Manual Scania DC 13 PDF

You might also like

Download as pdf or txt
Download as pdf or txt
You are on page 1of 60

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 impor-
tant to bear in mind the risk of injury.

Operator's manual
DC13
PDE
Industrial engine
en-GB 2 428 360
Issue 3.0

Start-up Report – Warranty


The warranty starts when the start-up report has been filled in and sent to Scania. The normal warranty pe-
riod is 1 year, but other conditions can apply.
Fill in the particulars in the start-up report below as well. This can make things easier if you need to contact
a workshop, for example.

Engine serial number


Date of entry into service
User's name and address

Signature
Engine type
Variant

Engine type and variant are indicated on the engine data plate.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Preparing the engine for storage . . . . . . . . . . .55
Environment and safety . . . . . . . . . . . . . . . . . . 4 Handling the engine . . . . . . . . . . . . . . . . . . . .55
Environmental responsibility . . . . . . . . . . . . . 4 Preservative coolant . . . . . . . . . . . . . . . . . . . .55
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Preservative fuel. . . . . . . . . . . . . . . . . . . . . . .55
Warnings and advisories . . . . . . . . . . . . . . . . . 5 Preservative oil. . . . . . . . . . . . . . . . . . . . . . . .55
Certification . . . . . . . . . . . . . . . . . . . . . . . . . 10 Preparations for storage . . . . . . . . . . . . . . . . .56
Engine data plate . . . . . . . . . . . . . . . . . . . . . . . 11 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . .58
Component identification . . . . . . . . . . . . . . . . 12 General data . . . . . . . . . . . . . . . . . . . . . . . . . .58
Starting and running . . . . . . . . . . . . . . . . . . . . 13 Lubrication system . . . . . . . . . . . . . . . . . . . . .58
Checks before running . . . . . . . . . . . . . . . . . 13 Injection system . . . . . . . . . . . . . . . . . . . . . . .59
Starting the engine . . . . . . . . . . . . . . . . . . . . 13 Cooling system. . . . . . . . . . . . . . . . . . . . . . . .59
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Intake system . . . . . . . . . . . . . . . . . . . . . . . . .59
Engine shutdown. . . . . . . . . . . . . . . . . . . . . . 16 Electrical system . . . . . . . . . . . . . . . . . . . . . .59
Checks after running . . . . . . . . . . . . . . . . . . . 16 Scania Assistance . . . . . . . . . . . . . . . . . . . . . . .60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engines with few hours of operation . . . . . . 18
Maintenance intervals . . . . . . . . . . . . . . . . . . 19
Lubrication system . . . . . . . . . . . . . . . . . . . . . 20
Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Checking oil level . . . . . . . . . . . . . . . . . . . . . 21
Changing the oil . . . . . . . . . . . . . . . . . . . . . . 22
Labels for top-up engine oil grade . . . . . . . . 23
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cleaning the centrifugal oil cleaner . . . . . . . 24
Operational testing . . . . . . . . . . . . . . . . . . . . 29
Renewing the oil filter. . . . . . . . . . . . . . . . . . 30
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 31
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Checking coolant level . . . . . . . . . . . . . . . . . 34
Checking antifreeze and corrosion inhibitor . 34
Antifreeze and corrosion inhibitor . . . . . . . . 35
Changing coolant . . . . . . . . . . . . . . . . . . . . . 36
Cleaning the cooling system . . . . . . . . . . . . . 38
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Reading the vacuum indicator. . . . . . . . . . . . 40
Renewing the filter element . . . . . . . . . . . . . 40
Renewing the safety cartridge. . . . . . . . . . . . 41
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking fuel level . . . . . . . . . . . . . . . . . . . . 42
Renewing the fuel filter. . . . . . . . . . . . . . . . . 43
Renewing the water separating fuel filter . . . 44
Bleeding the fuel system . . . . . . . . . . . . . . . . 45
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking the drive belt . . . . . . . . . . . . . . . . . 46
Checking for leaks . . . . . . . . . . . . . . . . . . . . 47
Checking and adjusting the valve clearance . 48
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Composition of the fuel. . . . . . . . . . . . . . . . . 53
Sulphur content of fuel . . . . . . . . . . . . . . . . . 53
Temperature dependency of the fuel. . . . . . . 53
Biodiesel (FAME). . . . . . . . . . . . . . . . . . . . . 54
Use of fuel oil in stand-by generator sets . . . 54

OPM 210 en-GB 2


© Scania CV AB 2016, Sweden
Introduction

Introduction
This Operator's manual describes the operation
and maintenance of Scania industrial engines.
The engines are direct-injection, liquid-cooled,
four-stroke turbocharged diesel engines.
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.

Note:
Only standard components are described in the
operator's manual. Information about special
equipment is contained in instructions from the
various manufacturers.

To ensure the maximum performance and the


longest service life for the engine remember the
following:
• 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 an authorised Scania work-
shop.

The information in this manual was correct at the


time of going to press. Scania reserves the right
to make alterations without prior notice.

Note:
Always use Scania spare parts for maintenance
and repair.

OPM 210 en-GB 3


© Scania CV AB 2016, Sweden
Environment and safety

Environment and safety Different types of advisory


Warning!
Environmental responsibility All advisories preceded by Warning! are very
Scania develops and produces engines that are as important. They warn of serious faults and incor-
environmentally-friendly as possible. Scania has rect operation that could lead to personal injury.
made major investments in the reduction of Example:
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 Block the starting device when working on the
a high level of performance and operating econ- engine. If the engine starts unexpectedly, there is
omy for Scania Industrial and Marine Engines. a serious risk of injury.
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 and lubricating oil as outlined in the Op-
erator's manual. Important!
Other green initiatives taken include ensuring Advisories preceded by Important! warn of
that, following maintenance and repair, waste faults and incorrect operation that could lead to
that is harmful to the environment (for example equipment being damaged. Example:
oil, fuel, coolant, filters and batteries) is disposed
of accordance with the applicable environmental IMPORTANT!
requirements.
For Scania to guarantee that the engine corre-
sponds to its certified configuration, and take re-
Safety sponsibility for any damage and injuries that
occur, maintenance must be carried out as above.
The following pages contain a summary of the
safety precautions to be complied with when op-
erating and maintaining Scania engines. The
equivalent text can also be found under the rele-
vant maintenance item.
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.

OPM 210 en-GB 4


© Scania CV AB 2016, Sweden
Environment and safety

Note: Safety precautions for running the


Advisories preceded by Note: refer to informa- engine
tion important to ensure the best possible opera- Daily maintenance
tion and functionality. Example:
Always carry out a visual inspection of the en-
Note: gine and engine compartment before starting the
Always use genuine Scania parts during mainte- engine or when the engine has been switched off
nance and repair so as to keep your engine in the after operation.
best possible working order. This inspection should be done to detect fuel, oil
or coolant leaks, or anything else that may re-
quire corrective action.

Environment
This Operator’s manual contains specially high- Fuel
lighted text with instructions to help protect the Use only fuel recommended in the Workshop
environment during maintenance. Example: Manual.

Environment WARNING!

Use a container to avoid spillage. The wrong fuel grade can cause breakdowns or
stoppages by causing the injection system to
malfunction. This can cause damage to the en-
gine and, possibly, personal injury.
Warnings and advisories
Smoking
Refuelling
WARNING! Never overfill the fuel tank as the fuel needs
space to expand. Also ensure that the filler cap is
Smoking is prohibited properly closed.

• in the vicinity of flammable or explosive ma-


terial, e.g. fuel, oils, batteries, chemicals WARNING!
• when refuelling and in the vicinity of the fill-
During refuelling there is a risk of fire and explo-
ing station
sion. The engine must be switched off and smok-
• when working on the fuel system ing is prohibited.

OPM 210 en-GB 5


© Scania CV AB 2016, Sweden
Environment and safety

Hazardous gases Running

WARNING! WARNING!

Only start the engine in a well ventilated area. The engine must not be run in environments
The exhaust gases contain carbon monoxide and where there is a risk of explosion, as all of the
nitrogen oxides, which are toxic. electrical or mechanical components can gener-
ate sparks.
If it is run in an enclosed space, there should be
an effective device to extract exhaust gases and Approaching a running engine always poses a
crankcase gases. 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 ro-
tating parts and hot surfaces must be fitted with
guards.
Starter lock

IMPORTANT!

If the control panel is not fitted with a starter Safety precautions for handling ma-
terials
lock, the engine compartment should be locked
to prevent unauthorised personnel from starting Fuel and lubricating oil
the engine. Alternatively, a lockable master
switch or battery master switch can be used.
WARNING!

All fuels and lubricants as well as many chemi-


cals are flammable. Always follow the instruc-
Starter gas tions on the relevant packaging.
The work must be carried out on a cold engine.
WARNING!
Fuel leaks and spillage on hot surfaces can cause
fire.
Never use starter gas or similar agents to help
start the engine. This can cause an explosion in Store used rags and other flammable materials
the intake manifold and possible injury. safely so as to avoid spontaneous combustion.

OPM 210 en-GB 6


© Scania CV AB 2016, Sweden
Environment and safety

Batteries Safety precautions for maintenance


and repair
WARNING! Switch off the engine
Always switch off the engine before carrying out
The batteries contain and form oxyhydrogen gas,
maintenance and repair work, unless otherwise
particularly during charging. Oxyhydrogen gas
indicated.
is flammable and highly explosive.
Make it impossible to start the engine: Remove
There must be no smoking, naked flames or
any starter key, or cut the power using the main
sparks near the batteries or the battery compart-
power switch or battery master switch and lock
ment. Incorrect connection of a battery cable or
them.
jump lead can cause a spark, which can cause the
battery to explode. Fix a warning plate somewhere appropriate,
showing that work is being carried out on the en-
gine.

Chemicals WARNING!

WARNING! Working with a running engine always poses a


safety risk. Parts of the body, clothes or dropped
Most chemicals such as glycol, anti-corrosive tools can get caught in rotating parts and cause
agents, preservative oils and degreasing agents, injury.
are hazardous to health.
Some chemicals, such as preservative oil, are
also flammable.
Hot surfaces and fluids
Always follow the safety precautions on the rel-
evant packaging.
WARNING!
Store chemicals and other materials which are
hazardous to health in approved containers, There is always a risk of sustaining burns when
marking them clearly and storing them where an engine is hot. Particularly hot parts are engine
they are inaccessible to unauthorised persons. manifolds, turbochargers, oil sumps, hot coolant
and oil in pipes and hoses.

Environment

Always hand in leftover and used chemicals to


an authorised waste disposal contractor.

OPM 210 en-GB 7


© Scania CV AB 2016, Sweden
Environment and safety

Lifting the engine Electrical system


Always use the engine lifting eyes. Always The engine must be switched off and the power
check that lifting accessories are in good condi- disconnected using the master switch or battery
tion and are designed to lift the weight. master switch before working on the electrical
system. External power supplies to extra equip-
Optional equipment on the engine can change ment on the engine must also be disconnected.
the centre of gravity. This means that it may be
necessary to use additional lifting devices to bal-
ance the engine correctly and lift it safely. IMPORTANT!

Always use Scania spare parts for the fuel and


WARNING! electrical systems. Scania spare parts are de-
signed to minimise the risk of fire and explosion.
Never work underneath a suspended engine!

Electric welding
Batteries
IMPORTANT!
WARNING!
When carrying out welding work on and near the
The batteries contain highly corrosive sulphuric engine, disconnect the battery and alternator
acid. Take care to protect your eyes, skin and leads. Pull out the multi-pin connector for the en-
clothes when charging or handling batteries. gine control unit as well.
Wear protective gloves and goggles.
Connect the welding clamp close to the compo-
If sulphuric acid comes in contact with the skin: nent to be welded. The welding clamp must not
Wash with soap and plenty of water. If it gets in be connected to the engine, or so that the current
your eyes: Rinse immediately with plenty of wa- can cross a bearing.
ter and seek medical attention.
When welding is finished:
1. Connect the alternator and control unit ca-
bles first.
Environment
2. Then connect the batteries.
Always hand in used batteries to an authorised
waste disposal contractor.

OPM 210 en-GB 8


© Scania CV AB 2016, Sweden
Environment and safety

Lubrication system Fuel system

WARNING! WARNING!

Hot oil can cause burns and skin irritation. Wear Always wear protective goggles when testing in-
protective gloves and goggles when changing jectors. Fuel escaping at high pressure can pene-
hot oil. trate tissues and cause serious injury.
Make sure that there is no pressure in the lubri- Always use Scania spare parts for the fuel and
cation system before starting work on it. electrical systems. Scania spare parts are de-
signed to minimise the risk of fire and explosion.
The oil filler cap must always be in place when
starting and running the engine to prevent oil be-
ing ejected.

Before starting
Environment Ensure that all guards are in place before starting
the engine. Ensure that no tools or other objects
Always hand in used oil to an authorised waste have been left on the engine.
disposal contractor.
WARNING!

The air filter must be fitted before starting the en-


Cooling system gine. 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.
WARNING!

Never open the coolant filler cap when the en-


gine is hot. Hot coolant and steam may spray out
and cause burns.
If the cap has to be opened do it slowly and care-
fully to release the pressure before removing the
cap. Wear gloves as the coolant is still very hot.

Environment

Always hand in used coolant to an authorised


waste disposal contractor.

OPM 210 en-GB 9


© Scania CV AB 2016, Sweden
Environment and safety

Certification
An emissions certified engine fulfils the emis-
sions requirements for a particular range of ap-
plication.
On each emissions certified engine there is a la-
bel 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.
The following are required for the certified en-
gine to fulfil the emissions requirements once it
has been taken into service:
• Maintenance is to be carried out in accord-
ance with the instructions in this Operator's
manual.
• Maintenance and repairs of injection equip-
ment are to be carried out by an authorised
Scania workshop.
• The engine may only be modified with equip-
ment that has been approved by Scania.
• Seals may be broken and setting data edited
only once approval has been granted by Sca-
nia. Modifications may be made by author-
ised personnel only.
• Modifications affecting the exhaust and in-
take systems must be approved by Scania.

Otherwise, the instructions in the Operator's


manual for the running and maintenance of the
engine shall apply. The safety precautions on the
following pages must be observed.

IMPORTANT!

For Scania to guarantee that the engine corre-


sponds to its certified configuration, and take re-
sponsibility for any damage and injuries that
occur, maintenance must be carried out as above.

OPM 210 en-GB 10


© Scania CV AB 2016, 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
operating 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 lo-
cated on the engine control unit.
The engine serial number is stamped onto the top
of the cylinder block at the front right.

Example: DC13 074A


DC Supercharged diesel engine with air-cooled charge air cooler.
13 Displacement in whole dm3.
074 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.

Made b y

Type DC13 074A


Engine No 1234567
Output . 257-368 kW 2100 r pm .
Output . kW r pm .
350 594

Example of an engine data plate

OPM 210 en-GB 11


© Scania CV AB 2016, Sweden
Component identification

Component identification

1 2 3
9
10
4
5 11

7 15
318 018
8
13 12

318 017
14

The illustrations show a normal version of a DC13 engine. The engine ordered may have different equip-
ment.

Note:
The water separating prefilter for the fuel is lo-
cated between the fuel tank and engine.

1. Turbocharger 9. Engine data plate


2. Oil cooler 10. Fuel filter
3. Oil filler 11. Fuel pump with hand pump
4. Engine serial number on the cylinder 12. Starter motor
block 13. Oil dipstick
5. Oil filter 14. Oil plug
6. Coolant pump 15. Engine control unit
7. Valve for draining coolant
8. Centrifugal oil cleaner

OPM 210 en-GB 12


© Scania CV AB 2016, Sweden
Starting and running

Starting and running If the fuel tank has been run dry or if the engine
has not been used for a long time, bleed the fuel
Note: system.
When the engine is started for the first time, car-
ry out the maintenance items listed under First WARNING!
start in the maintenance schedule. See the Main-
tenance section. Never use starter gas or similar agents to help
start the engine. An explosion may occur in the
intake manifold with a risk of personal injury.
Always check the following before running:
Only start the engine in a well ventilated area.
• oil level
When the engine is run in an enclosed space,
• coolant there must be effective devices to extract exhaust
• fuel level gases and crankcase gases.
• electrolyte level in batteries
• state of charge of the batteries
• condition of the drive belt. IMPORTANT!

Checks before running


The starter motor must only be cranked twice for
30 seconds at a time. After that, it must rest for at
Carry out daily maintenance as described in the least 5 minutes before the next attempt to start it.
maintenance schedule prior to operation. See the
Maintenance section.
Starting at low temperatures and at
high altitudes
WARNING!
Take the local environmental requirements into
account. Use a fuel heater and engine heater to
Block the starting device when working on the avoid starting problems and white smoke.
engine. If the engine starts unexpectedly, there is
a serious risk of injury. Scania recommends that an engine heater should
be used if the engine will be used at temperatures
below -10°C or at an altitude of more than 2,000
Starting the engine metres.
A low engine speed and a moderate load on a
For environmental reasons the Scania engine has cold engine limits white smoke, gives better
been developed to be started with a low fuel feed. combustion and warms up the engine more
Using unnecessarily large amounts of fuel when quickly than warming it up with no load.
starting the engine always results in emissions of
unburnt fuel. Avoid running it longer than necessary at idling
speed.
1. Open the fuel cock if fitted.
2. Disengage the engine.
3. If the engine has a battery master switch:
Connect the power using the battery master
switch.
4. Start the engine.

OPM 210 en-GB 13


© Scania CV AB 2016, Sweden
Starting and running

Running Throttle opening fault, but the idling switch is


working:
Check instruments and warning lamps at regular
intervals. • The throttle opening value can be increased
slowly between 0 and 50% by using the idling
switch.
Engine speed range CAN fault:
• The engine is switched off if the shutdown
600-750 rpm Low idling. Engine idling is function is activated.
controlled by the engine
management system.
Low idling up to Engine operating speed
2,100 rpm range. Controlled by the Driving at high altitude
engine management system. When driving at high altitudes engine power is
2,100-2,600 rpm Unsuitable operating speed, reduced automatically due to the lower oxygen
but a slightly higher engine content in the air. It is then not possible to run the
speed than the normal maxi- engine at maximum power.
mum operating speed may
occur when load is low or Note:
negative. Driving at a higher height than 4,000 metres
2,600-3,000 rpm Prohibited engine speed. above sea level is only permitted if it has first
been approved by Scania.

Limp home mode


If there is a fault in the normal throttle opening or
if CAN communication is interrupted, the fol-
lowing emergency operation option is provided:
A CAN fault or throttle opening fault in an all-
speed engine (both signal and idling switch):
• The throttle opening value is 0% and the en-
gine is running at normal idling speed.
• The throttle opening value is 0% and the en-
gine is running at raised idling speed (750
rpm) if this function is activated.

OPM 210 en-GB 14


© Scania CV AB 2016, Sweden
Starting and running

Coolant temperature Oil pressure


Normal coolant temperature during operation is Information about the normal oil pressure and
80-90°C/176-194°F. lowest permitted oil pressure is contained in the
section headed Technical Data.
Alarm levels are set in the engine control unit.
The default setting for the lowest and highest The engine management system has the follow-
limit values for high coolant temperature are ing alarm levels:
95°C/203°F and 105°C/221°F respectively.
• At an engine speed below 1,000 rpm and an
The high coolant temperature alarm has the fol- oil pressure below 0.7 bar/10.2 psi.
lowing functions: • At an engine speed above 1,000 rpm and an
• Alarm only. oil pressure below 2.5 bar/36.3 psi for longer
than 3 seconds.
• Alarm and torque reduction at the lowest lim-
it value. The incorrect oil pressure alarm has the follow-
• Alarm at the lowest limit value and engine ing functions:
shutdown at the highest limit value.
• Alarm only.
• Alarm, torque reduction at the lowest limit
• Alarm and torque reduction by 30%.
value and engine shutdown at the highest lim-
it value. • Alarm and engine shutdown.
• Alarm at the lowest limit value and engine • Alarm and engine shutdown override control.
shutdown at the highest limit value with the
possibility of engine shutdown override con- Note:
trol. High oil pressure (above 6 bar/87 psi) is normal
• Alarm, torque reduction at the lowest limit if the engine is cold when started
value and engine shutdown at the highest lim-
it value, with the possibility of engine shut-
down override control. Charging indicator lamp
If run for extended periods under an extremely If the lamp comes on during operation:
light load, the engine may have difficulty in • Check and adjust the alternator drive belts as
maintaining the coolant temperature. At an in- described under the corresponding mainte-
creased load the coolant temperature rises to the nance item. See the Maintenance section.
normal value.
If the charging indicator lamp is still on, this
could be due to an alternator fault or a fault in the
IMPORTANT!
electrical system.
An excessively high coolant temperature can Belt transmission
damage the engine.
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 op-
eration.
The noise does not affect the service life of the
belt transmission.

OPM 210 en-GB 15


© Scania CV AB 2016, Sweden
Starting and running

Engine shutdown Checks after running


1. Run the engine without a load for a few min-
utes if it has been run continuously with a WARNING!
heavy load.
2. Switch off the engine. Block the starting device when working on the
engine. If the engine starts unexpectedly, there is
Note: a serious risk of injury.
The battery voltage must remain on for a few There is always a risk of sustaining burns when
seconds after the 15 voltage is switched off so an engine is hot. Particularly hot parts are turbo-
that the control units can store the values and chargers, oil sumps, hot coolant and oil in pipes
switch to standby mode. and hoses.
10 prohibited engine shutdowns will cause a
torque reduction (70% of fuel quantity). Reset 1. Check that the power supply has been cut.
the engine by switching it off correctly once.
2. Fill the fuel tank. Make sure that the filler
cap and the area round the filler opening are
clean to avoid contamination of the fuel.
IMPORTANT! 3. If there is a risk of freezing, the cooling sys-
tem must contain enough glycol.
There is risk of post boiling and of damage to the
4. If the temperature is below 0°C/32°F: Pre-
turbocharger if the engine is switched off with-
pare for the next start by connecting the en-
out cooling.
gine heater (if fitted).
The power must not be switched off before the
engine has stopped.
IMPORTANT!

Check the coolant level following the first start.


Top up if necessary.

OPM 210 en-GB 16


© Scania CV AB 2016, Sweden
Maintenance

Maintenance
IMPORTANT!
The maintenance programme covers a number of
points that are divided into the following sec- On delivery a Scania engine is optimised for its
tions: application. However, regular maintenance is
necessary to:
• Lubrication system
• Cooling system • prevent unplanned stops
• Air cleaner • extend the service life of the engine
• Miscellaneous • maximise the long-term emission perfor-
mance 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.

The maintenance programme includes the fol-


lowing:
• S maintenance: Minimum basic maintenance.
• M maintenance: More extensive mainte-
nance.
• L maintenance: Includes nearly all mainte-
nance items.
• XL maintenance: Includes all maintenance
items.

During a period, the sequence is S-M-S-L-S-M-


S-L-S-M-S-XL.

XL
L L
M M M
S S S S S S

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
313 153

OPM 210 en-GB 17


© Scania CV AB 2016, Sweden
Maintenance

Engines with few hours of op-


eration

IMPORTANT!

On engines with few hours of operation, mainte-


nance must be carried out annually or every 5
years.

Stand-by generator sets and the like that are not


used regularly should be test run and checked in
accordance with the manufacturer's instructions.
The following maintenance items must be car-
ried out once the engine has been warmed up to
operating temperature.
1. Checking oil level.
2. Checking coolant level.
3. Checking the vacuum indicator.
4. Checking fuel level.
5. Check for engine leaks.

OPM 210 en-GB 18


© Scania CV AB 2016, Sweden
Maintenance

Maintenance intervals

Daily First time at Interval (hours) At least


first start 500 500 1,000 2,000 6,000 annu- every
R S M L XL ally 5
years
Lubrication system
Checking oil level X X
Changing the oil X X X X X X
Cleaning the centrifugal oil
X X X X X X
cleaner
Renewing the oil filter X X X X X X
Cooling system
Checking coolant level X X X X X X X
Checking antifreeze and corro-
X X X X
sion inhibitor
Cleaning the cooling system and
X X
changing coolant
Air cleaner
Reading the vacuum indicator X X X X X X
Renewing the filter element X X X
Renewing the safety cartridge X X X
Fuel system
Checking fuel level X X
Renewing the fuel filter X X X X
Miscellaneous
Checking the drive belt X X X X X
Checking for leaks X X X X X
Checking and adjusting the valve
X X X
clearance

OPM 210 en-GB 19


© Scania CV AB 2016, Sweden
Lubrication system

Lubrication system
Oil grade
Scania LDF stands for the Scania Long Drain
Field test standard. Scania LDF oils have been
carefully selected after extensive testing. The ap-
proval is only granted to the highest quality en-
gine oils available on the market.

Recommended oil
Scania Oil LDF
Scania Oil LDF-2
Scania Oil LDF-3
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.

Check with your oil supplier that the oil meets


these requirements.
If the engine is used in areas of the world where
lubricating oil with ACEA or API classification
is not available, the oil grade must be measured
in actual operation. In this case contact the near-
est Scania workshop.
For operation at extremely low outdoor tempera-
tures: Consult your nearest Scania representative
on how to avoid starting difficulties.

Viscosity class Outdoor temperature


SAE 20W-30 -15°C (5°F) - +30°C (86°F)
SAE 30 -10°C (14°F) - +30°C (86°F)
SAE 40 -5°C (23°F) - > +45°C (113°F)
SAE 50 0°C (32°F) - > +45°C (113°F)
SAE 5W-30 < -40°C (-40°F) - +30°C (86°F)
SAE 10W-30 -25°C (-13°F) - +30°C (86°F)
SAE 15W-40 -20°C (-4°F) - > +45°C (113°F)

OPM 210 en-GB 20


© Scania CV AB 2016, Sweden
Lubrication system

Oil analysis
To be able to extend the oil change intervals us-
ing an oil analysis, Scania LDF-2 and LDF-3 oils
must be used.
Oil companies can offer analysis of the engine
oil.
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 51452): < 3%

Such analysis measures the oil's TBN (Total


Base Number), TAN (Total Acid Number), fuel
dilution, water content, viscosity and the quanti-
ty 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 inter-
val.
If the conditions are changed, a new oil analysis
programme must be carried out to establish new
change intervals.

Checking oil level 2

Checking the oil level with the engine


switched off
1
Note:
Leave the engine off for at least 1 minute before
checking the oil level.

1. Remove the oil dipstick (1) and check the oil


312 506

level. The correct level is between the mini-


mum and maximum marks on the oil dip-
stick.
2. Top up with more oil (2) when the oil level is
at or below the lower mark.

Information on the correct oil type is found under


the heading Oil grade.

OPM 210 en-GB 21


© Scania CV AB 2016, Sweden
Lubrication system

Changing the oil

WARNING!

Hot oil can cause burns and skin irritation. Wear


protective gloves and goggles when changing
hot oil. Make sure that there is no pressure in the
lubrication system before starting work on it.
The oil filler cap must always be in place when
starting and running the engine to prevent oil be-
ing ejected.

Note:
Renew the oil filter and clean the centrifugal oil
cleaner when changing oil.

314 603
Change oil more often if the engine is subjected
to particularly demanding operation, such as a
dusty environment, or if deposits in the centrifu- Max. 45 litres (11.9 US gallons).
gal oil cleaner are thicker than 28 mm (1.1 in).
Min. 39 litres (10.3 US gallons).

Environment

Use a container to avoid spillage. Used oil must


be disposed of as specified in national and inter-
national law.

1. Unscrew the oil plug and drain the oil when 314 602
the engine is hot. In certain engines the oil is
pumped out by means of a bilge pump.
When draining with the valve, the oil should Max. 34 litres (9 US gallons).
be hot. Alternatively, use a pump. This so Min. 28 litres (7.4 US gallons).
that draining occurs more quickly.
2. Clean the magnet on the oil plug.
3. Refit the oil plug.
30°
4. Top up with oil.
30°
5. Check the level on the oil dipstick.
30° 30°
Maximum angles of inclination during opera-
tion
25°
Maximum permissible angles during operation 25°
vary, depending on the type of oil sump; see il- 30° 30°
lustration.
35°

35°
343 839

45° 45°

OPM 210 en-GB 22


© Scania CV AB 2016, Sweden
Lubrication system

Labels for top-up engine oil


grade
When changing oil it is important to use the cor-
rect engine oil grade.
The oil filler cap must be clearly marked with a
label showing the top-up oil grade.

If the label is missing or if the engine oil grade is


changed, a new label must be fitted.

336 492
Filling label in the cylinder block.

353 114
Filling label in the rocker cover.

Parts

Oil grade Colour Part No. Part No.


Filling in the cylinder Filling in the rocker cover
block
Scania LDF-2 Blue 2 132 424 2 296 064
Scania LDF-3 Red 2 132 426 2 296 066
Scania LDF Grey 2 269 345 2 296 071
ACEA E7 White 2 132 425 2 296 065
Scania Low Ash Green 2 132 427 2 296 067
Scania Bioethanol Black 2 132 428 2 296 068
Scania BEO-2 Orange 2 258 841 2 296 070
ACEA E9 - 2 132 429 2 296 069

OPM 210 en-GB 23


© Scania CV AB 2016, Sweden
Lubrication system

Cleaning the centrifugal oil


cleaner
Designation Illustration
Torque wrench 2-20 Nm with exchangeable ratchet head

340 130
When cleaning the centrifugal oil cleaner there
will be some dirt deposits in the rotor cover. If
this is the case, this indicates that the rotor is
working. If it is clean and not working, the cause
must be established immediately.
If the dirt deposit exceeds 28 mm at the recom-
mended intervals, the rotor cover should be
cleaned more often.

WARNING!

The oil may be hot. Carefully remove the cover x 1.5


from the centrifugal oil cleaner.

1. Clean the cover. Unscrew the nut securing


the outer cover.
2. Let the oil run out from the rotor.
3. Lift out the rotor. Wipe off the outside. Undo
the rotor nut and unscrew it about 1.5 turns to

133 315
protect the bearing.

Note:
Take care not to damage the rotor shaft.

OPM 210 en-GB 24


© Scania CV AB 2016, Sweden
Lubrication system

4. If the rotor nut is difficult to get loose, turn


the rotor upside down and fasten the rotor nut
in a vice. Turn the rotor anti-clockwise
1.5 turns by hand or use an M20 nut, see il- M20
lustration.

IMPORTANT!

The rotor must not be put in a vice. Never strike x 1.5


the rotor cover. This may cause damage resulting
in imbalance.

133 316
5. Remove the rotor cover by holding the rotor
in both hands and tapping the rotor nut
against the table. Never strike the rotor di-
rectly as this may damage its bearings.

133 317

OPM 210 en-GB 25


© Scania CV AB 2016, Sweden
Lubrication system

6. Remove the strainer from the rotor cover. If


the strainer is stuck, insert a screwdriver be-
tween the rotor cover and strainer and care-
fully prise them apart.

127 878
7. Remove the paper insert and scrape away
any remaining dirt deposits inside the rotor
cover. If the deposits are thicker than 28 mm,
the centrifugal oil cleaner must be cleaned
more often.

333 044

8. Wash all parts.


9. Inspect the 2 nozzles on the rotor. Ensure that
they are not blocked or damaged. Renew any
damaged nozzles.
10. Check that the bearings are undamaged.
333 037

OPM 210 en-GB 26


© Scania CV AB 2016, Sweden
Lubrication system

11. Fit a new paper insert on the inside of the ro-


tor cover.

2 3 4

337 178

OPM 210 en-GB 27


© Scania CV AB 2016, Sweden
Lubrication system

12. Fit the strainer onto the rotor.


13. Fit a new O-ring by sliding it over the strain-
er.
14. Refit the rotor cover. Ensure that the O-ring
is not outside the cover.
15. Tighten the rotor nut by hand.
16. Check that the shaft is not damaged or loose.

127 881
Note:
Take care not to damage the rotor shaft.

17. Refit the rotor and rotate it by hand to make


sure it rotates easily.

127 882

OPM 210 en-GB 28


© Scania CV AB 2016, Sweden
Lubrication system

18. Fit a new O-ring in the cover. Refit the cover


and tighten the lock nut.

IMPORTANT!

To reduce the risk of oil leakage it is important to


tighten the cover to the correct tightening torque.

From engine serial number 6 841 928:


Tightening torque 20 Nm.
Older engine serial number:
Tightening torque 15 Nm.

Note:

333 043
A torque wrench together with a ratchet head is
suitable for use during maintenance of the cen-
trifugal oil cleaner.

Operational testing
Operational testing need only be carried out if it
is suspected that the centrifugal oil cleaner is not
working properly. For example, if there is an ab-
normally small amount of deposit in the centrif-
ugal oil cleaner in relation to the distance driven.
The rotor rotates very fast and should continue to
turn when the engine has stopped.
1. Run the engine until it is warm.
2. Turn off the engine and listen for the sound
from the rotor. Use your hand to feel if the
333 039

filter housing is vibrating.


3. If the filter housing is not vibrating, disman-
tle and check the centrifugal oil cleaner.

OPM 210 en-GB 29


© Scania CV AB 2016, Sweden
Lubrication system

Renewing the oil filter


Designation Illustration
Hexagon socket, 1/2” drive, 36 mm

118 268
IMPORTANT!

Only use a Scania oil filter.

IMPORTANT!

Clean the centrifugal oil cleaner when renewing


the oil filter. Otherwise, the oil filter will be
blocked and resistance in the filter will increase.
If this happens, an overflow valve in the filter re-
tainer opens and lets the oil pass without being
filtered.

1. Unscrew the filter with the socket.

312 503
IMPORTANT!

Do not use an adjustable spanner or other open


tool as there is risk of damaging the filter cover.

2. Lift out the filter housing cover with filter el-


ement. The filter housing will drain automat-
ically once the filter has been removed.
3. Detach the old filter from the cover by hold-
ing the cover and carefully tapping the entire
filter element against something hard. Re-
member that there will be oil splashes.
4. Fit the new filter and tighten the filter cover
to 25 Nm (18 lbf/ft).
312 502

OPM 210 en-GB 30


© Scania CV AB 2016, Sweden
Cooling system

Cooling system Coolant resistance to cold


The following example shows coolant properties
Coolant with 30 percent by volume of antifreeze and cor-
rosion inhibitor:

WARNING! • Ice slush starts to form at -16°C (3°F).


• At -30°C (-22°F), there is a risk of cooling
Ethylene glycol can be fatal if ingested and can system malfunction.
cause skin irritation and eye damage. • There is no risk of damage by freezing with a
minimum antifreeze and corrosion inhibitor
content of 35 percent by volume.
The coolant recommended by Scania is a mix-
ture of water with antifreeze and corrosion inhib- The chart depicts coolant properties at different
itor (ethylene glycol). The coolant has several percents of antifreeze and corrosion inhibitor
characteristics which are important for the oper- concentration by volume.
ation of the cooling system:
0 10 20 30 40 50 %
• Corrosion inhibitor 0
• Antifreeze -10
• Increases the boiling point -16 1
-20
The coolant should always contain 35-55% by -30
volume of antifreeze and corrosion inhibitor so 3 2
that the coolant properties ensure that the coolant -40
works correctly.
-50

312 505
Note: °C B A
The coolant should be changed when the cooling
system is cleaned: every 6,000 hours or at least Curve A: Ice formation starts (ice slush)
every 5 years. Refer to Changing coolant. Curve B: Damage by freezing occurs
Area 1: Safe area
Area 2: Malfunctions may occur (ice
slush)
Area 3: Risk of damage by freezing

OPM 210 en-GB 31


© Scania CV AB 2016, Sweden
Cooling system

Antifreeze and corrosion inhibitor con-


centration table
35% by volume of Scania antifreeze provides
sufficient protection against corrosion.
Example:
1. The total volume of the cooling system is 40
litres in this example.
2. The measured concentration of ethylene gly-
col is 35% by volume (freezing point -21
°C). According to the table there are 14 litres
of ethylene glycol in the cooling system.
3. The required concentration of ethylene gly-
col is 45% by volume (freezing point -30
°C). According to the table, 18 litres of eth-
ylene glycol are required in the cooling sys-
tem.
4. Since there are already 14 litres in the cool-
ing system, 4 litres of ethylene glycol must
be added to the cooling system (18 - 14 = 4
litres).

For calculation Adequate protection against corrosion


Volume of ethylene glycol Cooling system
(%) 20 25 30 35 40 45 50 60 volume (litres)
Ice slush forms (°C) -6 -9 -12 -21 -24 -30 -38 -50
5 6 8 11 12 14 15 18 30
6 8 10 14 16 18 20 24 40
8 10 13 18 20 23 25 30 50
9 12 15 21 24 27 30 36 60
11 14 18 25 28 32 35 42 70
12 16 20 28 32 36 40 48 80
14 18 23 32 36 41 45 54 90
15 20 25 35 40 45 50 60 100
Volume of ethylene glycol (li- 17 22 28 39 44 50 55 66 110
tres) 18 24 30 42 48 54 60 72 120
20 26 33 46 52 59 65 78 130
21 28 35 49 56 63 70 84 140
23 30 38 53 60 68 75 90 150
24 32 40 56 64 72 80 96 160
26 34 43 60 68 77 85 102 170
27 36 45 63 72 81 90 108 180
29 38 48 67 76 86 95 114 190
30 40 50 70 80 90 100 120 200

OPM 210 en-GB 32


© Scania CV AB 2016, Sweden
Cooling system

Antifreeze and corrosion inhibitor con-


centration table
35% by volume of Scania antifreeze provides
sufficient protection against corrosion.
Example:
1. The total volume of the cooling system is
10.6 US gallons in this example.
2. The measured concentration of ethylene gly-
col is 35% by volume (freezing point -6°F).
According to the table there are 3.7 US gal-
lons of ethylene glycol in the cooling system.
3. The required concentration of ethylene gly-
col is 45% by volume (freezing point -22°F).
According to the table, 4.8 US gallons of eth-
ylene glycol are required in the cooling sys-
tem.
4. 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).

For calculation Adequate protection against corrosion


Volume of ethylene glycol Cooling system
(%) 20 25 30 35 40 45 50 60 volume (US gal-
Ice slush forms (°F) 21 16 10 -6 -11 -22 -36 -58 lons)
1.3 1.6 2.1 2.9 3.2 3.7 4 4.8 7.9
1.6 2.1 2.6 3.7 4.2 4.8 5.3 6.3 10.6
2.1 2.6 3.4 4.8 5.3 6.1 6.6 7.9 13.2
2.4 3.2 4 5.5 6.3 7.1 7.9 9.5 15.9
2.9 3.7 4.8 6.6 7.4 8.5 9.2 11.1 18.5
3.2 4.2 5.3 7.4 8.5 9.5 10.6 12.7 21.1
3.7 4.8 6.1 8.5 9.5 10.8 11.9 14.3 23.8
4 5.3 6.6 9.2 10.6 11.9 13.2 15.9 26.4
Volume of ethylene glycol 4.5 5.8 7.4 10.3 11.6 13.2 14.5 17.4 29.1
(US gallons) 4.8 6.3 7.9 11.1 12.7 14.3 15.9 19 31.7
5.3 6.9 8.7 12.2 13.7 15.6 17.2 20.6 34.3
5.5 7.4 9.2 12.9 14.8 16.6 18.5 22.2 37
6.1 7.9 10 14 15.9 18 19.8 23.8 39.6
6.3 8.5 10.6 14.8 16.9 19 21.1 25.4 42.3
6.9 9 11.4 15.9 18 20.3 22.5 26.9 44.9
7.1 9.5 11.9 16.6 19 21.4 23.8 28.5 47.6
7.7 10 12.7 17.7 20.1 22.7 25.1 30.1 50.2
7.9 10.6 13.2 18.5 21.1 23.8 26.4 31.7 52.8

OPM 210 en-GB 33


© Scania CV AB 2016, Sweden
Cooling system

Checking coolant level Checking antifreeze and cor-


The following instructions apply to Scania ex- rosion inhibitor
pansion tanks. For other types of expansion
tanks, follow the manufacturer's instructions. Designation Illustration
Refractometer

WARNING!

Never open the coolant filler cap when the en-


gine is hot. Hot coolant and steam may spray out
and cause burns.

305 523
If the cap has to be opened do it slowly and care-
fully to release the pressure before removing the

138008
cap. Wear gloves as the coolant is still very hot.
Note:
Use only pure fresh water that is free from parti-
1. Open the expansion tank cap and check the cles, sludge and other impurities.
coolant level.
The right coolant level on a cold engine is
even with the lower edge of the filler neck. 1. Pour a small amount of coolant into a con-
tainer and check that the coolant is pure and
The right coolant level on a hot engine is ap-
clear.
proximately 25 mm (1 in) over the lower
edge of the filler neck. 2. Change the coolant if it is contaminated or
cloudy.
IMPORTANT! 3. Measure the antifreeze content with a refrac-
tometer.
Do not top up large quantities of coolant through
the expansion tank. Top up in accordance with
the instructions in the section headed Changing The following rules apply to ethylene glycol-
coolant instead. based coolant:
Never fill a large amount of cold coolant in a hot • The antifreeze and corrosion inhibitor content
engine. There is great risk of cracks forming in must be minimum 35 percent by volume for
the cylinder block and cylinder heads corrosion protection to be sufficient.
Only pour pre-mixed coolant into the cooling • An antifreeze and corrosion inhibitor content
system. greater than 55 percent by volume impairs the
ability to protect against frost.
• If ice forms in the coolant, there are disrup-
2. Top up with coolant as necessary. tions initially, but there is no immediate risk
of damage. The engine should not be subject-
ed to heavy loads when ice starts to form.

OPM 210 en-GB 34


© Scania CV AB 2016, Sweden
Cooling system

Antifreeze and corrosion in-


hibitor
Only the product Scania coolant, or other prod-
ucts that are tested to provide proper antifreeze
and protection against corrosion for Scania, may
be used in Scania engines. Products that do not
satisfy the requirements for use in a Scania en-
gine can result in faults in and damage to 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 antifreeze and corrosion inhibitor used in
Scania engines should be of the ethylene glycol
type.

Scania concentrate
Designation Contents Part No. Volume Volume
litre US gallons
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 323 5 1.3
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 324 20 5.3
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 325 210 55
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 326 1,000 264

Scania Ready Mix


Designation Contents Part No. Volume Volume
litre US gallons
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 921 955 5 1.3
50/50
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 921 956 20 5.3
50/50
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 921 957 210 55
50/50
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 896 695 1,000 264
50/50

OPM 210 en-GB 35


© Scania CV AB 2016, Sweden
Cooling system

Changing coolant

IMPORTANT!

Mix the coolant as specified under the section


Coolant.

Draining coolant
1. Remove the expansion tank cap.
2. Drain the coolant at the following two
points:
Lowest point of the cylinder block.
The lowest point of the cooling system.
3. Close the drain taps.

Environment

Avoid spillage and use a suitable container. Used


coolant must be disposed of as specified in na-
tional and international law.

OPM 210 en-GB 36


© Scania CV AB 2016, Sweden
Cooling system

Filling coolant

Designation Illustration
Coolant trolley

333 980
IMPORTANT!

When it is necessary to fill a large quantity of


coolant, it must be pumped in from underneath.
This is to ensure that air does not get into the
cooling system, which can cause the coolant
pump to overheat.

1. Use a Scania coolant trolley, or other suitable


equipment, to fill with coolant through the
drain valve on the cylinder block. This facil-
itates the venting of the engine.
2. Start the engine when the cooling system has
been filled. Allow the engine to run for a
while. Then check the coolant level and top
up with coolant as necessary.
3. Air pockets may still be left in the cooling
system, which will disappear after the engine
has been operated for a period of time. It
may, therefore, need some topping up to start
with.

OPM 210 en-GB 37


© Scania CV AB 2016, Sweden
Cooling system

Cleaning the cooling system External: Cleaning the radiator and


charge air cooler
1. Check that the radiator and the charge air
WARNING! cooler are not clogged on the air side and that
the cooling fins are not damaged.
To ensure proper handling of cooling system de-
2. Carefully scrape away any deposits from the
tergent, study the warning text on the package.
radiator cooling fins. Use a paraffin-based
engine cleaner if necessary.
3. Carefully straighten bent cooling fins using a
IMPORTANT! steel brush or the like.

Do not use caustic soda or other alkaline deter-


gent as this could damage the aluminium.

Note:
Clean the cooling system more often than speci-
fied in the maintenance interval if necessary.

OPM 210 en-GB 38


© Scania CV AB 2016, Sweden
Cooling system

Internal: Removing oil and grease Internal: Removing deposits


1. Run the engine until it has reached operating 1. Run the engine until it has reached operating
temperature and then drain the cooling sys- temperature and then drain the cooling sys-
tem. tem.
2. Remove the thermostats. 2. Remove the thermostats.
3. Fill the system with clean, hot water mixed 3. Fill the system with clean, hot water mixed
with liquid dishwasher detergent intended with some commercially available radiator
for household machines. Concentration 1% detergent which is based on sulphamic acid
(0.1/10 litres). and contains dispersing agents. Follow the
4. Warm up the engine for approximately 20- manufacturer's instructions for the concen-
30 minutes. Remember to switch on the cab tration and cleaning period.
heating system, if one is installed. 4. Run the engine for the specified time. Re-
5. Drain the cooling system. member to switch on the cab heating system,
if one is installed.
6. Fill the system with clean, hot water and run
the engine for about 20-30 minutes. 5. Drain the cooling system.

7. Drain the water from the cooling system. 6. Fill the cooling system with clean, hot water
and run the engine for about 20-30 minutes.
8. Refit the thermostats.
7. Drain the water from the cooling system.
9. Fill the cooling system with new coolant fol-
lowing the specification under Coolants ear- 8. Refit the thermostats.
lier in the document. 9. Fill the system with new coolant following
the specification under Coolants earlier in
the document.

Environment Environment

Avoid spillage and use a suitable container. Used Avoid spillage and use a suitable container. Used
coolant must be disposed of as specified in na- coolant must be disposed of as specified in na-
tional and international law. tional and international law.

OPM 210 en-GB 39


© Scania CV AB 2016, Sweden
Air cleaner

Air cleaner
Reading the vacuum indicator
If the indicator's red plunger is fully visible, re-
new the air cleaner filter element following the
instructions.

326 671
Renewing the filter element

WARNING!

Never start the engine without the air filter as this


could cause injury and severe engine damage. A B

Note:
Renew the filter element earlier than the mainte-
nance interval if the indicator shows red.

There is always a risk that the filter element will


be damaged when it is cleaned.

336 100
The filter element must not be cleaned in water
or be blown clean with compressed air.
A Vacuum gauge.
1. Remove the cover from the air cleaner. B Filter element.
2. Renew the filter element.
3. Carry out a check by inserting an inspection
lamp into the element and checking from the
outside that there are no holes or cracks in the
filter paper.
4. Assemble the air cleaner.
5. Reset the vacuum indicator by pressing the
button.

OPM 210 en-GB 40


© Scania CV AB 2016, Sweden
Air cleaner

Renewing the safety cartridge

IMPORTANT!

When renewing the safety cartridge, take great


care to ensure that no dirt or other impurities get
into the engine. Do not remove the safety car-
tridge unnecessarily.

1. Remove the cover from the air cleaner.


2. Remove the filter element.
3. Remove the safety cartridge.
4. Fit a new, genuine safety cartridge.
5. Renew or clean the filter element.
6. Assemble the air cleaner.

OPM 210 en-GB 41


© Scania CV AB 2016, Sweden
Fuel system

Fuel system Checking fuel level


• Check the fuel level and top up with fuel as
IMPORTANT! necessary.

The whole fuel system is very sensitive to dirt Note:


and even very small particles. Foreign particles The fuel system must be bled if the tank has been
in the system can cause serious malfunctions. It run dry. Refer to the Bleeding the fuel system
is therefore very important that everything is as section.
clean as possible when work is carried out on the
fuel system. Before starting work on the fuel sys-
tem, 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 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 be-
fore removal. When cleaning, cloths or paper
which shed fibres must not be used. Use clean
and lint-free cloths.
Plug or cover the connections during removal.
Also clean the connections before fitting the
components. Removed components should be
placed on a thoroughly cleaned, dust-free sur-
face. Cover with a lint-free cloth.

OPM 210 en-GB 42


© Scania CV AB 2016, Sweden
Fuel system

Renewing the fuel filter


Designation Illustration
Hexagon socket, 1/2” drive, 36 mm

118 268
IMPORTANT!

Fit the filter elements in the filter covers before


placing them in the fuel filter housings or the fil-
ter elements may be damaged.

1. Unscrew the filter cover with the socket.


2. Lift out the filter cover and filter element.
The filter housing will drain automatically.
This applies only if the fuel tank is lower
than the engine. Otherwise the fuel shut-off
cock must be closed first.
3. Undo the removed filter element from the
cover by carefully bending it to one side.
4. Renew the O-ring in the cover. Lubricate the
O-ring with O-ring grease.
5. Check that the filter housing is drained of fu-
el. Contaminated fuel may enter the injectors

314 824
if the drainage does not work.
6. Press a new filter element into the snap fas-
tener in the cover.
7. Fit the filter element and cover in the filter
housing. Tighten the cover to 25 Nm (18.4
lbf/ft).
8. Bleed the fuel system after renewing the wa-
ter separating filter.

Environment

Avoid spillage and use a suitable container. Used


fuel must be disposed of as specified in national
and international law.

OPM 210 en-GB 43


© Scania CV AB 2016, Sweden
Fuel system

Renewing the water separat- 1


ing fuel filter
1. Close the shut-off cock in the fuel pipe and
position a container under the filter.
2. Open the drain tap in the filter cover and let
the fluid run down into the container.
3. Unscrew the filter cover.
4. Unscrew the filter from the filter head.
5. Discard the old filter and use a new filter.
6. Lubricate the O-ring in the filter cover with
engine oil.
7. Screw the filter cover onto the new filter by
hand. Make sure that the drain tap is fully
closed.
8. Lubricate the O-ring on the filter with engine
oil. 2
9. Fill the width of the filter with clean fuel.

316 148
10. Screw the filter into position until the O-ring
rests against the filter head. Tighten the filter
another 1/2-3/4 turn by hand. 1 Shut-off cock.
11. Open the shut-off cock and check the system 2 Drain tap.
for leaks.
12. Bleed the fuel system.

OPM 210 en-GB 44


© Scania CV AB 2016, Sweden
Fuel system

Bleeding the fuel system


1. Attach a clear plastic hose to the bleed nipple
on the fuel filter housing (1). Place the end of
the plastic hose in a container that holds at
least 3 litres (0.8 US gallons).
2. Open the bleed nipple and pump with the
hand pump until fuel comes out of the hose.
If the fuel system is empty, it is necessary to
pump approximately 100 strokes in order to
draw up the fuel. Depending on the installa-
tion, a much greater number of pump strokes
may be required before fuel comes out.
3. Pump until fuel without air bubbles comes 2
out, approximately 20 strokes.
4. Close the bleed nipple and remove the hose.

5. Transfer the plastic hose to the fuel manifold

314 909
bleed nipple (2).
6. Open the fuel manifold ventilating valve.
7. Pump with the hand pump until fuel without
air bubbles comes out, approximately 50
strokes.
8. Close the bleed nipple on the fuel manifold
and remove the plastic hose.
9. Pump approximately 20 strokes with the
hand pump until the overflow valve opens. A
hissing sound should be heard.
10. Start the engine. The engine should be easy
to start.

OPM 210 en-GB 45


© Scania CV AB 2016, Sweden
Miscellaneous

Miscellaneous
Checking the drive belt

IMPORTANT!

Refit the drive belt with the same direction of ro-


tation as it had before removal.

Check the drive belt thoroughly, particularly at


the idler rollers.

312158
Check the drive belt for cracks.

106 229

The drive belt must be renewed if it has cracks.

OPM 210 en-GB 46


© Scania CV AB 2016, Sweden
Miscellaneous

Check drive belt wear.

112 931
The drive belt is starting to become worn, but can be
refitted.

112 932
The belt is worn down to the cord. The drive belt
must be renewed.

Checking for leaks


• Start the engine.
• Check for oil, coolant, fuel, air or exhaust
leaks.
• Tighten or renew leaking connections. Check
the overflow holes which show whether the
O-rings between the cylinder liners and
crankcase are leaking.
• 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.

IMPORTANT!

If serious leakage occurs, contact your nearest


Scania workshop.

OPM 210 en-GB 47


© Scania CV AB 2016, Sweden
Miscellaneous

Checking and adjusting the


valve clearance
Special tools

Number Designation Illustration


99 309 Turning tool for rotating the flywheel from below.

142 238
99 109 Turning tool for rotating the flywheel from above. Can be used on newer
flywheels that are marked with TDC UP.

312 733
99 442 Setting tool

138 773
Designation Illustration
Torque screwdriver.

341 423

WARNING!

Block the starting device when working on the


engine. If the engine starts unexpectedly, there is
a serious risk of injury.

Note:
Checking and adjusting valve clearances should
also be done one more time after the first 500
hours of operation. Then the normal interval will
follow (every 2,000 hours).
Valve adjustment should be carried out on a cold
engine.

OPM 210 en-GB 48


© Scania CV AB 2016, Sweden
Miscellaneous

Checking and adjusting the valve


clearance
Check and adjust the valve clearance with the en-
gine cold.

Specifications
Valve clearance, intake 0.45 mm (0.018 in)
valve
Valve clearance, ex- 0.70 mm (0.028 in)
haust valve

Tightening torque
Lock nut for valves 35 Nm (26 lbf/ft)

Max. clearance between two valves under the


same valve bridge is 0.2 mm.

346 529
Readings can be taken from the flywheel through
openings in the flywheel housing either from
above or below depending on access when fit-
ting.

Note:
Valve transition occurs when the cylinder
switches from exhaust stroke to intake stroke.
The exhaust valve is closing while the intake
valve is opening.
310 343

Reading in the lower window: Openings for taking readings on the flywheel hous-
ing.
Rotate the flywheel in the normal direction of ro-
tation using turning tool 99 309. Read the mark
on the flywheel visible in the lower window of
the flywheel housing.
Reading in the upper window:
Fit turning tool 99 109 in the holes of the upper
window. Press the pinion into the external ring
gear and turn the flywheel with a ratchet handle
and a 14 mm socket. Read the mark on the fly-
wheel in the upper window of the flywheel hous-
ing.

OPM 210 en-GB 49


© Scania CV AB 2016, Sweden
Miscellaneous

Adjust valves according to the table below. Fol-


low the respective column depending on whether
the reading is in the lower or the upper window.
Start adjustment at the top of the table.
1 2 3 4 5 6

319 705
Cylinder location.
Reading in the lower window of the flywheel
housing:

Mark on flywheel Valve transition on Adjust valves on cylin- Adjust injector


cylinder der
TDC down 1 6 2
120° 5 2 4
240° 3 4 1
TDC Down 6 1 5
120° 2 5 3
240° 4 3 6

Reading from the upper window of the fly-


wheel housing:

Mark on flywheel Valve transition on Adjust valves on cylin- Adjust injector


cylinder der
TDC Up 1 6 2
300° 5 2 4
60° 3 4 1
TDC Up 6 1 5
300° 2 5 3
60° 4 3 6

It is a good idea to mark the rocker arm with a


pen after adjustment to keep track of what has al-
ready been adjusted.

IMPORTANT!

Remember to remove the flywheel rotation tool


after adjustment.

OPM 210 en-GB 50


© Scania CV AB 2016, Sweden
Miscellaneous

Checking and adjusting the unit in-


jector
Check and adjust the unit injector with the en-
gine cold.

Tightening torque
Lock nut for unit injec- 39 Nm (29 lbf/ft)
tors

WARNING!

When the unit injector is being checked and the


measurement is outside the setting dimension by
±0.5 mm, it is necessary to be very careful when
handling this unit injector. The spring is pre-ten-
sioned and can come loose, causing personal in-
jury.

1. Fit the setting tool with the metal plate


around the unit injector.

314 831
1
2. When adjusting, loosen the lock nut and ad-
just the unit injector with the adjusting screw
(1). The unit injector is correctly set when the
small piston (2) is level with the flat upper
surface of the tool. Use a finger to check.
Differences measured in tenths of millime-
tres can be felt. The setting dimension is 69.9
± 0.1 mm.

2
314 832

OPM 210 en-GB 51


© Scania CV AB 2016, Sweden
Miscellaneous

144 015

The setting tool piston is above or below the flat The setting tool piston is level with the flat upper
upper surface of the tool. Adjust the unit injector. surface of the tool. The unit injector is correctly ad-
justed.

3. Tighten the lock nut after adjusting.


4. Remove the setting tool.

OPM 210 en-GB 52


© Scania CV AB 2016, Sweden
Diesel

Diesel Temperature dependency of


the fuel
Composition of the fuel At temperatures lower than those specified for
The composition of the fuel is extremely impor- the fuel, paraffin wax may precipitate from the
tant for the operation and service life of the en- fuel and block filters and pipes. The engine can
gine and injection system. The engine output and then lose power or stop.
exhaust gases are also dependent on the fuel The fuel is adapted for use in the specific climate
grade. of each country. If a vehicle or an engine is to be
The requirements and testing standards for the operated in a temperature zone with a tempera-
most important characteristics are described in ture lower than normal, first identify the temper-
the Workshop Manual which can be ordered ature properties of that particular fuel.
from Scania dealers or directly from Scania. The properties of the fuel when cold can be im-
The fuel must conform to European standard proved by adopting one of the following meas-
EN 590. ures before the temperature drops:

The table shows some of the key properties. • Install an electric fuel heater if this particular
fuel is not suitable for the expected tempera-
ture and no fuel is available with the correct
Property Requirement temperature properties.
Viscosity at 40°C (104°F) 2.0-4.5 cSt • Add 0.5-2% alcohol (isopropanol) to prevent
Density at 15°C (59°F) 0.82-0.86 cSt any water in the fuel from freezing and form-
ing plugs of ice. Drain fuel tanks and drain or
Ignitability (CET rating) minimum 49 renew fuel filters regularly.
Flashpoint 56°C (132°F)

IMPORTANT!

Mixing kerosene or other paraffins with the fuel


Sulphur content of fuel is prohibited. The injectors may be damaged.
• A sulphur content of 0-2,000 ppm in the fuel Mixing petrol with the fuel is prohibited. In the
(0.2%) gives an oil change interval of up to long term petrol can cause wear in the injectors
500 hours. and engine.
• With a sulphur content of 2,000-4,000 ppm in
the fuel, the oil change interval is halved to
max. 250 hours.
• Maximum permitted sulphur content in the
fuel is 4,000 ppm.

Responsibility

IMPORTANT!

The machine operator is responsible for using


the correct type of fuel to ensure that local laws
are complied with.

OPM 210 en-GB 53


© Scania CV AB 2016, Sweden
Diesel

Biodiesel (FAME) Use of fuel oil in stand-by


Scania uses the term biodiesel according to the generator sets
EN 14214 standard to refer to renewable diesel Long-term storage of diesel, where the diesel
made from greases or oils and methanol. The comes into contact with water, may lead to the
biodiesel should conform to the requirements of growth of micro organisms (bacteria and fun-
European standard EN 14214. For biodiesel gus). To avoid this in fuel used in stand-by gen-
EN 14214 the generic term FAME is frequently erator sets, i.e. ESP engines, Scania permits the
used. use of fuel oil according to DIN 51603-1 and
All Scania engines are approved for diesel ac- ÖNORM C 1109.
cording to the EN 590 standard. EN 590 contains Use of fuel oil is only permitted for ESP engines
up to 7% biodiesel in accordance with and under the following conditions:
EN 14214. PDE engines may use up to 100%
EN 14214 biodiesel. • The fuel must not be stored or used in temper-
atures below -10°C (14°F).
Maintenance intervals • The engine must not be equipped with an
With a greater mixture of biodiesel than EN 590, SCR system.
the renewal intervals for the following are
halved: Definition of ESP
• Fuel filter. ESP is an output class for stand-by generator sets
in accordance with ISO 8528, which states that
• Oil filter. stand-by generator sets may be used under vary-
• Oil. ing loads for a maximum of 200 hours/year.

The oil viscosity must be xW-40. ESP engines are intended for use as stand-by
power supplies in the efficient electrical net-
works in Europe, North and South America,
Australia, New Zealand, Japan and Taiwan.

OPM 210 en-GB 54


© Scania CV AB 2016, Sweden
Preparing the engine for storage

Preparing the engine for Preservative fuel


storage Use diesel mixed with Lubrizol 560H or the
equivalent. Mix 1 cm3 (ml)/0.06 in3 Lubrizol
If the engine is not being used for an extended 560H in 10 dm3/2.3 US gallons of fuel.
period its cooling system, fuel system and com-
bustion chamber and outside must be protected
against rust. WARNING!
An alternative to preparing the engine for long-
term storage is to start the engine and warm it up Lubrizol 560H contains aromatic hydrocarbons
every 6 months. which are hazardous to health.
• Use spot extractors where there is a danger of
vapour build-up.
Handling the engine • Wear protective goggles and gloves when
handling the fuel.
The engine can normally stand idle for up to 6
months without preparation. For longer periods • Do not use contaminated clothing.
of downtime, the following measures should be • If it gets in your eyes: Flush with a gentle jet
taken. These measures provide protection for ap- of water for at least 15 minutes and contact a
proximately 4 years. doctor.
Preparations for storage: • If it gets on your skin: Wash with soap and
water.
• Thoroughly clean the engine. • If you inhale it: Fresh air, rest and warmth.
• Run the engine for a specific period using • Store in well-sealed containers in a dry, cool,
special preservative fuel, oil and coolant. place out of the reach of children.
• Otherwise prepare the engine for storage (fil-
ter renewal, lubrication, etc.). Lubrizol is flammable and has a 2A fire rating.
The flashpoint is +27°C/81°F. In case of fire: Ex-
tinguish with carbon dioxide, powder or foam.

Preservative coolant
If the engine is to be stored with a full cooling
system, use coolant containing 50 percent glycol Preservative oil
by volume. Glycol without nitrite-based inhibi-
tor should be used. Example: BASF G48 or Suitable preservative oils are supplied by most
BASF D542. oil companies. Example: Dinitrol 40 or equiva-
lent.

WARNING!

Ethylene glycol can be fatal if ingested. Avoid


contact with the skin.

OPM 210 en-GB 55


© Scania CV AB 2016, Sweden
Preparing the engine for storage

Preparations for storage 10. Drain the preservative oil from the engine.
Fill with new engine oil immediately or
when the engine is to be reused.
Environment
11. Drain the coolant if the engine is not to be
stored with coolant in the system. Plug and
Use a container to avoid spills when draining the tape all coolant connections if the engine is
oil and coolant. Dispose of used fluids through to be stored without a cooling system.
an authorised waste disposal contractor.
12. Air cleaner: Clean or renew the filter ele-
ment.
1. Drain and flush the cooling system. Top up 13. Cover air intakes and exhaust pipes.
with preservative coolant.
14. Alternator and starter motor: Spray with wa-
2. Warm up the engine on normal fuel. Stop the ter-repellent anti-corrosive oil, CRC 226,
engine and drain the oil. LPS1 or the equivalent.
3. Renew the fuel filter. 15. Spray the outside of bright engine parts, first
4. Fill the engine with preservative oil up to the with penetrating preservative oil such as
minimum level on the oil dipstick. Dinitrol 25B and then with Dinitrol 112 or
5. Mix preservative fuel in a can. Detach the
the equivalent.
fuel pipe at the feed pump suction line and Clearly mark the engine with the storage prepa-
connect a hose from the can. ration date, and state that the engine must not be
6. Detach the fuel pipe at the overflow valve started or cranked.
and connect a return hose to the can.
7. Start the engine and run it at about 1,000 rpm
for 20-25 minutes.
8. Stop the engine, remove the hoses and con-
nect the normal fuel pipes.
9. Remove the rocker covers and lubricate the
valve mechanisms with plenty of preserva-
tive oil. Refit the rocker covers.

Note:
Do not remove the injectors.

OPM 210 en-GB 56


© Scania CV AB 2016, Sweden
Preparing the engine for storage

Batteries Storage
Remove the batteries and trickle charge them at After the preparations, the engine should be
the battery charging station. This does not apply stored in a dry and warm place (room tempera-
to batteries specified as maintenance-free by the ture).
manufacturer.
The same applies to short-term storage, even if
the engine has not been prepared for storage as When the engine is to be taken into
above. operation again
1. Remove plugs and tape from coolant connec-
WARNING! tions, air intakes and exhaust pipes.
2. Fill the cooling system with coolant. For
Wear gloves and protective goggles when charg- more information refer to Maintenance.
ing and handling batteries. The batteries contain 3. Check the oil level in the engine or top up
a highly corrosive acid. with fresh engine oil.
4. Lubricate the valve mechanisms and their
pushrods and valve tappets as well as the in-
jector mechanisms with plenty of oil.
5. Drain the preservative fuel from the fuel
manifold and fuel filter.
6. Connect and bleed the fuel system. For more
information refer to Maintenance.
7. Wash off any preservative oil on the outside
using white spirit.

OPM 210 en-GB 57


© Scania CV AB 2016, Sweden
Technical data

Technical data
General data

Number of cylinders and configuration 6, straight


Working principle 4-stroke engine
Cylinder diameter (mm/in) 130/5.12
Piston stroke (mm/in) 160/6.30
Displacement (dm3/in3) 12.7/775.0
Firing sequence 1-5-3-6-2-4
Compression ratio 17.3:1
Engine direction of rotation viewed from rear Anti-clockwise
Fan direction of rotation viewed from front Clockwise
Cooling Coolant
Valve clearances, cold engine:
Intake valve (mm/in) 0.45/0.02
Exhaust valve (mm/in) 0.70/0.03
Number of teeth on the flywheel 158
Low idling speed (rpm) 500-1,050
Maximum full-load speed (rpm) 2,100
Fuel Diesel
Approximate weight, without coolant and oil (kg/lb) 1,050/2,315

Lubrication system

Oil volume See Maintenance


Oil cleaning Centrifugal oil cleaning
Oil cooler Coolant cooled, full
flow
Oil filter Paper filter from Scania
Interval between oil changes (h) 500
Oil pressure (bar)
Normal with the engine at operating temperature, operating speed 3-6
Minimum permitted at idling speed 0.7
Crankcase pressure with closed crankcase ventilation (mbar) -5.4 to 2.0

OPM 210 en-GB 58


© Scania CV AB 2016, Sweden
Technical data

Injection system

Type PDE (unit injector)


Control system EMS
Fuel filter Paper filter from Scania
Fuel filter with water separator Paper filter from Scania

Cooling system

Coolant volume, excluding radiator (dm3/US gallons)


DC13 071A 17/4.5
Other engine types 16/4.2
Coolant volume, including radiator (dm3/US gallons)
DC13 071A 39/10.3
Other engine types 38/10.0
Coolant temperature (°C/°F) 90-95/194-203
Number of thermostats 1
Thermostat opening temperature (°C/°F) 80/176 and 87/189

Intake system

Permissible pressure drop in the intake system with cleaned or new fil- 30
ter (mbar)
Permissible pressure drop in the intake system with blocked (dirty) fil- 65
ter (mbar)

Electrical system

Type 1-pin, 24 V, DC
Starter motor, standard equipment 1-pin, 24 V, 5.5 kW
Alternator, standard equipment 1-pin, 28 V, 100 A

OPM 210 en-GB 59


© Scania CV AB 2016, Sweden
Scania Assistance

Scania Assistance
Wherever you are, you can always get assistance
from the Scania service organisation, Scania As-
sistance, all day, every day of the year.
Always call the contact for your country.

AR 0800 999 722 642 IE +353 71 9634000


AT +43 1 256 44 11 IT +39 0461 996 222
AU 1300 SCANIA KR +82 1588 6575
1300 722642 LU +32 226 400 000
BE +32 2 264 00 00 MA +34 91 678 92 13
BG +359 886 660001 MX 01 800 4SCANIA
BR 0800 019 42 24 NL +31 70 4182666
CA +1-800-2-SCANIA NO +47 223 217 00
CH +41 800 55 24 00 PL +48 602 622 465
CL 188 800 722 642 PT +48 91 678 9247
CZ +420 225 020 225 RO +40 723 27 27 26
DE +49 261 887 8888 SE +46 42 100 100
DK +45 333 270 44 SK +421 903 722 048
ES +34 91 678 80 58 TR +90 212 335 04 40
FI +358 10 555 24 TZ +255 78 472 2642
FR +33 2 414 132 32 US 1-800-2-SCANIA
GB 0 800 800 660 UY 0800 8351
+44 1274 301260 ZA 0800 005 798
GR +30 6944 420 410 +27 11 661 9823
HU +36 209 727 197

Other countries: +46 8 52 24 24 24


Note:
Calls will be recorded for training purposes.

OPM 210 en-GB 60


© Scania CV AB 2016, Sweden

You might also like