Industrial & Marine Engines

IMPORTANT INFORMATION
When working on the engine, for example adjusting drive belts, oil change or adjusting the clutch,
it is important not to start the engine. The engine may be damaged and there is
! SERIOUS RISK OF INJURY
For this reason, always secure the starting device or disconnect a battery cable
before working on the engine.
This is especially important if the engine has a remote starter or automatic starting.
This warning symbol and text is reproduced beside those maintenance points where it is
especially important to consider the risk of injury.

Operator’s Manual
D11 DI11
Marine engine
opm96-11m en 1 588 296
1997-11:2

START-UP REPORT - WARRANTY

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

Engine number

Start-up date

User’s name and address

Signature
Engine type
Variant

Engine type and variant are indicated on the engine type plate
FOREWORD
This instruction manual describes the operation and maintenance of the Sca-
nia D11 and DI11 Marine Engines. The instructions apply to engines in
program 96 from engine number 5 364 870.
The engines are direct injection, fluid-cooled, four-stroke diesel engines with
6 cylinders in line. The engines are available with or without charge air coo-
ler, see page 4.
The engines may be equipped with two different cooling systems; heat
exchangers which are cooled by seawater or keel-cooling which means that
there are cooling pipes on the keel through which the engine’s internal coo-
lant is cooled.
Common applications are propulsion engines in small boats such as fishing
boats and ferries and in large recreational boats or as engines for driving
equipment onboard ships.
The engines can have different output and speed settings and may be classed
by different classification societies (classified engines are required for certain
marine installations).
The normal output setting of the engine (performance code) is indicated on
the type plate, see page 4.
Note Only standard components are described in the instruction
manual. For special equipment, refer to the instructions issued by
the manufacturer.
In order to obtain the best value and service life from your engine, there are
several points to bear in mind:
- Read through the Instruction Manual before starting to use your engine.
Even those experienced with Scania engines may find new information
in this manual.
- Follow the maintenance instructions. Maintenance according to the ins-
tructions forms the basis of good function and service life.
- Get to know your engine so that you know what it can do and how it
works.
- When necessary, always turn to an authorised Scania workshop. These
have special tools, genuine parts and staff with training and practical
experience of Scania engines.
The information in this manual was correct at the time of going to press.
However, we reserve the right to make alterations without prior notice.

Scania CV AB
Industrial and Marine Engines
S-151 87 Södertälje

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

 TABLE OF CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 2 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 26

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . .3 TEST READING
LOW PRESSURE INDICATOR . . . . . . . . . . . .26
TYPE DESIGNATIONS ............4
CLEANING THE AIR CLEANER
STARTING AND RUNNING . . . . . . . . . . . . 6 COARSE CLEANER . . . . . . . . . . . . . . . . . . . . .26
AT FIRST START . . . . . . . . . . . . . . . . . . . . . . . .6 CLEANING OR CHANGING
CHECKS BEFORE RUNNING . . . . . . . . . . . . . .7 FILTER INSERT . . . . . . . . . . . . . . . . . . . . . . . .26
STARTING THE ENGINE . . . . . . . . . . . . . . . . .7 CHANGING SAFETY CARTRIDGE . . . . . . . .28
At temperatures below 0 °C: . . . . . . . . . . . . . . .8
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 29
RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
CHECKING FUEL LEVEL . . . . . . . . . . . . . . . .29
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
CHANGING THE FUEL FILTER . . . . . . . . . . .29
Coolant temperature . . . . . . . . . . . . . . . . . . . . .9
CHECKING INJECTORS . . . . . . . . . . . . . . . . .30
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .10
STOPPING THE ENGINE . . . . . . . . . . . . . . . . .10 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 31
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . 10 CHECKING ELECTROLYTE LEVEL
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 IN BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . .31
CHECKS AFTER RUNNING . . . . . . . . . . . . . .11 CHECKING CHARGE STATE
IN THE BATTERIES . . . . . . . . . . . . . . . . . . . . .31
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 12 CLEANING BATTERIES . . . . . . . . . . . . . . . . .31
ENGINES WITH FEW HOURS CHECKING COOLANT
OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 12 LEVEL MONITOR . . . . . . . . . . . . . . . . . . . . . .32
MAINTENANCE SCHEDULE . . . . . . . . . . . . .13 CHECKING TEMPERATURE MONITOR . . .33
CHECKING TEMPERATURE SENSOR . . . . . 33
LUBRICATION OIL SYSTEM . . . . . . . . . 14
CHECKING THE OIL PRESSURE MONITOR 34
OIL GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
CHECKING OIL PRESSURE SENSOR . . . . . . 34
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . .14
CHECKING THE STOP FEATURE . . . . . . . . .34
CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . .15
Checking oil level during operation . . . . . . . .15 CHANGING BATTERY . . . . . . . . . . . . . . 36
OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . .15 MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 36
Maximum angle of inclination during CHECK/TENSION V-BELTS . . . . . . . . . . . .36
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LOOK FOR LEAKAGE,
CLEANING THE OIL CLEANER . . . . . . . . . . 16 REMEDY AS NECESSARY . . . . . . . . . . . . . .37
CHANGING THE TURBO FILTER . . . . . . .18 CHECK/ ADJUST VALVE CLEARANCE . .38
COOLING SYSTEM . . . . . . . . . . . . . . . . . . 18 CHANGING (OR CLEANING) VALVE FOR
CLOSED CRANKCASE VENTILATION . . .39
CHECKING COOLANT LEVEL . . . . . . . . . . .18
CHECKING CORROSION PROTECTION MOTHBALLING ENGINES . . . . . . . . . . . . 40
RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Fuel for mothballing . . . . . . . . . . . . . . . . . . . .40
CHECKING SEAWATER PUMP IMPELLER .19 Oil for mothballing . . . . . . . . . . . . . . . . . . . . .41
CHECKING COOLANT . . . . . . . . . . . . . . . . . .20 Mothballing . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Checking glycol content . . . . . . . . . . . . . . . . .20 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Checking Protection against corrosion . . . . . . 22 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Changing coolant . . . . . . . . . . . . . . . . . . . . .22 Taking out of mothballs . . . . . . . . . . . . . . . . .42
CLEANING COOLING SYSTEM . . . . . . . . . . . 23
Internal cleaning . . . . . . . . . . . . . . . . . . . . . . .25 TECHNICAL DATA . . . . . . . . . . . . . . . . . . 43
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
ALPHABETICAL INDEX . . . . . . . . . . . . . . 47

©
1997-11:2 Scania Industrial & Marine Engines 3
TYPE DESIGNATIONS
The engine designation indicates, in the form of a code: Engine type, size,
application etc.
The type designation and engine number are indicated on a type plate which
is located on the right-hand, front side of the engine. The engine number is
also stamped in the block beside the type plate.

DI 11 73 M 31 S LR

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

Stroke in whole dm3

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
M For marine use

Variant 01-99

Governor type
D Electronically controlled auxiliary governor
S RSV, all-speed and single-speed governor
T RQ, single-speed governor
K RQV-K, all-speed governor

Classification society (for classified engines)

ABS American Bureau of Shipping
BV Bureau Veritas
GL Germanischer Lloyd
LR Lloyd’s Register of Shipping
DNV Dwt Norske Veritas
RINA Registro Italiano Navale
SjöV Sjöfartsverket

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

 21 17 1, 2 20

15

16 6 11 12 10 4 14
19

18 3 7 5 22 13
The drawings illustrate a common type of DI11 engine.
Your engine may have other equipment not shown here.
1. Type plate 9. Turbocharger 17. Oil filling
2. Engine number, 10. Injection pump 18. Seawater pump
stamped in engine block 11. Fuel filter 19. Heat exchanger with expan-
3. Oil cooler 12. Stop solenoid sion tank
4. Oil dipstick 13. Starter motor 20. Sacrificial anodes
5. Oil cleaner 14. Alternator 21. Charge air cooler
6. Turbo filter 15. Fan belt, adjustment 22. Oil pressure monitor
7. Draining, engine oil 16. Draining, coolant
8. Coolant pump

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

STARTING AND RUNNING
AT FIRST START
When the engine is started for the first time, the maintenance points listed Coolant composition:
under ”First start” in the maintenance schedule should be followed, see
page 13. If there is a danger of freezing:
Since these points are important for the engine to work satisfactorily right at least 30% glycol by volume
from the start, they are also listed below.
Max. 60% glycol by volume
1. Checking oil level (see page 15).
If there is no danger of
8. Checking coolant (see page 20). freezing:
The coolant should contain anti-corrosive to protect the cooling system
from corrosion.
7-12% by volume
Scania Anti-corrosive
If there is a danger of freezing:
- Only glycol anti-freeze should be used in the coolant as protection The recommended glycols
against corrosion. We recommend only nitrite-free glycol anti-freeze
with the following supplier designations: may not be mixed with
glycol which has a nitrite-
BASF G48 or BASF D542 based anti-corrosive or with
- The concentration of glycol should be 30 - 60% by volume depending Scania Anti-corrosive
on ambient temperature. 30% by volume offers protection down to
-18 °C. See page 20.
- Never top up with water only or glycol only. Lost fluid should always
be replaced with pre-mixed coolant with the same glycol content as the
coolant in the engine. If the concentration of glycol drops, both anti- Scania Anti-corrosive must not
freeze and corrosion protection will suffer. be mixed with glycol.
Note A glycol concentration below 30% by volume will not provide suf- Mixing or over concentration
ficient protection against corrosion. A glycol concentration grea- can cause sludging
ter than 60% will not increase anti-freeze protection and reduces
engine cooling capacity.
If there is no danger of freezing:
Coolant should be topped up
- Only Scania Anti-corrosive should be used in the coolant to protect when the engine is stopped
against corrosion. The correct level of anti-corrosive is 7-12% by
volume and this must never drop below 7% by volume. The inhibitor in
after the first start
Scania Anti-corrosive is nitrate-free.
- First fill: Fill with Scania Anti-corrosive as indicated on the packaging.
- Never top up with water only or anti-corrosive only. Lost fluid should
always be replaced with pre-mixed coolant:
water + 10% Scania Anti-corrosive by volume.
- Only coolant filter without inhibitor may be used. The use of a coolant
filter increases the life of the coolant and reduces the risk of deposit cor-
rosion.

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

 14. Checking fuel level (see page 29).
17. Checking electrolyte level in batteries (see page 31).
18. Checking battery charge (see page 31).
20. Checking coolant level monitor (see page 32).
! WARNING

21. Checking temperature monitor (see page 33). Block the starter device
when working on the engine.
22. Checking oil pressure monitor (see page 34). If the engine starts out of
23. Checking stop feature (see page 34). control, there is a
24. Checking v-belt tension (see page 36). SERIOUS RISK OF
INJURY

CHECKS BEFORE RUNNING

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

STARTING THE ENGINE

If the fuel tank has been run dry or if the engine has not been used for a long
time, bleed the fuel system, see page 29.
Out of consideration to our common environment, your new Scania engine
has been designed to be started with less fuel. Unnecessarily large fuel supply
at start will always result in the release of uncombusted fuel.
- Engines with mechanical stop control: Set the stop control to operating
position.
- Open fuel valve (if fitted).
- Declutch the engine (does not apply to engines with a fixed clutch, e.g.
gensets).
- Engines with battery master switch: Switch on the power using the bat-
tery master switch.
- Set the speed control to raised idling. (Does not apply to gensets)
- Start the engine.

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

the stop solenoid is activated at start. The timer module can be
damaged resulting in the loss of the stop feature.

Starting at low temperatures

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

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

At temperatures below 0 °C:
Note Use only start aids recommended by Scania.
- The starter motor may only be used for 30 seconds, after which it must
rest for 2 minutes.
If the engine has flame start:
- Operating flame start without timer relay: Press the control button
which also acts as a pre-glow button (max. 20 s). The glow plug conti-
nues to glow as long as the button is held down after the engine is star-
ted. Max. time is 5 minutes.
- Operating flame start with timer relay: Press the pre-glow button (max.
20 s). Release the pre-glow button after the engine starts. The timer
relay keeps the glow plug working for 5 minutes. If a shorter on-time is
required, press the release button. The key must be set to 0 of the start
attempt fails.
Note If the engine is equipped with an INTERLOCK switch, this
should be held depressed until sufficient oil pressure has been
achieved. If the INTERLOCK switch is released too early, the
engine will stop.
- Gensets should be placed under load directly after start to avoid the risk
of white smoke. This applies especially to engines which are installed
without heating aids or addition of base load.
- Set the appropriate idle speed before the engine reaches 1,000 rpm (does
not apply to gensets).
- Run the engine until warm with a light load. A light load on a cold eng-
ine gives better combustion and faster heating than warming up with no
load.

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

RUNNING
Check instruments and warning lamps at regular intervals.

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

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

starting and stopping.
500 - 700 rpm yellow area: low idle.
700 - 2200 rpm green area: normal operating speed.
Highest torque and lowest
fuel consumption at
1400 - 1600 rpm.
Low operating speed gives less
engine wear.
2200 - 2600 rpm yellow/green
striped: unsuitable operating speed.
2600 - 3000 rpm red area: prohibited speed.

Coolant temperature
Correct coolant temperature during operation:
70 - 93 °C for system at atmospheric pressure.
70 - about 100 °C for system with positive pressure.
High coolant temperature leads to engine damage. Reduce the load on the
engine in order to lower the temperature. If the temperature does not drop,
stop the engine and look for the fault.
During long periods of operation with very low power take-off, the engine
may have difficulty in reaching 70 °C. However, if the load is increased, tem-
perature will rise.

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

Oil pressure
Max. oil pressure:
warm engine at speed above 800 rpm 6 bar
High lubrication oil pressure
Normal oil pressure:
(above 6 bar) is normal when
warm engine at operating speed 3 - 6 bar starting a cold engine.
Min. oil pressure:
warm engine at 800 rpm 0.7 bar
At speeds below 800 rpm, the gauge may show low oil pressure without there
being a fault.
Oil pressure below 0.7 bar at speeds above 800 rpm will cause engine
damage. The engine must be stopped immediately.
Charge test lamp
If the lamp lights during operation:
- Check/adjust the alternator drive belts as described under maintenance
point. See page 36.
- If the charge test lamp is still lit, there may be a fault in the alternator or
in the electrical system.

STOPPING THE ENGINE

1. Allow the engine to run without load for a few minutes if it has been run
with a high continuous load.
Danger of turbo damage or
2. Stop the engine using the stop control. Engines with a stop solenoid and boiling over if the engine is
fuel shut-off valve are stopped using the stop button. Hold the stop but- stopped without cooling off.
ton depressed until the engine has fully stopped.

3. Engines with battery master switch: Cut the power using the battery The power must not be cut
master switch. (Does not apply to emergency power back-up units).
until the engine has stopped.
4. Set the control switch to 0. (Does not apply to emergency power back-
up units).

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

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

Clutch
- See the manufacturer’s instructions for handling and operating the
clutch.
! WARNING
Always secure the clutch in
WARNING If the clutch output shaft is rotating (e.g. in multiple eng-
ine installations where other engines are running) the clutch can, disengaged position if there is
under its own power, be drawn to engaged position. a risk of the output shaft
THIS CAN CAUSE INJURY and engine damage. Always secure starting to rotate.
the clutch in disengaged position if there is a risk of the output If the engine is started
shaft starting to rotate. during e.g. service work,
there is a
SERIOUS RISK OF
INJURY

CHECKS AFTER RUNNING

- Check that the power is cut from the battery master switch and that the
control switch is set to ”0”.
- Fill the fuel tank. Make sure that the cap and the area around the filler
opening are clean to avoid contamination of the fuel.
- If there is a risk of freezing, the cooling system must be drained if it
does not contain sufficient anti-freeze, see page 20
- Close intake valve for seawater (if fitted).
- If there is a danger of freezing, the seawater must also be drained.
- At temperatures below 0 °C: Prepare for the next start by connecting the
engine heater (if fitted).

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

MAINTENANCE
The maintenance programme covers 27 points, divided into the following
main groups:
Lubrication oil system . . . . . . . . . . . . . . . . . page 14
Cooling system . . . . . . . . . . . . . . . . . . . . . . . page 18
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . page 26
Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . page 29
Electrical system, monitors, batteries etc. . . page 31
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . page 36

The maintenance points are divided into intervals as follows:

Daily maintenance
Maintenance before first start
Maintenance after the first 400 hours of operation
Periodic maintenance every 200 hours of operation (carried out after 200,
400, 600, 800 etc. hours)
Periodic maintenance after every 400 hours of operation (carried out after
400, 800, 1200, 1600 etc. hours)
Periodic maintenance after every 1,200 hours of operation (carried out after
1,200, 2,400, 3,600 etc. hours)
Periodic maintenance after every 2,400 hours of operation (carried out after
2,400, 4,800 etc. hours)
Periodic maintenance after every 4,800 hours of operation (carried out after
4,800, 9,600 etc. hours)
Maintenance every year
Maintenance every 5th year

ENGINES WITH FEW HOURS

OF OPERATION
Emergency back-up power units and the like which are not used regularly
should be test run and checked according to the unit manufacturer’s instruc-
tions.
The engine is run to operating temperature and the maintenance points below
should be carried out:
1. Checking oil level. For engines with few
5. Checking coolant level. operating hours which do not
10. Checking low pressure indicator. receive periodic maintenance
according to the maintenance
14. Checking fuel level.
schedule on page 13 ,
17. Checking electrolyte level in batteries. maintenance should be
18. Checking battery charge. carried out according to the
19. Cleaning batteries. schedules for:
25. Look for leaks. Remedy as necessary “Every year”
“Every 5th year”

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

MAINTENANCE SCHEDULE
First Interval At least
time at

Every 5th year

At first start

Every year
1200 h

2400 h

4800 h
400 h

200 h

400 h
Daily
LUBRICATION OIL SYSTEM, page 14
1. Checking oil level l l
2. Oil change l1 l
3. Cleaning the lubrication oil cleaner l1 l
4. Changing the turbo filter l1 l
COOLING SYSTEM, page 18
5. Checking coolant level l
6. Checking corrosion protection rods 4) l5 l
7. Checking seawater pump impeller 4) l5 l
8. Checking coolant l l6 l6
9. Cleaning cooling system l1 l
AIR CLEANER, page 26
10. Test reading low pressure indicator l
11. Cleaning coarse cleaner l1 l
12. Cleaning or changing filter insert l3 l
13. Changing safety cartridge l l
FUEL SYSTEM, page 29
14. Checking fuel level l l
15. Changing main filter l1 l
16. Checking injectors l l
ELECTRICAL SYSTEM, page 31
17. Checking electrolyte level in batteries l l2 l
18. Checking charge state of batteries l l2 l
19. Cleaning batteries l2 l
20. Checking level monitor l l l
21. Checking temperature monitor l l l
22. Checking oil pressure monitor l l l
23. Checking stop function l l l
MISCELLANEOUS, page 36
24. Checking V-belts l l l
25. Look for leaks. Remedy as necessary l
26. Checking/adjusting valve clearance. l l
27. Changing (or cleaning) valve for closed crankcase l
ventilation

1. More often if required

2. For engines with few operating hours, see page 12.
3. Earlier if low pressure indicator shows red.
4. Applies only to M engines with seawater pump.
5. Guidline values. Vary according to composition of seawater.
6. If inhibitor has not been topped up for five years, coolant should be changed.

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

LUBRICATION OIL SYSTEM
OIL GRADE
The engine oil should at least meet the requirements for one of the following
oil classifications:
-Service CE or CF as per API
-CCMC - D5
-Acea E3-96 Additives must not be used.
- Check with your oil supplier if the oil meets these requirements.
- Specified oil change intervals apply under the provision that the sulphur
content of the fuel does not exceed 0.3% by weight.
The oil should be able to cope
- Viscosities as illustrated. with all temperature
- At very low outside temperatures: Consult your nearest Scania represen- variations up until the next
tative to avoid difficulties. oil change.
Oil analysis
Some oil companies can offer analysis of the engine oil. This analysis measu-
res the oil’s total base number (TBN), total acid number (TAN), fuel dilution,
water content, viscosity and the content of wear particles and soot in the oil.
The result of a series of analyses forms the basis of establishing a suitable oil
change interval.
If the conditions are changed, a new oil analysis program must be undertaken
to establish a new change interval.

-40 -30 -20 -10 0 10 20 30 40 °C

SAE 20W-30

SAE 30

SAE 40

SAE 50

SAE 5W-30

SAE 10W-30

SAE 15W-40

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

 1. Daily:
CHECKING OIL LEVEL
Before checking oil level: Let the engine remain stationary 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”, page 14.

Checking oil level during operation

On some engines, 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
Min. or Max. mark.

10 mm
10 mm
2. Every 400 hours:
OIL CHANGE
If the engine is used for particularly demanding operation,
especially in a dusty environment or if the deposits in the
centrifugal cleaner are thicker than 20 mm: Change the oil
more often.
- Pump out the oil using the oil bilge pump when the engine is warm.
- Fill with new oil.
- Check the level on the dipstick.

! WARNING
The oil may be hot.
Wear protective gloves
and eye protection
1 dm3 = 1 litre

Maximum angle of inclination during operation

Maximum permitted angles during operation vary depending
on the type of oil sump, see drawing.
Note Given angles may only be used intermittently.

20° 30°

35° 15° (Alt 20°)

30° 30°

1997-11:2 © Scania Industrial & Marine Engines 15

 3. Every 400 hours:
CLEANING THE OIL CLEANER
(at same time as oil change)

- Unscrew the nut and remove the cover.

! WARNING
Open the bowl with care.
The oil may be hot.

- Lift out the rotor and slacken the nut for the rotor cover three turns.

- If the nut is stuck:

Secure the nut, absolutely not the rotor, in a vice and turn the rotor three
turns by hand or using a screwdriver.

- Gently tap the nut using your hand or a plastic hammer so that the rotor
bowl becomes detached from the bottom plate.

- Undo the nut and remove the rotor bowl.

- Carefully prise the strainer loose from the bottom plate.

- Scrape away deposits from the inside of the rotor bowl. If there are no
deposits, this shows that the cleaner is not working.
- If the deposits are thicker than 20 mm: Clean more often.

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

 - Wash all parts in diesel fuel oil.

- Place the O-ring in position in the rotor bowl. This must not be
damaged.
Change if necessary.

- Assemble the rotor

- Tighten the rotor nut hard by hand

- Refit the rotor.

- Check that it turns easily.

- Check that the O-ring in the bowl is not damaged.

A hardened or damaged O-ring should be replaced.
- Screw down the bowl hard by hand
If the nut is tightened using a tool, the rotor shaft, nut or bowl may be
damaged.

Operational test
The rotor turns very quickly and should continue to rotate when the engine
has stopped.
- Stop the engine when it is warm.
- Listen for the whirring from the rotor or feel whether the cleaner hous-
ing is vibrating.
The rotor normally rotates 30 - 60 seconds after the engine has stopped.
If not: Dismantle and check.

1997-11:2 © Scania Industrial & Marine Engines 17

 4. Every 400 hours:
CHANGING THE TURBO FILTER
(at the same time as the oil change)
- Remove the old filter and discard it according to environmental require-
ments.
- Oil the rubber gasket a fit a new Scania genuine filter.
- Tighten the filter by hand.
Never use tools as the filter may sustain damage, interfering with cir-
culation.
- Start the engine and check for leaks.
If the deposits in the centrifugal cleaner exceed 20 mm, the turbo filter
must be changed more often, at the same time as cleaning the centrifugal
filter and changing the oil.

COOLING SYSTEM
5. Daily:
CHECKING COOLANT LEVEL
- Open the expansion tank cap and check coolant level.
- Correct level: (integrated expansion tank in heat exchanger)
! WARNING
- Cold engine: Coolant level should be between 10 - 20 mm below Open the cover carefully.
the expansion tank’s inner upper part. water and steam can
spray out.
- Warm engine: Coolant level reach the expansion tank’s
inner upper part.
- Other types of expansion tank according to the installer’s instructions. Always top up using pre-
- Top up coolant as necessary, see point 6. mixed coolant.
Note When filling large amounts of coolant:
Never pour cold coolant into a warm engine.
This could crack the cylinder block and head.

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

 6. Every 400 hours:
CHECKING CORROSION PROTECTION
RODS
(Only engines with heat exchanger)
- Drain the seawater circuit and check the corrosion protection rods
(sacrificial anodes). Location as per drawing on page 5.
- Scrape away all loose material from the anode.
- Change if less than half the rod remains.
New rods are 55 mm long, diameter 17 mm.
If the corrosion protection rods are highly eroded, they should be checked
more often, e.g. every 200 hours.

7. Every 400 hours:

CHECKING SEAWATER PUMP
IMPELLER
(Only engines with heat exchanger)
- Close the bottom valve if the seawater pump is below the water line.
- Drain the seawater circuit.
- Remove the cover from the seawater pump.
- Check that the impeller vanes are not worn or damaged.
If the impeller often requires changing, it is necessary to improve
the purity of the seawater.

Changing the impeller

- Extract the impeller using extractor 98 482 (Scania special tool).
- Fit new impeller and the cover. Check that the cover seal is not hard or
damaged.
Note A spare impeller should be carried onboard.
- The impeller can become deformed after long periods of standstill.
Change before starting or remove the impeller before long periods of
disuse. Also see “Mothballing”.

1997-11:2 © Scania Industrial & Marine Engines 19

 8. Every 2,400 hours:
CHECKING COOLANT
Coolant should be checked as follows:
a) Check the appearance of the coolant.
b) Coolant with glycol: Check the glycol content.
c) Coolant with Scania Anti-corrosive:
Check the protection against corrosion. Coolant composition:
If there is a danger of freezing:
The composition of the coolant is also described under at least 30% glycol by volume,
“Starting and running”
max. 60% glycol by volume
a) If there is no danger of
Checking the appearance of the coolant freezing:
- Take a little coolant in a vessel and check that it is clean and clear. 7-12% by volume
- If the coolant is contaminated or cloudy: Consider changing the coolant Scania Anti-corrosive
- The water for the coolant should be free of dirt.
- Use drinking water with a pH of 6 - 9.

b)
Checking glycol content ! WARNING
If there is a danger of freezing, use only glycol as protection against corrosion Ethylene glycol is
in the coolant. toxic if ingested.
- Cooling systems with glycol must contain at least 30% glycol by
volume to offer sufficient protection against corrosion. Avoid contact with the skin.
- 30% glycol by volume provides anti-freeze protection down to -18 °C.
If more protection is required, see the table on the next page for calcula-
ting the necessary amount of glycol.
We recommend only nitrite-free glycol anti-freeze with the following supp- The coolant should be mixed
lier designations: before it is poured into the
cooling system.
BASF G48 or BASF D542
- Always top up the anti-freeze if the content drops below 30% by Never top up with only water
volume. A glycol content above 60% by volume will not improve the or only glycol.
protection against corrosion.
- The table shows the temperature at which ice (slush) starts to form. The
engine freezes and breaks at significantly lower temperatures, see graph. The recommended glycols
- Ice forming in the coolant often causes malfunction without any risk of must not be mixed with glycol
damage. The engine must not be loaded hard when ice is forming. which has nitrite-based anti-
Note The coolant should be changed when the cooling system is clea- corrosive.
ned: Every 4,800 hours or at least every 5th year. This could cause sludging and
Important If a coolant filter is used in the cooling system, it must not con- reduced cooling capacity.
tain an inhibitor.

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

 % Glycol by volume

Cold characteristics of glycol:

- Example with 30% glycol by volume
- Ice slush starts to form at -18 °C.
- At -30 °C there is a risk of malfunction
- The engine cannot be damaged if there is at
least 30% glycol by volume

Line A: Ice starts to form (slush)

Line B: Temperature at which engine freezes
and breaks
1. Safe range
2. Malfunction can arise (ice slush)
3. Coolant frozen
A
% Glycol Cooling
15 20 25 30 35 40 45 50
by volume system
Ice slush starts capacity,
-7 -10 -14 -18 -24 -30 -38 -40 dm3
to form at °C
5 6 8 9 11 12 14 15 30
6 8 10 12 14 16 18 20 40
8 10 13 15 18 20 23 25 50
9 12 15 18 21 24 27 30 60
11 14 18 21 25 28 32 35 70
12 16 20 24 28 32 36 40 80
14 18 23 27 32 36 41 45 90
15 20 25 30 35 40 45 50 100
Glycol dm3
(litres) 17 22 28 33 39 44 50 55 110
18 24 30 36 42 48 54 60 120
20 26 33 39 46 52 59 65 130
21 28 35 42 49 56 63 70 140
23 30 38 45 53 60 68 75 150
24 32 40 48 56 64 72 80 160
26 34 43 51 60 68 77 85 170
27 36 45 54 63 72 81 90 180
29 38 48 57 67 76 86 95 190
30 40 50 60 70 80 90 100 200
A= Range to be avoided. Only for calculation of glycol mix.
Freezing point of coolant when ice slush starts to form at different glycol mixes

1997-11:2 © Scania Industrial & Marine Engines 21

c)
Checking Protection against corrosion
There must always be sufficient anti-corrosive (inhibitor) in the coolant to
protect the cooling system against corrosion.
If there is no danger of freezing use only Scania Anti-corrosive.
The inhibitor in Scania Anti-corrosive is nitrite-free. Scania Anti-corrosive must not
The correct level of anti-corrosive is 7-12% by volume. be mixed with glycol.
- Fill with Scania Anti-corrosive as indicated on the packaging. Mixing or over concentration
can cause sludging and
- Topping up with 1.0% by volume of Scania Anti-corrosive should be
done after every 2,400 operating hours. reduced cooling capacity.
- Never top up with water only or anti-corrosive only. Lost fluid should
always be replaced with pre-mixed coolant:
water + 10% Scania Anti-corrosive by volume.
Any coolant filter must not
Note The coolant should be changed when the cooling system is clea-
ned: every 4,800 hours or at least every 5th year.
contain inhibitor.

Changing 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 drawing
- the ”lowest point” of the cooling system.
3. Close the valves.
4. Fill coolant through the expansion tank filler hole.
Mix coolant as described on page 20.

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

 9. Every 4,800 hours:
CLEANING COOLING SYSTEM
Note If necessary, the cooling system should be cleaned more often.
External cleaning
The cooling system must not
Heat exchanger be cleaned using caustic soda.
1. Drain the coolant from the engine, see “Changing coolant”. Risk of damaging
2. Drain the seawater circuit. aluminium parts.
3. Detach the heat exchanger hose and pipe connections.
4. Dismantle the heat exchanger as illustrated.
5. Clean the outside of the element. Use a paraffin-based engine cleaner. Note
There is a spring and a
6. Any deposit on the inside of the pipes is removed mechanically using a
round file. retainer in the heat exchanger,
between the housing and the
7. Assemble the heat exchanger. Change damaged and hardened O-rings. element, which are not
8. Refit hose and pipe connections. illustrated.
9. Fill the system with coolant as described in the specifications on
page 20.

1. Heat exchanger 17. O-ring

housing 18. Screw
5. Cover 19. Washer
6. Gasket 20. O-ring
7. Screw 21. Protective anode
8. Cooling element (4 pcs)
9. O-ring 22. Plug
10. Gasket 23. Gasket
11. O-ring 24. Pressure cap
(DS only) 28. Cover (DS only)
12. Cover 29. Gasket
13. Gasket (DS only)
14. Screw 30. Screw (DS only)
15. Washer
16. Cover

1997-11:2 © Scania Industrial & Marine Engines 23

Charge air cooler (DSI engine)
1. Drain the coolant from the engine, see “Changing coolant”.
2. Detach the upper part of the intake manifold.
3. Detach the charge air cooler hose and pipe connections. The cooling system must not
4. Dismantle the charge air cooler as illustrated. be cleaned using caustic soda.
Take care not to damage the element’s water connections.
Risk of damaging aluminium
5. Clean the outside of the element. Use a paraffin-based engine cleaner. parts.
6. Assemble the charge air cooler. Change all seals and gaskets.
7. Refit hose and pipe connections.
8. Fill coolant as described on page 20.
9. Connect the intake manifold from the turbo.

1. Intake manifold, lower

part
2. Gasket
3. Radiator element
4. Gasket
5. Intake manifold, upper
part
6. V-ring seal

Engines without heat exchanger (keel-cooling)

1. Check cooling elements/cooling pipes on the inside and outside of the
keel.
2. Clean as necessary using a paraffin-based engine cleaner or carefully
scrape off deposits from external pipes.
Take care - do not damage cooling elements or cooling pipes.

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

Internal cleaning
Removing oils and greases
- If possible, run the engine until it is warm and then drain the cooling
system.
- Remove the thermostat(s).
- Fill the system with clean, hot water mixed with liquid dishwasher
detergent designed for household machines.
Mix 1% (0.1/10 l). ! WARNING
- Run the engine until warm (about 20 or 30 minutes). Do not forget any When handling cleaners for
cab heating system. the cooling system:
- Drain the cooling system. Study the warning on the
- Fill the system again using clean, hot water and run the engine for about packaging.
20-30 minutes.
- Drain the water from the system.
- Refit the thermostat(s).
- Fill the system with coolant as described in the specifications on
page 20.

Removing deposits
- If possible, run the engine until it is warm and then drain the cooling
system.
- Remove the thermostat(s).
- Fill the system with clean, hot water mixed with one of the commerci-
ally available radiator cleaners based on sulphamin acid and containing
dispersing agents. Follow the manufacturer’s instructions for mix ratios
and cleaning times.
- Run the engine for the for the specified time and then drain the cooling
system.
- Fill the system again with hot water and run the engine for about 20 or
30 minutes.
- Drain the water from the system.
- Refit the thermostat(s).
- Fill the system with coolant as described in the specifications on
page 20.

1997-11:2 © Scania Industrial & Marine Engines 25

AIR CLEANER
10. Daily:
TEST READING
LOW PRESSURE INDICATOR
If the indicator’s red plunger is fully visible, change or clean the air cleaner
filter insert, point 12.

11. Every 200 hours:

The coarse cleaner should
CLEANING THE AIR CLEANER be fitted with the marking
COARSE CLEANER “TOP” facing up.

1. Detach the eccentric catch and remove the coarse cleaner.

2. Remove the plastic cover from the coarse cleaner and clean the parts.
3. Check that the plastic cover is intact and that it makes a seal against the
air cleaner housing during assembly.
4. Assemble the air cleaner

12. Every 1,200 hours:

CLEANING OR CHANGING 1. Pre-filter with cover
FILTER INSERT 2. Filter insert
3. Low pressure indicator
Note Earlier if low pressure indicator shows red 4. Safety cartridge
Dismantling
1. Remove and clean the coarse cleaner, see point 11.
Use only Scania genuine
2. Undo the nut securing the filter insert and remove it. air filter.
3. Change or clean the insert.
Note Cleaning the insert always means a risk of damage. The insert
may only be cleaned no more than four times. After cleaning, it Change damaged filter
has a lower dust capacity than a new insert.
inserts.
4. Mark the filter when it has been cleaned.
Major risk of engine
Cleaning insert damage if the filter insert is
- Carefully blow the filter insert clean using dry compressed air from the damaged.
inside.
Note This insert must not be washed using water.

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

Checking
- Insert a flashlamp into the insert and check from the outside that there
are no holes or cracks in the filter paper.
- Change the filter insert if there is any damage at all. Danger of engine
damage.
Assembly
1. Assemble the air cleaner in reverse order.
2. Reset the red plunger in the low pressure indicator by pressing in the
button

Filters with non-replaceable insert (unit cleaner)

Cleaning
- The filter must be cleaned no more than 3 times. Make a mark on it each
time it is cleaned.

- Use a solution of water and 1% mild detergent

1. Pour the washing solution into the filter intake while turning the filter so
that the solution runs out of it in the direction of air flow.
2. Leave the filter in the washing solution for 5 minutes and then lift it to
drain off the solution
3. Rinse the filter with about 30 litres of clean water at 30 - 40 °C. Pour the
rinse water into the filter in the same way as the washing solution.
4. Lift the filter and allow the rinse water to drain.
5. Repeat this procedure until the rinse water runs clear.
6. Leave the filter to dry in a warm place for several days.

Note The filter must not be blown dry using compressed air.

1997-11:2 © Scania Industrial & Marine Engines 27

13. Every 2,400 hours:
Do not remove the safety
CHANGING SAFETY CARTRIDGE cartridge unnecessarily.
1. Remove and clean the coarse cleaner, see point 11.
2. Undo the nut securing the filter insert and remove it.
3. Change or clean the filter insert, see point 12.
4. Undo the nut securing the safety cartridge and remove it.
5. Fit a new Scania genuine safety cartridge.
6. Assemble the air cleaner.

1. Pre-filter
with cover
2. Filter insert
3. Low pressure indicator
4. Safety cartridge

Never clean the safety

cartridge.

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

FUEL SYSTEM Be extremely careful with
cleanliness when working on
14. Daily: the fuel system.
CHECKING FUEL LEVEL Malfunctions
can easily arise and the
- Top up fuel if necessary.
injection equipment
- If the tank is run dry, bleed the fuel system, see point 15. can be damaged.

15. Every 1,200 hours:

CHANGING THE FUEL FILTER
Fuel tanks
- Drain any water from the fuel tanks.
Main filter
The filter consists of two parallel coupled filter units.
- Wash the outside of the filters and unscrew them. Dispose of the filters
according to environmental regulations.
- Do up the new filter by hand.

Never use tools. The filters may be damaged, inhibiting circulation.

- Bleed the fuel system as below.

- Start the engine and check for leaks.
Bleeding the fuel system
- Open the bleed screw 1 on the main filter.
- Pump the hand pump 2 until air-free fuel flows out at the maim bleed Use only Scania genuine
screw.
fuel filter
- Close the bleed screw. Pump a few times using the hand pump.
If the engine is difficult to start after bleeding . . . . .
- Slacken the injection pump overflow valve 3 one half turn
and try starting again. On the 8000 pump, the overflow valve is located
on the fuel shut-off valve.
If the engine still won’t start . . . . . . .
- Pump the hand pump until bubble-free fuel flows from the overflow
valve.
Tighten the overflow valve when the engine has started.

1 2 3

1997-11:2 © Scania Industrial & Marine Engines 29

16. Every 2,400 hours:
CHECKING INJECTORS
Injectors should be inspected by trained personnel with access to the required 1. Socket nut
equipment, at least once every year or every 2,400 hours.
2. O-ring
Removal 3. O-ring
1. Clean around the injectors and connections including the clamps and 4. Stop ring
brackets. 5. Guide pin
2. Detach the delivery pipe bundle and the leak-off fuel lines. 6. Seal
3. Unscrew the injector.
4. Place protective plugs on the injector and delivery pipe.
5. Lift the seal from the bottom of the injector seat if it does not come out
together with the injector.
6. Place a seal plug in the injector seat in the cylinder head.
7. Clean the injectors and check/adjust in an injector tester. The delivery pipes must not
Correct opening pressure, see Technical data, page 43. be bent.
Fitting All clamps must be refitted.
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 it.
3. Fit the injector.
4. Tighten the socket nut to 70 Nm (7.0 kpm).
5. Fit the delivery pipe and tighten the cap nuts to 20 Nm
(2.0 kpm). Fit clamps and brackets.
Take care to fit the delivery pipe without tension and make sure that
the cone on the delivery pipe is correctly positioned in the connector.
6. Fit the leak-off fuel line. Tighten the bolts to 11 Nm (1.1 kpm).

1. Delivery pipes
2. Cap nut
3. Washer
4. Cone
5. Connector on injector or
injection pump

Delivery pipe connection

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

ELECTRICAL SYSTEM
17. Every 200 hours:
CHECKING ELECTROLYTE LEVEL
IN BATTERIES
1. Undo the plugs and check the electrolyte level in all cells.
2. Top up using distilled water until the level is 10-15 mm above the plates.

18. Every 200 hours:

CHECKING CHARGE STATE
IN THE BATTERIES
Note Every 200 hours applies to gensets and the like. Other installa-
tions every 1,200 hours.
- Check specific gravity using a battery electrolyte tester.
In a fully charged battery it should be:
1,280 at +20°C
1,294 at 0°
1,308 at -20°C
- If the specific gravity is below 1.20, the battery must be charged.
A discharged battery freezes at -5 °C.
Avoid boost charging. This will damage the battery in the long term.

19. Every 200 hours:

CLEANING BATTERIES
Note Every 200 hours applies to gensets and the like.Other installa-
tions every 1,200 hours.
1. Clean batteries, cables and cable terminals.
2. Check that all cable terminals are well tightened.
3. Grease posts and cable terminals using petroleum jelly.

1997-11:2 © Scania Industrial & Marine Engines 31

20. Every 1,200 hours:
CHECKING COOLANT
LEVEL MONITOR
(optional equipment)
1. Start the engine.
2. Check the level monitor by turning the ”TEST” knob to the right.
3. Automatic stop in case of fault: Engine stops, warning lamp lights and
buzzer sounds if there is no fault in the level monitor.
4. No automatic stop in case of fault: Warning lamp lights, buzzer sounds
if there is no fault in the level monitor.
C = Common connection
NC =Connection NC - C breaks at
low coolant level
NO =Connection NC - C closes at
low coolant level
2-pole level monitor

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

21. Every 1,200 hours:
CHECKING TEMPERATURE MONITOR
1. Drain sufficient coolant for 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. C = Common connection
5. Dip the monitor sensor in water. Slowly heat the water (about 1° per 1 = Connection C -1 closes at
minute) using e.g. an immersion heater. stamped temperature
6. Set the control switch to ”ON”. Use a thermometer to check that the 2 = Connection C -2 opens at
warning lamp lights when the alarm is given at the correct temperature. stamped temperature
Correct temperature is stamped on the monitor’s hexagon. 2-pole temperature monitor
Tolerance is ± 3° for the monitor.

CHECKING TEMPERATURE SENSOR

1. Drain sufficient coolant for 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. Dip the sensor body into water. Slowly heat the water (about 1° per min-
ute) using e.g. an immersion heater.
6. Check the resistance at the temperatures given below.
7. The sensor should give the following readings:

At
Resis- Tolerance
temp.
tance Ω °C
°C
2-pole temperature sensor
60 134 ± 13,5 ±4

90 51,2 ± 4,3 ±3

100 38,5 ± 3 ±3

1997-11:2 © Scania Industrial & Marine Engines 33

22. Every 1,200 hours:
CHECKING THE OIL PRESSURE
MONITOR
Alternative 1
Connect an ohmmeter to the oil pressure monitor and check that the monitor
opens/closes at the correct pressure when the engine is started and stopped.
Alternative 2
Monitor coupled for automatic stop in case of fault:
1. Start the engine.
2. Check on the oil pressure gauge that oil pressure rises.
3. Stop the engine manually (using the emergency stop). 2-pole oil pressure monitor
4. Check on the oil pressure gauge at what pressure the stop solenoid ope-
rates and the monitor opens. Correct pressure: 0.7 ± 0.15 bar.
Monitor coupled to buzzer:
1. Main switch in operate position, check that buzzer sounds.
2. With the engine running, check that the buzzer stops sounding when oil
pressure is above 1.1 ± 0.15 bar and the monitor closes.

CHECKING OIL PRESSURE SENSOR

- Connect an ohmmeter to the oil pressure sensor and check the resis-
tance.
- The sensor should give the following readings:
0 bar - 10 ± 3 Ω
2 bar - 56 ± 6 Ω
4 bar - 88 ± 6 Ω
6 bar - 124 ± 6 Ω
2-pole oil pressure sensor
7 bar - 140 ± 6 Ω

23. Every 400 hours:

CHECKING THE STOP FEATURE
Check that the stop solenoid is activated and stops the engine when the stop
signal is given by the button, temperature monitor, coolant level monitor and
oil pressure monitor if these are coupled for automatic stop in the case of
fault.

Important Stop solenoids with a timer module may be activated for start
and stop a maximum of 3 times per minute. Otherwise, the
timer module may be damaged and the stop feature cease.

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

CHECKING STOP SOLENOID STOP POSITION
When changing the stop solenoid, or if the stop feature is not satisfactory, the
following should be done (the figures show the stop control with the engine
in stop position):
The stop position at “Pull to stop”.
- Check and/or set the length of the link rod so that the distance between
the locknuts (nut height 5.2 mm) is 21.0 ± 0.1 mm when the nuts are
tightened.
- Fit the stop solenoid in the bracket as in the figure.
- Connect the stop solenoid electrically, red to battery + and black to
battery -, and activate it so that it is fully pulled. Note: Pole reversal
will damage the timer module.
- Screw the clevis onto the stop lever using the link pin and check, in stop
position, that there is a small clearance (0.2-0.3 mm) between the stop
lever and the operating point on the governor
- Check the stop feature by starting the engine and then stopping it by
activating the stop solenoid.

Important The stop solenoid must not be activated more than 3 times per
minute as the timer module can be damaged.
Installation “Pull to stop”

Stop position at “Drawn during operation”.

- Check and/or set the length of the link rod so that the distance between
the locknuts (nut height 5.2 mm) is 26.0 ±0.1 mm when the nuts are
tightened.
- Fit the stop solenoid in the bracket as in the figure.
- Connect the stop solenoid electrically, red to battery + and black to
battery -, and activate it so that it is fully pulled. Note: Pole reversal
will damage the timer module.
- Turn the stop lever to operating position and screw the clevis onto the
stop lever using the link pin and check, in operating position, that there
is a small clearance (0.2-0.3 mm) between the stop lever and the opera-
ting point on the governor
- Activete the stop solenoid and start the engine. Stop the engine by cut-
ting the power to the stop solenoid.

Important The stop solenoid must not be activated more than 3 times per Installation “Pulled during
minute as the timer module can be damaged. operation”

1997-11:2 © Scania Industrial & Marine Engines 35

CHANGING BATTERY
Removal
1. Detach the negative lead (-) from the battery (cable to engine casing).
2. Detach the positive lead (+) from the battery (cable to starter motor).
Fitting
1. Connect the positive lead (+) to the battery (cable to starter motor).
2. Connect the negative lead (-) to the battery (cable to engine casing).

MISCELLANEOUS
24. Every 200 hours:
CHECK/TENSION V-BELTS
Correctly tensioned drive belts should be possible to depress
about 10 mm with a force of 35-50 N (depending on the free
length of the belt) when pressing on one belt.
Change worn or damaged belts.
1. Detach the securing screws.
2. Set the correct tension using the adjusting screw.
Do not over-tighten the belts.

Measurement using belt tension gauge Krikit

(Part. No. 587 495)
1. Zero the gauge by pressing the measuring arm.
2. Place the gauge on the V-belt at an equal distance from two pulleys.
3. Press until the gauge clicks.
4. Read the gauge.
- Recommended tension in Scania genuine belts
at test is 300 N.
- When changing belts, slightly higher (10-15%) tension should be used.

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

25. Daily:
LOOK FOR LEAKAGE,
REMEDY AS NECESSARY
- Start the engine.
- Look for leakage of oil, coolant, fuel, air and exhaust.
- Tighten or change leaking connections. Check the overflow holes (1)
which show whether the O-rings between the cylinder liner and crank-
case are leaking, see drawing.
a) If coolant is leaking out, the two upper O-rings are leaking.
b) If oil is leaking out, the lower O-ring is leaking.
- Check that the drain hole (2) on the coolant pump is not blocked, see
drawing. If there is a leakage, change the pump seal.

A small amount of leakage from the overflow holes when running in the
engine is normal. (Seals and O-rings are fitted lubricated with soap or
oil).
This leakage normally stops after a time.
If there is a large amount of leakage - contact your nearest Scania
workshop.

1 1 1 1 1 1

1997-11:2 © Scania Industrial & Marine Engines 37

26. Every 2,400 hours:
! WARNING
CHECK/ ADJUST
VALVE CLEARANCE Block the starter device
when working on the engine.
Checking/adjusting valve clearance can also be done after the first
400 hours of operation. If the engine starts, there is a
SERIOUS RISK OF
Valves should be adjusted when the engine is cold, at least 30 minutes after INJURY
operation.
Rocker cover gaskets should be changed as necessary. Tightening torque:
25 Nm.
Alternative 1
- Set No. 1 cylinder to TDC by turning the engine in its direction of rota- 1
tion until both valves are closed.
- Adjust the following valves. Correct valve clearance is indicated on the 2
instruction plate on one of the rocker covers:
Cylinder 1 Intake and exhaust
2 In
3
3 Ex
4 In 4
5 Ex
- Set No. 6 cylinder to TDC by turning the engine one revolution in its 5
direction of rotation.
- Adjust the following valves: 6
Cylinder 2 Ex
3 In FLYWHEEL
4 Ex Cylinder numbering
5 In
6 In and ex
TDC TDC
No. 6 cyl No. 1 cyl

Note:
On silumin casings readings can be
taken either from the top or from
underneath, depending on which
flywheel is used.
The cover not being used is covered
with a seal and an instruction plate.
On cast iron casings readings can
be taken from either the top or
from the side (60o) according to the
accessibility.
FLYWHEEL

Intake valve
Covers for reading
on flywheel casing Exhaust valve

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

Alternative 2
- Set the No. 1 cylinder to TDC by turning the engine in its direction of
rotation until both valves are closed.
- Adjust both the valves for the No.1 cylinder. Correct valve clearance is
indicated on the instruction plate on one of the rocker covers.
- Repeat this procedure with the remaining cylinders in the order
5 - 3 - 6 - 2 - 4 (firing sequence) by turning the engine 1/3 revolution in
its direction of rotation between each adjustment.

27. Every 2,400 hours:

CHANGING (or CLEANING) VALVE FOR
CLOSED CRANKCASE
VENTILATION
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 fuel oil overnight. Then
rinse it several times in diesel and let it drip off.
- Refit the valve.
- The valve may be reused (cleaned) a maximum of two times
after the first 2,400 hours of use. Take care to mark the valve
after cleaning it.

1997-11:2 © Scania Industrial & Marine Engines 39

LONG-TERM STORAGE
If the engine is not to be used for a long period of time, special measures
should be taken to protect against corrosion in the cooling system, fuel sys-
tem and combustion chamber and to protect against external corrosion.
The engine can normally stand idle for up to six months. If disuse is longer,
the following measures should be taken, providing protection for about four
years.
Preparing the the engine for long-term storage means:

- Thoroughly cleaning the engine

- Running the engine for a certain time with special preservative fuel, oil
and 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 50% glycol by
volume. If the engine is to be stored with an empty cooling system, use glycol
wihtout nitrite-based inhibitor, such as BASF G48 or BASF D542.

Note Only glycol, no water.

Nitrite-based inhibitors in an empty cooling system give rise to
ammonia vapour which can damage brass components such as
monitors and sensors.

Preservative fuel
- Use diesel fuel oil mixed with Lubrizol 560A or equivalent.
- Mix 1 cm3 (ml) Lubrizol 560A in 10 dm3 (l) fuel.

! HANDLING LUBRIZOL 560A

Hazardous!
Contains aromatic hydrocarbons
Use extractors where there is a risk of vapour build-up.
Wear eye protection and protective gloves when handling. Do not use contaminated clothing.

In case of contact with eyes: Rinse with a gentle stream of water (at least 15 minutes). Seek medical
attention.
In case of contact with skin: Wash with soap and water
In case of inhalation: Fresh air, rest and keep warm
Flammable: Fire class 2A. Flash point + 27°.
In case of fire: Extinguish using carbon dioxide, powder or foam
Storage: In well sealed vessel in dry, cool place. Keep out of reach of children.

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

Preservative oil
Suitable preservative oil can be supplied by most oil companies.
E.g. Dinitrol 40 or equivalent.

Preparations for storage

- Drain and flush the cooling system. Fill with preservative coolant.
- Run the engine until warm with ordinary fuel. Stop the engine and drain
the oil.
- Change fuel filter and turbo filter.
- Fill the engine with preservative oil to the minimum level on the dip-
stick.
- Mix the 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 (does not apply to single-
speed engines) for 20 - 25 minutes.
- Stop the engine, remove the hoses and connect the normal fuel lines.
- Oil the valve mechanism with plenty of preservative oil.
- Remove the injectors and spray preservative oil into each cylinder
max. 30 cm3 (ml).
Crank the engine several revolutions using the starter motor. Spray a
little more into each cylinder.
The engine must not then be cranked. Refit the injectors.

- Drain the preservative oil from the engine. New engine oil can be filled
directly or when taking out of storage.

- Drain the coolant if the engine is not to be stored with a full cooling sys-
tem. Plug and tape over all coolant connections (if the cooling system is
not completely assembled).
- Air cleaner: Clean and change the filter insert.

- Cover air intakes and exhaust pipes.

- Alternator and starter motor:
- Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or equiva-
lent.
- Spray the outside of shiny engine parts, first using penetrating preserva-
tive oil such as Dinitrol 25B and then using Dinitrol 112 or equivalent.

1997-11:2 © Scania Industrial & Marine Engines 41

 - Equip the engine with a clear notice giving the date of preservative
and stating that the engine must not be started or cranked.

STORED ENGINE
Date . . . . . . . . . . . .
Must not be started or cranked.

Batteries
Remove the batteries for maintenance charging in the charging station. (Does
not apply to batteries which, according to the manufacturer, are maintenance-
free). The same applies even for short periods of disuse, even if the engine is
not stored as above.

Storage
After the preparations, the engine should be stored in a dry, warm environ-
ment (room temperature).

Taking out of storage

(action when the engine is taken into operation)
- Remove plugs and tape from coolant connections, air intakes and
exhaust pipes.
- Fill the cooling system with coolant, see page 6.
- Check the oil level in the engine and top up with new oil.
- Crank the engine several revolutions with the injectors removed, oiling
the valve mechanism, pushrods and tappets with plenty of oil.

Important The engine must be cranked with the injectors removed so that
excess preservative oil can be forced out of the cylinders.

- Fit the injectors.

- Drain the fuel system’s main filter of preservative fuel.
- Bleed the fuel system.
- Wash off externally applied preservative oil using white spirit.

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

TECHNICAL DATA
GENERAL D11 DI11
Number of cylinders 6 in line
Cylinder bore mm 127
Stroke mm 145
Swept volume dm3 (litres) 11.0
Number of main bearings 7
Firing sequence 1-5-3-6-2-4
Compression ratio 15:1 High output: 13.5:1
Engine direction of rotation viewed from rear Anti-clockwise
Cooling Fluid
Valve clearance, cold engine
intake valve mm 0.45
exhaust valve mm 0.80
Weight, without coolant and oil
engine with heat exchanger kg 1100 1125
engine without heat exchanger (keel-cooling) kg 1010 1025
Output see “Engine record card”

LUBRICATION SYSTEM
Max. oil pressure
(warm engine at speed above 800 rpm) bar (kp/cm2) 6
Normal oil pressure
(warm engine at operating speed) bar (kp/cm2) 3-6
Min. oil pressure
(warm engine 800 rpm) bar (kp/cm2) 0.7
Oil capacity, see page 15

Crankcase pressure with closed crankcase

ventilation mm VP -55 - +20

1997-11:2 © Scania Industrial & Marine Engines 43

FUEL SYSTEM D11 DI11
Pump setting BTDC See plate on rocker cover
Injectors, opening pressure bar (kp/cm2) 300
Low idle rpm 700
Maximum full load speed See engine card
Fuel Diesel fuel oil1
Tightening torques:
Socket nut for injectors Nm 70
Cap nut for delivery pipe Nm 20
Oil leakage connection Nm 11
1
see page 45

COOLING SYSTEM
Number of thermostats 1
Thermostat, opening temperature °C 79
Coolant temperature:
system with atmospheric pressure °C 70 - 93
system with positive pressure °C 70 - about 100
Capacity
with heat exchanger dm3 (litres) about 52
without heat exchanger
(keel-cooling engine) dm3 (litres) about 23

ELECTRICAL SYSTEM
System voltage V 24
Alternator, current A 65 or 90
Starter motor power kW (hp) 6.7 (9.1)
Monitors, alarm values:
oil pressure monitor bar (kp/cm2) 0,7 ± 0,15
temperature monitor °C Stamped on monitor hexagon

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

FUEL
Diesel fuel oil
The composition of the diesel fuel oil is extremely important for engine and
injection pump function and service life. Even engine output and exhaust
emissions are dependent on fuel quality. The requirements and testing norms
for the most important properties are described in the service manual in sec-
tions which can be ordered from your Scania dealer or directly from Scania.
The address for Scania is printed on the cover.
The table below shows the requirements for some of the most important pro-
perties:

Property Requirement
Viscosity at 40 °C 2.0 - 4.5 mm2/s (cSt)

Density at 15 °C 0.80 - 0.86 kg/dm3

Sulphur (concentration by mass) max 0.3 %

Ignition characteristic min 49

(cetane number)

Flash point 56 °C

Environmentally-friendly fuels (low sulphur fuels)

There are three classes of so-called environmentally-friendly fuels. 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 output. Only class 1
fuel should be used with a catalytic converter.

© Scania Industrial & Marine Engines 45

Additives
At low temperatures, paraffin can precipitate and block filters and lines. This
can cause the engine to lose power or stop.
Winter fuel is usually available in cold climates. If necessary, the properties
of this can be improved before operating at low temperatures. However,
extremely low temperatures can cause problems.
The properties of the fuel when cold can be improved by doing one of the fol-
lowing before the temperature drops:
1. Lamp paraffin or heating oil: Max 50% may be added. Add the paraf-
fin first so that the fuel is blended fully. In a number of countries, the use
of paraffin as an engine fuel is prohibited.
2. Petrol: Only in emergencies and then no more than 30%. Petrol lowers
the ignition characteristics (cetane number) which can lead to difficulty
starting. There will also be emissions of blue smoke and fuel consump-
tion will be higher. Even very small quantities of petrol will lower the
flash point of the fuel which can mean the risk of fire.
3. Alcohol: 0.5 - 2% to prevent water in the fuel freezing to form ice.
4. Light diesel: Can be used for Scania engines in pure form or in the same
way as lamp paraffin to improve the properties of the fuel when cold.
Light diesel is paraffin with a suitable ignition characteristic and with a
lubricating additive. Without this, the injection pump would seize.

Drain fuel tank, drain fuel filter, clean the pre-filter and change
fuel filter regularly.

46 © Scania Industrial & Marine Engines

 ALPHABETICAL INDEX

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Air cleaner, low pressure indicator . . . . . . . . . 26 Maintenance schedule . . . . . . . . . . . . . . . . . . . 13
Air cleaner, pre-filter . . . . . . . . . . . . . . . . . . . 26 Mothballing . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Air cleaner, safety cartridge . . . . . . . . . . . . . . 28
Air filter, insert . . . . . . . . . . . . . . . . . . . . . . . . 26 Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Battery, changing . . . . . . . . . . . . . . . . . . . . . . 36 Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bleeding, fuel system . . . . . . . . . . . . . . . . . . . 29 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Checks after running . . . . . . . . . . . . . . . . . . . . 11 Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Checks before running . . . . . . . . . . . . . . . . . . . 7 Oil pressure monitor . . . . . . . . . . . . . . . . . . . . 34
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Commissioning report . . . . . . . . . . . . . . . . . . . . 1 Pre-filter, air cleaner . . . . . . . . . . . . . . . . . . . . 26
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Protection against corrosion . . . . . . . . . . . . . . 22
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Coolant level monitor . . . . . . . . . . . . . . . . . . . 32 Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Coolant temperature . . . . . . . . . . . . . . . . . . . . . 9
Coolant temperature monitor . . . . . . . . . . . . . 33 Safety cartridge, air cleaner . . . . . . . . . . . . . . . 28
Coolant, changing . . . . . . . . . . . . . . . . . . . . . . 22 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 18 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . 7
Cooling system, cleaning . . . . . . . . . . . . . . . . 23 Stopping the engine . . . . . . . . . . . . . . . . . . . . . 10
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical system . . . . . . . . . . . . . . . . . . . . . . . 31
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . 10 Taking out of mothballs . . . . . . . . . . . . . . . . . 42
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 43
Filter, air cleaner . . . . . . . . . . . . . . . . . . . . . . . 26 Temperature monitor . . . . . . . . . . . . . . . . . . . . 33
Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Turbo filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
First start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Type designations . . . . . . . . . . . . . . . . . . . . . . . 4
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel filter, changing . . . . . . . . . . . . . . . . . . . . 29 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fuel specification . . . . . . . . . . . . . . . . . . . . . . 45 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fuel system, bleeding . . . . . . . . . . . . . . . . . . . 29

Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Low pressure indicator . . . . . . . . . . . . . . . . . . 26
Lubrication oil pressure . . . . . . . . . . . . . . . . . 10
Lubrication oil pressure monitor . . . . . . . . . . . 34
Lubrication oil system . . . . . . . . . . . . . . . . . . . 14

1997-11:2 © Scania Industrial & Marine Engines 47