‘Scania Engines IMPORTANT When working on the engine, for example adjusting drive belts, ol change or adjusting the cluteh, FORMATION its important not to start the engine. The engine may be damaged and there is ZN SERIOUS RISK OF INJURY For this reason, always secure the starting deviee or disconnect a battery cable before working on the engine. ‘This is especially important if the engine has a remote starter oF automatic starting This warning symbol and text is reproduced beside those maintenance points where it is especially important to consider the risk of Operator's Manual DI12, DCI2 EMS with $6/PDE Industrial engine: opm03-12a en 1588 758 2n07-tts4 START-UP REPORT - WARRANTY When the commissioning report has boen filled in and sent to Sania, you havea I-year warranty from the date of commissioning, Also fill in the particulars below as this ean 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 e int Engine type and variant are indicated on the engine type plateFOREWORD This Operator's Manual describes the handling and maintenance of Seania C12 and DII2 Industrial Engines with EMS S6/PDE injection systems. ‘The engines are of direct injection, liquid-cooled, four-stroke, 6-cylinder in line diesel type. These engines have turbochargers and charge air coolers: see page |4. ‘Common applications are as power units in construction machines, generator sets, earth- moving, rallway and forestry machines as well as in irigation systems. ‘The engines can have different output and speed settings. The normal output setting ofthe engine (performance cad) is indicated on the type plate, see page 14 Not Only standard components are described in the instruction manual. Regarding special equipment, refer to the instructions of the relevant manufacturer. In order to obtain the best value and service life from your en, several points you should bear in mind! i, there are ~ 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 instruetions. Good working order and service life are ensured if maintenance is carried out according to the instructions, + In particular, read the safety information starting om page 10. = Gel to know your engine so that you know what it can do and how it ‘works, ~ Whenever necessary, always contact an authorised Scania workshop. ‘They have special tools, genuine Scania parts and staff with training and| practical experience of Seania engines. Not Always use genuine Scania parts during service and re to keep your engine in the best possible working order. 1 Important During the warranty period, ‘only genuine Scania parts may be used during service and repair otherwise the warranty vill be invalidated, The information inthis manual was correct atthe time of going to press However, we reserve the right to make alterations without prior notice, 2 © Scania CV 2007CONTENT: FOREWORD 2 CHECKING COOLANT LEVEL 36 ENVIRONMENTAL RESPONSIBILITY 4 CHECKING THE COOLANT 3 CERTIFIED ENGINES 5 ‘Checking protection against corrosion .... 39 SCANIA INDUSTRIAL AND MARINE ENGINE ‘Changing the coolant 39 WARRANTY FOR INDUSTRIAL ENGINES ...6 CLEANING THE COOLING SYSTEM |. 40 SAFETY DETAILS 0 Internal cleaning .......+0e0ececseeeedl Safety precautions for operation u Safety precautions for handling materials 12 AIR CLEANER vs vsseeseeseesesesee eA Safety precautions for care and maintenance 12 READING THE VACUUM INDICATOR ....42 TYPE DESIGNATIONS 4 ENGINE MANAGEMENT SYSTEM, EMS 16 Troubleshooting using flashing codes for the EMS control unit, 20 Overview of flashing codes for EMS control uait 21 ‘Troubleshooting using Mashing codes for the FMS coordinator 2 Overview of lashing codes for EMS coordinator 23 STARTING AND RUNNING . AT FIRST START (CHECKS BEFORE RUNNING. STARTING THE ENGINE ‘Starting at low temperatures DRIVING Rotation speed 26 Limp-home mode 27 Coolant temperature 27 Oil pressure 28 STOPPING THE ENGINE 29 CHECKS AFTER RUNNING 29 MAINTENANCE ...eeeeeeeeeeeeeee0 30 ENGINES WITH FEW HOURS OF OPERATION ..... eee a0 MAINTENANCE SCHEDULE 31 LUBRICATING OIL SYSTEM OIL GRADE Oil analysis 32 (CHECKING OIL LEVEL, 33 ‘Checking ol level during operation 33 OIL CHANGE 33 Maximum angles of inclination during operation 33 CLEANING THE OIL CLEANER M4 CHANGING THE OIL FILTER 36 COOLING SYSTEM . CLEANING THE AIR CLEANER COARSE CLEANER 2 CLEANING OR CHANGING THE FILTER ELEMENT a CHANGING THE SAFETY CARTRIDGE ....43, FUEL SYSTEM ....0sssesseseseeeeseee dd (CHECKING THE FUEL LEVEL “a CHANGING THE FUEL FIL 44 ELECTRICAL SYSTEM 46 (CHECKING ELECTROLYTE LEVEL IN BATTERIES 46 CHECKING STATE OF CHARGE IN BATTERIES 46 CLEANING BATTERIES 46 CHANGING THE BATTERY 47 CHECKING THE COOLANT LEVEL MONITOR a MISCELLANEOUS . 48 (CHECKING THE DRIVE BELT 48 LOOK FOR LEAKAGE, TAKE NECESSARY ACTION re) (CHECKING/ADIUSTING VALVE CLEARANCES 50 CHECKING/ADJUSTING THE PDE INIECTOR ROCKER ARMS, 5 CHANGING (on CLEANING) THE CLOSED. CRANKCASE VENTILATION VALVE, .... 54 LONG-TERM STORAGE . Preservative fue! Preservative oil Preparations for storage Batteries Storage ‘Taking out of storage TECHNICAL DATA ... FUEL ALPHABETICAL INDEX . © Scania CV 2007 3ENVIRONMENTAL RESPONSIBILITY cania has always been atthe foreftont in the development and production of Witonmentally safe engines. We have made great progress in reducing harmful exhaust emissions to be able to meet the stringent emission standards that are mandatory for slmost all markets We have done this without compromising the high quality of Seania industrial and marine engines in terms of performance and cost effective ‘operation To maintain these superior properties throughout the life ofthe engine itis important thatthe operator/owner follows the instructions of this manual as regards operation, maintenance and choice of fuel and lubricants, To further contribute to protecting the environment in service, maintenance ‘and repair, ensure that harmful waste (oil, fuel, coolant, filters, batteries ete-)-— ¢ Be teed eines is disposed of and destroyed according to applicable local regulations. environment! Always use suitable containers ‘This operator’s manual contains highlighted text urging you to protect the ‘environment in different service and maintenance operations. Refer to example 4 © Scania CV 2007CERTIFIED ENGINES ‘An emission centfied engine has been approved according to a specific certification standard. The cenified engines delivered by Scania meet the ‘most compelling emission standards in the European (EU) and non-European (USA) markets Scania guarantees that all engines ofa certified engine type that are delivered, ‘correspond to the engine approved for certification ‘The engine is Fitted with a certification plate, stating according 10 which certification rules (standard) the engine has Been approved. Refer to page 14. ‘The following is required forthe engine to meet the emission standards after being commissioned: = Service and maintenance must be performed according o this Operutor’s Manual. Only genuine Scania parts must be used. = Service work on the injection equipment must be performed by an ‘authorized workshop. The engine must not be modified with equipment not approved by Scania Seals and setting data may only be broken/modified by an authorised workshop. Changes affecting the exhaust system and intake system must be ‘approved by Scania. ‘Otherwise, follow the instructions in this manual for operation, care and ‘maintenance of the engine. Also observe the safety precautions described in the Following four pages Important! 1f service and maintenance are not performed as stated ‘above, Seania cannot guarantee thatthe engine corresponds to:the certified configuration and will not assumte liability for ‘any damage occurring, For products used in the U.S.A., see next pages for special warranty regulations © Scania CV 2007SCANIA INDUSTRIAL AND MARINE ENGINE WARRANTY FOR INDUSTRIAL ENGINES EMISSION CONTROL SYSTEMS WARRANTY Important Only applicable to engines used in the U.S.A. Table of contents General Warranty Provisions 6 Warranty Period 7 Parts covered by the Warranty ae) General Warranty Limitations .......266..2000268 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 ("Sania") industrial diesel engine were designed, built and tested using. ‘genuine parts, and were certified as being in conformity with federal emission control regulations. Scania warrants to the original owner, and to each subsequent owner, oF new Seania industrial diesel engine that the engine: 1. Was designed, built and equipped so as to conform atthe time of sale ‘with all applicable regulations under Section 213 of the (Clean Air Act 42 US.C. § 7547; and 2. 1s free from defects in material and workmanship which would cause such engine o fil to conform to applicable regulations for its warranty period, 6 © Scania CV 2007Warranty Period ‘This warranty shall apply for one ofthe following periods, whichever occurs first + 3,000 hours of operation, oF + Five years of use ‘The warranty period shall begin: the date the engine is delivered to the fist retail purchaser, oF + "Ifthe engine is placed in service for demonstration purposes prior to sale at retail, on the date the engine is frst placed in service, Parts covered by the Warranty ‘The following is a lst of parts consideredto be part ofthe Emission Control Systems covered by the Emission Warranty for Scania industrial engines Which were built to conform to federal emission control regulations 1, Fuel injection system 2. Air intake system 4. Intake manifold b. Turbocharger system «. Change air cooler system 3. Exhaust manifold 4, Combustion chamber . Piston ». Cylinder head 5. Components used in the above mentioned systems Important This list does not include all expendable maintenance parts. Expendable emission related parts requiring scheduled ‘maintenance are warranted until ther frst scheduled replacement point, See Specific Warranty Exclusions below. © Scania CV 2007General Warranty Limitations To retain the dependability of the exhaust emission eonteol originally built, into your Scania industrial diesel engine, i is essential thatthe engine is, installed according to Scania installation instructions and emission certificates In addition, you are responsible for the performance of all scheduled ‘maintenance and necessary repairs on your new Seania industrial diesel ‘engine. Scania may deny a warranty claim if your failure to perform maintenance resulted in the failure ofthe warranted par, listed under Paras ‘covered by the Warranty above. Receipts covering the performance of regular maintenance should be retained inthe event questions arise concerning maintenance. The receipts should be transferred to each subsequent owner ofthe engine withthe emission ‘warranted engine, ‘The Warranty covers the cost of repair and replacement parts und services of warranted components and systems performed by an authorized Seania distributor or dealer using genuine Seania parts. You may elect o 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 nt 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, itis recommended that only Scania repair or replacement parts be used for maintenanee, repair or replacement of emission control systems. Ifother than Scania parts are used for maintenance, repair or replacement, the owner should obtain assurance that such parts are warranted by thelr manufacturer to be equivalent to genuine Scania parts 8 © Scania CV 2007Specific Warranty Exclusions This warranty doesnot cover: 4. Malfunctions in any part caused by any ofthe following: misuse, abuse, inyproper adjustments, modifications alteration, tamperin disconnection, improper or inadequate maintenance, or use of fuels not recommended for the engine as described inthe Operator's Manu 2. Engine installation, including cooling system, intake system and exhaust, system installation, that is not completed in accordance with the 8 installation emissions certificate for this engine type. 3. Damage resulting from accidents, acts of nature or other events beyond the control of Seania, 4, The replacement of expendable maintenance items suchas filters, hoses, belts, oil, thermostat, exhaust system and coolant made in connection ‘with scheduled maintenance services once these parts have been replaced, 5. Replacement items which are not genuine Scania parts or not authorized by Scania 6. inconvenience, loss of use ofthe engine or commercial Loss. 7. Any engi e on which the actual use cannot be accurately determined 8. Any engine operating outside the United States Customer Support Inthe event that you do not receive the warranty service to which you believe ‘you are entitled ander the Warranty, or if you need additional support or information conceming the Warranty, please contact: Scania USA, Ine 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@scaniausaine.com © Scania CV 2007SAFETY DETAILS General This Operator's Manual contains safety information that must be observed in ‘order to avoid personal injuries and damage to the preuet or property, Refer to page | The text boxes to the right on the pages provide information that is important for the proper operation of the engine and to avoid damage tothe engine Failure to follow these instructions may void the warranty. Refer to example. Y important: Only use Seania genuine fuel filter. Correspondi texts may also appear in the text column, headed Note or Important ‘The warning text in text boxes tothe right on the pages provided with « warning triangle and headed WARNING is extremely important and warns| ‘of serious defeets to the engine or improper handiing that may lead to personal injury | Refer to example AX WARNING Immobilise the starting device when working on the engine. If the engine starts out of control, there is a SERIOUS RISK (OF INJURY. ‘The safety precautions that must be observed in the operation and maintenance of Scania engines are compiled on the following three pages. The corresponding text is also offen stated next to the maintenance step ‘concerned, shown with different degrees of significance as described above. Alitems are marked witha ! to highligh the importance of reading each item inthe sation A general safety ruk s that no smoking is allowed: + Near the engine and the engine bay + When refuelling and near the filling station + When work is performed on the fel system + Near flammable or explosive materials (fuel, ols, batteries, chemicals ste.) 10 © Scania CV 2007Safety precautions for operation ' ® Daily inspection ‘Always perform visual inspection of the engine and engine bay before the engine is started and when the engine has been stopped after opera~ tion, This will make it easy to detect any leakage of fuel, oil or coolant or any other abnormal condi tion that may require remedial action. * Refuelling When refuelling, there is a risk of fire and explo: sion. The engine must be stopped and smoking isnot allowed. Do not overill the tank, since the fuel may ex- ppand, and close the fuel filer cap properly. Only use fuel recommended in the service literature. Fuel of an incorrect grade may cause ‘matfunctions or stoppage by interfering with the ‘operation of the fuel injection pump and the in- ectors, This could cause engine damage and possibly personal injury. Harmful gases Only start the engine in a property ventilated area. The exhaust emissions contain carbon ‘monoxide and nitrogen oxides that are toxic. When operating the engine in an enclosed area, an effective extraction device for exhaust {gases and crankcase gases must be used. 1 * Starter lock the control panelis not fitted with akey switch, the engine bay should be fitted with a lock to prevent unauthorized starting of the engine. Alternatively, a lockable main switch or battery ‘master switch may be used. © starting spray Never use stating spray o similar asa stating aig, An expiosion may occur inthe intake pipe, which could cause personal injury. © operation The engine should not be operated in environ- ‘ments with surrounding explosive materials since electrical or mechanical components of the engine may emit sparks. His always a safety hazard to be near an engine that is running. Body parts or clothing, or a dropped tool may get stuck in rotating parts, such as the fan, causing bodily injury. Always cover rotating parts and hot surfaces as much as possible to ensure personal safety. © Scania CV 2007 "Safety precautions for handling 2 terials ! ‘cation oi * Fuel and lubrication oil Al fuels and lubricants as well as many chemi- cals are flammable. Always follow the instruc- tions stated on the container. Allwork on the fuel system must be performed when the engine is cold. Fuel leakage and spill age on hot surfaces may cause fire. ‘Store drenched rags and other flammable mate- rials ina safe way to avoid spontaneous com: bustion. T patories Batteries, particularly when being recharged, emit highly flammable fumes that can explode. Donot smoke or let open flame or sparks come near the batteries or the battery compartment. Incorrect connection of a battery cable or jump startcable may cause a spark, which intun may ccause the battery to explode. chemicats Most chemicals, such as glycol, corrosion inhib- itors, preservation oils, degreasers etc. are haz- ardous. Always follow the safety precautions stated on the container. ‘Some chemicals, e.g. preservative oil, are flam- mable, ‘Always store chemicals and other hazardous ‘materials in approved and distinctly marked containers and out of reach of unauthorized per- sons. Always dispose of superfluous or used chemicals through an authorized waste dispos- al contractor. Safety precautions for care and maintenance Stop the engine Always stop the engine before any maintenance and service work unless otherwise stated. Prevent unauthorized starting by removing the starter key and turning off the power by the main switch or the battery disconnect switch, locking itin the off postion. Also attach a warning tag, stating that work on the engine is in progress, at a suitable location. Itis always a safety hazard to work on an engine that is running. Parts of your bady or clothing, or ‘a dropped tool may get stuck in rotating parts, causing bodily injury. Stor surfaces and Maids Ahot engine always presents ask of scalding. ‘Aways take care nolo touch the exhaust manta, tubocharger, ol pan Not coolant and oilin pipes and hoses T Lantng the engine Use the engine lifting eyes when lifting the engine. First chock that the lting equipment is in proper condition and has sufcient it capac- iy rating ‘Auxiliary equipment fited tothe engine may cause the centre of gravity to be displaced Thus, additional lit devices may be required in crder to provide proper balance and a sate it. ‘Never work below a suspended engine! T paweries Batteries contain a highly corrosive electrolyte (sulphuric acid). Always take care to protect your eyes, skin and clothing when charging and handling batteries. Wear protective gloves and goagies. electrolyte splashes on the skin, wash the affected part of the body with soap and plenty of water. electrolyte splashes into the eyes, rinse eyes immediately with plenty of water and seek medical attention. Dispose of used batteries through an authorized waste disposal contractor. © Scania CV 2007Electrical system Before work is performed on the electrical sys- tem, turn off the power by the main switch or the battery disconnect switch. Aso disconnect any external power supply to auxiliary equipment on the engine. are Welding Bofore woding near or onthe engine, remove the battery and atrnator cables Also remove the contol unt connect, Connect the weldclampto the componentiobe welded, close othe weld oration. Never con nectito tre enghnoorinsuchawey that the cur- rent can pass though a beating After he welding is completed, connec he ca- bles tothe allmatorand the conto unt before connecting the bettie. ' * Lubrication system Hot oil may cause scalding and skin irritation. ‘Avoid skin contact with hot ol, ‘Make sure that the pressure in the lubrication systom is relieved before work is carried out. over start or operate the engine with the oil fill er cap removed since oil will be ejected forceful- ty Dispose of used oil through an authorized waste disposal contractor. F cooting system Never open the coolant filler cap while the en- gine is hot. Steam and hot coolant can come out forcefully and cause scalding, IM the cooling system must still opened or disas- sembled while the engine is hot, open the filer cap very cautiously and slowly to release the pressure before the capis removed. Use gloves since the coolant is still very hot. Dispose of used coolant through an authorized waste disposal contractor. © Fuel system ‘Always use gloves when chacking for leaks in or performing other work on the fuel system. Al- ways wear eye protection when testing inje tors. Fuel escaping under high pressure can pene- trate body tissue and cause serious injury. Never use non-genuine parts in the fuel system and the electrical system. Genuine parts are de- signed and manufactured to minimize fire and explosion hazard, 1 petore starting Install any guards that have been removed be- fore the engine is started. Check to ensue that no tools or oher objects have been et on the engine. Never start the engine unless the alr fiter is in- stalled. Otherwise there is a risk of objects en- tering the compressor wheel or a risk of personal injury trom contact with it © Scania CV 2007 13TYPE DESIGNATIONS The engine designation indicates, in the orm of a code, the type ofengine, its size an applications, tc The type designation and engine serial number are indicated on a type plate affixed to the right-hand side of the flywheel housing. The engine number is also stamped on the right hand side of engine block. See arrow ia the illustration DI 1254A 01P 1 ype J DC Supercharged diesel engine with air-cooled charge air cooler. DI Supercharged diesel engine with liquid-cooled charge air cooler Displacement in whole dm: Performance and certification code Indicates, together with the application code, the normal gross engine ouput. ‘The actual output setting of the engine is indicated on the engine card, Application A For general industrial use Variant 01-99 Type of regulator: P EDC engine management system with PDE and $6 “ © Scania CV 200715 14 The illustrations show a normal version of a 0112 engine, Your engine may have different equipment from that ilustrated. Type plate Engine number, ‘stamped into the engine lock Coolant pump Automatic belt tensioner Draining, coolant 6. Oi fiter 7. Oil cleaner 8. Oil dipstick 9. Draining, engine oil 10. Oil cooler 11. Turbocharger 12, Oiltop up © Scania CV 2007 13. 14. 15. 16. 17. 18. Hydraulic pump Fuel pump with hand pump Starter motor ‘$6 control unit Fuel fiter Charge air cooler 18ENGINE MANAGEMENT SYSTEM, EMS ‘This engine has an eleetronie management system, EMS (Engine Management System) with unit injectors (PDE) which provide each eylinder ‘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 tothe control uit With the aid ofthis input data and the programmed control software, the cconrect fuel amount and correct injection time are calculated for each unit injector (PDE) under the speeifie operating conditions. The EMS system sensors can also be used to emit signals tothe instruments inthe 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 ofa fault which would otherwise damage it. Inthe event of a fault, ‘eg. 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 16 © Scania CV 2007When the EMS control unit or the coordinator detects a fault, the diagnosties lamp on the instrument panel/s comes on, and it stays on as long asthe fault is active. At the same time, a fault code is generated wich can be read off via the coordinator on the diagnostics lamp in the form fa 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 deseribed 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 ifthe engine shutoff function is activated, the engine is shut off a 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, Emgine Management System EMS-S6: Troubleshooting. Only authorised personnel are allowed to carry out diagnostic procedures and program changes. ‘The positions ofthe sensors which emit signals tothe contral unit are shown in the illustrations on page 19. ‘See pages 20 and 22 for a description of how to read off flashing codes, See pages 21 and 23 fora list of flashing codes for the contro unit and ‘coordinator. © Scania CV 2007 718 35807 4. Oi pressure sensor 2, Sensorfor charge ar temperature and pressure 3. Coolant temperature sensor 4. Engine speed sensor (2) © Scania CV 2007Positions of sensors for EMS with 6 on DI12 L i pressure sensor ‘Sensor for charge air temperature and pressure Coolant temperature sensor Engine speed sensor (2) © Scania CV 2007 19‘Troubleshooting using flashing codes for the EMS control unit +The diagnostics lamp on the instrument panels 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 diagnosties 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 offand 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 41, Turn on the ignition 2. Activate the diagnosties switch tothe 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 | second long) and short flashes (033 seconds long). Long flashes are equivalent to tens and short flashes to unis Example: fong - short short = fault code 12. 4. Repeat this procedure until the firs lashing code is repeated. This means thatthe entire fault code memory has been flashed up. Ifthe fault ‘code memory is empty, only one long flash approximately 4 seconds long willbe given, 5. Sce 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 Seania workshop. 7. When a faulthas been rectified the fault code ean be erased as described below. Erasing fault codes 41, Tur the ignition off, I'he vessel has dual instrument must he switched off o both panels. jon the ignition 2. Activate the diagnostics switch in the same direction as the flashing ‘codes indicate, ie. to the ight for the coordinator (COO) orto the left for EMS. 3. Switeh on the ignition and keep atthe same time the diagnostics switeh activated, to the right (COO) orto the left (EMS), for 3 seconds. 4. This will erase passive fault codes which can be read off via Mashing ‘code for the relevant system. The rest ofthe Fault code will remain in the EEPROM and can only be deleted using the PC tool 20 © Scania CV 2007Overview of flashing codes for EMS control unit Code Description Code Description PDE in cylinder 5: The solenoid valve dose not 0 [No faut detected, 53 | Work correct, Qverspeed. One or bath engine speed. PDE in cylinder 4: The solenoid valve does not 11 | sersoisare sustayng speecsinGxcessot | 54 | FOR erly Se LR eR PP PUTT PDE in cylinder The solenoid valve does not 12. | Engine speed sensor 1 fauty orfauty signa, | 55 | POE cylin 13. |evonesressosorZinayertnysaras | 86 [POE ogre aaa Seat 14 _ | Codlant temperature sensor faut or faulty | 5 | PDE oyinder 7: The solenoid valve doas not signal 57 | work corey Charge ai tmporature sonsor faulty 0” Fault PDE In eyindor & Tho soloneid valve does nat 15 | Sonal a yormey’ | 58 [work corey 1a | Sree ree TBI eHOR | 55 Traut optim one ann 17 _[Oiltemperature sensor fauty or faulty signal. | 61 | Incorrect contol unt shutdown, 18 [Oil pressure sensor faulty or faulty signa 66 _ | Shutoff due to coolant level. ‘Starior motor funcion interrupted or not 20 | Coolant level sensor faulty. 69 | activated . 23 _| Fault code internally in the coordinator. 82 _ | Engine speed above refspeed at start, 2a | Accelerator. Wit accelerator andbrake | — gy | Faultin memory ercut (EEPROM) in corral have been operated simultaneously. unit 735 _ | Accelerator sensorile snitch 84 _ | Dale eanster tothe contol unit memory ‘Accelerator sensorhickdown switch (EEPROM) has been interrupted. (85 _ | correct temperature internally inthe control 27 [Engine shutdown bypassed te ‘Internal faultin the control unit’ Fault in 28. | shutoff dve tool pressure. 86 | frdnare conor 31_| Torque liitation due to ol pressure 87 _| Fauttin contol unit RAM. 32 [incorrect parameters for imp home unction. | 88 | intemal contol unit faut: Memory fault 33 _| Battery voltage incorrect or no signal 89 | incorrect seat: legal editing of software Eimergency shutoff switch acivaied in 37 | szordance win CAN messoge rom 93 | Engine speed sensors faulty or rot connected 43 | CAN circuit fauity in the contro! unit. 4 areata reece eee temparsture <7 | abba tain: ko cade 96 | xg aio se oR 48 [GAN moscage fom he coonatorincorect |g | routy vokage suply to one ofthe sensors, a9 eeineiee nee 99 | internal hardware fault in the processor (TPU). PDE incylinder 1 The solenokd valve does nat 51 | work correct PDE in cylinder 2. The solencid valve does nat 52. | work correct © Scania CV 2007 aSCANIA ‘Troubleshooting using flashing codes for the EMS coordinator +The diagnostics lamp on the instrument panels always comes on for two seconds when the system is powered up + As soon as a fault is detected by the coordinator, i is stored in the EEPROM fault code memory and the diagnosties lamp on the instrument panel/s comes on. ‘+ Even ifthe lamp has gone off and the fault ino longer active, the code can generally be read off in accordance with the instruction below. ator fault codes Reading off coordi 41. Turn on the ignition 2. Activate the diagnostics switch tothe right for 1 socond to view the flashing codes forthe coordinator (COO), 3. A fault code will then Mash on the diagnostics lamp. This flashing code ‘consists of long flashes (approximately | 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 firs flashing code is repeated. This means thatthe entire fault code memory has been flashed up. Ifthe fault ‘code memory is empty, only one long flash approximately 4 seconds long willbe given, 5. Sce the flashing code table on the next page for a description and localisation of the fault 6. Inorder to obtain further information on the Fault code, the PC-based diagnostics tool or Scania EMS Display must be used. Contact an authorised Seania workshop. 7. When a faulthas been rectified the fault code can be erased as described below. Erasing fault codes 1. Turn the ignition off If the vessel has dua instrumentation the ignition ust be switched off on both panels. 2. Activate the diagnostics switeh in the same direction as the flashing ‘codes indicate, ic. to the right for the coordinator (COO) orto the left for EMS, 3. Switch on the ignition and keep atthe same time the diagnostics switeh activated, to the right (COO) orto the left (EMS), for 3 seconds. ‘This will erase passive fault codes which ean be ead off via flashing code for the refevant system. The rest ofthe fault code will remain in the EEPROM. and ean only be deleted using the PC tool. 2 © Scania CV 2007Overview of flashing codes for EMS coordinator Flashing | Description of fault 111) | Faulty signal from the nominal speed signal fine adjustment. 117) | Faulty signals from the accelerator pedal sensor. 12") Incorrect signal from the resistor module for regulator setting. 127) Incorrect signal from the resistor module for idle and fixed speed setting. 13. [No communication (EMS) with the engine. 14 |Short-circultin the tachometer signal circuit. 15 _ | Faulty atmospheric pressure sensor. 17 | Short-circuit in the coolant temperature gauge signal cable. 18 | Short-circultin the oil pressure gauge signal circuit 19 |Short-circultin the oil pressure lamp signal circuit 21 [ferent version of the communications protocol between the coordinator and 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 |Faully remote start switch or short circuit. 31 [No communication from the stave-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 |Faultin CAN communication 1) Single speed engine 2) Allespeed engine © Scania CV 2007 23STARTING AND RUNNING AT FIRST START When the engine i started for the first time, the maintenance points listed under "First tart" in the maintenance schedule should be followed, see page 31 Since the points are important for satisfactory operation of the engine right from the outset, they are also listed below. 1. Checking the oil level (see page 33), 6, Checking the coolant level (see page 37). ‘The coolant should contain anti-carrasive to protect the cooling system from corrosion, Ir there is a danger of freezing: = Only anti-freeze giyeol should be used in the coolant as protection ‘against corrosion. We recommend oaly 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 0 -16°C. See page 37. = Never top up with only water or only glycol. Fluid losses must always ‘be replaced with pre-mixed coolant having the same glycol ‘concentration as that in the engine. Ifthe glycol content drops, both ‘anti-freeze protection and protection against corrosion are impaired. Note: A glycol concentration below 30% by volume will not provide sufficient protection against corrosion, Glycol concentrations higher than 60% do not improve anti-freeze protection and have a negative effect on engine cooling capacity. If there is no danger of freezing: = Only Scania Corrosion Inhibitor should be used in the coolant as protection against corrosion. The correct concentration of anticorrosivel is 812% by volume and this must never drop below 8% by volume. The itor in Seania Corrosion Inhibitor is free of nitcite ~ First filling: Fill up the system with water + 10% by volume Seania Corrosion Inhibitor. Use drinking water with a pH of 6 -9. ~ Never top up with only water or only anti-corrosive! Fluid losses must abways be replaced with blended coolant: water + 10% Scania Corrosion Inhibitor by volume. Coolant fi +r (not standard equipment) ‘Only coolant filter without inhibitor may be used. The use of coolant filters Coolant compositio ans sia minimum 30% glyeol by volume maximum 60% glycol by volume| 8-12% by volume ‘Scania corrosion inhibitor (no glycol) ZA\ wannine Ethylene glycol and corrosion inhibitor are toxic if ingested. Avoid contact with the skin. 4 dmportant- ‘The recommended glycols should not be mixed with glyco! containing nitrite-based corrosion inhi 4 important Overdosing with Scania Corrosion Inhibitor and mixing ‘with glycol can cause sludge to be formed. increases the life ofthe coolant and reduces the risk of deposition corrosion, Y dmportant Ia coolant filter has been fitted it must nat contain inhibitor. 24 © Scania CV 200712, Checking the fuel level (see page 44). 14, Checking the electrolyte level in batteries (see page 46). 15. Checking th ss 18, Checking the drive belt tension (see page 48) sate of charge in batter © page 46), ZX WARNING 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 31. STARTING THE ENGINE ZX Warne Only war the engine i a well ventilated area, : Itt is rum na enclosed spac, Cot consiterao frou omimon covirnnent, your Scania engin as : ee there should he an effective unnecessarily large amounts of fuel when starting te engine always results i] device to draw off exhaust gases the dchrge of aut el eee ~ Open the uel cok if ited seagaaecagae = Engines with ry master swish: Swish onthe powerhy mamsat -—/\. WARNING: the battery master switch, [he fuel tank has been run dry or ithe engine bas not been used for a long| time, bleed the fuel system (see page 45), Never use starting spray or similar as a starting aid, An explosion may oceur in the intake manifold with a risk of personal injury. Start the engine withthe key ia the control pas Dutton (only from RCB), 1 (SCP) or the start ‘$6: The diagnostics lamp should go out after approximately 2 seconds ‘when starting. © Scania CV 2007 25Starting at low temperatures Local environmental requirements must be complied wih, Stating aids, engine heaters andior Mame start devices should be used to avoid starting problems and white smoke “To limit white smoke, the engine should be run at low speed and under moderate load. A light load on a cold engine gives better combustion and faster heating than Warming up with no Toad, ‘Avoid running it longer than necessary at idling speed. At temperatures below 0°C: Note: Only use starting aids recommended by Scania = The starter motor may only be used for 30 seconds ata time. After that time it must rest for 2 minutes, Note: Ifthe engine is equipped with an INTERLOCK switeh, this switch should be depressed and held down until the oil pressure hhas reached a sufficiently high level. DRIVING Cheek instruments and warning lamps at regular interval, Rotation speed ‘The Scania tachometer is divided into sectors of different colours, as follows: (0-800 rpm red area: prohibited engine speed, passed through when stopping and starting. 500-7001pm ——yellowarea:—_slow/idle. Engine idling is Controlled by the S6 control system. Raised idling speed with a cold engine. See page 26. 700-2200 1pm green area: normal operating speed. ‘The engine operating speed range is controled by the ‘$6 control system. 2200-2600 1pm —_yellow/green__unsuitable operating speed. striped: May occur when switching off 2600-3000 1pm red area: prohibited engine speed 26 © Scania CV 2007 1 Important ‘The starter motor may only be connected for a maximum of 30 seconds. There is risk of overheating. Allow the engine to rest for 2 minutes between each attempt to start itLimp-home mode there is a fault on the normal accelerator pedal or if‘ CAN com 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 agcelerator pedal value can be increased slowly between 0% - 50% by using the idling switeh, CAN open circui = The engine is switched off ithe shutdown funetion is activate, Coolant temperature [Normal coolant temperature when the engine is running should be 70 - 90°C The $6 control system has the following alarm levels: 1 important + Hfthe temperature is high, 98°C - 103°, for certain prod (I second), Swill end a CAN message which switches onthe warning lamp and diggnosis lamp via the coordinator. Tam wil ome on Torque redaction i actted, econ psc | Pressure in the system, he will duos the fel guantity to 70%. A fault code is generated inthe | PPeSsure caps must not be used Control unt ‘on expansion tanks. Cooling systems with Seani radiators and plastic expansion tanks must not have excess = At temperatures exceeding 103°C and with engine shutdown activated, the warning lamp and diagnostics lamp come on and the engine is switched off. Ifthe override function is activated, only torque reduction takes place when this function is activated. A fault code is generated in the control unit, Afier an alarm, approved values should be registered for more than 2 seconds to reset the alarm, Excessively high coolant temperature can damage the engine. fun for extended periods under an extremely light load, the engine may have difficulty in maintaining normal operating temperature. However, the temperature will rise toa normal level again when the load on the engine is increased. © Scania CV 2007 2Oil pressure ‘Mas, oll pressure: ‘warm engine running ata specd above 800 rpm 6 bar Normal oil pressure: ‘warm engine running at an operating spesd of 3-6 bar oil pressure (above 6 bar) is normal when starting a cold engine. ‘Min. oil pressure warm engine running at speed of 1000 rpm 2.3 bar ‘The comtrol system has the following alarm levels: = ata speed of less than 1000 rpm and an oi pressure of less than 1.0 bar = at aspeed of more than 1000 pm 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 diagnosties lamp. The ‘engine is switched off if engine shutdown is activated, Ifthe override function is activated, only torque reduction takes place when this function is activate. A fault code is generated in the control unit Afer an alarm, approved values should be registered for more than I second to reset the alarm. 28 © Scania CV 2007Charging indicator lamp the lamp comes on dh g operation: (Check/adjust the altemator drive belts as deseribed under the maintenance point. See page 48, If the charging indicator lamp is sill on this could be due to an alternator fault or a fault in the electrical system, STOPPING THE ENGINE 41, Run the engine without a load for 2 few minutes if it has been run 1 portant: continuously with a heavy load. lm 2. Stoke ensne wth ie stop bution. Keep th sto buton depressed |, Tre danger of turbo ‘until the engine is completely stationary. Sree aa ‘cngine Is stopped without 3. Engines with battery master switch: Switeh off the power by means of cooling. that maar och 4. Set the control switch to "0" 1 Important [the pomer mst nat be switched df before the engine has mopped CHECKS AFTER RUNNING ‘Check that the power is cut from the battery master switch and that the ‘control switch is in the "O" position, Fill the fuel tank, Make sure that the filler cap and the area round the filler opening are clean to avoid contamination ofthe fue. I there isa risk of freezing, the cooling system must contain enough glycol, See pages 24 and 37. _Attemperatures below 0°C: Prepare for the next start by connecting the engine heater. © Scania CV 2007 ING Immobilise the starting device ‘when working on the engine. Ifthe engine starts out of control, there is a SERIOUS RISK OF INJURY 4 important: Coolant should be topped up witen the engine is stopped after the first start. 29MAINTENANCE The maintenance programme covers 20 points, divided into the following main groups: Lubricating oil system page 32 Cooling system. page 36 Air cleaner page 42 Fuel system page 44 Electrical system, batteries, ete page 46 Miscellaneous page 48 ‘The maintenance points are divided into intervals as follows: Daily maintenance Maintenance before the first start M Periodic maintenance every 200 hours of operation (carried out after 200, 400, 600, 800, ete. hours) Periodic maintenance every 400 hours of operation (carried out after 400, 800, 1200, 1600, ete hours) Periodic maintenance every 1200 hours of operation (carried out after 1200, 2400, 3600, et. hours) Periodic maintenance every 2400 hours of operation (carried out after 2400, 4800, ete. hours) Periodic maintenance every 4800 hours of operation (carried out after 4800, 9600, ete. hours) ‘Annual Maintenance nance after the first 400 hours of operation Maintenance every Sth year ENGINES WITH FEW HOURS OF OPERATION Emergency generator sets and the like that are not used regularly should be run on test and checked in accordance with the generator set manufacturer's instructions. Run the engine until it reaches operating temperature and then carry out the ‘maintenance points below: 1 Checking oi level 5. Checking coolant level. 8. Checking low pressure indicator. 2. Checking fuel level 14, Checking electrolyte level in batteries, 15. Checking state of charge in batteries. 16, Cleaning batteries. 19. Look for leakage, rectify as necessary 30 © Scania CV 2007 ZX WARMING Immobilise the starting device ‘when working on the engine. If the engine starts out of control, there is a SERIOUS RISK OF INJURY 4 important- For engines with few operating hours that do not receive periodic maintenance according to the maintenance schedule on page 31, maintenance should be carried out in accordance with ‘the schedule: Annually" "Every Sth year"MAINTENANCE SCHEDULE Daily First time at Interval Atleast First stare 0h 200% 1008 20h 20h 4800 h Annwally Every Sth year| [LUBRICATING OM. SYSTEM, page 32 1. Checking oil vel 2. Oil change 3. Cleaning oil Cleaner 4. Renewing the oi filter [COOLING SYSTEM, page 36 5. Checking coolant level 6. Checking coolant 5 7. Cleaning cooling sy [AIR CLEANER, page 42 8, Test reading low pressure indicator 9. Cleaning the course cleaner TO. Cleaning or changing filter element TE. Changing safety eartidge [FUEL SYSTEM, page 44 12, Checking fuel level 13. Changing main filter ECTRICAL SYSTEM, page 46 14, Checking electrolyte level in batteries TS. Checking state of charge in batteries 16, Cleaning batteries T7._Checking coolant level monitor MISCELLANEOUS, page 48 18, Checking drive belt 19. Look for leakage, retiy as necessary 20. Checkingladjusting valve clearances, 21. Checking/adjusting PDE injector rocker arms 22. Renewing (or cleaning) the valve for closed erankease ventilation 1. Moce often if required 2. Earlier if low pressure indicator shows red 3. If inhibitor has not been topped up for five years, the coolant should be changed. © Scania CV 2007 atLUBRICATING OIL SYSTEM OIL GRADE The engine oil must at least mest the requirements for one of the following, oil classifications - ACEA E3, E4 or ES = The Total Base Number (TN) should be minimum 12-13 (ASTM 2896). = Check with your oil supplier that the oil meets these requirements, - The specified oil ehange intervals are applicable provided thatthe fet sulphur content does not exceed 0.3% by weight. Ifthe sulphur The oil should be ‘content is greater than 0.3% but no more than 1.0%, the oil change | temperature vau next interval must be halved (200 h. = Viseosities are hown in the Figure below. 4 important- ‘es must not be used. able for all = When ambient temperatures are extremely low: Consult your ncarest Scania represeatative to avoid starting difficulties, Oil analysis Some oil companies can offer analysis ofthe engine oil. Such analysis measures the oil's TBN (Total Base Number), TAN (Total Acid Number), fuel dilucion, water content, viscosity and the quantity of wear particles and. soot ia the oil ‘The result ofa series of analyses is used as the basis for establishing a suitable oil change interval Ifthe conditions are changed, a new oil analysis programme must be carried out to establish the new change interval 400-300-200 100 10 (20 30 40 °C ett + SAE 20W-30 SAE 30 SAE 40 SAE 50 VY <= SAE 5W-30 SAE 15W-40 32 © Scania CV 2007‘The correct level is between the marks on the dipstick. Top up when the level is atthe lower mark. ~ Correct type, see "Oil grade" on page 12. Checking oil level during operation On some engines the oil level ean be checked during operation. ~ Remove the oil filler cap to release the pressure in the crankease, = Check the le 1: 10 mm below the Mir or Max. mark. 2, Every 400 hours: OIL CHANGE Note: Ifthe engine is used for especially demanding operations, particularly in a dusty environment or ifthe deposits in the centrifugal cleaner are thicker than 20 mm: change the oil at wore frequent intervals. on the dipstick. Correct oil le Unscrew the plug and drain the oil when the engine is hot. ~ Incertain engines the oi is pumped out by means of bilge pump. = Clean the magnet on the plug. Refit the plug + Fill up with il Max. 33 dm? ~ Check the level on the dipstick Min. 28 dm? 1dm3= 1 litre DX, WARNING The oil may be hot. Wear protective gloves and goggles Usea container to avoid spillage ‘when changing the oil. Dispose Maximum angles of inclination during operation of used oil through an Maximum permissible angles during operation vary, depending onthetype of] authorised waste disposal oil sump, see ilustration contractor. Note: Specified angle may only occur intermittently. se q 38s © Scania CV 2007 333. Every 400 hours: CLEANING THE OIL CLEANER (at same time as an change) ~ Clean the cover. Unserew the nut and remove the cover. LN, WARNING ‘Open the cap carefully. The oil may be hot. ~ Lif out the rotor and wipe the outside, Unscrew the rotor bol nut about ‘one and a half turns = If the rotor nat i jammed: ‘Tur the rotor upside down and fasten the nut, absolutely not the rotor, ina vice, and tur the rotor one and a half turn anti-clockwise by hand, ‘or use an M20 nut a illustrated, = Hold the rotor and tap lightly on the rotor nut with aplastic mallet or ‘against the workbench, so thatthe rotor bowl comes loose from the bot- tom plate, Never strike on the rotor directly as this may damage the bea- rings = Remove the nut and the rotor bowl. ~ Remove the strainer. IFthe strainer has seized in the rotor bowl, pry carefully witha screwdriver between the rator bow! and the strainer, = Ifthe strainer has seized inthe rotor, pry carefully between the rotor and the strainer, Scrape off the deposits from the inside ofthe rotor bowl. If there are no ‘deposits, this indicates thatthe cleaner is not working propery. = Ifthe deposits ate thicker than 28 mm: Clean more often. 4 © Scania CV 2007~ Clean all parts in diesel = Make sure the nozzles on the rotor are not blocked or damaged, ~ Make sure the bearings are not damaged. Ifthey are damaged the entire rotor must be renewed, Fita mew O-ring on the rotor and fit the strainer. ~ Reassemble the rotor = Tighten the rotor aut firmly By hand. ~ Make sue the shaft is not loose. Ifit is loose, use locking compound 561 200 and tighten it to 34 Nm using tool 98 421 ~ In order to tighten the rotor shat it is necessary to modify socket ‘wrench 98 421 ~ Drill out the threads from a M20 nut so that it fits onthe square drive ‘of the socket wrench, = Weld on the nut ~ Refit the rotor = Check that it rotates easily by rotating it manually ~ Fita mew O-ring om the bow! and fit the bowl. ~ Serew 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 itis warn fen for a whirring sound from the rotor or fel whether the cleaner housing is vibrating. ‘The rotor normally continues spinning for 30 - 60 seconds after the engine has stopped. If not: Dismantle and check. © Scania CV 2007 354. Every 400 hours: CHANGING THE OIL FILTER (at same time as an oil change) ~ Remove the old filter, ~ Oil the rubber gasket and fit a new genuine Seania filter. «= Tighten the filter by hand, Never use tools for his. The filter could sustain damage, obstructing circulation. = Start the gine and check for leaks, Important! 1/the deposits in the centrifugal cleaner are more than 20 mm thick, he a filter has to be replaced more often. The same is rue {for cleaning the centrifugal filter and changing the oil. @% Mind tne Fat emironmemt Use a container to avoid spillage when changing the filter. Dispose of used filters through an authorised waste disposal contractor. COOLING SYSTEM 5. Daily: CHECKING COOLANT LEVEL ~ Open the expansion tank filler cap and check the coolant level ~ Correct level: Seania plastic expansion tank) = Cold engine: ‘The coolant should be level with the bottom ofthe filler neck, ~ Hot engine: The coolant should be about 25 mm above the lower edge of the filler hole. ~ Other types of expansion tank according tothe instructions of the fitter. = Top up the coolant as necessary, see point 6, Note: When filing large amounts of coolant: Never pour cold coolant into a hot engine. LN, WARNING: ‘Open the cap carefully. Water and steam may spray out. Y important Always top up with ready mixed coolant. This could erack the eylinder block and cylinder head. 38 © Scania CV 20076. Every 2400 hours: CHECKING THE COOLANT Coolant should be checked as follows: a) Check the appearance of the coolant b) Coolant with glycot onl: cheek the glycol cont ) Coolant with Scania Corrosion Inhibitor onl: ‘Cheek the anti-corrosive content. ‘The composition ofthe eootant is described in more detail under "Starting and running" a) Checking the appearance of the coolant Coolant composition: eee, oe nimum 30% glycol by volume ‘maximum 60% glycol by volume 8-12% by volume Scania corrosion inhibitor Fill a container with a litle coolant and check that it is clean and cleat. ~ If the coolant is contaminated or cloudy, consider changing it = Water added to the coolant should be elean and free from dirt of any kind. Use drinking water with a pH of 6-9. by Checking the glycol content there isa danger of freezing, use only glycol as an anti-corrosive in the coolant, ~ Cooling systems with glycol should contain atleast 30% glycol by ‘volume to provide acceptable protection against corrosion. LX WARNING cis highly dangerous to consume corrosion inhibitor. 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 withthe following supplier designations: BASF G48 or BASF D542 ~ Absays top up the anti-freeze if its glycol content drops below 30% by volume. A glycol content above 60% by volume will not provide greater protection against freesing. ‘The tble shows the temperature at which ice tarts to form. The engine ‘will freeze and break at appreciably lower temperatures, see diagram, ~ [ce forming in the coolant often causes malfunetioning without any risk ‘of damage. The engine should not be subjected to heavy loads whea ice stats to form, Note: The coolant should be changed when the cooling system is cleaned: every 4800 hours oF at least every Sth year. Important! 1fa coolant fiter is used in the cooling system it must not 4 important: The coolant should be ready mixed when it is poured into the cooling system. Never top up with only water or only glycol. 1 important. ‘The recommended glycol must not be mixed with glycol having Risk for build up of sludge and reduced cooling eapacity. contain an inhibitor © Scania CV 2007 a7Antistreeze glycol, % by volume 10 20 30 40 50 Characterstis of glycol tlw temperatures: “10 7 = Example with 30% gveo! by volume Wo «fee sash starts o form at-16°C += There is risk for malfunctions at -30°C a 2 = No risk of damage by freecing with a minimum -40] ‘content of 30% glycol by volume ’ oa WT s Cc B A? 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 % glycol by volume Ice slush starts to form at °C Glycol dm? (litres) 8 88 Salsas ass sagas A= Area to be avoided. Only for calculating glycol mix. Coolant freecing temperature when ice starts to form at different glycol mixes 38 © Scania CV 2007CO) Checking protection against corrosion ‘There must always be sufficient corrosive inhibitor in the coolant to protect the cooling system against corrosion, If there is no danger of freezing, only Seania Corrosion Inhibitor should be used in the coolant. ‘The inhibitor ip Seania Corrosion Inhibitor is five of witite ‘The correct proportion of anti-corrosive is 8-12%by volume. opping up with 1.0% Seania Corrosion Inhibitor by volume should be. done after every 2400 hours of operation. = Never top up with only water or only anticcorrasive! Fluid tosses must aways be replaced with blended coolant: ‘water + 10% Scania Corrosion Inhibitor by volume. Note: The coolant should be changed when the cooling system is ‘loaned: every 4800 hours oF at least every Sth Vear. ZX WARMING Corrosion inhibitor is highly dangerous if ingested and can prove fatal. Avoid contact with the skin, 1 important. Mixing with glycol or the use of too much corrosion inhibitor ‘can lead to build up of sludge and reduced cooling capacity. Changing the coolant 41. Remove the filler cap from the expansion tank. 2. The coolant is drained at two points: the “lowest point” ofthe engine block, see illustration the “lowest point” ofthe cooling system. +3. Close the cocks. 4, Fill up with coolant through the expansion tank's filler hole Mix coolant as deseribed on page 37 © Scania CV 2007 4 important: Ifa coolant filter has been fitted it must not contain inhibitor. @% Mind the [SP environment 7 Use a container to avoid spills when changing the coolant. Dispose of used coolant through aan authorised waste disposal contractor. 397. Every 4800 hours: CLEANING THE COOLING SYSTEM Note: If necessary, the cooling system should be leaned more often. External cleaning Radiator Check thatthe radiator is ot logged on their sie and that the cooling fins are nt daaze important ~ Carefully serape the deposit off the radiator’ cooling fins. If necessary, ‘ paraffin-based engine cleaner can be used, ‘The cooling system must never be cleaned with caustie soda, There is a risk of damage to aluminium parts. ~ Bent fins can be straightened using a wire brush, for example, and ‘exercising care. Charge air cooler (DI engine) 1. Drain the coolant from the engine, see "Changing the coolant” 2. Detach the intake manifold from the turbo. 3. Detach the charge air cooler inlet and outlet connections. 4. Unbalt the charge air cooler assembly from the intake manifold. The ‘charge air clement is integrated into the housing. Take care not to damage the element's water connections. 5. Clean the outside ofthe clement. This is especially important if the ‘engine is equipped with closed crankcase ventilation. Use a paraffi based engine cleaner, 6. Clean and degrease the sealing surfaces on the element and on the intake manifold witha spiri-based cleaning agent. 7. Apply a smooth head of sealing agent (silicone 816 064), approximately 2-3 mm, onto the intake manifold sealing surface 8. Screw on the charge air cooler within 15 min of application ofthe sealing agent, Tighten the bolts to 26 Nm. 9. Refit the inlet and outlet connections with new O-rings. 10. Refit the delivery pipe clamps. 14, Connect the intake manifold from the turbo, 12, Fill up with coolant according to the specification ‘on page 37 Important! Let the sealing compound harden ‘for atleast 24 hours before the engine is ‘used again. 1. Charge air cooler element 2. O-ring 3. Sealing agent 816 064 4. Intake manifold 40 © Scania CV 2007Internal cleaning Removing oil and grease = Ifpossible, run the engine until it has reached operating temperature and then drain the cooling system, = Remove the thermostats. + Fill the system with clean, ot water mixed with liquid dishwasher LAN WARNING detergent designed for household use Concentration 1% (0.1/10 1) Handling cleaning agents for ~ Ruin the engine until warm for about 20-30 minutes. Do not Forget the the cooling system: cab heating system (filed), Read the warning label on the = Dain the cooling system container. «ll the system again using clean, hot water and ran the engine for abou 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, — iM Mind the Removing deposits Ge canironment: Use a container to avoid spills = lfposible, run the engine unt ithas reached operating temperature and] when changing the coolant. then drain the cooling system, : Dispose of used coolant through ~ Remove the thermostats. an authorised waste disposal Fill the system with clean, hot water mixed with one ofthe ‘contractor. commercially available radiator cleaners based on sphamic aid and containing dispersing agents. Follow the manufctarer’s instructions for ‘mixing proportions and cleaning times, = Run the engine forthe specified time and then drain the cooling system. ~ Refill the systom 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. © Scania CV 2007 aAIR CLEANER 8. Daily: READING THE VACUUM INDICATOR IF te endear lal i entirely vsbe; change ocean the ai leaner element, point 10. This is particularly important if the engine is run at high onde and gh epee 9. Every 200 hours: tmportant. CLEANING THE AIR CLEANER ‘The coarse cleaner must always COARSE CLEANER be fitted in an upright position. 41, Remove the cover fom coarse cleaner 2. 2. Remove the conical course separator. Empty out the particles of dirt and clean it 3. Fitthe coarse separator as shown in the Figure and serew the cover in 10. Every 1200 hours: CLEANING OR CHANGING THE FILTER ELEMENT 1, Fer aomont Coarse leaner Note: Ear the lw pressure Indeatr showered oe Dismantling 4. Vacuum indicator 1. Remove the side cover from the air cleaner. Air: adie ae 2. Change or clean the element. Vimy ” Note: Cleaning the clement always entails a risk of damaging it. The important Ciementeamonlybeciernedamatinam offerte Aner | Only axe Scania genuine air Slaning. than pore dest cape thant ew clement ter. 3. Mark the filter when it has been cleaned. ‘Change the filter element if it is : “tumaged Cleaning the element = Carefully blow the fiter dry compressed air from | Danger of engine damage if the theme iter element is damaged Note: This iter clement must not be washed wih wate. Z\ WARNING : : Neverstat the engine without the ale iter ; “There ars of injury oF seriou engine damage, 7 Cover 2. Filler element 3. Filler housing 42 © Scania CV 2007Check = Insert a torch into the element and check from the outside that there are no holes or eracks in the filter paper. = Change the filter element if it has the slightest damage. Danger of engine damage. Assembly 41. Assemble the ar cleaner in reverse onder 2. Reset the red plunger in the low pressure indicator by depressing the button, f 11. Every 2400 hours: CHANGING THE SAFETY CARTRIDGE 1 important Do not remove the safety Note: Not all filters are equipped with a safety cartridge. When cartridge unnecessarily. changing the safety cartridge, take great care to ensure that no dlirtor other impurities ean get into the engine. Remove the side cover from the air cleaner. Remove the filter element, Remove the safety cartridge. Fita new genuine Scania safety cartridge. ‘Change or clean the filter element, see point 10. onbena Assomble the air cleaner. 1. Safety cartridge Aircleaner with safety cartridge dmportant Never clean the safety cartridge! © Scania CV 2007 43UEL SYSTEM 4 important: 12. Daily: ees yore oo a: CHECKING THE FUEL LEVEL aed ecee tae There is a risk of engine ~ Top up with fuel ifnecessary. malfunction and damage to the = Ifthe tank has been run dy, bleed the fel system, se pint 13. injection equipment. 13. Every 1200 hours: CHANGING THE FUEL FILTER Fuel tanks ~ Drain any water from the fuel tanks. Filter ‘The filter consists ofa filter unit. = Wash the outside ofthe filter and unscrew it, Discard the filter according. to environmental requirements, ~ Fit the new filter and tighten it by hand, Important [Never use tools for this. The filter could sustain damage, obstructing = circulation. Only use Seania genuine fuel filters. ~ Bleed the fuel system as described below Start the engine and check for leaks @% Mind the — 8 smronrents — Water separating filter ‘components. ~ Drainage must be carried out when filling fuel = The filler must be changed atthe same replacement interval asthe main filter. ~ Close the drain tap J before the filter. = Unserew the container and drain valve 3 ~ Unserew and change the filter 2. Lubricat the seal before tightening the new filter by hand. ~ Serew the container and drain valve into position. = Open the drain tap 7. ~ Bleed the fuel system after changing both filters. 1. Shut-off cock 2. Filter 3. Drain valve “4 © Scania CV 2007Blceding the fuel system oe iene = Attach a clear plastic hose to the bleeder nipple / to channel fuel into a -— ,@ onvg pain craahes icicle ssasbse i tadofieoamaatoa] — wae environment the front ofthe engine. Use a container to avoi spillage = Open the bleeder nipple. een eee ae cones components, = Pump hand pump 2 until fuel without air bubbles flows out ofthe ‘opened bleeder nipple. + Ifthe system is completely empty, it will take approximately 250 9 1 strokes, + After renewing the fuel filter, it will take approximately 170 strokes. — + Approximately 150 strokes are required to bleed the fuel manifold ~ Close the bleed nipple and remove the hose. ~ Undo the banjo screw for overflow valve 3 slightly. Pump the hand ‘pump an additional 20 strokes until the overflow valve opens. the engine fils to start after bleeding. ~ Open the bleeder nipple again and pump the hand pump until fuel ‘without air bubbles flows out. ~ Tighten the bleeder nipple. Start the engine and check for leaks. © Scania CV 2007 45SCANIA ELECTRICAL SYSTEM 14. Every 200 hours: id naked flames or sparks Avoi CHECKING ELECTROLYTE LEVEL IN near the batteries. BATTERIES ‘When the batteries are charged, sen gas is formed flammable and 2. Top up with distilled water until the level is 10-15 mm above the plates. explosive. —A\ mannine— 1. Unscrew the plugs and check the electrolyte level in all cell ule 15. Every 1200 hours: CHECKING STATE OF CHARGE IN BATTERIES —A WARNING— ‘Cheek the density with an acid tester Wear gloves and protective goggles when charging and In. fully-charged battery it should be: Pang bee fete ‘The batteries contain a highly 1.294 ato” corrosive aci 1,308 at 20°C ~ Ifthe density is below 1.20, the battery must be charged. A discharged battery freezes at -5° Do not rapid-charge the battery. This will damage the battery in the rn AN ING: Do not connect the terminals up 16. Every 1200 hours: eee CLEANING BATTERIES This ean cause serious damage to the electrical system. 41. Clean batteries, cables and cable terminals If the terminals are shorted, 2. Check that ll eable terminals ate firmly tightened sparking will occur. 3. Grease battery terminal posts and cable terminals with vaseline 46 © Scania CV 2007‘SCANIA CHANGING THE BATTERY Removal LX warm 41. Disconnect the negative cable (-) from the battery (cable connected to earth. Do not connect the term incorrectly. ‘This can cause serious damage 2. Disconnect the positive eable (+) from the battery (cable connected to starter motor) iB to the electrical system. 8 If the terminals are shorted, 41. Connect the positive eable (+) to the battery (cable connected to starter sparking will oceur. moto? ) 0 the battery (cabl 2. Connect the negative cable @% Mind the — 29 emironmentt — spose of used batteries Fiahaph torent pease 17. Every 1200 hours: CHECKING THE COOLANT LEVEL MONITOR (optional equipment) 4, Start the engine, 2. Lower the coolant level in the expansion tank. 2.pin level monitor installed in the 3. Automatie stop incase of faut: Engine stops, indicator lamp lights and Pin fevel monty instalind 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 eee eee: ceoude will be generated and can be read off on the diagnostics lamp, 4, No automatic stop in ease of fault: Indicator lamp lights, buzzer (where £ bx isc descleeie fitted) sounds if there is no fault in the level monitor. environment! 5. ‘Top up coolant to the correct level, sce page 36. Use a container to avoid spills when draining the coolant. Dispose of used coolant through an authorised waste disposal contractor. © Scania CV 2007 47MISCELLANEOUS 18. Every 1200 hours: CHECKING THE DRIVE BELT ~ If the drive belt (1), which isa poly-V’ belt, is wom or damaged it must be changed. ~ Also check thatthe automatic belt tensioner (2) isin proper working ‘order and keeps the drive belt correctly tensioned, = On installations with dual belt circuits, the second belt eiteuit has wo drive belts with a manual belt tensioner. ~ These drive belts should be tensioned to 15-20 Nm as shown in the figure 48 © Scania CV 200719. Dai LOOK FOR LEAKAGE, TAKE NECESSARY ACTION Start the engine, ~ Cheek for oil, coolant, fuel, air and exhaust leakages. Tighten or change leaking connections. Check the overflow holes (1) (below the side covers) which show whether the O-rings between the cylinder liners and erankease are leaking, see figure. 4) If coolant is running out, the O-ring is leaking. >) Ifoilis running out, the liner shelFis leaking ~ Check thatthe coolant pump drain hole (2) is not clogged, see figure. 1 there is leakage, change the pump seal or the complete coolant pump. A small amount of leakage from the overflow holes during the engine running-in period is normal. (Seals and O-rings are lubricated with soap] ‘or ill when fitted) This leakage normally stops after a time. 16484 © Scania CV 2007 7% Mind the [— &P eavironment! ‘Take eare to ensure that any leaks do not eause pollution. Important: Ifserious leakage occurs, contact your nearest Scania ‘workshop. 4920. Every 2400 hours: CHECKING/ADJUSTING VALVE CLEARANCES Not : Checking/adjusting valve clearances should also be done after the first 400 hours of operation. Valve clearances should be adjusted when the engine is cod, a least 30 minutes after running. ‘The rocker cover gaskets should be changed as nec 26NNm, Intake valve clearance: 0.45 mm. Exhaust valve clearance: 0.70 mm, sary. Tightening torque: Lock nut tightening torque: 35 Nm Adjusting order = Tuan the flywheel (counterclockwise) so that the marks on the flywheel ‘ean be seen in the lower opening in the flywheel casing. See table. = Measure the valve clearance with a feeler gauge and adjust the valves as per the order of adjustment inthe table below. Correct valve clearances are also given on the instruction plate on ome of the rocker eovers. = Checkingiadjusting of the PDE- injector rocker arms should be perfor- med atthe same time as the checking/adjusting of valve clearances. See item 21 ~ If reading cannot be performed from undemeath but only in the upper ‘opening: Start with the TDC Up position and turn the flywheel counter- clockwise 120° (1/3 turn) at a time, observe the valve change and adjust valves in accordance with the table below. Important The markings on the flywheel are only valid when taking the reading from underneath, Mark on flywheel Valve. Adjust (reading from changeon _vaives on underneath) cylinder cylinder TDC Down (0") 1 6 120° 5 2 240° 3 4 TDC Down (360°) 6 1 480° 2 6 00° 4 3 50 © Scania CV 2007 LN, WARNING Immobilise the starting device ‘when working on the engine. If the engine starts out of control, there is a SERIOUS RISK OF INJURY. Cylinder numberingNote: Readings can be taken from the flywheel through covers in the flywheel housing either from above or underneath depending on aecess when fitting. It says up resp down on the ‘flywheel Both covers are fitted with a cover Covers for reading _—at delivery. ‘on the flywheel housing 21. Every 2400 hours: CHECKING/ADJUSTING THE PDE INJECTOR ROCKER ARMS Note: Checkingiadjusting 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 PDE 31 unit injector is adjusted using setting tool 99 414 or a digital sliding caliper. The PDE32 unit injector is adjusted using setting tool 99 442 or a digital sliding caliper. This adjustment is essential as a fault in the position of the Dimension A= unit injector can result in poor performance and possible PDES1: 66.940.1 mm breakdown. PDE32: 69.940.1 mm Adjusting order Dimension B= PDES1: 36.5 mm ‘The able below is only valid when reading inthe lower opening. See PDE: 38.8 mm previous page when reading ia the upper opening. Marcon hos! vae Au “Gndereents” cy” fOEKGr a TDC Down (0°) 1 2 ie 5 3 0° 3 1 TDC Down (360°) 6 5 260° 2 3 oor az 5 © Scania CV 2007 st‘SCANIA PDE3I: 4. Firstly, measure the distance 4 between plane «and the top edge of te valve spring washer on the PDE injector using a digital sie rule, See Figure 2. Dimension 4 should be 66.9 mm for PDE3I (dimension 16.5 mm), 3. The dimension is adjusted by undoing the lock nut and serewing the rocker arm adjusting serew / tothe 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 released. 4. Position setting too! 99 414 with the metal plate around the injector spring. 5. Finly adjust dimension 4 by simultancously using a finger to sense tht the smal piston 2 is level with the flat upper surface of te tool 18 possible to sense differences of less than a tenth of a millimetre 6. Ifthe seting too! is not available, a digital slide rule can also be used for fine adjustment. The rocker position is adjusted by means of the adjusting serew to 66.9 +-0.1 mm as stated above. 7. Tighten the adjusting serew lock nut to 39 Nm and remove the tool 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. Piston above or below the flat surface. Adjustment necessary Piston level withthe flat surface. The adjustment is correct 52 © Scania CV 2007‘SCANIA PDE32: 4. Firstly, measure the distance A between plane «and dhe top edge ofthe valve spring washer nthe PDE injector using a digital slide rl, See Figure 2. Dimension A should be 69.9 mm for PDE32 (dimension 8.8 mm), 3. ‘The dimension is adjusted by undoing the lock nut and serewing the rocker arm adjusting serew / to the correct measurement, 19! 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 itis released. 4, Position seting too] 99 442 withthe metal plate around the injector spring. 5, Finely adjust dimension 4 by simultaneously using a finger to sense that the small piston 2i level with the flat upper surface ofthe tool. 1s, possible to sense differences of les thaa a tenth ofa willimete 6. Ifthe seting too! is not available, a digital slide rule can also be used for fine adjustment. The rocker positon is adjusted by means of the adjusting serew to 69,9 +/-0.1 mm as stated above. 7. Tighten the adjusting serew lock nut to 39 Nm and remove the tool 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. Piston above or below the flat surface. Adjustment necessary Piston level with the flat surface. The adjustment is correct, © Scania CV 2007 5322. Every 2400 hours: CHANGING (or CLEANING) THE CLOSED CRANKCASE VENTILATION VALVE. Alternative 1: cn Alternative 2: = Remove the valve afer the specified interval ge the valve atthe specified interval ~ Clean the valve by placing it ina bath of diesel oil overnight. Then rinse it several times in diesel oil and allow it to dip dry «= Refit the valve = The valve may be reused (cleaned), maximum nwice after the initial 2400 hours of operation, Take care to mark the valve after cleaning it. 54 © Scania CV 2007LONG-TERM STORAGE [the engine is not to be used fora 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. 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 o 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 fora certain time using special preservative fuel ol and coolant = Otherwise preparing the en ne for storage (filter changes, lubrication, os eer ZX WaRnine fe engines to be tre witha ful cotng ystems coolant containing} Ethylene glycol highly jbibed and can rove fatal. Avoid contact with the skin. 50% glycol by volume. Glycol withour nitrite-based inhibitor should be used.| dangerous if For example BASF G48 or BASF D542. Preservative fuel ~ Use diesel fuel oi! mixed with Lubrizol S60H or the equivalent = Mix 1 em? (ml) Lubrizol S60H in 10 dim () of fuel A HANDLING LUBRIZOL 560H. Hazardous! Contains aromatic hydrocarbons Use spt extractors where there is danger of vapour build-up, Wear protective gloves and goggles when handling Lubrizol, Do not use contaminated clothing ‘fit gets in your eyes: Rinse with a gentle stream of water (at least 15 minutes). Seek medical attention. If gets om your skin: Wesh the affected area with soap and water I inhated: Fresh alr, rest and warmth Inflammable: Fire class 2A. Flashpoint +278 In case of fire: Extinguish with carbon dioxide, powder or foam, Storage: In well-scaled receptacle in a dry, coo! place. Keep out of reach of ehil © Scania CV 2007 55Preservative oil Suitable preservative ol can be supplied by most petroleum companies E.g, Dinitrol 40 or the equivalent. Preparations for storage Drain and fush the cooling system. Top up with preservative coolant ‘Warm up the engine on regular fuel. Stop the engine and drain the ol. = Renew the fuel filter. Fill the engine with preservative oil up tothe minimum level on the dipstick Mix preservative fuel in a can. Detach the fuel pipe at the feed pump suetion line and connect @ hose fram the ean. Detach the fuel pipe atthe overflow valve and connect a return hose to the ean, 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 fue 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 overall coolant connections (ifthe cooling system iS not completely assembled), ~ Air leaner: Clean or change the filter element. Coverair intakes and exhaust pipes. Alternator and starter motor: «Spray with water-repellent anti-corrosive oil, CRC 226, LPSI or the equivalent, Spray the outside of bright engine parts, first with penetrating preservative oil such as Dinitrol 25B and then with Dinitrol 112 oF the ‘equivalent 58 © Scania CV 2007 @% Mind the Tae environment Use a container to avoid spills when draining the oil and ‘coolant. Dispose of used oil and coolant through an authorised waste disposal contractor.~ Attach a label to the engine showing the date of preservation and ‘elearly stating that it must not be started or cranked. STORED ENGINE Date 7 Do not start or crank! Batteries Remove the batteries for tickle 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| ‘engine has not been prepared for storage us above, Storage After the preparations the engine shouldbe stored ina dry and warm place {room temperature). LN, WARNING Wear gloves and protective goggles when charging and handling batteries ‘The batteries contain a highly corrosive acid. Taking out of storage (Procedure when the engine is to be put into operation) ~ Remove plugs and tape from coolant connections, sir intakes and exhaust pipes. ~ Fill the system with coolant, see page 24 ~ Cheek the oil level in the engine or fill up with fresh motor oil ~ Lubricate the valve mechanisms and their pushrod and valve tappets as ‘well a the PDE injector mechanisms. = Drain dhe preservative fuel from the fuel manifold and fuel filter + Connect and bleed the fuel system, see page 45. ~ Wash offany externally applied preservative oil using white spirit TECHNICAL DAT. GENERAL Dc12 ‘Number of eylinders jlinder diameter ra ‘Stoke Capacity © Scania CV 2007 87‘No. off main beatings 7 Firing order 1-5-3-6-2-4 Compression ratio 18:1 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, without coolant or oi kg 1085" 8 995, With charge air cooler, radiator, expansion tank and pipes Power see engine card, "Engine record card” LUBRICATION SYSTEM Max. oll pressure (thot engine at engine speeds above a 6 1000 r/min) bar (kpéem?) ‘Normal oil pressure z {hot engine at operating speeds) bar (kpem?) 3-6 Min, il pressure i: {hot engine 1000 rpm) bar (kpiem?) 1.0 ‘Ol capacity see page 33 CCrankcase pressure with closed erankease ventilation mm VP “55 -+20 58 © Scania CV 2007FUEL SYSTEM pe12 pn2 Pump setting BTDC ‘See plate on rocker cover Low idle speed ‘pm 700 (adjustable 500-800) ‘Maximum Full oad speed ‘See engine card Fuel Diesel fuel oil? " see page 60 COOLING SYSTEM ‘Number of thermostats 1 (dual thermostat) ‘Thermostat, opening temperature °¢ 83 ‘Coolant temperature: system at atmospheric pressure © 83-93 system at overpressure 83 - approx. 100 ‘Capacity, including radiator, engine and expansion tank and, for DI12, also charge air cooler sith 0.75 m? radiator di lire) 4 56 mith 1.0 me radiator an (ire) 53 81 with 1.2 m? radiator dm? (litres) 63, 65 ELECTRICAL SYSTEM System volage v 24 “Altemator,curent x 65 0r 100 ‘Starter motor output kW (hp)| 6.7 (9.1) Monitor alam vale : ‘ol pressure monitor bar pion?) 4.00.15 temperate monitor "e ‘Stamped on hexagonal part of monitor © Scania CV 2007 59FUEL Diese! fuel oil The composition of the diesel fuel oil has a great influence on the funetioning 1 the service life ofthe engine and the injection system. The engine output id exhaust emissions are also dependent on the fuel quality. The requirements and testing standards for the most important properties are

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