SCANIA DC 12 Manual Del Operador

Operators Manual
DI12 DC12
Industrial engine
opm96-12a en 1 588 546
2001-05:1
Industrial & Marine Engines
IMPORTANT INFORMATION
When working on the engine, e.g. when adjusting the belts, changing oil or adjusting the clutch it is
important that the engine does not start. The engine may be damaged but above all there is -
SERIOUS RISK OF INJ URY.
For this reason, always secure the starting device or disconnect a battery cable
before working on the engine.
This is especially important if the engine has a remote starter or automatic starting.
This warning symbol and text is reproduced beside those maintenance points where it is
especially important to consider the risk of injury.
!
START-UP REPORT - WARRANTY
When the start-up report has been filled in and sent to Scania there is a 1 year warranty starting from
the start-up date. Also enter the below information since this will facilitate contacts with e.g. service
workshops.
Engine number
Start-up date
Users name and address
Signature
Engine type
Variant
Engine type and variant are indicated on the engine type plate
2 Scania Industrial & Marine Engines 2001-05:1
FOREWORD
This operators manual describes the operation and maintenance of Scania
DC12 and DI12 Industrial Engines. The instructions apply to engines
in programme 96 from engine serial number 5 997 001 onwards.
The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder
inline diesel type. The engines are equipped with turbocharger and charge air
cooler, refer to page 10.
The engines are typically used in earthmoving equipment, generator sets,
agricultural, railway and forestry machinery as well as power units in
irrigation systems.
The engines are available with different power output and engine speed
settings.
The normal output setting of the engine (performance code) is indicated on
the type plate, see page 10.
Note: Only standard components are described in the operators
manual. Regarding special equipment, refer to the instructions of
the relevant manufacturer.
In order to obtain the best value and service life from your engine, there are a
few points to bear in mind:
- Read the manual before starting to use the engine. You will find new
information in this Operators Manual even if you have previous
experience of Scania engines.
- Follow the maintenance instructions. Proper maintenance is essential to
keep the engine operating correctly and to increase engine life.
- Pay special attention to the safety information beginning on page 6.
- Get to know your engine so that you know what it can do and how it
works.
- Whenever necessary, always contact an authorised Scania workshop.
They have special tools, genuine Scania parts and trained staff with
practical experience of Scania engines.
Note: Always use genuine Scania parts in service and repair to keep the
engine operating correctly.
The information in this manual was correct at the time of going to press.
However, we reserve the right to make changes at any time, without prior
notice.
Scania CV AB
Industrial and Marine Engines
S-151 87 Sdertlje, Sweden
During the warranty period,
only use genuine Scania parts in
service and repair for the
warranty to be valid.
2001-05:1 Scania Industrial & Marine Engines 3
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ENVIRONMENTAL RESPONSIBILITY . . . . . . 4
CERTIFIED ENGINES . . . . . . . . . . . . . . . . . . . . 5
SAFETY DETAILS . . . . . . . . . . . . . . . . . . . . . . . 6
Safety precautions for operation . . . . . . . . . . . . 7
Safety precautions for handling materials . . . . . 8
Safety precautions for care and maintenance . . 8
TYPE DESIGNATIONS . . . . . . . . . . . . . . . 10
DEC2 CONTROL SYSTEM . . . . . . . . . . . . 12
STARTING AND RUNNING . . . . . . . . . . . 19
AT FIRST START . . . . . . . . . . . . . . . . . . . . . . . 19
CHECKS BEFORE RUNNING . . . . . . . . . . . . . 21
STARTING THE ENGINE . . . . . . . . . . . . . . . . 21
At temperatures below 0 C: . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Coolant temperature . . . . . . . . . . . . . . . . . . . . 23
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STOPPING THE ENGINE . . . . . . . . . . . . . . . . . 24
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CHECKS AFTER RUNNING . . . . . . . . . . . . . . 25
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 26
ENGINES WITH FEW HOURS OF
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MAINTENANCE SCHEDULE . . . . . . . . . . . . . 27
LUBRICATING OIL SYSTEM . . . . . . . . . 28
OIL GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
CHECKING THE OIL LEVEL . . . . . . . . . . . . . 29
Checking oil level during operation . . . . . . . . 29
OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Maximum angles of inclination during
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CLEANING THE OIL CLEANER . . . . . . . . . . 30
RENEWING THE OIL FILTER . . . . . . . . . . . . 32
COOLING SYSTEM . . . . . . . . . . . . . . . . . . 32
CHECKING THE COOLANT LEVEL . . . . . . . 32
CHECKING THE COOLANT . . . . . . . . . . . . . . 33
Checking the corrosion inhibitor . . . . . . . . . . 35
Changing the coolant . . . . . . . . . . . . . . . . . . . 35
CLEANING THE COOLING SYSTEM . . . . . . 36
Internal cleaning . . . . . . . . . . . . . . . . . . . . . . . 37
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 38
CHECKING THE VACUUM INDICATOR . . . 38
CLEANING THE AIR CLEANER COARSE
CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CLEANING OR CHANGING THE
FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . 38
RENEWING THE SAFETY CARTRIDGE . . . . 39
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 40
CHECKING THE FUEL LEVEL . . . . . . . . . . . . 40
RENEWING THE FUEL FILTER . . . . . . . . . . . 40
CHECKING THE INJECTORS . . . . . . . . . . . . . 41
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 42
CHECKING THE ELECTROLYTE LEVEL IN
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CHECKING THE STATE OF CHARGE IN
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
CLEANING THE BATTERIES . . . . . . . . . . . . . 42
CHECKING THE COOLANT LEVEL
MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CHECKING THE TEMPERATURE
MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CHECKING THE TEMPERATURE SENSOR . 44
CHECKING THE OIL PRESSURE
SENSOR/MONITOR . . . . . . . . . . . . . . . . . . . . . 45
CHECKING THE OIL PRESSURE MONITOR
FOR DEC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
RENEWING THE BATTERY . . . . . . . . . . 46
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 46
CHECKING THE DRIVE BELT . . . . . . . . . . . . 46
CHECKING FOR LEAKAGE, RECTIFY AS
NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CHECKING/ADJUSTING VALVE
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CHANGING (OR CLEANING) THE CLOSED
CRANKCASE VENTILATION VALVE. . . . . . 50
LONG-TERM STORAGE . . . . . . . . . . . . . . 51
Preservative fuel . . . . . . . . . . . . . . . . . . . . . . . 51
Preservative oil . . . . . . . . . . . . . . . . . . . . . . . . 52
Preparations for storage . . . . . . . . . . . . . . . . . 52
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Taking out of storage . . . . . . . . . . . . . . . . . . . 53
TECHNICAL DATA . . . . . . . . . . . . . . . . . . 54
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
ALPHABETICAL INDEX . . . . . . . . . . . . . . 58
ENVIRONMENTAL RESPONSIBILITY
Scania has always been at the forefront in the development and production of
environmentally safe engines.
We have made great progress in reducing harmful exhaust emissions to be
able to meet the stringent emission standards that are mandatory for almost
all markets.
We have done this without compromising the high quality of Scania
industrial and marine engines in terms of performance and cost effective
operation.
To maintain these superior properties throughout the life of the engine it is
important that the operator/owner follows the instructions of this manual as
regards operation, maintenance and choice of fuel and lubricants.
To further contribute to protecting the environment in service, maintenance
and repair, ensure that harmful waste (oil, fuel, coolant, filters, batteries etc.)
is disposed of and destroyed according to applicable local regulations.
This operators manual contains highlighted text urging you to protect the
environment in different service and maintenance operations.
Refer to example
Always use suitable containers
to avoid spillage when bleeding
systems or renewing
components.
CERTIFIED ENGINES
An emission certified engine has been approved according to a specific
certification standard. The certified engines delivered by Scania meet the
most compelling emission standards in the European (EU) and non-European
(USA) markets.
Scania guarantees that all engines of a certified engine type that are delivered,
correspond to the engine approved for certification.
The engine is fitted with a certification plate, stating according to which
certification rules (standard) the engine has been approved. Refer to page 10.
The following is required for the engine to meet the emission standards after
being commissioned:
- Service and maintenance must be performed according to this
Operators Manual.
- Only genuine Scania parts must be used.
- Service work on the injection equipment must be performed by an
authorized Scania workshop.
- The engine must not be modified with equipment not approved by
Scania.
- Seals and setting data may only be broken/modified after approval by
Scania, Sdertlje. Changes should only be made by qualified
personnel.
- Changes affecting the exhaust system and intake system must be
approved by Scania.
Otherwise, follow the instructions in this manual for operation, care and
maintenance of the engine. Also observe the safety precautions described in
the following four pages.
Important! If service and maintenance are not performed as stated
above, Scania cannot guarantee that the engine corresponds
to the certified configuration and will not assume liability for
any damage occurring.
SAFETY DETAILS
General
This Operators Manual contains safety information that must be observed in
order to avoid personal injuries and damage to the product or property. Refer
to page 1.
The text boxes to the right on the pages provide information that is important
for the proper operation of the engine and to avoid damage to the engine.
Failure to follow these instructions may void the warranty.
Refer to example.
Corresponding texts may also appear in the text column, headed Note or
Important
The warning text in text boxes to the right on the pages provided with a
warning triangle and headed WARNING is extremely important and warns
of serious defects to the engine or improper handling that may lead to
personal injury.
Refer to example
The safety precautions that must be observed in the operation and
maintenance of Scania engines are compiled on the following three pages.
The corresponding text is also often stated next to the maintenance step
concerned, shown with different degrees of significance as described above.
All items are marked with a ! to highlight the importance of reading each
item in the section.
A general safety rule is that no smoking is allowed:
Near the engine and the engine bay
When refuelling and near the filling station
When work is performed on the fuel system
Near flammable or explosive materials (fuel, oils, batteries, chemicals
etc.)
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK
OF INJURY.
Only use Scania genuine fuel
filter.
Safety precautions for operation
Daily inspection
Always perform visual inspection of the engine
and engine bay before the engine is started and
when the engine has been stopped after oper-
ation.
This will make it easy to detect any leakage of
fuel, oil or coolant or any other abnormal condi-
tion that may require remedial action.
Refuelling
When refuelling, there is a risk of fire and explo-
sion. The engine must be stopped and smoking
is not allowed.
Do not overfill the tank, since the fuel may ex-
pand, and close the fuel filler cap properly.
Only use fuel recommended in the service
literature. Fuel of an incorrect grade may cause
malfunctions or stoppage by interfering with the
operation of the fuel injection pump and the in-
jectors.
This could cause engine damage and possibly
personal injury.
Harmful gases
Only start the engine in a properly ventilated
area. The exhaust emissions contain carbon
monoxide and nitrogen oxides that are toxic.
When operating the engine in an enclosed
area, an effective extraction device for exhaust
gases and crankcase gases must be used.
Starter lock
If the control panel is not fitted with a key
switch, the engine bay should be fitted with a
lock to prevent unauthorized starting of the en-
gine.
Alternatively, a lockable main switch or battery
master switch may be used.
Starting spray
Never use starting spray or similar as a starting
aid. An explosion may occur in the intake pipe,
which could cause personal injury.
Operation
The engine should not be operated in environ-
ments with surrounding explosive materials
since electrical or mechanical components of
the engine may emit sparks.
It is always a safety hazard to be near an en-
gine that is running. Body parts or clothing, or a
dropped tool may get stuck in rotating parts,
such as the fan, causing bodily injury.
Always cover rotating parts and hot surfaces as
much as possible to ensure personal safety.
Safety precautions for handling
materials
Fuel and lubrication oil
All fuels and lubricants as well as many chemi-
cals are flammable. Always follow the instruc-
tions stated on the container.
All work on the fuel system must be performed
when the engine is cold. Fuel leakage and spill-
age on hot surfaces may cause fire.
Store drenched rags and other flammable ma-
terials in a safe way to avoid spontaneous com-
bustion.
Batteries
Batteries, particularly when being recharged,
emit highly flammable fumes that can explode.
Do not smoke or let open flame or sparks come
near the batteries or the battery compartment.
Incorrect connection of a battery cable or jump
start cable may cause a spark, which in tun may
cause the battery to explode.
Chemicals
Most chemicals, such as glycol, corrosion in-
hibitors, preservation oils, degreasers etc. are
hazardous. Always follow the safety precau-
tions stated on the container.
Some chemicals, e.g. preservative oil, are
flammable.
Always store chemicals and other hazardous
materials in approved and distinctly marked
containers and out of reach of unauthorized
persons. Always dispose of superfluous or
used chemicals through an authorized waste
disposal contractor.
Safety precautions for care and
maintenance
Stop the engine
Always stop the engine before any mainte-
nance and service work unless otherwise
stated.
Prevent unauthorized starting by removing the
starter key and turning off the power by the
main switch or the battery disconnect switch,
locking it in the off position. Also attach a warn-
ing tag, stating that work on the engine is in
progress, at a suitable location.
It is always a safety hazard to work on an en-
gine that is running. Parts of your body or cloth-
ing, or a dropped tool may get stuck in rotating
parts, causing bodily injury.
Hot surfaces and fluids
A hot engine always presents a risk of scalding.
Always take care not to touch the exhaust
manifold, turbocharger, oil pan, hot coolant and
oil in pipes and hoses.
Lifting the engine
Use the engine lifting eyes when lifting the
engine. First check that the lifting equipment is
in proper condition and has sufficient lift capac-
ity rating.
Auxiliary equipment fitted to the engine may
cause the centre of gravity to be displaced.
Thus, additional lift devices may be required in
order to provide proper balance and a safe lift.
Never work below a suspended engine!
Batteries
Batteries contain a highly corrosive electrolyte
(sulphuric acid). Always take care to protect
your eyes, skin and clothing when charging and
handling batteries. Wear protective gloves and
goggles.
If electrolyte splashes on the skin, wash the
affected part of the body with soap and plenty
of water. If electrolyte splashes into the eyes,
rinse eyes immediately with plenty of water and
seek medical attention.
Dispose of used batteries through an author-
ized waste disposal contractor.
Electrical system
Before work is performed on the electrical sys-
tem, turn off the power by the main switch or the
battery disconnect switch.
Also disconnect any external power supply to
auxiliary equipment on the engine.
Arc Welding
Before welding near or on the engine, remove
the battery and alternator cables. Also remove
the control unit connector.
Connect the weld clamp to the component to be
welded, close to the weld location. Never con-
nect it to the engine or in such a way that the
current can pass through a bearing.
After the welding is completed, connect the ca-
bles to the alternator and the control unit before
connecting the batteries.
Lubrication system
Hot oil may cause scalding and skin irritation.
Avoid skin contact with hot oil.
Make sure that the pressure in the lubrication
system is relieved before work is carried out.
Never start or operate the engine with the oil fill-
er cap removed since oil will be ejected force-
fully.
Dispose of used oil through an authorized
waste disposal contractor.
Cooling system
Never open the coolant filler cap while the en-
gine is hot. Steam and hot coolant can come
out forcefully and cause scalding.
If the cooling system must still opened or disas-
sembled while the engine is hot, open the filler
cap very cautiously and slowly to release the
pressure before the cap is removed. Use
gloves since the coolant is still very hot.
Dispose of used coolant through an authorized
waste disposal contractor.
Fuel system
Always use gloves when checking for leaks in
or performing other work on the fuel system. Al-
ways wear eye protection when testing injec-
tors.
Fuel escaping under high pressure can pene-
trate body tissue and cause serious injury.
Never use non-genuine parts in the fuel system
and the electrical system. Genuine parts are
designed and manufactured to minimize fire
and explosion hazard.
Before starting
Install any guards that have been removed be-
fore the engine is started. Check to ensure that
no tools or other objects have been left on the
engine.
Never start the engine unless the air filter is in-
stalled. Otherwise there is a risk of objects en-
tering the compressor wheel or a risk of
personal injury from contact with it.
TYPE DESIGNATIONS
The engine designation indicates, in the form of a code, the type of engine, its
size and intended use, etc.
The type designation and engine serial number are indicated on a type plate
affixed to the right-hand side of the flywheel housing. The engine serial
number is also stamped into the cylinder block on the right hand side.
See arrow in the illustration.
Engines that are certified regarding smoke and emissions are fitted with a
certification plate specifying the documents they conform to.
DI 12 40 A 01 E
Type
DC Supercharged diesel engine with air-cooled charge air cooler
DI Supercharged diesel engine with liquid-cooled charge air cooler
Displacement in whole dm
3
Performance and certification code
Indicates, together with the application code, the normal gross engine
output.
The actual output setting of the engine is indicated on the engine card.
Application
A For general industrial use
Variant 01-99
Type of governor
E Electronically controlled governor (DEC2)
D RQ, single-speed governor and electronically controlled auxiliary
governor (GAC)
T RQ, single-speed governor
The illustrations show a typical DI12 engine configuration.
Your engine may have different equipment from the one shown.
1. Type plate
2. Engine serial number,
stamped into the cylinder
block
3. Oil cooler
4. Oil dipstick
5. Oil cleaner
6. Oil filter
7. Draining, engine oil
8. Coolant pump
9. Charge air cooler
10. Turbocharger
11. Injection pump
12. Fuel filter
13. Starter motor
14. Alternator
15. Automatic belt tensioner
16. Draining, coolant
17. Oil top up
3
4
1, 2
12
15
8
17
7
10
16
9
5
13
6
14
11
DEC2 CONTROL SYSTEM
This engine has an injection pump with an electromagnetic actuator which
adjusts the control rack to give the correct amount of fuel.
The system which controls the pump is called DEC2 (Digital Engine Control,
generation 2).
The control unit (DEC2) continuously receives signals from sensors for
engine speed, charge air temperature and pressure, coolant temperature, oil
pressure, throttle position and control rack travel in the injection pump. Using
this input data and a control program, the correct amount of fuel for the
current operating conditions can be calculated.
The systems sensors may be used only for DEC2, not for other instruments
or other monitoring purposes.
The control unit contains monitoring functions to protect the engine in the
event of a fault which would otherwise damage it. Faults and the more
important monitoring functions are indicated on the control unit in the form
of light emitting diodes. See illustration on page 15 for a description.
In case of a fault, the Power - or Shutdown indicator on the DEC2 control
unit as well as the main indicator lamp on the main supply box and the
instrument panel will illuminate.
If a fault has been indicated on the main indicator lamp the operator can
determine the cause of the fault with the help of the LEDs on the control unit
and the troubleshooting schedule on page 18, and carry out the required
investigation and remedy.
Depending on the nature of the fault, the control system will take different
actions to protect the engine such as reducing the power output, keeping the
engine running at a constant low speed or, in case of a function impairing
fault, shutting down the engine (Shutdown).
To enable readout of LED fault codes there is a lamp test/fault code switch
located in the main supply box near the control unit.
A PC based program is also available to help service personnel to detect and
rectify faults and to adjust certain parameters in the operating program.
Diagnostics and changes to programs must only be performed by
authorized personnel.
The locations of the sensors and monitors that send signals to the control unit
are shown in the illustrations on pages 13 and 14.
There is a description of the functions of the LEDs during normal operation
on page 15.
On page 16 there is a description of the functions of the LEDs in case of a
fault and actions in case of Power- and Shutdown indication.
Troubleshooting and fault code reading are described on pages 17 and 18.
Location of sensors for DEC2 on DI12
1. Connection of lead to charge air
temperature sensor
2. Charge air temperature sensor
3. Oil pressure monitor
4. Connector panel
5. Coolant temperature sensor
6. Engine speed sensors
6
Location of sensors for DEC2 on DC12
1. Connection of lead to charge air
temperature sensor
2. Charge air temperature sensor
3. Oil pressure monitor
4. Connector panel
5. Coolant temperature sensor
6. Engine speed sensors
LED functions during normal operation
Note: The lamp test/fault code switch should not be
depressed. All LEDs come on briefly when
the control unit is powered up.
CONTROL STATUS
The LED flashes continuously when the control
unit is supplied with current, regardless of
whether the engine is running or not.
SHUTDOWN
The LED is out.
STARTING
The LED lights up as soon as the engine turns
over on cranking and follows the programmed
starting sequence until it has been completed
and then goes out.
RUNNING
The LED comes on when the engine has started
and the "Starting" LED goes out. It remains on
until the engine is stopped.
TORQUE LIMIT
The LED comes on when the control unit
detects that the engine has received the
maximum permissible quantity of injected fuel
according to its power curve. This means 100%
power output at the current rpm. If the load
increases, engine rpm will decrease.
BOOST LIMIT
The LED comes on when the control unit smoke
limiter restricts the maximum fuel quantity.
Operation of the smoke limiter is dependent on
the charge air pressure.
POWER-
The LED remains out during normal operation
as long as no fault is detected by the control
unit. See next page for the procedure to be
adopted in the event of a fault.
POWER+
If the control unit is programmed to allow the
engine to be operated according to more than
one power/torque curve (map), the following
applies.
The LED comes on when the engine is run at
more than 100% power output (MAP 2). It goes
out when the engine returns to the 100% power
output curve (MAP 1) or when the power output
required is less than 100%.
Action in case of a fault
LED indications in case of a fault
Note: The main indicator lamp in the main supply
box and at the instrument panel has
indicated a fault. The lamp test/fault code
switch should not be depressed.
CONTROL STATUS
The LED will continue to flash even in case of a
fault as long as voltage is supplied to the control
unit.
POWER -
If the LED comes on, the control unit has
detected a defect that could cause damage to the
engine if operation continues.
The control unit automatically reduces engine
power output to a predefined level if the
corresponding function has been selected.
Action: Reduce engine speed to idle if possible
and conduct troubleshooting according to
instructions on page 17 and the chart on page 18
SHUTDOWN
The LED comes on and the engine is switched
off automatically in case of a severe fault that
could cause damage to the engine if operation
continues.
Action: Conduct troubleshooting according to
instructions on page 17 and the chart on page 18
If the engine has not stopped, reduce engine
speed to idle and conduct troubleshooting.
Changing functions using the DIP
switches in the control unit
There are 8 DIP switches in the control unit under the
round black rubber cover.
These switches shall be in the ON position to obtain
normal functions according to the operating program.
However, for single-speed engines, the normal
position of DIP switches 6, 7, and 8 may also be OFF
Shutdown at threshold values for low oil pressure and
high coolant temperature can be selected by setting
DIP switch 4 to OFF
With DIP switch 4 in position ON, Power- indication
is obtained for these threshold values. Engine output
reduction (LOP) can be selected to prevent damage to
the engine. Changes to the program must only be
performed by authorized personnel.
Note: Do not operate the engine with a Power-
indication except for in emergencies.
Readout of fault codes
Note: If the engine has stopped or lost power but
the main indicator lamp is out and neither
POWER- nor SHUTDOWN are on, the fault
is outside the control unit detection range.
Probable causes: fuel shortage, temporary
overload, mechanical fault.
- Activate the lamp test/fault code switch. In
Scania electrical equipment the main indicator
lamp is located in this switch on the main supply
box.
- All LEDs will then come on for 2 seconds to
indicate that they are intact and in working order.
This also applies to the main indicator lamp in the
main supply box and the instrument panel. Make
a note of any LED that is defective.
- All LEDs will then be out for approximately 4
seconds.
- Following this, a fault code will be indicated on
one of the LEDs for 2 seconds. Note which LED
it is.
- The control unit then resumes the operating mode
automatically.
- After having made a note of the fault code, reset
the lamp test/fault code switch and reset the
control unit by turning off its power supply
momentarily.
- The most probable cause of the fault can then be
found in the trouble shooting schedule on the next
page.
- When the fault or faults have been rectified the
engine can be restarted.
- If the control system continues to indicate a fault
by way of the main indicator lamp, further faults
may have been recorded. The fault code readout
must then be repeated as per above since the
system can only display one fault code at a time.
- The fault(s) will be stored in a special memory in
the control unit along with information about the
operating time when it(they) occurred. Stored
faults can be accessed and erased by authorised
service personnel.
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STARTING AND RUNNING
AT FIRST START
When the engine is started for the first time, follow the maintenance points
listed under "First start" in the maintenance schedule, see page 27.
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 (refer to page 29).
6. Checking the coolant (refer to page 33).
The coolant should contain anti-corrosive to protect the cooling system
from corrosion.
If there is a danger of freezing:
- Only anti-freeze glycol should be used in the coolant as protection
against corrosion. We recommend only nitrite-free anti-freeze 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. A content of 30 % by volume provides
protection down to -16 C. Refer to page 33.
- Never top up with only water or only glycol. 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
anti-freeze 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.
Coolant composition:
minimum 30% glycol by volume
maximum 60 % glycol by volume
If there is no danger of freezing:
7-12% by volume
Scania Corrosion Inhibitor
(no glycol)
The recommended glycol must
not be mixed with glycol having
nitrite-based anti-corrosive.
Ethylene glycol and corrosion
inhibitor, if swallowed can be
fatal.
Avoid contact with the skin.
- Only Scania Corrosion Inhibitor should be used in the coolant as
protection against corrosion. The correct corrosion inhibitor content is
7-12% by volume and must never be less than 7% by volume. The
inhibitor in Scania Corrosion Inhibitor is free of nitrite.
- First filling: Fill the cooling system with water + 10% by volume of
Scania Corrosion Inhibitor. Use drinkable water with a pH value of
6 - 9.
- Never top up with only water or only anti-corrosive! Fluid losses
must always be replaced with premixed coolant:
water + 10 % by volume of Scania Corrosion Inhibitor.
Coolant filter (not standard equipment)
Only coolant filter without inhibitor may be used. The use of coolant filters
increases the life of the coolant and reduces the risk of deposition corrosion.
12. Checking the fuel level (refer to page 40).
15. Checking the electrolyte level in batteries (refer to page 42).
16. Checking the state of charge in batteries refer to page 42).
18. Checking the coolant level monitor (if fitted) (refer to page 43).
19. Checking the temperature monitor (refer to page 44).
20. Checking the oil pressure monitor (refer to page 45).
21. Checking the tension of drive belts (refer to page 46).
Ethylene glycol and corrosion
inhibitor, if swallowed
can be fatal.
control, there is a
SERIOUS RISK
OF INJURY.
The use of too much Scania
Corrosion Inhibitor as mixed
with glycol may cause deposits.
If a coolant filter has been fitted
it must not contain inhibitor.
CHECKS BEFORE RUNNING
Before running, "Daily maintenance" as described in the maintenance
schedule should be carried out, see page 27.
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 40).
For environmental reasons, your new Scania engine has been designed to use
a smaller amount of fuel when starting. Using unnecessarily large amounts of
fuel when starting the engine always results in the discharge of unburnt fuel.
- Open the fuel cock, if fitted.
- Declutch the engine (not engines with fixed clutch, e.g. generator sets).
- Engines with battery master switch: Switch on the power by means of
the battery master switch.
- DEC2: If the main indicator lamp comes on or flashes when the power is
turned on, this indicates the presence of a fault in the control system or
engine which must be found and rectified before the engine is started.
Refer to page16.
- Start the engine by means of the starter button or starter key.
Starting at low temperatures
Local environmental requirements must be complied with. Starting aids,
engine heaters and/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. Avoid running it longer than necessary at idling speed.
Only start the engine in a
properly ventilated area.
When operating the engine in
an enclosed area, an effective
extraction device for exhaust
gases and crankcase gases
must be used.
Never use starting spray or
similar as a starting aid.
An explosion may occur in the
intake pipe, which could cause
personal injury.
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
time it must cool for 2 minutes.
If the engine has flame start:
- Operating flame start without timer relay: Press the control button,
which also acts as a pre-glow button (max. 20 seconds). The glow plug
continues to glow as long as this button is depressed after the engine has
started. Maximum time is 5 minutes.
- Operating flame start with timer relay: Press the pre-glow button (a
maximum of 20 seconds). Release it when the engine starts. The timer
relay keeps the glow plug glowing for 5 minutes. If a shorter glow time
is required, press the release button. The key must be turned to the 0
position if the start attempt fails.
Note: If the engine is equipped with an INTERLOCK switch, this
switch should be depressed and held until the oil pressure has
reached a sufficiently high level.
- Generator sets should be operated under load immediately after starting
to avoid the risk of white smoke. This applies in particular to engines
that have been installed without aids for heating or applying a basic
load.
- Warm up the engine with a light load. A light load on a cold engine
gives better combustion and faster heating than warming up with no
load.
Maximum starter engagement
time is 30 seconds. Risk of
overheating. Allow starter to
cool for 2 minutes after a
starting attempt before
cranking again.
OPERATION
Check instruments and warning lamps at regular intervals.
Engine speed
The Scania tachometer is divided into sectors of different colours, as follows:
Coolant temperature
Normal coolant temperature when the engine is running should be 70 - 90C.
DEC2: If the temperature is high, 98C or above, you can select for the
control system to reduce power output (Power -) in order to bring down the
temperature. Refer to the DEC section on page 17.
If the temperature continues to rise, the engine will be shut down
automatically (Shutdown) at 103C. Refer to the DEC section on page 17.
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.
0-500 rpm red area: prohibited engine speed,
passed when stopping and
starting.
500-700 rpm yellow area: low idle.
700-2200 rpm green area: normal operating speed.
The engines operating
speed range is controlled by
the DEC2 control system.
2200-2600 rpm yellow/green
striped:
unsuitable operating speed.
May occur when switching
off and during downhill
engine braking
2600-3000 rpm red area: prohibited engine speed
WARNING! When driving a vehicle down a steep descent
or in other installations, where the engine may be pro-
pelled by the vehicle motion, DEC2 will set the fuel
feed to zero to protect against engine overspeed and
shut down the engine. The clutch must not be released
in such a situation since this may cause vital functions
such as steering and brake system to become inopera-
tive when the engine stops.
!
Overpressure is not allowed in
cooling systems with Scania
radiators and expansion tanks
made of plastic, i.e. the
expansion tank must not be
fitted with a pressure cap.
Oil pressure
Max. oil pressure:
hot engine at engine speed exceeding 800 rpm 6 bar
Normal oil pressure:
hot engine at operating speed 3 - 6 bar
Min. oil pressure:
hot engine at 800 rpm 0.7 bar
At engine speeds below 800 rpm the gauge may indicate low oil pressure
although no fault is present.
Oil pressures below 0.7 bar at engine speeds above 800 rpm will cause
engine damage. The engine must be stopped immediately.
DEC2: The engine is shut down automatically if this function has been
selected. Refer to the DEC section on page 17.
Charging indicator lamp
If the lamp comes on during operation:
- Check/adjust the alternator drive belts as described in the maintenance
step. Refer to page 46.
- If the charging indicator lamp is still on, this could be due to an alter-
nator 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. Keep the stop button depressed
until the engine is completely stationary.
3. DEC2: Before switching off, check that the control systems main
indicator lamp is not on or flashing.
Refer to page 16 for troubleshooting.
4. Engines with battery master switch: Switch the power off with the
battery master switch. (Does not apply to emergency generator sets).
5. Set the control switch to "0". (Does not apply to emergency generator
sets).
High lubricating oil pressure
(above 6 bar) is normal when
starting a cold engine.
High lubricating oil pressure
(above 6 bar) is normal when
starting a cold engine.
There is danger of turbo damage
and post boiling if the engine is
stopped without cooling.
The power must not be switched
off before the engine has
stopped.
Clutch
- See the manufacturers instructions for handling and operating the
clutch.
WARNING If the clutch output shaft is rotating (e.g. in multiple
engine installations where other engines are running), the clutch
can, under its own power, be drawn to the engaged position.
THIS MAY CAUSE PERSONAL INJURY and engine damage.
For this reason, always secure the clutch in the disengaged posi-
tion if there is a risk of the output shaft starting to rotate.
CHECKS AFTER RUNNING
- Check that the power is cut from the battery master switch and that the
control switch is 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 be drained if it
does not contain a sufficient amount of glycol, refer to page 33
- At temperatures below 0 C: Prepare for the next start by switching on
the engine heater (if fitted).
Top up engine coolant when the
engine has been stopped after
being started for the first time.
control, there is a
SERIOUS RISK
OF INJURY.
MAINTENANCE
The maintenance programme covers 24 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, monitors, batteries etc. . . page 42
Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . page 46
The maintenance points are divided into intervals as follows:
Daily maintenance
Maintenance before first start
Maintenance after the first 400 hours of operation
Periodic maintenance every 200 hours of operation (carried out after 200,
400, 600, 800, etc. hours)
800, 1200, 1600, etc. hours)
2400, 3600, etc. hours)
4800 etc. hours)
9600, etc. hours)
Annual Maintenance
Maintenance every 5th year
ENGINES WITH FEW HOURS OF
OPERATION
Emergency generator sets and the like that are not used regularly should be
run on test and checked in accordance with the generator set manufacturers
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 sensor.
12. Checking the fuel level.
15. Checking the electrolyte level in batteries.
16. Checking the state of charge in batteries.
17. Cleaning the batteries.
22. Checking for leakage, rectify as necessary
control, there is a
SERIOUS RISK
OF INJURY
For engines with few operating
hours that are not subject to
periodic maintenance according
to the maintenance schedule on
page 27, maintenance should be
carried out in accordance with
the schedule:
"Every year"
"Every 5 years"
MAINTENANCE SCHEDULE
1. More often if required
2. For engines with few operating hours, see page 26.
3. Earlier if vacuum indicator shows red.
4. If inhibitor has not been topped up for five years, the coolant should be changed.
D
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LUBRICATING OIL SYSTEM, page 28
1. Checking the oil level
l l
2. Oil change l1 l
3. Cleaning the oil cleaner l1 l
4. Renewing the oil filter l1 l
COOLING SYSTEM, page 32
5. Checking the coolant level
l
6. Checking the coolant l l4 l
7. Cleaning the cooling system l1 l
AIR CLEANER, page 38
8. Checking the vacuum sensor
l
9. Cleaning the coarse cleaner l1 l
10. Cleaning or renewing filter element l3 l
11. Renewing the safety cartridge l l
FUEL SYSTEM, page 40
12. Checking the fuel level
l l
13. Renewing the main filter l1 l
14. Checking the injectors l l
ELECTRICAL SYSTEM, page 42
15. Checking the electrolyte level in batteries
l l2 l
16. Checking the state of charge in batteries l l2 l
17. Cleaning the batteries l2 l
18. Checking the level monitor l l l
19. Checking the temperature monitor l l l
20. Checking the oil pressure monitor l l l
MISCELLANEOUS, page 46
21. Checking the drive belt
l l l
22. Checking for leakage, rectify as necessary l
23. Checking/adjusting valve clearance l l
24. Renewing (or cleaning) the valve for closed crankcase
ventilation
l
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.
- The specified oil change intervals apply provided that the fuel sulphur
content does not exceed 0.3% by weight. If the sulphur content exceeds
0.3 % but is maximum 1.0%, the oil change intervals must be halved
(200 h).
- Viscosities as illustrated 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 TBN (Total Base Number), TAN (Total Acid Number), fuel
dilution, water content, viscosity and the quantity of friction 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 -10 0 10 20 30 40 C
SAE 10W-30
SAE 20W-30
SAE 30
SAE 40
SAE 50
SAE 5W-30
SAE 15W-40
1. Daily:
CHECKING THE OIL LEVEL
Note Before checking oil level: Allow the engine to remain stopped 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.
- Correct type, see "Oil grade" on page 28.
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
minimum and the maximum mark
2. Every 400 hours:
OIL CHANGE
Note Under extremely severe operating conditions, especially in dusty
environment or if the deposits in the centrifugal cleaner are
thicker than 20 mm: change oil more frequently.
- Unscrew the 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 plug.
- Refit the plug.
- Fill up with oil.
- Check the level on the dipstick.
Max. 33 dm
3
Min. 28 dm
3
1 dm
3
= 1 litre
Maximum angles of inclination during operation
Maximum permissible angles during operation vary, depending on the type
of oil sump, see illustration.
Note: Specified angles may only occur intermittently.
35
25
25
35
10 mm
10 mm
WARNING
The oil may be hot.
Wear protective gloves and
goggles
Always use a suitable container
to avoid spillage when
changing oil.
Dispose of used oil through an
authorized waste disposal
contractor.
3. Every 400 hours:
CLEANING THE OIL CLEANER
(at same time as an oil change)
- Unscrew the nut and remove the cover.
- Lift out the rotor and loosen the nut on the rotor bowl three turns.
- If the nut is jammed:
Clamp the nut, not the rotor, in a vise and turn the rotor three
revolutions by hand or using a screwdriver.
- Tap the nut lightly with your hand or a plastic hammer, to detach the
rotor bowl from the bottom plate.
- Unscrew the nut and remove the rotor bowl.
- Prize carefully to detach the strainer from the bottom plate.
- Scrape off the deposits from the inside of the rotor bowl. If there are no
deposits, this indicates that the cleaner is not working properly.
- If the deposits are thicker than 20 mm: clean more frequently.
Open the cap carefully. The
oil may be hot.
Scania Industrial & Marine Engines 31
- Rinse all parts in diesel fuel.
- Fit the O-ring in the rotor bowl. Make sure it is not damaged.
Renew parts if necessary.
- Assemble the rotor.
- Tighten the rotor nut firmly by hand
- Refit the rotor.
- Make sure that it spins easily.
- Check that the O-ring in the bowl is undamaged.
Renew the O-ring if hard or damaged.
- Secure the bowl firmly, tightening the nut
If the nut is tightened with a tool, the rotor shaft, nut or bowl may be
damaged.
Operational test
The rotor rotates very fast and should continue to turn 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 inspect.
4. Every 400 hours:
RENEWING THE OIL FILTER
(at same time as an oil change)
- Remove the old filter.
- Oil the rubber gasket and fit a new genuine Scania filter.
- Tighten the filter by hand.
Never use a tool for tightening. The filter could be damaged,
obstructing circulation.
- Start the engine and check for leaks.
Important If the deposits in the centrifugal cleaner are thicker than 20
mm the oil filter should be renewed more frequently. This
includes cleaning the centrifugal filter and changing oil.
COOLING SYSTEM
5. Daily:
- 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 lower edge of the
filler neck.
- Hot engine: The coolant should be approximately 25 mm above the
lower edge of the filler neck.
- 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 cause cracks in the cylinder block and the cylinder
head.
Always top up with ready mixed
coolant.
Carefully open the cap.
Hot water and steam
may blow out.
Always collect oil in a suitable
container to avoid spillage when
renewing the oil filter.
Dispose of used filters through
an authorized waste disposal
contractor.
6. Every 2400 hours:
CHECKING THE COOLANT
Coolant should be checked as follows:
a) Check the appearance of the coolant.
b) Coolant with only glycol: Check the glycol content.
c) Coolant with only Scania Anti-corrosive:
Check the corrosion inhibitor.
The composition of the coolant is described in detail under
"Starting and running"
a)
Checking the appearance of the coolant
- Fill a container with a little coolant and check that it is clean and clear.
- If the coolant is contaminated or cloudy: consider changing the coolant
- Water added to the coolant should be clean and free from dirt of any
kind.
- Use drinkable water with a pH value 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.
- A content of 30% glycol by volume protects against freezing down to
-16C. If further protection is needed, refer to the table on the next page
for calculating the required amount of glycol.
We recommend only nitrite-free anti-freeze glycol with the following
supplier designations:
BASF G48 or BASF D542
- Always top up the anti-freeze if its 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: Change the coolant when cleaning the cooling system: every 4800
hours or minimum every 5 years.
Important!If a coolant filter is used in the cooling system it must not
contain an inhibitor.
Coolant composition:
minimum 30% glycol by
volume
maximum 60% glycol by
volume
7-12% by volume
Scania Anti-corrosive
The coolant should be ready
mixed when it is poured into the
cooling system.
Never top up with only water or
only glycol.
Ethylene glycol is highly
dangerous if ingested and can
prove fatal.
Avoid skin contact with glycol.
The recommended glycol must
not be mixed with glycol having
nitrite-based anti-corrosive.
Risk for build up of sludge and
reduced cooling capacity.
A
A= Area to be avoided. Only for calculating glycol mix.
Coolant freezing temperature when ice starts to form at different glycol mixes
% glycol by
volume
15 20 25 30 35 40 45 50 60
Cooling
system
capacity, dm
3 Ice slush starts
to form at C
-6 -9 -12 -16 -22 -27 -36 -46 -55
Glycol dm
3
(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 build up starts (slush)
Curve B: Temperature at which damage due to
freezing can occur
1. Safe range
2. Malfunctions may occur (ice slush)
3. Risk of damage by freezing
Properties of glycol at low temperatures:
- Example with 30% glycol by volume
- Ice slush starts to form at -16C.
- There is risk for malfunctions at -30C
- No risk of damage by freezing with a
minimum content of 30% glycol by volume
% glycol by volume
c)
Checking the corrosion inhibitor
There must always be sufficient corrosive inhibitor in the coolant to protect
the cooling system against corrosion.
If there is no danger of freezing, only Scania Anti-corrosive should be used
in the coolant.
The inhibitor in Scania Anti-corrosive is free of nitrite.
The correct proportion of anti-corrosive is 7-12% by volume.
- Topping up with 1.0% Scania Anti-corrosive by volume should be done
after every 2400 hours of operation.
- Never top up with only water or only anti-corrosive!
Fluid losses must always be replaced with premixed coolant:
water + 10% by volume of Scania Anti-corrosive.
Note: The coolant should be changed when the cooling system is
cleaned: every 4800 hours or minimum every 5 years.
Changing the coolant
1. Remove the filler cap from the expansion tank.
2. The coolant is drained at two points:
- the "lowest point" of the engine block, see illustration.
- the "lowest point" of the cooling system.
3. Close the cocks.
4. Fill up with coolant through the expansion tanks filler hole.
Mix coolant as described on page 33.
Always collect fluid in a suitable
changing coolant.
Dispose of used coolant through
contractor.
If a coolant filter has been fitted
it must not contain inhibitor.
Mixing corrosion inhibitor with
glycol or adding too much
corrosion inhibitor may cause
deposits and reduced cooling
capacity.
Corrosion inhibitor, if
swallowed can be fatal.
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 radiators 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.
The cooling system must never
be cleaned with caustic soda.
There is a risk of damage to
aluminium parts.
Charge air cooler (DI engine)
1. Drain the coolant from the engine, refer to "Changing the coolant".
2. Detach the intake manifold from the turbo.
3. Detach the charge air cooler inlet and outlet connections.
4. Unbolt the charge air cooler assembly from the intake manifold. The
charge air element is integrated into the housing.
Be careful - do not damage the core water connections.
5. Clean the outside of the element. 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 core and the air intake
pipe with a spirit based cleaner.
7. Apply sealant (silicone 816 064) in a uniform bead, approximately
2-3 mm, on the sealing surface of the air intake pipe.
8. Install the charge air cooler within 15 minutes of applying the sealant.
Torque 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 33.
Important Allow the sealant to cure for minimum
24 hours before the engine is used.
1. Charge air
cooler housing
with core
2. O-ring
3. Sealant 816 064
4. Air intake pipe
1
2
3
4
Internal cleaning
Removing oil and grease
- If possible, run the engine until it has reached the operating temperature
and then drain the cooling system.
- Remove the thermostat.
- Fill the system with clean, hot water mixed with liquid dishwasher
detergent intended 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
approximately 20-30 minutes.
- Drain the water from the system.
- Refit the thermostat.
- Fill up with new coolant according to the specification on page 33.
Removing deposits
- If possible, run the engine until it has reached operating temperature and
then drain the cooling system.
- Remove the thermostat.
- Fill the system with clean, hot water mixed with a commercially
available radiator cleaner based on sulphamic acid and containing
dispersing agents. Follow the manufacturers instructions for mixing
proportions and cleaning times.
- Run the engine for the specified time and then drain the cooling system.
- Refill the system with hot water and run the engine for approximately
20-30 minutes.
- Drain the water from the system.
- Refit the thermostat.
- Fill up with new coolant according to the specification on page 33.
Handling cleaning agents for
the cooling system:
Read the warning label on the
container.
Always collect fluid in a suitable
draining coolant.
contractor.
AIR CLEANER
8. Daily:
CHECKING THE VACUUM INDICATOR
If the entire red plunger of the indicator is visible, renew or clean the air filter
element, paragraph 10. This is especially important if the engine is operated
under heavy load and at high engine speed.
9. Every 200 hours:
CLEANING THE AIR CLEANER
COARSE CLEANER
1. Remove the cover from coarse cleaner 2.
2. Remove the conical coarse separator. Empty out the particles of dirt and
clean it.
3. Fit the coarse separator as shown in the figure and screw the cover in
place.
4 3
2 1
1. Filter element
2. Coarse cleaner
3. Cover
4. Vacuum sensor
Air cleaner with safety cartridge
The coarse cleaner must always
be fitted in an upright position.
CLEANING OR CHANGING THE
FILTER ELEMENT
Note: Earlier if the vacuum indicator shows red
Dismantling
1. Remove the side cover from the air cleaner.
2. Change or clean the element.
Note Cleaning the element always entails a risk of damaging it. The
element can be cleaned a maximum of four times. After cleaning,
it has less dust separation capacity than a new element.
3. Mark the filter when it has been cleaned.
Cleaning the 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 housing
Only use Scania genuine air
filter. Change the filter element
if it is damaged.
Danger of engine damage if the
filter element is damaged.
Never start the engine unless
the air filter is installed.
Danger of personal injury or
engine damage.
1 2
3
Checking
- Insert a torch into the element and check from the outside that there are
no holes or cracks in the filter paper.
- Change 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 red plunger in the vacuum indicator by depressing the button.
RENEWING THE 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 side 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, refer to paragraph 10.
6. Assemble the air cleaner.
1. Safety cartridge
Air cleaner with safety cartridge
1
Do not remove the safety
cartridge unnecessarily.
Never clean the safety cartridge
FUEL SYSTEM
12. Daily:
CHECKING THE FUEL LEVEL
- Top up with fuel if necessary.
- If the tank has been run dry, bleed the fuel system, refer to paragraph 13.
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.
- Tighten the new filter by hand.
Never use a tool for tightening. The filters can be damaged,
obstructing circulation.
- Bleed the fuel system as described below.
- Start the engine and check for leaks.
Bleeding the fuel system
- Turn on the power so that the fuel shut-off valve opens.
- Undo the connection on fuel filter outlet 1 (upwards).
- Pump hand pump 3 until fuel without air bubbles flows out of the
opened connection.
- Tighten the connection on the filter.
- Undo the overflow valve 2 at the fuel shut-off valve outlet.
- Pump with the hand pump until the fuel coming out of the open
overflow valve is free of air bubbles.
- Tighten the overflow valve and pump the hand pump an additional 10
strokes.
If the engine fails to start after bleeding. . . . . . .
- Open the overflow valve again and pump the hand pump until fuel
without air bubbles flows out.
- Close the overflow valve firmly and start the engine.
1
3
2
Always collect fuel in a suitable
bleeding system or renewing
components.
Only use Scania genuine fuel
filter.
Observe the utmost cleanliness
when working on the fuel
system.
Malfunctions could easily occur
and the injection equipment
could be damaged.
CHECKING THE INJECTORS
Injectors should be inspected by trained personnel with access to the
necessary equipment. Inspection should be carried out at least once a year or
every 2400 hours.
Removal
1. Clean around the injectors and connections, including clamps and
brackets.
2. Detach the delivery pipe bundle and leak-off fuel lines.
3. Unscrew the injector.
4. Fit protective plugs on the injector and delivery pipe.
5. Lift up the seal from the bottom of the injector seat if it does not come
out together with the injector.
6. Fit a core plug in the injector seat in the cylinder head.
7. Clean the injectors and check/adjust in a nozzle tester.
Correct opening pressure, see Technical data, page 54.
Fitting
1. Check that there is no old seal in place and fit a new seal in the bottom
of the injector seat.
2. Fit a new O-ring in the socket nut and a new seal under the socket nut.
3. Fit the injector.
4. Tighten the socket nut to 70 Nm (7.0 kpm).
5. Fit the delivery pipe and tighten the union nuts to 20 Nm (2.0 kpm). Fit
clamps and brackets.
Important Take care to fit the delivery pipe without tension and make sure
that the cone on it is correctly positioned in the connection.
6. Fit the leak-off fuel line. Tighten the bolts to 11 Nm (1.1 kpm).
1. Threaded
socket nut
2. O-ring
3. O-ring
4. Stop ring
5. Guide pin
6. Seal
1. Delivery pipe
2. Union nut
3. Washer
4. Cone
5. Connection on injector or
injection pump
The delivery pipes must
not be bent.
All clamps must be refitted.
Always wear gloves and eye
protection when testing
injectors.
Fuel escaping under high
pressure can penetrate body
tissue and cause serious injury.
ELECTRICAL SYSTEM
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.
CHECKING THE STATE OF CHARGE IN
BATTERIES
Note: Every 200 hours applies to generator sets and the like. Other
installations every 1200 hours.
- Check the density with an acid tester.
In a fully-charged battery it should be:
1.280 at +20C
1.294 at 0
1.308 at -20C
- If the density is below 1.20, the battery must be charged. A discharged
battery freezes at -5C.
Do not rapid-charge the batteries. This will damage the battery in the
long run.
CLEANING THE BATTERIES
Note: Every 200 hours applies to generator sets and the like. Other
installations every 1200 hours.
1. Clean batteries, cables and cable terminals.
2. Check that all cable terminals are firmly tightened.
3. Grease battery terminal posts and cable terminals with vaseline.
Wear gloves and eye protection
when charging and
handling batteries.
Batteries contain a highly
corrosive acid.
Do not connect the cables to the
wrong terminals.
This could cause serious
damage to the electrical system.
If the terminals are
shortcircuited, sparks
will be generated.
Do not let open flame or sparks
come near the batteries.
When batteries are charged,
they emit highly flammable
fumes that can explode.
Do not let open flame or sparks
come near the batteries.
When batteries are charged,
they emit highly flammable
fumes that can explode.
MONITOR
(optional equipment)
1. Start the engine.
2. Lower the coolant level in the expansion tank.
3. Automatic stop in case of fault: The engine stops, the indicator lamp
comes on and the buzzer sounds if the level monitor is OK.
4. Without automatic stop in case of fault: The indicator lamp comes on
and the buzzer sounds if the level monitor is OK.
5. Top up coolant to the correct level, refer to page 32.
2-pin level monitor installed in
coolant expansion tank delivered
by Scania
draining coolant.
contractor.
MONITOR
1. Drain the coolant, allowing the temperature monitor to be removed.
2. Remove the temperature monitor cable(s).
3. Unscrew the monitor.
4. Refit the cable(s) to the monitor.
5. Submerge the monitor sensor body in water. Heat the water slowly
(approx. 1 minute) using e.g. an immersion heater.
6. Set the control switch to "ON". Use a thermometer to check that the
warning lamp comes on or that an alarm is initiated at the correct
temperature.
The correct temperature is stamped on the hexagonal part of the
monitor.
The monitor tolerance is 3.
SENSOR
1. Drain the coolant, allowing the temperature sensor to be removed.
2. Remove the temperature sensor cable(s).
3. Unscrew the sensor.
4. Connect an ohmmeter to the temperature sensor.
5. Submerge the sensor body in water. Heat the water slowly
(approximately 1 per minute) using e.g. an immersion heater.
6. Check the resistance at the temperatures given below.
7. The sensor should give the following readings:
At temp. C Resistance Tolerance C
60 134 13.5
4
90 51.2 4.3
3
100 38.5 3
3
2-pole temperature sensor
C =Common connection
1 = Connection C -1 closes at the
stamped temperature
2 =Connection C -2 opens at the
stamped temperature
2-pole temperature monitor
draining coolant.
contractor.
SENSOR/MONITOR
Sensor function
Measure the sensor output voltage (pin 3) at different oil pressures. The
sensor output voltage shall be as follows:
0.85-1.15 bar = 2.45 volt
1.80-2.20 bar = 3.70 volt
2.75-3.25 bar = 4.50 volt
3.79-4.20 bar = 5.20 volt
4.55-5.45 bar = 5.70 volt
5.40-6.6 bar = 6.10 volt
The tolerances apply at +30C - 110C. At lower temperatures the tolerance
range is wider, e.g. 0C = x 1.4.
Monitor function
Connect a test lamp to the oil pressure monitor, pin 4 (- ground), and check
that the monitor switches on at the correct pressure when the engine is started
and stopped. The monitor shall switch on at 0.7 0.15 bar when the engine is
stopped.
Important The sensor/monitor must be supplied with voltage during the
measurement. Maximum 4 W load from a test lamp.
MONITOR FOR DEC 2
Connect an ohmmeter or a test lamp to the oil pressure monitor and check
that the monitor switches off/on at the correct pressure when the engine is
started and stopped. The monitor shall switch off at 1.1 0.15 bar when the
engine is started and switch on at 0.7 0.15 bar when the engine is stopped.
4
1
3
2
RENEWING THE BATTERY
Removal
1. Disconnect the negative cable (-) from the battery (cable connected to
ground).
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
ground).
MISCELLANEOUS
CHECKING THE DRIVE BELT
Replace the drive belt (1) (poly V-belt) if worn or damaged.
Also check that the automatic belt tensioner (2) is working and keeps the
drive belt correctly tensioned.
On installations with dual belt circuits, the second belt circuit has a drive belt
with manual belt tensioner.
This drive belt should be tensioned to 15-20 Nm as shown in the figure.
Do not connect the cables to the
wrong terminals.
This could cause serious
damage to the electrical system.
If the terminals are short-
circuited, sparks will be
generated.
Dispose of used batteries
through an authorized waste
22. Daily:
CHECKING FOR LEAKAGE, RECTIFY
AS NECESSARY
- Start the engine.
- Check for oil, coolant, fuel, air and exhaust leakage.
- Tighten or change 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, refer to illustration.
a) If coolant is evident, the O-ring is leaking.
b) If oil is running out, the liner shelf is leaking.
- Check that the coolant pump drain hole (2) is not clogged, refer to
illustration. If there is leakage, renew the pump seal or the coolant pump
assembly.
A small amount of leakage from the overflow holes during the engine
running-in period is normal. (Seals and O-rings are lubricated with soap
or oil when fitted).
This leakage normally stops after a time.
Ensure that any leakage does
not pollute the environment.
In case of major leakage,
contact the nearest Scania
workshop.
CHECKING/ADJUSTING VALVE
CLEARANCE
Note: Checking/adjusting valve clearance 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 changed as necessary. Tightening
torques: 26 Nm.
Intake valve clearance: 0.45 mm
Outlet valve clearance: 0.70 mm.
Alternative 1
- Position No. 1 cylinder at TDC by turning the crankshaft in its normal
direction of rotation until all four valves are closed.
- Adjust the following valves. The correct valve clearance is also stated
on the instruction plate on one of the valve covers:
- Position No. 6 cylinder at TDC by turning the crankshaft one revolution
in its normal direction of rotation and adjust the following valves:
Cylinder 1 Intake and outlet
2 Intake
3 Outlet
4 Intake
5 Outlet
Cylinder 2 Outlet
3 Intake
4 Outlet
5 Intake
6 Intake and outlet
TDC
no. 6 cylinder
TDC
no. 1 cylinder
Intake valve
exhaust valve
5
4
3
2
1
6
Cylinder numeration
FLYWHEEL
FLYWHEEL
WARNING
control, there is a
SERIOUS RISK
OF INJURY.
Alternative 2
- Position No. 1 cylinder at TDC by turning the crankshaft in its normal
direction of rotation until all four valves are closed.
- Adjust all valves for No. 1 cylinder. Correct valve clearances are
indicated on the instruction plate on one of the rocker covers.
- Proceed in the same way for the remaining cylinders in the sequence
5 - 3 - 6 - 2 - 4 (firing order) by turning the crankshaft 1/3 of a
revolution in its normal direction of rotation after each adjustment.
Note:
Readings can be taken from the
flywheel through covers in the
flywheel housing either from
above or underneath depending
on access when fitting.
It says up and down respectively
on the flywheel
Both covers are fitted with a
cover at delivery.
Covers for reading
on the flywheel housing
CHANGING (or CLEANING) THE
CLOSED CRANKCASE VENTILATION
VALVE.
Alternative 1:
Change the valve at the specified interval.
Alternative 2:
- Remove the valve after the specified interval.
- Clean the valve by placing it in a bath of diesel 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), maximum twice after the initial
2400 hours of operation. Take care to mark the valve after cleaning it.
LONG-TERM 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 the engine for long-term storage means:
- Thoroughly cleaning the engine
- To run the engine for a period of time with preservative fuel,
preservative oil and preservative coolant.
- Otherwise preparing the engine for storage (filter changes, lubrication,
etc.).
Preservative coolant
If the engine is to be stored with a full cooling system, use coolant containing
50% glycol by volume. Glycol without nitrite-based inhibitor must be used.
E.g. BASF G48 or BASF D542.
Preservative fuel
- Use diesel fuel mixed with Lubrizol 560A or equal.
- Mix 1 cm
3
(ml) of Lubrizol 560A with 10 dm
3
(l) of fuel.
HANDLING LUBRIZOL 560A
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.
In case of splashes in the eye: Rinse with moderate water spray (for min. 15 minutes). Seek medical attention.
In case of skin contact: Wash affected areas with soap and water.
If you inhale it: Fresh air, rest and warmth
Flammable: Fire class 2A. Flash point + 27.
In case of fire: Extinguish using carbonic acid, powder or foam
Storage: In properly sealed container in a dry, cool place. Keep out of reach of children.
!
Ethylene glycol, if swallowed
can be fatal.
Preservative oil
Suitable preservative oil can be supplied by most petroleum companies.
E.g. Dinitrol 40 or the equivalent.
Preparations for storage
- Drain and flush the cooling system. Top up with preservative coolant.
- Warm up the engine on regular fuel. Stop the engine and drain the oil.
- Change the fuel filter and turbo 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 approximately 1000 rpm (not single-speed
engines) for 20-25 minutes.
- Stop the engine, remove the hoses and connect the normal fuel lines.
- Oil the valve mechanism generously with preservative oil.
- Remove the injectors and spray preservative oil into each cylinder,
maximum 30 cm
3
(ml).
Turn the engine over a few revolutions using the starter motor. Spray an
additional small amount of oil into each cylinder.
After this the engine must not be cranked. Refit the injectors.
- 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 a full cooling
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 equal.
- Spray the outside of bright metal engine parts, first with penetrating
preservative oil such as Dinitrol 25B and then with Dinitrol 112 or
equal.
Always use suitable containers
draining oil and coolant.
Dispose of used oil and coolant
through an authorized waste
- Attach a label to the engine showing the date of preservation and
clearly stating that it must not be started or cranked.
Batteries
Remove the batteries for trickle charging at a charging station. (Does not
apply to batteries, which the manufacturer specifies to be maintenance free).
The same is applicable for short-term storage 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 when the engine is to be put into operation)
- Remove plugs and tape from coolant connections, air intakes and
exhaust pipes.
- Fill the cooling system with coolant, refer to page 19.
- Check the oil level in the engine or fill up with fresh motor oil.
- Turn the engine over a few times with the injectors removed, at the same
time copiously oiling the valve mechanism with pushrods and tappets.
Important The engine must be cranked with the injectors removed so that
surplus preservative oil will be pressed out of the cylinders.
- Fit the injectors.
- Empty the fuel systems main filter of preservative oil.
- Bleed the fuel system, refer to page 40.
- Wash off any externally applied preservative oil, using white spirit.
STORED ENGINE
Date . . . . . . . . . . .
Do not start or crank!
Wear gloves and eye protection
when charging and handling
batteries.
Batteries contain a highly
corrosive acid.
TECHNICAL DATA
GENERAL DC12 DI12
Number of cylinders
6 in line
Bore mm
127
Stroke mm
154
Displacement dm
3
(litres)
11.70
No. of main bearings
7
Firing order
1 - 5 - 3 - 6 - 2 - 4
Compression ratio
15:1(DC12 40=17:1) 17:1
Engine direction of rotation viewed from rear
Anti-clockwise
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 and oil kg
*With charge air cooler, radiator, expansion tank and
pipes
1065* 995
Power
refer to, "Engine record card"
LUBRICATION SYSTEM
Max. oil pressure
(warm engine at engine speed
exceeding 800 rpm) bar (kp/cm
2
)
6
Normal oil pressure
(warm engine at operating speed) bar (kp/cm
2
)
3 - 6
Min. oil pressure
(warm engine 800 rpm) bar (kp/cm
2
)
0.7
Oil capacity, refer to page 29
Crankcase pressure with closed crankcase
ventilation mm H2O
-55 - +20
FUEL SYSTEM DC12 DI12
Pump setting BTDC
See plate on rocker cover
Injectors, opening pressure bar (kp/cm
2
)
300
Low idle speed rpm
700
Maximum full load speed
See engine card
Fuel
Diesel fuel
1
Tightening torques:
Socket nut for injectors Nm
Union nut for delivery pipe Nm
Leak-off connection Nm
70
20
11
1
refer to page 56
COOLING SYSTEM
Number of thermostats 1 (dual thermostat)
Thermostat, opening temperature C 83
Coolant temperature:
System with ambient pressure C
System with overpressure C
70 - 93
70 - approx. 100
Capacity, including radiator, engine and expansions tank
and, for DI12, charge air cooler
with 0.75 m
2
radiator dm
3
(litres)
with 1.0 m
2
radiator dm
3
(litres)
with 1.2 m
2
radiator dm
3
(litres)
54 56
59 61
63 65
ELECTRICAL SYSTEM
System voltage V
24
Alternator, charging current A
65 or 90
Starter motor output kW (hp)
6.7 (9.1)
Monitors, alarm values:
oil pressure monitor bar (kp/cm
2
)
temperature monitor C
0.7 0.15
Stamped on hexagonal part of monitor
FUEL
Diesel fuel
The composition of the diesel fuel is vitally important to the operation and
life of the engine and the fuel injection pump. The engine power output and
the exhaust emissions are also dependent on the fuel quality.
The requirements and the test standards for the most important properties are
described in the workshop manual in sections that can be ordered from your
Scania dealer or directly from Scania. The address of Scania is printed on the
cover.
The diesel fuel shall comply with the following standard:
EN 590 (European standard).
The table below shows the requirements for some of the most important
properties:
Environmentally favourable fuels (low sulphur fuels)
There are three different grades of so called environmentally favorable fuels
(SS15 54 35). Grade 1 is sulphur-free and grade 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 Requirement
Viscosity at 40C 2.0 - 4.5 mm
2
/s (cSt)
Density at 15C 0.82 - 0.86 kg/dm
3
Sulphur (concentration by mass) max. 0.3%
Ignitability (CET rating) min. 49
Flashpoint 56C
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
loose 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 is not intended for the expected temperature and no
diesel fuel with the correct temperature properties is available, we
recommend that an electric fuel heater be installed as a preventative
measure.
- The low temperature properties of diesel fuel may be improved by
adding kerosene as a preventative measure. A maximum of 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, maximum
0.5-2% alcohol (isopropanol) may be added.
Drain fuel tanks and drain or renew fuel filters at regular intervals.
It is not permitted to mix
kerosene with diesel fuel that is
already adapted for the climate
concerned. The injection pump
may be damaged. All use of
paraffin other than kerosene is
forbidden, as it causes
engine damage.
It is not permissible to mix
petrol with diesel fuel. Petrol
may cause wear to the fuel
injection pump and it may also
cause damage to the engine.
ALPHABETICAL INDEX
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Air cleaner, prefilter . . . . . . . . . . . . . . . . . . . . 38
Air cleaner, safety cartridge . . . . . . . . . . . . . . 39
Air filter, element . . . . . . . . . . . . . . . . . . . . . . 38
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Battery, renewing . . . . . . . . . . . . . . . . . . . . . . 46
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Bleeding, fuel system . . . . . . . . . . . . . . . . . . . 40
Certified engines . . . . . . . . . . . . . . . . . . . . . . . . 5
Checks after running . . . . . . . . . . . . . . . . . . . 25
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Coolant level monitor . . . . . . . . . . . . . . . . . . . 43
Coolant temperature . . . . . . . . . . . . . . . . . . . . 23
Coolant temperature monitor . . . . . . . . . . . . . 44
Coolant temperature sensor . . . . . . . . . . . . . . 44
Coolant, changing . . . . . . . . . . . . . . . . . . . . . . 35
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 32
Cooling system, cleaning . . . . . . . . . . . . . . . . 36
Corrosion inhibitor . . . . . . . . . . . . . . . . . . . . . 35
DEC2 Control system . . . . . . . . . . . . . . . . . . . 12
Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Electrical system . . . . . . . . . . . . . . . . . . . . . . . 42
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Environmental responsibility . . . . . . . . . . . . . . 4
Fault codes DEC2 . . . . . . . . . . . . . . . . . . . . . . 17
Filter, air cleaner . . . . . . . . . . . . . . . . . . . . . . . 38
Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel filter, renewing . . . . . . . . . . . . . . . . . . . . 40
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuel specifications . . . . . . . . . . . . . . . . . . . . . 56
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuel system, bleeding . . . . . . . . . . . . . . . . . . . 40
Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
LED functions . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lubricating oil pressure sensor/monitor . . . . . 45
Lubricating oil system . . . . . . . . . . . . . . . . . . 28
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Maintenance schedule . . . . . . . . . . . . . . . . . . . 27
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Oil pressure monitor, DEC2 . . . . . . . . . . . . . . 45
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Prefilter, air cleaner . . . . . . . . . . . . . . . . . . . . 38
Pre-operation checks . . . . . . . . . . . . . . . . . . . . 21
Preparations for storage . . . . . . . . . . . . . . . . . 51
Safety cartridge, air cleaner . . . . . . . . . . . . . . 39
Safety details . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety precautions for care and maintenance . . 8
Safety precautions for handling materials . . . . 8
Safety precautions for operation . . . . . . . . . . . . 7
Sensors for DEC2 . . . . . . . . . . . . . . . . . . . . . . 13
Starting the engine . . . . . . . . . . . . . . . . . . . . . 21
Stopping the engine . . . . . . . . . . . . . . . . . . . . 24
Taking out of storage . . . . . . . . . . . . . . . . . . . 53
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 54
Temperature monitor . . . . . . . . . . . . . . . . . . . 44
Troubleshooting DEC2 . . . . . . . . . . . . . . . . . . 16
Type designations . . . . . . . . . . . . . . . . . . . . . . 10
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . 48
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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