Scania DI12, DC12 Operator's Manual

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Operator’s Manual

DI12, DC12

EMS with S6/PDE

Industrial engine

opm_d12ind_en-GB01 1 920 785

IMPORTANT INFORMATION

When work is being carried out on the engine such as adjusting drive belts, changing oil or

adjusting the clutch, it is important not to start the engine. The engine may be damaged and

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 is reproduced beside those maintenance points where the risk of

injury is particularly great.

COMMISSIONING REPORT - WARRANTY

When the commissioning report has been filled in and sent to Scania, you have a 1-year warranty from the date of commissioning. Also fill in the particulars below as this can make things easier if you need to contact for example a service workshop.

Engine number

Date of commissioning

User’s name and address

Signature

Engine type

Variant

Engine type and variant are indicated on the engine type plate

2 © Scania CV 2009

Foreword

This Operator’s Manual describes the handling and maintenance of Scania DC12 and DI12 Industrial Engines with EMS S6/PDE injection systems.

The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder inline diesel type. These engines have turbochargers and charge air coolers; see page 14.

Common applications are as power units in construction machines, generator sets, earth-moving, railway and forestry machines as well as in irrigation systems.

The engines can have different output and speed settings.

The normal output setting of the engine (performance code) is indicated on the type plate, see page 14.

Note: Only standard components are described in the Operator’s

Manual. Please see the manufacturer’s instructions regarding special equipment.

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

- Read the manual before starting to use the engine. Even though you may have experience of Scania engines you may find new information in this Operator’s Manual.

- Follow the maintenance instructions. Good working order and service life are ensured if maintenance is carried out according to the instructions.

- In particular, read the safety information starting on page 6.

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

- If necessary, contact an authorised Scania workshop. They have special tools, genuine Scania parts and staff with training and practical experience of Scania engines.

Note: Always use genuine Scania parts during service and repair so as

to keep your engine in the best possible working order.

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

During the warranty period,

only genuine Scania parts may

be used during service and

repair; otherwise the warranty

will be invalidated.

Important

Contents

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Environmental responsibility .........................4

Certified engines ............................................5

Scania industrial and marine engine warranty

for industrial engines.......................................6

Safety information ........................................10

Safety precautions before running . . . . . . . . .11

Safety precautions for materials handling . . . .12

Safety precautions for care and maintenance .12

Type designations . . . . . . . . . . . . . . . . . . . . . 14

Engine management system, EMS . . . . . . . 16

Troubleshooting using flash codes for the

EMS control unit . . . . . . . . . . . . . . . . . . . . . . .20

Overview of flash codes for the EMS

control unit . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Troubleshooting using flash codes for the

EMS coordinator . . . . . . . . . . . . . . . . . . . . . . .22

Overview of flash codes for the EMS

coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Starting and driving . . . . . . . . . . . . . . . . . . . 24

First start .......................................................24

Checks before running .................................25

Starting the engine ........................................25

Starting at low temperatures . . . . . . . . . . . . . .26

Running ........................................................26

Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . .26

Limp home mode . . . . . . . . . . . . . . . . . . . . . . .27

Coolant temperature . . . . . . . . . . . . . . . . . . . .27

Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Stopping the engine ......................................29

Checks after running ....................................29

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 30

Engines with few hours of operation ...........30

Maintenance schedule .................................. 31

Lubricating oil system . . . . . . . . . . . . . . . . . 32

Oil grade .......................................................32

Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Checking the oil level ...................................33

Checking oil level during operation . . . . . . . . 33

Oil change ....................................................33

Maximum angles of inclination during

operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Cleaning the oil filter unit ............................ 34

Renewing the oil filter .................................. 36

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 36

Checking coolant level .................................36

Checking coolant ..........................................37

Checking the corrosion protection . . . . . . . . . 39

Changing the coolant . . . . . . . . . . . . . . . . . . .39

Cleaning the cooling system .........................40

Internal cleaning . . . . . . . . . . . . . . . . . . . . . . .41

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Test reading of vacuum indicator .................42

Cleaning the air cleaner coarse cleaner ........42

Cleaning or changing filter element .............42

Renewing the safety cartridge ......................43

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Checking the fuel level .................................44

Changing the fuel filter .................................44

Electrical system . . . . . . . . . . . . . . . . . . . . . . 46

Checking the electrolyte level in batteries ...46

Checking the state of charge in batteries ......46

Cleaning batteries .........................................46

Renewing the battery ....................................47

Checking coolant level monitor ...................47

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . 48

Checking the drive belt .................................48

Look for leakage, rectify as necessary .........49

Check and adjust valve clearance .................50

Checking and adjusting the unit injector

rocker arms ...................................................52

Renewing (or cleaning) the closed

crankcase ventilation valve ..........................56

Preparing the engine for storage . . . . . . . . . 57

Preservative fuel . . . . . . . . . . . . . . . . . . . . . . .57

Preservative oil . . . . . . . . . . . . . . . . . . . . . . . .58

Preparation for storage . . . . . . . . . . . . . . . . . .58

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Taking out of storage . . . . . . . . . . . . . . . . . . .59

Technical data . . . . . . . . . . . . . . . . . . . . . . . . 60

Fuel ...............................................................62

Alphabetical index . . . . . . . . . . . . . . . . . . . . . 64

Scania Assistance . . . . . . . . . . . . . . . . . . . . . . 65

4 © Scania CV 2009

Environmental responsibility

Scania has always been very much at the leading edge when it comes to developing and producing engines which are as environmentally friendly as possible.

Major progress has been made on reducing harmful exhaust emissions as required to be able to meet the stringent environmental standards stipulated on almost all markets.

At the same time, we have been able to maintain high quality in terms of performance and operating economy for Scania Industrial and Marine Engines.

To preserve these qualities throughout the entire service life of the engine, it is important for the operator/owner to follow the instructions on running, maintenance and the choice of fuel and oil as outlined in the manual.

Other efforts to preserve the environment we all share are possible by ensuring that the person carrying out servicing and maintenance always makes sure that environmentally hazardous waste after servicing and repairs (oil, fuel, coolant, filters, batteries, etc.) is dealt with and disposed of in accordance with applicable environmental standards.

On a number of pages, this Operator’s Manual contains specially highlighted text with instructions to help protect our environment during certain servicing and maintenance work.

See example

Use a container to avoid spillage

when bleeding and changing

components.

Help protect our

environment!

Certified engines

Emissions-certified engines have been approved in accordance with a special certification standard. The certified engines supplied by Scania meet the most stringent emissions standards which apply on European (EU) and nonEuropean (USA) markets.

Scania guarantees that all the engines it supplies of a certified type are equivalent to the engine approved for certification.

The engine comes with a special certification plate which indicates the certification rules (standard) to which the engine has been approved. See page 14.

The following is required for the certified engine to meet emissions standards once it has been commissioned:

- Servicing and maintenance must be carried out in accordance with the instructions in this manual.

- Only genuine Scania parts are to be used.

- Injection equipment is to be serviced by an authorised Scania workshop.

- The engine must not be modified with equipment not approved by Scania.

- Seals may be broken and setting data edited only once approval has been granted by Scania in Södertälje. Changes may be made by authorised personnel only.

- Changes which affect the exhaust system and intake system must be approved by Scania.

Otherwise, the instructions in the manual in respect of running, care and maintenance of the engine shall apply. The safety precautions described over the next four pages must also be observed.

Important! If servicing and maintenance are not carried out as

specified above, Scania can no longer guarantee that the engine will comply with the certified design, nor can it take responsibility for any damage that occurs.

6 © Scania CV 2009

Scania industrial and marine engine warranty for industrial engines

Emission Control Systems Warranty

Important! Only applicable to engines used in the U.S.A.

Table of contents

General Warranty Provisions ......................... 6

Warranty Period ............................................. 7

Parts covered by the Warranty ....................... 7

General Warranty Limitations ....................... 8

Specific Warranty Exclusions ....................... 9

Customer Support ........................................... 9

Emission Control System Warranty Statement

General warranty provisions

The emission control systems of your new Scania Industrial and Marine ("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 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, and all applicable regulations under Chapter 1 and 2, Part 5, Division 26 of 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.

Warranty Period

This warranty shall apply for one of the following periods, whichever occurs first:

• 3,000 hours of operation, or

• Five years of use

The warranty period shall begin:

• "On the date the engine is delivered to the first retail purchaser, or

• "If the engine is placed in service for demonstration purposes prior to

sale at retail, on the date the engine is first placed in service.

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 emission control regulations:

1. Fuel injection system

2. Air intake system

• Intake manifold

• Turbocharger system

• Charge air cooler system

3. Exhaust manifold

4. Combustion chamber

• Piston

• Cylinder head

5. Components used in the above mentioned systems

Important! This list does not include all expendable maintenance parts.

Expendable emission related parts requiring scheduled maintenance are warranted until their first scheduled replacement point. See Specific Warranty Exclusions below.

8 © Scania CV 2009

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.

In addition, you are responsible for the performance of all scheduled maintenance and necessary repairs on your new Scania industrial diesel engine. Scania may deny a warranty claim if your failure to perform maintenance resulted in the failure of the warranted part, listed under Parts covered by the Warranty above.

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.

The Warranty covers the cost of 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.

WARNING!Use of replacement parts which are not of equivalent

quality may impair the effectiveness of emission control systems. Accordingly, it is recommended that only Scania repair or replacement parts be used for maintenance, repair or replacement of emission control systems. 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

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.

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 601, 78216, San Antonio, Texas

Mailing address: 121 Interpark Blvd, suite 601, 78216, San Antonio,

Texas

Telephone: +1 210 403 0007

Fax: +1 210 403 0211

E-mail: contact@scaniausainc.com

10 © Scania CV 2009

Safety information

General

This Operator’s Manual contains safety information which is important so as to avoid both personal injury and damage to the product/other property. See also page 1.

The text highlighted in text boxes on the right of a number of pages is important for engine function and in order to avoid damage to the engine. If these instructions are not followed, your warranty may be invalidated.

See example

Similar text may also appear in the text column, and in this instance it will be marked

Note: or Important!.

The warning text found in text boxes on the right of a number of pages which is marked with a warning triangle and starts with

WARNING is extremely

important and warns you of serious engine faults or incorrect handling which may lead to injury.

See example

A list of the safety precautions to be followed when running and maintaining Scania engines can be found on the next three pages. Similar text can often be found at the relevant maintenance points, and here different levels of importance are attached to such text in accordance with the above description.

All points are marked

!, so as to indicate how important it is to read through

each point in this section.

For safety reasons, smoking is not allowed:

• In the vicinity of the engine and in the engine room

• When fuelling and close to the filling station

• When working on the fuel system

• In the vicinity of inflammable or explosive material (fuel, oils, batteries, chemicals, etc.)

Block the starting device when

working on the engine.

If the engine starts accidentally,

there is a

SERIOUS RISK OF INJURY.

Only use genuine Scania fuel

filters.

Important

WARNING

Safety precautions for running the engine

Daily inspection

Always visually inspect the engine and engine compartment before starting the engine and once you have stopped the engine after running.

This will enable you to easily detect fuel, oil or coolant leaks, or any other abnormalities which may require rectification.

Refuelling

There is a risk of fire and explosion when refuelling. The engine must be stopped and smoking is not allowed.

Do not overfill the tank due to a risk of expansion, and close the filler cap properly.

Use only fuel recommended in the service literature. Fuel of the wrong quality can cause the engine to malfunction or stop by preventing the injection pump and injectors from operating as they should.

This can cause damage to the engine and, possibly, injury.

Hazardous gases

Only start the engine in a well ventilated area. The exhaust fumes contain carbon monoxide and nitric oxides, which are toxic.

If it is run in a enclosed space, there should be an effective device to extract exhaust gases and crankcase gases.

Starter lock

If the control panel is not fitted with a key operated switch, there should be a lock on the engine room to prevent unauthorised starting of the engine.

Alternatively, a lockable on/off master switch or battery master switch can be used.

Starter spray

Never use starting spray or similar as a starting aid. 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 for 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 therefore be shielded as much as possible.

12 © Scania CV 2009

Safety precautions for handling materials

Fuel and lubricating oil

All fuels and lubricants and many chemicals are flammable. Always follow the instructions on the relevant packaging.

All work on the fuel system must be done with the engine cold. Fuel leaks and spillage on hot surfaces can cause fire.

Store soaked rags and other flammable materials safely so as to avoid spontaneous combustion.

Batteries

The batteries contain and emit oxyhydrogen gas, particularly during charging, and this 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 in turn can cause the battery to explode.

Chemicals

Most chemicals such as glycol, corrosion inhibitors, preservative oils, degreasing agents, etc. are hazardous to health. Always follow the safety precautions on the relevant packaging.

Some chemicals, such as preservative oil, are also flammable.

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 or used chemicals to an authorised waste disposal contractor.

Safety precautions for care and maintenance

Stop the engine

Always stop the engine before maintenance and servicing unless stated otherwise.

Prevent unwanted starting by taking out the ignition key where applicable and disconnecting the power using the master switch or battery master switch and locking them. Also put up a warning sign somewhere appropriate, indicating that work is in progress 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.

Hot surfaces and fluids

There is always a risk of sustaining burns when an engine is hot. Therefore, take care not to come into contact with manifolds, the turbocharger, the sump, hot coolant and oil in pipes and hoses.

Lifting the engine

The engine lifting eyes must be used when lifting the engine. Check first that your lifting devices are in good condition and of the correct size to lift the weight.

Extra equipment on the engine can alter the centre of gravity, which is why you may need additional lifting devices to balance the engine correctly and lift it safely.

Never work underneath a suspended engine!

Batteries

The batteries contain a highly corrosive electrolyte (sulphuric acid). Take care to protect your eyes, skin and clothes when charging or handling batteries. Wear protective gloves and goggles.

If the acid splashes on your skin, wash it off with soap and copious amounts of water. If acid splashes in your eyes, flush them immediately with copious amounts of water and contact a doctor.

Dispose of used batteries through an authorised waste disposal contractor.

Electrical system

The engine must be stopped 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.

Electric welding

When carrying out welding work close to and on the engine, remove the battery leads and the cables to the alternator. Also remove the multi-pin connector to the control unit.

Connect the weld clamp to the component to be welded and close to the welding point, never to the engine or in such a manner that the current can pass over to a mounting.

When you have finished welding, connect the cables to the alternator and control unit before connecting the batteries.

Lubrication system

Hot oil can cause burns and skin irritation. Therefore, avoid skin contact with hot oil.

Make sure that there is no pressure in the lubricating system before starting work on it. Never start or run the engine with the oil filler cap removed, as this may cause oil to be thrown out.

Dispose of used oil through an authorised waste disposal contractor.

Cooling system

Never open the coolant filler cap if the engine is hot. Hot coolant or steam may spray out and cause burns.

If you have to open or remove a cooling system component when the engine is hot, open the cap very carefully and slowly to relieve the system pressure before removing the cap. Wear gloves as the coolant is still very hot.

Dispose of used coolant through an authorised waste disposal contractor.

Fuel system

Always wear gloves when looking for leaks or carrying out any other work on the fuel system. Also wear protective goggles when testing injectors.

Fuel escaping at high pressure can penetrate tissues and cause serious injury.

Never use non-genuine parts in the fuel and electrical systems as genuine parts are designed and manufactured to minimise the risk of fire and explosion.

Before starting

Fit all removed shields before starting the engine again. Check that you have not left any tools or other objects on the engine.

Never start the engine without the air filter fitted. There is a risk of objects being sucked into the compressor impeller or of injury if you come into contact with it.

14 © Scania CV 2009

Type designations

The engine type designation indicates engine type, size and applications in code form.

The type designation and engine serial number are specified on a type plate affixed to the right-hand side of the flywheel housing. The engine number is also stamped on the right-hand side of the cylinder block. See the arrow in illustration.

Version

DC Supercharged diesel engine with air-cooled charge air cooler DI Supercharged diesel engine with liquid-cooled charge air cooler

Displacement in whole dm

Performance and certificate

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

Made by

Type Engine No Output. Output

kWkWrpm.

rpm.

DI12 54A 6521399

2200331

308 664

DI 12 54 A

1, 2

1. Type plate

2. Engine number, stamped

into the cylinder block

3. Coolant pump

4. Automatic belt tensioner

5. Draining, coolant

6. Oil filter

7. Oil filter unit

8. Oil dipstick

9. Draining, engine oil

10. Oil cooler

11. Turbocharger

12. Oil filler

13. Hydraulic pump

14. Fuel pump with hand pump

15. Starter motor

16. S6 control unit

17. Fuel filter

18. Charge air cooler

The illustrations show a normal version of a DI12-engine.

Your engine may have different equipment from that illustrated.

16 © Scania CV 2009

EMS engine management system

This engine has an electronic management system, EMS (Engine Management System) with unit injectors (PDE) which provide each cylinder with the right amount of fuel at the right time in all operating situations.

The EMS system consists of a control unit (S6) and sensors for speed, charge air temperature and pressure, coolant temperature, oil pressure, accelerator pedal/throttle actuation which constantly emit signals to the control unit. With the aid of this input data and the programmed control software, the correct fuel amount and correct injection time are calculated for each unit injector under the specific operating conditions.

The EMS system sensors can also be used to emit signals to the instruments in the instrument panel.

The control unit constantly checks the sensors to make sure they are operational.

The control unit contains monitoring functions to protect the engine in the event of a fault which would otherwise damage it. In the event of a fault, for example alarm level for low oil pressure or high coolant temperature, the S6 control unit sends a CAN message to a coordinator.

The main task of the coordinator is to pass on data by means of CAN communication from the engine control unit to other control units and signals to gauges and lamps in the instrument panel. The coordinator also has monitoring functions.

When the EMS control unit or the coordinator detects a fault, the diagnostics lamp on the instrument panels(s) comes on, and it stays on as long as the fault is active. At the same time, a fault code is generated which can be read off via the coordinator on the diagnostics lamp in the form of a flash code when the diagnostics switch is activated. A flash code may consist of a number of different fault codes.

Diagnosis and troubleshooting using Scania EMS Display is described in the Operator’s Manual for Scania EMS Instrumentation.

If the torque reduction function is activated, the amount of fuel and the engine power output are reduced to 70%, and if the engine shutdown function is activated, the engine is switched off at programmed alarm levels.

A separate PC-based diagnostics program is used to read off the contents of the flash codes. For an in-depth analysis of fault codes, contact an authorised Scania dealer.

Reading off the fault codes, and descriptions of these, are also covered in a separate document in the workshop manual, Engine Management System EMS-S6: Troubleshooting.

Only authorised personnel are allowed to carry out diagnostic procedures and program changes.

The positions of the sensors which emit signals to the control unit are shown in the illustrations on page 16.

See pages 20 and 22 for a description of how to read off flash codes.

See pages 21and 23 for a list of flash codes for the control unit and coordinator.

18 © Scania CV 2009

Positions of sensors for EMS with S6 on DI12

1. Oil pressure sensor

2. Charge air temperature and pressure sensor

3. Coolant temperature sensor

4. Engine speed sensor (2)

Location of sensors for EMS with S6 on DC12

1. Oil pressure sensor

2. Charge air temperature and pressure sensor

3. Coolant temperature sensor

4. Engine speed sensor (2)

20 © Scania CV 2009

Troubleshooting using flash codes for the EMS control unit

• The diagnostics lamp on the instrument panel(s) always comes on for two seconds when the system is powered up.

• As soon as a fault is detected by the control unit, it is stored in the EEPROM fault code memory and the diagnostics lamp on the instrument panel(s) comes on.

• The diagnostic lamp will stay on for as long as a fault is active. Even if the lamp has gone off and the fault is no longer active, the code can generally be read off by following the instructions below.

Reading off control unit fault codes

1. Turn on the ignition.

2. Activate the diagnostics switch to the left to view the flash codes for the

control unit (EMS).

3. A fault code will then flash on the diagnostics lamp. This flash code

consists of long flashes (approximately 1 second long) and short flashes (0.3 seconds long). Long flashes are equivalent to tens and short flashes to units. Example: long - short - short = fault code 12.

4. Repeat this procedure until the first flash code is repeated. This means

that the entire fault code memory has been flashed out. If the fault code memory is empty, only one long flash approximately 4 seconds long will be given.

5. See the flash code table on the next page for a description and to locate

the fault.

6. In order to obtain further information on the fault code, the PC-based

diagnostics tool or Scania EMS Display must be used. Contact an authorised Scania workshop.

7. When a fault has been rectified the fault code can be erased as described

below.

Clearing fault codes

1. Switch off the ignition. If there is dual instrumentation the ignition must

be switched off on both panels.

2. Activate the diagnostics switch in the same direction as the flash codes

indicate, i.e. to the right for the coordinator (COO) or to the left for EMS.

3. Switch on the ignition and at the same time keep the diagnostics switch

activated, to the right (COO) or to the left (EMS), for 3 seconds.

4. This will erase passive fault codes which can be read off via flash code

for the relevant system. The rest of the fault codes will remain in the EEPROM and can only be deleted using the PC tool.

Overview of flash codes for the EMS control unit

Code Description

Code

Description

No fault detected.

PDE in cylinder 3: The solenoid valve is not working properly.

Overrevving. One or both engine speed sensors displays a speed in excess of 3,000 rpm.

PDE in cylinder 4: The solenoid valve is not working properly.

Engine speed sensor 1 faulty, or incorrect signal.

PDE in cylinder 5: The solenoid valve is not working properly.

Rotation speed sensor 2 faulty, or incorrect signal.

PDE in cylinder 6: The solenoid valve is not working properly.

Coolant temperature sensor faulty, or incorrect signal.

PDE in cylinder 7: The solenoid valve is not working properly.

Charge air temperature sensor faulty, or incorrect signal.

PDE in cylinder 8: The solenoid valve is not working properly.

Charge air pressure sensor faulty, or incorrect signal.

Incorrect signal in extra analogue input.

Oil temperature sensor faulty, or incorrect signal.

Incorrect control unit shutdown.

Oil pressure sensor faulty, or incorrect signal.

Shutdown due to coolant level.

Coolant level sensor faulty.

Alternator charging incorrectly.

Internal fault code in the coordinator.

Starter motor function interrupted or not activated.

Accelerator pedal / brake. If the accelerator and brake pedals have been operated simultaneously.

Rotation speed above ref.speed at start.

Accelerator pedal sensor / idling switch Accelerator pedal sensor / kickdown switch

Fault in memory circuit (EEPROM) in control unit.

Engine shutdown bypassed.

Data transfer to the control unit memory (EEPROM) has been interrupted.

Shutdown due to oil pressure.

Incorrect internal temperature in the control unit.

Torque limitation due to oil pressure.

Internal fault in the control unit: Fault in hardware control.

Incorrect parameters for limp home function.

Fault in control unit RAM.

Battery voltage incorrect or no signal.

Internal control unit fault: Memory fault.

Emergency shutdown switch activated in accordance with CAN message from coordinator.

Defective seal: Illegal editing of software.

CAN circuit faulty in the control unit.

Rotation speed sensors faulty or not connected.

Immobiliser function. Starter key code incorrect.

Shutdown due to high coolant temperature.

CAN message from the coordinator incorrect or missing.

Torque limitation due to high coolant temperature.

Incorrect CAN version in control unit or coordinator.

Incorrect voltage supply to one of the sensors.

PDE in cylinder 1: The solenoid valve is not working properly.

Internal hardware fault in the processor (TPU).

PDE in cylinder 2: The solenoid valve is not working properly.

22 © Scania CV 2009

Troubleshooting using flash codes for the EMS co-coordinator

• The diagnostics lamp on the instrument panel(s) always comes on for two seconds when the system is powered up.

• As soon as a fault is detected by the coordinator, it is stored in the EEPROM fault code memory and the diagnostics lamp on the instrument panel(s) comes on.

• Even if the lamp has gone off and the fault is no longer active, the code can generally be read off by following the instructions below.

Reading off coordinator fault codes

1. Turn on the ignition.

2. Activate the diagnostics switch to the right for 1 second to view the flash

codes for the coordinator (COO).

3. A fault code will then flash on the diagnostics lamp. This flash code

4. Repeat this procedure until the first flash code is repeated. This means

that the entire fault code memory has been flashed out. If the fault code memory is empty, only one long flash (approximately 4 seconds long) will be given.

5. See the flash code table on the next page for a description and to locate

the fault.

6. In order to obtain further information about the fault code, the PC-based

diagnostics tool or Scania EMS Display must be used. Contact an authorised Scania workshop.

7. When a fault has been rectified the fault code can be erased as described

below.

Clearing fault codes

1. Switch off the ignition. If there is dual instrumentation the ignition must

be switched off on both panels.

2. Activate the diagnostics switch in the same direction as the flash codes

indicate, i.e. to the right for the coordinator (COO) or to the left for EMS.

3. Switch on the ignition and at the same time keep the diagnostics switch

activated, to the right (COO) or to the left (EMS), for 3 seconds.

4. This will erase passive fault codes which can be read off via flash code

for the relevant system. The rest of the fault codes will remain in the EEPROM and can only be deleted using the PC tool.

Overview of flash codes for the EMS co-coordinator

1) Single speed engine

2) All-speed engine

Flash code Fault description

Incorrect signal from the fine adjustment for the nominal engine speed signal.

Incorrect signals from the accelerator pedal sensor.

Incorrect signal from the resistor module for governor setting.

Incorrect signal from the resistor module for idle and fixed speed setting.

13 No communication (EMS) with the engine.

14 Short circuit in the tachometer signal cable.

15 Faulty atmospheric pressure sensor.

17 Short circuit in the coolant temperature gauge signal cable.

18 Short circuit in the oil pressure gauge signal cable.

19 Short circuit in the oil pressure lamp signal cable.

21 Different versions of the communications protocol in the coordinator and EMS.

22 Faulty start switch or short circuit.

23 The supply voltage is too high.

24 The supply voltage is too low.

25 Check value from End of line (EOL) is incorrect.

26 Road speed sensor signal missing or incorrect.

27 The signals from the RCB (Remote Control Box) switches are implausible.

28 Incorrect signals from the droop setting switches.

29 Faulty remote start switch or short circuit.

31 No communication from the slave coordinator or the master coordinator.

32 Short circuit in the signal cable to the coolant temperature warning lamp.

33 Short circuit in the signal cable to the charge warning lamp.

34 Incorrect signal from the Fixed speed switches.

35 Fault in CAN communication.

24 © Scania CV 2009

Starting and driving

First start

When the engine is started for the first time, carry out the maintenance points listed under "First start" in the maintenance schedule; see page 31.

Since the points are important for satisfactory operation of the engine right from the outset, they are also listed below.

1. Checking the oil level; see page 33.

6. Checking the coolant; see page 34.

The coolant must contain corrosion inhibitor to protect the cooling system from corrosion.

If there is a danger of freezing:

- Only antifreeze glycol should be used in the coolant as protection

against corrosion. We recommend only nitrite-free antifreeze glycols with the following supplier designations:

BASF G48 or BASF D542

- The concentration of glycol should be 30-60% by volume depending on

the ambient temperature. 30% glycol by volume provides anti-freeze protection down to -16°C. See page 37.

- Never top up with water alone or glycol alone! Fluid losses must always

be replaced with pre-mixed coolant having the same glycol concentration as that in the engine. If the glycol content drops, both antifreeze protection and protection against corrosion are impaired.

Note: A glycol concentration below 30% by volume will not provide

sufficient protection against corrosion. Glycol concentrations higher than 60% do not improve anti-freeze protection and have a negative effect on engine cooling capacity.

If there is no danger of freezing:

- Only Scania Corrosion Inhibitor should be used in the coolant as

protection against corrosion. The correct corrosion inhibitor content is 8-12% by volume, and this must never drop below 8% by volume. The inhibitor in Scania Corrosion Inhibitor is free of nitrites.

- First filling: Fill up the system with water + 10% by volume Scania

Corrosion Inhibitor. Use drinking water with a pH of 6-9.

- Never top up with water alone or corrosion inhibitor alone!

Fluid losses must always be replaced with pre-mixed coolant: water + 10% Scania Corrosion Inhibitor by volume.

Coolant filter (not standard equipment)

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

Coolant composition:

If there is a danger of freezing:

minimum 30% glycol by

volume

maximum 60% glycol by volume

If there is no danger of freezing:

8-12% by volume

Scania Corrosion Inhibitor

(no glycol)

The recommended glycols must

not be mixed with glycol

containing nitrite-based

corrosion inhibitor.

Ethylene glycol and corrosion

inhibitor can be fatal if

imbibed.

Avoid contact with the skin.

Overdosing with Scania

Corrosion Protection and mixing

with glycol can cause sludge to

form.

If a coolant filter has been fitted

it must not contain inhibitor.

Important

WARNING

12. Checking the fuel level; see page 44.

14. Checking the electrolyte level in batteries; see page 46.

15. Checking the state of charge in batteries; see page 46.

18. Checking the drive belt tension; see page 48.

Checks before running

Before running, carry out "Daily maintenance" as described in the maintenance schedule, see page 31.

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 45.

Out of consideration for our common environment, your Scania engine has been designed to use less fuel when starting. Using unnecessarily large amounts of fuel when starting the engine always results in emissions of unburnt fuel.

- Open the fuel cock, if fitted.

- Disengage the engine.

- Engines with battery master switch: Switch on the power by means of the battery master switch.

- Start the engine with the key on the control panel (SCP).

- S6: All lamps should go out after approximately 2 seconds when starting the engine.

Block the starting device when

working on the engine.

If the engine starts accidentally,

there is a

SERIOUS RISK OF INJURY.

Only start the engine in a well

ventilated area.

If it is run in a enclosed space,

there should be an effective

device to draw off exhaust gases

and crankcase gases.

Never use starter spray or

similar agents to help start the

engine.

An explosion may occur in the

intake manifold with a risk of

personal injury.

WARNING

26 © Scania CV 2009

Starting at low temperatures

Local environmental requirements must be complied with. Starting aids, engine heaters or flame start devices should be used to avoid starting problems and white smoke.

To limit white smoke, the engine should be run at low speed and under moderate load. A moderate load on a cold engine gives better combustion and faster heating than warming up with no load.

Avoid running it longer than necessary at idling speed.

At temperatures below 0°C:

Note: Only use starting aids recommended by Scania.

- The starter motor may only be used for 30 seconds at a time. After that it must rest for 30 seconds before attempting to start it again. Only 5 attempts may be made to start the engine. After that the starter motor must rest for 15 minutes before the procedure can be repeated.

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

switch should be depressed and held down until the oil pressure has reached a sufficiently high level.

RUNNING

Check instruments and warning lamps at regular intervals.

Engine speed

The Scania tachometer is divided into different coloured sectors, as follows:

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

through when stopping and starting.

500-700 rpm yellow area: slow idle. Engine idling is

controlled by the S6 control system. Raised idling speed with a cold engine. See page 26.

700-2,200 rpm green area: normal operating speed.

The engine operating speed range is controlled by the S6 control system.

2,200-2,600 rpm yellow/green

striped:

unsuitable operating speed. May occur when switching off.

2,600-3,000 rpm red area: prohibited engine speed

The starter motor may only be

cranked for a maximum of

30 seconds. There is risk of

overheating. Let the starter

motor rest for 30 seconds

between each start attempt.

Important

Limp home mode

If there is a fault on the normal accelerator pedal or if CAN communication is interrupted, the following limp-home option is provided:

CAN outage or accelerator pedal malfunction (both signal and idling switch):

- The accelerator pedal value is 0% and the engine is running at normal idling speed.

- The accelerator pedal value is 0% and the engine is running at raised idling speed (750 rpm) if this function is activated.

Accelerator pedal malfunction but the idling switch is working:

- The accelerator pedal value can be increased slowly between 0% and 50% by using the idling switch.

CAN outage:

- The engine is switched off if the shutdown function is activated.

Coolant temperature

Normal coolant temperature when the engine is running should be 70-90°C.

The S6 control system has the following alarm levels:

- If the temperature is high, 98°C-103°C, for a certain period (1 second), S6 will send a CAN message which switches on the warning lamp and diagnostics lamp via the coordinator.

- If the temperature exceeds 103°C, the warning lamp and diagnostics lamps will come on. If torque reduction is activated, the control system will reduce the fuel quantity to 70%. A fault code is generated in the control unit.

- At temperatures exceeding 103°C and with engine shutdown activated, the warning lamp and diagnostics lamp come on and the engine is switched off. If the override function is activated, only torque reduction takes place when this function is activated. A fault code is generated in the control unit.

After an alarm, approved values should be registered for more than 2 seconds to reset the alarm.

Excessively high coolant temperature can damage the engine.

If run for extended periods under an extremely light load, the engine may have difficulty in maintaining normal operating temperature. However, the temperature will rise to a normal level again when the load on the engine is increased.

28 © Scania CV 2009

Oil pressure

Maximum oil pressure:

warm engine running at a speed above 800 rpm 6 bar

Normal oil pressure:

warm engine at operating speed 3-6 bar

Minimum oil pressure:

warm engine running at a speed of 1,000 rpm 2.3 bar

The control system has the following alarm levels:

- at a speed of less than 1,000 rpm and an oil pressure of less than 1.0 bar

- at a speed of more than 1,000 rpm and an oil pressure of less than 2.3 bar for longer than 5 seconds.

The following functions are available if there is an alarm:

- Alarm which only switches on the warning lamp and diagnostics lamp.

- Alarm which switches on the warning lamp and diagnostics lamp as well as torque reduction if this function is activated (70% of fuel quantity). A fault code is generated in the control unit.

- Alarm which switches on the warning lamp and diagnostics lamp. The engine is switched off if engine shutdown is activated. If the override function is activated, only torque reduction takes place when this function is activated. A fault code is generated in the control unit.

After an alarm, approved values should be registered for more than 1 second to reset the alarm.

High lubricating oil pressure (above 6 bar) is normal when

starting a cold engine.

Charging indicator lamp

If the lamp comes on during operation:

- Check and adjust the alternator drive belts as described under the maintenance point. See page 48.

- If the charging indicator lamp is still on, this could be due to an alternator fault or a fault in the electrical system.

Stopping the engine

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

continuously with a heavy load.

2. Stop the engine with the stop button or the starter key (depending on

version). Keep the stop button depressed until the engine has stopped completely.

3. Set the control switch to the "0" position.

4. Engines with battery master switch: Switch the power off with the

battery master switch.

Note: 10 prohibited engine stops will cause torque reduction (70% of

fuel quantity). To reset the engine, switch off the engine once in the prescribed manner.

Checks after running

- Check that the power is cut from the battery master switch and that the control switch is in the "0" position.

- 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.

- If there is a risk of freezing, the cooling system must contain enough glycol. See pages 24 and 37.

- At temperatures below 0°C: prepare for the next start by connecting the engine heater (if fitted).

There is danger of turbocharger

damage and post boiling if the

engine is stopped without

cooling.

Coolant should be topped up

when the engine is stopped after

the first start.

Block the starting device when

working on the engine.

If the engine starts accidentally,

there is a

SERIOUS RISK OF INJURY.

The power must not be switched

off before the engine has

stopped.

The system is pressurised.

Major risk of burns.

Important

WARNING

30 © Scania CV 2009

Maintenance

The maintenance programme covers 20 points, divided into the following main groups:

Lubricating oil system . . . . . . . . . . . . . . . . .page 28

Cooling system . . . . . . . . . . . . . . . . . . . . . . .page 32

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . .page 38

Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . page 40

Electrical system, batteries, etc. . . . . . . . . . .page 42

Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . .page 44

The maintenance points are divided into intervals as follows:

Daily maintenance

Maintenance before the first start

Maintenance after the first 400 hours of operation

Periodic maintenance every 200 hours of operation (carried out at 200, 400, 600, 800, etc. hours)

Periodic maintenance every 400 hours of operation (carried out at 400, 800, 1,200, 1,600, etc. hours)

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

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

Periodic maintenance every 4,800 hours of operation (carried out at 4,800, 9,600 etc. hours)

Annual maintenance

Maintenance every 5 years

Engines with few hours of operation

Emergency generator sets and the like that are not used regularly should be test run and checked in accordance with the generator set manufacturer’s instructions.

Run the engine until it reaches operating temperature and then carry out the maintenance points below:

1. Checking the oil level.

5. Checking the coolant level.

8. Checking the vacuum indicator.

12. Checking the fuel level.

14. Checking the electrolyte level in batteries.

15. Checking the state of charge in batteries.

16. Cleaning the batteries.

19. Check for leaks, rectify as necessary.

Block the starting device when

working on the engine.

If the engine starts accidentally,

there is a

SERIOUS RISK OF INJURY.

For engines with few operating

hours that do not receive

periodic maintenance according

to the maintenance schedule on

page 29, maintenance should be

carried out in accordance with

the schedule:

"Annually"

"Every 5th year"

Important

WARNING

Maintenance schedule

1. More often if required.

2. Earlier if the vacuum indicator shows red.

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

Daily

First

time at

Interval At least

First start

400 h

200 h

400 h

1,200 h

2,400 h

4,800 h

Annually

Every 5 years

Lubricating oil system, page 28

1. Checking the oil level

2. Oil change

z1 z

3. Cleaning the lubricating oil cleaner.

z1 z

4. Renewing the oil filter

z1 z

Cooling system, page 32

5. Checking the coolant level

6. Checking the coolant

zz3 z

7. Cleaning the cooling system

z1 z

Air cleaner, page 38

8. Test reading of vacuum indicator

9. Cleaning the coarse cleaner

z1 z

10. Cleaning or renewing the filter element

z2 z

11. Renewing the safety cartridge

Fuel system, page 40

12. Checking the fuel level

13. Changing the main filter and water separating filter

z1 z

Electrical system, page 42

14. Checking the electrolyte level in batteries

zz z

15. Checking the state of charge in batteries

zzz

16. Cleaning the batteries

17. Checking the coolant level monitor

Miscellaneous, page 44

18. Checking the drive belt

zzz

19. Check for leaks, rectify as necessary

20. Checking and adjusting valve clearances

21. Checking and adjusting the unit injector rocker arms

22. Renewing (or cleaning) the closed crankcase ventilation valve

32 © Scania CV 2009

Lubricating oil system

Oil grade

The engine oil must at least meet the requirements for one of the following oil classifications:

-ACEA E3, E4 or E5

- The Total Base Number (TBN) should be minimum 12-13 (ASTM

2896).

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

- Specified oil change intervals apply provided that the sulphur content of the fuel does not exceed 0.3% by weight. If the sulphur content is greater than 0.3% but no more than 1.0%, the oil change interval must be halved (200 h).

- Viscosities are shown in the figure below.

- For operation at extremely low ambient temperature: Consult your nearest Scania representative on how to avoid starting difficulties.

Oil analysis

Some oil companies can offer analysis of the engine oil. Such analysis measures the oil’s TBN (Total Base Number), TAN (Total Acid Number), fuel dilution, water content, viscosity and the quantity of wear particles and soot in the oil.

The result of a series of analyses is used as the basis for establishing a suitable oil change interval.

If the conditions are changed, a new oil analysis programme must be carried out to establish the new change interval.

Additives must not be used.

The oil should be suitable for all temperature variations until the

next oil change.

-40-30-20-100 10203040

°C

SAE 10W-30

SAE 20W-30

SAE 30

SAE 40

SAE 50

SAE 5W-30

SAE 15W-40

Important

1. Daily:

Checking the oil level

Note: Before checking oil level: Leave the engine switched off for at

least 1 minute.

- The correct level is between the marks on the dipstick. Top up when the level is at the lower mark.

- For the correct oil grade, see page 32.

Checking oil level during operation

On some engines the oil level can be checked during operation.

- Remove the oil filler cap to release the pressure in the crankcase.

- Check the level on the dipstick. Correct oil level: 10 mm below the Min. or Max. mark.

2. Every 400 hours:

Oil change

Note: If the engine is used for especially demanding operations,

particularly in a dusty environment or if the deposits in the centrifugal cleaner are thicker than 20 mm: change the oil more frequently.

- Unscrew the oil plug and drain the oil when the engine is hot.

- In certain engines the oil is pumped out by means of a bilge pump.

- Clean the magnet on the oil plug.

- Refit the oil plug and top up with oil.

- Check the level on the oil dipstick.

Max. 33 dm

Min. 28 dm

1 dm3 = 1 litre

Maximum angles of inclination during operation

Maximum permissible angles during operation vary, depending on the type of oil sump, see illustration.

Note: The specified angles may only occur intermittently.

35°

25°

35°

The oil may be hot.

Wear protective gloves and

goggles.

Max.

Min.

Use a container to avoid spillage

when changing the oil. Dispose

of used oil through an

authorised waste disposal

contractor.

WARNING

Help protect our

environment!

34 © Scania CV 2009

3. Every 400 hours:

Cleaning the oil cleaner

(in connection with oil change)

- Clean the cover. Unscrew the nut and remove the cover.

- Lift out the rotor and wipe the outside. Unscrew the rotor cover nut about one and a half turns.

- If the rotor nut is jammed: Turn the rotor upside down and fasten the nut in a vice, and turn the rotor one and a half turns counterclockwise by hand, or use an M20 nut as illustrated.

Note: The rotor must never be put in a vice.

- Hold the rotor and tap lightly on the rotor nut with a plastic mallet or against the workbench, so that the rotor bowl comes loose from the bottom plate. Never strike on the rotor directly as this may damage the bearings.

- Unscrew the nut and remove the rotor cover.

- Remove the strainer. If the strainer has seized in the rotor bowl, pry carefully using a screwdriver between the rotor bowl and the strainer.

- If the strainer has seized in the rotor, pry carefully between the rotor and the strainer.

- Scrape off the deposits from the inside of the rotor cover. If there are no deposits, this indicates that the cleaner is not working properly.

- If the deposits are thicker than 28 mm: clean more often.

Open the cover carefully. The

oil may be hot.

WARNING

- Wash all parts in diesel oil.

- Make sure the nozzles on the rotor are not blocked or damaged.

- Check that the bearings are undamaged. If they are damaged the entire rotor must be renewed.

- Fit a new O-ring on the rotor and fit the strainer.

- Reassemble the rotor.

- Tighten the rotor nut firmly by hand.

- Check that the shaft is not loose. If it is loose, use locking compound 561 200 and torque tighten to 34 Nm using tool 98 421.

- In order to tighten the rotor shaft, it is necessary to modify socket wrench 98 421:

- Drill out the threads from a M20 nut so that it fits on the square drive of the socket wrench.

- Weld the nut into place.

- Refit the rotor.

- Check that it rotates easily by rotating it manually.

- Fit a new O ring on the bowl and fit the bowl.

- Screw the bowl on and tighten the lock nut to 15 Nm.

Tighten the nut carefully so as not to damage the rotor shaft, nut or cover.

Functional inspection

The rotor rotates very fast and should continue to rotate when the engine has stopped.

- Stop the engine when it is warm.

- Listen for a whirring sound from the rotor or feel whether the cleaner housing is vibrating.

The rotor normally continues spinning for 30-60 seconds after the engine has stopped.

If not: dismantle and check.

36 © Scania CV 2009

4. Every 400 hours:

Renewing the oil filter

(in connection with oil change)

- Remove the old filter.

- Fit a new Scania genuine filter. Oil the seal on the filter before fitting.

- Tighten the filter by hand.

Never use tools for this. The filter could sustain damage, obstructing circulation.

- Start the engine and check for leaks.

Important! If the deposits in the centrifugal cleaner are more than

20 mm thick, the oil filter must be renewed more often. The same is true for cleaning the centrifugal filter and changing the oil.

Cooling system

5. Daily:

Checking coolant level

- Open the expansion tank filler cap and check the coolant level.

- Correct level: (Scania plastic expansion tank)

- Cold engine: The coolant should be level with the bottom of the filler neck.

- Hot engine: The coolant should be about 25 mm above the lower edge of the filler hole.

- Other types of expansion tank according to the instructions of the fitter.

- Top up the coolant as necessary; see point 6.

Note: When filling large amounts of coolant:

Never pour cold coolant into a hot engine. This could crack the cylinder block and cylinder head.

Always top up with pre-mixed

coolant.

Open the cap carefully.

Water and steam can spray out.

Use a container to avoid spillage

when renewing the filter.

Dispose of used filters through

an authorised waste disposal

contractor.

Important

WARNING

Help protect our

environment!

6. Every 2,400 hours:

Checking coolant

Coolant should be checked as follows:

a) Check the appearance of the coolant.

b) Coolant with glycol only: Check the glycol content.

c) Coolant containing only Scania Corrosion Inhibitor: check the corrosion

inhibitor content

The composition of the coolant is described in more detail under

"Starting and running"

a) Checking the appearance of the coolant

- Pour a small amount of coolant in a container, and check that the coolant is pure and clear.

- If the coolant is contaminated or cloudy: Consider changing the coolant.

- Water for the coolant must be clean and free from contamination.

- Use drinking water with a pH of 6-9.

b) Checking the glycol content

If there is a danger of freezing, use only glycol as an anti-corrosive in the coolant.

- Cooling systems with glycol should contain at least 30% glycol by volume to provide acceptable protection against corrosion.

- 30% glycol by volume provides protection against freezing to -16°C. If additional protection against freezing is required, see the table on the next page to help you calculate how much glycol you need.

We recommend only nitrite-free antifreeze glycols with the following supplier designations:

BASF G48 or BASF D542

- Always add glycol if the glycol content drops below 30% by volume. A glycol content above 60% by volume will not provide greater protection against freezing.

- The table shows the temperature at which ice starts to form. The engine will freeze and break at appreciably lower temperatures; see diagram.

- Ice forming in the coolant often causes malfunctioning without any risk of damage. The engine should not be subjected to heavy loads when ice starts to form.

Note: The coolant should be changed when the cooling system is

cleaned: every 4,800 hours or at least every 5 years.

Important! If a coolant filter is used in the cooling system it must not

contain an inhibitor.

Coolant composition:

If there is a danger of freezing:

minimum 30% glycol by

volume

maximum 60% glycol by

volume

If there is no danger of freezing:

8-12% by volume

Scania Corrosion Inhibitor

The coolant should be pre-

mixed when it is poured into the

cooling system.

Never top up with only water or

only glycol.

Ethylene glycol is highly

dangerous if imbibed and can

prove fatal.

Avoid skin contact with glycol.

The recommended glycols must

not be mixed with glycol

containing nitrite-based

corrosion inhibitor.

Risk of sludge build-up and

reduced cooling capacity.

Important

WARNING

38 © Scania CV 2009

A = Area to be avoided. Only for calculating glycol mix.

Coolant freezing point (when ice starts to form) for different glycol mixes

Glycol % by

volume

15 20 25 30 35 40 45 50 60

Cooling system

volume, dm

Ice slush starts to

form at °C

-6 -9 -12 -16 -22 -27 -36 -46 -55

Glycol dm

(litres)

5 6 8 9 11 12 14 15 18 30

6 8 10 12 14 16 18 20 24 40

8 10 13 15 18 20 23 25 30 50

9 12 15 18 21 24 27 30 36 60

11 14 18 21 25 28 32 35 42 70

12 16 20 24 28 32 36 40 48 80

14 18 23 27 32 36 41 45 54 90

15 20 25 30 35 40 45 50 60 100

17 22 28 33 39 44 50 55 66 110

18 24 30 36 42 48 54 60 72 120

20 26 33 39 46 52 59 65 78 130

21 28 35 42 49 56 63 70 84 140

23 30 38 45 53 60 68 75 90 150

24 32 40 48 56 64 72 80 96 160

26 34 43 51 60 68 77 85 102 170

27 36 45 54 63 72 81 90 108 180

29 38 48 57 67 76 86 95 114 190

30 40 50 60 70 80 90 100 120 200

Curve A: Ice formation starts (ice slush) Curve B: Temperature at which there is a risk of damage by freezing

1. Safe range

2. Malfunctions may occur (ice slush)

3. Risk of damage by freezing

Characteristics of glycol at low temperatures:

- Example with 30% glycol by volume

- Ice slush starts to form at -16°C.

- There is a risk of malfunctions at -30°C

- No risk of damage by freezing with a minimum content of 30% glycol by volume

Antifreeze glycol, % by volume

Checking the corrosion inhibitor

There must always be sufficient corrosion protection (inhibitor) in the coolant to protect the cooling system against corrosion.

If there is no danger of freezing, only Scania Corrosion Inhibitor should be used in the coolant.

The inhibitor in Scania Corrosion Inhibitor is free of nitrites.

The correct corrosion inhibitor content is 8-12% by volume.

- Topping up with 1.0% Scania Corrosion Inhibitor by volume should be done after every 2,400 hours of operation.

- Never top up with water alone or corrosion inhibitor alone! Fluid losses must always be replaced with pre-mixed coolant: water + 10% Scania Corrosion Inhibitor by volume.

Note: The coolant should be changed when the cooling system is

cleaned: every 4,800 hours or at least every 5 years.

Changing coolant

1. Remove the filler cap from the expansion tank.

2. The coolant is drained at two points:

- the lowest point of the cylinder block, see illustration.

- the lowest point of the cooling system.

3. Close the cocks.

4. Top up with coolant through the expansion tank’s filler hole.

Mix coolant as described on page 35.

Use a container to avoid spills

when changing the coolant.

Dispose of used coolant through

an authorised waste disposal

contractor.

If a coolant filter has been fitted

it must not contain inhibitor.

Mixing with glycol or the use of

too much corrosion protection

can lead to build up of sludge

and reduced cooling capacity.

Corrosion inhibitor is highly

dangerous if ingested and can

prove fatal.

Avoid contact with the skin.

Important

WARNING

Help protect our

environment!

40 © Scania CV 2009

7. Every 4,800 hours:

Cleaning the cooling system

Note: If necessary, the cooling system should be cleaned more often.

External cleaning

Radiator

- Check that the radiator is not clogged on the air side and that the cooling fins are not damaged.

- Carefully scrape the deposit off the radiator’s cooling fins. If necessary, a paraffin-based engine cleaner can be used.

- Bent fins can be straightened using a wire brush, for example, and exercising care.

Charge air cooler, DI engine

1. Drain the coolant from the engine, see "Changing the coolant".

2. Detach the intake manifold from the turbo.

3. Detach the charge air cooler’s inlet and outlet connections.

4. Unbolt the charge air cooling package from the intake manifold. The

charge air element is integrated into the housing.

Take care not to damage the element’s water connections.

5. Clean the outside of the core. This is especially important if the engine is

equipped with closed crankcase ventilation. Use a paraffin-based engine cleaner.

6. Clean and degrease the sealing surfaces on the element and on the intake

manifold with a spirit-based cleaning agent.

7. Apply a smooth bead of sealing agent (silicone 816 064), approximately

2-3 mm, onto the intake manifold sealing surface.

8. Assemble the charge air cooler within 15 minutes of applying the

sealant. Tighten the bolts to 26 Nm.

9. Refit the inlet and outlet connections with new

O-rings.

10. Refit the delivery pipe clamps.

11. Connect the intake manifold from the turbo.

12. Fill up with coolant according to the

specification on page 35.

Important! Let the sealing compound harden

for at least 24 hours before the engine is used again.

1. Charge air

cooler element

2. O-ring

3. Sealant 816 064

4. Intake manifold

The cooling system must never

be cleaned with caustic soda.

There is a risk of damage to

aluminium parts.

Important

Internal cleaning

Removing oil and grease

- If possible, run the engine until it has reached operating temperature and then drain the cooling system.

- Remove the thermostats.

- Fill the system with clean, hot water mixed with liquid dishwasher detergent designed for household use. Concentration 1% (0.1/10 l).

- Run the engine until warm for about 20-30 minutes. Do not forget the cab heating system (if fitted).

- Drain the cooling system.

- Fill the system again using clean, hot water and run the engine for about 20-30 minutes.

- Drain the water from the system.

- Refit the thermostats.

- Top up the system with new coolant according to the specification on page 35.

Removing deposits

- If possible, run the engine until it has reached operating temperature and then drain the cooling system.

- Remove the thermostats.

- Fill the system with clean, hot water mixed with some of the radiator cleaning agent available on the market which is based on sulphamic acid and contains dispersing agents. Follow the manufacturer’s instructions for the concentration and cleaning period.

- Run the engine for the specified time and then drain the cooling system.

- Refill the system with hot water and run the engine for about 20-30 minutes.

- Drain the water from the system.

- Refit the thermostats.

- Top up the system with coolant according to the specification on page 35.

When handling cooling system

detergent:

read the warning text on the

containers.

Use a container to avoid spills

when changing the coolant.

Dispose of used coolant through

an authorised waste disposal

contractor.

WARNING

Help protect our

environment!

42 © Scania CV 2009

Air cleaner

8. Daily:

Test reading of vacuum indicator

If the red indicator bar is entirely visible, change or clean the air cleaner filter element, point 10. This is particularly important if the engine is run at high loads and high speed.

9. Every 200 hours:

Cleaning the air cleaner’s coarse cleaner

1. Remove the cover from the coarse cleaner (2).

2. Remove the conical coarse separator. Empty out the particles of dirt and

clean it.

3. Fit the coarse cleaner as shown in the figure and screw the cover into

place.

10. Every 1,200 hours: Cleaning or changing filter element

Note: Clean or renew the filter element earlier if the vacuum indicator

shows red.

Dismantling

1. Remove the cover from the air cleaner.

2. Renew or clean the filter element.

Note: There is always a risk that the filter element will be damaged

during cleaning. The filter element can only be cleaned a maximum of four times. After cleaning, it has poorer dust capacity than a new filter element.

3. Mark the filter when it has been cleaned.

Cleaning the filter element

- Carefully blow the filter element clean using dry compressed air from the inside.

Note: This filter element must not be washed with water.

1. Cover

2. Filter element

3. Filter house

Only use genuine Scania air

filters.

Renew the filter element if it is

damaged.

Danger of engine damage if the

filter element is damaged.

Never start the engine without

the air filter.

There is a risk of injury or

engine damage.

The coarse cleaner must always

be fitted in an upright position.

1. Filter element

2. Coarse cleaner

3. Cover

4. Vacuum indicator

Important

WARNING

Check

- Insert a torch into the element and check from the outside that there are no holes or cracks in the filter paper.

- Renew the filter element if it has the slightest damage. Danger of engine damage.

Assembly

1. Assemble the air cleaner in reverse order.

2. Reset the vacuum indicator by pressing the button.

11. Every 2,400 hours: Changing safety cartridge

Note: Not all filters are equipped with a safety cartridge. When

changing the safety cartridge, take great care to ensure that no dirt or other impurities can get into the engine.

1. Remove the cover from the air cleaner.

2. Remove the filter element.

3. Remove the safety cartridge.

4. Fit a new genuine Scania safety cartridge.

5. Renew or clean the filter element, see point 10.

6. Assemble the air cleaner.

1. Safety cartridge

Air cleaner with safety cartridge

Do not remove the safety

cartridge unnecessarily.

Important

Never clean the

safety cartridge.

Important

44 © Scania CV 2009

Fuel system

12. Daily:

Checking fuel level

- Top up with fuel if necessary.

- If the tank has been run dry, bleed the fuel system, see point 13.

13. Every 1,200 hours: Renewing the fuel filter

Fuel tanks

- Drain any water from the fuel tanks.

Filter

The filter consists of a filter unit.

- Wash the outside of the filter and unscrew it. Discard the filter according to environmental requirements.

- Fit the new filter and tighten it by hand.

Never use tools for this. The filter could sustain damage, obstructing circulation.

- Bleed the fuel system as described below.

- Start the engine and check for leaks.

Water separating filter

- Drainage must be carried out when filling fuel.

- The filter must be changed at the same renewal interval as the main filter.

- Close the cock (1) upstream of the filter.

- Unscrew the container and drain valve (3).

- Unscrew and change the filter (2). Lubricate the seal before tightening the new filter by hand.

- Screw the container and drain valve into position.

- Open the cock (1).

- Bleed the fuel system after renewing both filters.

Use a container to avoid spillage

when bleeding and renewing

components.

Use only genuine Scania fuel

filters.

1. Shut-off cock

2. Filter

3. Drain valve

Observe the utmost cleanliness

when working on the fuel

system.

There is a risk of engine

malfunction and damage to the

injection equipment.

Important

Help protect our

environment!

Bleeding the fuel system

- Attach a clear plastic hose to the bleed nipple (1) to channel fuel into a container. The bleed nipple is located at the end of the fuel manifold at the front of the engine.

- Open the bleed nipple.

- Pump the hand pump (2) until fuel without air bubbles flows out of the opened bleed nipple.

• If the system is completely empty, it will take approximately

250 strokes.

• After renewing the fuel filter, it will take approximately 170 strokes.

• Approximately 150 strokes are required to bleed the fuel manifold.

- Close the bleed nipple and remove the hose.

- Undo the banjo screw for overflow valve (3) slightly. Pump the hand pump an additional 20 strokes until the overflow valve opens.

If the engine fails to start after bleeding:

- Open the bleed nipple again and pump the hand pump until fuel without air bubbles flows out.

- Tighten the bleed nipple. Start the engine and check for leaks.

Use a container to avoid spillage

when bleeding and renewing

components.

Help protect our

environment!

Electrical system

14. Every 200 hours: Checking the electrolyte level in

batteries

1. Unscrew the plugs and check the electrolyte level in all cells.

2. Top up with distilled water until the level is 10-15 mm above the plates.

15. Every 1,200 hours: Checking state of charge in batteries

- Check the density with an acid tester.

In a fully-charged battery it should be:

1.280 at +20°C

1.294 at 0°C

1.308 at -20°C

- If the density is below 1.20, the battery must be charged. A discharged battery freezes at -5°C.

Do not boost charge the battery. This will damage the battery in the long run.

16. Every 1,200 hours: Cleaning batteries

1. Clean batteries, cables and cable terminals.

2. Check that all cable terminals are firmly tightened.

3. Grease the battery terminal posts and cable terminals with Vaseline.

Wear gloves and protective goggles when charging and

handling batteries.

The batteries contain a highly

corrosive acid.

Do not connect the terminals

incorrectly.

This can cause serious damage

to the electrical system.

If the terminals are shorted,

sparking will occur.

Avoid naked flames or sparks

near the batteries.

When the batteries are charged,

oxyhydrogen gas is formed

which is flammable and

explosive.

WARNING

Renewing the battery

Removing

1. Disconnect the negative cable (-) from the battery (cable connected to

earth).

2. Disconnect the positive cable (+) from the battery (cable connected to

starter motor).

Fitting

1. Connect the positive cable (+) to the battery (cable connected to starter

motor).

2. Connect the negative cable (-) to the battery (cable connected to earth).

17. Every 1,200 hours: Checking coolant level monitor

(Optional equipment)

1. Start the engine.

2. Lower the coolant level in the expansion tank.

3. Automatic stop in the event of a fault: The engine stops, the indicator

lamp comes on and the buzzer (if fitted) sounds if there is no fault in the level monitor. If the function is connected via the coordinator, the emergency stop fault code will be generated and can be read off on the diagnostics lamp.

4. No automatic stop in the event of a fault: The indicator lamp comes on

and the buzzer (if fitted) sounds if there is no fault in the level monitor.

5. Top up coolant to the correct level, see page 36.

Do not connect the terminals

incorrectly.

This can cause serious damage

to the electrical system.

If the terminals are shorted,

sparking will occur.

Dispose of used batteries

through an authorised waste

disposal contractor.

2-pin level monitor installed in the

expansion tank for radiators

supplied by Scania

Use a container to avoid spills

when draining the coolant.

Dispose of used coolant through

an authorised waste disposal

contractor.

WARNING

Help protect our

environment!

Help protect our

environment!

20 Nm 2 Nm

307 939

20 Nm 2 Nm

307 938

Miscellaneous

18. Every 1,200 hours: Checking drive belt

- If the drive belt (1), which is a poly-V belt, is worn or damaged it must be renewed.

- Also check that the automatic belt tensioner (2) is in proper working order and keeps the drive belt correctly tensioned.

- On installations with dual belt circuits, the second belt circuit has two drive belts with one manual belt tensioner. These drive belts should be tensioned to 20 Nm ±2 Nm as illustrated.

19. Daily: Look for leakage, rectify as necessary

- Start the engine.

- Check for oil, coolant, fuel, air and exhaust leaks.

- Tighten or renew leaking connections. Check the overflow holes (1) (below the side covers) which show whether the O-rings between the cylinder liners and crankcase are leaking, see figure.

a) If coolant is running out, the O-ring is leaking.

b) If lubricating oil is running out, the liner shelf is leaking.

- Check that the coolant pump drain hole (2) is not clogged, see figure. If there is a leak, renew the pump seal or the complete coolant pump.

A small amount of leakage from the overflow holes during the engine running-in period is normal. (Sealing rings and O-rings are lubricated with soap or oil when fitted).

- This leakage normally stops after a time.

Take care to ensure that any

leaks do not cause pollution.

If serious leakage occurs,

contact your nearest Scania

workshop.

Important

Help protect our

environment!

20. Every 2,400 hours: Check and adjust valve clearance

Note: Checking and adjusting valve clearances should also be done

after the first 400 hours of operation.

Valve clearances should be adjusted when the engine is cold, at least 30 minutes after running.

The rocker cover gaskets should be renewed as necessary. Tightening torques: 26 Nm.

Intake valve clearance: 0.45 mm. Exhaust valve clearance: 0.70 mm.

Tightening torque for lock nut: 35 Nm.

Block the starting device when

working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK OF INJURY.

Openings for reading

on the flywheel housing

Readings can be taken from the flywheel through covers in the flywheel housing either from above or underneath depending on access when fitting. Up or down is shown on the flywheel. Both openings are fitted with a cover at delivery.

WARNING

Order of adjustment

- Turn the flywheel counterclockwise so that the marks on the flywheel can be seen in the lower opening in the flywheel housing (depending on which opening the reading is to be taken from). Refer to table.

- Measure the valve clearance with a feeler gauge and adjust the valves as per the order of adjustment in the table below. Correct valve clearances are also given on the instruction plate on one of the rocker covers.

- Checking and adjustment of the rocker arms for the PDE injectors should be done together with the valve clearance check/adjustment. See step 21.

- If it is not possible to take a reading in one of the covers, observe the valve overlap, turn the flywheel counterclockwise 120° (1/3 turn) at a time and adjust the valves according to the table below and the unit injectors as described on the next page.

Mark on flywheel

(reading taken through the

lower opening)

Valve overlap on

cylinder

Adjust the valves

on cylinder

TDC Down (0°) 1 6

120° 5 2

240° 3 4

TDC Down (360°) 6 1

120° 2 5

240° 4 3

Mark on flywheel

(reading taken through the

upper opening)

Valve overlap on

cylinder

Adjust the valves

on cylinder

TDC Up (0°) 1 6

300° 5 2

60° 3 4

TDC Up (360°) 6 1

300° 2 5

60° 4 3

FLYWHEEL

Cylinder numbering

21. Every 2,400 hours Checking and adjusting the unit

injector rocker arms

Note: Checking/adjusting the rocker arms for the PDE injectors

should also be done together with the valve clearance check/adjustment after the first 400 hours of operation.

Important! The PDE 31 unit injector is adjusted using setting tool

99 414 or a digital sliding calliper.

The PDE32 unit injector is adjusted using setting tool 99 442 or a digital sliding calliper.

This adjustment is essential as a fault in the position of the unit injector can result in poor performance and possible breakdown.

Measurement A=

PDE31: 66.9 ±0.1 mm PDE32: 69.9 ±0.1 mm

Measurement B=

PDE31: 36.5 mm PDE32: 38.8 mm

Order of adjustment

Turn the flywheel counterclockwise so that the marks on the flywheel can be seen in the lower opening in the flywheel housing (depending on which opening the reading is to be taken from). Refer to table.

Mark on flywheel

(reading taken through the

lower opening)

Valve overlap on

cylinder

Adjust injector

rocker arm on

cylinder

TDC Down (0°) 1 2

120° 5 4

240° 3 1

TDC Down (360°) 6 5

120° 2 3

240° 4 6

Mark on flywheel

(reading taken through the

upper opening)

Valve overlap on

cylinder

Adjust injector

rocker arm on

cylinder

TDC Up (0°) 1 2

300° 5 4

60° 3 1

TDC Up (360°) 6 5

300° 2 3

60° 4 6

PDE31:

1. Firstly, measure the distance (A) between plane (a) and the top edge of

the valve spring washer on the unit injector using a digital sliding calliper. See figure.

2. Dimension (A) should be 66.9 mm for PDE31 (dimension B=36.5 mm).

3. The dimension is adjusted by undoing the lock nut and screwing the

rocker arm adjusting screw (1) to the correct measurement.

WARNING! Take care when carrying out the adjustment if the

dimension is well outside the adjustment dimension. The spring is pre-tensioned and can cause personal injury if it is released.

4. Position setting tool 99 414 with the metal plate around the injector

spring.

5. Finely adjust dimension (A ) by simultaneously using a finger to sense

that the small piston (2) is level with the flat upper surface of the tool. It is possible to feel differences of less than a tenth of a millimetre.

6. If the setting tool is not available, a digital sliding calliper can also be

used for fine adjustment. The rocker position is adjusted using the adjusting screw to 66.9 +/-0.1 mm as stated above.

7. Tighten the adjusting screw lock nut to 39 Nm and remove the tool.

Note: No further checking or adjustment of the unit injector, such as

checking the opening pressure, must be done. If an injector is defective, the whole injector must be replaced.

Piston level with the flat surface. Adjustment is correct.

Piston above or below the flat surface. Adjustment necessary.

66.9

99 414

PDE32:

1. Firstly, measure the distance (A) between plane (a) and the top edge of

the valve spring washer on the PDE injector using a digital sliding calliper. See figure.

2. Dimension (A) should be 69.9 mm for PDE32 (dimension B=38.8 mm).

3. The dimension is adjusted by undoing the lock nut and screwing the

rocker arm adjusting screw (1) to the correct measurement.

WARNING! Take care when carrying out the adjustment if the

dimension is well outside the adjustment dimension. The spring is pre-tensioned and can cause personal injury if it is released.

4. Position setting tool 99 442 with the metal plate around the injector

spring.

5. Finely adjust dimension (A ) by simultaneously using a finger to sense

that the small piston (2) is level with the flat upper surface of the tool. It is possible to feel differences of less than a tenth of a millimetre.

6. If the setting tool is not available, a digital sliding calliper can also be

used for fine adjustment. The rocker position is adjusted using the adjusting screw to 69.9 +/-0.1 mm as stated above.

7. Tighten the adjusting screw lock nut to 39 Nm and remove the tool.

Note: No further checking or adjustment of the unit injectors, such as

checking the opening pressure, must be done. If an injector is defective, the whole injector must be replaced.

Piston above or below the flat surface. Adjustment necessary.

Piston level with the flat surface. Adjustment is correct.

69.9

99 442

22. Every 2,400 hours: Renewing (or cleaning) the closed

crankcase ventilation valve

Alternative 1:

Renew the valve at the specified interval.

Alternative 2:

- Dismantle the valve after the specified interval.

- Clean the valve by placing it in a bath of diesel fuel oil overnight. Then rinse it several times in diesel oil and allow it to drip dry.

- Refit the valve.

- The valve may be reused (cleaned), but not more than twice after the first 2,400 hours of use. Take care to mark the valve after cleaning it.

Preparing the engine for storage

If the engine is not to be used for a lengthy period of time, special measures should be taken to protect the cooling system, fuel system and combustion chamber from corrosion and the exterior from rusting.

The engine can normally stand idle for up to six months. If it remains unused for longer than this the following measures, which provide protection for about four years, should be adopted. An alternative to preparing the engine for long-term storage is to start the engine and warm it up every 6 months.

Preparing for storage means:

- Thoroughly cleaning the engine.

- Running the engine for a certain time using special preservative fuel, oil and coolant.

- Otherwise preparing the engine for storage (filter renewal, lubrication, etc.).

Preservative coolant

If the engine is being stored with coolant in the system, the coolant should contain 50% glycol by volume. Glycol without nitrite-based inhibitor should be used. For example BASF G48 or BASF D542.

Preservative fuel

- Use diesel fuel oil mixed with Lubrizol 560H or equivalent.

-Mix 1 cm

(ml) Lubrizol 560H in 10 dm3 (l) of fuel.

Ethylene glycol is highly

dangerous if imbibed and can

prove fatal.

Avoid contact with the skin.

HANDLING LUBRIZOL 560H

Hazardous!

Contains aromatic hydrocarbons

Use spot extractors where there is a danger of vapour build-up.

Wear protective gloves and goggles when handling Lubrizol. Do not use contaminated clothing.

If it gets in your eyes: Rinse with a gentle stream of water (at least 15 minutes). Seek medical attention.

If it gets on your skin: Wash the affected area with soap and water.

If inhaled: Fresh air, rest and warmth.

Flammable: Fire class 2A. Flashpoint +27°C.

In the event of fire: Extinguish with carbon dioxide, powder or foam.

Storage: In well-sealed receptacle in a dry, cool place. Keep out of reach of children.

WARNING

Preservative oil

Suitable preservative oils are available from most oil companies.

For example Dinitrol 40 or equivalent.

Preparations for storage

- Drain and flush the cooling system. Top up with preservative coolant.

- Warm up the engine on normal fuel. Stop the engine and drain the oil.

- Renew the fuel filter.

- Fill the engine with preservative oil up to the minimum level on the dipstick.

- Mix preservative fuel in a can. Detach the fuel pipe at the feed pump suction line and connect a hose from the can.

- Detach the fuel pipe at the overflow valve and connect a return hose to the can.

- Start the engine and run it at about 1,000 rpm (not single-speed engines) for 20-25 minutes.

- Stop the engine, remove the hoses and connect the normal fuel pipes.

- Remove the rocker covers and lubricate the valve mechanisms and unit injector mechanisms with preservative oil. Refit the rocker covers.

Note: The unit injectors are not to be removed.

- Drain the preservative oil from the engine. Fresh engine oil can be filled directly or when the engine is taken out of storage.

- Drain the coolant if the engine is not to be stored with coolant in the system. Plug and tape over all coolant connections (if the cooling system is not completely assembled).

- Air cleaner: Clean or renew the filter element.

- Cover air intakes and exhaust pipes.

- Alternator and starter motor:

- Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or the equivalent.

- Spray the outside of bright engine parts with penetrating preservative oil, for example Dinitrol 25B, and then with Dinitrol 112 or equivalent.

Use a container to avoid spills

when draining the oil and

coolant.

Dispose of used oil and coolant

through an authorised waste

disposal contractor.

Help protect our

environment!

- Attach a label to the engine, clearly stating the storage preparation date and that the engine must not be started or cranked.

Batteries

Remove the batteries for trickle charging at the battery charging station. (Does not apply to batteries which according to the manufacturer do not require any maintenance). The same applies to short-term storage, even if the engine has not been prepared for storage as above.

Storage

After the preparations, the engine should be stored in a dry and warm place (room temperature).

Taking out of storage

(Procedure for taking the engine into operation)

- Remove plugs and tape from coolant connections, air intakes and exhaust pipes.

- Fill the system with coolant, see page 24.

- Check the oil level in the engine or fill up with fresh motor oil.

- Lubricate the valve mechanisms and their pushrods and valve tappets as well as the unit injector mechanisms.

- Drain the preservative fuel from the fuel manifold and fuel filter.

- Connect and bleed the fuel system, see page 44.

- Wash off any externally applied preservative oil using white spirit.

ENGINE PREPARED FOR

LONG-TERM STORAGE

Date. . . . . . . . . . . .

Do not start or crank!

Wear gloves and protective goggles when charging and

handling batteries.

The batteries contain a highly

corrosive acid.

WARNING

Technical data

General DC12 DI12

Number of cylinders

6 in line

Cylinder diameter mm

127

Piston stroke mm

154

Displacement dm

(litres)

11.70

No. of main bearings

Firing order

1 - 5 - 3 - 6 - 2 - 4

Compression ratio

18:1

Engine direction of rotation viewed from rear

Counterclockwise

Fan direction of rotation viewed from front

Clockwise

Cooling

Liquid

Valve clearances, cold engine

intake valve mm outlet valve mm

0.45

0.70

Weight, without coolant or oil kg

*With charge air cooler, radiator, expansion tank and pipes

1,065* § 995

Power

see "Engine record card"

Lubrication system

Maximum oil pressure

(warm engine at a speed above 1,000 rpm bar (kp/cm

)

Normal oil pressure

(hot engine at operating speed) bar (kp/cm

)

3-6

Minimum oil pressure

(hot engine 1,000 rpm bar (kp/cm

)

1.0

Oil capacity, see page 33

Crankcase pressure with closed crankcase

ventilation mm VP

-55 - +20

Fuel system DC12 DI12

Pump setting BTDC

See plate on rocker cover

Low idling rpm

700 (adjustable 500-800)

Maximum full load speed

See engine card

Fuel

Diesel fuel oil

see page 62

Cooling system

Number of thermostats 1 (dual thermostat)

Thermostat, opening temperature °C 75

Coolant temperature:

system at atmospheric pressure °C system at overpressure °C

70-93

70 - approximately 100

Capacity, including radiator, engine and expansion tank

and, for DI12, also charge air cooler with 0.75 m

radiator dm3 (litres)

with 1.0 m

radiator dm3 (litres)

with 1.2 m

radiator dm3 (litres)

54 56 59 61 63 65

Electrical system

System voltage V

Alternator, current A

65 or 100

Starter motor output kW (hp)

6.7 (9.1)

Monitors, threshold values:

oil pressure monitor bar (kp/cm

)

temperature monitor °C

1.0

± 0.15

Stamped on hexagonal part of monitor

Fuel

Diesel fuel oil

The composition of the diesel fuel oil has a great influence on the functioning and the service life of the engine and the injection system. The engine output and exhaust emissions are also dependent on the fuel quality. The requirements and testing standards for the most important properties are described in the workshop manual in sections which can be ordered from Scania dealers or directly from Scania. Scania’s address is printed on the cover.

Diesel fuel must comply with the following standard: EN 590 (European standard).

The table below shows the requirements for some of the most important properties.

Environmentally friendly fuels (low sulphur fuels)

There are three classes of environmentally friendly fuels (SS15 54 35). Class 1 is sulphur-free and class 2 is low in sulphur. Compared with class 3 (normal fuel), these fuels are less dense and this reduces engine power output. Only class 1 fuel should be used with a catalytic converter.

Short term use of fuel with a higher sulphur content than 0.05% by weight will not cause permanent damage to the catalytic converter.

The catalytic converter may, however, require fuel with low sulphur content for some time after this to regain its normal efficiency.

Property Requirements

Viscosity at 40°C 2.0-4.5 mm2/s (cSt)

Density at 15°C 0.82-0.86 kg/dm

Sulphur (concentration by mass) max. 0.3%

Ignitability (CET rating) min. 49

Flashpoint 56°C

Temperature dependence of diesel fuel

At temperatures lower than those specified for the diesel fuel, paraffin wax may precipitate from the fuel and block filters and pipes. The engine can then lose power or stop.

The diesel fuel is adapted for use in the specific climate of each country. If a vehicle or an engine is to be operated in a temperature zone with lower temperature than normal, first identify the temperature properties of the fuel concerned.

The properties of the fuel when cold can be improved by adopting one of the following measures before the temperature drops:

- If the fuel concerned cannot cope with the expected temperatures, and diesel fuel is not available with the correct temperature properties, we recommend that an electric fuel heater is installed as a preventative measure.

- The low temperature properties of diesel fuel may be improved by adding kerosene as a preventative measure. Maximum 20% may be added. When refuelling, the kerosene should be added first, so that it mixes thoroughly with the diesel fuel.

Note: It is prohibited to use kerosene in engine fuel in

some countries.

- To prevent water in the fuel from freezing and forming ice, a maximum of 0.5-2% alcohol (isopropanol) may be added.

Drain fuel tanks and drain or renew fuel filters regularly.

It is not permitted to mix

kerosene with diesel fuel that is

already adapted for the climate

concerned. The unit injectors

can fail. All use of paraffin

other than kerosene is

forbidden, as it causes engine

damage.

It is not permissible to mix

petrol with diesel fuel. In the

long term, petrol may cause

wear to the unit injectors and at

worst it may also cause damage

to the engine.

Important

WARNING

Alphabetical index

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Air cleaner, prefilter . . . . . . . . . . . . . . . . . . . . 42

Air cleaner, safety cartridge . . . . . . . . . . . . . . 43

Air cleaner, vacuum indicator . . . . . . . . . . . . 43

Air filter, element . . . . . . . . . . . . . . . . . . . . . . 42

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Battery, renewing . . . . . . . . . . . . . . . . . . . . . . 47

Bleeding, fuel system . . . . . . . . . . . . . . . . . . . 45

Certified engines . . . . . . . . . . . . . . . . . . . . . . . . 5

Checks after running . . . . . . . . . . . . . . . . . . . 29

Checks before running . . . . . . . . . . . . . . . . . . 25

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Coolant, changing . . . . . . . . . . . . . . . . . . . . . . 39

Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Coolant level monitor . . . . . . . . . . . . . . . . . . . 47

Coolant temperature . . . . . . . . . . . . . . . . . . . . 27

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 36

Cooling system, cleaning . . . . . . . . . . . . . . . . 40

Corrosion protection . . . . . . . . . . . . . . . . . . . . 39

Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Electrical system . . . . . . . . . . . . . . . . . . . . . . . 46

EMS engine management system . . . . . . . . . . 20

EMS sensors . . . . . . . . . . . . . . . . . . . . . . . 19, 20

Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Environmental responsibility . . . . . . . . . . . . . . 4

Filter, air cleaner . . . . . . . . . . . . . . . . . . . . . . . 42

Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

First start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Flash codes, control unit . . . . . . . . . . . . . . . . . 21

Flash codes, coordinator . . . . . . . . . . . . . . . . . 23

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Fuel filter, renewing . . . . . . . . . . . . . . . . . . . . 44

Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Fuel specifications . . . . . . . . . . . . . . . . . . . . . 62

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Fuel system, bleeding . . . . . . . . . . . . . . . . . . . 45

Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Lubricating oil pressure . . . . . . . . . . . . . . . . . 28

Lubricating oil system . . . . . . . . . . . . . . . . . . 32

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Maintenance schedule . . . . . . . . . . . . . . . . . . . 31

Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Oil filter unit . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Prefilter, air cleaner . . . . . . . . . . . . . . . . . . . . 42

Preparations for storage . . . . . . . . . . . . . . . . . 57

Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Safety cartridge, air cleaner . . . . . . . . . . . . . . 43

Safety information . . . . . . . . . . . . . . . . . . . . . . 6

Safety precautions for care and maintenance . 10 Safety precautions for handling materials . . . 12 Safety precautions for running the engine . . . 11

Starting the engine . . . . . . . . . . . . . . . . . . . . . 25

Stopping the engine . . . . . . . . . . . . . . . . . . . . . 29

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Taking out of storage . . . . . . . . . . . . . . . . . . . 59

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 60

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 20

Troubleshooting, control unit . . . . . . . . . . . . . 20

Troubleshooting, coordinator . . . . . . . . . . . . . 22

Type designations . . . . . . . . . . . . . . . . . . . . . . 14

Unit injector. . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Vacuum indicator . . . . . . . . . . . . . . . . . . . . . . 42

Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . 50

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Scania Assistance

Wherever you are you can always get assistance from our service organization, Scania Assistance. All day, every day of the year. Using Scania Assistance is free, but the cost of repairs, spare parts and help from mechanics will be debited.

Always call your own country!

Other countries: +46 8 52 24 24 24

Note: Calls will be recorded for training purposes.

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

CH +41 800 55 24 00 NO +47 223 217 00

CL 188 800 722 642 PL +48 602 622 465

CZ +420 225 020 225 PT +48 91 678 9247

DE +49 261 887 8888 RO +40 723 27 27 26

DK +45 333 270 44 SE +46 42 100 100

ES +34 91 678 80 58 SK +421 903 722 048

FI +358 10 555 24 TR +90 212 335 04 40

FR +33 2 414 132 32 TZ +255 78 472 2642

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

Scania DI12, DC12 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual