Scania ASU-600-270-SCP Operator's Manual
Property of American Airlines
Scania Engine
Important information
WARNING!
IMPORTANT!
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.
This warning symbol and text can be found next to those inspection points where it is particularly important
to bear in mind the risk of injury.
Operator's manual
DC13
XPI
Industrial engine
en-GB 2 397 828
Issue 2.1
The owner is responsible for making sure that inspection 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.
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Start-up Report – Warranty
When the start-up report has been filled in and
sent to Scania, you have a 1-year warranty from
the date of entry into service. Fill in the particulars 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.
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OPM 200 en-GB 2
©
Scania CV AB 2014, Sweden
Start-up Report – Warranty . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Environment and safety . . . . . . . . . . . . . . . . . . 5
Environmental responsibility . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings and advisories . . . . . . . . . . . . . . . . . 6
Certification . . . . . . . . . . . . . . . . . . . . . . . . . 11
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
SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Starting and running . . . . . . . . . . . . . . . . . . . . 23
Checks before running . . . . . . . . . . . . . . . . . 23
Starting the engine . . . . . . . . . . . . . . . . . . . . 23
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine shutdown . . . . . . . . . . . . . . . . . . . . . . 27
Checks after running . . . . . . . . . . . . . . . . . . . 27
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Engines with few hours of operation . . . . . . 29
Cleaning the engine. . . . . . . . . . . . . . . . . . . . 29
Inspection interval . . . . . . . . . . . . . . . . . . . . . 30
Lubrication system . . . . . . . . . . . . . . . . . . . . . 31
Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Checking oil level . . . . . . . . . . . . . . . . . . . . . 32
Changing the oil . . . . . . . . . . . . . . . . . . . . . . 33
Labels for top-up engine oil grade . . . . . . . . 34
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cleaning the centrifugal oil cleaner . . . . . . . 35
Operational testing . . . . . . . . . . . . . . . . . . . . 40
Renewing the oil filter. . . . . . . . . . . . . . . . . . 41
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 42
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking coolant level . . . . . . . . . . . . . . . . . 46
Checking antifreeze and corrosion inhibitor . 47
Antifreeze and corrosion inhibitor . . . . . . . . 48
Changing coolant . . . . . . . . . . . . . . . . . . . . . 49
Cleaning the cooling system . . . . . . . . . . . . . 51
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Reading the vacuum indicator. . . . . . . . . . . . 54
Renewing the filter element . . . . . . . . . . . . . 54
Renewing the safety cartridge. . . . . . . . . . . . 55
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
General information on the XPI fuel system 56
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Checking fuel level . . . . . . . . . . . . . . . . . . . .56
Renewing the fuel filter . . . . . . . . . . . . . . . . .57
Bleeding the fuel system . . . . . . . . . . . . . . . .61
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . .62
Checking the drive belt . . . . . . . . . . . . . . . . .62
Checking for leaks . . . . . . . . . . . . . . . . . . . . .64
Checking and adjusting the valve clearance .64
Renewing the reductant filter . . . . . . . . . . . . .67
Cleaning the reductant tank filler filter . . . . .69
Cleaning the reductant tank ventilation filter .69
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Composition of the fuel . . . . . . . . . . . . . . . . .69
Sulphur content of fuel. . . . . . . . . . . . . . . . . .70
Temperature dependency of the fuel . . . . . . .72
Reductant for SCR . . . . . . . . . . . . . . . . . . . . . .73
Responsibility and quality requirements . . . .73
Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Preparing the engine for storage . . . . . . . . . . .75
Handling the engine . . . . . . . . . . . . . . . . . . . .75
Preservative coolant . . . . . . . . . . . . . . . . . . . .76
Preservative fuel . . . . . . . . . . . . . . . . . . . . . . .76
Preservative oil . . . . . . . . . . . . . . . . . . . . . . . .77
Preparations for storage . . . . . . . . . . . . . . . . .77
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . .80
General data . . . . . . . . . . . . . . . . . . . . . . . . . .80
Lubrication system . . . . . . . . . . . . . . . . . . . . .80
Injection system . . . . . . . . . . . . . . . . . . . . . . .81
Cooling system . . . . . . . . . . . . . . . . . . . . . . . .81
Intake system . . . . . . . . . . . . . . . . . . . . . . . . .81
Electrical system . . . . . . . . . . . . . . . . . . . . . .81
Scania Assistance . . . . . . . . . . . . . . . . . . . . . . .82
OPM 200 en-GB 3
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Scania CV AB 2014, Sweden
Introduction
Note:
This Operator's Manual describes the operation
and inspection of Scania industrial engines.
The engines are direct-injection, liquid-cooled,
four-stroke, turbocharged diesel engines. Certain
engines are also equipped with an SCR system
for emission control.
The engines are available with different output
and engine speed settings. The normal output
setting of the engine (performance code) is indicated on the engine data plate.
Only standard components are described in the
operator's manual. Information about special
equipment is contained in instructions from the
various manufacturers.
Introduction
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 inspection 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 inspection and repair.
The information in this manual was correct at the
time of going to press. Scania reserves the right
to make alterations without prior notice.
Property of American Airlines
OPM 200 en-GB 4
©
Scania CV AB 2014, Sweden
Environment and safety
WARNING!
IMPORTANT!
Note:
Environment
Environment and safety
Environmental responsibility
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.
At the same time, we have been able to maintain
a high level of performance and operating economy for Scania Industrial and Marine Engines.
To maintain these throughout the entire service
life of the engine, it is important for the user to
follow the instructions on running, inspection
and fuel and lubricating oil as outlined in the Operator's Manual.
Other green initiatives taken include ensuring
that, following inspection 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.
Safety
Different types of advisory
Warning!
All advisories preceded by Warning! are very
important. They warn of serious faults and incorrect operation that could lead to personal injury.
Example:
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:
For Scania to guarantee that the engine corresponds to its certified configuration, and take responsibility for any damage and injuries that
occur, inspection must be carried out as above.
The following pages contain a summary of the
safety precautions to be complied with when operating and inspecting Scania engines. The
equivalent text can also be found under the relevant inspection point.
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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Note:
Advisories preceded by Note: refer to information important to ensure the best possible operation and functionality. Example:
Leave the engine off for at least 1 minute before
checking the oil level.
Environment
This Operator’s Manual contains specially highlighted text with instructions to help protect the
environment during inspection. Example:
Use a container to avoid spillage.
OPM 200 en-GB 5
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Scania CV AB 2014, Sweden
Environment and safety
WARNING!
WARNING!
WARNING!
WARNING!
IMPORTANT!
Warnings and advisories
Smoking
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
Safety precautions for running the
engine
Daily inspection
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.
Refuelling
Never overfill the fuel tank as the fuel needs
space to expand. Also ensure that the filler cap is
properly closed.
During refuelling there is a risk of fire and explosion. The engine must be switched off and smoking is prohibited.
Hazardous gases
Only start the engine in a well ventilated area.
The exhaust gases contain carbon monoxide and
nitrogen oxides, which are toxic.
If it is run in an enclosed space, there should be
an effective device to extract exhaust gases and
crankcase gases.
This inspection should be done to detect fuel, oil
or coolant leaks, or anything else that may require corrective action.
Fuel
Use only fuel recommended in the workshop
manual.
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.
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Starter lock
If the control 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.
OPM 200 en-GB 6
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Scania CV AB 2014, Sweden
Environment and safety
WARNING!
WARNING!
WARNING!
WARNING!
WARNING!
Environment
Starter gas
Never use starter gas or similar agents to help
start the engine. This can cause an explosion in
the intake manifold and possible injury.
Running
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.
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.
Batteries
The batteries contain and form oxyhydrogen gas,
particularly during charging. Oxyhydrogen gas
is flammable and highly explosive.
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.
Chemicals
Most chemicals such as glycol, anti-corrosive
agents, preservative oils and degreasing agents,
are hazardous to health.
Some chemicals, such as preservative oil, are
also flammable.
Safety precautions for handling materials
Fuel and lubricating oil
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.
Store used rags and other flammable materials
safely so as to avoid spontaneous combustion.
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Always follow the safety precautions on the relevant packaging.
Store chemicals and other materials which are
hazardous to health in approved containers,
marking them clearly and storing them where
they are inaccessible to unauthorised persons.
Always hand in leftover and used chemicals to
an authorised waste disposal contractor.
OPM 200 en-GB 7
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Scania CV AB 2014, Sweden
Environment and safety
WARNING!
WARNING!
WARNING!
WARNING!
Reductant
Reductant (AdBlue/DEF) is used in the reductant
tank on engines equipped with an SCR system.
Avoid contact with the skin.
If reductant comes in contact with the skin: Wash
with soap and plenty of water. If reductant
splashes in the eyes: Rinse immediately with
plenty of water. Contact a doctor if it is ingested
or causes skin irritations.
Safety precautions for inspection
and repair
Switch off the engine
Always switch off the engine before carrying out
inspections and repairs, unless otherwise indicated.
Hot surfaces and fluids
There is always a risk of sustaining burns when
an engine is hot. Particularly hot parts are exhaust manifolds, turbochargers, oil sumps, hot
coolant and oil in pipes and hoses.
Lift the engine out
Always use the engine lifting eyes. Always
check that lifting devices are in good condition
and are designed to lift the weight.
Optional equipment on the engine can change
the centre of gravity. This means that it may be
necessary to use additional lifting devices to balance the engine correctly and lift it safely.
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.
Fix a warning plate somewhere appropriate,
showing that work is being carried out on the engine.
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.
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Never work underneath a suspended engine!
OPM 200 en-GB 8
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Scania CV AB 2014, Sweden
Environment and safety
WARNING!
Environment
IMPORTANT!
IMPORTANT!
WARNING!
Environment
Batteries
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.
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.
Always hand in used batteries to an authorised
waste disposal contractor.
Electrical system
Electric welding
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.
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.
When welding is finished:
1.
Connect the alternator and control unit cables first.
2.
Then connect the batteries.
Lubrication system
The engine must be switched off and the power
disconnected using the master switch or battery
master switch before working on the electrical
system. External power supplies to extra equipment on the engine must also be disconnected.
Scania recommends that Scania spare parts are
used for the fuel and electrical systems. Scania
spare parts are designed to minimise the risk of
fire and explosion.
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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 being ejected.
Always hand in used oil to an authorised waste
disposal contractor.
OPM 200 en-GB 9
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Scania CV AB 2014, Sweden
Cooling system
WARNING!
Environment
WARNING!
WARNING!
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 and carefully to release the pressure before removing the
cap. Wear gloves as the coolant is still very hot.
Always hand in used coolant to an authorised
waste disposal contractor.
Environment and safety
Fuel system
Always wear protective goggles when testing injectors. Fuel escaping at high pressure can penetrate tissues and cause serious injury.
Scania recommends that Scania spare parts are
used for the fuel and electrical systems. Scania
spare parts are designed to minimise the risk of
fire and explosion.
Before starting
Ensure that all guards are in place before starting
the engine. Ensure that no tools or other objects
have been left on the engine.
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.
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OPM 200 en-GB 10
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Scania CV AB 2014, Sweden
Certification
IMPORTANT!
An emissions certified engine fulfils the emissions requirements for a particular range of application.
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.
The following are required for the certified engine to fulfil the emissions requirements once it
has been taken into service:
• Inspection is to be carried out in accordance
with the instructions in this Operator's Manual.
• The inspection and repair of injection equipment are to be carried out by a qualified
workshop or person.
• 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.
Environment and safety
Otherwise, the instructions in the Operator's
Manual for the running and inspection of the engine shall apply. The safety precautions should
be observed.
For Scania to guarantee that the engine corresponds to its certified configuration, and take responsibility for any damage and injuries that
occur, inspection must be carried out as above.
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OPM 200 en-GB 11
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Scania CV AB 2014, Sweden
Scania engines engine warranty for industrial engines
IMPORTANT!
Scania engines engine warranty for industrial engines
Emission control systems warranty
Only applicable to engines used in the U.S.A.
Table of Contents
General warranty provisions 12
Warranty period 12
Parts covered by the Warranty 13
General warranty limitations 14
Specific warranty exclusions 15
Customer support 15
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.
Warranty period
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
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
General warranty provisions
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:
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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The Warranty on emission-related
parts shall be interpreted as follows:
1.
Any warranted part which is not scheduled
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.
OPM 200 en-GB 12
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Scania CV AB 2014, Sweden
Scania engines engine warranty for industrial engines
Any warranted part which is scheduled for
3.
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
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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
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.
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).
OPM 200 en-GB 13
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Scania CV AB 2014, Sweden
Scania engines engine warranty for industrial engines
IMPORTANT!
WARNING!
Miscellaneous items used in the above sys-
11.
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.
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.
See Specific Warranty Exclusions below.
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.
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.
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.
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.
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.
Property of American Airlines
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.
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.
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.
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Scania engines engine warranty for industrial engines
Specific warranty exclusions
This warranty does not cover:
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.
Customer support
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:
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: contact@scaniausainc.com
California customers shall also be furnished a
copy of the California Emission Control Warranty Statement applicable to each new Scania engine purchased.
Property of American Airlines
OPM 200 en-GB 15
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Scania CV AB 2014, Sweden
California emission control warranty statement
California emission control
warranty statement
Your warranty rights and obligations
The California Air Resources Board is pleased to
explain the emission control system warranty on
your 2015 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.
Owner's warranty responsibilities
• 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.
Manufacturer's warranty coverage
The 2015 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.
Property of American Airlines
If you have any questions regarding your warranty rights and responsibilities, you should contact Scania U.S.A. Inc +1-210-403-0007.
OPM 200 en-GB 16
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Scania CV AB 2014, Sweden
SCR catalytic converter
WARNING!
SCR catalytic converter
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.
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.
Property of American Airlines
OPM 200 en-GB 17
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Scania CV AB 2014, Sweden
SCR catalytic converter
WARNING!
• Do not dispose of the spent SCR catalytic
converter or its constituent parts into any waterways, storm drains or sanitary sewers.
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.
• 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.
Property of American Airlines
OPM 200 en-GB 18
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Scania CV AB 2014, Sweden
Engine data plate
Made by
Type
Engine No
Output. kW rpm.
DC13 070A
6950106
331
Ty p e a p pr o va l No :
e 5 x 97 / 68 L Ax 2 00 4 /2 6 x0 14 2 x0 0
2100
319 989
Example of an engine data plate
The engine data plate indicates, in the form of a
code, the engine type, its size and applications.
The engine EU type approval for exhaust emissions is indicated under Output, where applicable.
The engine serial number is stamped onto the top
of the cylinder block at the front right.
Example: DC13 070A
DC Supercharged diesel engine with air-cooled charge air cooler.
13 Displacement in whole dm3.
070 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.
Engine data plate
Property of American Airlines
OPM 200 en-GB 19
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Scania CV AB 2014, Sweden
Component identification
336 872
1
2 3 4 5 6 7 8 9
10
11
12 13
14
15 16 17 13
18
1920
The illustration shows a normal version of a DC13 engine. The engine ordered may have different equipment
Component identification
1.
Engine data plate
2.
EGR valve
3.
Exhaust brake
4.
Actuator
5.
Turbocharger
6.
EGR cooler
7.
Oil cooler
8.
Oil filter
9.
Engine serial number on the cylinder
block
10.
Coolant pump
11.
Draining coolant
12.
Centrifugal oil cleaner
13.
Oil filler
14.
Engine control unit
15.
Water separating prefilter for fuel
16.
Hand pump for fuel
17.
Fuel filter
18.
Starter motor
19.
Oil dipstick
20.
Oil plug
Property of American Airlines
OPM 200 en-GB 20
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Scania CV AB 2014, Sweden
SCR system
6
11
5
9
4
13
3
8
7
10
2
12
1
14
336 907
The illustration provides an overview of SCR
system components.
Component identification
1.
Evaporator
2.
Pressure line for reductant
3.
Coolant hose for tank and pump heating
4.
Coolant valve
5.
Reductant return line
6.
Reductant tank
7.
Reductant pump and control unit
1. DC13 084/085/087/089A only.
2. DC13 084/087/089A only.
Property of American Airlines
8.
Coolant hose, return from tank and pump heating
9.
NOx sensor with control unit
10.
Oxidation catalytic converter
11.
Exhaust gas temperature sensor
12.
SCR catalytic converter
13.
NOx sensor with control unit
14.
Reductant doser
1
2
OPM 200 en-GB 21
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Scania CV AB 2014, Sweden
Reductant tank
319 991
38 litres (10 US gallons)
319 992
60 litres (15.8 US gallons)
340 426
69 litres (18.2 US gallons)
The reductant tank comes in 3 sizes. The volumes indicated for each tank are filling volumes.
The total volume is approx. 10 litres (2.6 US gallons) greater.
A filler filter with magnet is fitted in the reductant tank to prevent the reductant from becoming
contaminated when topping up. The filler filter
with magnet is used when topping up at a filling
station.
A filler filter without a magnet is also supplied
for use when manually topping up reductant.
Component identification
OPM 200 en-GB 22
Property of American Airlines
©
Scania CV AB 2014, Sweden
Starting and running
Note:
WARNING!
WARNING!
WARNING!
IMPORTANT!
When the engine is started for the first time, carry out the inspection points listed under First
start-up in the inspection schedule. See the Inspection section.
Always check the following before running:
• oil level
• coolant
• fuel level
• electrolyte level in batteries
• state of charge of the batteries
• condition of the drive belt
• the level in the reductant tank, if the engine is
equipped with an SCR system.
Starting and running
3.
If the engine has a battery master switch:
Switch on the power by means of the battery
master switch.
4.
Start the engine.
If the fuel tank has been run dry or if the engine
has not been used for a long time, bleed the fuel
system.
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.
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.
Running the engine without reductant in the reductant tank violates emissions legislation and
will damage the SCR system.
Checks before running
Carry out a daily inspection as described in the
inspection schedule prior to operation. See the
Inspection section.
Block the starting device when working on the
engine. If the engine starts unexpectedly, there is
a serious risk of injury.
Starting the engine
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.
Property of American Airlines
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.
Starting at low temperatures and at
high altitudes
Take the local environmental requirements into
account. Use a fuel heater and engine heater to
avoid starting problems and white smoke.
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
metres.
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.
1.
Open the fuel cock if fitted.
2.
Disengage the engine.
OPM 200 en-GB 23
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Scania CV AB 2014, Sweden
Starting and running
319 562
Symbol for low reductant level
Running
Check instruments and warning lamps at regular
intervals.
Engine speed range
600-750 rpm Low idling. Engine idling is controlled by the engine management system.
Low idling up to 2,100 rpm Engine operating speed range. Controlled by the engine management sys-
tem.
2,100-2,600 rpm Unsuitable operating speed, but a slightly higher engine speed than the nor-
mal maximum operating speed may occur when load is low or negative.
2,600-3,000 rpm Prohibited engine speed.
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
Reductant
level
20% Constant
10% Flashing Torque is reduced by
0% Flashing rap-
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%.
Warning
lamp
light
idly
Torque reduction
1% per minute to
70% of the highest
torque
Torque is reduced to
0% (low idling)
within 2-10 minutes
Property of American Airlines
1
OPM 200 en-GB 24
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Scania CV AB 2014, Sweden
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