Operator Manual DC9 Im - Opm - 110en-GB01

Important information
Serious risk of injury

When working on the engine, for example when adjusting drive belts and the clutch, or when changing the
oil, it is important not to start the engine. The engine could be damaged, but more importantly there is a
serious risk of injury.
For this reason, always secure the starting device or disconnect a battery cable before working on the engine.
This is especially important if the engine has a remote starter or automatic starting.
WARNING!
This warning symbol and text can be found next to those inspection points where it is particularly important
to bear in mind the risk of injury.
Operator's manual
DC09
PDE
Industrial engine
en-GB 2 291 776
Issue 1.0
Start-up Report – Warranty

When the start-up report has been filled in and sent to Scania, you have a 1-year warranty from the date of
entry into service. Fill in the particulars below as well. This can make things easier if you need to contact a
workshop for example.
Engine serial number

Date of entry into service
User's name and address
Signature
Engine type
Variant
Engine type and variant are indicated on the engine data plate.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Handling the engine . . . . . . . . . . . . . . . . . . . .64
Environment and safety . . . . . . . . . . . . . . . . . . 4 Preservative coolant . . . . . . . . . . . . . . . . . . . .64
Environmental responsibility . . . . . . . . . . . . . 4 Preservative fuel. . . . . . . . . . . . . . . . . . . . . . .65
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Preservative oil. . . . . . . . . . . . . . . . . . . . . . . .65
Warnings and advisories . . . . . . . . . . . . . . . . . 6 Preparations for storage . . . . . . . . . . . . . . . . .66
Certification . . . . . . . . . . . . . . . . . . . . . . . . . 15 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . .69
Engine data plate . . . . . . . . . . . . . . . . . . . . . . . 16 General data . . . . . . . . . . . . . . . . . . . . . . . . . .69
Component identification . . . . . . . . . . . . . . . . 17 Lubrication system . . . . . . . . . . . . . . . . . . . . .69
Starting and running . . . . . . . . . . . . . . . . . . . . 18 Injection system . . . . . . . . . . . . . . . . . . . . . . .70
Checks before running . . . . . . . . . . . . . . . . . 18 Cooling system. . . . . . . . . . . . . . . . . . . . . . . .70
Starting the engine . . . . . . . . . . . . . . . . . . . . 19 Intake system . . . . . . . . . . . . . . . . . . . . . . . . .70
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical system . . . . . . . . . . . . . . . . . . . . . .70
Engine shutdown. . . . . . . . . . . . . . . . . . . . . . 23 Scania Assistance . . . . . . . . . . . . . . . . . . . . . . .71
Checks after running . . . . . . . . . . . . . . . . . . . 24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engines with few hours of operation . . . . . . 26
Inspection interval. . . . . . . . . . . . . . . . . . . . . 27
Lubrication system . . . . . . . . . . . . . . . . . . . . . 28
Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Checking oil level . . . . . . . . . . . . . . . . . . . . . 29
Changing the oil . . . . . . . . . . . . . . . . . . . . . . 30
Renewing the oil filter. . . . . . . . . . . . . . . . . . 31
Labels for top-up engine oil grade . . . . . . . . 32
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cleaning the centrifugal oil cleaner . . . . . . . 33
Operational testing . . . . . . . . . . . . . . . . . . . . 38
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 39
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Checking coolant level . . . . . . . . . . . . . . . . . 43
Checking antifreeze and corrosion inhibitor . 44
Antifreeze and corrosion inhibitor . . . . . . . . 45
Changing coolant . . . . . . . . . . . . . . . . . . . . . 46
Cleaning the cooling system . . . . . . . . . . . . . 48
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Reading the vacuum indicator. . . . . . . . . . . . 51
Renewing the filter element . . . . . . . . . . . . . 51
Renewing the safety cartridge. . . . . . . . . . . . 52
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking fuel level . . . . . . . . . . . . . . . . . . . . 52
Renewing the fuel filter. . . . . . . . . . . . . . . . . 53
Renewing the water separating fuel filter . . . 54
Bleeding the fuel system . . . . . . . . . . . . . . . . 55
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Checking the drive belt . . . . . . . . . . . . . . . . . 56
Checking for leaks . . . . . . . . . . . . . . . . . . . . 58
Checking and adjusting the valve clearances and
unit injector rocker arms . . . . . . . . . . . . . . . . 58
Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Composition of the fuel. . . . . . . . . . . . . . . . . 62
Sulphur content of fuel . . . . . . . . . . . . . . . . . 62
Temperature dependency of the fuel. . . . . . . 63
Preparing the engine for storage . . . . . . . . . . 64
OPM 110 en-GB 2

© Scania CV AB 2014, Sweden
Introduction
Introduction
This Operator's Manual describes the operation
and inspection of Scania industrial engines.
The engines are direct-injection, liquid-cooled,
four-stroke, turbocharged diesel engines.
The engines are available with different output
and speed settings. The normal output setting of
the engine (performance code) is indicated on
the engine data plate.
Note:
Only standard components are described in the
operator's manual. Information about special
equipment is contained in instructions from the
various manufacturers.
To ensure the maximum performance and the

longest service life for the engine remember the
following:
• Read through the Operator's Manual before
starting to use the engine. Even regular users
of Scania engines will get new information
from the Operator's Manual.
• Always follow the inspection instructions.
• Read the section on safety carefully.
• Get to know your engine so that you know
what it can do and how it works.
• Always contact an authorised Scania work-
shop.
The information in this manual was correct at the

time of going to press. Scania reserves the right
to make alterations without prior notice.
Note:
Always use Scania spare parts for inspection and
repair.
OPM 110 en-GB 3

Environment and safety

Environmental responsibility
Scania develops and produces engines that are as
environmentally-friendly as possible. Scania has
made major investments in the reduction of
harmful exhaust emissions in order to fulfil the
environmental requirements in force in almost
every market.
At the same time, we have been able to maintain
a high level of performance and operating econ-
omy for Scania Industrial and Marine Engines.
To maintain these throughout the entire service
life of the engine, it is important for the user to
follow the instructions on running, inspection
and fuel and lubricating oil as outlined in the Op-
erator's Manual.
Other green initiatives taken include ensuring
that, following inspection and repair, waste that
is harmful to the environment (for example oil,
fuel, coolant, filters and batteries) is disposed of
accordance with the applicable environmental
requirements.
Safety
The following pages contain a summary of the
safety precautions to be complied with when op-
erating and inspecting Scania engines. The
equivalent text can also be found under the rele-
vant inspection point.
To prevent damage to the engine and to ensure
that it runs optimally, follow the instructions in
the warnings and advisories.
If the instructions are not followed, the warranty
can cease to apply.
OPM 110 en-GB 4

Different types of advisory

Warning!
All advisories preceded by Warning! are very
important. They warn of serious faults and incor-
rect operation that could lead to personal injury.
Example:
WARNING!
Block the starting device when working on the

engine. If the engine starts unexpectedly, there is
a serious risk of injury.
Important!
Advisories preceded by Important! warn of
faults and incorrect operation that could lead to
equipment being damaged. Example:
IMPORTANT!
For Scania to guarantee that the engine corre-

sponds to its certified configuration, and take re-
sponsibility for any damage and injuries that
occur, inspection must be carried out as above.
Note:
Advisories preceded by Note: refer to informa-
tion important to ensure the best possible opera-
tion and functionality. Example:
Note:
Always use genuine Scania parts during inspec-
tion and repair so as to keep your engine in the
best possible working order.
Environment
This Operator’s Manual contains specially high-
lighted text with instructions to help protect the
environment during inspection. Example:
Environment
Use a container to avoid spillage.
OPM 110 en-GB 5

Warnings and advisories

Smoking
WARNING!
Smoking is prohibited
• in the vicinity of flammable or explosive ma-
terial, e.g. fuel, oils, batteries, chemicals
• when refuelling and in the vicinity of the fill-
ing station
• when working on the fuel system
Safety precautions for running the

engine
Daily inspection
Always carry out a visual inspection of the en-
gine and engine compartment before starting the
engine or when the engine has been switched off
after operation.
This inspection should be done to detect fuel, oil
or coolant leaks, or anything else that may re-
quire corrective action.
Fuel
Use only fuel recommended in the workshop
manual.
WARNING!
The wrong fuel grade can cause breakdowns or

stoppages by causing the injection system to
malfunction. This can cause damage to the en-
gine and, possibly, personal injury.
OPM 110 en-GB 6

Refuelling
Never overfill the fuel tank as the fuel needs
space to expand. Also ensure that the filler cap is
properly closed.
WARNING!
During refuelling there is a risk of fire and explo-

sion. The engine must be switched off and smok-
ing is prohibited.
Hazardous gases
WARNING!
Only start the engine in a well ventilated area.

The exhaust gases contain carbon monoxide and
nitrogen oxides, which are toxic.
If it is run in an enclosed space, there should be
an effective device to extract exhaust gases and
crankcase gases.
Starter lock
IMPORTANT!
If the control panel is not fitted with a starter

lock, the engine compartment should be locked
to prevent unauthorised personnel from starting
the engine. Alternatively, a lockable master
switch or battery master switch can be used.
OPM 110 en-GB 7

Starter gas
WARNING!
Never use starter gas or similar agents to help

start the engine. This can cause an explosion in
the intake manifold and possible injury.
Running
WARNING!
The engine must not be run in environments

where there is a risk of explosion, as all of the
electrical or mechanical components can gener-
ate sparks.
Approaching a running engine always poses a
safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts such as the
fan and cause injury. For personal safety all ro-
tating parts and hot surfaces must be fitted with
guards.
Safety precautions for handling ma-

terials
Fuel and lubricating oil
WARNING!
All fuels and lubricants as well as many chemi-

cals are flammable. Always follow the instruc-
tions on the relevant packaging.
The work must be carried out on a cold engine.
Fuel leaks and spillage on hot surfaces can cause
fire.
Store used rags and other flammable materials
safely so as to avoid spontaneous combustion.
OPM 110 en-GB 8

Batteries
WARNING!
The batteries contain and form oxyhydrogen gas,

particularly during charging. Oxyhydrogen gas
is flammable and highly explosive.
There must be no smoking, naked flames or
sparks near the batteries or the battery compart-
ment. Incorrect connection of a battery cable or
jump lead can cause a spark, which can cause the
battery to explode.
Chemicals
WARNING!
Most chemicals such as glycol, anti-corrosive

agents, preservative oils and degreasing agents,
are hazardous to health.
Some chemicals, such as preservative oil, are
also flammable.
Always follow the safety precautions on the rel-
evant packaging.
Store chemicals and other materials which are
hazardous to health in approved containers,
marking them clearly and storing them where
they are inaccessible to unauthorised persons.
Environment
Always hand in leftover and used chemicals to

an authorised waste disposal contractor.
OPM 110 en-GB 9

Safety precautions for inspection

and repair
Switch off the engine
Always switch off the engine before carrying out
inspections and repairs, unless otherwise indicat-
ed.
Make it impossible to start the engine: Remove
any starter key, or cut the power using the main
power switch or battery master switch and lock
them.
Fix a warning plate somewhere appropriate,
showing that work is being carried out on the en-
gine.
WARNING!
Working with a running engine always poses a

safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts and cause
injury.
Hot surfaces and fluids
WARNING!
There is always a risk of sustaining burns when

an engine is hot. Particularly hot parts are engine
manifolds, turbochargers, oil sumps, hot coolant
and oil in pipes and hoses.
OPM 110 en-GB 10

Lift the engine out

Always use the engine lifting eyes. Always
check that lifting devices are in good condition
and are designed to lift the weight.
Optional equipment on the engine can change
the centre of gravity. This means that it may be
necessary to use additional lifting devices to bal-
ance the engine correctly and lift it safely.
WARNING!
Never work underneath a suspended engine!
Batteries
WARNING!
The batteries contain highly corrosive sulphuric

acid. Take care to protect your eyes, skin and
clothes when charging or handling batteries.
Wear protective gloves and goggles.
If sulphuric acid comes in contact with the skin:
Wash with soap and plenty of water. If it gets in
your eyes: Rinse immediately with plenty of wa-
ter and seek medical attention.
Environment
Always hand in used batteries to an authorised

waste disposal contractor.
OPM 110 en-GB 11

Electrical system
The engine must be switched off and the power
disconnected using the master switch or battery
master switch before working on the electrical
system. External power supplies to extra equip-
ment on the engine must also be disconnected.
IMPORTANT!
Always use Scania spare parts for the fuel and

electrical systems. Scania spare parts are de-
signed to minimise the risk of fire and explosion.
Electric welding
IMPORTANT!
When carrying out welding work on and near the

engine, disconnect the battery and alternator
leads. Pull out the multi-pin connector for the en-
gine control unit as well.
Connect the welding clamp close to the compo-
nent to be welded. The welding clamp must not
be connected to the engine, or so that the current
can cross a bearing.
When welding is finished:
1. Connect the alternator and control unit ca-
bles first.
2. Then connect the batteries.
OPM 110 en-GB 12

Lubrication system
WARNING!
Hot oil can cause burns and skin irritation. Wear

protective gloves and goggles when changing
hot oil.
Make sure that there is no pressure in the lubri-
cation system before starting work on it.
The oil filler cap must always be in place when
starting and running the engine to prevent oil be-
ing ejected.
Environment
Always hand in used oil to an authorised waste

disposal contractor.
Cooling system
WARNING!
Never open the coolant filler cap when the en-

gine is hot. Hot coolant and steam may spray out
and cause burns.
If the cap has to be opened do it slowly and care-
fully to release the pressure before removing the
cap. Wear gloves as the coolant is still very hot.
Environment
Always hand in used coolant to an authorised

waste disposal contractor.
OPM 110 en-GB 13

Fuel system
WARNING!
Always wear protective goggles when testing in-

jectors. Fuel escaping at high pressure can pene-
trate tissues and cause serious injury.
Always use Scania spare parts for the fuel and
electrical systems. Scania spare parts are de-
signed to minimise the risk of fire and explosion.
Before starting
Ensure that all guards are in place before starting
the engine. Ensure that no tools or other objects
have been left on the engine.
WARNING!
The air filter must be fitted before starting the en-

gine. Otherwise there is a risk of objects being
sucked into the compressor impeller or of injury
if you come into contact with the air filter.
OPM 110 en-GB 14

Certification
An emissions certified engine fulfils the emis-
sions requirements for a particular range of ap-
plication.
On each emissions certified engine there is a la-
bel which shows which requirements the engine
fulfils. Scania guarantees that each such engine
fulfils the emissions requirements for the range
of application for which it is certified.
The following are required for the certified en-
gine to fulfil the emissions requirements once it
has been taken into service:
• Inspection is to be carried out in accordance
with the instructions in this Operator's Manu-
al.
• The inspection and repair of injection equip-
ment are to be carried out by an authorised
Scania workshop.
• The engine may only be modified with equip-
ment that has been approved by Scania.
• Seals may be broken and setting data edited
only once approval has been granted by Sca-
nia. Modifications may be made by author-
ised personnel only.
• Modifications affecting the exhaust and in-
take systems must be approved by Scania.
Otherwise, the instructions in the Operator's

Manual for the running and inspection of the en-
gine shall apply. The safety precautions on the
following pages must be observed.
IMPORTANT!
For Scania to guarantee that the engine corre-

sponds to its certified configuration, and take re-
sponsibility for any damage and injuries that
occur, inspection must be carried out as above.
OPM 110 en-GB 15

Engine data plate
Engine data plate

The engine data plate indicates, in the form of a
code, the engine type, its size and applications.
The engine EU type approval for exhaust emis-
sions is indicated under Output, where applica-
ble.
The engine serial number is stamped onto the top
of the cylinder block at the front right.
Example: DC09 074A

DC Supercharged diesel engine with air-cooled charge air cooler.
09 Displacement in whole dm3.
074 Performance and certification code. The code indicates, together
with the application code, the normal gross engine output.
A Code for application. A means for general industrial use.
Made by
Type DC09 74A

Engine No 6950103
Output. 202 kW 1500 rpm.
Output 202 kW 1800 rpm.
315 820
Example of an engine data plate
OPM 110 en-GB 16

Component identification
Component identification
1 2 3
9 4 10
5 11
7
15
8
318 392
318 391
13 12
14
The illustrations show a normal version of a DC09 engine. The engine ordered may have different equip-
ment.
Note:
The water separating prefilter for the fuel is lo-
cated between the fuel tank and engine.
1. Turbocharger 9. Engine data plate

2. Oil cooler 10. Fuel filter
3. Oil filler 11. Fuel pump with hand pump
4. Engine serial number on the cylinder 12. Starter motor
block 13. Oil dipstick
5. Oil filter 14. Oil plug
6. Coolant pump 15. Engine control unit
7. Coolant drain tap
8. Centrifugal oil cleaner
OPM 110 en-GB 17

Starting and running

Note:
When the engine is started for the first time, car-
ry out the inspection points listed under First
start-up in the inspection schedule. See the In-
spection section.
Always check the following before running:

• oil level
• coolant
• fuel level
• electrolyte level in batteries
• state of charge of the batteries
• condition of the drive belt.
Checks before running

Carry out a daily inspection as described in the
inspection schedule prior to operation. See the
Inspection section.
WARNING!

OPM 110 en-GB 18

Starting the engine

For environmental reasons the Scania engine has
been developed to be started with a low fuel feed.
Using unnecessarily large amounts of fuel when
starting the engine always results in emissions of
unburnt fuel.
• Open the fuel cock if fitted.
• Disengage the engine.
• If the engine has a battery master switch:
Switch on the power by means of the battery
master switch.
• Start the engine.
If the fuel tank has been run dry or if the engine

has not been used for a long time, bleed the fuel
system.
WARNING!
Never use starter gas or similar agents to help

start the engine. An explosion may occur in the
intake manifold with a risk of personal injury.
Only start the engine in a well ventilated area.
When the engine is run in an enclosed space,
there must be effective devices to extract exhaust
gases and crankcase gases.
IMPORTANT!
The starter motor must only be cranked twice for

30 seconds at a time. After that, it must rest for at
least 5 minutes before the next attempt to start it.
Starting at low temperatures and at

high altitudes
Take the local environmental requirements into
account. Use a fuel heater and engine heater to
avoid starting problems and white smoke.
Scania recommends that an engine heater should
be used if the engine will be used at temperatures
below -10°C or at an altitude of more than 2,000
metres.
A low engine speed and a moderate load on a
cold engine limits white smoke, gives better
combustion and warms up the engine more
quickly than warming it up with no load.
Avoid running it longer than necessary at idling
speed.
OPM 110 en-GB 19

Running
Check instruments and warning lamps at regular
intervals.
Engine speed range
600-750 rpm Low idling. Engine idling is controlled by the engine management system.
Low idling up to 2,100 rpm Engine operating speed range. Controlled by the engine management sys-
tem.
2,100-2,600 rpm Unsuitable operating speed, but a slightly higher engine speed than the nor-
mal maximum operating speed may occur when load is low or negative.
2,600-3,000 rpm Prohibited engine speed.
Limp home mode

If there is a fault in the normal throttle opening or
if CAN communication is interrupted, the fol-
lowing emergency operation option is provided:
A CAN fault or throttle opening fault in an all-
speed engine (both signal and idling switch):
• The throttle opening value is 0% and the en-
gine is running at normal idling speed.
• The throttle opening value is 0% and the en-
gine is running at raised idling speed (750
rpm) if this function is activated.
Throttle opening fault, but the idling switch is
working:
• The throttle opening value can be increased
slowly between 0 and 50% by using the idling
switch.
CAN fault:
• The engine is switched off if the shutdown
function is activated.
OPM 110 en-GB 20

Coolant temperature
Normal coolant temperature during operation is
80-90°C/176-194°F.
Alarm levels are set in the engine control unit.
The default setting for the lowest and highest
limit values for high coolant temperature are
95°C/203°F and 105°C/221°F respectively.
The high coolant temperature alarm has the fol-
lowing functions:
• Alarm only.
• Alarm and torque reduction at the lowest lim-
it value.
• Alarm at the lowest limit value and engine
shutdown at the highest limit value.
• Alarm, torque reduction at the lowest limit
value and engine shutdown at the highest lim-
it value.
• Alarm at the lowest limit value and engine
shutdown at the highest limit value with the
possibility of engine shutdown override con-
trol.
• Alarm, torque reduction at the lowest limit
value and engine shutdown at the highest lim-
it value, with the possibility of engine shut-
down override control.
If run for extended periods under an extremely
light load, the engine may have difficulty in
maintaining the coolant temperature. At an in-
creased load the coolant temperature rises to the
normal value.
IMPORTANT!
An excessively high coolant temperature can

damage the engine.
OPM 110 en-GB 21

Oil pressure
Information about the normal oil pressure and
lowest permitted oil pressure is contained in the
section headed Technical Data.
The engine management system has the follow-
ing alarm levels:
• At an engine speed below 1,000 rpm and an
oil pressure below 0.7 bar/10.2 psi.
• At an engine speed above 1,000 rpm and an
oil pressure below 2.5 bar/36.3 psi for longer
than 3 seconds.
The incorrect oil pressure alarm has the follow-

ing functions:
• Alarm only.
• Alarm and torque reduction by 30%.
• Alarm and engine shutdown.
• Alarm and engine shutdown override control.
Note:
High oil pressure (above 6 bar/87 psi) is normal
if the engine is cold when started
Charging indicator lamp

If the lamp comes on during operation:
• Check and adjust the alternator drive belts as
described under the corresponding inspection
point. See the Inspection section.
If the charging indicator lamp is still on, this
could be due to an alternator fault or a fault in the
electrical system.
Belt transmission
When the belt transmission is new, it may make
a squeaking noise when running. The noise is
normal and disappears after 50-100 hours of op-
eration.
The noise does not affect the service life of the
belt transmission.
OPM 110 en-GB 22

Engine shutdown
1. Run the engine without a load for a few min-
utes if it has been run continuously with a
heavy load.
2. Switch off the engine.
Note:
The battery voltage must remain on for a few
seconds after the 15 voltage is switched off so
that the control units can store the values and
switch to standby mode.
10 prohibited engine shutdowns will cause a
torque reduction (70% of fuel quantity). Reset
the engine by switching it off correctly once.
IMPORTANT!
There is risk of post boiling and of damage to the

turbocharger if the engine is switched off with-
out cooling.
The power must not be switched off before the
engine has stopped.
OPM 110 en-GB 23

Checks after running
WARNING!

There is always a risk of sustaining burns when
an engine is hot. Particularly hot parts are turbo-
chargers, oil sumps, hot coolant and oil in pipes
and hoses.
• Check that the power supply has been cut.

• Fill the fuel tank. Make sure that the filler cap
and the area round the filler opening are clean
to avoid contamination of the fuel.
• If there is a risk of freezing, the cooling sys-
tem must contain enough glycol.
• If the temperature is below 0°C/32°F: Prepare
for the next start by connecting the engine
heater (if fitted).
IMPORTANT!
Check the coolant level following the first start.

Top up if necessary.
OPM 110 en-GB 24

Inspection
Inspection
The inspection programme covers a number of
points that are divided into the following sec-
tions:
• Lubrication system
• Cooling system
• Air cleaner
• Miscellaneous
WARNING!

The inspection programme includes the follow-

ing inspections:
• S inspection: Minimum basic inspection.
• M inspection: More extensive inspection.
• L inspection: Includes nearly all inspection
points.
• XL inspection: Includes all inspection points.
During a period, the sequence is S-M-S-L-S-M-

S-L-S-M-S-XL.
XL
L L
M M M
S S S S S S
500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
313 153
OPM 110 en-GB 25

Inspection
Engines with few hours of op-

eration
IMPORTANT!
On engines with few hours of operation, inspec-

tion must be carried out annually or every 5
years.
Stand-by generator sets and the like that are not

used regularly should be test run and checked in
accordance with the manufacturer's instructions.
The following inspection points must be carried
out once the engine has been warmed up to oper-
ating temperature.
1. Checking oil level.
2. Checking coolant level.
3. Checking vacuum indicator.
4. Checking fuel level.
5. Check for engine leaks.
OPM 110 en-GB 26

Inspection
Inspection interval
Daily First time at Interval (hours) At least

first start 500 500 1,000 2,000 6,000 annu- every
S M L XL ally 5
years
Lubrication system
X X
Checking oil level
Changing the oil X1 X1 X1 X1 X
Cleaning the centrifugal oil X1 X1 X1 X1 X
cleaner
Renewing the oil filter X1 X1 X1 X1 X
Cooling system
X
Checking coolant level
Checking coolant antifreeze or X X X X
corrosion protection
Cleaning the cooling system and X X
changing coolant
Air cleaner
X
Reading the vacuum indicator
Renewing the filter element X1 X X
Renewing the safety cartridge X X X
Fuel system
X X
Checking the fuel level
Renewing the fuel filter X1 X1 X1 X
Miscellaneous
X X X X X
Checking the drive belt
Checking for leaks X X X
Checking and adjusting valve X X X
clearances and injectors
1 More often if required.
OPM 110 en-GB 27

Lubrication system
Lubrication system
Oil grade
Scania LDF stands for the Scania Long Drain
Field test standard. Scania LDF oils have been
carefully selected after extensive testing. The ap-
proval is only granted to the highest quality en-
gine oils available on the market.
Recommended oil
Scania Oil LDF
Scania Oil LDF-2
Scania Oil LDF-3
Scania Oil E7
The engine oil must fulfil the following quality

requirements:
• ACEA E5/API CI-4
• ACEA E7/API CI-4+
• For engines not run on low-sulphur fuel, the
TBN (Total Base Number) should be at least
12 (ASTM 2 896).
• Oils with a low ash content (ACEA E9/API
CJ4) are not recommended.
Check with your oil supplier that the oil meets

these requirements.
If the engine is used in areas of the world where
lubricating oil with ACEA or API classification
is not available, the oil grade must be measured
in actual operation. In this case contact the near-
est Scania workshop.
For operation at extremely low outdoor tempera-

tures: Consult your nearest Scania representative
on how to avoid starting difficulties.
Viscosity class Outdoor temperature

SAE 20W-30 -15°C (5°F) - +30°C (86°F)
SAE 30 -10°C (14°F) - +30°C (86°F)
SAE 40 -5°C (23°F) - > +45°C (113°F)
SAE 50 0°C (32°F) - > +45°C (113°F)
SAE 5W-30 < -40°C (-40°F) - +30°C (86°F)
SAE 10W-30 -25°C (-13°F) - +30°C (86°F)
SAE 15W-40 -20°C (-4°F) - > +45°C (113°F)
OPM 110 en-GB 28

Lubrication system
Oil analysis
To be able to extend the oil change intervals us-
ing an oil analysis, Scania LDF-2 and LDF-3 oils
must be used.
Oil companies can offer analysis of the engine
oil.
The following conditions must remain fulfilled
when the oil is changed.
• Viscosity at 100°C (212°F): max. ±20% of
original value of the fresh oil.
• TBN (in accordance with ASTM D4739): >
3.5
• TBN (in accordance with ASTM D4739): >
TAN (in accordance with ASTM D664)
• Soot (DIN 51452): < 3%
Such analysis measures the oil's TBN (Total

Base Number), TAN (Total Acid Number), fuel
dilution, water content, viscosity and the quanti-
ty of particles and soot in the oil.
The result of a series of analyses is used as the
basis for establishing a suitable oil change inter-
val.
If the conditions are changed, a new oil analysis
programme must be carried out to establish new
change intervals.
Checking oil level 2
Checking the oil level with the engine

switched off
1
Note:
Leave the engine off for at least 1 minute before
checking the oil level.
1. Remove the oil dipstick (1) and check the oil

312 506
level. The correct level is between the mini-

mum and maximum marks on the oil dip-
stick.
2. Top up with more oil (2) when the oil level is
at or below the lower mark.
Information on the correct oil type is found under

the heading Oil grade.
OPM 110 en-GB 29

Lubrication system
Changing the oil

Note:
Renew the oil filter and clean the centrifugal oil
cleaner when changing oil.
WARNING!
Hot oil can cause burns and skin irritation. Wear

protective gloves and goggles when changing
314 600
hot oil.
Make sure that there is no pressure in the lubri- Max. 36 litres (9.5 US gallons)
cation system before starting work on it.
Min. 31 litres (8.2 US gallons)
The oil filler cap must always be in place when
starting and running the engine to prevent oil be-
ing ejected.
Environment
Use a container to avoid spillage. Used oil must

be disposed of as specified in national and inter-
national law.
Note:
Change oil more often if the engine is subjected
to particularly demanding operation, such as a
dusty environment, or if deposits in the centrifu- 314 601
gal oil cleaner are thicker than 28 mm (1.1 in).

Max. 34 litres (9 US gallons)
1. Unscrew the oil plug and drain the oil when Min. 29 litres (7.7 US gallons)
the engine is hot.
In certain engines the oil is pumped out by
means of a bilge pump.
2. Clean the magnet on the oil plug.
3. Refit the oil plug.
4. Top up with oil.
5. Check the level on the oil dipstick.
OPM 110 en-GB 30

Lubrication system
Maximum angles of inclination during opera-

tion
30°
Maximum permissible angles during operation
30°
vary, depending on the type of oil sump; see il- 30° 30°
lustration.
25°
25°
343 838
30° 30°
Renewing the oil filter
IMPORTANT!
Only use a Scania oil filter.
IMPORTANT!
Clean the centrifugal oil cleaner when renewing

the oil filter. Otherwise, the oil filter will be
blocked and resistance in the filter will increase.
If this happens, an overflow valve in the filter re-
tainer opens and lets the oil pass without being
filtered.
312 503
1. Unscrew the filter with a socket wrench with

hexagon driver e.g. 36 mm socket 588 475.
IMPORTANT!
Do not use an adjustable spanner or other open

tool as there is risk of damaging the filter cover.
2. Lift out the filter housing cover with filter el-

ement. The filter housing will drain automat-
ically once the filter has been removed.
3. Detach the old filter from the cover by hold-
ing the cover and carefully tapping the entire
filter element against something hard. Re-
member that there will be oil splashes.
4. Fit the new filter and tighten the filter cover
312 502
to 25 Nm (18 lbf/ft).
OPM 110 en-GB 31

Lubrication system
Labels for top-up engine oil

grade
When changing oil it is important to use the cor-
rect engine oil grade.
The oil filler cap must be clearly marked with a
label showing the top-up oil grade.
If the label is missing or if the engine oil grade is
changed, a new label must be fitted.
336 492
The illustration shows the label for oil grade Scania
LDF-2.
Parts
Oil grade Colour Part No.

Scania LDF-2 Blue 2 132 424
Scania LDF-3 Red 2 132 426
Scania LDF Grey 2 269 345
ACEA E7 White 2 132 425
OPM 110 en-GB 32

Lubrication system
Cleaning the centrifugal oil

cleaner
When cleaning the centrifugal oil cleaner there
will be some dirt deposits in the rotor cover. If
this is the case, this indicates that the rotor is
working. If it is not working, the cause must be
established immediately.
If the dirt deposit exceeds 28 mm at the recom-
mended intervals, the rotor cover should be
cleaned more often.
WARNING!
The oil may be hot. Carefully remove the cover x 1.5

from the centrifugal oil cleaner.
1. Clean the cover. Unscrew the nut securing

the outer cover.
2. Let the oil run out from the rotor.
3. Lift out the rotor. Wipe off the outside. Undo
the rotor nut and unscrew it about 1.5 turns to
133 315
protect the bearing.
Note:
Take care not to damage the rotor shaft.
4. If the rotor nut is difficult to get loose, turn

the rotor upside down and fasten the rotor nut
in a vice. Turn the rotor counterclockwise
M20
1.5 turns by hand or use an M20 nut, see il-
lustration.
IMPORTANT! x 1.5
The rotor must not be put in a vice. Never strike
the rotor cover. This may cause damage resulting
in imbalance.
133 316
OPM 110 en-GB 33

Lubrication system
5. Remove the rotor cover by holding the rotor

in both hands and tapping the rotor nut
against the table. Never strike the rotor di-
rectly as this may damage its bearings.
133 317
6. Remove the strainer from the rotor cover. If
the strainer is stuck, insert a screwdriver be-
tween the rotor cover and strainer and care-
fully prise them apart.
127 878
OPM 110 en-GB 34

Lubrication system
7. Remove the paper insert and scrape away

any remaining dirt deposits inside the rotor
cover. If the deposits are thicker than 28 mm,
the centrifugal oil cleaner must be cleaned
more often.
333 044
8. Wash the parts.
9. Inspect the 2 nozzles on the rotor. Ensure that
they are not blocked or damaged. Renew any
damaged nozzles.
10. Check that the bearings are undamaged.
333 037
OPM 110 en-GB 35

Lubrication system
11. Fit a new paper insert on the inside of the ro-

tor cover. Fit the strainer onto the rotor.
2 3 4
337 178
12. Fit the strainer onto the rotor.

13. Fit a new O-ring by sliding it over the strain-
er.
14. Refit the rotor cover. Make sure that the O-
ring is seated correctly on the inside.
15. Screw the rotor nut back on by hand.
16. Check that the shaft is not loose. Secure with
thread-locking fluid 561 200 if it is loose.
First clean thoroughly using a suitable sol-
vent. Tighten the rotor shaft using socket
wrench 99 520. Tightening torque 27 Nm.
Note:
Take care not to damage the rotor shaft.
127 881
OPM 110 en-GB 36

Lubrication system
17. Refit the rotor and rotate it by hand to make

sure it rotates easily.
127 882
18. Renew the O-ring on the cover of the oil
cleaner housing and fit the cover. Tighten the
lock nut to 15 Nm. 15 Nm
127 883
OPM 110 en-GB 37

Lubrication system
Operational testing
Operational testing need only be carried out if it
is suspected that the centrifugal oil cleaner is not
working properly. For example, if there is an ab-
normally small amount of deposit in the centrif-
ugal oil cleaner in relation to the distance driven.
The rotor rotates very fast and should continue to
turn when the engine has stopped.
1. Run the engine until it is warm.
2. Stop the engine and listen for noise coming
from the rotor. Use your hand to feel if the
333 039
filter housing is vibrating.
3. If the filter housing is not vibrating, disman-
tle and check the centrifugal oil cleaner.
OPM 110 en-GB 38

Cooling system
Cooling system
Coolant
WARNING!
Ethylene glycol can be fatal if ingested and can

cause skin irritation and eye damage.
The coolant recommended by Scania is a mix-

ture of water with antifreeze and corrosion inhib-
itor (ethylene glycol). The coolant has several
characteristics which are important for the oper-
ation of the cooling system:
• Corrosion inhibitor
• Antifreeze
• Increases the boiling point
The coolant should always contain 35-55% by

volume of antifreeze and corrosion inhibitor so
that the coolant properties ensure that the coolant
works correctly.
Note:
The coolant should be changed when the cooling
system is cleaned: every 6,000 hours or at least
every 5 years. Refer to Changing coolant.
Coolant resistance to cold

The following example shows coolant properties
with 30 percent by volume of antifreeze and cor-
rosion inhibitor:
• Ice slush starts to form at -16°C (3°F).
• At -30°C (-22°F), there is a risk of cooling
system malfunction.
0 10 20 30 40 50 %
• There is no risk of damage by freezing with a 0
minimum antifreeze and corrosion inhibitor -10
content of 35 percent by volume. -16 1
-20
The chart depicts coolant properties at different
percents of antifreeze and corrosion inhibitor -30
concentration by volume. 3 2
-40
-50
312 505
Curve A: Ice formation starts (ice slush) °C B A

Curve B: Damage by freezing occurs
Area 1: Safe area
Area 2: Malfunctions may occur (ice
slush)
OPM 110 en-GB 39

Cooling system
Area 3: Risk of damage by freezing
OPM 110 en-GB 40

Cooling system
Antifreeze and corrosion inhibitor con-

centration table
35% by volume of Scania antifreeze provides
sufficient protection against corrosion.
Example:
1. The total volume of the cooling system is 40
litres in this example.
2. The measured concentration of ethylene gly-
col is 35% by volume (freezing point -21
°C). According to the table there are 14 litres
of ethylene glycol in the cooling system.
3. The required concentration of ethylene gly-
col is 45% by volume (freezing point -30
°C). According to the table, 18 litres of eth-
ylene glycol are required in the cooling sys-
tem.
4. Since there are already 14 litres in the cool-
ing system, 4 litres of ethylene glycol must
be added to the cooling system (18 - 14 = 4
litres).
For calculation Adequate protection against corrosion

Volume of ethylene glycol Cooling system
(%) 20 25 30 35 40 45 50 60 volume (litres)
Ice slush forms (°C) -6 -9 -12 -21 -24 -30 -38 -50
5 6 8 11 12 14 15 18 30
6 8 10 14 16 18 20 24 40
8 10 13 18 20 23 25 30 50
9 12 15 21 24 27 30 36 60
11 14 18 25 28 32 35 42 70
12 16 20 28 32 36 40 48 80
14 18 23 32 36 41 45 54 90
15 20 25 35 40 45 50 60 100
Volume of ethylene glycol (li- 17 22 28 39 44 50 55 66 110
tres) 18 24 30 42 48 54 60 72 120
20 26 33 46 52 59 65 78 130
21 28 35 49 56 63 70 84 140
23 30 38 53 60 68 75 90 150
24 32 40 56 64 72 80 96 160
26 34 43 60 68 77 85 102 170
27 36 45 63 72 81 90 108 180
29 38 48 67 76 86 95 114 190
30 40 50 70 80 90 100 120 200
OPM 110 en-GB 41

Cooling system
Antifreeze and corrosion inhibitor con-

centration table
35% by volume of Scania antifreeze provides
sufficient protection against corrosion.
Example:
1. The total volume of the cooling system is
10.6 US gallons in this example.
2. The measured concentration of ethylene gly-
col is 35% by volume (freezing point -6°F).
According to the table there are 3.7 US gal-
lons of ethylene glycol in the cooling system.
3. The required concentration of ethylene gly-
col is 45% by volume (freezing point -22°F).
According to the table, 4.8 US gallons of eth-
ylene glycol are required in the cooling sys-
tem.
4. Since the cooling system already contains
3.7 US gallons, fill another 1.1 US gallons of
ethylene glycol in the cooling system (4.8 -
3.7 = 1.1 US gallons).
For calculation Adequate protection against corrosion

Volume of ethylene glycol Cooling system
(%) 20 25 30 35 40 45 50 60 volume (US gal-
Ice slush forms (°F) 21 16 10 -6 -11 -22 -36 -58 lons)
1.3 1.6 2.1 2.9 3.2 3.7 4 4.8 7.9
1.6 2.1 2.6 3.7 4.2 4.8 5.3 6.3 10.6
2.1 2.6 3.4 4.8 5.3 6.1 6.6 7.9 13.2
2.4 3.2 4 5.5 6.3 7.1 7.9 9.5 15.9
2.9 3.7 4.8 6.6 7.4 8.5 9.2 11.1 18.5
3.2 4.2 5.3 7.4 8.5 9.5 10.6 12.7 21.1
3.7 4.8 6.1 8.5 9.5 10.8 11.9 14.3 23.8
4 5.3 6.6 9.2 10.6 11.9 13.2 15.9 26.4
Volume of ethylene glycol 4.5 5.8 7.4 10.3 11.6 13.2 14.5 17.4 29.1
(US gallons) 4.8 6.3 7.9 11.1 12.7 14.3 15.9 19 31.7
5.3 6.9 8.7 12.2 13.7 15.6 17.2 20.6 34.3
5.5 7.4 9.2 12.9 14.8 16.6 18.5 22.2 37
6.1 7.9 10 14 15.9 18 19.8 23.8 39.6
6.3 8.5 10.6 14.8 16.9 19 21.1 25.4 42.3
6.9 9 11.4 15.9 18 20.3 22.5 26.9 44.9
7.1 9.5 11.9 16.6 19 21.4 23.8 28.5 47.6
7.7 10 12.7 17.7 20.1 22.7 25.1 30.1 50.2
7.9 10.6 13.2 18.5 21.1 23.8 26.4 31.7 52.8
OPM 110 en-GB 42

Cooling system
Checking coolant level

The following instructions apply to Scania ex-
pansion tanks. For other types of expansion
tanks, follow the manufacturer's instructions.
WARNING!
Never open the coolant filler cap when the en-

gine is hot. Hot coolant and steam may spray out
and cause burns.
If the cap has to be opened do it slowly and care-
fully to release the pressure before removing the
cap. Wear gloves as the coolant is still very hot.
1. Open the expansion tank cap and check the

coolant level.
The right coolant level on a cold engine is
even with the lower edge of the filler neck.
The right coolant level on a hot engine is ap-
proximately 25 mm (1 in) over the lower
edge of the filler neck.
2. Top up with coolant as necessary.
IMPORTANT!
Do not top up large quantities of coolant through

the expansion tank. Top up in accordance with
the instructions in the section headed Changing
coolant instead.
Never fill a large amount of cold coolant in a hot
engine. There is great risk of cracks forming in
the cylinder block and cylinder heads.
Only pour pre-mixed coolant into the cooling
system.
OPM 110 en-GB 43

Cooling system
Checking antifreeze and cor-

rosion inhibitor
Note:
Use only pure fresh water that is free from parti-
cles, sludge and other impurities.
1. Pour a small amount of coolant into a con-

tainer and check that the coolant is pure and
clear.
2. Change the coolant if it is contaminated or
cloudy.
3. Measure the antifreeze content with one of
the following instruments:
Part No. Designation

588 805 Refractometer
588 226 Refractometer
The following rules apply to ethylene glycol-
based coolant:
• The antifreeze and corrosion inhibitor content
must be minimum 35 percent by volume for
corrosion protection to be sufficient.
• An antifreeze and corrosion inhibitor content
greater than 55 percent by volume impairs the
ability to protect against frost.
• If ice forms in the coolant, there are disrup-
tions initially, but there is no immediate risk
of damage. The engine should not be subject-
ed to heavy loads when ice starts to form.
OPM 110 en-GB 44

Cooling system
Antifreeze and corrosion in-

hibitor
Only the product Scania coolant, or other prod-
ucts that are tested to provide proper antifreeze
and protection against corrosion for Scania, may
be used in Scania engines. Products that do not
satisfy the requirements for use in a Scania en-
gine can result in faults in and damage to the
cooling system. This can lead to the invalidation
of Scania's warranty for faults and damage
caused by the use of inappropriate coolant.
The antifreeze and corrosion inhibitor used in
Scania engines should be of the ethylene glycol
type.
Scania concentrate
Designation Contents Part No. Volume Volume (US
gallons)
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 323 5l 1.3 gallons
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 324 20 l 5.3 gallons
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 325 210 l 55 gallons
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 326 1,000 l 264 gallons
Scania Ready Mix

Designation Contents Part No. Volume Volume (US
gallons)
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 921 955 5l 1.3 gallons
50/50
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 921 956 20 l 5.3 gallons
50/50
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 921 957 210 l 55 gallons
50/50
Coolant Scania antifreeze and corrosion inhibitor Ready Mix 1 896 695 1,000 l 264 gallons
50/50
OPM 110 en-GB 45

Cooling system
Changing coolant
Environment
Avoid spillage and use a suitable container. Used

coolant must be disposed of as specified in na-
tional and international law.
IMPORTANT!
Mix the coolant as specified under the section

Coolant.
1. Remove the expansion tank cap.

2. Drain the coolant at the following two
points:
Lowest point of the cylinder block.
The lowest point of the cooling system.
3. Close the drain taps.
OPM 110 en-GB 46

Cooling system
Filling coolant
1. Connect the hose from unit 588 540 to the

engine's drain valve.
2. Ensure that the cooling system bleed pipes
are not blocked or damaged. There are bleed
307 399
pipes from the radiator, engine and expan-
sion tank.
Unit 588 540
3. Open the expansion tank cap.
4. Pump in coolant using coolant unit 588 540.
Fill with coolant to the max. level of the ex-
pansion tank.
5. Disconnect the hose.
6. Set the heating control to maximum heating
and start the engine. Idling speed must not
exceed 600 rpm. Leave the engine idling for
15 minutes.
7. Stop the engine and top up with coolant to
the maximum level through the expansion
tank.
8. Air pockets may still be left in the cooling
system, which will disappear after the engine
has been operated for a period of time. It
may, therefore, need some topping up to start
with.
IMPORTANT!
When it is necessary to fill a large quantity of

coolant, it must be pumped in from underneath.
This is to ensure that air does not get into the
cooling system, which can cause the coolant
pump to overheat.
OPM 110 en-GB 47

Cooling system
Cleaning the cooling system

Note:
Clean the cooling system more often than the in-
spection interval if necessary.
IMPORTANT!
Do not use caustic soda or other alkaline deter-

gent as this could damage the aluminium.
External: Cleaning the radiator and

charge air cooler
1. Check that the radiator and the charge air
cooler are not clogged on the air side and that
the cooling fins are not damaged.
2. Carefully scrape away any deposits from the
radiator cooling fins. Use a paraffin-based
engine cleaner if necessary.
3. Carefully straighten bent cooling fins using a
steel brush or the like.
WARNING!
To ensure proper handling of cooling system de-

tergent, study the warning text on the package.
OPM 110 en-GB 48

Cooling system
Internal: Removing oil and grease

1. Run the engine until it has reached operating
temperature and then drain the cooling sys-
tem.
2. Remove the thermostats.
3. Fill the system with clean, hot water mixed
with liquid dishwasher detergent intended
for household machines. Concentration 1%
(0.1/10 litres).
4. Warm up the engine for approximately 20-
30 minutes. Remember to switch on the cab
heating system, if one is installed.
5. Drain the cooling system.
6. Fill the system with clean, hot water and run
the engine for about 20-30 minutes.
7. Drain the water from the cooling system.
8. Refit the thermostats.
9. Fill the cooling system with new coolant fol-
lowing the specification under Coolants ear-
lier in the document.
Environment

OPM 110 en-GB 49

Cooling system
Internal: Removing deposits

1. Run the engine until it has reached operating
temperature and then drain the cooling sys-
tem.
2. Remove the thermostats.
3. Fill the system with clean, hot water mixed
with some commercially available radiator
detergent which is based on sulphamic acid
and contains dispersing agents. Follow the
manufacturer's instructions for the concen-
tration and cleaning period.
4. Run the engine for the specified time. Re-
member to switch on the cab heating system,
if one is installed.
5. Drain the cooling system.
6. Fill the cooling system with clean, hot water
and run the engine for about 20-30 minutes.
7. Drain the water from the cooling system.
8. Refit the thermostats.
9. Fill the system with new coolant following
the specification under Coolants earlier in
the document.
Environment

OPM 110 en-GB 50

Air cleaner
Air cleaner
Reading the vacuum indicator
If the indicator's red plunger is fully visible, re-
new the air cleaner filter element following the
instructions.
326 671
Renewing the filter element
Note:
Renew the filter element earlier than the inspec-
tion interval if the indicator shows red. A B
There is always a risk that the filter element will

be damaged when it is cleaned.
The filter element must not be cleaned in water
or be blown clean with compressed air.
WARNING!
336 100
Never start the engine without the air filter as this
could cause injury and severe engine damage. A Vacuum gauge
B Filter element
1. Remove the cover from the air cleaner.
2. Renew the filter element.
3. Carry out a check by inserting an inspection
lamp into the element and checking from the
outside that there are no holes or cracks in the
filter paper.
4. Assemble the air cleaner.
5. Reset the vacuum indicator by pressing the
button.
OPM 110 en-GB 51

Fuel system
Renewing the safety cartridge
IMPORTANT!
When renewing the safety cartridge, take great

care to ensure that no dirt or other impurities get
into the engine. Do not remove the safety car-
tridge unnecessarily.
1. Remove the cover from the air cleaner.

2. Remove the filter element.
3. Remove the safety cartridge.
4. Fit a new, genuine safety cartridge.
5. Renew or clean the filter element.
6. Assemble the air cleaner.
Fuel system
Sulphur content in fuel and its effect on oil
change interval
• A sulphur content of 0-2,000 ppm in the fuel
gives an oil change interval of up to 500
hours.
• With a sulphur content of 2,000-4,000 ppm in
the fuel, the oil change interval is halved to
max. 250 hours.
Checking fuel level

• Check the fuel level and top up with fuel as
necessary.
Note:
The fuel system must be bled if the tank has been
run dry. Refer to the Bleeding the fuel system
section.
OPM 110 en-GB 52

Fuel system
Renewing the fuel filter
Environment

fuel must be disposed of as specified in national
and international law.
1. Unscrew the filter cover with a socket

wrench with hexagon driver, e.g. 587 637, so
as not to damage the filter cover.
2. Lift out the filter cover and filter element.
The filter housing will drain automatically.
This applies only if the fuel tank is lower
than the engine. Otherwise the fuel shut-off
cock must be closed first.
3. Undo the removed filter element from the
cover by carefully bending it to one side.
4. Renew the O-ring in the cover. Lubricate the
O-ring with O-ring grease.
5. Check that the filter housing is drained of fu-
el. Contaminated fuel may enter the injectors
314 824
if the drainage does not work.
6. Press a new filter element into the snap fas-
tener in the cover.
7. Fit the filter element and cover in the filter
housing. Tighten the cover to 25 Nm (18.4
lbf/ft).
8. Bleed the fuel system after renewing the wa-
ter separating filter.
IMPORTANT!
Fit the filter elements in the filter covers before

placing them in the fuel filter housings or the fil-
ter elements may be damaged.
OPM 110 en-GB 53

Fuel system
Renewing the water separat- 1

ing fuel filter
1. Close the shut-off cock in the fuel pipe and
position a container under the filter.
2. Open the drain tap in the filter cover and let
the fluid run down into the container.
3. Unscrew the filter cover.
4. Unscrew the filter from the filter head.
5. Discard the old filter and use a new filter.
6. Lubricate the O-ring in the filter cover with
engine oil.
7. Screw the filter cover onto the new filter by
hand. Make sure that the drain tap is fully
closed.
8. Lubricate the O-ring on the filter with engine
oil. 2
9. Fill the width of the filter with clean fuel.
316 148
10. Screw the filter into position until the O-ring
rests against the filter head. Tighten the filter
another 1/2-3/4 turn by hand. 1 Shut-off cock
11. Open the shut-off cock and check the system 2 Drain tap
for leaks.
12. Bleed the fuel system.
OPM 110 en-GB 54

Fuel system
Bleeding the fuel system

1. Attach a clear plastic hose to the bleed nipple
on the fuel filter housing (1). Place the end of
the plastic hose in a container that holds at
least 3 litres (0.8 US gallons).
2. Open the bleed nipple and pump with the
hand pump until fuel comes out of the hose. 2
If the fuel system is empty, it is necessary to
pump approximately 100 strokes in order to
draw up the fuel. Depending on the installa-
tion, a much greater number of pump strokes
may be required before fuel comes out. 1
3. Pump until fuel without air bubbles comes
out, approximately 20 strokes.
4. Close the bleed nipple and remove the hose.
5. Transfer the plastic hose to the fuel manifold
314 909
bleed nipple (2).
6. Open the fuel manifold ventilating valve.
7. Pump with the hand pump until fuel without
air bubbles comes out, approximately 50
strokes.
8. Close the bleed nipple on the fuel manifold
and remove the plastic hose.
9. Pump approximately 20 strokes with the
hand pump until the overflow valve opens. A
hissing sound should be heard.
10. Start the engine. The engine should be easy
to start.
OPM 110 en-GB 55

Miscellaneous
Miscellaneous
Checking the drive belt
IMPORTANT!
Refit the drive belt with the same direction of ro-

tation as it had before removal.
Check the drive belt thoroughly, particularly at

the idler rollers.
312158
Check the drive belt for cracks.
106 229
The drive belt must be renewed if it has cracks.
OPM 110 en-GB 56

Miscellaneous
Check drive belt wear.
112 931
The drive belt is starting to become worn, but can be
refitted.
112 932
The belt is worn down to the cord. The drive belt
must be renewed.
OPM 110 en-GB 57

Miscellaneous
Checking for leaks

• Start the engine.
• Check for oil, coolant, fuel, air or exhaust
leaks.
• Tighten or renew leaking connections. Check
the overflow holes which show whether the
O-rings between the cylinder liners and
crankcase are leaking.
• Check whether the drain hole on the coolant
pump is blocked. If there is a leak, renew the
seal in the pump or the complete coolant
pump.
IMPORTANT!
If serious leakage occurs, contact your nearest

Scania workshop.
Checking and adjusting the

valve clearances and unit in-
jector rocker arms
Note:
Checking and adjusting valve clearances should
also be done after the first 500 hours of opera-
tion.
Valve clearances should be adjusted when the

engine is cold, at least 30 minutes after running.
WARNING!

Readings can be taken from the flywheel through

openings in the flywheel housing either from
above or below depending on access when fit-
ting.
“TDC up” or ”"TDC down" is found on the fly-
wheel. Both openings are fitted with a blanking
piece on delivery.
310 343
Openings for taking readings on the flywheel hous-

ing.
OPM 110 en-GB 58

Miscellaneous
Specifications
Valve clearance, intake 0.45 mm (0.018 in)
312 879
valve
Valve clearance, ex- 0.70 mm (0.028 in)
haust valve Special tool 99 309 is used when turning from be-
low.
Tightening torques
Lock nut for valves 35 Nm (26 lbf/ft)
Lock nut for unit injec- 39 Nm (29 lbf/ft)
tors
312 878
Special tool 99 109 is used when turning from
above.
314 829
Special tool 99 442 is used to check the height of the

unit injectors.
OPM 110 en-GB 59

Miscellaneous
From below Valve transition Valve adjust- Injector From above

ment
TDC down 1 2 TDC up
72/432 5 252/612
144/504 2 4 324/684
216/576 3 36/396
288/648 4 5 108/468
TDC down 1 TDC up
72/432 5 3 252/612
144/504 2 324/684
216/576 3 1 36/396
288/648 4 108/468
• Turn the flywheel in the engine's direction of

rotation so that TDC down or TDC up is vis-
ible in the flywheel housing window.
• If there is valve clearance on cylinder 1, start
the adjustment as indicated in the table.
• If there is valve transition on cylinder 1, work
should start at row six of the table.
1
B
Checking and adjusting the unit injector a
The unit injectors are adjusted using setting tool A
99 442 or a digital sliding caliper.
314 823
Dimension A = 69.9 +/- 0.1 (2.75 in)

Dimension B = 38.8 (1.53 in)
OPM 110 en-GB 60

Miscellaneous
11. Fit the setting tool with the metal plate

around the unit injector
WARNING!
Be very careful when checking the unit injector

if the measurement is outside the setting dimen-
sion. The spring is pre-tensioned and can come
loose, causing personal injury.
314 831
1
12. When adjusting, undo the lock nut around

the adjusting screw and adjust the unit injec-
tor using the adjusting screw (1).
The unit injector is correctly set when the
small piston (2) is level with the flat upper
surface of the tool. Use a finger to check. The
setting dimension is 69.9 +/- 0.1 mm (2.75
in).
2
314 832
OPM 110 en-GB 61

Diesel
Diesel
Composition of the fuel
The composition of the fuel is extremely impor-
tant for the operation and service life of the en-
gine and injection system. The engine output and
exhaust gases are also dependent on the fuel
grade.
The requirements and testing standards for the
most important characteristics are described in
the Workshop Manual which can be ordered
from Scania dealers or directly from Scania.
The fuel must conform to EU standard EN590.
The table shows some of the key properties.
Property Requirements
Viscosity at 40°C (104°F) 2.0-4.5 cSt
Density at 15°C (59°F) 0.82-0.86 cSt
Ignitability (CET rating) minimum 49
Flashpoint 56°C (132°F)
Sulphur content of fuel

• A sulphur content of 0-2,000 ppm in the fuel
(0.2%) gives an oil change interval of up to
500 hours.
• With a sulphur content of 2,000-4,000 ppm in
the fuel, the oil change interval is halved to
max. 250 hours.
• Maximum permitted sulphur contents in the
fuel is 4,000 ppm.
OPM 110 en-GB 62

Diesel
Temperature dependency of
the fuel
At temperatures lower than those specified for
the fuel, paraffin wax may precipitate from the
fuel and block filters and pipes. The engine can
then lose power or stop.
The fuel is adapted for use in the specific climate
of each country. If a vehicle or an engine is to be
operated in a temperature zone with a tempera-
ture lower than normal, first identify the temper-
ature properties of that particular fuel.
The properties of the fuel when cold can be im-
proved by adopting one of the following meas-
ures before the temperature drops:
• Install an electric fuel heater if this particular
fuel is not suitable for the expected tempera-
ture and no fuel is available with the correct
temperature properties.
• Add 0.5-2% alcohol (isopropanol) to prevent
any water in the fuel from freezing and form-
ing plugs of ice. Drain fuel tanks and drain or
renew fuel filters regularly.
IMPORTANT!
Mixing kerosene or other paraffins with the fuel

is prohibited. The injectors may be damaged.
Mixing petrol with the fuel is prohibited. In the
long term petrol can cause wear in the injectors
and engine.
OPM 110 en-GB 63

Preparing the engine for storage
Preparing the engine for

storage
If the engine is not being used for an extended
period its cooling system, fuel system and com-
bustion chamber and outside must be protected
against rust.
An alternative to preparing the engine for long-
term storage is to start the engine and warm it up
every 6 months.
Handling the engine

The engine can normally stand idle for up to 6
months without preparation. For longer periods
of downtime, the following measures should be
taken. These measures provide protection for ap-
proximately 4 years.
Preparations for storage:
• Thoroughly clean the engine.
• Run the engine for a specific period using
special preservative fuel, oil and coolant.
• Otherwise prepare the engine for storage (fil-
ter renewal, lubrication, etc.).
Preservative coolant
If the engine is to be stored with a full cooling
system, use coolant containing 50 percent glycol
by volume. Glycol without nitrite-based inhibi-
tor should be used. Example: BASF G48 or
BASF D542.
WARNING!
Ethylene glycol can be fatal if ingested. Avoid

contact with the skin.
OPM 110 en-GB 64

Preservative fuel
Use diesel mixed with Lubrizol 560H or the
equivalent. Mix 1 cm3 (ml)/0.06 in3 Lubrizol
560H in 10 dm3/2.3 US gallons of fuel.
WARNING!
Lubrizol 560H contains aromatic hydrocarbons

which are hazardous to health.
• Use spot extractors where there is a danger of
vapour build-up.
• Wear protective goggles and gloves when
handling the fuel.
• Do not use contaminated clothing.
• If it gets in your eyes: Flush with a gentle jet
of water for at least 15 minutes and contact a
doctor.
• If it gets on your skin: Wash with soap and
water.
• If you inhale it: Fresh air, rest and warmth.
• Store in well-sealed containers in a dry, cool,
place out of the reach of children.
Lubrizol is flammable and has a 2A fire rating.
The flashpoint is +27°C/81°F. In case of fire: Ex-
tinguish with carbon dioxide, powder or foam.
Preservative oil
Suitable preservative oils are supplied by most
oil companies. Example: Dinitrol 40 or equiva-
lent.
OPM 110 en-GB 65

Preparations for storage
Environment
Use a container to avoid spills when draining the

oil and coolant. Dispose of used fluids through
an authorised waste disposal contractor.
1. Drain and flush the cooling system. Top up

with preservative coolant.
2. Warm up the engine on normal fuel. Stop the
engine and drain the oil.
3. Renew the fuel filter.
4. Fill the engine with preservative oil up to the
minimum level on the oil dipstick.
5. Mix preservative fuel in a can. Detach the
fuel pipe at the feed pump suction line and
connect a hose from the can.
6. Detach the fuel pipe at the overflow valve
and connect a return hose to the can.
7. Start the engine and run it at about 1,000 rpm
for 20-25 minutes.
8. Stop the engine, remove the hoses and con-
nect the normal fuel pipes.
9. Remove the rocker covers and lubricate the
valve mechanisms with plenty of preserva-
tive oil. Refit the rocker covers.
Note:
Do not remove the injectors.
OPM 110 en-GB 66

10. Drain the preservative oil from the engine.

Fill with new engine oil immediately or
when the engine is to be reused.
11. Drain the coolant if the engine is not to be
stored with coolant in the system. Plug and
tape all coolant connections if the engine is
to be stored without a cooling system.
12. Air cleaner: Clean or renew the filter ele-
ment.
13. Cover air intakes and exhaust pipes.
14. Alternator and starter motor: Spray with wa-
ter-repellent anti-corrosive oil, CRC 226,
LPS1 or the equivalent.
15. Spray the outside of bright engine parts, first
with penetrating preservative oil such as
Dinitrol 25B and then with Dinitrol 112 or
the equivalent.
Clearly mark the engine with the storage prepa-

ration date, and state that the engine must not be
started or cranked.
Batteries
Remove the batteries and trickle charge them at
the battery charging station. This does not apply
to batteries specified as maintenance-free by the
manufacturer.
The same applies to short-term storage, even if
the engine has not been prepared for storage as
above.
WARNING!
Wear gloves and protective goggles when charg-

ing and handling batteries. The batteries contain
a highly corrosive acid.
OPM 110 en-GB 67

Storage
After the preparations, the engine should be
stored in a dry and warm place (room tempera-
ture).
When the engine is to be taken into

operation again
1. Remove plugs and tape from coolant connec-
tions, air intakes and exhaust pipes.
2. Fill the cooling system with coolant. For
more information refer to the section headed
Inspection.
3. Check the oil level in the engine or top up
with fresh engine oil.
4. Lubricate the valve mechanisms and their
pushrods and valve tappets as well as the in-
jector mechanisms with plenty of oil.
5. Drain the preservative fuel from the fuel
manifold and fuel filter.
6. Connect and bleed the fuel system. For more
information refer to the section headed In-
spection.
7. Wash off any preservative oil on the outside
using white spirit.
OPM 110 en-GB 68

Technical data
Technical data
General data
Number of cylinders and configuration 5, straight

Working principle 4-stroke engine
Cylinder diameter (mm/in) 130/5.12
Piston stroke (mm/in) 140/5.51
Displacement (dm3/in3) 9.3/567.5
Firing sequence 1-2-4-5-3
Compression ratio 16:11
Engine direction of rotation viewed from rear Anti-clockwise
Fan direction of rotation viewed from front Clockwise
Cooling Coolant
Valve clearances, cold engine
Intake valve (mm/in) 0.45/0.02
Outlet valve (mm/in) 0.70/0.03
Number of teeth on the flywheel 158
Low idling speed (rpm) 500-1,050
Maximum full-load speed (rpm) 2,100
Fuel Diesel
Approximate weight, without coolant and oil (kg/lb) 950/2,094
1. For engines with performance and certification code 076, the compression ratio is 18:1.
Lubrication system
Oil volume See Inspection

Oil cleaning Centrifugal oil cleaning
Oil cooler Coolant cooled, full
flow
Oil filter Paper filter from Scania
Interval between oil changes (h) 500
Oil pressure (bar)
Normal with the engine at operating temperature, operating speed 3-6
Minimum permitted at idling speed 0.7
Crankcase pressure with closed crankcase ventilation (mbar) -5.4 to 2.0
OPM 110 en-GB 69

Technical data
Injection system
Type PDE (unit injector)

Control system EMS
Fuel filter Paper filter from Scania
Fuel filter with water separator Paper filter from Scania
Cooling system
Volume, excluding radiator (dm3/US gallons) 15/4.0

Coolant temperature (°C/°F) 90-95/194-203
Number of thermostats 1
Thermostat opening temperature (°C/°F) 80/176 and 87/189
Intake system
Permissible pressure drop in the intake system with cleaned or new fil- 30
ter (mbar)
Permissible pressure drop in the intake system with blocked (dirty) fil- 65
ter (mbar)
Electrical system
Type 1-pin, 24 V, DC
Starter motor, standard equipment 1-pin, 24 V, 5.5 kW
Alternator, standard equipment 1-pin, 28 V, 100 A
OPM 110 en-GB 70

Scania Assistance
Scania Assistance
Wherever you are, you can always get assistance
from the Scania service organisation, Scania As-
sistance, all day, every day of the year.
Always call the contact for your country.
AR 0800 999 722 642 IE +353 71 9634000

AT +43 1 256 44 11 IT +39 0461 996 222
AU 1300 SCANIA KR +82 1588 6575
1300 722642 LU +32 226 400 000
BE +32 2 264 00 00 MA +34 91 678 92 13
BG +359 886 660001 MX 01 800 4SCANIA
BR 0800 019 42 24 NL +31 70 4182666
CA +1-800-2-SCANIA NO +47 223 217 00
CH +41 800 55 24 00 PL +48 602 622 465
CL 188 800 722 642 PT +48 91 678 9247
CZ +420 225 020 225 RO +40 723 27 27 26
DE +49 261 887 8888 SE +46 42 100 100
DK +45 333 270 44 SK +421 903 722 048
ES +34 91 678 80 58 TR +90 212 335 04 40
FI +358 10 555 24 TZ +255 78 472 2642
FR +33 2 414 132 32 US 1-800-2-SCANIA
GB 0 800 800 660 UY 0800 8351
+44 1274 301260 ZA 0800 005 798
GR +30 6944 420 410 +27 11 661 9823
HU +36 209 727 197
Other countries: +46 8 52 24 24 24

Note:
Calls will be recorded for training purposes.
OPM 110 en-GB 71


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Important information

Serious risk of injury

Start-up Report – Warranty

Engine serial number

OPM 110 en-GB 2

To ensure the maximum performance and the

The information in this manual was correct at the

OPM 110 en-GB 3

Environment and safety

OPM 110 en-GB 4

Different types of advisory

Block the starting device when working on the

For Scania to guarantee that the engine corre-

Use a container to avoid spillage.

OPM 110 en-GB 5

Warnings and advisories

Safety precautions for running the

The wrong fuel grade can cause breakdowns or

OPM 110 en-GB 6

During refuelling there is a risk of fire and explo-

Only start the engine in a well ventilated area.

If the control panel is not fitted with a starter

OPM 110 en-GB 7

Never use starter gas or similar agents to help

The engine must not be run in environments

Safety precautions for handling ma-

All fuels and lubricants as well as many chemi-

OPM 110 en-GB 8

The batteries contain and form oxyhydrogen gas,

Most chemicals such as glycol, anti-corrosive

Always hand in leftover and used chemicals to

OPM 110 en-GB 9

Safety precautions for inspection

Working with a running engine always poses a

Hot surfaces and fluids

There is always a risk of sustaining burns when

OPM 110 en-GB 10

Lift the engine out

Never work underneath a suspended engine!

The batteries contain highly corrosive sulphuric

Always hand in used batteries to an authorised

OPM 110 en-GB 11

Always use Scania spare parts for the fuel and

When carrying out welding work on and near the

OPM 110 en-GB 12

Hot oil can cause burns and skin irritation. Wear

Always hand in used oil to an authorised waste

Never open the coolant filler cap when the en-

Always hand in used coolant to an authorised

OPM 110 en-GB 13

Always wear protective goggles when testing in-

The air filter must be fitted before starting the en-

OPM 110 en-GB 14

Otherwise, the instructions in the Operator's

For Scania to guarantee that the engine corre-

OPM 110 en-GB 15

Engine data plate

Example: DC09 074A

Type DC09 74A