Scania DI 16

Industrial & Marine Engines
Start of Warranty - Start-up Report

In order for the Scania organisation to be able to handle the engine, it is required that the engine is
START OF WARRANTY = START-UP REPORT

registered as put into operation. This registration means that preparedness to take care of service
and spare parts matters can be built up and that a correct warranty handling can take place.
It is you as the user of the engine who should report when the engine is put into operation.
The easiest way for you is to report the start-up via the INTERNET:
http://www.scania.com/products/engines/Start_up_report_ASURIM/start_up_report.asp
An alternative with longer handling time:
Fill in the information below, tear off the page, fold it, tape it, stamp it and send it to Scania.
The address is already printed. Or send it by telefax: +46 8 553 858 20.
Normally the warranty is valid for one year from the date of start-up.
If the start-up report is not submitted to us - within 12 months from the date of delivery -
the warranty period will be regarded as having started on the date of delivery from Scania.
Operator’s manual
DI16
EMS with S6/PDE
Marine engine
opm03-16m en 1 588 883
2003-09:4
START-UP REPORT
(From end user)
Engine No.
Start-up date
Name of company
Contact person
Address (street)
Postal code
Name of town
State or Territory
Country
For
stamp
Scania CV AB
Industrial and Marine Engines
Marketing & Communications
S-151 87 SÖDERTÄLJE
Sweden
Industrial & Marine Engines
IMPORTANT INFORMATION
When working on the engine, for example adjusting drive belts, changing the oil 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
DI16
EMS with S6/PDE
Marine engine
opm03-16m en 1 588 883
2003-09:4
START-UP REPORT - WARRANTY

When the commissioning report has been filled in and sent to Scania, you have a 1-year warranty from the date
of commissioning. Also fill in the particulars below as this can make things easier if you need to contact for
example a service workshop.
Engine number
Commissioning date
User's name and address
Signature
Engine type
Variant
Engine type and variant are indicated on the engine type plate
PREFACE
This Operator's Manual describes the handling and maintenance of Scania
DI16 Marine Engines with EMS S6/PDE injection system.
The four stroke V8 diesel engines have direct-injection and are liquid-cooled.
They are supercharged and equipped with a charge air cooler which is
coolant-cooled. See page 14.
The engines may have two different cooling systems, a heat exchanger which
is cooled by sea water or keel cooling which has cooling coils on the keel in
which the engine coolant is cooled.
Common areas of usage include forward propulsion engines in small boats
like fishing boats and ferries, and in larger pleasure crafts, or as aggregate
engines on-board ships.
The engines can have different output and speed settings and are classified in
different class categories (classed engines must be used in certain marine
installations).
The normal output setting of the engine (performance code) is indicated on
the type plate, see page 14.
Note: Only standard components are described in the Operator's
Manual. 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
several points you should bear in mind:
- Read the manual before starting to use the engine. Even though you may
be experienced with Scania engines you may find new information in
this Operator's Manual.
- Follow the maintenance instructions. Good working order and service
life are ensured if maintenance is carried out according to the
instructions. During the warranty period,
- In particular, read the safety information starting on page 6. only genuine Scania parts may
be used during service and
- Get to know your engine so that you know what it can do and how it repair otherwise the warranty
works.
will be invalidated.
- Whenever necessary, always contact an authorised Scania workshop.
They have special tools, genuine Scania parts and staff with training and
practical experience of Scania engines.
Note: Always use genuine Scania parts during service and repair so as
to keep your engine in the best possible working order.
The information in this manual was correct at the time of going to press.
However, we reserve the right to make alterations without prior notice.
Scania CV AB
Industrial and Marine Engines
S-151 87 Södertälje, Sweden
2 © Scania Industrial & Marine Engines 2003-09:4

CONTENTS
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHECKING THE MARINE WATER PUMP

CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 IMPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
ENVIRONMENTAL RESPONSIBILITY . . . . . .4 CHECKING THE COOLANT . . . . . . . . . . . . . .37
CERTIFIED ENGINES . . . . . . . . . . . . . . . . . . . .5 Checking the glycol content . . . . . . . . . . . . . .37
SCANIA INDUSTRIAL AND MARINE ENGINE Checking protection against corrosion . . . . . .39
WARRANTY FOR MARINE ENGINES . . . . . .6 Changing the coolant . . . . . . . . . . . . . . . . . . .39
SAFETY INFORMATION . . . . . . . . . . . . . . . . .10 CLEANING THE COOLING SYSTEM . . . . . .40
Safety precautions for running the engine . . .11 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .40
Safety precautions for handling materials . . . .12 Charge air cooler . . . . . . . . . . . . . . . . . . . . . . .42
Safety precautions for care and maintenance .12
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 44
TYPE DESIGNATIONS . . . . . . . . . . . . . . . 14 READING THE
Troubleshooting using flashing codes for VACUUM INDICATOR . . . . . . . . . . . . . . . . . .44
the EMS control unit . . . . . . . . . . . . . . . . . . . .18 CLEANING OR CHANGING THE
Overview of flashing codes for EMS FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . .44
control unit . . . . . . . . . . . . . . . . . . . . . . . . . . .19
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 46
Troubleshooting using flashing codes for
the EMS coordinator . . . . . . . . . . . . . . . . . . . .20 CHECKING THE FUEL LEVEL . . . . . . . . . . . .46
Overview of flashing codes for EMS CHANGING THE FUEL FILTER . . . . . . . . . . .46
coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Bleeding the fuel system . . . . . . . . . . . . . . . . .47
STARTING AND RUNNING . . . . . . . . . . . 22 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 48

AT FIRST START . . . . . . . . . . . . . . . . . . . . . . .22 CHECKING THE ELECTROLYTE LEVEL IN
CHECKS BEFORE RUNNING . . . . . . . . . . . . .23 BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
STARTING THE ENGINE . . . . . . . . . . . . . . . .23 CHECKING THE STATE OF CHARGE
IN BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . .48
Starting at low temperatures . . . . . . . . . . . . . .24
CLEANING BATTERIES . . . . . . . . . . . . . . . . .48
DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
CHECKING THE COOLANT
Rotation speed . . . . . . . . . . . . . . . . . . . . . . . . .24 MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Limp-home mode . . . . . . . . . . . . . . . . . . . . . .25
Coolant temperature . . . . . . . . . . . . . . . . . . . .25 MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 50
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .26 CHECKING DRIVE BELT . . . . . . . . . . . . . . . .50
STOPPING THE ENGINE . . . . . . . . . . . . . . . . .27 CHECKING FOR LEAKAGE,
CHECKS AFTER RUNNING . . . . . . . . . . . . . .27 NECESSARY ACTION . . . . . . . . . . . . . . . . . . .51
CHECKING/ADJUSTING
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 28 VALVE CLEARANCES . . . . . . . . . . . . . . . . . .52
ENGINES WITH FEW OPERATING HOURS .28 CHECKING/ADJUSTING THE PDE
MAINTENANCE SCHEDULE . . . . . . . . . . . . .29 INJECTOR ROCKERS . . . . . . . . . . . . . . . . . . .52
LUBRICATING OIL SYSTEM . . . . . . . . . 30 LONG-TERM STORAGE . . . . . . . . . . . . . . 55

OIL GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Preservative fuel . . . . . . . . . . . . . . . . . . . . . . .55
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Preservative oil . . . . . . . . . . . . . . . . . . . . . . . .56
CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . .31 Preparations for storage . . . . . . . . . . . . . . . . .56
OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . .31 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Maximum angles of inclination during Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Taking out of storage . . . . . . . . . . . . . . . . . . .57
CLEANING THE OIL CLEANER . . . . . . . . . .32
TECHNICAL DATA . . . . . . . . . . . . . . . . . . 58
CHANGING THE OIL FILTER . . . . . . . . . . . .34
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
CHANGING THE FILTER FOR CLOSED
CRANKCASE VENTILATION . . . . . . . . . . . . .35 ALPHABETICAL INDEX . . . . . . . . . . . . . . 62
COOLING SYSTEM . . . . . . . . . . . . . . . . . . 35
CHECKING COOLANT LEVEL . . . . . . . . . . .35
CHECKING CORROSION BARS . . . . . . . . . . .36
2003-09:4 © Scania Industrial & Marine Engines 3

ENVIRONMENTAL RESPONSIBILITY
Scania has always been very much at the leading edge when it comes to
developing and producing engines which are as environmentally friendly as
possible.
Major progress has been made on reducing harmful exhaust emissions as
required to be able to meet the stringent environmental standards stipulated
on almost all markets.
At the same time, we have been able to maintain high quality in terms of
performance and operating economy for Scania Industrial and Marine
Engines.
To preserve these qualities throughout the entire service life of the engine, it
is important for the operator/owner to follow the instructions on running,
maintenance and the choice of fuel and oil as outlined in the manual.
Other efforts to preserve the environment we all share are possible by
ensuring that the person carrying out servicing and maintenance always
makes sure that environmentally hazardous waste after servicing and repairs
(oil, fuel, coolant, filters, batteries, etc.) is dealt with and disposed of in
accordance with applicable environmental standards.
On a number of pages, this Operator's Manual contains specially highlighted Always use suitable containers
text with instructions to help protecting our environment during certain to avoid spillage when bleeding
servicing and maintenance work. systems or renewing
See example components.

CERTIFIED ENGINES
Emissions-certified engines have been approved in accordance with a special
certification standard. The certified engines supplied by Scania meet the most
stringent emissions standards which apply on European (EU) and non-
European (USA) markets.
Scania guarantees that all the engines it supplies of a certified type are
equivalent to the engine approved for certification.
The engine comes with a special certification plate which indicates the
certification rules (standard) to which the engine has been approved. See
page 14.
The following is required for the certified engine to meet emissions standards
once it has been commissioned:
- Servicing and maintenance must be carried out in accordance with the
instructions in this manual.
- Only genuine Scania parts are to be used.
- Injection equipment is to be serviced by an authorised Scania
workshop.
- The engine must not be modified with equipment not approved by
Scania.
- Seals may be broken and setting data edited only once approval has
been granted by Scania in Södertälje. Changes may be made by
authorised personnel only.
- Changes which affect the exhaust system and intake system must be
approved by Scania.
Otherwise, the instructions in the manual in respect of running, care and
maintenance of the engine shall apply. The safety precautions described over
the next four pages must also be observed.
Important! If servicing and maintenance are not carried out as specified

above, Scania can no longer guarantee that the engine will
comply with the certified design, nor can it take responsibility for
any damage that occurs.
For products used in the U.S.A., see next pages for special warranty
regulations.

SCANIA INDUSTRIAL AND MARINE
ENGINE WARRANTY FOR MARINE
ENGINES
EMISSION CONTROL SYSTEMS WARRANTY
Important Only applicable to engines used in the U.S.A.
Table of contents
General Warranty Provisions . . . . . . . . . . . . . . . . . . . 6
Warranty Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parts covered by the Warranty . . . . . . . . . . . . . . . . . . 7
General Warranty Limitations . . . . . . . . . . . . . . . . . . 8
Specific Warranty Exclusions . . . . . . . . . . . . . . . . . . 9
Customer Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EMISSION CONTROL SYSTEM

WARRANTY STATEMENT
General Warranty Provisions

The emission control systems of your new Scania Industrial and Marine
("Scania") marine diesel engine were designed, built and tested using genuine
parts, and the engine is certified as being in conformity with federal emission
control regulations. Scania warrants to the original owner, and to each
subsequent owner, of a new Scania marine diesel engine that the emission
control system of your engine:
1. Was designed, built and equipped so as to conform at the time of sale
with all applicable regulations under Section 213 of the Clean Air Act
42 U.S.C. § 7547; and
2. Is free from defects in material and workmanship which would cause
such engine to fail to conform to applicable regulations for its warranty
period.

Warranty Period
This warranty shall apply for one of the following periods, whichever occurs
first:
• A period of operating hours equal to at least 50 percent of the engine's
useful life in operating hours, or
• A period of years equal to at least 50 percent of the engine's useful life

in years;
• Except that the warranty period shall apply for a period not less than
any mechanical warranties provided by Scania to the owner.
The warranty period shall begin:
• "On the date the marine vessel is delivered to the first retail purchaser,
or
• "If the marine vessel is placed in service for demonstration purposes

prior to sale at retail, on the date the engine is first placed in service.
Parts covered by the Warranty

The following is a list of parts considered a part of the Emission Control
Systems and is covered by the Emission Warranty for engines which were
built to conform to applicable U.S. Environmental Protection Agency
regulations:
1. Fuel injection system
2. Air intake system
a. Intake manifold
b. Turbocharger system
c. Charge air cooler system
3. Exhaust manifold
4. Combustion chamber
a. Piston
b. Cylinder head
5. Components used in the above mentioned systems
Important This list does not include all expendable maintenance parts.
Expendable emission related parts requiring scheduled
maintenance are warranted until their first scheduled
replacement point. See Specific Warranty Exclusions below.

General Warranty Limitations
To retain the dependability of the exhaust emission control originally built
into your Scania marine diesel engine, it is essential that the engine is
installed according to Scania installation instructions and emission
certificates.
In addition, you are responsible for the performance of all scheduled
maintenance or repairs on your new Scania marine diesel engine. Scania may
deny a warranty claim if your failure to perform maintenance resulted in the
failure of the warranted part (listed under Section C above).
Receipts covering the performance of regular maintenance should be retained
in the event questions arise concerning maintenance. The receipts should be
transferred to each subsequent owner of the marine vessel with the emission
warranted engine.
The Warranty covers the cost of repair and replacement parts and services of
warranted components and systems performed by an authorized Scania
distributor or dealer using genuine Scania parts. You may elect to have
maintenance, replacement or repair of these components and systems
performed by any repair establishment or individual without invalidating the
Warranty.
The use of other than Scania replacement parts also does not invalidate the
warranty on other components unless such parts cause damage to warranted
parts. However, the cost of such services or parts will not be covered by the
Warranty.
WARNING Use of replacement parts which are not of equivalent
quality may impair the effectiveness of emission control systems.
Accordingly, it is recommended that only Scania repair or
replacement parts be used for maintenance, repair or
replacement of emission control systems.
If other than Scania parts are used for maintenance, repair or
replacement, the owner should obtain assurance that such parts
are warranted by their manufacturer to be equivalent to genuine
Scania parts

Specific Warranty Exclusions
This warranty does not cover:
1. Malfunctions in any part caused by any of the following: misuse, abuse,
improper adjustments, modifications, alteration, tampering,
disconnection, improper or inadequate maintenance, or use of fuels not
recommended for the engine as described in the Operator's Manual.
2. Damage resulting from accidents, acts of nature or other events beyond
the control of Scania.
3. The replacement of expendable maintenance items such as filters, hoses,
belts, oil, thermostat, exhaust system and coolant made in connection
with scheduled maintenance services once these parts have been
replaced.
4. Replacement items which are not genuine Scania parts or not authorized
by Scania.
5. Inconvenience, loss of use of the marine vessel or commercial loss.
6. Any marine vessel on which the actual use cannot be accurately
determined.
7. Any marine vessel operating outside the United States.
Customer Support
In the event that you do not receive the warranty service to which you believe
you are entitled under the Warranty, or if you need additional support or
information concerning the Warranty, please contact:
Scania USA, Inc

Address: 121 Interpark Blvd, suite 601, 78216, San Antonio, Texas
Mailing address: 121 Interpark Blvd, suite 601,
78216, San Antonio, Texas
Telephone: +1 210 403 0007
Fax: +1 210 403 0211
E-mail: contact@scaniausainc.com

SAFETY INFORMATION
General
This Operator's Manual contains safety information which is important so as
to avoid both personal injury and damage to the product/other property. See
also page 1.
The text highlighted in text boxes on the right of a number of pages is Only use Scania genuine fuel
important for engine function and in order to avoid damage to the engine. If
these instructions are not followed, your warranty may be invalidated. filter.
See example
Similar text may also appear in the text column, and in this instance it will be
marked Note: or Important
The warning text found in text boxes on the right of a number of pages which
is marked with a warning triangle and starts with WARNING is extremely Immobilise the starting device
important and warns you of serious engine faults or incorrect handling which when working on the engine.
may lead to injury. If the engine starts out of
control, there is a
See example
SERIOUS RISK
OF INJURY.
A list of the safety precautions to be followed when running and maintaining

Scania engines can be found on the next three pages. Similar text can often be
found at the relevant maintenance points, and here different levels of
importance are attached to such text in accordance with the above
description.
All points are marked !, so as to indicate how important it is to read through
each point in this section.
For safety reasons, smoking is not allowed:
• In the vicinity of the engine and in the engine room
• When fuelling and close to the filling station
• When working on the fuel system
• In the vicinity of inflammable or explosive material (fuel, oils,

batteries, chemicals, etc.)

Safety precautions for running the engine
Daily inspection Starter lock

Always carry out a visual check of the engine If the control panel is not fitted with a key
and engine room before starting the engine and operated switch, there should be a lock on the
once you have stopped the engine after engine room to prevent unauthorised starting of
running. the engine.
This will enable you to easily detect and fuel, oil Alternatively, a lockable on/off master switch
or coolant leaks, or any other abnormalities or battery master switch can be used.
which may require rectification.
Starting spray
Refuelling Never use starting spray or similar to help you
There is a risk of fire and explosion when start the engine. This can cause an explosion in
refuelling. The engine must be stopped and the intake manifold and possible injury.
smoking is not allowed.
Do not overfill the tank due to a risk of
expansion, and close the filler cap properly. Journey
Use only fuel recommended in the service The engine must not be run in environments
literature. Fuel of the wrong quality can cause where there is a risk for explosion as all of the
the engine to malfunction or stop by preventing electrical or mechanical components can
the injection pump and injectors from operating generate sparks.
as they should. Approaching a running engine always poses a
This can cause damage to the engine and, safety risk. Parts of the body, clothes or
possibly, injury. dropped tools can get caught in rotating parts
such as the fan and cause injury.
Therefore, all rotating parts and hot surfaces
Hazardous gases must be shielded as much as possible to aid
Start the engine only in a well ventilated area. personal safety.
The exhaust fumes contain carbon monoxide
and nitric oxides, which are toxic.
When running the engine in a closed area,
there must be an efficient device for dissipating
exhaust fumes and crankcase gases.

Safety precautions for handling Prevent unwanted starting by taking out the
materials ignition key where applicable and disconnecting
the power using the master switch or battery
Fuel and oil master switch and locking them. Also put up a
All fuels and lubricants and many chemicals are warning sign somewhere appropriate,
inflammable. Always follow the instructions on indicating that work is in progress on the
the relevant packaging. engine.
All work on the fuel system must be done with Working with a running engine always poses a
the engine cold. Fuel leaks and spillage on hot safety risk. Parts of the body, clothes or
surfaces can cause fire. dropped tools can get caught in rotating parts
and cause injury.
Store soaked rags and other inflammable
materials safely so as to avoid spontaneous
combustion.
Hot surfaces and fluids
There is always a risk of sustaining burns when
Batteries an engine is hot. Therefore, take care not to
come into contact with manifolds, the turbo, the
The batteries contain and emit oxyhydrogen
sump, hot coolant and oil in pipes and hoses.
gas, particularly during charging, and this gas is
inflammable and highly explosive. Therefore,
there must be no smoking, naked flames or
Lifting the engine
sparks near the batteries or the battery
compartment. The engine lifting eyes must be used when
lifting the engine. Check first that your lifting
Incorrect connection of a battery cable or jump
devices are in good condition and of the correct
lead can cause a spark, which in turn can
size to lift the weight.
cause the battery to explode.
Extra equipment on the engine can alter the
centre of gravity, which is why you may need
Chemicals additional lifting devices to balance the engine
correctly and lift it safely.
Most chemicals such as glycol, corrosion
inhibitor, inhibiting oils, degreasing agents, etc. Never work underneath a suspended
are hazardous to health. Always follow the engine!
safety precautions on the relevant packaging.
Some chemicals, such as inhibiting oil, are also
inflammable. Batteries
Store chemicals and other materials which are The batteries contain a highly corrosive
hazardous to health in approved containers, electrolyte (sulphuric acid). Take care to
marking them clearly and storing them where protect your eyes, skin and clothes when
they are inaccessible to unauthorised persons. charging or handling batteries. Wear protective
Always hand in leftover or used chemicals to an gloves and goggles.
authorised waste disposal contractor. If the acid splashes on your skin, wash it off
with soap and copious amounts of water. If acid
splashes in your eyes, flush them immediately
Safety precautions for care and with copious amounts of water and contact a
maintenance doctor.
Dispose of used batteries through an
Stop the engine authorised waste disposal contractor.
Always stop the engine before maintenance
and servicing unless stated otherwise.

Electrical system Cooling system
The engine must be stopped and the power Never open the coolant filler cap if the engine is
disconnected using the master switch or hot. Hot coolant or steam may spray out and
battery master switch before working on the cause burns.
electrical system. If you have to open or remove a cooling system
External power supplies to extra equipment on component when the engine is hot, open the
the engine must also be disconnected. cap very carefully and slowly to relieve the
system pressure before removing the cap.
Wear gloves as the coolant is still very hot.
Electric welding Dispose of used coolant through an authorised
When carrying out welding work close to and waste disposal contractor.
on the engine, remove the battery leads and
the leads to the alternator. Also remove the
multi-pin connector to the control unit. Fuel system
Connect the weld clamp to the component to be Always wear gloves when looking for leaks or
welded and close to the welding point, never to carrying out any other work on the fuel system.
the engine or in such a manner that the current Also wear protective goggles when testing
can pass over to a mounting. injectors.
When you have finished welding, connect the Fuel escaping at high pressure can penetrate
leads to the alternator and control unit before tissues and cause serious injury.
connecting the batteries. Never use non-genuine parts in the fuel and
electrical systems as genuine parts are
designed and manufacture to minimise the risk
Lubrication system of fire and explosion.
Hot oil can cause burns and skin irritation.
Therefore, avoid skin contact with hot oil.
Make sure that there is no pressure in the Before starting
lubricating system before starting work on it. Fit all removed shields before starting the
Never start or run the engine with the oil filler engine again. Check that you have not left any
cap removed, as this may cause oil to be tools or other objects on the engine.
thrown out. Never start the engine without the air filter
Dispose of used oil through an authorised fitted. There is a risk of objects being sucked
waste disposal contractor. into the impeller or of injury if you come into
contact with it.

TYPE DESIGNATIONS
The engine type designation indicates, in the form of a code, the type of
engine, its size and applications, etc.
The type designation and engine number are shown on a type plate located on
the block at the rear end of the engine just above the sea water pump. The
engine number is also stamped into the engine block at the front, right part,
ahead of cylinder head 1. Refer to the illustration.
Engines which hold certification in respect of smoke and emissions are fitted
with a plate which indicates the documents in accordance with which they are
certified.
DI 16 42 M 01 P
Type
DI Supercharged diesel engine with fluid-cooled charge air cooler
Displacement 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
Type of regulator
P EMS engine management system with PDE and S6

11 21 21
20
19
18
23 10
17
7
22
16 15
2 13 14
12
1 3
11 10 4
9 8 7 5
6
The illustrations show a normal version of a DI16 engine.
Your engine may have different equipment from that illustrated.
1. Type plate 7. Heat exchanger (main 15. Starter motor
2. Engine number, circuit) 16. Control unit
stamped into the engine 8. Sea water outlet 17. Fuel filter
block 9. Heat exchanger (charge air 18. Oil dipstick
circuit)
3. Thermostat housing with 19. Fuel pump with hand pump
thermostat (double) 10. Sea water intake
20. Oil filter
4. Outlet from engine 11. Expansion tank
21. Turbocharger
5. Outlet from heat exchanger 12. Filling coolant
22. Corrosion protection bars
6. Draining, engine oil 13. Alternator (2)
14. Catwalk 23. Seawater pump

ENGINE MANAGEMENT SYSTEM, EMS
This engine has an electronic management system, EMS (Engine
Management System) with unit injectors (PDE) which provide each cylinder
with the right amount of fuel at the right time in all operating situations.
The EMS system consists of a control unit (S6) and sensors for speed, charge
air temperature and pressure, coolant temperature, oil pressure, accelerator
pedal/throttle actuation which constantly emit signals to the control unit.
With the aid of this input data and the programmed control software, the
correct fuel amount and correct injection time are calculated for each unit
injector (PDE) under the specific operating conditions.
The EMS system sensors can also be used to emit signals to the instruments
in the instrument panel.
The control unit constantly checks the sensors to make sure they are
operational.
The control unit contains monitoring functions to protect the engine in the
event of a fault which would otherwise damage it. In the event of a fault, e.g.
alarm level for low oil pressure or high coolant temperature, the S6 control
unit sends a CAN message to a coordinator.
The main task of the coordinator is to pass on data by means of CAN
communication from the engine control unit to other control units and signals
to gauges and lamps in the instrument panel. The coordinator also has
monitoring functions.
When the EMS control unit or the coordinator detects a fault, the diagnostics
lamp on the instrument panel/s comes on, and it stays on as long as the fault is
active. At the same time, a fault code is generated which can be read off via
the coordinator on the diagnostics lamp in the form of a flashing code when
the diagnostic switch is activated. A flashing code may consist of a number of
different fault codes.
Diagnosis and troubleshooting with Scania EMS Display is described in the
Operator's Manual for Scania Instrumentation.
If the torque reducing function is activated, the fuel amount and the engine
power output are reduced to 70%, and if the engine shutoff function is
activated, the engine is shut off at programmed alarm levels.
A separate PC-based diagnostics program is used to read off the contents of
the flashing codes. For in-depth analysis of fault codes, contact an authorised
Scania dealer.
Reading off the fault codes, and descriptions of these, are also covered in a
separate document in the workshop manual, Engine Management System
EMS-S6: Troubleshooting.
Only authorised personnel are allowed to carry out diagnostic procedures
and program changes.
The positions of the sensors which emit signals to the control unit are shown
in the illustrations on page 17.
See pages 18 and 20 for a description of how to read off flashing codes.
See pages 19 and 21 for a list of flashing codes for the control unit and
coordinator.

Positions of sensors for EMS with S6 on DI16
1. Oil pressure sensor

2. Coolant temperature sensor
3. Sensor for charge air temperature and
pressure
4. Engine speed sensor (2)

Troubleshooting using flashing codes for the EMS
control unit
• The diagnostics lamp on the instrument panel/s always comes on for
two seconds when the system is powered up.
• As soon as a fault is detected by the control unit, it is stored in the
EEPROM fault code memory and the diagnostics lamp on the
instrument panel/s comes on.
• The diagnostics lamp will stay on for as long as a fault is active. Even
if the lamp has gone off and the fault is no longer active, the code can
generally be read off in accordance with the instruction below.
Reading off control unit fault codes

1. Turn on the ignition.
2. Activate the diagnostics switch to the left to view the flashing codes for
the control unit (EMS).
3. A fault code will then flash on the diagnostics lamp. This flashing code
consists of long flashes (approximately 1 second long) and short flashes
(0.3 seconds long). Long flashes are equivalent to tens and short flashes
to units.
Example: long - short - short = fault code 12.
4. Repeat this procedure until the first flashing code is repeated. This
means that the entire fault code memory has been flashed up. If the fault
code memory is empty, only one long flash approximately 4 seconds
long will be given.
5. See the flashing code table on the next page for a description and
localisation of the fault.
6. In order to obtain further information on the fault code, the PC-based
diagnostics tool or Scania EMS Display must be used. Contact an
authorised Scania workshop.
7. When a fault has been rectified the fault code can be erased as described
below.
Erasing fault codes (flashing codes)

1. Turn the ignition off. If the vessel has dual instrumentation the ignition
must be switched off on both panels.
2. Activate the diagnostics switch in the same direction as the flashing
codes indicate, i.e. to the right for the coordinator (COO) or to the left
for EMS.
3. Switch on the ignition and keep at the same time the diagnostics switch
activated, to the right (COO) or to the left (EMS), for 3 seconds.
4. This will erase passive fault codes which can be read off via flashing
code for the relevant system. The rest of the fault code will remain in the
EEPROM and can only be deleted using the PC tool.

Overview of flashing codes for EMS control unit
Code Description Code Description

PDE in cylinder 3: The solenoid valve does not
0 No fault detected. 53 work correctly.
Overspeed. One or both engine speed
11 sensors are displaying speeds in excess of 54 work correctly.
3000 r/min.
12 Engine speed sensor 1 faulty or faulty signal. 55 work correctly.
13 Engine speed sensor 2 faulty or faulty signal. 56 work correctly.
Coolant temperature sensor faulty or faulty PDE in cylinder 7: The solenoid valve does not
14 signal. 57 work correctly.
Charge air temperature sensor faulty or faulty PDE in cylinder 8: The solenoid valve does not
15 signal. 58 work correctly.
Charge air pressure sensor faulty or faulty
16 signal. 59 Faulty signal in extra analog input.
17 Oil temperature sensor faulty or faulty signal. 61 Incorrect control unit shutdown.
18 Oil pressure sensor faulty or faulty signal. 66 Shut-off due to coolant level.
Starter motor function interrupted or not

20 Coolant level sensor faulty. 69 activated.
23 Fault code internally in the coordinator. 82 Engine speed above ref.speed at start
Accelerator/brake. If the accelerator and brake Fault in memory circuit (EEPROM) in control
24 have been operated simultaneously. 83 unit.
Accelerator sensor/idle switch Data transfer to the control unit memory
25 Accelerator sensor/kickdown switch 84 (EEPROM) has been interrupted.
Incorrect temperature internally in the control
27 Engine shutdown bypassed. 85 unit.
Internal fault in the control unit: Fault in
28 Shut-off due to oil pressure. 86 hardware control.
31 Torque limitation due to oil pressure 87 Fault in control unit RAM.
32 Incorrect parameters for limp home function. 88 Internal control unit fault: Memory fault
33 Battery voltage incorrect or no signal. 89 Incorrect seal: Illegal editing of software.
Emergency shut-off switch activated in

37 accordance with CAN message from 93 Engine speed sensors faulty or not connected.
coordinator.
43 CAN circuit faulty in the control unit. 94 Shut-off due to coolant temperature.
Immobiliser function. Ignition key code Torque limitation due to high

47 incorrect. 96 coolant temperature.
CAN message from the coordinator incorrect
48 or missing. 98 Faulty voltage supply to one of the sensors.
Incorrect CAN version in control unit or

49 coordinator. 99 Internal hardware fault in the processor (TPU).

51 work correctly.
52 work correctly.

Troubleshooting using flashing codes for the EMS
coordinator
• The diagnostics lamp on the instrument panel/s always comes on for
two seconds when the system is powered up
• As soon as a fault is detected by the coordinator, it is stored in the
EEPROM fault code memory and the diagnostics lamp on the
instrument panel/s comes on.
• Even if the lamp has gone off and the fault is no longer active, the code
can generally be read off in accordance with the instruction below.
Reading off coordinator fault codes

1. Turn on the ignition.
2. Activate the diagnostics switch to the right for 1 second to view the
flashing codes for the coordinator (COO).
3. A fault code will then flash on the diagnostics lamp. This flashing code
consists of long flashes (approximately 1 second long) and short flashes
(0.3 seconds long). Long flashes are equivalent to tens and short flashes
to units.
Example: long - short - short = fault code 12.
4. Repeat this procedure until the first flashing code is repeated. This
means that the entire fault code memory has been flashed up. If the fault
code memory is empty, only one long flash approximately 4 seconds
long will be given.
5. See the flashing code table on the next page for a description and
localisation of the fault.
6. In order to obtain further information on the fault code, the PC-based
diagnostics tool or Scania EMS Display must be used. Contact an
authorised Scania workshop.
7. When a fault has been rectified the fault code can be erased as described
below.
Erasing fault codes

1. Turn the ignition off. If the vessel has dual instrumentation the ignition
must be switched off on both panels.
2. Activate the diagnostics switch in the same direction as the flashing
codes indicate, i.e. to the right for the coordinator (COO) or to the left
for EMS.
3. Switch on the ignition and keep at the same time the diagnostics switch
activated, to the right (COO) or to the left (EMS), for 3 seconds.
4. This will erase passive fault codes which can be read off via flashing
code for the relevant system. The rest of the fault code will remain in the
EEPROM and can only be deleted using the PC tool.

Overview of flashing codes for EMS co-ordinator
Flashing Description of fault

code
111) Faulty signal from the nominal speed signal fine adjustment.
112) Faulty signals from the accelerator pedal sensor.
121) Incorrect signal from the resistor module for regulator setting.
122) Incorrect signal from the resistor module for idle and fixed speed setting.
13 No communication (EMS) with the engine.
14 Short-circuit in the tachometer signal circuit.
15 Faulty atmospheric pressure sensor.
17 Short-circuit in the coolant temperature gauge signal cable.
18 Short-circuit in the oil pressure gauge signal circuit.
19 Short-circuit in the oil pressure lamp signal circuit.
Different versions of the communications protocol between the coordinator and

21 EMS.
22 Faulty start switch or short circuit.
23 The supply voltage is too high.
24 The supply voltage is too low.
25 Check value from End of line (EOL) is incorrect.
26 Road speed sensor signal missing or faulty.
27 The signals from the RCB (Remote Control Box) switches are implausible.
28 Incorrect signals from the droop-setting switches.
29 Faulty remote start switch or short circuit..

31 No communication from the slave-coordinator or the master-coordinator.
32 Short circuit in the signal cable to the coolant temperature warning lamp.
33 Short circuit in the signal cable to the charge indicator lamp.
34 Incorrect signal from the Fixed speed switches.
35 Fault in CAN communication.

1) Single speed engine
2) All-speed engine

STARTING AND RUNNING
AT FIRST START
When the engine is started for the first time, the maintenance points listed
under "First start" in the maintenance schedule should be followed, see page
29. Coolant composition:
Since the points are important for satisfactory operation of the engine right If there is a danger of freezing:
from the outset, they are also listed below. minimum 30% glycol by
1. Checking the oil level (see page 27). volume
8. Checking the coolant level (see page 33). maximum 60% glycol by volume
If there is no danger of freezing:
The coolant should contain anti-corrosive to protect the cooling system
from corrosion. 8-12% by volume
Scania Corrosion Inhibitor
If there is a danger of freezing:
(no glycol)
- Only anti-freeze glycol should be used in the coolant as protection
against corrosion. We recommend only nitrite-free anti-freeze glycol
with the following supplier designations:
BASF G48 or BASF D542
- The concentration of glycol should be 30 - 60% by volume depending
on the ambient temperature. 30% glycol by volume provides anti-freeze
protection down to -16°C. See page 33. Ethylene glycol and corrosion
inhibitor are
- Never top up with only water or only glycol. Fluid losses must always
be replaced with pre-mixed coolant having the same glycol toxic if ingested.
concentration as that in the engine. If the glycol content drops, both Avoid contact with the skin.
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. The recommended glycols
If there is no danger of freezing: should not be mixed with glycol
containing nitrite-based
- Only Scania Corrosion Inhibitor should be used in the coolant as
protection against corrosion. The correct concentration of anti-corrosive corrosion inhibitor.
is 8-12% by volume and this must never drop below 8% by volume. The
inhibitor in Scania Corrosion Inhibitor is free of nitrite.
- First filling: Fill up the system with water + 10% by volume Scania
Corrosion Inhibitor. Use drinking water with a pH of 6 - 9.
Overdosing with Scania
- Never top up with only water or only anti-corrosive!
Fluid losses must always be replaced with blended coolant: Corrosion Inhibitor and mixing
water + 10% Scania Corrosion Inhibitor by volume. with glycol can cause sludge to
be formed.
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.
If a coolant filter has been fitted
it must not contain inhibitor.

12. Checking the fuel level (see page 46).
14. Checking the electrolyte level in batteries (see page 48).
15. Checking the state of charge in batteries (see page 48).
18. Checking the drive belt tension (see page 50).
Immobilise the starting device

when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK OF INJURY.
CHECKS BEFORE RUNNING

Before running, "Daily maintenance" as described in the maintenance
schedule should be carried out, see page 29.
STARTING THE ENGINE

Start the engine only in a well
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 47). ventilated area.
If it is run in a enclosed space,
Out of consideration for our common environment, your Scania engine has
been designed to use a smaller amount of fuel when starting. Using there should be an effective
unnecessarily large amounts of fuel when starting the engine always results in device to draw off exhaust gases
the discharge of unburnt fuel. and crankcase gases.
- Open the inlet valve for the sea water system (if fitted).
- Open any fuel valve.
- Disengage the engine.
- Engines with battery master switch: Switch on the power by means of Never use starting spray or
the battery master switch. similar to help you start the
- Start the engine with the key in the control panel (SCP) or the start engine.
button (only from RCB). An explosion may occur in the
- S6: The diagnostics lamp should go out after approximately 2 seconds intake manifold with a risk of
when starting. personal injury.

Starting at low temperatures
Local environmental requirements must be complied with. Starting aids,
engine heaters should be used to avoid starting problems and white smoke.
To limit white smoke, the engine should be run at low speed and under
moderate load. A light load on a cold engine gives better combustion and
faster heating than warming up with no load.
Avoid running it longer than necessary at idling speed. The starter motor may only be
At temperatures below 0°C: connected for a maximum of 30
seconds. There is risk of
Note: Only use starting aids recommended by Scania. overheating. Allow the engine to
- The starter motor may only be used for 30 seconds at a time. After that rest for 2 minutes between each
time it must rest for 2 minutes. attempt to start it.
Note: If the engine is equipped with an INTERLOCK switch, this
switch should be depressed and held down until the oil pressure
has reached a sufficiently high level.
DRIVING
Check instruments and warning lamps at regular intervals.
Rotation speed
The Scania tachometer is divided into sectors of different colours, as follows:
0 - 500 rpm red area: prohibited engine speed,

passed through when
stopping and starting.
500 - 700 rpm yellow area: slow idle. Engine idling is

controlled by the EMS/S6
control system. Raised idling
speed with a cold engine.
See page 24.
700 - 2200 rpm green area: normal operating speed.

The engine operating speed
range is controlled by the
EMS/S6 control system.
2200 - 2600 rpm yellow/green unsuitable operating speed.

striped: May occur when switching
off.
2600 - 3000 rpm red area: prohibited engine speed

Limp-home mode
If there is a fault on the normal accelerator pedal or if CAN communication is
interrupted, the following limp-home option is provided:
CAN open circuit or accelerator pedal fault (both signal and idling switch):
- The accelerator pedal value is 0% and the engine is running at normal
idling speed.
- The accelerator pedal value is 0% and the engine is running at raised
idling speed (750 rpm) if this function is activated.
Accelerator pedal fault but the idling switch is working:
- The accelerator pedal value can be increased slowly between 0% - 50%
by using the idling switch.
CAN open circuit:
- The engine is switched off if the shutdown function is activated.
Coolant temperature
Normal coolant temperature when the engine is running should be 70 - 90°C.
The EMS/S6 control system has the following alarm levels:
- If the temperature is high, 98°C - 103°C, for a certain period (1 second),
S6 will send a CAN message which switches on the warning lamp and
diagnostics lamp via the coordinator.
- If the temperature exceeds 103°C, the warning lamp and diagnostics
lamps will come on. If torque reduction is activated, the control system
will reduce the fuel quantity to 70%. A fault code is generated in the
control unit.
- At temperatures exceeding 103°C and with engine shutdown activated,
the warning lamp and diagnostics lamp come on and the engine is
switched off. If the override function is activated, only torque reduction
takes place when this function is activated. A fault code is generated in
the control unit.
After an alarm, approved values should be registered for more than 2
seconds to reset the alarm.
Excessively high coolant temperature can damage the engine.
If run for extended periods under an extremely light load, the engine may
have difficulty in maintaining normal operating temperature. However, the
temperature will rise to a normal level again when the load on the engine is
increased.

Oil pressure
Maximum oil pressure:
warm engine running at a speed above 800 rpm 6 bar
Normal oil pressure:
warm engine running at an operating speed of 3 - 6 bar
High lubricating oil pressure
Minimum oil pressure: (above 6 bar) is normal when
warm engine running at a speed of 1000 rpm 2.3 bar starting a cold engine.
The control system has the following alarm levels:
- at a speed of less than 1000 rpm and an oil pressure of less than 1.0 bar
- at a speed of more than 1000 rpm and an oil pressure of less than 2.3 bar
for longer than 5 seconds.
The following functions are available if there is an alarm:
- Alarm which only switches on the warning lamp and diagnostics lamp.
- Alarm which switches on the warning lamp and diagnostics lamp as
well as torque reduction if this function is activated (70% of fuel
quantity).
A fault code is generated in the control unit.
- Alarm which switches on the warning lamp and diagnostics lamp. The
engine is switched off if engine shutdown is activated. If the override
function is activated, only torque reduction takes place when this
function is activated.
A fault code is generated in the control unit.
After an alarm, approved values should be registered for more than 1
second to reset the alarm.

Charging indicator lamp
If the lamp comes on during operation:
- Check/adjust the alternator drive belt as described under the
maintenance point. See page 50.
- If the charging indicator lamp is still on, this could be due to an
alternator fault or a fault in the electrical system.
STOPPING THE ENGINE

1. Run the engine without a load for a few minutes if it has been run
continuously with a heavy load.
2. Stop the engine with the stop button. Keep the stop button depressed There is danger of turbo
until the engine is completely stationary. damage and post boiling if the
engine is stopped without
3. Before disconnecting the power, check that the control system
diagnostic lamp is not on. See page 18 for troubleshooting. cooling.
4. Engines with battery master switch: Switch on the power by means of

the battery master switch.
5. Set the control switch to "0".

The power must not be switched
off before the engine has
stopped.
CHECKS AFTER RUNNING

- Check that the power is cut from the battery master switch and that the
control switch is in the "0" position.
Immobilise the starting device
- Fill the fuel tank. Make sure that the filler cap and the area round the when working on the engine.
filler opening are clean to avoid contamination of the fuel.
If the engine starts out of
- If there is a risk of freezing, the cooling system must contain enough control, there is a
glycol. See pages 22 and 33. SERIOUS RISK OF
- Switch off inlet valve for the sea water system (if fitted). INJURY
- If there is danger of freezing the sea water system must be emptied.
- At temperatures below 0°C: Prepare for the next start by connecting the
engine heater.
Topping up with coolant should
be carried out when the engine
is stopped after the first start.

MAINTENANCE
The maintenance programme covers 21 points, divided into the following
main groups:
Lubricating oil system . . . . . . . . . . . . . . . . . page 26
Cooling system . . . . . . . . . . . . . . . . . . . . . . . page 31
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . page 44
Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . page 46
Electrical system, batteries, etc . . . . . . . . . . page 48
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . page 50
The maintenance points are divided into intervals as follows:

Daily maintenance
Maintenance before the first start
Maintenance after the first 400 hours of operation
Periodic maintenance every 200 hours of operation (carried out 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 OPERATING

HOURS
Emergency generator sets and the like that are not used regularly should be
run on test and checked in accordance with the generator set manufacturer's
instructions.
For engines with few operating
Run the engine until it reaches operating temperature and then carry out the hours that do not receive
maintenance points below:
periodic maintenance according
1. Checking oil level. to the maintenance schedule on
5. Checking coolant level. page 29, maintenance should be
carried out in accordance with
10. Checking low pressure indicator.
the schedule:
12. Checking fuel level.
"Annually"
14. Checking electrolyte level in batteries. "Every 5th year"
15. Checking state of charge in batteries.
16. Cleaning batteries.
19. Look for leakage, rectify as necessary

MAINTENANCE SCHEDULE
First Interval At least
time at
Every 5th year

First start
Annually
1200 h
2400 h
4800 h
400 h
200 h
400 h
Daily
LUBRICATING OIL SYSTEM, page 26
1. Checking oil level
2. Oil change 1
3. Cleaning oil cleaner 1
4. Changing the oil filter and filter for closed crankcase 1
ventilation
COOLING SYSTEM, page 31
5. Checking coolant level
6. Checking corrosion protection bars 4) 5
7. Checking the marine water pump impeller 4) 5
8. Checking coolant 6 6
9. Cleaning cooling system 1
AIR CLEANER, page 44
10. Test reading low pressure indicator
11. Cleaning or changing filter element 3
FUEL SYSTEM, page 46
12. Checking fuel level
13. Changing the main filter and water separating filter 1
ELECTRICAL SYSTEM, page 48
14. Checking electrolyte level in batteries 2
15. Checking state of charge in batteries 2
16. Cleaning batteries 2
17. Checking coolant level monitor
MISCELLANEOUS, page 50
18. Checking drive belt
19. Look for leakage, rectify as necessary
20. Checking/adjusting valve clearances
21. Checking/adjusting PDE injector rocker arms
1. More often if required

2. For engines with few operating hours, see page 28.
3. Earlier if low pressure indicator shows red.
4. Only applies to M engines with marine water pump and heat exchanger.
5. Reference value. Varies depending on the composition of the sea water.
6. If inhibitor has not been topped up for five years, the coolant should be changed.

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 oil change intervals stated apply provided that the sulphur content Additives must not be used.
of the fuel is not in excess of 0.3% by weight. If the sulphur content is The oil should be suitable for all
greater than 0.3% but no more than 1.0%, the oil change interval must temperature variations until the
be halved (200 h). next oil change.
- Viscosities are shown in the figure below.
- When ambient temperatures are extremely low: Consult your nearest
Scania representative to avoid starting difficulties.
Oil analysis
Some oil companies can offer analysis of the engine oil. Such analysis
measures the oil's TBN (Total Base Number), TAN (Total Acid Number),
fuel dilution, water content, viscosity and the quantity of wear particles and
soot in the oil.
The result of a series of analyses is used as the basis for establishing a
suitable oil change interval.
If the conditions are changed, a new oil analysis programme must be carried
out to establish the new change interval.
-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

1. Daily:
CHECKING OIL LEVEL
Note: Before checking oil level: Allow the engine to remain stationary
for at least 1 minute.
- The oil is at the correct level when it comes to between the marks on the
dipstick. Top up when the oil level is at the lower mark on the dipstick.
- Correct type, see "Oil grade" on page 30.
Checking oil level during operation

On some engines the oil level can be checked during operation.
- Remove the oil filler cap to release the pressure in the crankcase.
- Check the level on the dipstick. Correct oil level: 10 mm below the Min.
or Max. mark.
Max.
2. Every 400 hours:
Min.
OIL CHANGE
Note: If the engine is used for especially demanding operations,
particularly in a dusty environment or if the deposits in the
centrifugal cleaner are thicker than 20 mm: change the oil at
more frequent intervals.
- 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. 40 dm3
Min. 35 dm3
Max. 33 dm3
Min. 25 dm3
The oil may be hot. 1 dm3 = 1 litre

Wear protective gloves and
goggles.
Use a container to avoid spillage

when changing the oil. Dispose
of used oil through an
authorised waste disposal
contractor.

Maximum angles of inclination during operation
Maximum permissible angles during operation vary, depending on the type of
oil sump, see illustration.
Note: Specified angle may only occur intermittently.
24° 25°
26° 25°
30° 30°
3. Every 400 hours:

CLEANING THE OIL CLEANER
(at same time as an oil change)
- Clean the cover. Unscrew the nut and remove the cover.
Open the cap carefully.

The oil may be hot.
- Lift out the rotor and loosen the nut on the rotor bowl three turns.
- If the nut is jammed:

Clamp the nut, absolutely not the rotor, in a vice and turn the rotor three
turns by hand or with 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.
- Remove the strainer located on the rotor. If the strainer is stuck, you can
prise its bottom edge carefully until it comes loose 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 often.
- Wash all parts in diesel oil.

- Make sure the nozzles on the rotor are not blocked or damaged.
- Make sure the bearings are not damaged.
- Fit the O-ring in the rotor bowl. Make sure it is not damaged.
Change if necessary.
- Reassemble the rotor.
- Tighten the rotor nut firmly by hand.

- Make sure the shaft is not loose. If it is loose, use locking compound
561 200 and tighten it to a torque of 34 Nm.
- Refit the rotor.

- Check that it rotates easily by rotating it manually.

- Check that the O-ring in the bowl is undamaged.
A hardened or damaged O-ring must be changed.
- Screw on the bowl and tighten the lock nut to 15 Nm.
Tighten the nut carefully so as not to damage the rotor shaft, nut or bowl.
Functional inspection
The rotor rotates very fast and should continue to rotate when the engine has
stopped.
- Stop the engine when it is warm.
- Listen for a whirring sound from the rotor or feel whether the cleaner
housing is vibrating.
The rotor normally continues spinning for 30 - 60 seconds after the engine
has stopped.
If it does not: dismantle it and inspect the component parts.
4. Every 400 hours:

CHANGING THE OIL FILTER
(at same time as an oil change)
- Unscrew the filter lid with a closed tool with hexagon driver, e.g. socket
587637, so as not to damage the filter lid.
- Lift out the filter housing lid with filter element. The filter housing will
drain automatically once the filter has been removed.
- Undo the old filter from the lid by carefully bending it to one side.
- Lubricate a new O-ring with engine oil and place it in the lid.
- Press a new filter element into the snap fastener in the lid.
- Make sure the oil filter drain has emptied the oil from the filter housing.
- Screw on the filter lid with a closed tool with hexagon driver, e.g. socket
587 637. Tightening torque 25 Nm.
- Start the engine and check for leaks.
Important! If the deposits in the centrifugal cleaner are more than 20 mm Use a container to avoid spillage
thick, the oil filter has to be replaced more often. The same is true when changing the filter.
for cleaning the centrifugal filter and changing the oil. Dispose of used filters through
an authorised waste disposal
contractor.

CHANGING THE FILTER FOR CLOSED
CRANKCASE VENTILATION
In the case of engines with closed crankcase ventilation, the filter element
must be changed at the same time as the main oil filter as described below:
- Remove the drainage line at the filter base.
- Release clamps 1 holding the container to the filter head.
- Remove the container 2. There may be oil in the bottom.
- Remove and replace the filter element.
- Replace the O-ring at the base of the head, and check that there is an
O-ring on top of the new filter element.
- Fit the new filter and press into the centre of the filter head.
3
- Refit the container and lock firmly.
- If the indicator 3 on top of the filter showed red, remove the plastic
cover and press the indicator button.
- Refit the drainage line.
COOLING SYSTEM
5. Daily:
CHECKING COOLANT LEVEL
- Open the expansion tank filler cap and check the coolant level.
- Correct level:
- Cold engine: Coolant level must be approximately 50 mm below
the Full line.
- Hot engine: Coolant level must be approximately 25 mm below
the Full line.
- Other types of expansion tank according to the instructions of the fitter.
Open the cap carefully.
- Top up the coolant as necessary, see point 6. Water and steam may
Note: When filling large amounts of coolant: spray out.
Never pour cold coolant into a hot engine.
This could crack the cylinder block and cylinder head.
Always top up with ready mixed

coolant.

6. Every 400 hours:
CHECKING CORROSION BARS
(Only engines with heat exchanger)
- Empty the sea water circuit and check the corrosion bars (protection
anodes). There are 4 corrosion bars. Only two are shown in the picture.
- Scrape off all loose material on the anode.
- Change if less than half the bar is left.
A new bar is 63 mm long with a diameter of 17 mm.
Note: If the corrosion bars are very corroded they need to be checked
more often, for example every 200 hours.
7. Every 400 hours:

CHECKING THE MARINE WATER
PUMP IMPELLER
(Only engines with heat exchanger)
- Close the sea valve if the marine water pump is under the water level.
- Drain the seawater circuit.
- Take off the marine water pump cap.
- Check that the impeller vanes are not worn or damaged.
Note: If the impeller must be changed frequently, the cleaning of the sea
water must be improved.
Changing the impeller

- Pull out the impeller with puller 98 482 (Scania Special Tools).
- Fit new impeller and cap. Check that the cap seal is not hard or
damaged.
Note: A spare impeller should be kept on board.
- The impeller can be deformed at longer periods of inactivity. Change
before or remove the impeller before longer periods of stoppage. Also
see "Preparations of storage".

8. Every 2400 hours:
Coolant should be checked as follows:
a) Check the appearance of the coolant.
b) Coolant with glycol only: check the glycol content.
c) Coolant with Scania Corrosion Inhibitor only: Coolant composition:
Check the anti-corrosive content. If there is a danger of freezing:
minimum 30% glycol by
volume
The composition of the coolant is described in more detail under
"Starting and running" maximum 60% glycol by
volume
a) If there is no danger of freezing:
Checking the appearance of the coolant 8-12% by volume
- Fill a container with a little coolant and check that it is clean and clear. Scania Corrosion Inhibitor
- If the coolant is contaminated or cloudy, consider changing it.
- Water added to the coolant should be clean and free from dirt of any
kind.
- Use drinking water with a pH of 6 - 9.
b)
Checking the glycol content
It is highly dangerous to
If there is a danger of freezing, use only glycol as an anti-corrosive in the
coolant.
consume
corrosion inhibitor.
- Cooling systems with glycol should contain at least 30% glycol by
volume to provide acceptable protection against corrosion.
Avoid skin contact
with glycol.
- 30% glycol by volume provides protection against freezing to -16°C. If
additional protection against freezing is required, see the table on the
next page to help you calculate how much glycol you need.
We recommend only nitrite-free anti-freeze glycol with the following
supplier designations:
The coolant should be ready
BASF G48 or BASF D542 mixed when it is poured into the
- Always top up the anti-freeze if its glycol content drops below 30% by cooling system.
volume. A glycol content above 60% by volume will not provide greater Never top up with only water or
protection against freezing. only glycol.
- 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. The recommended glycol must
Note: The coolant should be changed when the cooling system is not be mixed with glycol having
cleaned: every 4800 hours or at least every 5th year. nitrite-based anti-corrosive.
Risk for build up of sludge and
Important! If a coolant filter is used in the cooling system it must not
contain an inhibitor. reduced cooling capacity.

Anti-freeze glycol, % by volume
Characteristics of glycol at low temperatures:

- Example with 30% glycol by volume
- Ice slush starts to form at -16 °C
- There is risk for malfunctions at -30 °C
- No risk of damage by freezing with a minimum
content of 30% glycol by volume
Curve A: Ice formation starts (ice slush)

Curve B: Temperature at which there is a risk of
damage by freezing
1. Safe area
2. Malfunctions may occur (ice slush)
3. Risk of damage by freezing
A
% glycol by Cooling
15 20 25 30 35 40 45 50
volume system
Ice slush starts capacity,
-6 -9 -12 -16 -21 -24 -30 -37 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
Ethylene glycol 17 22 28 33 39 44 50 55 110
dm3 (litres) 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= Area to be avoided. Only for calculating glycol mix.
Coolant freezing temperature when ice starts to form at different glycol mixes

c)
Checking protection against corrosion
There must always be sufficient corrosive inhibitor in the coolant to protect
the cooling system against corrosion. It is highly dangerous to
If there is no danger of freezing, only Scania Corrosion Inhibitor should be consume corrosion inhibitor.
used in the coolant. Avoid contact with the skin.
The inhibitor in Scania Corrosion Inhibitor is free of nitrite.
The correct proportion of anti-corrosive is 8-12%by volume.
- Topping up with 1.0% Scania Corrosion Inhibitor by volume should be
done after every 2400 hours of operation. Mixing with glycol or the use of
too much corrosion inhibitor
- Never top up with only water or only anti-corrosive!
Fluid losses must always be replaced with blended coolant: can lead to build up of sludge
water + 10% Scania Corrosion Inhibitor by volume. and reduced cooling capacity.
Note: The coolant should be changed when the cooling system is
cleaned: every 4800 hours or at least every 5th year.
If a coolant filter has been fitted

it must not contain inhibitor.
Changing the coolant

1. Remove the filler cap from the expansion tank.
2. The coolant is drained at three points:
- 2 drain taps in two hoses fastened in the side cover on the right side of
the block, see illustration. At draining the hoses should be unfastened
and folded outwards.
- drain tap on the lower left side of the block, see illustration
and
- at the lowest point of the cooling system, remove two stoppers below
the heat exchanger.
3. Close the drain taps.
4. Fold in the hoses with taps and attach them to the bracket.
5. Fill up with coolant through the expansion tank's filler hole.
Mix coolant as described on page 37.

when changing the coolant.
Dispose of used coolant through
contractor.

CLEANING THE COOLING SYSTEM
Note: If necessary, the cooling system should be cleaned more often.
External cleaning
Heat exchanger Use a container to avoid spillage
when changing the coolant.
1. Drain the coolant from the engine and the heat exchanger, see
"Changing the coolant". Dispose of used coolant through
2. Empty the sea water circuit and detach the heat exchanger sea water
inlet and outlet pipes. Remove the radiator where fitted with the pipe contractor.
from the top of the heat exchanger.
3. Remove the pipes to and from the engine cooling system.
4. Remove the pipes to and from the charge air cooler.
5. Remove the entire heat exchanger unit.
6. Unscrew the rear cover and remove the charge air cooler element with
O-rings.
7. Remove the charge air cooler housing and the loose flange with O-rings.
8. Unscrew the spacer with the sea water outlet. The cooling system must never
be cleaned with caustic soda.
9. Unscrew the front cover and remove the loose flange with O-rings.
There is a risk of damage to
10. Remove the radiator element for main engine circuit. aluminium parts.
11. Clean the outside of the elements. Use a paraffin-based engine cleaner.
12. Any internal deposits in the pipes can be removed mechanically using a
round rod.
13. Lubricate all new O-rings.
14. Fit a new O-ring inside the main element flange and push the element
into the housing.
15. Fit new O-rings on the end of the element with a loose flange between.
16. Fit the front cover and tighten the hexagon screws to 26 Nm.
17. Fit a new O-ring in the spacer and screw this to the heat exchanger at
26 Nm.
18. Fit the small heat exchanger housing on the stud bolts.
19. Fit a new O-ring inside the small element flange and push it into the
housing.
20. Fit new O-rings on the end of the element with a loose flange between,
and push the housing with element fully up to the spacer.
21. Fit a new O-ring inside the small element flange and fit the rear cover.
Tighten the flange nuts to 26 Nm.
22. Fit the complete heat exchanger to the engine and tighten the screws to
92 Nm.
23. Connect the sea water pipe and the radiator where fitted. Connect the
pipe to the engine and charge air coolers.

1. Heat exchanger housing, main 10. Rear cover
section 11. Element, charge air section
2. O-ring 12. Heat exchanger housing, charge
3. Flange air section
4. Front cover 13. Flange nut
5. Seal 14. Flange
6. Plug 15. O-ring
7. Screw 16. Flange screw
8. Housing, intermediate section
9. Element, main section

Charge air cooler
1. Drain the coolant from the engine, see "Changing the coolant".
2. Remove the catwalk, belt cover and expansion tank.
3. Remove the pipes from the turbo and the pipe between the charge air
coolers.
4. Release the charge air cooler pipe connections for the coolant inlet and
outlet. Use a container to avoid spillage
5. Remove the closed crankcase ventilation valve where fitted. when changing the coolant.
6. Dismantle the charge air cooler according to the illustration.
Take care not to damage the element's water connections. contractor.
7. Clean the outside of the element. Use a paraffin-based engine cleaner.
8. Fit a new gasket to the underside of the charge air cooler
9. Screw the element into the lower part. Tighten the bolts to 26 Nm.
10. Fit the upper part of the charge air cooler. Tighten the bolts to 50 Nm.
11. Refit the pipe connections for the charge air cooler inlet and outlet, and
clamp the outlet pipe together with the thermostat housing to the charge
air cooler.
12. Refit the pipes from the turbo and the pipe between the charge air
coolers.
13. Refit the expansion tank, belt cover and catwalk.
1. Intake manifold, upper part

2. Element
3. V-ring seal
4. O-ring
5. Pipe connection
6. Gasket
7. Intake manifold, lower part

Internal cleaning
Removing oil and grease
- If possible, run the engine until it has reached operating temperature and
then drain the cooling system.
- Remove the thermostats.
- Fill the system with clean, hot water mixed with liquid dishwasher
detergent designed for household use.
Concentration 1% (0.1/10 l). when changing the coolant.
- Run the engine until warm for about 20-30 minutes. Do not forget the
cab heating system (if fitted). an authorised waste disposal
contractor.
- Drain the cooling system.
- Fill the system again using clean, hot water and run the engine for about
20-30 minutes.
- Drain the water from the system.
- Refit the thermostats.
- Top up the system with new coolant according to the specification on
page 37.
Handling cleaning agents for

Removing deposits the cooling system:
- If possible, run the engine until it has reached operating temperature and Read the warning label on the
then drain the cooling system. container.
- Remove the thermostats.
- Fill the system with clean, hot water mixed with some of the radiator
cleaning agent available on the market which is based on sulphamic acid
and contains dispersing agents. Follow the manufacturer's instructions
for the concentration and cleaning period.
- Run the engine for the specified time and then drain the cooling system.
- Refill the system with hot water and run the engine for about 20-30
minutes.
- Drain the water from the system.
- Refit the thermostats.
- Top up the system with new coolant according to the specification on
page 37.

AIR CLEANER
10. Daily:
READING THE
VACUUM INDICATOR
If the red indicator telltale is entirely visible, change or clean the air cleaner
filter element, point 11. This is particularly important if the engine is run at
high loads and high speed.

CLEANING OR CHANGING THE
FILTER ELEMENT
Note: Earlier if the vacuum indicator shows red Only use Scania genuine air
filter. Change the filter element
Dismantling if it is damaged.
1. Remove the side cover from the air cleaner.
Danger of engine damage if the
2. Change or clean the element. filter element is damaged.
Note: Cleaning the element always entails a risk of damaging it. The
element can only be cleaned a maximum of four times. After
cleaning, it has poorer dust capacity than a new element. Never start the engine unless
3. Mark the filter when it has been cleaned. the air filter is installed.
Cleaning the element Danger of personal injury or
engine damage.
- Carefully blow the filter element clean using dry compressed air from
the inside.
Note: This filter element must not be washed with water.
1 2 3
1. Cover
2. Filter element
3. Filter housing

Check
- 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.
Filter with a non-changeable element (unit cleaner)

Cleaning
- The filter may be cleaned a maximum of 3 times. Mark the filter after
each time it has been cleaned.
- Use a cleaning solution consisting of water mixed with approximately

1% mild detergent.
1. Pour the cleaning solution into the element outlet at the same time as
turning the element so that the cleaning solution pours through the
element against the direction of the air flow.
2. Leave the element in the cleaning solution for 5 minutes and then take it
out so that all the cleaning solution drains away.
3. Rinse the element with ca 30 litres clean water at 30 - 40°C. Pour the
rinsing water into the element in the same way as the cleaning solution.
4. Take out the element and allow the rinsing water to drain off.
5. Repeat the procedure until the rinsing water is clean.
6. Leave the element to dry in a warm place for approximately 24 hours.
7. The filter must not be dried with compressed air.

FUEL SYSTEM
12. Daily: Observe the utmost cleanliness
when working on the fuel
CHECKING THE FUEL LEVEL system.
Malfunctions could easily occur
- Top up with fuel if necessary. At the same time, drain the water
separating filter. and the injection equipment
could be damaged.
- If the tank has been run dry, bleed the fuel system, see point 13.

CHANGING THE FUEL FILTER
Fuel tanks Only use Scania genuine fuel
- Drain any water from the fuel tanks. filter.
Main filter
The filter consists of a filter unit.
- Wash the outside of the filter and unscrew it.
- Fit the new filter and tighten it by hand.
Never use tools for this. The filters can be damaged, obstructing
circulation.
- Bleed the fuel system according to the instructions overleaf.

when bleeding and changing
components.

Water separating filter
- Drainage must be carried out when filling fuel.
- The filter must be changed at the same replacement interval as the main
filter.
- Close the drain tap 1 before the filter.

- Unscrew the container and drain valve 3.
- Unscrew and change the filter 2. Lubricate the seal before tightening the
new filter by hand.
- Screw the container and drain valve into position. 1. Shut-off cock
- Open the drain tap 1. 2. Filter
3. Drain valve
- Bleed the fuel system after changing both filters.

when bleeding and changing
components.
Bleeding the fuel system
- Fit transparent plastic hoses on the bleed nipples of the fuel rail. Lead
the hoses to a receptacle.
- Open the bleeder nipples and pump the hand pump 1 until fuel without
air bubbles comes out of the open bleeder nipple. This may take around
130-150 pump strokes.
- Shut off the bleed nipples and remove the hoses.
- Continue hand pumping until it feels tight.
• After renewing the fuel filter, it will take approximately 20 strokes.
• Approximately 50 pump strokes after renewing a unit injector.
Important! The starter motor may only be used for 30 seconds at a time.
After that time it must rest for 2 minutes.
If the engine fails to start after bleeding. . . . . . .

- Open the bleeder nipples again and pump the hand pump until fuel
without air bubbles flows out.
- Tighten the bleed nipples. Start the engine and check for leaks.

ELECTRICAL SYSTEM
Do not let open flame or sparks
CHECKING THE ELECTROLYTE come near the batteries.
LEVEL IN BATTERIES When batteries are charged,
they emit highly flammable
1. Unscrew the plugs and check the electrolyte level in all cells.
fumes that can explode.
2. Top up with distilled water until the level is 10-15 mm above the plates.

CHECKING THE STATE OF CHARGE
IN BATTERIES
- Check the density with an acid tester.
In a fully-charged battery it should be:
Wear gloves and eye protection
1.280 at +20°C when charging and
1.294 at 0° handling batteries.
1.308 at -20°C Batteries contain a highly
corrosive acid.
- If the density is below 1.20, the battery must be charged. A discharged
battery will freeze at -5°C.
Do not rapid-charge the battery. This will damage the battery in the
long run.

CLEANING BATTERIES Do not connect the cables to the
1. Clean batteries, cables and cable terminals. wrong terminals.
2. Check that all cable terminals are firmly tightened. This could cause serious
3. Grease battery terminal posts and cable terminals with Vaseline. damage to the electrical system.
If the terminals are
shortcircuited, sparks
will be generated.

CHANGING THE BATTERY
Removal
1. Disconnect the negative cable (-) from the battery (cable connected to
earth). Do not connect the cables to the
2. Disconnect the positive cable (+) from the battery (cable connected to wrong terminals.
starter motor). This could cause serious
Fitting damage to the electrical system.
If the terminals are short-
1. Connect the positive cable (+) to the battery (cable connected to starter
motor). circuited, sparks will be
generated.
2. Connect the negative cable (-) to the battery (cable connected to earth).
Dispose of used batteries

through an authorized waste
disposal contractor.

MONITOR
(optional equipment)
1. Start the engine.
2. Reduce the coolant level in the expansion tank to below the level
monitor.
3. Automatic stop in case of fault: Engine stops, indicator lamp lights and
buzzer (where fitted) sounds if there is no fault in the level monitor. If
the function is connected via the coordinator, the emergency stop fault Level indicator in expansion
code will be generated and can be read off on the diagnostics lamp. tank
4. No automatic stop in case of fault: Indicator lamp lights, buzzer (where
fitted) sounds if there is no fault in the level monitor.
5. Top up coolant to the correct level, see page 31.

when draining the coolant.
contractor.

MISCELLANEOUS
1
CHECKING DRIVE BELT
- If the drive belt (1), which is a poly-V belt, is worn or damaged it must
be changed.
- Also check that the automatic belt tensioner (2) is in proper working
order and keeps the drive belt correctly tensioned.

19. Daily:
CHECKING FOR LEAKAGE,
NECESSARY ACTION
- Start the engine.
- Check for oil, coolant, fuel, air and exhaust leakages.
Take care to ensure that any
- Tighten or change leaking connections. Check the overflow holes (1) in leaks do not cause pollution.
the block which show whether the O-rings between the cylinder liners
and crankcase are leaking, see figure.
a) If coolant is running out, the O-ring is leaking.
b) If oil is running out, the liner shelf is leaking.
- Check that there are no leaks from the coolant pump. If a leak occurs,
replace the pump seal or complete coolant pump. If serious leakage occurs,
- A small amount of leakage from the overflow holes during the engine contact your nearest Scania
running-in period is normal. (Seals and O-rings are lubricated with soap workshop.
or oil when fitted).
- This leakage normally stops after a time.

CHECKING/ADJUSTING WARNING
VALVE CLEARANCES Immobilise the starting device
when working on the engine.
Note: Checking/adjusting valve clearances should also be done after the If the engine starts out of
first 400 hours of operation. control, there is a
Valve clearances should be adjusted when the engine is cold, at least SERIOUS RISK
30 minutes after running. OF INJURY.
The rocker cover gaskets should be changed as necessary. Tightening torque:
26 Nm.
Intake valve clearance: 0.45 mm.
Exhaust valve clearance: 0.70 mm.
Lock nut tightening torque: 35 Nm
Order of adjustment
- Turn the flywheel so that the marks on the flywheel can be seen in the
5 1
lower opening in the flywheel casing.
- Measure the valve clearance with a feeler gauge and adjust the valves as 6 2
per the order of adjustment in the table below. Correct valve clearances
are also given on the instruction plate on one of the rocker covers: 7
3
Adjust Adjust 8 4
Valve
intake exhaust
Mark on flywheel change on
valves on valves on
cylinder
cylinder cylinder
FLYWHEEL
TDC Down (0°) 6 7 and 8 4 and 5 Cylinder numbering
TDC Up (180°) 7 1 and 5 2 and 6
TDC Down (360°) 1 2 and 4 3 and 7
TDC Up (540°) 4 3 and 6 1 and 8

CHECKING/ADJUSTING THE PDE
INJECTOR ROCKERS
Note: Checking/adjusting the rockers for the PDE injectors should also
be done together with the valve clearance check/adjustment after
the first 400 hours of operation.
Important! The unit injectors PDE31 are adjusted using

setting tool 99 414 or a digital sliding caliper.
The unit injectors PDE32 are adjusted using
setting tool 99 442 or a digital sliding calliper.
This adjustment is important as incorrect positioning of the unit Dimension A= PDE31:
injector can lead to poor performance and possible damage. 66.9±0.1 mm
PDE32:
69.9±0.1 mm
Dimension B= PDE31: 36.5 mm
PDE32: 38.8 mm
PDE31:
1. Firstly, measure the distance A between plane a and the top edge of the
valve spring washer on the PDE injector using a digital slide rule. See
figure.
2. Dimension A should be 66.9 mm for PDE31 (dimension B=36.5 mm).
3. The dimension is adjusted by undoing the lock nut and screwing the
rocker arm adjusting screw 1 to the correct measurement.
WARNING! Take care when carrying out the adjustment if the
dimension is well outside the adjustment dimension. The
spring is pre-tensioned and can cause personal injury if it is
released.
4. Position setting tool 99 414 with the metal plate around the injector
spring.
5. Finely adjust dimension A by simultaneously using a finger to sense that
the small piston 2 is level with the flat upper surface of the tool. It is
possible to sense differences of less than a tenth of a millimetre.
6. If the setting tool is not available, a digital slide rule can also be used for
fine adjustment. The rocker position is adjusted by means of the
adjusting screw to 66.9 +/-0.1 mm as stated above.
7. Tighten the adjusting screw lock nut to 39 Nm and remove the tool.
8. The order in which the injector rockers are to be checked/adjusted is
shown in the table below.
Note: No additional checking/adjustment of the PDE injectors,
such as checking the opening pressure, is to be carried out. Faulty
injectors must always be replaced completely.
Order of adjustment: 66.9
99 414
lower opening in the flywheel casing.
Valve Adjust injector

Mark on flywheel change on rocker arm on
cylinder cylinder
TDC Down (0°) 6 4 and 5 Piston above or below the flat

surface. Adjustment necessary
TDC Up (180°) 7 2 and 6
TDC Down (360°) 1 3 and 7
TDC Up (540°) 4 1 and 8
Piston level with the flat surface.

The adjustment is correct

PDE32:
1. Firstly, measure the distance A between plane a and the top edge of the
valve spring washer on the PDE injector using a digital slide rule. See
figure.
2. Dimension A should be 69.9 mm for PDE32 (dimension B=38.8 mm).
3. The dimension is adjusted by undoing the lock nut and screwing the
rocker arm adjusting screw 1 to the correct measurement.
WARNING! Take care when carrying out the adjustment if the
dimension is well outside the adjustment dimension. The
spring is pre-tensioned and can cause personal injury if it is
released.
4. Position setting tool 99 442 with the metal plate around the injector
spring.
5. Finely adjust dimension A by simultaneously using a finger to sense that
the small piston 2 is level with the flat upper surface of the tool. It is
possible to sense differences of less than a tenth of a millimetre.
6. If the setting tool is not available, a digital slide rule can also be used for
fine adjustment. The rocker position is adjusted by means of the
adjusting screw to 69.9 +/-0.1 mm as stated above.
7. Tighten the adjusting screw lock nut to 39 Nm and remove the tool.
8. The order in which the injector rockers are to be checked/adjusted is
shown in the table below.
Note: No additional checking/adjustment of the PDE injectors,
such as checking the opening pressure, is to be carried out. Faulty
injectors must always be replaced completely.
Order of adjustment: 69.9
99 442
lower opening in the flywheel casing
Valve Adjust injector

Mark on flywheel change on rocker arm on
cylinder cylinder
TDC Down (0°) 6 4 and 5 Piston above or below the flat

surface. Adjustment necessary
TDC Up (180°) 7 2 and 6
TDC Down (360°) 1 3 and 7
TDC Up (540°) 4 1 and 8
Piston level with the flat surface.

The adjustment is correct

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
- Running the engine for a certain time using 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 coolant containing Ethylene glycol is
50% glycol by volume. Glycol without nitrite-based inhibitor should be used. toxic if ingested.
For example BASF G48 or BASF D542. Avoid contact with the skin.
Preservative fuel
- Use diesel fuel oil mixed with Lubrizol 560H or the equivalent.
- Mix 1 cm3 (ml) Lubrizol 560H in 10 dm3 (l) of fuel.
! HANDLING LUBRIZOL 560H

Hazardous!
Contains aromatic hydrocarbons
Use spot extractors where there is a danger of vapour build-up.
Wear protective gloves and goggles when handling Lubrizol. Do not use contaminated clothing.
If it gets in your eyes: Rinse with a gentle stream of water (at least 15 minutes). Seek medical attention.
If it gets on your skin: Wash the affected area with soap and water
If inhaled: Fresh air, rest and warmth
Inflammable: Fire class 2A. Flashpoint + 27.
In case of fire: Extinguish with carbon dioxide, powder or foam.
Storage: In well-sealed receptacle in a dry, cool place. Keep out of reach of children.

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.
- Renew the fuel filter. when draining the oil and
- Fill the engine with preservative oil up to the minimum level on the coolant.
dipstick. Dispose of used oil and coolant
- Mix preservative fuel in a can. Detach the fuel pipe at the feed pump through an authorised waste
suction line and connect a hose from the can. disposal contractor.
- Detach the fuel pipe at the overflow valve and connect a return hose to
the can.
- Start the engine and run it at about 1000 rpm (not single-speed engines)
for 20-25 minutes.
- Stop the engine, remove the hoses and connect the regular fuel lines.
- Remove the rocker covers and lubricate the valve mechanisms and PDE
mechanisms with preservative oil. Refit the rocker covers.
Note: The PDE injectors should not be removed.
- Drain the preservative oil from the engine. Fresh engine oil can be filled
directly or when the engine is taken out of storage.
- Drain the coolant if the engine is not to be stored with a full cooling
system. Plug and tape over all coolant connections (if the cooling system
is not completely assembled).
- Drain the seawater system.
- Air cleaner: Clean or change the filter element.
- Cover air intakes and exhaust pipes.
- Alternator and starter motor:
- Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or the
equivalent.
- Spray the outside of bright engine parts, first with penetrating
preservative oil such as Dinitrol 25B and then with Dinitrol 112 or the
equivalent.
Winter storage
- To reduce the risk of condensation in the fuel tank during winter storage,
fill the tank with fuel.

- Attach a label to the engine showing the date of preservation and
clearly stating that it must not be started or cranked.
STORED ENGINE
Date . . . . . . . . . . .
Do not start or crank!
Batteries
Remove the batteries for trickle charging at the battery charging station.
(Does not apply to batteries which according to the manufacturer do not
require any maintenance). The same is applicable for short-term storage if the Wear gloves and protective
engine has not been prepared for storage as above. goggles when charging and
handling batteries
Storage The batteries contain a highly
After the preparations, the engine should be stored in a dry and warm place corrosive acid.
(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 system with coolant, see page 22.
- Connect the seawater system.
- Check the oil level in the engine or fill up with fresh motor oil.
- Lubricate the valve mechanisms and their pushrods and valve tappets as
well as the PDE injector mechanisms.
- Drain the preservative fuel from the fuel manifolds and fuel filter.
- Connect and bleed the fuel system, see page 47.
- Wash off any externally applied preservative oil, using white spirit.

TECHNICAL DATA
GENERAL DI16
Number of cylinders 8 (V8, 90°)
Cylinder diameter mm 127
Stroke mm 154
Capacity dm3 (litres) 15,60
No. of main bearings 5
Firing order 1-5-4-2-6-3-7-8
Compression ratio 16:1
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 0,45
exhaust valve mm 0,70
Weight with heat exchanger, without coolant or oil kg 1550
Power see engine card, "Engine record card"
LUBRICATION SYSTEM
Maximum oil pressure
hot engine at engine speeds 6
above 1000 rpm bar (kp/cm2)
Normal oil pressure
hot engine at operating speed bar (kp/cm2) 3-6
Minimum oil pressure
hot engine, 1000 rpm bar (kp/cm2) 3,0
Minimum oil pressure
hot engine, idling bar (kp/cm2) 1,4
Oil capacity, see page 27
Crankcase pressure with closed -55 - +20

crankcase ventilation mm VP

FUEL SYSTEM DI16
Low idle speed rpm 700 (adjustable 500-800)
Maximum full load speed See engine card
Fuel Diesel fuel oil1
1
see page 60
COOLING SYSTEM
Number of thermostats 1 (dual thermostat)
Thermostat, opening temperature °C 79
Coolant temperature:
system at atmospheric pressure °C 70 - 93
system at overpressure °C 70 - approx. 100
Volume including heat exchanger and expansion tank 95
ELECTRICAL SYSTEM
System voltage V 24
Alternator, current A 140
Starter motor output kW (hp) 6,7 (9,1)
Monitors, alarm values:
oil pressure monitor bar (kp/cm2) 1,0 ± 0,15
temperature monitor °C Stamped on hexagonal part of monitor

FUEL
Diesel fuel oil
The composition of the diesel fuel oil has a great influence on the functioning
and the service life of the engine and the injection system. The engine output
and exhaust emissions are also dependent on the fuel quality. The
requirements and testing standards for the most important properties are
described in the service manual in sections which can be ordered from Scania
dealers or directly from Scania. The address of Scania is printed on the cover.
The diesel fuel must meet European standard EN 590.
The table below shows the requirements for some of the most important
properties:
Property Requirement
Viscosity at 40°C 2.0 - 4.5 mm2/s (cSt)
Density at 15°C 0.82 - 0.86 kg/dm3
Sulphur (concentration by mass) max. 0.3%
Ignitability (CET rating) min. 49
Flashpoint 56°C
Environmentally favourable fuels (low sulphur fuels)

There are three classes of so called environmentally favourable fuels
(SS15 54 35). Class 1 is sulphur-free and class 2 is low in sulphur. Compared
with class 3 (normal fuel), these fuels are less dense and this reduces engine
power output. Only class 1 fuel should be used with a catalytic converter.
Short term use of fuel with a higher sulphur content than 0.05% by weight
will not cause permanent damage to the catalytic converter.
The catalytic converter may, however, require fuel with low sulphur content
for some time after this to regain its normal efficiency.

Temperature dependence of diesel fuel
At temperatures lower than those specified for the diesel fuel, paraffin wax
may precipitate from the fuel and block filters and pipes. The engine can then
lose power or stop.
The diesel fuel is adapted for use in the specific climate of each country. If a
It is not permitted to mix
vehicle or an engine is to be operated in a temperature zone with lower kerosene with diesel fuel that is
temperature than normal, first identify the temperature properties of the already adapted for the climate
fuel concerned. concerned. This can damage the
The properties of the fuel when cold can be improved by adopting one of the PDE injectors. All use of
following measures before the temperature drops: paraffin other than kerosene is
- If the fuel concerned cannot cope with the expected temperatures, and
forbidden, as it causes engine
diesel fuel is not available with the correct temperature properties, we damage.
recommend that an electric fuel heater is installed as a preventative
measure.
- The low temperature properties of diesel fuel may be improved by
adding kerosene as a preventative measure. A maximum of 20% may
be added. When refuelling, the kerosene should be added first, so that it
mixes thoroughly with the diesel fuel.
It is not permissible to mix
Note: It is prohibited to use kerosene in engine fuel in some countries. petrol with diesel fuel. In the
- To prevent water in the fuel from freezing and forming ice, a maximum long term, petrol may cause
of 0.5-2 % alcohol (isopropanol) may be added. wear to the PDE injectors and it
Drain fuel tanks and drain or change fuel filters regularly. may also cause damage to the
engine.

ALPHABETICAL INDEX
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Air cleaner, vacuum indicator . . . . . . . . . . . . 44 Lubricating oil system . . . . . . . . . . . . . . . . . . 30
Air filter, element . . . . . . . . . . . . . . . . . . . . . . 44 Lubrication pressure . . . . . . . . . . . . . . . . . . . . 26
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bleeding, fuel system . . . . . . . . . . . . . . . . . . . 47 Maintenance Schedule . . . . . . . . . . . . . . . . . . 29
Certified engines . . . . . . . . . . . . . . . . . . . . . . . . 5 Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Changing the battery . . . . . . . . . . . . . . . . . . . 49 Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Changing the fuel filter . . . . . . . . . . . . . . . . . . 46 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Checks after running . . . . . . . . . . . . . . . . . . . 27 Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Checks before running . . . . . . . . . . . . . . . . . . 23 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Coolant level monitor . . . . . . . . . . . . . . . . . . . 49
Coolant temperature . . . . . . . . . . . . . . . . . . . . 25 PDE injectors . . . . . . . . . . . . . . . . . . . . . . . . . 52
Coolant, changing . . . . . . . . . . . . . . . . . . . . . . 39 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 35 Preparations for storage . . . . . . . . . . . . . . . . . 55
Cooling system, cleaning . . . . . . . . . . . . . . . . 40
Corrosion inhibitor . . . . . . . . . . . . . . . . . . . . . 39 Safety information . . . . . . . . . . . . . . . . . . . . . 10
Safety precautions for care and maintenance . 12
Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Safety precautions for handling materials . . . 12
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Safety precautions for running the engine . . . 11
Starting the engine . . . . . . . . . . . . . . . . . . . . . 23
Electrical system . . . . . . . . . . . . . . . . . . . . . . . 48 Stopping the engine . . . . . . . . . . . . . . . . . . . . 27
EMS sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Environmental responsibility . . . . . . . . . . . . . . 4 Taking out of storage . . . . . . . . . . . . . . . . . . . 57
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 58
Filter, air cleaner . . . . . . . . . . . . . . . . . . . . . . . 44 Troubleshooting, control unit . . . . . . . . . . . . . 18
Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Troubleshooting, coordinator . . . . . . . . . . . . . 20
First start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Type designations . . . . . . . . . . . . . . . . . . . . . . 14
Flashing codes, control unit . . . . . . . . . . . . . . 19
Flashing codes, coordinator . . . . . . . . . . . . . . 21 Vacuum indicator . . . . . . . . . . . . . . . . . . . . . . 44
Fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Valve clearances . . . . . . . . . . . . . . . . . . . . . . . 52
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fuel specifications . . . . . . . . . . . . . . . . . . . . . 60 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fuel system, bleeding . . . . . . . . . . . . . . . . . . . 47
Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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What are the important safety precautions mentioned in the manual?

What are the important safety precautions mentioned in the manual?

What are the different maintenance schedules mentioned in the manual?

What are the different maintenance schedules mentioned in the manual?

Industrial & Marine Engines

Start of Warranty - Start-up Report

START OF WARRANTY = START-UP REPORT

START-UP REPORT - WARRANTY

User's name and address

2 © Scania Industrial & Marine Engines 2003-09:4

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CHECKING THE MARINE WATER PUMP

STARTING AND RUNNING . . . . . . . . . . . 22 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 48

LUBRICATING OIL SYSTEM . . . . . . . . . 30 LONG-TERM STORAGE . . . . . . . . . . . . . . 55

2003-09:4 © Scania Industrial & Marine Engines 3

4 © Scania Industrial & Marine Engines 2003-09:4

Important! If servicing and maintenance are not carried out as specified

2003-09:4 © Scania Industrial & Marine Engines 5

EMISSION CONTROL SYSTEM

General Warranty Provisions

6 © Scania Industrial & Marine Engines 2003-09:4

• A period of years equal to at least 50 percent of the engine's useful life

• "If the marine vessel is placed in service for demonstration purposes

Parts covered by the Warranty

2003-09:4 © Scania Industrial & Marine Engines 7

8 © Scania Industrial & Marine Engines 2003-09:4

Scania USA, Inc

2003-09:4 © Scania Industrial & Marine Engines 9

A list of the safety precautions to be followed when running and maintaining

• When fuelling and close to the filling station

• When working on the fuel system

• In the vicinity of inflammable or explosive material (fuel, oils,

10 © Scania Industrial & Marine Engines 2003-09:4

Daily inspection Starter lock

2003-09:4 © Scania Industrial & Marine Engines 11

12 © Scania Industrial & Marine Engines 2003-09:4

2003-09:4 © Scania Industrial & Marine Engines 13

Displacement in whole dm3

Performance and certification code

14 © Scania Industrial & Marine Engines 2003-09:4

2003-09:4 © Scania Industrial & Marine Engines 15

16 © Scania Industrial & Marine Engines 2003-09:4

1. Oil pressure sensor

2003-09:4 © Scania Industrial & Marine Engines 17

Reading off control unit fault codes

Erasing fault codes (flashing codes)

18 © Scania Industrial & Marine Engines 2003-09:4

Code Description Code Description

Starter motor function interrupted or not

31 Torque limitation due to oil pressure 87 Fault in control unit RAM.

33 Battery voltage incorrect or no signal. 89 Incorrect seal: Illegal editing of software.

Emergency shut-off switch activated in

Immobiliser function. Ignition key code Torque limitation due to high

Incorrect CAN version in control unit or

PDE in cylinder 1: The solenoid valve does not

2003-09:4 © Scania Industrial & Marine Engines 19

Reading off coordinator fault codes

Erasing fault codes

20 © Scania Industrial & Marine Engines 2003-09:4

Flashing Description of fault

112) Faulty signals from the accelerator pedal sensor.