personal injury or death. Cautions are
provided for the user to operate the engine in a proper way, so as to avoid damage to
engine parts and engine performance deterioration. Warnings and cautions in this
manual are not complete since Shanghai Diesel Engine Co., Ltd. (SDEC) has no
possibility and is not able to foresee all potential risks resulted from failures to follow the
safety cautions and operation instructions.
Repair, Technical Consultation, Complaint and Suggestion
For engine repair, technical consultation, complaints or suggestions, please contact
Please provide the following information for product repair:
The engine model
The engine order number
The engine serial number
The date of the equipment procurement
The detailed description of the fault
The address and phone number of the contact person
Table of Contents
1 Introduction.................................................................................................................................. 1
1.1 To User and Operator..................................................................................................... 1
1.2 Notices for Engine Quality Feedback........................................................................... 1
1.3 Safety Instructions .......................................................................................................... 1
1.4 Engine Operation Instructions....................................................................................... 2
2 About the Engine ........................................................................................................................ 3
2.1 Engine Outline Diagrams ............................................................................................... 3
2.2 Engine Model Identification ......................................................................................... 11
2.3 Engine Nameplate ........................................................................................................ 11
2.4 Specifications and Parameters ................................................................................... 12
3 Engine Operation...................................................................................................................... 14
3.1 Lubricating oil................................................................................................................. 14
3.2 Coolant............................................................................................................................ 14
3.3 Engine Start ................................................................................................................... 14
3.4 Engine Operation .......................................................................................................... 15
3.5 Engine Shutdown .......................................................................................................... 16
3.6 Running-In of a New or Overhauled Engine ............................................................. 16
4 Engine Maintenance ................................................................................................................ 17
4.1 Maintenance Plan ......................................................................................................... 17
4.2 Maintenance Record..................................................................................................... 18
4.3 Tasks and Methods of Engine Maintenance............................................................. 19
5 Engine System and Dedicated Components ....................................................................... 32
5.1 Abbreviation ................................................................................................................... 32
5.2 Engine Control System................................................................................................. 32
5.3 Dedicated Components................................................................................................ 33
6 Electronic Control Module Fault Code .................................................................................. 37
6.1 MIL and System Fault Code ........................................................................................ 37
6.2 Fault Diagnosis without Diagnostic Tool .................................................................... 37
6.3 Fault Code...................................................................................................................... 38
7 Troubleshooting Guidelines .................................................................................................... 40
8 Engine Storage ......................................................................................................................... 50
Operation and Maintenance Manual E Series Natural Gas Engine
1
1 Introduction
1.1 To User and Operator
Thank you for purchasing a product of Shanghai Diesel Engine Co., Ltd!
The E series natural gas engine, available in two displacements of 10L and 12L, is a large-power four-valve
electronic-controlled natural gas engine with four or six cylinders that is newly developed by SDEC. Featuring strong
power and low gas consumption and with the emissions conforming to relevant national regulations, the E series
natural gas engine is a perfect power for middle- and high-end vehicles and industrial equipment.
This manual mainly covers the technical specifications, operation and maintenance instruction, with an aim to
familiarize you with the engine, as well as the proper operation and maintenance thereof. Before using the engine,
read carefully the relevant contents and requirements in this manual. Due to the continuous improvement of
performance and structure of the engine, the technical specifications and illustrations of the engine in this manual
may be slightly different from those of the engine you have, please note that we will provide the supplement and
perfection in the later editions without notice. In case of any question during your engine operation and maintenance,
please never hesitate to contact SDEC’s after-sale service center [email protected] for technical advice or
guidance.
SDEC has adopted the latest technology and high-quality parts for the engine. The genuine SDEC spare parts are
recommended to be used for repair and maintenance. Please contact SDEC’s after-sale service center
1.2 Notices for Engine Quality Feedback
To better our service, please provide following information when you make feedback about quality issues, whereby,
we can understand and analyze quality issues and the root causes thereof, and make the improvement in time:
1) When and where fault occurred;
2) Engine serial number, model, order number, delivery date and the detailed address of consignee;
3) Service conditions, cumulative operation time (in hours or kilometers), operating conditions (power, speed) and the
specification of the lubricating oil that has been used;
4) The characteristics of the driven equipment (model, power consumption and structural feature, etc.)
5) The description of faults;
6˅Parts or components claimed for compensation or repair should be mailed or sent in person to SDEC headquarter
with the damage process record or description for facilitating analysis. If there are several problems or a very serious
problem, please leave the site as it was and inform us promptly, and then SDEC will send staff for a joint analysis.
Quality issues should be settled based on the relevant provisions in the quality warranty manual.
1.3 Safety Instructions
ƔDo not wear a loose garment or any jewelry when working around the engine or its driven equipment. If necessary,
wear the safety goggles, work clothes, safety helmet or other protective items.
ƔAll the exposed rotating parts should be provided with guards in firm installation to prevent personal injury.
ƔThe workroom of the engine should be well ventilated with waste gas exhausted outside.
ƔDo not operate the gas engine in a place where there is or may be flammable gas, for the gas may enter the air
intake system of the engine and cause the engine to speed up or overspeed, which leads to fire, explosion or serious
engine damage.
ƔTake all tools, wires, other odds and ends away from the engine prior to starting.
ƔMake sure to shutdown the engine before any adjustment is performed to it and its driven equipment.
ƔSmoking is not allowed during filling gas, otherwise, gas steam can cause fire easily.
ƔSmoking is also not allowed when checking electrolyte level because electrolyte will release flammable gas.
ƔContact between electrolyte and skin or eyes must be prevented when replenishing electrolyte for the battery,
because it is an acid. In case of skin contact, please flush the contacted part with soap and clean water; in case of
eyes contact, flush your eyes for 15 minutes with clean water and seek for medical treatment immediately.
ƔAdded with an odorous chemist, natural gas can be smelled when it leaks. Be on alert when smelling natural gas.
When entering the engine cabinet or being close to the engine and smelling natural gas, shut down the engine and
check and remove gas leakage. And keep the area free from spark, arc switch or device, smoking, indicator lamp, fire
or other fire source and take a good ventilation measures. Do not start the equipment or the equipment nearby until
the leakage has been removed and the area has been well ventilated. Avoid placing the equipment fueled with natural
Operation and Maintenance Manual E Series Natural Gas Engine
2
gas in a bad ventilated room overnight or for a longer period of time. Keep or maintain the equipment in a large, well
ventilated place instead.
ƔCool down the engine first when filling coolant to avoid being hurt by the coolant steam. Open the pressure cap only
when the coolant is lower than 50 , and then slowly loosen the cap to release the pressure ofćcooling system.
ƔWipe up overflowed lubricating oil, coolant or other liquids. Put oily rags into a fire-protection container, but do not
leave it on the engine.
ƔBefore starting a repaired engine, make sure to be ready to cut ECM power supply. In case of any abnormal, switch
off the power supply immediately.
ƔDo not rotate the engine with the fan, otherwise severe personal injury or damage to fan blades can be caused.
ƔThe exhaust system experiences higher working temperature than that of diesel engine. Do not touch the parts of
the exhaust system to avoid scald.
ƔRelease the pressure in the air, lubricating or cooling system prior to dismantling or loosening any pipelines,
permanent joints, connectors or relevant parts. Do not use hand to check leakage, otherwise the high temperature
and high pressure natural gas, lubricating oil and coolant can cause personal injury.
ƔIf the engine will not be used for a long time or is under repair, separate it from the battery to prevent an unexpected
start-up.
ƔThe ignition system of the engine will produce high voltage during engine operation. Never touch the ignition wire or
ignition part when the engine is in operation unless using a proper insulated tool. A bad electric shock will happen if
failing to do so.
ƔUsed lube oil may contain carcinogenic substance which can result in reproductive toxicity, therefore, inhalation of or
longtime exposure to oil steam should be avoided. Waste oil should be disposed in proper, safe and reliable manner.
ƔTo prevent choke or cold injury, removal of air-conditioning refrigerant (Freon) pipeline should be conducted in well
ventilated environment with protective clothing on. For environment protection, the refrigerating system should be
emptied or filled using dedicated equipment so as to prevent diffusion of Freon into atmosphere.
Refrigerant should be recovered and recycled.
1.4 Engine Operation Instructions
ƔRead this manual carefully, and be in strict accordance with operation instructions and maintenance procedure
specified in this manual.
ƔConduct daily and 4-level maintenance as specified in this manual, and keep the record of scheduled maintenance.
ƔUse the proper gas, lubricating oil and coolant specified in this manual.
Ɣ60 hours’ running-in must be conducted for a new or overhauled engine. Refer to Section 3.6 for the running-in
requirements.
ƔDo not run the engine without air filter, otherwise, early engine wear will happen.
ƔWhen welding is required, cut power supply for the vehicle or equipment before welding or it will cause damage to
the ECM and sensors. Do not ground the welding device onto the ignition part or on the ignition wire. Ground the
welding device to the place near the parts to be welded.
ƔDo not connect a starting jumper cable or battery charge cable to the ignition control circuit. Failure to do so will
cause damage to the ignition system.
ƔThe exhaust system experiences higher working temperature than that of diesel engine of same kind. So gas lines
should not be located close to the exhaust system to prevent their hoses from deterioration due to hot.
ƔThe cooling system of the engine should adopt a specified coolant in any king of climate.
ƔWhen filling lubricating oil, it is not allowed to use the mixture of oil of different specifications.
ƔPreparations should be well done before starting the engine. Be sure to remember that the engine must be started
without any load.
ƔCheck if coolant, lubricating oil and gas are enough before starting the engine.
ƔObserve the engine operation and all instrument readings. In case of critical situation, an emergency stop should be
performed to prevent the seizure of moving parts caused by low oil pressure or overheating due to lack of coolant.
ƔThe belt tension and the other drive devices can only be inspected when the engine is in stop.
ƔClose the hand gas supply valve first when maintaining or repairing the engine.
ƔMalfunction thermostat should be replaced in time but the use of thermostat cannot be omitted.
ƔDo not water the engine for cleaning.
Operation and Maintenance Manual E Series Natural Gas Engine
3
2 About the Engine
2.1 Engine Outline Diagrams
2.1.1 SC10ET natural gas engine (10L)
1
2
3
4 5 6 7 9
11
13
1418 1719
8
20
Intake Side
10
12
21
16 15
1 AC Compressor 2 Fan belt (Outer) 3 Fan belt (Inner)
4 Alternator 5 Oil dipstick 6 Low pressure gas filter
7 Low pressure gas shut-off valve 8 Oil pressure sensor 9 Starter motor
10 Flywheel housing 11 Ignition Module 12 Rear lifting ring
13 Valve cover 14 Fuel metering valve 15 Intake manifold
16 Ignition coil 17 Intake air temperature and pressure sensor
18Electronic throttle 19 Intake air pressure sensor 20 Front lifting ring
21 Gas mixture inlet pipe
Operation and Maintenance Manual E Series Natural Gas Engine
4
1
2
3
4
5 6 7 8
10
11
12
131415
9
Exhaust Side
1 Oil separator2 Oil separatorgas outlet pipe
3 Oil separator oil return pipe 4 Air compressor
5 Oil filter (2 Pcs)6 Oil drain plug
7 Oil pan8 Turbocharger oil drain pipe
9 Oil cooler 10 Water pump
11 Oil filler cap12 Turbocharger
13 Turbocharger oil inlet pipe14 Exhaust manifold heatshield
15 Engine coolant inlet pipe
Operation and Maintenance Manual E Series Natural Gas Engine
5
1
2
3
4
5
6
7
8
9
10
Front End
1 Water temperature sensor2 Fan pulley
3 Water pump pulley4 Fan belt tensioner (outer)
5 Alternator belt tensioner (inner)6 Vibration damper
7 Alternator 8 Idler pulley
9 AC compressor pulley10 Ignition wire
Operation and Maintenance Manual E Series Natural Gas Engine
6
1
2
3
Rear End
1 Speed sensor2 Flywheel 3 Roller bearing
Operation and Maintenance Manual E Series Natural Gas Engine
7
2.1.2 SC12ET natural gas engine (12L)
Intake Side
1
2
3
4 5 6 7 9
10
11
12
13
1418 1719
8
20
15
16
1 AC Compressor 2 Fan belt (Outer)
3 Drive belt (Inner) 4 Alternator
5 Oil dipstick 6 Low pressure gas filter
7 Low pressure gas shut-off valve 8 Oil pressure sensor
9 Air compressor 10 Air compressor water outlet pipe (1)
11 Air compressor water inlet pipe (2) 12 Ignition module
13 Valve cover 14 Fuel metering valve
15 Intake manifold 16 Ignition coil
17 Intake air temperature and pressure sensor 18Electronic throttle
19 Intake air pressure sensor 20 Gas mixture inlet pipe
Operation and Maintenance Manual E Series Natural Gas Engine
8
1
2
3
4
5
6
7
8 9 10 11
12
13
1415
161718
Exhaust Side
1 Rear lifting ring 2 Oil separator gas outlet pipe
3 Oil separator oil return pipe 4 Air compressor water inlet pipe (1)
5 Air compressor water outlet pipe (2) 6 Flywheel housing
7 Starter motor 8 Oil filter (2 Pcs)
9 Oil drain plug 10 Turbocharger oil drain pipe
11 Oil cooler 12 Water pump
13 Front lifting ring 14 Engine coolant inlet pipe
15 Turbocharger 16 Turbocharger oil inlet pipe
17 Exhaust manifold heatshield 18 Oil separator
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