en-GB 2 668 173 Operator`s manual DC09 XPI Industrial engine

Important information
Serious risk of injury
When working on the engine, for example when adjusting drive belts and the clutch, or when changing the
oil, it is important not to start the engine. The engine could be damaged, but more importantly there is a
serious risk of injury.
For this reason, always secure the starting device or disconnect a battery cable before working on the engine.
This is especially important if the engine has a remote starter or automatic starting.
WARNING!
This warning symbol and text can be found next to those maintenance items where it is particularly important to bear in mind the risk of injury.
Operator's manual
DC09 XPI Industrial engine
en-GB 2 668 173
Issue 5.1
IMPORTANT!
The owner is responsible for making sure that maintenance is carried out on time and in accordance with
the instructions.
The owner must entrust the maintenance, renewal and repair of emission-related components and systems
to a qualified workshop or person.
Start of warranty . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power classes . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Environment and safety . . . . . . . . . . . . . . . . . . 6
Environmental responsibility . . . . . . . . . . . . . 6
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Warnings and advisories . . . . . . . . . . . . . . . . . 7
Scania engines engine warranty for industrial
engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Emission control systems warranty. . . . . . . . 12
Emission control system warranty statement 12
California emission control warranty statement
16
Your warranty rights and obligations . . . . . . 16
Manufacturer's warranty coverage . . . . . . . . 16
Owner's warranty responsibilities . . . . . . . . . 16
SCR catalytic converter . . . . . . . . . . . . . . . . . 17
Engine data plate . . . . . . . . . . . . . . . . . . . . . . . 19
Component identification . . . . . . . . . . . . . . . . 20
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Starting and running . . . . . . . . . . . . . . . . . . . . 22
Checks before first start . . . . . . . . . . . . . . . . 22
Checks before running . . . . . . . . . . . . . . . . . 23
Starting the engine . . . . . . . . . . . . . . . . . . . . 24
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine shutdown. . . . . . . . . . . . . . . . . . . . . . 28
Checks after running . . . . . . . . . . . . . . . . . . . 28
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cleaning the engine. . . . . . . . . . . . . . . . . . . . 30
Maintenance intervals . . . . . . . . . . . . . . . . . . 31
Lubrication system . . . . . . . . . . . . . . . . . . . . . 32
Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Checking oil level . . . . . . . . . . . . . . . . . . . . . 35
Maximum angles of inclination during operation
35
Changing the oil . . . . . . . . . . . . . . . . . . . . . . 36
Cleaning the centrifugal oil cleaner . . . . . . . 37
Operational testing of the centrifugal oil cleaner
41
Renewing the oil filter. . . . . . . . . . . . . . . . . . 42
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Reading the vacuum indicator. . . . . . . . . . . . 43
Renewing the air cleaner filter element and safety cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 45
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Checking coolant level . . . . . . . . . . . . . . . . . 50
Checking coolant antifreeze and corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Changing the coolant and cleaning the cooling
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system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Cleanliness requirements . . . . . . . . . . . . . . . .58
Checking fuel level . . . . . . . . . . . . . . . . . . . .58
Renewing the fuel filters . . . . . . . . . . . . . . . .59
Bleeding the fuel system . . . . . . . . . . . . . . . .64
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . .66
Checking the drive belt . . . . . . . . . . . . . . . . .66
Checking for leaks . . . . . . . . . . . . . . . . . . . . .67
Checking and adjusting the valve clearance .68
Renewing the reductant filter . . . . . . . . . . . . .71
Cleaning the reductant tank filler filter . . . . .74
Cleaning the reductant tank ventilation filter.74
Cleaning the reductant tank . . . . . . . . . . . . . .75
Quality requirements for fuel . . . . . . . . . . . . .76
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Biodiesel (FAME) . . . . . . . . . . . . . . . . . . . . .78
Reductant for SCR . . . . . . . . . . . . . . . . . . . . . .79
Preparing the engine for storage . . . . . . . . . . .80
Preservative products . . . . . . . . . . . . . . . . . . .80
Preparations for storage . . . . . . . . . . . . . . . . .81
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . .83
General data . . . . . . . . . . . . . . . . . . . . . . . . . .83
Lubrication system . . . . . . . . . . . . . . . . . . . . .83
Intake system . . . . . . . . . . . . . . . . . . . . . . . . .84
Cooling system. . . . . . . . . . . . . . . . . . . . . . . .84
Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . .84
Electrical system . . . . . . . . . . . . . . . . . . . . . .84
Scania Assistance . . . . . . . . . . . . . . . . . . . . . . .85
General tightening torques for screw joints . .86
Hexagon screws, hexagon socket screws, Torx
screws, hexagon nuts . . . . . . . . . . . . . . . . . . .86
Flange screws with hexagonal head and hexagonal flange nuts . . . . . . . . . . . . . . . . . . . . . . . .86
Hose clamps . . . . . . . . . . . . . . . . . . . . . . . . . .87
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Start of warranty
Start of warranty
The more we know about you, your company and your equipment, the more effectively we can adapt our
services to you. If you have started to use a new Scania engine, it is very important that you send in the warranty start report to us immediately. Quite simply, we need to register all the details on engine ownership
etc., so we can monitor it for you.
You 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 below the details you enter in the warranty report. These details can facilitate contact with a
workshop, for example. The engine serial number is on the engine data plate and is also engraved on the
cylinder block.
Engine serial number (e.g. 1111111)
Ship ID (for example MMSI 111111111 or IMO 1111111)
Start date (yyyy-mm-dd)
Company name
Contact person
Telephone number
E-mail address
Address
Post code
Postal town
State/County
Country
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Introduction
Introduction
Certification
This Operator's manual describes the operation
and maintenance of Scania industrial engines.
IMPORTANT!
The engines are direct-injection, liquid-cooled,
four-stroke turbocharged diesel engines. Certain
engines are also equipped with an SCR system
for emission control.
For Scania to guarantee that the engine corresponds to its certified configuration, and take responsibility for any damage and injuries that
occur, maintenance must be carried out in accordance with the instructions in this Operator's
manual.
The engines are available with different output
and engine speed settings. Engine power for the
engine ordered is indicated on a plate located on
the engine control unit.
An emissions certified engine fulfils the emissions requirements for a particular range of application.
Note:
Only standard components are described in the
operator's manual. Information about special
equipment is contained in instructions from the
various manufacturers.
On each emissions certified engine there is a label which shows which requirements the engine
fulfils. Scania guarantees that each such engine
fulfils the emissions requirements for the range
of application for which it is certified.
To ensure the maximum performance and the
longest service life for the engine remember the
following:
The following are required for the certified engine to fulfil the emissions requirements once it
has been taken into service:
• Read through the Operator's manual before
starting to use the engine. Even regular users
of Scania engines will get new information
from the Operator's manual.
• Always follow the maintenance instructions.
• Read the section on safety carefully.
• Get to know your engine so that you know
what it can do and how it works.
• Always contact a workshop with qualified
personnel for maintenance and repair.
• Maintenance is to be carried out in accordance with the instructions in this Operator's
manual.
• Maintenance and repairs of injection equipment are to be carried out by an authorised
Scania workshop.
• The engine may only be modified with equipment that has been approved by Scania.
• Seals may be broken and setting data edited
only once approval has been granted by Scania. Modifications may be made by authorised personnel only.
• Modifications affecting the exhaust and intake systems must be approved by Scania.
The information in this Operator's manual was
correct at the time of going to press. Scania reserves the right to make alterations without prior
notice.
Otherwise, the instructions in the Operator's
manual for the running and maintenance of the
engine shall apply. Follow the safety precautions
on the following pages.
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Power classes
Power classes
Scania supplies engines in 4 different power classes:
ICFN, Continuous service: Intended for continual use and an unlimited number of operational hours per
year at a total load factor of 100%.
IFN, Intermittent service: Intended for periodic use, where the rated power is available for one hour per
three-hour period. The total load factor must not exceed 80% of the rated power. Unlimited number of operational hours per year.
PRP, Prime power: Intended for continual use and an unlimited number of operational hours with varying
loads. The average load factor must not exceed 70% of the rated power in a 24-hour period. Accumulated
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
operational hours.
The engine serial numbers and power classes for the engines that are used in this installation should be listed
below: You can find the power class of your engine in the engine type data sheet on the Scania website,
www.scania.com.
Engine serial no.:
Engine type:
Engine power:
kW at
ICFN, Continuous service
IFN, Intermittent service
PRP, Prime power
COP, Continuous Power
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rpm
Environment and safety
Environment and safety
Different types of advisory
Warning!
Environmental responsibility
All advisories preceded by Warning! are very
important. They warn of serious faults and incorrect operation that could lead to personal injury.
Example:
Scania develops and produces engines that are as
environmentally-friendly as possible. Scania has
made major investments in the reduction of
harmful exhaust emissions in order to fulfil the
environmental requirements in force in almost
every market.
WARNING!
At the same time, we have been able to maintain
a high level of performance and operating economy for Scania engines. To maintain these
throughout the entire service life of the engine, it
is important for the user to follow the instructions on running, maintenance and fuel, lubricating oil and coolant as outlined in the Operator's
manual.
Block the starting device when working on the
engine. If the engine starts unexpectedly, there is
a serious risk of injury.
Important!
Advisories preceded by Important! warn of
faults and incorrect operation that could lead to
equipment being damaged. Example:
Other green initiatives taken include ensuring
that, following maintenance and repair, waste
that is harmful to the environment (for example
oil, fuel, coolant, filters and batteries) is disposed
of accordance with the applicable environmental
requirements.
IMPORTANT!
An excessive coolant temperature can cause engine damage.
Safety
Note:
The following pages contain a summary of the
safety precautions to be complied with when operating and maintaining Scania engines. The
equivalent text can also be found under the relevant maintenance item.
Advisories preceded by Note: refer to information important to ensure the best possible operation and functionality. Example:
Note:
Leave the engine off for at least 7 minutes before
you check the oil level.
To prevent damage to the engine and to ensure
that it runs optimally, follow the instructions in
the warnings and advisories.
If the instructions are not followed, the warranty
can cease to apply.
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Environment and safety
Fuel
Environment
This Operator’s Manual contains specially highlighted text with instructions to help protect the
environment during maintenance. Example:
WARNING!
The wrong fuel grade can cause breakdowns or
stoppages by causing the injection system to
malfunction. This can cause damage to the engine and, possibly, personal injury.
Environment
Use a suitable container. The fuel collected must
be disposed of as specified in national and international laws and regulations.
REQUIREMENT!
Use only fuel which fulfils the requirements in
the Quality requirements for fuel section.
Warnings and advisories
Smoking
Refuelling
WARNING!
WARNING!
Smoking is prohibited
During refuelling there is a risk of fire and explosion. The engine must be switched off and smoking is prohibited.
• in the vicinity of flammable or explosive material, e.g. fuel, oils, batteries, chemicals
• when refuelling and in the vicinity of the filling station
• when working on the fuel system
Never overfill the tank as the fuel needs space to
expand. Make sure that the filler cap is fully
closed.
Safety precautions for running the
engine
Hazardous gases
WARNING!
Daily maintenance
Always carry out a visual inspection of the engine and engine compartment before starting the
engine or when the engine has been switched off
after operation.
Only start the engine in a well-ventilated area.
The exhaust gases contain carbon monoxide and
nitrogen oxides, which are toxic.
This inspection should be done to detect fuel, oil
or coolant leaks, or anything else that may require corrective action.
When the engine is run in an enclosed space,
there must be an effective device to extract exhaust gases and crankcase gases.
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Environment and safety
Safety precautions for handling materials
Starter lock
IMPORTANT!
Fuel and lubricating oil
If the instrument panel is not fitted with a starter
lock, the engine compartment should be locked
to prevent unauthorised personnel from starting
the engine. Alternatively, a lockable master
switch or battery master switch can be used.
WARNING!
All fuels and lubricants as well as many chemicals are flammable. Always follow the instructions on the relevant packaging.
The work must be carried out on a cold engine.
Fuel leaks and spillage on hot surfaces can cause
fire.
Starter gas
WARNING!
Store used rags and other flammable materials
safely so as to avoid spontaneous combustion.
Never use starter gas or similar agents to help
start the engine. This can cause an explosion in
the intake manifold and possible injury.
Batteries
Running
WARNING!
The batteries contain and form oxyhydrogen gas,
particularly during charging. Oxyhydrogen gas
is flammable and highly explosive.
WARNING!
The engine must not be run in environments
where there is a risk of explosion, as all of the
electrical or mechanical components can generate sparks.
There must be no smoking, naked flames or
sparks near the batteries or the battery compartment. Incorrect connection of a battery cable or
jump lead can cause a spark, which can cause the
battery to explode.
Approaching a running engine always poses a
safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts such as the
fan and cause injury. For personal safety all rotating parts and hot surfaces must be fitted with
guards.
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Environment and safety
Chemicals
REQUIREMENT!
WARNING!
Use only reductant which fulfils the requirements in the Reductant for SCR section.
Most chemicals such as glycol, anti-corrosive
agents, preservative oils and degreasing agents,
are hazardous to health. Some chemicals are also
flammable: preservative oil, for example. Always follow the safety precautions on the packaging.
Safety precautions for maintenance
Switch off the engine
Store chemicals and other materials which are
hazardous to health in approved and clearly
marked containers, where they are inaccessible
to unauthorised persons.
WARNING!
Working with a running engine always poses a
safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts and cause
injury.
Environment
Always switch off the engine before carrying out
maintenance, unless otherwise indicated.
Excess and used chemicals must be disposed of
as specified in national and international laws
and regulations.
Reductant
Make it impossible to start the engine: Remove
any starter key, or cut the power using the main
power switch or battery master switch and lock
them.
Reductant (AdBlue®, DEF, ARLA 32 eller
AUS 32) is used in the reductant tank on engines
equipped with an SCR system.
Fix a warning plate somewhere appropriate,
showing that work is being carried out on the engine.
The reductant is not toxic, but it is still important
to observe the following when working on the reductant circuit:
Hot surfaces and fluids
WARNING!
• If reductant comes in contact with the skin:
Wash with soap and plenty of water.
• If reductant splashes in the eyes: Rinse immediately using an eye bath and then seek medical attention.
• Change out of clothes which have spills on.
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There is always a risk of sustaining burns when
an engine is hot. Particularly hot parts are engine
manifolds, turbochargers, oil sumps, as well as
hot coolant and oil in pipes and hoses.
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Environment and safety
Fuel system
Lubrication system
WARNING!
WARNING!
Hot oil can cause burns and skin irritation. Wear
protective gloves and goggles when changing
hot oil.
Maintenance and repairs of injection equipment
are to be carried out by an authorised Scania
workshop.
Make sure that there is no pressure in the lubrication system before starting work on it.
Always use Scania spare parts for the fuel and
electrical systems. Scania spare parts are designed to minimise the risk of fire and explosion.
Make sure that the oil filler cover is fitted when
starting and running in order to avoid oil escaping.
Environment
Use a suitable container. The fuel collected must
be disposed of as specified in national and international laws and regulations.
Environment
Used oil must be disposed of as specified in national and international laws and regulations.
SCR system
Cooling system
IMPORTANT!
WARNING!
Cleanliness is very important when working on
the reductant circuit. Clean thoroughly around
all parts to be dismantled to prevent dirt from entering the system.
Never open the coolant filler cap when the engine is hot. Hot coolant and steam may spray out
and cause burns. If the cap has to be opened do it
slowly to release the pressure before removing
the cap. Wear protective gloves as the coolant is
still very hot.
When working on the SCR system, the reductant
connections may only be lubricated with soapy
water or with distilled water with a 3% urea mixture. Any other types of lubricants may block
and damage the components in the SCR system.
Avoid skin contact with coolant as this may
cause irritation to the skin. Wear protective goggles and gloves when handling coolant.
Reductant causes certain metals to corrode. Always rinse away reductant spillage on connections and other parts with lukewarm water to
prevent corrosion. If reductant seeps into electrical connections or electrical cables, these must
be renewed.
Ethylene glycol can be fatal if ingested.
Environment
Used coolant must be disposed of as specified in
national and international laws and regulations.
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Environment and safety
Electrical system
Batteries
WARNING!
WARNING!
Switch off the engine and switch off the power
by disconnecting the electrical cables to the battery. External power supplies to extra equipment
on the engine must also be disconnected.
The batteries contain highly corrosive sulphuric
acid. Take care to protect your eyes, skin and
clothes when charging or handling batteries.
Wear protective gloves and goggles.
Always use Scania spare parts for the fuel and
electrical systems. Scania spare parts are designed to minimise the risk of fire and explosion.
If sulphuric acid comes in contact with the skin:
Wash with soap and plenty of water. If it gets in
your eyes: Rinse immediately with plenty of water and seek medical attention.
Electric welding
Environment
WARNING!
Used batteries must be disposed of as specified
in national and international laws and regulations.
When carrying out welding work on and near the
engine, disconnect the battery and alternator
leads. Pull out the multi-pin connector for the engine control unit as well.
Before starting
Connect the welding clamp close to the component to be welded. The welding clamp must not
be connected to the engine, or so that the current
can cross a bearing.
WARNING!
Ensure that all guards are in place before starting
the engine. Ensure that no tools or other objects
have been left on the engine.
When welding is finished:
1. Connect the alternator and engine control
The air filter must be fitted before starting the engine. Otherwise there is a risk of objects being
sucked into the compressor impeller or of injury
if you come into contact with the air filter.
unit cables.
2. Connect the batteries.
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Scania engines engine warranty for industrial engines
Scania engines engine warranty for industrial engines
in the engine manufacturer's application for
certification.
Where a warrantable condition exists, Scania
will repair your heavy-duty off-road engine at no
cost to You including diagnosis, parts, and labor.
Emission control systems
warranty
IMPORTANT!
Warranty period
Only applicable to engines used in the U.S.A.
Table of Contents
General warranty provisions
Warranty period
Parts covered by the Warranty
General warranty limitations
Specific warranty exclusions
Customer support
This warranty shall apply for one of the following periods, whichever occurs first:
• 3,000 hours of operation as determined by a
device to measure hours of use, or
• Five years
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12
13
14
15
15
Each engine is equipped with a device to measure hours of use. If that device fails to account for
hours of use due to defects in materials or workmanship, the engine shall be warranted for a period of five years. The warranty period shall
begin on the date the engine is delivered to the
first ultimate purchaser who, in good faith, purchases the engine for purposes other than imminent resale.
Emission control system warranty statement
The Warranty on emission-related
parts shall be interpreted as follows:
General warranty provisions
1. Any warranted part which is not scheduled
The emission control systems of your new Scania Engines (“Scania”) industrial diesel engine
were designed, built and tested using genuine
parts, and were certified as being in conformity
with federal emission control regulations. Scania
warrants to the original owner, and to each subsequent owner, of a new Scania industrial diesel
engine (“You”) that the engine:
for replacement as required maintenance in
Scania's written instructions for maintenance
and use of the engine by owner shall be warranted for the warranty period defined above.
If any such part fails during the period of
warranty coverage, it shall be repaired or replaced by the engine manufacturer according
to Subsection (4) below. Any such part repaired or replaced under the Warranty shall
be warranted for the remaining warranty period.
2. Any warranted part which is scheduled only
for regular inspection in Scania's written instructions for maintenance and use of the engine by owner shall be warranted for the
warranty period defined above. A statement
in such written instructions to the effect of
“repair or replace as necessary” shall not reduce the period of warranty coverage. Any
such part repaired or replaced under warranty shall be warranted for the remaining warranty period.
1. Was designed, built and equipped so as to
conform at the time of sale with all applicable regulations under Section 213 of the
Clean Air Act, 42 U.S.C. § 7547, for their
full useful life and designed, built and
equipped so as to conform with all applicable
regulations adopted by the California Air Resources Board pursuant to its authority under
Chapters 1 and 2, Part 5, Division 26 of the
California Health and Safety Code, and;
2. Is free from defects in material and workmanship which would cause such engine to
fail to conform to applicable regulations for
its warranty period or otherwise cause the
failure of a warranted part to be identical in
all material respects to the part as described
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Scania engines engine warranty for industrial engines
3. Any warranted part which is scheduled for
shall not be liable under this article to warrant failures of warranted parts caused by the
use of a non-exempted add-on or modified
part.
11. The Executive Officer of the California Air
Resources Board may request, and in such
case, the engine manufacturer shall provide,
any documents which describe that manufacturer's warranty procedures or policies.
replacement as required maintenance in Scania's written instructions for maintenance
and use of the engine by owner shall be warranted for the period of time prior to the first
scheduled replacement point for that part. If
the part fails prior to the first scheduled replacement, the part shall be repaired or replaced by the engine manufacturer according
to Subsection (4) below. Any such part repaired or replaced under warranty shall be
warranted for the remainder of the period
prior to the first scheduled replacement point
for the part.
4. Repair or replacement of any warranted part
under the warranty provisions of this article
shall be performed at no charge to the owner
at a warranty station.
5. Notwithstanding the provisions of Subsection (4) above, warranty services or repairs
shall be provided at all manufacturer distribution centers that are franchised to serve the
subject engines.
6. The owner shall not be charged for diagnostic labor that leadsto the determination that a
warranted part is in fact defective, provided
that such diagnostic work is performed at a
warranty station.
7. The engine manufacturer shall be liable for
damages to other engine components proximately caused by a failure under warranty of
any warranted part.
8. Throughout the engine's warranty period defined above, the engine manufacturer shall
maintain a supply of warranted parts sufficient to meet the expected demand for such
parts.
9. Any replacement part, as defined in Section
1900(b), Title 13 of the California Code of
Regulations, may be used in the performance
of any maintenance or repairs and must be
provided without charge to the owner. It is
not necessary for replacement parts to be the
same brand or by the same manufacturer as
the original part sold with the engine. Such
use shall not reduce the warranty obligations
of the engine manufacturer.
10. Add-on or modified parts, as defined in Section 1900(b), Title 13 of the California Code
of Regulations, that are not exempted by the
California Air Resources Board may not be
used. The use of any non-exempted add-on
or modified parts shall be grounds for disallowing a warranty claim made in accordance
with this article. The engine manufacturer
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Parts covered by the Warranty
The following is a list of parts considered to be
part of the Emission Control Systems covered by
the Emission Warranty for Scania industrial engines which were built to conform to federal and
California emission control regulations:
1. Fuel injection system.
2. Air induction system.
3. Exhaust manifold system.
4. Smoke puff limiter (included in ECU).
5. Oil filler cap.
6. EGR system (when applicable):
a) Cooler.
b) EGR valve.
7. Exhaust brake (when applicable).
8. NOx sensors:
a) NOx sensor, engine out.
b) NOx sensor, tail pipe.
9. DOC (when applicable).
10. SCR system:
a) DEF tank.
b) DEF tank level, temperature and quality
sensors.
c) DEF hose.
d) DEF injector.
e) DEF injector pressure and temperature
sensors.
f) Evaporator.
g) SCR catalyst inlet temperature sensor.
h) SCR catalyst including the ammonia-slip
catalyst.
i) SCR control unit (EEC3).
13
© Scania CV AB 2017, Sweden
Scania engines engine warranty for industrial engines
11. Miscellaneous items used in the above sys-
Receipts covering the performance of regular
maintenance should be retained in the event
questions arise concerning maintenance. The receipts should be transferred to each subsequent
owner of the engine with the emission warranted
engine. Scania cannot, however, deny warranty
solely for the lack of receipts or for your failure
to ensure the performance of all scheduled maintenance.
tem:
a) Electronic control unit (ECU), sensors,
wiring harnesses.
b) Hoses, belts, connectors, assemblies,
clamps, fittings tubing, sealing gaskets or
devices and mounting hardware.
c) Pulleys, belts and idlers.
d) Emission control information label.
The Warranty covers the cost of diagnosis, repair
and replacement parts and services of warranted
components and systems performed by an authorized Scania distributor or dealer using genuine Scania parts. You may elect to have
maintenance, replacement or repair of these
components and systems performed by any repair establishment or individual without invalidating the Warranty.
IMPORTANT!
This list does not include all expendable maintenance parts.
• Expendable emission related parts requiring
scheduled maintenance are warranted until
their first scheduled replacement point.
• Emission related parts scheduled for inspection and replacement only as necessary are
not considered expendable and if repaired or
replaced under warranty shall be warranted
for the remaining warranty period.
The use of other than Scania replacement parts
also does not invalidate the warranty on other
components unless such parts cause damage to
warranted parts. However, the cost of such services or parts will not be covered by the Warranty.
See Specific Warranty Exclusions below.
You are responsible for initiating the warranty
process. The California Air Resources Board
suggests that You present your heavy-duty offroad engine to an authorized Scania dealer as
soon as a problem exists. The warranty repairs
should be completed by the dealer as expeditiously as possible.
General warranty limitations
To retain the dependability of the exhaust emission control originally built into your Scania industrial diesel engine, it is essential that the
engine is installed according to Scania installation instructions and emission certificates. Your
engine is designed to operate on diesel fuel only.
Use of any other fuel may result in your engine
no longer operating in compliance with state or
federal emissions requirements. The use of alternative fuels shall not void the warranties on any
engine certified to use such fuel.
WARNING!
Use of replacement parts which are not of equivalent quality may impair the effectiveness of
emission control systems. Accordingly, it is recommended that only Scania repair or replacement parts be used for maintenance, repair or
replacement of emission control systems.
In addition, as the engine owner, You are responsible for the performance of all scheduled maintenance listed in your owner's manual, and all
necessary repairs, on your new Scania industrial
diesel engine. Scania may deny a warranty claim
if the engine or part has failed due to abuse, neglect, improper maintenance or unapproved
modifications.
OPM 100 en-GB
If other than Scania parts are used for maintenance, repair or replacement, the owner should
obtain assurance that such parts are warranted by
their manufacturer to be equivalent to genuine
Scania parts.
14
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Scania engines engine warranty for industrial engines
Specific warranty exclusions
Customer support
This warranty does not cover:
In the event that You do not receive the warranty
service to which You believe You are entitled
under the Warranty, or if You need additional
support or information concerning the Warranty,
please contact:
1. Malfunctions in any part caused by any of
the following: misuse, abuse, improper adjustments, modifications, alteration, tampering, disconnection, improper or inadequate
maintenance, or use of fuels not recommended for the engine as described in the Operator's Manual.
2. Engine installation, including cooling system, intake system and exhaust system installation, that is not completed in
accordance with the Scania installation instructions and emissions certificate for this
engine type.
3. Damage resulting from accidents, acts of nature or other events beyond the control of
Scania.
4. The replacement of expendable maintenance
items such as filters, hoses, belts, oil, thermostat, exhaust system and coolant made in
connection with scheduled maintenance services once these parts have been replaced.
5. Replacement items which are not genuine
Scania parts or not authorized by Scania.
6. Inconvenience, loss of use of the engine or
commercial loss.
7. Any engine on which the actual use cannot
be accurately determined due to a failure of
the device to track hours of use unrelated to
defects in materials or workmanship.
8. Any engine operating outside the United
States.
OPM 100 en-GB
Scania USA, Inc.
Address: 121 Interpark Blvd, suite 1002, 78216,
San Antonio, Texas
Mailing address: 121 Interpark Blvd, suite
1002, 78216, San Antonio, Texas
Telephone: +1 210 403 0007
Fax: +1 210 403 0211
E-mail: na.contact@scania.com
California customers shall also be furnished a
copy of the California Emission Control Warranty Statement applicable to each new Scania engine purchased.
15
© Scania CV AB 2017, Sweden
California emission control warranty statement
California emission control
warranty statement
Owner's warranty responsibilities
Your warranty rights and obligations
• As the off-road engine owner, you are responsible for the performance of the required
maintenance listed in your owner's manual.
Scania CV AB recommends that you retain
all receipts covering maintenance on your
off-road engine, but Scania CV AB cannot
deny warranty solely for the lack of receipts
or for your failure to ensure the performance
of all scheduled maintenance.
• As the off-road engine owner, you should
however be aware that Scania CV AB may
deny you warranty coverage if your off-road
engine or a part has failed due to abuse, neglect, improper maintenance or unapproved
modifications.
• Your engine is designed to operate on ultra
low-sulfur diesel fuel only. Use of any other
fuel may result in your engine no longer operating in compliance with California's emissions requirements.
• You are responsible for initiating the warranty process. The ARB suggests that you present your off-road engine to a Scania CV AB
dealer as soon as a problem exists. The warranty repairs should be completed by the
dealer as expeditiously as possible.
The California Air Resources Board is pleased to
explain the emission control system warranty on
your 2018 engine. In California, new heavy-duty
off-road engines must be designed, built and
equipped to meet the State's stringent anti-smog
standards. Scania CV AB must warrant the
emission control system on your engine for the
periods of time listed below provided there has
been no abuse, neglect or improper maintenance
of your engine.
Your emission control system may include parts
such as the fuel injection system and the air induction system. Also included may be hoses,
belts, connectors and other emission-related assemblies.
Where a warrantable condition exists,
Scania CV AB will repair your heavy-duty offroad engine at no cost to you including diagnosis, parts and labor.
Manufacturer's warranty coverage
If you have any questions regarding your warranty rights and responsibilities, you should contact Scania U.S.A. Inc +1-210-403-0007.
The 2018 heavy-duty off-road engines are warranted for a period of five years or 3,000 hours,
whichever occurs first. If any emission-related
part on your engine is defective, the part will be
repaired or replaced by Scania CV AB.
OPM 100 en-GB
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© Scania CV AB 2017, Sweden
SCR catalytic converter
SCR catalytic converter
Environmental protection measures
• The SCR catalytic converter is a manufactured article that contains vanadium pentoxide, a hazardous substance. Before disposing
of, or scrapping, a spent SCR catalytic converter, it should be tested for any hazardous
characteristics (ignitability, corrosivity, reactivity, acute hazardousness, and toxicity), as
those categories are described in 22 CCR §
66261.30. If the spent SCR catalytic converter exhibits hazardous characteristics and is
being disposed of, it will be considered by the
State of California to be a hazardous waste
subject to Title 22, California Code of Regulations. Before disposing of hazardous waste,
review and follow all pertinent federal and
California requirements.
• Vanadium pentoxide is a listed commercial
chemical product - P120 - pursuant to 22
CCR § 66261.33(e). According to the State of
California, commercial chemical products
that are discarded or intended to be discarded
are hazardous wastes and are subject to all
provisions of Title 22, California Code of
Regulations. Before disposing of vanadium
pentoxide, review and follow all pertinent
federal and California requirements.
• If the SCR catalytic converter is opened for
maintenance, any dust spillages from the catalyst should be collected and tested for the
presence of vanadium pentoxide prior to
proper disposal. Dust spillages should also be
tested for any hazardous characteristics (ignitability, corrosivity, reactivity, acute hazardousness, and toxicity), as those categories
are described in 22 CCR § 66261.30, prior to
proper disposal. If the dust contains either vanadium pentoxide or exhibits hazardous characteristics and is being disposed of, it will be
considered by the State of California to be a
hazardous waste subject to Title 22, California Code of Regulations. Before disposing of
hazardous waste, review and follow all pertinent federal and California requirements.
WARNING!
The SCR catalytic converter contains vanadium
pentoxide, a chemical known to the State of California to cause cancer.
The SCR catalytic converter is fitted in the silencer and does not constitute a health hazard
during normal use and handling.
When carrying out work on the SCR catalytic
converter which may result in exposure to dust,
safety precautions must be taken. Such work includes, for example, opening the silencer machining and scrapping the SCR catalytic
converter.
Safety precautions when working on the SCR
system.
• Inhalation: If dust is inhaled, the person
should be provided with fresh air immediately. Seek medical attention.
• Eye contact: Rinse eyes with water immediately. If irritation persists, seek medical attention.
• Skin contact: Wash with water and soap. Remove contaminated clothes.
• Ingestion: If large amounts have been ingested, drink plenty of water and induce vomiting. Seek medical attention
Environmental hazards
• Vanadium pentoxide is toxic to water organisms and can cause detrimental long term effects to water environment.
OPM 100 en-GB
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© Scania CV AB 2017, Sweden
SCR catalytic converter
• Do not dispose of the spent SCR catalytic
converter or its constituent parts into any waterways, storm drains or sanitary sewers.
• Any dust from the SCR catalytic converter
should be removed using a vacuum cleaner
with microfilter to minimize exposure.
• Make sure that the work surface is cleaned after completed work; Vacuum first then swab.
• Make sure you clean your hands after working with SCR catalytic converter to avoid ingestion.
• Work done on the SCR catalytic converter
may generate waste considered by the State
of California to be a hazardous waste subject
to Title 22, California Code of Regulations.
Before disposing of hazardous waste, review
and follow all pertinent federal and California
requirements.
WARNING!
The SCR catalytic converter contains vanadium
pentoxide, a chemical known to the State of California to cause cancer.
Additional considerations when working on the
SCR system
• Carry out work on the SCR catalytic converter in all well ventilated area. Use protective
goggles and gloves if there is any risk of
splashing or spraying of reductant or coolant.
• When engine is running, the exhaust system
parts can reach such high temperatures that
there is a risk of personal injury. Make sure
that the exhaust system temperature has decreased to a suitable level before starting to
work.
• The SCR system is heated by water from the
engine cooling system. The cooling system
runs at overpressure and when the engine is
hot the coolant is hot. Do not open any hoses
without first stopping the coolant flow in the
hose.
• A P3 type respirator/filter mask or a type
FFP3 fine dust musk, protective goggles and
gloves should be used for any work where
there is a risk of exposure to dust from the
SCR catalytic converter.
• Use a disposable overall and dispose of it
properly after machining.
• Eating, drinking or smoking while working is
not permitted.
OPM 100 en-GB
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© Scania CV AB 2017, Sweden
Engine data plate
Engine data plate
The engine data plate indicates, in the form of a
code, the engine type, its size and applications. It
also indicates the engine type power range and
the nominal engine speed. The engine EU type
approval for exhaust emissions is indicated under Output, where applicable.
The engine power is stated on a plate which is located on the engine control unit. The engine serial number is stamped onto the top of the cylinder
block at the front right.
OPM 100 en-GB
Made b y
Type
DC09 085A
Engine No
6950106
Output.
232-257
kW
2100
r pm.
348 325
Example: DC09 085A
DC
Supercharged diesel engine with aircooled charge air cooler.
09
Displacement in whole dm3.
085
Performance and certification code. The
code indicates, together with the application code, the normal gross engine output.
A
Code for application. A means for general
industrial use.
Example of an engine data plate.
19
© Scania CV AB 2017, Sweden
Component identification
Component identification
Engine
6
2
1
7
8
9
3
4
5
6
11 10
381 629
12
The illustration shows a normal version of a DC09 engine. The engine ordered may have different equipment.
1. Engine data plate.
2. Oil filter.
3. Engine number, stamped into the cylinder block.
4. Nipple for draining and filling coolant.
5. Centrifugal oil cleaner.
6. Oil filler.
7. Water separating prefilter for fuel.
8. Hand pump for fuel.
9. Fuel filter.
10. Oil dipstick.
11. Oil plug.
12. Engine control unit.
OPM 100 en-GB
20
© Scania CV AB 2017, Sweden
Component identification
SCR system
For engines equipped with SCR systems, the illustration shows an overview of the component
parts of the SCR system.
5
2
1
4
6
3
14
13
7
11
12
10
9
336 907
8
1. Evaporator
8. Coolant hose, return from tank and pump heating
2. Pressure line for reductant
9. NOx sensor with control unit1
3. Coolant hose for tank and pump heating
10. Oxidation catalytic converter1
4. Coolant valve
11. Exhaust gas temperature sensor
5. Reductant return line
12. SCR catalytic converter
6. Reductant tank
13. NOx sensor with control unit
7. Reductant pump and control unit
14. Reductant doser
1. DC09 084/384/085/385/086/386/087/387/089/389A only.
OPM 100 en-GB
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© Scania CV AB 2017, Sweden
Starting and running
Starting and running
1
Checks before first start
Before the engine is started for the first time, carry out the maintenance items listed under First
start in the maintenance schedule. Check the following:
•
•
•
•
•
•
•
Oil level.
Coolant.
Fuel level.
Fluid level in batteries.
State of battery charge.
Condition of the drive belt.
Level in the reductant tank, if the engine is
equipped with an SCR system.
2
See also Maintenance intervals.
IMPORTANT!
Running the engine without reductant in the reductant tank violates emissions legislation and
will damage the SCR system.
3
Reductant tank
Reductant tanks come in 5 different sizes. The
volumes indicated for each tank are filling volumes.
1. 38 litres (10 US gallons).
4
2. 60 litres (15.8 US gallons).
3. 45 litres (11.9 US gallons).
4. 63 litres (16.6 US gallons).
5. 70 litres (18.5 US gallons).
A filler filter with magnet is fitted in the reductant tank to prevent the reductant from becoming
contaminated when topping up. It is used when
refuelling at a filling station. A filler filter without a magnet is also supplied for use when filling
manually.
381 626
5
OPM 100 en-GB
22
© Scania CV AB 2017, Sweden
Starting and running
Reductant pump
When the reductant pump is new, the check
valves may need to be slackened.
IMPORTANT!
Blow the reductant pump suction nipple with
compressed air (approx. 6 bar/87 psi) for at least
3 seconds before starting the engine for the first
time.
336 838
Start the reductant pump immediately after the
reductant tank has been filled for the first time.
Reductant pump suction nipple.
Checks before running
Carry out daily maintenance as described in the
maintenance schedule prior to operation. See
Maintenance intervals.
OPM 100 en-GB
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© Scania CV AB 2017, Sweden
Starting and running
Starting the engine
Starting at low temperatures and at
high altitudes
WARNING!
Take the local environmental requirements into
account. Use a fuel heater and engine heater to
avoid starting problems and white smoke.
Never use starter gas or similar agents to help
start the engine. This can cause an explosion in
the intake manifold and possible injury.
Scania recommends that an engine heater should
be used if the engine will be used at temperatures
below -10°C (14°F) or at an altitude of more than
2,000 metres.
Only start the engine in a well ventilated area.
When the engine is run in an enclosed space,
there must be effective devices to extract exhaust
gases and crankcase gases.
A low engine speed and a moderate load on a
cold engine limits white smoke, gives better
combustion and warms up the engine more
quickly than warming it up with no load.
Avoid running it longer than necessary at idling
speed.
IMPORTANT!
The starter motor must only be cranked twice for
30 seconds at a time. After that, it must rest for at
least 5 minutes before the next attempt to start it.
Running
Check instruments and warning lamps at regular
intervals.
For environmental reasons the Scania engine has
been developed to be started with a low fuel feed.
Using unnecessarily large amounts of fuel when
starting the engine always results in emissions of
unburnt fuel.
Engine speed range
The engine operating speed range is between low
idling and the nominal engine speed. The nominal engine speed is indicated on the engine data
plate. Low idling can be set between 500 and 975
rpm.
1. Open the fuel cock if fitted.
2. Disengage the engine.
A slightly higher engine speed than the nominal
engine speed may occur at low or negative load.
3. If the engine has a battery master switch:
Switch on the power by means of the battery
master switch.
4. Start the engine.
Driving at high altitude
When driving at high altitudes engine power is
reduced automatically due to the lower oxygen
content in the air. It is then not possible to run the
engine at maximum power.
If the fuel tank has been run dry or if the engine
has not been used for a long time, bleed the fuel
system. See the section Bleeding the fuel system.
Note:
Driving at a higher height than 4,000 metres
above sea level is only permitted if it has first
been approved by Scania.
OPM 100 en-GB
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© Scania CV AB 2017, Sweden
Starting and running
Emission control
The system provides a warning if there are faults
on the SCR system or if the level of reductant in
the reductant tank is too low. In the case of some
faults, for example if doser cooling is not working, the torque is reduced.
Reaction at low reductant level
10%
0%
Warning
lamp
Constant
light
Flashing
Torque reduction1
Torque is reduced by
1% per minute to
70% of the highest
torque
Flashing rap- Torque is reduced to
idly
0% (low idling)
within 2-10 minutes
319 562
Reductant
level
20%
Symbol for low reductant level
1. Applies only to engines that are certified according to
Tier 4.
The engine resumes normal torque after reductant has been filled to a level of at least 20%.
Reaction to fault in SCR system
Time
Warning
lamp
Fault detect- Constant
ed
light
After 30
Flashing
minutes
Torque reduction1
319 563
Torque is reduced by
1% per minute to
70% of the highest
torque
After 4 hours Flashing rap- Torque is reduced to
idly
0% (low idling)
within 2-10 minutes
Symbol for fault in SCR system
1. Applies only to engines that are certified according to
Tier 4.
OPM 100 en-GB
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© Scania CV AB 2017, Sweden
Starting and running
Coolant temperature
Once the fault has been remedied and the engine
control unit has received an indication that it is
working, torque returns to the normal level.
IMPORTANT!
If a new fault occurs within 40 hours of operation since the first fault, the warning lamp will
come on. After 30 minutes of operation, the
warning lamp will flash rapidly and torque will
be reduced to 0% (low idling) within 30 minutes.
An excessive coolant temperature can cause engine damage.
Normal coolant temperature during operation is
90 to 95°C (194 to 203°F).
IMPORTANT!
The alarm levels are set in the engine control
unit. The default setting for the lowest and highest limit values for high coolant temperature are
95 °C (203 °F) and 105°C (221°F) respectively.
The following function is standard as alarm for
high coolant temperature:
If the torque has been reduced to 0% (low
idling), the control unit does not detect that the
SCR system is functioning again. A service technician must then reset the system so that the
torque returns to the normal level.
• Alarm and torque reduction at the lowest limit value.
Note:
The torque reduction applies only to engines that
are certified according to Tier 4. Some emergency vehicles do not have torque reduction.
Depending on the engine configuration, the following alarm functions may also be available:
• Alarm only.
• Alarm and engine shutdown at the highest
limit value.
• Alarm, torque reduction at the lowest limit
value and engine shutdown at the highest limit value.
• Alarm and engine shutdown at the highest
limit value with the possibility of engine shutdown override control.
• Alarm, torque reduction at the lowest limit
value and engine shutdown at the highest limit value, with the possibility of engine shutdown override control.
If run for extended periods under an extremely
light load, the engine may have difficulty in
maintaining the coolant temperature. At an increased load the coolant temperature rises to the
normal value.
OPM 100 en-GB
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© Scania CV AB 2017, Sweden
Starting and running
Oil pressure
Belt transmission
Normal oil pressure during operation is 3-6 bar
(43.5-87 psi). The lowest permitted oil pressure
when idling is 0.7 bar (10.2 psi).
When the belt transmission is new, it may make
a squeaking noise when running. The noise is
normal and disappears after 50-100 hours of operation. The noise does not affect the service life
of the belt transmission.
The engine management system issues an alarm
at the following levels:
• At an engine speed below 1,000 rpm and an
oil pressure below 0.7 bar (10.2 psi).
• At an engine speed above 1,000 rpm and an
oil pressure below 2.5 bar (36.3 psi) for
longer than 3 seconds.
Raised idling speed on engines with
SCR and EGR system
If the engine is run without load for an extended
period of time, the SCR system needs to be heated by raising the idling speed. The function is
called periodic hydrocarbon evaporation and is
used to avoid damaging the SCR catalytic converter.
The following function is standard as alarm for
incorrect oil pressure:
• Alarm and torque reduction by 30%.
Depending on the engine configuration, the following alarm functions may also be available:
Periodic hydrocarbon evaporation functions differently depending on how the engine is
equipped. A warning is output for all engines if
the engine needs to be warmed up. The warning
is output after approx. eight hours if the engine is
idling without load and the outdoor temperature
is 20°C (68°F). The time is reduced as the outdoor temperature becomes colder.
• Alarm only.
• Alarm and engine shutdown.
• Alarm and engine shutdown override control.
Note:
High oil pressure (above 6 bar/87 psi) is normal
if the engine is cold when started.
For some engines, a request for automatic raising
of the idling speed is also output after the warning. If the request is confirmed, the idling speed
is raised automatically. The function is active for
45 minutes or less and is deactivated automatically. If the request is not confirmed, the engine
is switched off after approx. 45 minutes, if the
engine has been configured with engine shutdown.
Charging indicator lamp
If the lamp comes on during operation: Check
and adjust the alternator drive belt according to
the instructions in the section Checking the drive
belt.
If the charging indicator lamp is still on, this
could be due to an alternator fault or a fault in the
electrical system.
OPM 100 en-GB
27
© Scania CV AB 2017, Sweden
Starting and running
Engine shutdown
Checks after running
IMPORTANT!
WARNING!
There is risk of post boiling and of damage to the
turbocharger if the engine is switched off without cooling. The power must not be switched off
before the engine has stopped.
Block the starting device when working on the
engine. If the engine starts unexpectedly, there is
a serious risk of injury.
There is always a risk of sustaining burns when
an engine is hot. Particularly hot parts are engine
manifolds, turbochargers, oil sumps, as well as
hot coolant and oil in pipes and hoses.
If the engine is equipped with a battery master
switch and an SCR system, the SCR system must
run for a while after the engine has been switched
off to allow it to cool down. During this period
the power must not be cut using the battery master switch.
IMPORTANT!
Note:
The battery voltage must remain on for a few
seconds after the 15 voltage is switched off so
that the control units can store the values and
switch to standby mode.
Check the coolant level following the first start.
Top up with coolant as necessary.
10 prohibited engine shutdowns will cause a
torque reduction (70% of fuel quantity). Reset
the engine by switching it off correctly once.
cap and the area round the filler opening are
clean to avoid contamination of the fuel.
3. If the engine is equipped with an SCR system: Top up the reductant tank. Make sure
that the filler cap and the area round the filler
opening are clean to avoid contamination of
the reductant.
4. If there is a risk of freezing, the cooling system must contain enough glycol. See the section Risk of freezing.
5. If the temperature is below 0°C (32°F): Prepare for the next start by connecting the engine heater (if fitted).
1. Check that the power supply has been cut.
2. Top up the fuel tank. Make sure that the filler
1. Run the engine without a load for a few min-
utes if it has been run continuously with a
heavy load.
2. Switch off the engine.
OPM 100 en-GB
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© Scania CV AB 2017, Sweden
Maintenance
Maintenance
IMPORTANT!
The maintenance programme covers a number of
points that are divided into the following sections:
•
•
•
•
•
On delivery a Scania engine is optimised for its
application. However, regular maintenance is
necessary to:
Lubrication system.
Air cleaner.
Cooling system.
Fuel system.
Other.
• prevent unplanned stops
• extend the service life of the engine
• maximise the long-term emission performance of the engine
• give the best possible operating economy.
WARNING!
Block the starting device when working on the
engine. If the engine starts unexpectedly, there is
a serious risk of injury.
There is always a risk of sustaining burns when
an engine is hot. Particularly hot parts are engine
manifolds, turbochargers, oil sumps, as well as
hot coolant and oil in pipes and hoses.
The maintenance programme includes the following:
• R maintenance: One event when taken into
service.
• S maintenance: Minimum basic maintenance.
• M maintenance: More extensive maintenance.
• L maintenance: Includes nearly all maintenance items in the form.
• XL maintenance: Includes all maintenance
items in the form.
During a period, the sequence is S-M-S-L-S-MS-L-S-M-S-XL.
XL
L
M
S
1000
1500
S
2000
2500
S
3000
3500
M
S
4000
4500
S
5000
5500
6000
313 153
500
S
L
M
OPM 100 en-GB
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© Scania CV AB 2017, Sweden
Maintenance
Cleaning the engine
WARNING!
Beware of hot washing water. Wear eye protection, protective clothes and protective gloves.
Environment
Dispose of the washing water in compliance with
relevant national or local regulations.
Wash the engine before relevant maintenance.
Clean the engine with hot water. Also use a degreasing agent, if necessary.
314 905
Do not spray water on the engine control unit,
which is marked in the illustration.
Clean within the marked area.
OPM 100 en-GB
30
© Scania CV AB 2017, Sweden
Maintenance
Maintenance intervals
Daily
Lubrication system
Checking oil level
Changing the oil
Cleaning the centrifugal oil
cleaner
Renewing the oil filter
Air cleaner
Reading the vacuum indicator
Renewing the filter element
Renewing the safety cartridge
Cooling system
Checking coolant level
Checking coolant antifreeze
and corrosion protection
Changing the coolant and
cleaning the cooling system
Fuel system
Checking fuel level
Renewing the fuel filters
Miscellaneous
Checking the drive belt
Checking for leaks
Checking and adjusting the
valve clearance
Renewing the reductant filter
Cleaning the reductant tank
filler filter
Cleaning the reductant tank
ventilation filter
OPM 100 en-GB
X
First time at
first start 500
R
X
X
X
X
Interval (hours)
At least
500 1,000 2,000 6,000 annual- every 5
ly
years
S
M
L
XL
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
31
© Scania CV AB 2017, Sweden
X
X
Lubrication system
Lubrication system
For operation at extremely low outdoor temperatures: Consult your nearest Scania representative
on how to avoid starting difficulties.
Oil grade
Scania LDF stands for the Scania Long Drain
Field test standard. Scania LDF oils have been
carefully selected after extensive testing. The approval is only granted to the highest quality engine oils available on the market.
Recommended engine oil
Scania Oil LDF-3
Scania Oil LDF-2
Scania Oil LDF
Scania Oil E7
The engine oil must fulfil the following quality
requirements:
• ACEA E5/API CI-4.
• ACEA E7/API CI-4 +.
• For engines not run on low-sulphur fuel, the
TBN (Total Base Number) should be at least
12 (ASTM D2896).
• Oils with a low ash content (ACEA E9/API
CJ4) are not recommended.
Viscosity
class
SAE 20W-30
SAE 30
SAE 40
SAE 50
SAE 5W-30
SAE 10W-30
SAE 15W-40
Outdoor temperature in °C
Viscosity
class
SAE 20W-30
SAE 30
SAE 40
SAE 50
SAE 5W-30
SAE 10W-30
SAE 15W-40
Outdoor temperature in °F
Check with your oil supplier that the oil meets
these requirements.
If the engine is used in areas of the world where
engine oil with ACEA or API classification is
not available, the oil grade must be measured in
actual operation. In this case contact the nearest
Scania workshop.
OPM 100 en-GB
32
© Scania CV AB 2017, Sweden
-15°C
-10°C
-5°C
0°C
< -40°C
-25°C
-20°C
5°F
14°F
23°F
32°F
< -40°F
-13°F
-4°F
-
-
+30°C
+30°C
+45°C
+45°C
+30°C
+30°C
+45°C
86°F
86°F
113°F
113°F
86°F
86°F
113°F
Lubrication system
Labels for filled engine oil grade
When changing oil it is important to use the correct engine oil grade. The oil filler cap must be
clearly marked with a label showing the filled oil
grade. However, there are only labels for oils
from Scania and oil grade ACEA E7.
336 492
Stick on a new label if the oil type or oil grade is
changed in favour of any of the oil types above.
Replace the label if it is missing.
353 114
Filling label in the cylinder block.
Filling label in the rocker cover.
If the oil grades below are used, it is possible to
order labels for the oil filler cap from Scania.
Oil grade
Colour
Scania LDF-3
Scania LDF-2
Scania LDF
ACEA E7
Red
Blue
Grey
White
OPM 100 en-GB
Part No.
Filling in the cylinder block
2 132 426
2 132 424
2 269 345
2 132 425
33
© Scania CV AB 2017, Sweden
Part No.
Filling in the rocker cover
2 296 066
2 296 064
2 296 071
2 296 065
Lubrication system
Oil analysis
To be able to extend the oil change intervals using an oil analysis, Scania LDF-3 and LDF-2 oils
must be used. Certain laboratories offer engine
oil analysis.
The following conditions must remain fulfilled
when the oil is changed:
• Viscosity at 100°C (212°F): max. ±20% of
original value of the fresh oil.
• TBN (in accordance with ASTM D4739): >
3.5.
• TBN (in accordance with ASTM D4739): >
TAN (in accordance with ASTM D664).
• Soot (DIN 51 452): < 3%.
Such analysis measures the oil's TBN (Total
Base Number), TAN (Total Acid Number), fuel
dilution, water content, viscosity and the quantity of particles and soot in the oil.
The result of a series of analyses is used as the
basis for establishing a suitable oil change interval.
If the conditions are changed, a new oil analysis
programme must be carried out to establish new
oil change intervals. Work out the new oil
change interval for the engine in conjunction
with the workshop.
Note:
Only Scania LDF oils may be used in conjunction with oil analysis and a possible extended oil
change interval.
Depending on the market, the warranty conditions may also change if the oil change intervals
differ from the recommended Scania timetable.
OPM 100 en-GB
34
© Scania CV AB 2017, Sweden
Lubrication system
Checking oil level
2
Note:
Leave the engine off for at least 7 minutes before
you check the oil level.
2
1
1. Remove the oil dipstick (1) and check the oil
381 873
level. The correct level is between the minimum and maximum marks on the oil dipstick.
2. Top up with more oil via the oil filler (2)
when the oil level is at or below the minimum mark.
For information on the correct oil type, see the
section Oil grade.
Maximum angles of inclination during operation
Maximum permissible angles of inclination during operation vary, depending on the type of oil
sump. See illustration.
30°
30°
30°
30°
25°
OPM 100 en-GB
35
© Scania CV AB 2017, Sweden
30°
30°
343 838
25°
Lubrication system
Changing the oil
WARNING!
Hot oil can cause burns and skin irritation. Wear
protective gloves and eye protection when
changing hot oil. Make sure that there is no pressure in the lubrication system before changing
the oil. The oil filler cap must always be in place
when starting and running the engine to prevent
oil being ejected.
314 600
Note:
Change oil more often if the engine is subjected
to particularly demanding operation, such as a
dusty environment, or if deposits in the centrifugal oil cleaner are thicker than 28 mm (1.1 in).
Oil volume for oil sump with deep front:
Renew the oil filter and clean the centrifugal oil
cleaner when changing oil.
Min. 31 litres (8.2 US gallons).
Max. 36 litres (9.5 US gallons).
Environment
Use a suitable container. Used oil must be disposed of as specified in national and international laws and regulations.
1. Unscrew the oil plug and drain the oil when
314 601
the engine is hot. In certain engine types the
oil is pumped out by means of a bilge pump.
If the engine is drained via the valve, the oil
should be hot. Alternatively, use a pump.
This so that draining occurs more quickly.
2. Wipe off the magnet on the oil plug.
3. Renew the gasket on the oil plug.
4. Refit the oil plug.
5. Fill with the amount of oil specified for the
oil sump.
6. Wait at least 7 minutes.
7. Check the level on the oil dipstick.
Oil capacity for low oil sump:
Min. 28 litres (7.4 US gallons).
Max. 35 litres (9.2 US gallons).
OPM 100 en-GB
36
© Scania CV AB 2017, Sweden
Lubrication system
Cleaning the centrifugal oil
cleaner
WARNING!
The oil may be hot. Carefully remove the cover
from the centrifugal oil cleaner.
Use eye protection and protective gloves when
working on the centrifugal oil cleaner.
When the centrifugal oil cleaner is cleaned, there
should be some 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, investigate the cause of this.
Renew the paper more frequently if the dirt deposits are thicker than 28 mm (1.1 inches) during
a scheduled oil change.
1. Clean the cover.
2. Unscrew the nut securing the outer cover.
3. Let the oil run out from the rotor.
x 1.5
4. Lift out the rotor. Wipe off the outside.
5. Undo the rotor nut and unscrew it about
1.5 turns.
133 315
Note:
Take care not to damage the rotor shaft.
OPM 100 en-GB
37
© Scania CV AB 2017, Sweden
Lubrication system
6. If the rotor nut is jammed: Turn the rotor up-
side down and fasten the rotor nut in a vice.
See illustration.
7. Use protective jaws so as not to damage the
grooves of the rotor nut.
8. Turn the rotor 1.5 turns anti-clockwise.
9. If this does not work: Screw two nuts together with an M20 screw.
10. Position 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.
M20
x 1.5
IMPORTANT!
Do not attach the rotor directly to the vice. Never
strike the rotor cover.
12. Remove the rotor cover by holding the rotor
in both hands and tapping the rotor nut
against the table. Never strike the rotor directly as this may damage its bearings.
13. Remove the strainer from the rotor cover. If
133 317
the strainer is stuck, insert a screwdriver between the rotor cover and strainer and carefully prise them apart.
OPM 100 en-GB
38
© Scania CV AB 2017, Sweden
Lubrication system
14. Remove the paper insert.
15. Scrape off any remaining dirt deposits from
333 044
the inside of the rotor cover. If the deposits
on the paper are thicker than 28 mm (1.1 in),
the centrifugal oil cleaner must be cleaned
more often.
16. Wash the parts according to the applicable
333 037
industrial method.
17. Inspect the 2 nozzles on the rotor. Ensure that
they are not blocked or damaged.
Renew any damaged nozzles.
18. Check that the bearings are undamaged.
Renew damaged bearings.
1
19. Fold and fit a new paper insert on the inside
of the rotor cover as illustrated.
3
4
387 437
2
OPM 100 en-GB
39
© Scania CV AB 2017, Sweden
Lubrication system
20. Fit the strainer onto the rotor.
21. Fit a new O-ring to the foot of the centrifugal
oil cleaner.
22. 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 workshop with qualified personnel
if the rotor shaft needs to be renewed.
Note:
Take care not to damage the rotor shaft.
25. Refit the rotor and rotate it by hand to make
127 882
sure it rotates easily.
OPM 100 en-GB
40
© Scania CV AB 2017, Sweden
Lubrication system
26. Fit a new O-ring in the cover.
27. Refit the cover and tighten the lock nut.
Tightening torque 20 Nm (15 lb-ft).
IMPORTANT!
333 043
To reduce the risk of oil leakage it is important to
tighten the cover to the correct tightening torque.
Operational testing of the
centrifugal oil cleaner
Operational testing need only be carried out if it
is suspected that the centrifugal oil cleaner is
malfunctioning. For example, if there are unusually few deposits given the distance driven.
1. Run the engine until it reaches normal oper-
OPM 100 en-GB
333 039
ating temperature.
2. Stop the engine and listen for noise coming
from the rotor. It should continue rotating for
a time, even when the engine has stopped.
3. Use your hand to feel if the filter housing is
vibrating.
4. If the filter housing is not vibrating, dismantle and check the centrifugal oil cleaner.
41
© Scania CV AB 2017, Sweden
Lubrication system
Renewing the oil filter
Tool
Illustration
118 268
Description
Hexagon socket, drive
1/2", 36 mm
1. Unscrew the filter cover using the socket.
IMPORTANT!
150 318
Do not use an adjustable spanner or other open
tool, as there is a risk of damaging the filter cover.
2. Lift out the filter housing cover with filter el-
150 319
ement. The filter housing will drain automatically once the filter has been removed.
3. Detach the old filter from the cover by holding the cover and carefully tapping the entire
filter element against something hard. Remember that there will be oil splashes.
4. Fit the new filter and tighten the filter cover
to 25 Nm (18 lb/ft).
OPM 100 en-GB
42
© Scania CV AB 2017, Sweden
Air cleaner
Air cleaner
WARNING!
3
Never start the engine without the air filter in position. Without the air filter, there is a risk of dirt
being sucked into the engine.
2
The engine turbocharger will continue to rotate
and take in air for a time, even after the engine
has stopped. Therefore, wait for a few minutes
before opening the air cleaner.
1
IMPORTANT!
4
Renew the filter element earlier than the maintenance interval if the vacuum indicator shows red.
The filter element must not be cleaned in water
or be blown clean with compressed air. There is
always a risk that the filter element will be damaged when it is cleaned.
385 833
5
Air cleaner with safety cartridge.
1.
2.
3.
4.
5.
Filter element.
O-ring.
Vacuum indicator.
Safety cartridge.
Cover.
2
1
If the vacuum indicator's red plunger is fully visible, renew the air cleaner filter element in accordance with the following section.
4
Air cleaner without safety cartridge.
1.
2.
3.
4.
OPM 100 en-GB
Filter element.
Vacuum indicator.
O-ring.
Cover.
43
© Scania CV AB 2017, Sweden
3
385 832
Reading the vacuum indicator
Air cleaner
Renewing the air cleaner filter
element and safety cartridge
1. Remove the cover from the air cleaner.
2. Renew the filter element.
3. If the air cleaner has a safety cartridge: Re-
326 671
move the safety cartridge and fit a new one.
4. Insert a torch into the filter element and
check that the filter paper is free of holes and
cracks.
5. Renew the O-ring if it is damaged or hard.
6. Assemble the air cleaner.
7. Ensure that the O-ring is not outside the edges.
8. Reset the vacuum indicator by pressing in
the button marked in the illustration.
OPM 100 en-GB
44
© Scania CV AB 2017, Sweden
Cooling system
Cooling system
Antifreeze and corrosion inhibitor
The antifreeze and corrosion protection used in
Scania engines should be antifreeze (ethylene
glycol) and corrosion inhibitor.
Coolant
Note:
The coolant should be changed when the cooling
system is cleaned: every 6,000 hours or at least
every 5 years. See Changing the coolant and
cleaning the cooling system.
Only Scania coolant or another product with
functioning antifreeze and corrosion protection
may be used in Scania engines. Products not fulfilling the demands in this section may lead to
faults and damage occurring in the cooling system. This can lead to the invalidation of Scania's
warranty for faults and damage caused by the use
of inappropriate coolant.
The coolant recommended by Scania is a mixture of water with antifreeze (ethylene glycol)
and corrosion inhibitor. The coolant has several
characteristics which are important for the operation of the cooling system:
Addition of antifreeze and corrosion
inhibitor to water
The coolant should contain 35-55% by volume
antifreeze (ethylene glycol) and corrosion inhibitor. The percentage varies depending on the
need for antifreeze.
• Corrosion inhibitor.
• Antifreeze.
• Increases the boiling point.
A minimum of 35% by volume of Scania antifreeze and corrosion inhibitor is needed to provide sufficient protection against corrosion.
Water
Use only pure fresh water that is free from particles, sludge and other impurities. If there is uncertainty about the quality of the water, Scania
recommends use of Scania ready-mixed coolants. See the section Recommended Scania products.
Note:
Too high a dose of antifreeze and corrosion inhibitor will increase the amount of sludge and
blockages accumulating in the radiator. Too low
a concentration can lead to corrosion of the cooling system and ice formation at low temperatures.
Measure the ethylene glycol content (antifreeze
and corrosion protection) with a refractometer
following the instructions in the Checking coolant antifreeze and corrosion protection section.
OPM 100 en-GB
45
© Scania CV AB 2017, Sweden
Cooling system
Risk of freezing
IMPORTANT!
The engine should not be subjected to heavy
loads when ice starts to build up in the cooling
system.
As the coolant starts to freeze, the water in the
coolant starts to crystallise and the percentage of
ethylene glycol in the coolant therefore rises. If
freezing produces a great increase in the amount
of ice, circulation problems could arise. There is
no risk of damage by freezing if the content of
Scania antifreeze and corrosion inhibitor, or an
equivalent mixture of a similar product, is at
least 35% by volume.
Minimal ice formation in the coolant sometimes
causes minor problems without any risk of damage. For example, the auxiliary heater may not
work for up to 1 hour after the engine has been
started.
The chart depicts coolant properties at different
percents of antifreeze and corrosion inhibitor
concentration by volume.
30
40
60%
50
o
-10 C
-16 C o
-20 C
1
o
Curve A:
Curve B:
Area 1:
Area 2:
Ice formation starts (ice slush)
Damage by freezing
Safe range
Malfunctions may occur (ice
slush)
Area 3: Risk of damage by freezing
o
-30 C
o
-40 C
3
2
o
o
-60 C
• Ice slush starts to form at -16°C (3°F).
• At -30°C (-22°F), there is a risk of cooling
system malfunction.
• There is no risk of damage by freezing with a
minimum antifreeze and corrosion inhibitor
content of 35 percent by volume.
Example: If the temperature is -16 C (3°F), there
is a risk of damage by freezing if the percentage
of antifreeze and corrosion inhibitor is 20% by
volume. At 30% antifreeze and corrosion protection by volume the coolant will not contain any
ice.
46
© Scania CV AB 2017, Sweden
B
A
121 134
-50 C
The following example shows coolant properties
with 30 percent by volume of antifreeze and corrosion inhibitor:
OPM 100 en-GB
20
10
Cooling system
Warm climates
Recommended Scania products
In order to retain the corrosion protection and the
higher boiling point, it is essential to use coolant
consisting of water mixed with antifreeze and
corrosion inhibitor (ethylene glycol). This also
applies in countries where the temperature never
drops below 0°C (32°F).
Scania Ready Mix 50/50
Scania Ready Mix 50/50 is a ready-mixed coolant containing 50% antifreeze (ethylene glycol)
and corrosion protection and 50% water. It
should be used in cold countries where there is a
risk of freezing in the cooling system.
The coolant should always contain 35-55% by
volume of antifreeze and corrosion inhibitor so
that the coolant properties ensure that the coolant
works correctly.
Part No.
1 921 955
1 921 956
1 921 957
1 896 695
Topping up
Coolant must only be topped up with pre-mixed
coolant. The pre-mixed coolant can either be
concentrate mixed with clean freshwater or premixed coolant from the factory. Use only pure
fresh water that is free from particles, sludge and
other impurities.
Volume
US gallons
1.3
5.3
55
264
Scania Ready Mix 35/65
Scania Ready Mix 35/65 is a ready-mixed coolant containing 35 % antifreeze (ethylene glycol)
and corrosion protection and 65 % water. It
should be used in warm countries where there is
no risk of freezing in the cooling system.
IMPORTANT!
Containers, which are used for mixing coolant,
must be intended for the purpose and free from
any dirt or contaminants. When the containers
not in use they must be kept closed to avoid collecting dirt and dust.
Part No.
2 186 291
2 186 292
2 186 293
2 186 294
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 contaminated with oil or fuel, it must not be reused.
Volume
litres
5
20
210
1,000
Volume
US gallons
1.3
5.3
55
264
Scania concentrate
Scania also produces coolant with antifreeze and
corrosion inhibitor in the form of a concentrate.
Part No.
1 894 323
1 894 324
1 894 325
1 894 326
OPM 100 en-GB
Volume
litres
5
20
210
1,000
47
© Scania CV AB 2017, Sweden
Volume
litres
5
20
210
1,000
Volume
US gallons
1.3
5.3
55
264
Cooling system
Antifreeze and corrosion protection
concentration table, litres
35% by volume of Scania antifreeze provides
sufficient protection against corrosion.
Example:
• The total volume of the cooling system is 40
litres.
• The measured concentration of ethylene glycol is 35% by volume (freezing point -21°C).
According to the table there are 14 litres of
ethylene glycol in the cooling system.
• The required concentration of ethylene glycol
is 45% by volume (freezing point -30°C). According to the table, 18 litres of ethylene glycol are required in the cooling system.
• Since there are already 14 litres in the cooling
system, 4 litres of ethylene glycol must be
added to the cooling system (18 - 14 = 4 litres).
Volume of ethylene glycol (%)
Ice slush forms (°C)
Volume of ethylene glycol (litres)
OPM 100 en-GB
Adequate protection against corrosion
35
40
45
50
60
Cooling system volume
-21
-24
-30
-38
-50
(litres)
11
12
14
15
18
30
14
16
18
20
24
40
18
20
23
25
30
50
21
24
27
30
36
60
25
28
32
35
42
70
28
32
36
40
48
80
32
36
41
45
54
90
35
40
45
50
60
100
39
44
50
55
66
110
42
48
54
60
72
120
46
52
59
65
78
130
49
56
63
70
84
140
53
60
68
75
90
150
56
64
72
80
96
160
60
68
77
85
102
170
63
72
81
90
108
180
67
76
86
95
114
190
70
80
90
100 120
200
48
© Scania CV AB 2017, Sweden
Cooling system
Antifreeze and corrosion protection
concentration table, US gallons
35% by volume of Scania antifreeze provides
sufficient protection against corrosion.
Example:
• The total volume of the cooling system is
10.6 US gallons.
• The measured concentration of ethylene glycol is 35% by volume (freezing point -6 °F).
According to the table there are
3.7 US gallons of ethylene glycol in the cooling system.
• The required concentration of ethylene glycol
is 45% by volume (freezing point -22 °F). According to the table, 4.8 US gallons of ethylene glycol are required in the cooling system.
• Since the cooling system already contains
3.7 US gallons, fill another 1.1 US gallons of
ethylene glycol in the cooling system (4.8 3.7 = 1.1 US gallons).
Adequate protection against corrosion
Volume of ethylene glycol (%)
35
40
45
50
60
Cooling system volume
Ice slush forms (°F)
-6
-11
-22
-36
-58
(US gallons)
2.9
3.2
3.7
4
4.8
7.9
3.7
4.2
4.8
5.3
6.3
10.6
4.8
5.3
6.1
6.6
7.9
13.2
5.5
6.3
7.1
7.9
9.5
15.9
6.6
7.4
8.5
9.2 11.1
18.5
7.4
8.5
9.5 10.6 12.7
21.1
8.5
9.5 10.8 11.9 14.3
23.8
9.2 10.6 11.9 13.2 15.9
26.4
29.1
Volume of ethylene glycol (US gal- 10.3 11.6 13.2 14.5 17.4
lons)
11.1 12.7 14.3 15.9
19
31.7
12.2 13.7 15.6 17.2 20.6
34.3
12.9 14.8 16.6 18.5 22.2
37
14
15.9
18
19.8 23.8
39.6
14.8 16.9
19
21.1 25.4
42.3
15.9
18
20.3 22.5 26.9
44.9
16.6
19
21.4 23.8 28.5
47.6
17.7 20.1 22.7 25.1 30.1
50.2
18.5 21.1 23.8 26.4 31.7
52.8
OPM 100 en-GB
49
© Scania CV AB 2017, Sweden
Cooling system
Checking coolant level
Checking coolant antifreeze
and corrosion protection
WARNING!
Tool
Do not open the coolant filler cap in the expansion tank if the engine is hot. Hot coolant and
steam may spray out and cause burns. If the cap
has to be opened do it slowly to release the pressure before removing the cap.
Description
Refractometer
Illustration
305 523
Use protective gloves as coolant can cause irritation if it comes in contact with the skin.
138008
IMPORTANT!
It is not permissible to top up large amounts of
coolant via the expansion tank. Filling via the expansion tank leads to air locks in the cooling system which can lead to e.g. cavitation damage to
the coolant pump shaft seal. If a large amount of
coolant needs to be added, follow the instructions in the section Filling coolant.
WARNING!
Avoid skin contact with coolant as this may
cause irritation to the skin. Wear protective goggles and gloves when handling coolant.
Only pour pre-mixed coolant into the cooling
system.
IMPORTANT!
The following instructions apply to Scania expansion tanks. For other types of expansion
tanks, follow the manufacturer's instructions.
Use only pure fresh water that is free from particles, sludge and other impurities.
1. Open the expansion tank cap and check the
1. Pour a small amount of coolant into a con-
coolant level.
– The right coolant level on a cold engine is
even with the lower edge of the filler neck.
– The right coolant level on a hot engine is
approximately 25 mm (1 in) over the lower edge of the filler neck.
2. Top up with coolant as necessary.
tainer and check that the coolant is pure and
clear.
2. Change the coolant if it is contaminated or
cloudy.
3. Measure the antifreeze and corrosion inhibitor content with the refractometer.
The following rules apply to ethylene glycolbased coolant:
• The antifreeze and corrosion inhibitor content
must be minimum 35 percent by volume for
corrosion protection to be sufficient.
• An antifreeze and corrosion inhibitor content
greater than 55 percent by volume impairs the
ability to protect against frost.
• If ice forms in the coolant, there are disruptions initially, but there is no immediate risk
of damage. The engine should not be subjected to heavy loads when ice starts to form.
OPM 100 en-GB
50
© Scania CV AB 2017, Sweden
Cooling system
Changing the coolant and
cleaning the cooling system
Draining coolant
WARNING!
Do not open the coolant filler cap in the expansion tank if the engine is hot. Hot coolant and
steam may spray out and cause burns. If the cap
has to be opened do it slowly to release the pressure before removing the cap.
Use protective gloves as coolant can cause irritation if it comes in contact with the skin.
Environment
Use a suitable container. Used coolant must be
disposed of as specified in national and international laws and regulations.
Draining coolant with coolant pump
Special tool
Illustration
360 625
Number, designation
2 443 679, coolant
pump
1. Open the expansion tank cap.
OPM 100 en-GB
51
© Scania CV AB 2017, Sweden
Cooling system
2. Position the hose from the coolant pump in
an empty container.
3. Connect the pump to the draining nipple in
the cylinder block. See illustration.
4. Connect the pump's 2 cable terminals to the
battery's negative and positive terminal.
Make sure that the drainage starts. If the
drainage does not start: Change the position
of the cable terminals.
5. Repeat the procedure at the cooling system's
lowest drainage point. The location of the
lowest drainage point on the engine may differ depending on engine application.
352 794
Draining coolant with coolant trolley
Tool
Illustration
333 980
Description
Coolant trolley
1. Open the expansion tank cap.
2. Position the hose from the coolant trolley in
an empty container.
3. Connect the trolley to the draining nipple in
the cylinder block. See the illustration above.
4. Drain the coolant.
5. Repeat the procedure at the cooling system's
lowest drainage point. The location of the
lowest drainage point on the engine may differ depending on engine application.
OPM 100 en-GB
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Cooling system
Cleaning the cooling system
Internal cleaning: Removing oil and
grease in the cooling system
Note:
Clean the cooling system more often than specified in the maintenance interval if necessary.
Environment
Use a suitable container. Used coolant must be
disposed of as specified in national and international laws and regulations.
External cleaning Cleaning the radiator
and charge air cooler
IMPORTANT!
Always fit a new thermostat 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 filter.
Do not use caustic soda or other alkaline detergent as this could damage the aluminium.
Read the warning text on the detergent packaging.
It may be necessary to wash it multiple times if
the cooling system is very dirty. One cause of
contamination can be that oil is lying on top of
the coolant and collecting high up in the cooling
system. If several rinses are needed, this is not
necessarily because work has been carried out
incorrectly. Oil residues often need to be rinsed
repeatedly from the expansion tank and the external heating system to be completely clean.
1. Check that the radiator and the charge air
cooler are not clogged on the air side and that
the cooling fins are not damaged.
2. Carefully scrape away any deposits from the
radiator cooling fins. Use a paraffin-based
engine cleaner if necessary.
3. Carefully straighten bent cooling fins using a
steel brush or the like.
Repeated washing is more effective and preferable to using higher concentrations of detergent
(max. 10%) or cleaning for a longer period (max
30 minutes).
If only a small amount of dirt has collected in the
expansion tank after cleaning, one extra rinse
and clean of the expansion tank only is usually
sufficient. There is no need to clean the whole
cooling system again.
1. Run the engine until it has reached operating
temperature and then drain the cooling system following the previous description.
2. Remove the thermostat.
OPM 100 en-GB
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Cooling system
Internal cleaning: Removing deposits in
the cooling system
3. Fill the cooling system with clean, hot water
mixed with detergent 2 479 017. Detergent
2 479 017 must make up 5-10% (depending
on the degree of dirt) of the total coolant volume.
If detergent 2 479 017 is not available, use a
dishwasher detergent for household dishwashers that does not foam. Concentration
1%.
4. Run the engine until it has reached operating
temperature for approximately 20-30 minutes. Remember to switch on the cab heating
system, if one is installed.
5. Drain the cooling system.
6. Fill the cooling system with clean, hot water
and run the engine for about 20-30 minutes.
7. Repeat steps 3-6 if the cooling system is not
clean.
8. Drain the water from the cooling system.
9. If necessary, clean the expansion tank by detaching all hoses and rinsing and cleaning
with a degreasing agent and a dishwashing
brush.
Alternatively, dismantle the expansion tank
and clean it with water with 10% of detergent
2 479 017. Fill the expansion tank with the
mixture, shake it around and drain it. Renew
the cover of the expansion tank.
10. Fit a new thermostat.
11. Fill the cooling system with new coolant as
described in the next section.
12. Check again whether further dirt or oil has
collected in the expansion tank. Decide
whether it it is necessary to carry out another
full cleaning or whether only rinsing or
cleaning of the expansion tank will suffice.
OPM 100 en-GB
Environment
Use a suitable container. Used coolant must be
disposed of as specified in national and international laws and regulations.
1. Run the engine until it has reached operating
temperature and then drain the cooling system following the previous description.
2. Remove the thermostats.
3. Fill the cooling system with clean, hot water
mixed with radiator detergent which is based
on sulphamic acid and contains dispersing
agents. Follow the manufacturer's instructions for the concentration and cleaning period.
4. Run the engine for the specified time. Remember to switch on the cab heating system,
if one is installed.
5. Drain the cooling system.
6. Fill the cooling system with clean, hot water
and run the engine for about 20-30 minutes.
7. Drain the water from the cooling system.
8. Refit the thermostats.
9. Fill the cooling system with new coolant as
described in the next section.
54
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Cooling system
Filling coolant
These procedures apply when the cooling system
has been drained and needs to be filled with a
large amount of coolant.
WARNING!
Use protective gloves as coolant can cause irritation if it comes in contact with the skin. Hot coolant can also cause scalding.
IMPORTANT!
Mix the coolant as specified in the section headed Coolant.
It is not permissible to top up large amounts of
coolant via the expansion tank. Filling via the expansion tank leads to air locks in the cooling system which can lead to e.g. damage to the coolant
pump shaft seal. If a large amount of coolant
needs to be added, follow the instructions in the
section Filling coolant.
Never fill a large amount of cold coolant in a hot
engine. There is great risk of cracks forming in
the cylinder block and cylinder heads.
Do not start the engine until the correct coolant
level has been obtained. If the engine is started
with an insufficient coolant level, it can damage
the coolant pump shaft seal, which leads to coolant leakage.
OPM 100 en-GB
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Cooling system
Filling coolant with coolant pump
Special tool
Illustration
360 625
Number, designation
2 443 679, coolant
pump
1. Open the expansion tank cap.
2. Connect the coolant pump to the filler nipple
in the cylinder block. See illustration.
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 cable terminals.
4. Start the engine and run it at idling for
15 minutes.
IMPORTANT!
352 794
It is very important that the engine is idling. Engine overspeed could damage the coolant pump
shaft seal, which leads to coolant leakage.
5. Switch off the engine and fill with coolant to
the maximum level through the expansion
tank.
Air pockets may still be left in the cooling system. These will disappear after the engine has
been operated for a period of time. Therefore, the
coolant may need topping up at a later stage.
OPM 100 en-GB
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Cooling system
Refilling coolant with coolant trolley
Tool
Illustration
333 980
Description
Coolant trolley
1. Open the expansion tank cap.
2. Connect the coolant trolley to the filler nip-
ple in the cylinder block. See illustration.
3. Fill with coolant using coolant trolley to
pump up to the maximum level of the expansion tank.
4. Disconnect the coolant trolley.
5. Start the engine and run it at idling for
15 minutes.
IMPORTANT!
352 794
It is very important that the engine is idling. Engine overspeed could damage the coolant pump
shaft seal, which leads to coolant leakage.
6. Switch off the engine and fill with coolant to
the maximum level through the expansion
tank.
Air pockets may still be left in the cooling system. These will disappear after the engine has
been operated for a period of time. Therefore, the
coolant may need topping up at a later stage.
After filling, it may be good to start the engine
and check that no coolant leakage occurs.
OPM 100 en-GB
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Fuel system
Fuel system
Checking fuel level
Cleanliness requirements
Check the fuel level and top up with fuel as necessary.
Note:
If the fuel tank has been run dry or if the engine
has not been used for a long time, bleed the fuel
system. See the section Bleeding the fuel system.
IMPORTANT!
The whole fuel system is very sensitive to dirt
and even very small particles. Foreign particles
in the system can cause serious malfunctions. It
is therefore very important that everything is as
clean as possible when work is carried out on the
fuel system. Before repair work, the engine must
be washed. If possible, a hot water wash should
be used.
It is strictly forbidden to carry out any machining
work or work with compressed air near an open
fuel system.
Be extra careful and always use clean, lint-free
and dust-free clothes and disposable gloves
when working on the fuel system. Scania recommends using Tegera 848 gloves.
Clean tools before they are used and do not use
any worn or chrome-plated tools. Material and
flakes of chrome may come off.
Clean connections and the surrounding area before removal. When cleaning, cloths or paper
which shed fibres must not be used. Use clean
and lint free cloths, part number 588 879.
Plug or cover the connections during removal.
Also clean the connections before the components are fitted. Place removed components on a
thoroughly cleaned, dust-free surface. Scania
recommends using a stainless steel bench top,
part number 2 403 296. Cover the components
with a lint free cloth.
OPM 100 en-GB
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Fuel system
Renewing the fuel filters
Tool
Illustration
118 268
Description
Hexagon socket, drive
1/2", 36 mm
Environment
Use a suitable container. The fuel collected must
be disposed of as specified in national and international laws and regulations.
If the fuel tank is positioned higher than the fuel
filter housing, the shut-off valve between the fuel
tank and the fuel filter housing must be closed.
This is to prevent fuel running into the fuel filter
housing.
Removing the fuel filters using a
draining nipple
On certain engines, there is a draining nipple (1)
on the fuel filter housing. If there is no draining
nipple, see the following section.
1. Open the draining nipple.
1
351 550
To ensure that the filter housings are drained
properly, the filter covers must be removed as
follows:
2. On the main filter (B): Make a mark on the
cover. Unscrew the cover 3 to 4 turns with a
socket.
3. Repeat the procedure with the water separat-
ing prefilter (A).
B
329 083
A
A. Water separating prefilter.
B. Main filter.
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Fuel system
4. Wait at least 2 minutes to ensure the filter
housings have drained properly.
5. On the main filter: Unscrew the filter cover
and lift it up slowly with the filter element.
6. On the water separating prefilter: Unscrew
the filter cover and lift it up slowly with the
filter element.
The remaining fuel will drain out of fuel filter housing automatically once the filter element has been removed.
7. Check that no fuel or particles remain in the
bottom of the filter housings. Draw off remaining fuel and any particles.
A. Water separating prefilter.
IMPORTANT!
B. Main filter.
It is important to remove remaining fuel and particles from the filter housings to prevent fuel system contamination.
8. Undo the old filter elements from the covers
by carefully bending them to one side.
9. Close the draining nipple.
OPM 100 en-GB
B
329 083
A
60
© Scania CV AB 2017, Sweden
Fuel system
Removing the fuel filters using a suction tool
Tool
Illustration
A
337 297
Description
Suction tool
B
To ensure that the filter housings are drained
properly, the filter covers must be removed as
follows:
329 083
IMPORTANT!
Start with the water separating prefilter (A). Do
not open the main filter cover (B) until the filter
housing for the water separating prefilter is completely drained.
A. Water separating prefilter.
B. Main filter.
1. Make a mark on the water separating prefil-
A
ter cover (A). Unscrew the cover 3 to 4 turns
with the socket.
IMPORTANT!
Do not use an adjustable spanner or other open
tool to remove the filter covers, as the filter covers may then get damaged.
OPM 100 en-GB
329 084
Wait for at least 2 minutes to allow as much of
the fuel as possible to drain out of the filter housing.
61
© Scania CV AB 2017, Sweden
Fuel system
2. Unscrew the filter cover (A) and lift it up
slowly with the filter element.
3. Make sure the suction tool is completely
drained before starting work. Draw out remaining fuel and any particles using the suction tool or a similar tool.
A
4. Keep the suction tool hose in the filter hous-
329 085
ing for the water separating prefilter (A).
5. Make a mark on the main filter cover (B).
Unscrew the cover 3 to 4 turns with the socket. Draw out fuel which may drain into the
water separating prefilter housing when the
main filter is detached.
B
IMPORTANT!
329 086
Wait for at least 2 minutes to allow as much of
the fuel as possible to drain out of the filter housing.
6. Unscrew the main filter cover (B) and lift it
B
up slowly with the filter element.
7. Fuel from the main filter housing (B) will
flow into the water separating prefilter housing (A). Leave the suction tool in the water
separating suction filter housing until it is
completely drained of fuel.
329 087
A
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Fuel system
8. Move the suction tool to the main filter hous-
ing (B). Draw out remaining fuel and particles.
B
IMPORTANT!
It is important to remove remaining fuel and particles from the filter housings to prevent fuel system contamination.
329 088
9. Undo the old filter elements from the covers
by carefully bending them to one side.
Fitting the fuel filters
IMPORTANT!
Check that there is no remaining packaging material stuck to the new filter elements. Secure the
filter elements in the filter covers before positioning them in the fuel filter housings. Otherwise, the filter elements may break.
In order to prevent back pressure in the filter
housings when the filter elements are screwed
on, the bleed nipple should be open.
1. Fit a new O-ring on the cover. Lubricate the
O-ring with O-ring grease.
2. Press the filter elements into the snap fasteners on the covers.
3. Check that the filter housing is clean before
fitting. Use lint free cloths.
4. Press down the filter elements into the fuel
filter housings with the filter covers.
5. Screw down the filter covers until the cover
seals are in contact with the filter housings.
Use the socket.
6. Tighten the filter housings to 25 Nm (18 lb/
ft).
7. Bleed the fuel system as per the following
section.
8. Start the engine and check that there is no
fuel leakage between the filter covers and filter housings. If there is leakage, undo the filter covers and start again from step 4.
OPM 100 en-GB
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Fuel system
Bleeding the fuel system
IMPORTANT!
The collected fuel must not be poured back into
the fuel tank.
Environment
Use a suitable container. The fuel collected must
be disposed of as specified in national and international laws and regulations.
Bleeding the fuel system using a suction tool
Tool
Illustration
337 297
Description
Suction tool
Note:
Scania recommends bleeding the fuel system using suction tools rather than with a hand pump.
This is a quicker and simpler method, which ensures a complete bleeding.
1. Open the bleed nipple on the high pressure
329 119
pump and connect the suction tool.
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© Scania CV AB 2017, Sweden
Fuel system
2. Hold the suction tool straight and draw out at
least a full container of fuel.
3. Once the fuel coming out of the hose is free
of air bubbles, then bleeding is complete.
4. Close the bleed nipple on the high pressure
pump. Remove the hose and suction tool.
5. Start the engine and check that no leakage
occurs.
Bleeding the fuel system using a
hand pump
2
1. Attach a clear plastic hose to the bleed nipple
1
381 668
on the fuel filter housing. Let the plastic hose
drop into a container that holds at least 5 litres (1.3 US gallons).
2. Loosen the hand pump handle.
3. Open the bleed nipple on the fuel filter housing and pump until fuel runs out, which will
take around 100 pump strokes. Close the
bleed nipple.
4. Start the engine and open the bleed nipple
carefully. Approximately 3 litres (0.8 US
gallons) will run out into the container before
the fuel coming out will be free of air.
1. Bleed nipple.
2. Hand pump.
OPM 100 en-GB
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Miscellaneous
Miscellaneous
5
Checking the drive belt
2
4
IMPORTANT!
Before starting, make a note of how the drive belt
is fitted. Refit the drive belt with the same direction of rotation as it had before removal.
3
2
at the idler rollers.
2. Check the drive belt for cracks. Renew the
drive belt if deep cracks have formed.
1
339 160
1. Check the drive belt thoroughly, particularly
Example of a drive belt.
1.
2.
3.
4.
5.
Crankshaft.
Idler roller.
Alternator.
Belt tensioner.
Coolant pump.
381 640
106 229
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 cracks, or if parts of the
drive belt have started to come off, the drive belt
must then be renewed.
Example of a minor crack in the drive belt. The drive The drive belt has deep cracks and must be renewed.
belt can be refitted.
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Miscellaneous
3. Check drive belt wear. Renew the drive belt
112 932
112 931
if it is too worn.
The drive belt is starting to become worn, but can be The belt is worn down to the cord. The drive belt
refitted.
must be renewed.
Checking for leaks
IMPORTANT!
If serious leakage occurs, contact your nearest
Scania workshop.
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 and crankcase are leaking.
4. Check whether the drain hole on the coolant
pump is blocked. If there is a leak, renew the
seal in the pump or the complete coolant
pump.
OPM 100 en-GB
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Miscellaneous
Checking and adjusting the
valve clearance
Special tools
Description
Turning tool for rotating the flywheel from below
99 109
Turning tool for rotating the flywheel from above
Illustration
312 733
142 238
Number
99 309
Other tools
Torque wrench, 0-50 Nm
Waterproof felt-tip pen
Feeler gauge 0.45 and 0.70 mm
Flash light
Mirror
WARNING!
Block the starting device. If the engine starts unexpectedly, there is a serious risk of injury.
IMPORTANT!
The engine must be cold when the work is carried out.
Remember to remove the turning tool from the
flywheel after adjustment.
Note:
Carry 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 according to
the regular interval takes place, which is every
2,000 operational hours.
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Miscellaneous
On the flywheel is engraved the reference information UP TDC, DOWN TDC and the angle indications listed in the table below. Depending on
the engine installation, this information is visible
in one of the windows, either furthest up or furthest down on the flywheel. See illustration.
Tightening torque
Lock nut for valves
310 343
Valve clearance, specifications
Intake valve
0.45 mm (0.018 in)
Exhaust valve
0.70 mm (0.028 in)
Upper and lower window to read the engraving on
the flywheel.
35 Nm (26 lb/ft)
Adjust valves according to the table below. Follow the respective column depending on whether
you are reading the engraving on the flywheel in
the lower or the upper window. Start adjustment
at the top of the table.
Reading in the lower
window
DOWN TDC
72/432
144/504
216/576
288/648
DOWN TDC
72/432
144/504
216/576
288/648
Revolutions Valve transition on
cylinder
1
1
5
1
1
3
1
2
1
2
2
2
2
2
4
Adjust valves on
cylinder
1
2
4
5
3
2
3 4
5
319 704
1
Reading in the upper
window
UP TDC
252/612
324/684
36/396
108/468
UP TDC
252/612
324/684
36/396
108/468
Order of cylinders.
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Miscellaneous
1. Clean the rocker covers and the area around
them.
2. Remove the rocker covers.
3. Use the turning tool appropriate to the installation of the engine. Tool 99 309 is used to
rotate the flywheel from the underside of the
engine and tool 99 109 is used from the top
side.
4. Start adjusting one cylinder according to the
table. Rotate the flywheel until the correct
engraving can be read on the flywheel. It
may be necessary to rotate it more than 1 revolution.
Rotate the flywheel in the rotational direction of the engine, which is clockwise
viewed from the front of the engine and anticlockwise viewed from the back of the engine.
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 in the window furthest up on the
flywheel. The DOWN TDC engraving is visible in the lower window.
5. Read the table on the previous page to see
1
which valve to adjust.
6. Stick the feeler gauge under the pressure pad
of the rocker arm and check the valve clearance.
7. If necessary, adjust the valve clearance by
a) loosening the lock nut on the end of the
rocker arm
b) adjusting the valve clearance with the adjusting screw
c) tightening the lock nut.
8. Mark the rocker arm with the felt-tip pen and
then continue with the next cylinder according to the table.
2
3
5
1.
2.
3.
4.
5.
OPM 100 en-GB
Adjusting screw.
Lock nut.
Rocker arm.
Valve bridge.
Feeler gauge.
70
© Scania CV AB 2017, Sweden
382 364
4
Miscellaneous
Renewing the reductant filter
1. Wipe clean around the filter housing to pre-
3
vent impurities from penetrating it.
2. Remove the filter housing. Use a 46 mm
socket.
4
WARNING!
There may be a lot of reductant in the filter housing and it may spill out. Wear protective gloves.
5
1
IMPORTANT!
Always rinse away reductant spillage on connections and other parts with lukewarm water to prevent corrosion. If reductant seeps into electrical
connections or electrical cables, these must be
renewed.
6
372 124
2
3. Remove the sealing diaphragm.
1.
2.
3.
4.
5.
6.
Pump.
Filter.
Sealing diaphragm.
O-ring.
Antifreeze.
Filter housing.
4. Remove the old reductant filter and fit a new
372 126
one.
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© Scania CV AB 2017, Sweden
Miscellaneous
5. If the anti-freeze protection in the filter hous-
372 130
ing comes loose, wipe both the anti-freeze
protection and filter housing thoroughly so
that they are completely dry before they are
assembled again.
6. Wipe the sealing diaphragm and fit it over
372 127
the filter.
Ensure that the edge of the diaphragm is sitting in the groove.
7. Lubricate the sealing diaphragm and threads
372 128
with the accompanying spray.
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Miscellaneous
8. Renew the O-ring. Place the new O-ring in
372 129
the filter housing.
9. Refit the filter housing. Use a 46 mm socket.
372 125
Tighten to 80 Nm (59 lb-ft).
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© Scania CV AB 2017, Sweden
Miscellaneous
Cleaning the reductant tank
filler filter
Make sure that the filler filter (1) is clean. If it is
dirty: Clean the filler filter with clean water and
refit it.
350 114
1
Cleaning the reductant tank
ventilation filter
Make sure that the ventilation filter (2) is clean.
If it is dirty: Clean the ventilation filter with
clean water and refit it.
352 009
2
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© Scania CV AB 2017, Sweden
Miscellaneous
Cleaning the reductant tank
1. If necessary, empty the reductant tank by
sucking out the fluid or opening the drain
plug.
2. Detach all connections to the reductant tank.
3. Clamp the coolant hoses (1) using pliers to
stop the coolant flow.
1
WARNING!
316 080
The coolant hoses contains coolant from the engine. Open the coolant filler cap first to relieve
any pressure.
4. Pull out the coolant hoses. These connec-
Example of coolant hose.
tions may be tight.
Note:
Plug the connections and reductant hoses again
when they are detached so that no contamination
enters the reductant circuit.
5. Remove the reductant tank.
6. Fit two M10 screws in the holes on the re-
ductant pick-up unit. Detach the reductant
pick-up unit by turning it anti-clockwise with
a handle, see illustration.
7. Rinse the reductant tank clean with hot wa-
368 748
ter.
8. Fit the reductant tank.
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© Scania CV AB 2017, Sweden
Quality requirements for fuel
Quality requirements for
fuel
Sulphur content
IMPORTANT!
Quality requirements and testing standards for
the most important properties of different types
of fuel are described in the Workshop Manual.
This can be ordered from Scania dealers or directly from Scania.
The operator is responsible for using the correct
type of diesel to ensure that local laws are complied with.
Diesel
Important to use low sulphur diesel
It is important for sulphur-free or ultra-low sulphur diesel to be used on engines with SCR systems certified in accordance with Stage III B/
Tier 4i or Stage IV/Tier 4f to ensure that the engine operates correctly. If diesel with an excessive sulphur content is used, it can cause damage
to the engine and the SCR system.
Properties
The quality of the diesel is very important for the
operation and service life of the engine and the
fuel system, and also for the engine performance.
REQUIREMENT!
From January 2011 legislation in the USA and
Europe requires all diesel engines not used on the
road to be run on sulphur-free or ultra-low sulphur diesel.
The diesel should comply with the requirements
of European standard EN590.
However, Scania accepts larger tolerances of
certain properties. Please see the table below.
Property
Viscosity at 40°C
(104°F)
Density at 15°C (59°F)
REQUIREMENT!
In Europe, the diesel should be sulphur-free according to standard EN 590. This means that the
sulphur content must not exceed 10 ppm.
Requirement
1.4-4.5 cSt
In the USA, the diesel must be ultra-low sulphur
in accordance with the ASTM D975 standard.
This means that the sulphur content must not exceed 15 ppm.
0.79-0.87 kg/dm3
Ignitability (CET rating) minimum 49
Lowest flashpoint
56°C (132°F)
Particulate contamina- Classification 22/20/17
tion level
according to ISO 4406
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© Scania CV AB 2017, Sweden
Quality requirements for fuel
Permitted sulphur content in diesel
Engine type
Engines without EGR and SCR
systems
Max. sulphur content
4,000 ppm (0.4%)
Engines with SCR system only
500 ppm (0.05%)
Engines with both EGR and SCR
systems
350 ppm (0.035%)
Diesel with a higher sulphur content than
500 ppm for engines with SCR systems
If diesel with a higher sulphur content than permitted is used on a short-term basis, this will not
cause permanent damage to the SCR catalytic
converter. The SCR catalytic converter may,
however, require diesel with a low sulphur content for some time after this to regain its normal
efficiency.
If diesel with too high a sulphur content is used
for a prolonged period, there is a risk that the
SCR catalytic converter will not operate correctly, which will result in a reduction in engine
torque.
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© Scania CV AB 2017, Sweden
Note
If the sulphur content is higher than
2,000 ppm, the oil change intervals
must be halved. A higher sulphur
content than 4,000 ppm is not permitted, since this will result in engine damage.
A higher sulphur content than
10 ppm for Europe or 15 ppm for
the USA may only be used where
Stage III A/Tier 3 or less restrictive
emission laws apply.
A higher sulphur content than
10 ppm for Europe or 15 ppm for
the USA may only be used where
Stage III A/Tier 3 or less restrictive
emission laws apply.
Quality requirements for fuel
Biodiesel (FAME)
Temperature dependence of diesel
Use of biodiesel
IMPORTANT!
IMPORTANT!
Mixing kerosene or other paraffins with the diesel is prohibited. The injectors may be damaged.
For engines with SCR systems, a maximum of
10% mixture of biodiesel should be used.
It is not permissible to mix petrol with diesel. In
the long term petrol can cause wear in the injectors and engine.
Scania uses the term biodiesel to refer to a renewable diesel made from greases or oils and
methanol. The biodiesel should conform to the
requirements of European standard EN 14214 or
Brazilian standard ANP-45. For biodiesel in accordance with EN 14214 or ANP-45, the generic
term FAME is frequently used.
At temperatures lower than those specified for
the diesel, paraffin wax may precipitate from the
diesel and block filters and pipes. The engine can
then lose power or stop.
The diesel is adapted for use in the specific climate of each country. If an engine is to be operated in a temperature zone with a temperature
lower than normal, first identify the temperature
properties of that particular diesel.
Normal diesel in accordance with EN 590 can
contain up to 7% biodiesel from the diesel supplier. There are grades of diesel that comply with
EN 590 but contain a higher mixture of biodiesel.
Scania approves up to a 10% mixture of biodiesel for all engines.
HVO
HVO is a synthetic diesel which is manufactured
through the hydrogenation of plants and animal
fats. To the user, HVO is reminiscent of diesel in
accordance with EN590, apart from HVO having
a somewhat lower density.
Storage of biodiesel
IMPORTANT!
Biodiesel must not be stored for more than 6
months.
Scania approves the use of up to 100% HVO for
all engines in accordance with the European
standard EN 15940.
Biodiesel has a maximum storage life of
6 months from the date of production to the expiry date. Biodiesel is affected by light, temperature, water, etc. during storage, which affects
the characteristics and durability of the biodiesel.
Biodiesel also has lower stability against oxidation than diesel. This can result in a thickening of
the biodiesel and blocking of parts of the fuel
system, e.g. the fuel filter. Bacterial growth can
occur when fuel is stored in tanks under unfavourable conditions. Avoid storage in barrels or
auxiliary tanks, except when fuel turnover rates
are high. Check tank cleanliness whenever refuelling takes place.
If the engine has been refuelled with biodiesel,
and is stationary for a long period, condensation
water can form in the fuel tank resulting in bacterial growth.
See also the section Preservative fuel.
OPM 100 en-GB
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© Scania CV AB 2017, Sweden
Reductant for SCR
Reductant for SCR
Reductant is normally colourless if no dye has
been added. It is not harmful to the skin. Nor is it
toxic in small quantities, but it tastes very unpleasant.
IMPORTANT!
Reductant is highly corrosive. Therefore, rinse
any reductant spillage from connections and other details using lukewarm water. Water works
very well for cleaning purposes. Please use hot
water. If reductant seeps into electrical connections or electrical cables, these must be renewed.
The operator is responsible for using the correct
type of reductant to ensure that local laws are
complied with.
REQUIREMENT!
Reductant has a low surface tension and rapidly
spreads over large areas, which then become
very slippery.
In order for the emission control to meet the
emission requirements set by the public authorities, the reductant should be specified in accordance with ISO 22241.
Reductant can dry out and form white or greyish
brown crystals or deposits that can be washed
away with warm water.
The risk of crystal formation increases with low
outdoor temperatures. When the outdoor temperature is below -20°C (-4°F), reductant dosing is
switched off to avoid the risk of crystals forming
in the SCR system.
Reductant is a solution consisting of urea and
water, and is usually called AdBlue®, DEF,
ARLA 32 eller AUS 32, depending on the market. If the engine is equipped with an SCR system, the reductant is added to the exhaust gases
upstream of the catalytic converter. This reduces
nitrogen oxide emissions.
Reductant in accordance with ISO 2241 contains
32.5% by weight of urea and freezes at approximately -11°C (12°F). When the solution freezes,
ice and urea always maintain the same concentration. Always store reductant at a temperature
between -11°C and 30°C (12-86°F).
Rec. % by weight of
urea
32.5%
OPM 100 en-GB
Limit values according
to ISO 22241
31.8-33.2%
79
© Scania CV AB 2017, Sweden
Preparing the engine for storage
Preparing the engine for
storage
Preservative fuel
Preservative fuel must not contain biodiesel.
Even small amounts of 5-10% biodiesel can have
adverse effects on the engine when in long-term
storage.
If the engine is not being used for an extended
period its cooling system, fuel system and combustion chamber and outside must be protected
against rust.
Long-term storage of diesel, where the diesel
comes into contact with water, may lead to the
growth of micro organisms (bacteria and fungus).
The engine can normally stand idle for up to
6 months without needing preparation. For
longer periods of than 6 months, however, the
measures in the following sections must be taken. These measures provide protection for approximately 3 years, then the preparing
procedure must be repeated. An alternative to
preparing the engine for long-term storage is to
start the engine and warm it up every 6 months.
In order to minimise the growth of micro-organisms, preservative fuel should contain the following additives. The additives should be
selected and added by the fuel supplier.
Preservative fuel should comply with the following requirements:
Preparation means that the following measures
are taken:
•
•
•
•
• The engine is cleaned thoroughly.
• Run the engine for a specific period using
special preservative fuel, oil and coolant.
• Otherwise prepare the engine for storage (filter renewal, lubrication, etc.).
Reductant
Over time, the water in the reductant evaporates
and there is only urea left. The reductant then begins to crystallise. The reductant tank is not sensitive to crystals, but the ball valves in the
reductant pump may become clogged. However,
note that corrosion or other particles can also
clog the ball valves.
Preservative products
Preservative oil
Use a normal engine oil that meets the requirements in the Oil grade section.
Preservative coolant
So that the water in the reductant does not evaporate, all connections in the SCR system must be
closed before storage. The SCR system should
then be stored in a cool location and not in direct
sunlight. If the reductant tank has never been
filled with reductant, it can be stored when empty for an unlimited time.
Use coolant containing 50% by volume of glycol. Example: BASF MPG Glysacorr P113 and
Valvoline Zerex P113 FP.
WARNING!
When the engine is taken into operation again,
all reductant must be drained and changed. If old
reductant is used, the SCR system will not work.
Ethylene glycol can be fatal if ingested and can
cause skin irritation and eye damage.
OPM 100 en-GB
0% biodiesel.
Max. sulphur content 50 ppm.
Max. water content 200 ppm.
The fuel must contain additives to stop the
growth of micro-organisms.
80
© Scania CV AB 2017, Sweden
Preparing the engine for storage
Preparations for storage
9. Detach the fuel pipe at the overflow valve
and connect a return hose to a separate can.
10. Connect and bleed the fuel system.
11. Start the engine and run it at about 1,100 rpm
for 20 minutes.
If the engine has an SCR system and the reductant tank is empty, it is possible to run the
engine for this limited time without damaging the components of the SCR system. This
applies if the engine is run without load.
12. If the engine has an SCR system and the reductant tank is full of reductant: Seal all connections in the SCR system.
13. Remove the rocker covers and lubricate the
valve mechanisms with pushrods and the
valve tappets, as well as the injector mechanism, using a liberal amount of preservative
oil. Refit the rocker covers.
14. Drain the coolant if the engine is not to be
stored with coolant in the system. Plug and
tape all coolant connections if the engine is
to be stored without coolant in the cooling
system.
15. Renew or clean the filter element in the air
cleaner.
16. Cover the air intake and exhaust pipe.
17. Spray the outside of the alternator and starter
motor with water-repellent anti-corrosive
oil: CRC 226, LPS1 or equivalent.
18. Spray the outside of bright engine parts, first
with penetrating preservative oil such as
Dinitrol 25B and then with Dinitrol 112 or
the equivalent.
19. Clearly mark the engine with the storage
preparation date, and state that the engine
must not be started or cranked.
Environment
Use a suitable container. Used oil, coolant and
reductant must be disposed of as specified in national and international laws and regulations.
Note:
Do not remove the injectors.
1. Remove plugs and tape from the coolant
connections, air intake and exhaust pipe.
2. Drain the oil.
3. Renew the oil filter and fuel filter.
4. Clean the centrifugal oil cleaner.
5. Fill with engine oil to the minimum level on
the oil dipstick.
6. Drain and flush the cooling system of any old
coolant.
7. Top up with preservative coolant.
8. Mix preservative fuel in a can. Detach the
fuel pipe at the feed pump suction line and
connect a hose from the can.
OPM 100 en-GB
81
© Scania CV AB 2017, Sweden
Preparing the engine for storage
Batteries
When the engine is to be taken into
operation again
1. If the engine is equipped with an SCR sys-
WARNING!
tem: Drain and clean the reductant tank and
fill with new reductant.
2. Remove plugs and tape from the coolant
connections, air intake and exhaust pipe.
3. Fill the cooling system with coolant.
4. Drain the preservative oil.
5. Renew the oil filter and fuel filter.
6. Fill with new engine oil.
7. Remove the rocker covers and lubricate the
valve mechanisms with pushrods and the
valve tappets, as well as the injector mechanism, using a liberal amount of oil. Refit the
rocker covers.
8. Drain the preservative fuel from the fuel
manifold.
9. Connect and bleed the fuel system.
10. Wash off any preservative oil on the outside
using white spirit.
Wear protective gloves and protective goggles
when charging and handling batteries. The batteries contain a highly corrosive acid.
Remove the batteries and trickle charge them at
the battery charging station. This does not apply
to batteries specified as maintenance-free by the
manufacturer.
The same applies to short-term storage, even if
the engine has not been prepared for storage as
above.
Storage
After the preparation, the engine should be
stored indoors in a dry location at room temperature. The engine must be packed in packaging
made of VCI plastic to protect against dust, dirt
and moisture.
OPM 100 en-GB
82
© Scania CV AB 2017, Sweden
Technical data
Technical data
General data
Number of cylinders and configuration
Working principle
Cylinder diameter (mm/in)
Piston stroke (mm/in)
Displacement (dm3/in3)
Firing sequence
Compression ratio
DC09 076/078/080A
DC09 084/384/085/385/086/386/087/387/089/389A
Other engine types
Engine direction of rotation viewed from rear
Fan direction of rotation viewed from front
Cooling
Valve clearances, cold engine
Intake valve (mm/in)
Exhaust valve (mm/in)
Number of teeth on the flywheel
Low idling speed (rpm)
Maximum full-load speed (rpm)
Fuel
Approximate weight, without coolant and oil (kg/lb)
DC09 084/384/085/385/086/386/087/387/089/389A
Other engine types
5, straight
4-stroke engine
130/5.12
140/5.51
9.3/567.5
1-2-4-5-3
18:1
17:1
16:1
Anti-clockwise
Clockwise
Coolant
0.45/0.018
0.70/0.028
158
500-975
1,800/2,100
Diesel
975/2,150
950/2,094
Lubrication system
Oil volume
Oil cleaning
Oil cooler
Oil filter
Interval between oil changes (h)
Oil pressure (bar/psi)
Normal with hot engine and nominal engine speed
Minimum permitted at idling speed
Crankcase pressure with closed crankcase ventilation (mbar/psi)
OPM 100 en-GB
83
© Scania CV AB 2017, Sweden
See Maintenance
Centrifugal oil cleaning
Coolant cooled, full flow
Paper filter from Scania
500
3-6/43.5-87
0.7/10.2
-5.4 to 2.0/-0.08 to 0.03
Technical data
Intake system
Permissible pressure drop in the intake system with cleaned or new filter
(mbar/psi)
Permissible pressure drop in the intake system with blocked (dirty) filter
(mbar/psi)
30/0.44
65/0.94
Cooling system
Coolant volume, excluding radiator (dm3/US gallons)
DC09 084/085/086/087/089/384/385/386/387/389A
Other engine types
Coolant volume including 1.1 m2 radiator (dm3/US gallons)
DC09 084/085/086/087/089/384/385/386/387/389A
Other engine types
Coolant temperature (°C/°F)
Number of thermostats
Thermostat opening temperature (°C/°F)
16/4.2
15/4.0
38/10.0
37/9.8
90-95/194-203
1
80/176 and 87/189
Fuel system
Injection system
XPI (Extra High Pressure Injection)
EMS
Paper filter from Scania
Paper filter from Scania
Engine management system
Fuel filter
Water separating prefilter
Electrical system
Type
Starter motor, standard equipment
Alternator, standard equipment
OPM 100 en-GB
1-pin, 24 V, DC
1-pin, 24 V, 6 kW
1-pin, 28 V, 100 A
84
© Scania CV AB 2017, Sweden
Scania Assistance
Scania Assistance
Wherever you are, you can always get assistance
from the Scania service organisation, Scania Assistance, all day, every day of the year.
Always call the contact for your country.
AR
AT
AU
0800 999 722 642
+43 1 256 44 11
1300 SCANIA
1300 722 642
BA +387 61 225 917
BE +32 2 264 00 00
BG +359 886 660 001
BR 0800 019 42 24
BW +27 11 226 5005
CA +1-800-2-SCANIA
CH +41 800 55 24 00
CL 188 800 722 642
CZ +420 225 020 225
DE +49 261 887 8888
DK +45 333 270 44
EE +372 5153 388 (Tallinn)
+372 5126 333 (Tartu)
+372 5071 477 (Pärnu)
+372 5047 655 (Rakvere)
ES +34 91 678 80 58
FI
+358 10 555 24
FR +33 2 41 41 32 32
GB 0 800 800 660
+44 1274 301 260
GR +30 6944 420 410
HU +36 209 727 197
IE
+353 71 963 4000
IT
+39 0461 996 222
KR +82 1588 6575
LU
MA
ME
MW
MY
+32 226 400 000
+32 2264 0000
+381 60 8484 122
+27 11 2265005
1800 08 8500
+603 55909077
MX 01 800 4SCANIA
NA +27 11 226 5005
NL +31 76 52 54 111
NO +47 223 217 00
PE 0800 51 727
PL +48 22 331 22 33
PT +34 91 678 9237
RO +40 723 27 27 26
RS +381 60 8484 122
SE +46 42 100 100
SG (65) 6591 7180
+65 6861 9181
SI
+386 1 2427 606
SK +421 903 722 048
TR +90 444 72 44
TZ +27 11 226 5005
US 1-800-2-SCANIA
UY 0800 8351
ZA 0800 005 798
+27 11 226 5005
ZM +27 11 2265005
ZW +27 11 2265005
Other countries: +46 8 52 24 24 24
Note:
Calls will be recorded for training purposes.
OPM 100 en-GB
85
© Scania CV AB 2017, Sweden
General tightening torques for screw joints
General tightening torques
for screw joints
Hexagon screws, hexagon
socket screws, Torx screws,
hexagon nuts
Metric thread. Strength class 8.8/8.
Thread
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
Tightening torque
Nm
Lb-ft
2.9
21
6
4
9.5
7
24
18
47
35
84
62
135
100
210
155
290
214
420
310
580
428
730
538
Flange screws with hexagonal head and hexagonal
flange nuts
Thread
M5
M6
M8
M10
M12
M14
M16
OPM 100 en-GB
321 515
Metric thread. Strength class 8.8/8.
Tightening torque
Nm
Lb-ft
6.7
5
10.2
8
26
19
50
37
92
38
149
110
184
136
86
© Scania CV AB 2017, Sweden
General tightening torques for screw joints
Hose clamps
Specifications in the tables show tightening
torque when tightening by hand.
A = width
(mm)
7.5-9
12
Tightening torque
Nm
Lb-ft
1.5
1
5
4
D
327 162
A
Tightening torque for new unfitted hose clamp is
max 1 Nm (0.7 lb-ft).
OPM 100 en-GB
87
© Scania CV AB 2017, Sweden
A
326 615
20
25
Tightening torque
Nm
Lb-ft
10
7
20
15
A
326 616
A = width
(mm)
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