Scania DI11, DC11, D11 Operator's Manual

IMPORTANT INFORMATION

When working on the engi ne, for example adjusting drive belts, oil change or adjusting the clutch,

it is important not to start the engine. The engine may be damaged and there is

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 is reproduced beside those maintenance points where it is

especially important to consider the risk of injury.

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
start-up. Also fill in the particulars below as this can make things easier if you need to contact for example a
service workshop.

Operator’s Manual

D11 DC11 DI1 1

Industrial engine

opm96-11a en 1 588 293

1997-11:2

Engine number

Start-up date

User’s name and address

Signature
Engine type
Variant

Engine type and variant are indicated on the engine type plate

!

Industrial & Marine Engines

2 © Scania Industrial & Marine Engines 1997-11:2

FOREWORD

This instruction manual describes the operation and maintenance of the
Scania D11, DC11 and DI11 Industrial Engines. These instructions apply to
engines in program 96 from engine number 5 364 870.

The engines are direc t inj ection, fluid-cooled, f our-stroke diesel e ngi nes with
6 cylinders in line. The engines are available with or without charge air
cooler, see page 4.

Common applications are construction machinery and gensets, in agricul­tural, railw ay and forestry machinery and as power fo r irrigation installa­tions.

The engines may have different powers and speed settings.
The normal power setting of the engine (performance code) is indicated on

the type plate, see page 4.

Note! Only standard components are described in the instruction man-

ual. For special equipment, refer to the instructions issued by the
manufacturer.

In order to obtain the best value and service life from your engine, there are
several points to bear in mind:

- Read through the Instruction Manual before starting to use your engine.
Even those experienced with Scania engines may find new information
in this manual.

- Follow the maintenance instructions. Maintenance according to the
instructions forms the basis of good function and service life.

- Get to know your engine so that you know what it can do and how it
works.

- When necessary, always turn to an authorised Scania workshop. These
have special tools, genuine parts and staff with training and practical
experience of Scania engines.

The information in this manual was correct at the time of going to press.
However, we retain the right to make alterations without prior notice.

Scania CV AB
Industrial and Marine Engines

S-151 87 Södertälje

1997-11:2 © Scania Industrial & Marine Engines 3

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TYPE DESIGNATIONS . . . . . . . . . . . . . . . 4

STARTING AND RUNNING . . . . . . . . . . . . 6

AT FIRST START . . . . . . . . . . . . . . . . . . . . . . . .6

CHECKS BEFORE RUNNING . . . . . . . . . . . . . .7

STARTING THE ENGINE . . . . . . . . . . . . . . . . .7

At temperatures below 0 °C: . . . . . . . . . . . . . . .8

RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Coolant temperature . . . . . . . . . . . . . . . . . . . . .9

Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .10

STOPPING THE ENGINE . . . . . . . . . . . . . . . . .10

Emergency stop . . . . . . . . . . . . . . . . . . . . . . . .10

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

CHECKS AFTER RUNNING . . . . . . . . . . . . . .11

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 12

ENGINES WITH FEW HOURS OF

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .12

MAINTENANCE SCHEDULE . . . . . . . . . . . . . 1 3

LUBRICATION OIL SYSTEM . . . . . . . . . 14

OIL GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . .14

CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . .15

Checking oil level during operation . . . . . . . .15

OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . .15

Maximum angle of inclination during

operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

CLEANING THE OIL CLEANER . . . . . . . . . .16

CHANGING THE TURBO FILTER . . . . . . .18

COOLING SYSTEM . . . . . . . . . . . . . . . . . . 18

CHECKING COOLANT LEVEL . . . . . . . . . . .18

CHECKING COOLANT . . . . . . . . . . . . . . . . . .19

Checking protection against corrosion . . . . . .2 1

Changing coolant . . . . . . . . . . . . . . . . . . . . .21

CLEANING COOLING SYSTEM . . . . . . . . . . .22

Internal cleaning . . . . . . . . . . . . . . . . . . . . . . .23

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 24

TEST READING

LOW PRESSURE INDICATOR . . . . . . . . . . . .24

CLEANING THE AIR CLEANER

COARSE CLEANER . . . . . . . . . . . . . . . . . . . . .24

CLEANING OR CHANGING

FILTER INSERT . . . . . . . . . . . . . . . . . . . . . . . .24

CHANGING THE SAFETY CARTRIDGE . . . .25

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 26

CHECKING FUEL LEVEL . . . . . . . . . . . . . . . .26

CHANGING THE FUEL FILTER . . . . . . . . . . .26

CHECKING INJECTORS . . . . . . . . . . . . . . . . .27

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 28

CHECKING ELECTROLYTE LEVEL

IN BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . .28

CHECKING CHARGE

STATE IN THE BATTERIES . . . . . . . . . . . . . .28

CLEANING BATTERIES . . . . . . . . . . . . . . . . .28

CHECKING COOLANT

LEVEL MONITOR . . . . . . . . . . . . . . . . . . . . . .29

CHECKING TEMPERATURE MONITOR . . .30

CHECKING TEMPERATURE SENSOR . . . . .30

CHECKING THE OIL PRESSURE MONITOR 31

CHECKING OIL PRESSURE SENSOR . . . . . .31

CHECKING THE STOP FEATURE . . . . . . . . .31

CHANGING BATTERY . . . . . . . . . . . . . . 33

MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 33

CHECK/TENSION

V-BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

LOOK FOR LEAKAGE,

REMEDY AS NECESSARY . . . . . . . . . . . . . .34

CHECK/ADJUST

VALVE CLEARANCE . . . . . . . . . . . . . . . . . . .35

CHANGING (

OR CLEANING) VALVE

FOR CLOSED CRANKCASE VENTILATION 36

LONG-TERM STORAGE . . . . . . . . . . . . . . 37

Preservative fuel . . . . . . . . . . . . . . . . . . . . . . .37

Preservative oil . . . . . . . . . . . . . . . . . . . . . . . .38

Preparations for storage . . . . . . . . . . . . . . . . .38

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Taking out of storage . . . . . . . . . . . . . . . . . . . 39

TECHNICAL DATA . . . . . . . . . . . . . . . . . . 40

FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

ALHPABETIC INDEX . . . . . . . . . . . . . . . . 44

LIST OF CONTENTS

4 © Scania Industrial & Marine Engines 1997-11:2

TYPE DESIGNATIONS

The engine designation indicates, in the form of a code: Engine type, size,
application etc.

The type designation and engi ne number ar e indic ated on a type plate l ocated
on the right-hand f ront s ide o f the eng ine. The engin e number is a lso st amped
in the engine block above the type plate.

Engines which are certified for smoke and emissions are equipped with a
plate which indicates which documents they are certified to. This plate is
located on th e forward rocker cover behind the oil fi ller.

Certification plate

DI 11 71 A 31 S

Type

D Supercharged diesel engine (with turbo)
DC like D but with air-cooled charge air cooler
DI like D but with fluid-cooled charge air cooler

Stroke in whole dm

3

Performance and certification code

Indicates, together with the application code, the normal gross engine
output.
The actual output setting of the engine is indicated on the engine card.

Application

A For general industrial use

Variant 01-99

Governor type

D Electronically controlled auxiliary governor
S RSV, all-speed and single-speed governor
T RQ, single-speed governor

1997-11:2 © Scania Industrial & Marine Engines 5

1. Typskylt

2. Engine number,

stamped in engine block

3. Oil cooler

4. Oil dipstick

5. Oil cleaner

6. Turbo filter

7. Draining, engine oil

8. Coolant pump

9. Charge air cooler

10. Turbocharger

11. Injection pump

12. Fuel filter

13. Starter motor

14. Alternator

15. Fan belt, adjutstment

16. Draining, coolant

17. Oil filling

The drawings illustrate a common type of DI 11 engine.

Your engine may have other equipment not shown here.

3

5 13

6

4

1, 2

12 14

15

8

17

7 11

10

9

16

6 © Scania Industrial & Marine Engines 1997-11:2

STARTING AND RUNNING

AT FIRST START

When the engine is started for the first time, the maintenance points listed
under ”First start” in the maintenance schedule should be followed,
see page 13.

Since these points are important for the engine to work satisfactorily right
from the start, they are also listed below.

1. Checking oil level (see page 15).

6. Checking coolant (see page 19).
The coolant should contain anti-corrosive to protect the cooling system

from corrosion.

If there is a danger of freezing:

- Only glycol anti-freeze should be used in the coolant as protection

against corrosion. We recommend only nitrite-free glycol anti-freeze
with the following supplier designations:

BASF G48 or BASF D542

- The concentration of glycol should be 30 - 60% by volume depending
on ambient temperature. 30% by volume offers protection down to

-18 °C. See page 19.

- Never top up with water only or glycol only. Lost fluid should always
be replaced with pre-mixe d coolant wi th the same gl ycol cont ent as the
coolant in the engine. If the concentration of glycol drops, both anti­freeze and corrosion protection will suffer.

Note! A glycol concentration below 30% by vol ume will no t provide suf-

ficient protection against corrosion. A glycol concentration
greater than 60% will not increase anti-freeze protection and
reduces engine cooling capacity.

If there is no danger of freezing:

- Only Scania Anti-corrosive should be used in the coolant to protect
against corrosion. The correct level of anti-corrosive is 7-12% by vol­ume and this must never drop below 7% by volume. The inhibitor in
Scania Anti-corrosive is nitrate- free.

- First fill: Fill with Scania Anti-corrosive as indicated on the packaging.

- Never top up with water only or anti-corrosive only. Lost fluid should
always be replaced with pre-mixed coolant:
water + 10% Scania Anti-corrosive by volume.

- Only coolant filter without inhibitor may be used. The use of a coolant
filter increases the life of the coolant and reduces the risk of deposit cor­rosion.

Coolant should be topped up

when the engine is stopped

after the first start

The recommended glycols

may not be mixed with glycol

which has a nitrite-based

anti-corrosive or with
Scania Anti-corrosive

Scania Anti-corrosive must not

be mixed with glycol.

Mixing or over concentration

can cause sludging

Coolant composition:

If there is a danger of freezing:

at least 30% glycol by volume

Max. 60% glycol by volume

If there is no danger of

freezing:

7-12% by volume

Scania Anti-corrosive

1997-11:2 © Scania Industrial & Marine Engines 7

12. Checking fuel level (see page 26).

15. Checking electrolyte level in batteries (see page 28).

16. Checking battery charge (see page 28)

18. Checking coolant level monitor (see page 29).

19. Checking temperature monitor (see page 30).

20. Checking oil pressure monitor (see page 31).

21. Checking stop feature (see page 31).

22. Checking v-belt tension (see page 33).

CHECKS BEFORE RUNNING

Before running, ”Daily maintenance” as described in the maintenance sched­ule should be carried out, see page 13.

STARTING 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, see page 26.

Out of consideration to our common environment, your new Scania engine
has been designed to be s tarted wi th less fuel . Unnecessar ily large f uel suppl y
at start will always result in the release of uncombusted fuel.

- Engines w ith mechani cal stop control: Set the stop control to operating
position.

- Open fuel valve (if fitted).

- Declutch the engine (does not apply to engines with a fixed clutch, e.g.
gensets).

- Engines with battery master switch: Switch on the power using the bat­tery master switch.

- Set the speed control to raised idling. (Does not apply to gensets)

- Start the engine.

Important!A maximum of 3 start attempts per minute may be made when

the stop solenoid is a ctiva ted at s t art. The timer modu le can be
damaged resulting in the loss of the stop feature.

Starting at low temperatures

Local environmental requirements should be complied with. Start aids,
engine heater and/or flame start should be used to avoid starting problems
and white smoke.

WARNING

Block the starter device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK OF

INJURY

!

8 © Scania Industrial & Marine Engines 1997-11:2

At temperatures below 0 °C:

Note! Use only start aids recommended by Scania.

- The starter motor may only be used for 30 seconds, after which it must
rest for 2 minutes.

If the engine has flame start:

- Operating flame start without timer relay: Press the control button
which also acts as a pre-glow button (max. 20 s). The glow plug contin­ues to glow as long as t he bu tton i s held down aft er th e engin e is s tarte d.
Max. time is 5 minutes.

- Operating flame start with timer relay: Press the pre-glow button (max.
20 s). Release the pre-glow button after the engine starts. The timer
relay keeps the glow plug working for 5 minutes. If a shorter on-time is
required, press the release button. The key must be set to 0 of the start
attempt fails.

Note! If the engine is equipped with an INTERLOCK switch, this

should be held depressed until sufficient oil pressure has been
achieved. If the INTERLOCK switch is released too early, the
engine will stop.

- Gensets should be placed und er load directly after start to avoid the risk
of white smoke. This applies especially to engines which are installed
without heating aids or addition of base load.

- Set the appropriate idle spee d before the eng ine reach es 1,000 rpm ( does
not apply to gensets).

- Run the engine until warm with a light load. A light load on a cold
engine gives better c ombusti on and f aster heati ng tha n warming u p with
no load.

1997-11:2 © Scania Industrial & Marine Engines 9

RUNNING

Check instruments and warning lamps at regular intervals.

Speed

The Scania tachometer is divided into different coloured sections as follows.

0 - 500 rpm red area: prohibited speed, passed when

starting and stopping.
500 - 700 rpm yellow area: low idle.
700 - 2200 rpm green area: normal operating speed.

Highest torque and lowest
fuel consumption at
1400 - 1600 rpm.
Low operating speed gives less
engine wear.

2200 - 2600 rpm yellow/green

striped: unsuitable operating speed. Can
arise when switching off and
when using engine brake downhill.

2600 - 3000 rpm red area: prohibited speed.

Coolant temperature

Correct coolant temperature during operation:
70 - 93 °C for system a t atmospheri c pressure.
70 - about 100 °C for system with positive pressure.
High coolant temperature leads to engine damage. Reduce the load on the

engine in order to lower the temperature. If the temperature does not drop,
stop the engine and look for the fault.

During long periods of operation with very low power take-off, the engine
may have difficulty i n r eac hin g 70 °C. However, if the load is increased, tem­perature will rise.

Cooling systems with a

Scania radiator and plastic

expansion tank must not
have positive pressure in

the system, i.e. a pressure

cap must not be used on

the expansion tank.

10 © Scania Industrial & Marine Engines 1997-11:2

Oil pressure

Max. oil pressure:

warm engine at speed above 800 rpm 6 bar

Normal oil pressure:

warm engine at operating speed 3 - 6 bar

Min. oil pressure:

warm engine at 800 rpm 0.7 bar
At speeds below 800 rpm, the gauge may show low oil pr essure wit hout there

being a fault.

Oil pressure below 0.7 bar at speeds above 800 rpm will cause engine dam­age. The engine must be stopped immediately.

Charge test lamp

If the lamp lights during operation:

- Check/adjust the alternator drive belts as described under maintenance
point See page 33.

- If the charge test lamp is still lit, there may be a fault in the alternator or
in the electrical system.

STOPPING THE ENGINE

1. Allow the engine to run without load for a few minutes if it has been run

with a high continuous load.

2. Stop the engine using the stop control. Engines with a stop solenoid are

stopped using the stop button. Hold the stop button depressed until the
engine has fully stopped.

3. Engines with battery master switch: Cut the power using the battery

master switch. (Does not apply to emergency power back-up units).

4. Set the control switch to 0. (Does not apply to emergency power back-

up units).

Emergency stop

The stop solenoid linkage system has a knob marked ”STOP”. Pull the link­age system to the stop position using this knob if it is not possible to stop the
engine using the stop solenoid.

Danger of turbo damage or

boiling over if the engine is

stopped without cooling off.

The power must not be cut

until the engine has stopped.

High lubrication oil pressure

(above 6 bar) is normal when

starting a cold engine.

1997-11:2 © Scania Industrial & Marine Engines 1 1

Clutch

- See the manufacturer’s instructions for handling and operating the
clutch.

WARNING!If the clutch output shaft is rotating (e.g. in multiple

engine installations where other engines are running) the
clutch can, under its own power, be drawn to engaged posi­tion.
THIS CAN CAUSE INJURY and engine damage. Always
secure the clutch in disengaged position if there is a risk of
the output shaft starting to rotate.

CHECKS AFTER RUNNING

- Check that the power is cut from the battery master switch and that the
control switch is set to ”0”.

- Fill the fuel tank. Make sure that the cap and the area around the filler
opening are clean to avoid contamination of the fuel.

- If there is a risk of freezing, the cooling system must be drained if it
does not contain sufficient anti-freeze, see page 19.

- At temperatures below 0 °C: Prepare for the next star t by c onnecti ng the
engine heater (if fitted).

WARNING

Always secure the clutch in

disengaged position if there is

a risk of the output shaft

starting to rotate.

If the engine is started

during e.g. service work,

there is a

SERIOUS RISK OF

INJURY

!

12 © Scania Industrial & Marine Engines 1997-11:2

MAINTENANCE

The maintenance programme covers 25 points, divided into the following
main groups:

Lubrication oil system . . . . . . . . . . . . . . . . .page 14

Cooling system. . . . . . . . . . . . . . . . . . . . . . .page 18

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . .page 24

Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . .page 26

Electrical system, monitors, batteries etc. . .page 28

Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . .page 33

The maintenance points are divided into intervals as follows:
Daily maintenance
Maintenance before first start
Maintenance after the first 400 hours of operation
Periodic maintenance every 200 hours of operation (carried out after 200,

400, 600, 800 etc. hours)
Periodic maintenance after every 400 hours of operation (carried out after

400, 800, 1200, 1600 etc. hours)
Periodic maintenance after every 1,200 hours of operation (carried out after

1,200, 2,400, 3,600 etc. hours)
Periodic maintenance after every 2,400 hours of operation (carried out after

2,400, 4,800 etc. hours)
Periodic maintenance after every 4,800 hours of operation (carried out after

4,800, 9,600 etc. hours)
Maintenance every year
Maintenance every 5th year

ENGINES WITH FEW HOURS OF
OPERATION

Emergency back-up power units and the like which are not used regularly
should be test run and checked according to the unit manufacturer’s instruc­tions.

The engine is run to operating temperat ure and t he mainten ance poi nts bel ow
should be carried out:

1. Checking oil level.

5. Checking coolant level.

8. Checking low pressure indicator.

12. Checking fuel level.

15. Checking electrolyte level in batteries.

16. Checking battery charge.

17. Cleaning batteries.

23. Look for leaks. Remedy as necessary

For engines with few operating

hours which do not receive

periodic maintenance

according to the maintenance

schedule on page 13,

maintenance should be carried

out according to the schedules

for:

“Every year”

“Every 5th year”

1997-11:2 © Scania Industrial & Marine Engines 13

MAINTENANCE SCHEDULE

1. More often if required

2. For engines with few operating hours, see page 12.

3. Earlier if low pressure indicator shows red.

4. If inhibitor has not been topped up for five years, coolant should be changed.

Daily

First

time at

Interval At least

At first start

400 h

200 h

400 h

1200 h

2400 h

4800 h

Every year

Every 5th year

LUBRICATION OIL SYSTEM, page 14

1. Checking oil level

l l

2. Oil change

l1 l

3. Cleaning the lubrication oil cleaner

l1 l

4. Changing the turbo filter

l1 l

COOLING SYSTEM, page 18

5. Checking coolant level

l

6. Checking coola nt

l l4 l

7. Cleaning cooling system

l1 l

AIR CLEANER, page 24

8. Test reading low pressure indicator

l

9. Cleaning coarse cleaner

l1 l

10. Cleaning or changing filter insert

l3 l

11. Chang ing saf et y cart ri dge

l l

FUEL SYSTEM, page 26

12. Checking fuel level

l l

13. Changing main filter

l1 l

14. Checking injectors

l l

ELECTRICAL SYSTEM, page 28

15. Checking electrolyte level in batteries

l l2 l

16. Chec king charge state of batteries

l l2 l

17. Cleaning batteries

l2 l

18. Checking level monitor

l l l

19. Chec king temperature moni tor

l l l

20. Checking oil pressure monitor

l l l

21. Checking stop function

l l l

MISCELLANEOUS, page 33

22. Checking v-belts

l l l

23. Look for leakage. Remedy as necessary

l

24. Checking/adjusti ng val ve cle arance

l l

25. Changing (or cleaning) valve for closed crankcase
ventilation

l

14 © Scania Industrial & Marine Engines 1997-11:2

LUBRICATION OIL SYSTEM

OIL GRADE

The engine oil shoul d at least meet the requi re me nt s f or one of the following
oil classifications:

-Service CE or CF as per API

-CMC - D5

-Acea E3-96

- Check with your oil supplier if the oil meets these requirements.

- Specified oil change interv als appl y under th e prov ision that the sulp hur
content of the fuel does not exceed 0.3% by weight.

- Viscosities as illustrated.

- At very low outside temperatures: Consult your nearest Scania repre­sentative to avoid difficulties.

Oil analysis

Some oil companies can offer analysis of the engine oil. This analysis meas­ures the oil’s total base nu mber (TBN), total acid number (TAN), fuel dilu­tion, water content, viscosi ty and the con tent of wear partic les and soo t in the
oil.

The result of a series of anal ys es f orms the basis of establishing a s uit abl e oi l
change interval.

If the conditions are changed, a new oil a nalysi s progr am must be un derta ken
to establish a new change in terval.

-40 -30 -20 -10 0 10 20 30 40

°C

SAE 10W-30

SAE 20W-30

SAE 30

SAE 40

SAE 50

SAE 5W-30

SAE 15W-40

Additives must not be used.

The oil should be able to cope

with all temperature

variations up until the next

oil change.