Industrial & Marine Engines

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

Operator’s Manual
DI9 55 - DI9 59
Marine engine
opm99-9m en 1 588 713
2001-05:1

START-UP REPORT - WARRANTY

When the start-up report has been filled in and sent to Scania there is a 1 year warranty starting from
the start-up date. Also enter the below information since this will facilitate contacts with e.g. service
workshops.

Engine number

Start-up date

User’s name and address

Signature
Engine type
Variant

Engine type and variant are indicated on the engine type plate
FOREWORD
This operator’s manual describes the operation and maintenance of the Scania
DI9 55 and DI9 59 marine engines. The instructions apply to these engine
types in program 99, starting with engine number 5 134 340.
The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder in
line diesel type. They are supercharged and equipped with a charge air cooler
which is coolant-cooled. See also page 10.
These engines have a cooling system with a heat exchanger, which is cooled
by sea water, in which the engine coolant is cooled.
These engine types have electronic control of the injection system’s governor
to optimize engine performance and such important operating factors as fuel
consumption and exhaust emissions.
The electronic control system is called DEC2 (Digital Electronic Control)
and is described in greater detail on page 12.
A common application is as the propulsion unit in patrol boats (DI9 55) and
in larger pleasure craft (DI9 59).
The engines have different output and speed settings and can be classified in
different classification socities (classed engines must be used in certain
marine installations).
The normal output setting of the engine (performance code) is indicated on
the type plate, see page 10.
Note Only standard components are described in the operator’s man-
ual. Regarding special equipment, refer to the instructions of the
relevant manufacturer.
In order to obtain the best value and service life from your engine, there are a
few points to bear in mind:
- Read the manual before starting to use the engine. You will find new
information in this Operator’s Manual even if you have previous
experience of Scania engines.
- Follow the maintenance instructions. Proper maintenance is essential to
keep the engine operating correctly and to increase engine life.
- Pay special attention to the safety information beginning on page 6.
- Get to know your engine so that you know what it can do and how it During the warranty period,
works. only use genuine Scania parts in
- Whenever necessary, always contact an authorised Scania workshop. service and repair for the
They have special tools, genuine Scania parts and trained staff with warranty to be valid.
practical experience of Scania engines.
Note: Always use genuine Scania parts in service and repair to keep the
engine operating correctly.
The information in this manual was correct at the time of going to press.
However, we reserve the right to make changes at any time, without prior
notice.

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

2 © Scania Industrial & Marine Engines 2001-05:1

 CONTENTS

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 2 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 38

READING THE VACUUM INDICATOR . . . .38
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CLEANING THE AIR CLEANER
ENVIRONMENTAL RESPONSIBILITY . . . . . .4 COARSE CLEANER . . . . . . . . . . . . . . . . . . . . .38
CERTIFIED ENGINES . . . . . . . . . . . . . . . . . . . . 5 CLEANING OR CHANGING THE
SAFETY DETAILS . . . . . . . . . . . . . . . . . . . . . . .6 FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . .38
Safety precautions for operation . . . . . . . . . . . . 7 CHANGING SAFETY CARTRIDGE . . . . . . . .40
Safety precautions for handling materials . . . . .8
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 41
Safety precautions for care and maintenance . . 8
CHECKING FUEL LEVEL . . . . . . . . . . . . . . . .41
TYPE DESIGNATIONS . . . . . . . . . . . . . . . 10 CHANGING THE FUEL FILTER . . . . . . . . . . .41
CHECKING INJECTORS . . . . . . . . . . . . . . . . .42
DEC2 CONTROL SYSTEM . . . . . . . . . . . . 12
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 43
STARTING AND RUNNING . . . . . . . . . . . 18
CHECKING THE
AT FIRST START . . . . . . . . . . . . . . . . . . . . . . .18 ELECTROLYTE LEVEL IN BATTERIES . . . .43
CHECKS BEFORE RUNNING . . . . . . . . . . . . .19 CHECKING THE STATE OF CHARGE
STARTING THE ENGINE . . . . . . . . . . . . . . . .19 IN BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . .43
At temperatures below 0 °C: . . . . . . . . . . . . . .20 CLEANING BATTERIES . . . . . . . . . . . . . . . . .43
RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 CHECKING THE COOLANT LEVEL
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . .21 MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Coolant temperature . . . . . . . . . . . . . . . . . . . .21 CHECKING THE
TEMPERATURE MONITOR . . . . . . . . . . . . . . 45
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .22
CHECKING THE TEMPERATURE SENSOR . 45
STOPPING THE ENGINE . . . . . . . . . . . . . . . . .22
CHECKING THE OIL PRESSURE SEN-
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 SOR/MONITOR . . . . . . . . . . . . . . . . . . . . . . . . .46
CHECKS AFTER RUNNING . . . . . . . . . . . . . .23 CHECKING THE OIL PRESSURE MONITOR
FOR DEC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 24
ENGINES WITH FEW HOURS CHANGING THE BATTERY . . . . . . . . . . 47
OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 24
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 47
MAINTENANCE SCHEDULE . . . . . . . . . . . . .25
CHECKING THE DRIVE BELT . . . . . . . . . . . .47
LUBRICATING OIL SYSTEM . . . . . . . . . 26 CHECKING FOR LEAKAGE, RECTIFY
OIL GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 AS NECESSARY . . . . . . . . . . . . . . . . . . . . . . . . 48
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . .26 CHECKING/ADJUSTING VALVE
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .49
CHECKING THE OIL LEVEL . . . . . . . . . . . . .27
CHANGING (OR CLEANING) THE CLOSED
OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . .27 CRANKCASE VENTILATION VALVE . . . . . 50
Maximum angles of inclination during
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 LONG-TERM STORAGE . . . . . . . . . . . . . . 51
CLEANING THE OIL CLEANER . . . . . . . . . . 28 Preservative fuel . . . . . . . . . . . . . . . . . . . . . . . 51
CHANGING THE OIL FILTER . . . . . . . . . . . .30 Preservative oil . . . . . . . . . . . . . . . . . . . . . . . .52
Preparations for storage . . . . . . . . . . . . . . . . .52
COOLING SYSTEM . . . . . . . . . . . . . . . . . . 30
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
CHECKING COOLANT LEVEL . . . . . . . . . . .30
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
CHECKING CORROSION BARS . . . . . . . . . . . 31
Taking out of storage . . . . . . . . . . . . . . . . . . . 53
CHECKING THE SEA WATER PUMP
IMPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 TECHNICAL DATA . . . . . . . . . . . . . . . . . . 54
CHECKING THE COOLANT . . . . . . . . . . . . . .32 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Changing the coolant . . . . . . . . . . . . . . . . . . . 34
CLEANING THE COOLING SYSTEM . . . . . . 35 ALPHABETIC INDEX . . . . . . . . . . . . . . . . 58
Internal cleaning . . . . . . . . . . . . . . . . . . . . . . .37

2001-05:1 © Scania Industrial & Marine Engines 3

ENVIRONMENTAL RESPONSIBILITY
Scania has always been at the forefront in the development and production of
environmentally safe engines.
We have made great progress in reducing harmful exhaust emissions to be
able to meet the stringent emission standards that are mandatory for almost
all markets.
We have done this without compromising the high quality of Scania
industrial and marine engines in terms of performance and cost effective
operation.
To maintain these superior properties throughout the life of the engine it is
important that the operator/owner follows the instructions of this manual as
regards operation, maintenance and choice of fuel and lubricants.
To further contribute to protecting the environment in service, maintenance
and repair, ensure that harmful waste (oil, fuel, coolant, filters, batteries etc.)
is disposed of and destroyed according to applicable local regulations.
This operator’s manual contains highlighted text urging you to protect the
environment in different service and maintenance operations. Always use suitable containers
to avoid spillage when bleeding
Refer to example systems or renewing
components.

4 © Scania Industrial & Marine Engines 2001-05:1

CERTIFIED ENGINES
An emission certified engine has been approved according to a specific
certification standard. The certified engines delivered by Scania meet the
most compelling emission standards in the European (EU) and non-European
(USA) markets.
Scania guarantees that all engines of a certified engine type that are delivered,
correspond to the engine approved for certification.
The engine is fitted with a certification plate, stating according to which
certification rules (standard) the engine has been approved. Refer to page 10.
The following is required for the engine to meet the emission standards after
being commissioned:
- Service and maintenance must be performed according to this
Operator’s Manual.
- Only genuine Scania parts must be used.
- Service work on the injection equipment must be performed by an
authorized Scania workshop.
- The engine must not be modified with equipment not approved by
Scania.
- Seals and setting data may only be broken/modified after approval by
Scania, Södertälje. Changes should only be made by qualified
personnel.
- Changes affecting the exhaust system and intake system must be
approved by Scania.
Otherwise, follow the instructions in this manual for operation, care and
maintenance of the engine. Also observe the safety precautions described in
the following four pages.

Important! If service and maintenance are not performed as stated

above, Scania cannot guarantee that the engine corresponds
to the certified configuration and will not assume liability for
any damage occurring.

2001-05:1 © Scania Industrial & Marine Engines 5

SAFETY DETAILS
General
This Operator’s Manual contains safety information that must be observed in
order to avoid personal injuries and damage to the product or property. Refer
to page 1.
The text boxes to the right on the pages provide information that is important Only use Scania genuine fuel
for the proper operation of the engine and to avoid damage to the engine.
Failure to follow these instructions may void the warranty. filter.
Refer to example.
Corresponding texts may also appear in the text column, headed Caution! or
Important

The warning text in text boxes to the right on the pages provided with a
warning triangle and headed WARNING is extremely important and warns Immobilise the starting device
of serious defects to the engine or improper handling that may lead to when working on the engine.
personal injury.
If the engine starts out of
Refer to example 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 often stated next to the maintenance step
concerned, shown with different degrees of significance as described above.
All items are marked with a ! to highlight the importance of reading each
item in the section.
A general safety rule is that no smoking is allowed:
• Near the engine and the engine bay

• When refuelling and near the filling station

• When work is performed on the fuel system

• Near flammable or explosive materials (fuel, oils, batteries, chemicals

etc.)

6 © Scania Industrial & Marine Engines 2001-05:1

 Safety precautions for operation

Daily inspection Starter lock

Always perform visual inspection of the engine If the control panel is not fitted with a key
and engine bay before the engine is started and switch, the engine bay should be fitted with a
when the engine has been stopped after oper- lock to prevent unauthorized starting of the en-
ation. gine.
This will make it easy to detect any leakage of Alternatively, a lockable main switch or battery
fuel, oil or coolant or any other abnormal condi- master switch may be used.
tion that may require remedial action.

Starting spray
Refuelling Never use starting spray or similar as a starting
When refuelling, there is a risk of fire and explo- aid. An explosion may occur in the intake pipe,
sion. The engine must be stopped and smoking which could cause personal injury.
is not allowed.
Do not overfill the tank, since the fuel may ex-
pand, and close the fuel filler cap properly. Operation
Only use fuel recommended in the service The engine should not be operated in environ-
literature. Fuel of an incorrect grade may cause ments with surrounding explosive materials
malfunctions or stoppage by interfering with the since electrical or mechanical components of
operation of the fuel injection pump and the in- the engine may emit sparks.
jectors. It is always a safety hazard to be near an en-
This could cause engine damage and possibly gine that is running. Body parts or clothing, or a
personal injury. dropped tool may get stuck in rotating parts,
such as the fan, causing bodily injury.
Always cover rotating parts and hot surfaces as
Harmful gases much as possible to ensure personal safety.
Only start the engine in a properly ventilated ar-
ea. The exhaust emissions contain carbon
monoxide and nitrogen oxides that are toxic.
When operating the engine in an enclosed ar-
ea, an effective extraction device for exhaust
gases and crankcase gases must be used.

2001-05:1 © Scania Industrial & Marine Engines 7

Safety precautions for handling Safety precautions for care and
materials maintenance
Fuel and lubrication oil Stop the engine
All fuels and lubricants as well as many chemi- Always stop the engine before any mainte-
cals are flammable. Always follow the instruc- nance and service work unless otherwise
tions stated on the container. stated.
All work on the fuel system must be performed Prevent unauthorized starting by removing the
when the engine is cold. Fuel leakage and spill- starter key and turning off the power by the
age on hot surfaces may cause fire. main switch or the battery disconnect switch,
Store drenched rags and other flammable ma- locking it in the off position. Also attach a warn-
terials in a safe way to avoid spontaneous com- ing tag, stating that work on the engine is in
bustion. progress, at a suitable location.
It is always a safety hazard to work on an en-
gine that is running. Parts of your body or cloth-
Batteries ing, or a dropped tool may get stuck in rotating
Batteries, particularly when being recharged, parts, causing bodily injury.
emit highly flammable fumes that can explode.
Do not smoke or let open flame or sparks come
near the batteries or the battery compartment. Hot surfaces and fluids
Incorrect connection of a battery cable or jump A hot engine always presents a risk of scalding.
start cable may cause a spark, which in tun may Always take care not to touch the exhaust
cause the battery to explode. manifold, turbocharger, oil pan, hot coolant and
oil in pipes and hoses.

Chemicals
Lifting the engine
Most chemicals, such as glycol, corrosion in-
hibitors, preservation oils, degreasers etc. are Use the engine lifting eyes when lifting the
hazardous. Always follow the safety precau- engine. First check that the lifting equipment is
tions stated on the container. in proper condition and has sufficient lift capac-
ity rating.
Some chemicals, e.g. preservative oil, are
flammable. Auxiliary equipment fitted to the engine may
cause the centre of gravity to be displaced.
Always store chemicals and other hazardous Thus, additional lift devices may be required in
materials in approved and distinctly marked order to provide proper balance and a safe lift.
containers and out of reach of unauthorized
persons. Always dispose of superfluous or Never work below a suspended engine!
used chemicals through an authorized waste
disposal contractor.
Batteries
Batteries contain a highly corrosive electrolyte
(sulphuric acid). Always take care to protect
your eyes, skin and clothing when charging and
handling batteries. Wear protective gloves and
goggles.
If electrolyte splashes on the skin, wash the
affected part of the body with soap and plenty
of water. If electrolyte splashes into the eyes,
rinse eyes immediately with plenty of water and
seek medical attention.
Dispose of used batteries through an author-
ized waste disposal contractor.

8 © Scania Industrial & Marine Engines 2001-05:1

 Electrical system Cooling system
Before work is performed on the electrical sys- Never open the coolant filler cap while the en-
tem, turn off the power by the main switch or the gine is hot. Steam and hot coolant can come
battery disconnect switch. out forcefully and cause scalding.
Also disconnect any external power supply to If the cooling system must still opened or disas-
auxiliary equipment on the engine. sembled while the engine is hot, open the filler
cap very cautiously and slowly to release the
pressure before the cap is removed. Use
Arc Welding gloves since the coolant is still very hot.
Before welding near or on the engine, remove Dispose of used coolant through an authorized
the battery and alternator cables. Also remove waste disposal contractor.
the control unit connector.
Connect the weld clamp to the component to be
welded, close to the weld location. Never con- Fuel system
nect it to the engine or in such a way that the Always use gloves when checking for leaks in
current can pass through a bearing. or performing other work on the fuel system. Al-
After the welding is completed, connect the ca- ways wear eye protection when testing injec-
bles to the alternator and the control unit before tors.
connecting the batteries. Fuel escaping under high pressure can pene-
trate body tissue and cause serious injury.
Never use non-genuine parts in the fuel system
Lubrication system and the electrical system. Genuine parts are
Hot oil may cause scalding and skin irritation. designed and manufactured to minimize fire
Avoid skin contact with hot oil. and explosion hazard.
Make sure that the pressure in the lubrication
system is relieved before work is carried out.
Never start or operate the engine with the oil fill- Before starting
er cap removed since oil will be ejected force- Install any guards that have been removed be-
fully. fore the engine is started. Check to ensure that
Dispose of used oil through an authorized no tools or other objects have been left on the
waste disposal contractor. engine.
Never start the engine unless the air filter is in-
stalled. Otherwise there is a risk of objects en-
tering the compressor wheel or a risk of
personal injury from contact with it.

2001-05:1 © Scania Industrial & Marine Engines 9

TYPE DESIGNATIONS
The engine designation indicates, in the form of a code, the type of engine, its
size and intended use, etc.
The type designation and engine serial number are indicated on a type plate
affixed to the right-hand side of the engine. The engine number is also stam-
ped on the top of the engine block beside the first cylinder head.
Engines that are certified regarding smoke and emissions are fitted with a cer-
tification plate specifying the documents they conform to. The plate is fitted
to rocker cover number two as viewed from the front.

DI 9 59 M 31 E LR

Version
DI Turbocharged diesel engine with liquid-cooled charge air cooler

Displacement in whole dm3

Performance and certification code

Indicates, together with the application code, the normal gross engine
output.
The actual output setting of the engine is indicated on the engine card.

Application
M For marine use

Variant code for equipment options 01-99

Governor type
E Electronically controlled governor (DEC2)

Classification society (applies to classed engines)

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

10 © Scania Industrial & Marine Engines 2001-05:1

 15
16
18

17 3

6 5 19 7 1

9
13

14

10 4 11 7 12
The drawings illustrate a common type of DI9 engine.
Your engine may have other equipment not shown here.
1. Type plate 7. Draining, engine oil 14. Draining, coolant
2. Engine number, 8. Coolant pump 15. Oil filling
stamped in engine block 9. Turbo charger 16. Sea water pump
3. Oil cooler 10. Injection pump 17. Heat exchanger
4. Oil dipstick 11. Fuel filter 18. Charge air cooler
5. Oil cleaner 12. Starter motor 19. Turbo filter
6. Protective anode 13. Alternator

2001-05:1 © Scania Industrial & Marine Engines 11

DEC2 CONTROL SYSTEM
This engine has an injection pump with an electromagnetic actuator which
adjusts the control rack to give the correct amount of fuel.
The system which controls the actuator/pump is called DEC2 (Digital Engine
Control, generation 2).
The control unit (DEC2) continuously receives signals from sensors for
engine speed, charge air temperature and pressure, coolant temperature, oil
pressure, throttle pedal position and control rod travel in the injection pump.
Using this input data and a control program, the correct amount of fuel for the
current operating conditions can be calculated.
The system’s sensors may be used only for DEC2, not for other instruments
or other monitoring purposes.
The control unit contains monitoring functions to protect the engine in the
event of a fault which would otherwise damage it. Faults and the more
important monitoring functions are indicated on the control unit in the form
of light emitting diodes. See illustration on page 13 for a description.
In case of a fault, the Power - or Shutdown indicator on the DEC2 control
unit as well as the main indicator lamp on the main supply box and the
instrument panel will illuminate.
If a fault has been indicated on the main indicator lamp the operator can
determine the cause of the fault with the help of the LEDs on the control unit
and the troubleshooting schedule on page 17, and carry out the required
investigation and remedy.
Depending on the nature of the fault, the control system will take different
actions to protect the engine such as reducing the power output, keeping the
engine running at a constant low speed or, in case of a function impairing
fault, shutting down the engine (Shutdown).
To enable readout of LED fault codes there is a lamp test/fault code switch
located in the main supply box near the control unit.
A PC based program is also available to help service personnel to detect and
rectify faults and to adjust certain parameters in the operating program.
Diagnostics and changes to programs must only be performed by
authorized personnel.
The locations of the sensors and monitors which send signals to the control
unit will be evident from the illustrations on page 13.
There is a description of the functions of the LEDs during normal operation
on page 14.
On page 15 there is a description of the functions of the LEDs in case of a
fault and actions in case of Power- and Shutdown indication.
Troubleshooting and fault code reading are described on pages 16 and 17.

12 © Scania Industrial & Marine Engines 2001-05:1

 Location of sensors for DEC2 on DI9

2
3 6

1. Charge air temperature sensor

2. Connection of lead to charge air
temperature sensor
3. Coolant temperature sensor
4. Engine speed sensor
5. Oil pressure sensor
6. Junction box

2001-05:1 © Scania Industrial & Marine Engines 13

 LED functions during normal operation

Note The lamp test/fault code switch should not POWER-

be depressed. All LEDs come on briefly
when the control unit is powered up. ❍ The LED remains out during normal operation
as long as no fault is detected by the control
CONTROL STATUS unit. See next page for the procedure to be adop-
ted in the event of a fault.
✹ The LED flashes continuously when the control
unit is supplied with current, regardless of POWER+
whether the engine is running or not.
✹ If the control unit is programmed to allow the
SHUTDOWN engine to be operated according to more than
one power/torque curve (map), the following
❍ The LED is out. applies.
STARTING The LED comes on when the engine is run at
more than 100% power output (MAP 2). It goes
✹ The LED lights up as soon as the engine starts to out when the engine returns to the 100% power
rotate during an attempt to start it and follows output curve (MAP 1) or when the power output
the programmed starting sequence until it has required is less than 100%.
been completed and then goes out.

RUNNING
✹ The LED comes on when the engine has started
and the "Starting"-LED goes out. It remains on
until the engine is stopped.

TORQUE LIMIT
✹ The LED comes on when the control unit
detects that the engine has received the maxi-
mum permissible quantity of injected fuel accor-
ding to its power curve. This means 100%
power output at the current rpm. If the load
increases, engine rpm will decrease.

BOOST LIMIT
✹ The LED comes on when the control unit smoke
limiter restricts the maximum fuel quantity.
Operation of the smoke limiter is dependent on
the charge air pressure.

14 © Scania Industrial & Marine Engines 2001-05:1

 Action in case of a fault

LED indications in case of a fault

Note The main indicator lamp in the main supply
box and at the instrument panel has
indicated a fault. The lamp test/fault code
switch should not be depressed.

CONTROL STATUS
✹ The LED will continue to flash even in case of a
fault as long as voltage is supplied to the control
unit.

POWER -
✹ If the LED comes on, the control unit has
detected a defect that could cause damage to the
engine if operation continues.
The control unit automatically reduces engine
power output to a predefined level if the
corresponding function has been selected.
Action: Reduce engine speed to idle if possible
and conduct troubleshooting according to
instructions on page 16 and the chart on page 17

SHUTDOWN
✹ The LED comes on and the engine is switched
off automatically in case of a severe fault that
could cause damage to the engine if operation
continues.
Action: Conduct troubleshooting according to
instructions on page 16 and the chart on page 17
If the engine has not stopped, reduce engine
speed to idle and conduct troubleshooting.

2001-05:1 © Scania Industrial & Marine Engines 15

Changing functions using the DIP Readout of fault codes
switches in the control unit Note If the engine has stopped or lost power but
There are 8 DIP switches in the control unit under the the main indicator lamp is out and neither
round black rubber cover. POWER- nor SHUTDOWN are on, the
fault is outside the control unit detection
These switches shall be in the ON position to obtain
range. Probable causes: fuel shortage,
normal functions according to the operating program.
temporary overload, mechanical fault.
However, for single-speed engines, the normal
position of DIP switches 6, 7, and 8 may also be OFF - Activate the lamp test/fault code switch. In
Shutdown at threshold values for low oil pressure and Scania electrical equipment the main indicator
high coolant temperature can be selected by setting lamp is located in this switch on the main supply
DIP switch 4 to OFF box.

With DIP switch 4 in position ON, Power- indication - All LEDs will then come on for 2 seconds to
is obtained for these threshold values. Engine output indicate that they are intact and in working order.
reduction (LOP) can be selected to prevent damage to This also applies to the main indicator lamp in the
the engine. Changes to the program must only be main supply box and the instrument panel. Make
performed by authorized personnel. a note of any LED that is defective.
- All LEDs will then be out for approximately 4
Note Do not operate the engine with a Power- seconds.
indication except for in emergencies.
- Following this, a fault code will be indicated on
one of the LEDs for 2 seconds. Note which LED
it is.
- The control unit then resumes the operating mode
automatically.
- After having made a note of the fault code, reset
the lamp test/fault code switch and reset the
control unit by turning off its power supply
momentarily.
- The most probable cause of the fault can then be
found in the trouble shooting schedule on the next
page.
- When the fault or faults have been rectified the
engine can be restarted.
- If the control system continues to indicate a fault
by way of the main indicator lamp, further faults
may have been recorded. The fault code readout
must then be repeated as per above since the
system can only display one fault code at a time.
- The fault(s) will be stored in a special memory in
the control unit along with information about the
operating time when it(they) occurred. Stored
faults can be accessed and erased by authorised
service personnel.
DIP switches are shown in the ON position

16 © Scania Industrial & Marine Engines 2001-05:1

 READOUT OF FAULT CODES
LED INDICATION WHEN THE LAMP TEST/FAULT CODE SWITCH IS ACTIVATED

2001-05:1
Probable cause Action

CONTROL STATUS
SHUTDOWN
STARTING
RUNNING
TORQUE LIMIT
BOOST LIMIT
POWER -
POWER +
Send in the control unit for repair as soon as
✹ DEC2 has detected an internal fault in the control unit.
possible.

The engine temperature has reached the threshold level Check the cooling system. Check the temperature
✹ or the temperature sensor is inoperative. sensor and cable routing.

The engine has reached the overrevving limit or the Check the wiring and connector.
✹ engine speed sensor is inoperative. Renew the engine speed sensor.

✹ Control rack position sensor inoperative. Check connectors and cables to governor.

The intake air temperature has reached the threshold Check the intake system. Check the temperature
✹ level or the charge air temperature sensor is inoperative. sensor and cable routing.

DEC2 detects no charge air pressure. Check the charge air pressure hose. Send in the
✹ The charge air pressure sensor is inoperative. control unit for repair if the connection is damaged.

© Scania Industrial & Marine Engines

Engine speed potentiometer or the idling safety switch Check the cable routing, connectors and cables.
✹ is inoperative.

The oil pressure has dropped to the threshold level or Check oil level, connector and cable.
✹ the oil pressure monitor is inoperative. Renew the oil pressure monitor.

✹=LED on

17
STARTING AND RUNNING
AT FIRST START Coolant composition:
When the engine is started for the first time, follow the maintenance points
listed under "First start" in the maintenance schedule, see page 25.
If there is a danger of freezing:
Since the points are important for satisfactory operation of the engine right minimum 30% glycol by volume
from the outset, they are also listed below.
maximum 60 % glycol by volume
1. Checking the oil level (see page 27).
8. Checking the coolant (see page 32). If there is no danger of freezing:
The coolant should contain corrosion inhibitor to protect the cooling 7-12% by volume
system from corrosion. Scania Anti-corrosive
If there is a danger of freezing: (no glycol)
- Only anti-freeze glycol should be used in the coolant as protection
against corrosion. We recommend only nitrite-free anti-freeze glycol
with the following supplier designations:
BASF G48 or BASF D542
- The concentration of glycol should be 30 - 60% by volume depending Ethylene glycol and corrosion
on the ambient temperature. A content of 30 % by volume provides inhibitor, if swallowed can be
protection down to -16 °C. See page 32. fatal.
- Never top up with only water or only glycol. Fluid losses must always Avoid contact with the skin.
be replaced with pre-mixed coolant having the same glycol
concentration as that in the engine. If the glycol content drops, both
anti-freeze protection and protection against corrosion are impaired.
Note A glycol concentration below 30% by volume will not provide
sufficient protection against corrosion. Glycol concentrations
higher than 60% do not improve anti-freeze protection and have The recommended glycol must
a negative effect on engine cooling capacity. not be mixed with glycol having
nitrite-based anti-corrosive.
If there is no danger of freezing:
- Only Scania Anti-corrosive should be used in the coolant as protection
against corrosion. The correct concentration of anti-corrosive is 7-12%
by volume and this must never drop below 7% by volume. The inhibitor
in Scania Anti-corrosive is nitrite-free.
- First top up: Top up with Scania Anti-corrosive as indicated on the The use of too much Scania
packaging. Anti-corrosive as mixed with
glycol may cause deposits.
- Never top up with only water or only anti-corrosive! Fluid losses
must always be replaced with premixed coolant:
water + 10 % by volume of Scania Anti-corrosive.

Coolant filter (not standard equipment)

If a coolant filter has been fitted
Only coolant filter without inhibitor may be used. The use of coolant filters it must not contain inhibitor.
increases the life of the coolant and reduces the risk of deposition corrosion.

©
18 Scania Industrial & Marine Engines 2001-05:1
 14. Checking the fuel level (see page 41).
17. Checking the electrolyte level in batteries (see page 43).
18. Checking the state of charge in batteries (see page 43).
20. Checking the coolant level monitor (see page 44) (if fitted).
Immobilise the starting device
21. Checking the temperature monitor (see page 45). when working on the engine.
22. Checking the oil pressure monitor (see page 46). If the engine starts out of
control, there is a
23. Checking transmission tension (see page 47).
SERIOUS RISK
OF INJURY.

CHECKS BEFORE RUNNING

Before running, "Daily maintenance" as described in the maintenance
schedule should be carried out, see page 25.

STARTING THE ENGINE

If the fuel tank has been run dry or if the engine has not been used for a long
time, bleed the fuel system (see page 41).
Out of consideration for our common environment, your new Scania engine
has been designed to use a smaller amount of fuel when starting. Using Only start the engine in a
unnecessarily large amounts of fuel when starting the engine always results in properly ventilated area.
the discharge of unburnt fuel. When operating the engine in
- Open the fuel cock, if fitted. an enclosed area, an effective
- Declutch the engine.
extraction device for exhaust
gases and crankcase gases
- Engines with battery master switch: Switch on the power by means of must be used.
the battery master switch.
- DEC2: If the main indicator lamp comes on or flashes when the power is
turned on, this indicates the presence of a fault in the control system or
engine which must be found and rectified before the engine is started.
See page 15.
- Start the engine by means of the starter button or starter key.
Starting at low temperatures Never use starting spray or
similar as a starting aid.
Local environmental requirements must be complied with. Starting aids,
engine heaters and/or flame start devices should be used to avoid starting
An explosion may occur in the
problems and white smoke. intake pipe, which could cause
personal injury.
To limit white smoke, the engine should be run at low speed and under
moderate load. Avoid running it longer than necessary at idling speed.

©
2001-05:1 Scania Industrial & Marine Engines 19
At temperatures below 0 °C:
Note Only use starting aids recommended by Scania.
- The starter motor may only be used for 30 seconds at a time. After that
time it must cool for 2 minutes.
If the engine has flame start:
- Operating flame start without timer relay: Press the control button,
which also acts as a pre-glow button (max. 20 seconds). The glow plug Maximum starter engagement
continues to glow as long as this button is depressed after the engine has time is 30 seconds. Risk of
started. Maximum time is 5 minutes. overheating. Allow starter to
- Operating flame start with timer relay: Press the pre-glow button cool for 2 minutes after a
(a maximum of 20 seconds). Release it when the engine starts. The timer starting attempt before
relay keeps the glow plug glowing for 5 minutes. If a shorter glow time cranking again.
is required, press the release button. The key must be set to the
0 position if the start attempt fails.
Note If the engine is equipped with an INTERLOCK switch, this
switch should be depressed and held down until the oil pressure
has reached a sufficiently high level.
- Warm up the engine with a light load. A light load on a cold engine
gives better combustion and faster heating than warming up with no
load.

©
20 Scania Industrial & Marine Engines 2001-05:1
RUNNING
Check instruments and warning lamps at regular intervals.

Engine speed
The Scania tachometer is divided into sectors of different colours, as follows:

0 - 500 r/min red area: prohibited engine speed,

passed when stopping and
starting.

500 - 700 r/min yellow low idle.

area:

700 - 2200 r/min green normal operating speed.

area: The engine’s operating
speed range is controlled by
the DEC2 control system.

2200 - 2600 r/min yellow/gre unsuitable operating speed.

en striped: May occur when switching
off.

2600 - 3000 r/min red area: prohibited engine speed.

Coolant temperature
Normal coolant temperature when the engine is running should be 70 - 90°C.
DEC2: If the temperature is high, 98°C or above, you can select for the
control system to reduce power output (Power -) in order to bring down the
temperature. Refer to the DEC section on page 16.
If the temperature continues to rise, the engine will be shut down
automatically (Shutdown) at 103°C. Refer to the DEC section on page 16.
Excessively high coolant temperature can damage the engine.
If run for extended periods under an extremely light load, the engine may
have difficulty in maintaining normal operating temperature. However, the
temperature will rise to a normal level again when the load on the engine is
increased.

©
2001-05:1 Scania Industrial & Marine Engines 21
Oil pressure
Max. oil pressure:
warm engine running at a speed above 800 rpm 6 bar
Normal oil pressure: High lubricating oil pressure
warm engine running at operating speed 3 - 6 bar (above 6 bar) is normal when
starting a cold engine.
Min. oil pressure:
warm engine running at 800 rpm 0.7 bar
At speeds below 800 rpm the gauge may show low oil pressure although no
fault is present.
Oil pressure below 0.7 bar at speeds above 800 rpm will cause engine
damage. The engine must be stopped immediately.
DEC2: The engine is shut down automatically if this function has been
selected. Refer to the DEC section on page 16.

Charging indicator lamp

If the lamp comes on during operation:
- Check/adjust the alternator drive belts as described under the
maintenance point. See page 47.
- If the charging indicator lamp is still on, this could be due to an
alternator fault or a fault in the electrical system.

STOPPING THE ENGINE

1. Run the engine without a load for a few minutes if it has been run
continuously with a heavy load. There is danger of turbo damage
and post boiling if the engine is
2. Stop the engine with the stop button. Keep the stop button depressed stopped without cooling.
until the engine is completely stationary.
3. DEC2: Before switching off, check that the control system’s main
indicator lamp is not on or flashing.
Refer to page 15 for troubleshooting.
The power must not be switched
4. Engines with battery master switch: Switch the power off with the off before the engine has
battery master switch. stopped.
5. Set the control switch to "0".

©
22 Scania Industrial & Marine Engines 2001-05:1
Clutch
- See the manufacturer’s instructions for handling and operating the
clutch.
WARNING! If the clutch output shaft is rotating (e.g. in multiple
engine installations where other engines are running), the
clutch can, under its own power, be drawn to the engaged
position.
THIS CAN PERSONAL CAUSE INJURY and engine
damage. For this reason, always secure the clutch in the
disengaged position if there is a risk of the output shaft
starting to rotate.

CHECKS AFTER RUNNING

- Check that the power is cut from the battery master switch and that the
control switch is in the "0" position. Immobilise the starting device
when working on the engine.
- 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 the engine starts out of
control, there is a
- If there is a risk of freezing, the cooling system must be drained if it SERIOUS RISK
does not contain a sufficient amount of glycol, refer to page 32.
OF INJURY.
- Close inlet valve for the sea water system (if fitted).
- If there is danger of freezing the sea water system must be emptied.
- At temperatures below 0 °C: Prepare for the next start by connecting the
engine heater (if fitted).
Top up engine coolant when the
engine has been stopped after
being started for the first time.

©
2001-05:1 Scania Industrial & Marine Engines 23
MAINTENANCE
The maintenance programme covers 26 points, divided into the following
main groups:
Lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 30
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 38 Immobilise the starting device
Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 41 when working on the engine.
Electrical system, monitors, batteries, etc. . . . . . . . . . . . . . . .page 43 If the engine starts out of
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 47 control, there is a
SERIOUS RISK
The maintenance points are divided into intervals as follows: OF INJURY
Daily maintenance
Maintenance before the first start
Maintenance after the first 400 hours of operation
Periodic maintenance every 200 hours of operation (carried out after 200,
400, 600, 800, etc. hours)
Periodic maintenance every 400 hours of operation (carried out after 400,
800, 1200, 1600, etc. hours)
Periodic maintenance every 1200 hours of operation (carried out after 1200,
2400, 3600, etc. hours)
Periodic maintenance every 2400 hours of operation (carried out after 2400,
4800, etc. hours)
Periodic maintenance every 4800 hours of operation (carried out after 4800,
9600, etc. hours)
Annual Maintenance
Maintenance every 5th year

ENGINES WITH FEW HOURS

OF OPERATION
Run the engine until it reaches operating temperature and then carry out the
following maintenance points: For engines with few operating
2. Checking the oil level. hours that are not subject to
5. Checking the coolant level. periodic maintenance according
to the maintenance schedule on
10. Checking the vacuum indicator.
page 25, maintenance should be
14. Checking the fuel level. carried out in accordance with
17. Checking the electrolyte level in batteries. the schedule:
18. Checking the state of charge in batteries. "Every year"
"Every 5 years"
19. Cleaning the batteries.
24. Checking for leakage, rectify as necessary.

24 © Scania Industrial & Marine Engines 2001-05:1

MAINTENANCE SCHEDULE
First Interval At least
time at

Every 5th year

First start

Annually
1200 h

2400 h

4800 h
400 h

200 h

400 h
Daily
LUBRICATING OIL SYSTEM, page 26
1. Checking oil level ● ●
2. Oil change ●1 ●
3. Cleaning oil cleaner ●1 ●
4. Changing the turbo filter ●1 ●
COOLING SYSTEM, page 30
5. Checking coolant level ●
6. Checking the corrosion bars 4) ●5 ●
7. Checking the sea water pump impeller 4) ●5 ●
8. Checking coolant ● ●6 ●6
9. Cleaning cooling system ●1 ●
AIR CLEANER, page 38
10. Test reading low pressure indicator ●
11. Cleaning the coarse cleaner ●1 ●
12. Cleaning or changing filter element ●3 ●
13. Changing safety cartridge ● ●
FUEL SYSTEM, page 41
14. Checking fuel level ● ●
15. Changing main filter ●1 ●
16. Checking injectors ● ●
ELECTRICAL SYSTEM, page 43
17. Checking electrolyte level in batteries ● ●2 ●
18. Checking state of charge in batteries ● ●2 ●
19. Cleaning batteries ●2 ●
20. Checking coolant level monitor ● ● ●
21. Checking temperature monitor ● ● ●
22. Checking oil pressure monitor ● ● ●
MISCELLANEOUS, page 47
23. Checking drive belt ● ● ●
24. Look for leakage, rectify as necessary ●
25. Checking/adjusting valve clearance ● ●
26. Changing (or cleaning) valve for closed crankcase ●
ventilation

1. More often if required.

2. For engines with few operating hours, see page 24.
3. Earlier if low pressure indicator shows red.
4. Only applies to M engines with sea water pump.
5. Reference value. Varies depending on the composition of the sea water.
6. If inhibitor has not been topped up for five years, the coolant should be changed.

©
2001-05:1 Scania Industrial & Marine Engines 25
LUBRICATING OIL SYSTEM
OIL GRADE
The engine oil must at least meet the requirements for one of the following
oil classifications:
-ACEA E3, E4 or E5
- The Total Base Number (TBN) should be minimum 12-13
(ASTM 2896).
- Check with your oil supplier that the oil meets these requirements.
- The specified oil change intervals apply provided that the fuel sulphur Additives must not be used.
content does not exceed 0.3% by weight. If the sulphur content exceeds The oil should be suitable for all
0.3 % but is maximum 1.0%, the oil change intervals must be halved temperature variations until the
(200 h). next oil change.
- Viscosities as illustrated below.
- For operation at extremely low ambient temperature: Consult your
nearest Scania representative on how to avoid starting difficulties.

Oil analysis
Some oil companies can offer analysis of the engine oil. Such analysis
measures the oil TBN (Total Base Number), TAN (Total Acid Number), fuel
dilution, water content, viscosity and the quantity of friction particles and
soot in the oil.
The result of a series of analyses is used as the basis for establishing a
suitable oil change interval.
If the conditions are changed, a new oil analysis programme must be carried
out to establish the new change interval.

-40 -30 -20 -10 0 10 20 30 40 °C

SAE 20W-30

SAE 30

SAE 40

SAE 50

SAE 5W-30

SAE 10W-30

SAE 15W-40

©
26 Scania Industrial & Marine Engines 2001-05:1
 1. Daily:
CHECKING THE OIL LEVEL
Note Before checking oil level: Allow the engine to remain stopped for
at least 1 minute.
- The correct level is between the marks on the dipstick. Top up when the
level is at the lower mark.
- Correct type, see "Oil grade" on page 26.

Note Checking of oil level during operation can not be performed on

engines with standard oil sump, see picture.

2. Every 400 hours:

OIL CHANGE
Note Under extremely severe operating conditions, especially in dusty
environment or if the deposits in the centrifugal cleaner are
thicker than 20 mm: change oil more frequently.
- Pump out the oil with the oil bilge pump when the engine is warm.
- Fill up with oil.
- Check the level on the dipstick.
Max 25 dm3
Min 20 dm3

Max 20 dm3
Min 16 dm3
Always use a suitable container
to avoid spillage when 1 dm3 = 1 litre
WARNING changing oil.
The oil may be hot. Dispose of used oil through an
Wear protective gloves and authorized waste disposal
goggles contractor.

Maximum angles of inclination during operation

Maximum permissible angles during operation vary, depending on
the type of oil sump, see illustration.
Note Specified angle may only occur intermittently.

©
2001-05:1 Scania Industrial & Marine Engines 27
 3. Every 400 hours:
CLEANING THE OIL CLEANER
(at same time as oil change)

- Unscrew the nut and remove the cover.

Open the cap carefully. The

oil may be hot.

- Lift out the rotor and slacken the rotor bowl retaining nut three turns.

- If the nut is jammed:

Clamp the nut, never the rotor, in a vice and turn the rotor three turns by
hand or with a screwdriver.

- Tap the nut lightly with your hand or a plastic hammer, to detach the
rotor bowl from the bottom plate.

- Unscrew the nut and remove the rotor bowl.

- Prise carefully to detach the strainer from the bottom plate.

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

©
28 Scania Industrial & Marine Engines 2001-05:1
 - Clean all parts in diesel fuel..

- Fit the O-ring in the rotor bowl. Make sure it is not damaged.
Change if necessary.

- Assemble the rotor.

- Tighten the rotor nut firmly by hand.

- Refit the rotor.

- Make sure that it spins easily.

- Check that the O-ring in the bowl is undamaged.

Renew the O-ring if hard or damaged.
- Secure the bowl firmly, tightening the nut by hand.
If the nut is tightened with a tool, the rotor shaft, nut or bowl may be
damaged.

Functional test
The rotor spins very fast and should continue to rotate when the engine has
stopped.
- Stop the engine when it is warm.
- Listen for a whirring sound from the rotor or feel whether the cleaner
housing is vibrating.
The rotor normally continues spinning for 30 - 60 seconds after the engine
has stopped.
If not: Dismantle and inspect.

©
2001-05:1 Scania Industrial & Marine Engines 29
 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 Scania filter.
- Tighten the filter by hand.
Never use a tool for tightening. The filter could be damaged,
obstructing circulation.
- Start the engine and check for leaks.

Important If the deposits in the centrifugal cleaner are thicker than 20

mm the oil filter should be renewed more frequently. This
includes cleaning the centrifugal filter and changing oil.

Always collect oil in a suitable

container to avoid spillage when
renewing the oil filter.
Dispose of used filters through
an authorized waste disposal
COOLING SYSTEM contractor.

5. Daily:
CHECKING COOLANT LEVEL Carefully open the cap.
- Open the expansion tank filler cap and check the coolant level. Hot water and steam
may blow out.
- Correct level: (integral expansion tank in the heat exchanger)
- Cold engine: The coolant level should be 10 - 20 mm under the
expansion tank upper inner part.
- Warm engine: The coolant level should be at the expansion tank
upper inner part.
- Other types of expansion tank according to the installer’s instructions. Always top up with ready mixed
- Top up the coolant as necessary, see point 6. coolant.
Note When filling large amounts of coolant:
Never pour cold coolant into a hot engine.
This could cause cracks in the cylinder block and the cylinder
head.

©
30 Scania Industrial & Marine Engines 2001-05:1
 6. Every 400 hours:
CHECKING CORROSION BARS
(Only engines with heat exchanger)
- Empty the sea water circuit and check the corrosion bars (protection
anodes). Located as illustrated.
- Scrape off all loose material on the anode.
- Change if less than half the bar is left.
A new bar is 55 mm long with a diameter of 17 mm.

Important If the corrosion bars are very corroded they need to be

checked more often, for example every 200 hours.

7. Every 400 hours:

CHECKING THE SEA WATER PUMP
IMPELLER
(Only engines with heat exchanger)
- Close the bottom valve if the seawater pump is below the water line.
- Empty the sea water circuit.
- Take off the seawater pump cap.
- Check that the impeller vanes are not worn or damaged.

Important If the impeller must be changed frequently, the cleaning of

the sea water must be improved.

Changing the impeller

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

©
2001-05:1 Scania Industrial & Marine Engines 31
 8. Every 2400 hours:
CHECKING THE COOLANT
Coolant should be checked as follows:
a) Check the appearance of the coolant.
Coolant composition:
If there is a danger of freezing:
b) Coolant with glycol: Check the glycol content.
minimum 30% glycol by
c) Coolant with Scania Anti-corrosive: volume
Check the anti-corrosive content.
maximum 60% glycol by
volume
The coolant composition is also described under If there is no danger of freezing:
"Starting and running". 7-12% by volume
a) Scania Anti-corrosive
Checking the appearance of the coolant
- Fill a receptacle with a little coolant and check that it is clean and clear.
- If the coolant is contaminated or cloudy, consider changing it.
- Water added to the coolant should be clean and free from dirt of any
kind.
- Use drinking water with a pH of 6 - 9.

b)
Checking the glycol content
If there is a danger of freezing, use only glycol as an anti-corrosive in the
coolant.
- Cooling systems with glycol should contain at least 30% glycol by Ethylene glycol is highly
volume to provide acceptable protection against corrosion. dangerous if ingested and can
prove fatal.
- A content of 30% glycol by volume protects against freezing down to
-16°C. If further protection is needed, refer to the table on the next page Avoid skin contact with glycol.
for calculating the required amount of glycol.
We recommend only nitrite-free anti-freeze glycol with the following
supplier designations: BASF G48 or BASF D542
- Always top up the anti-freeze if its glycol content drops below 30% by
volume. A glycol content above 60% by volume will not provide greater The coolant should be ready
protection against freezing. mixed when it is poured into the
- The table shows the temperature at which ice starts to form. The engine cooling system.
will freeze and fracture at appreciably lower temperatures, see diagram. Never top up with only water or
- Ice forming in the coolant often causes malfunctioning without any risk only glycol.
of damage. The engine should not be subjected to heavy loads when ice
starts to form.
Note Change the coolant when cleaning the cooling system: Every 4800
hours or minimum every 5 years.
The recommended glycol must
Important If a coolant filter is used in the cooling system, it must not con- not be mixed with glycol having
tain an inhibitor. nitrite-based anti-corrosive.
Risk for build up of sludge and
reduced cooling capacity.

32 © Scania Industrial & Marine Engines 2001-05:1

 % glycol by volume

Properties of glycol at low temperatures:

- Example with 30% glycol by volume
- Ice slush starts to form at -16°C.
- There is risk for malfunctions at -30°C
- No risk of damage by freezing with a minimum
content of 30% glycol by volume

Curve A: Ice build up starts (slush)

Curve B: Temperature at which damage due to
freezing can occur
1. Safe range
2. Malfunctions may occur (ice slush)
3. Risk of damage by freezing
A
% glycol by
15 20 25 30 35 40 45 50
Cooling 60
volume
system
Ice slush starts 3
-6 -9 -12 -16 -22 -27 -36 -46 -55 capacity, dm
to form at °C
5 6 8 9 11 12 14 15 18 30
6 8 10 12 14 16 18 20 24 40
8 10 13 15 18 20 23 25 30 50
9 12 15 18 21 24 27 30 36 60
11 14 18 21 25 28 32 35 42 70
12 16 20 24 28 32 36 40 48 80
14 18 23 27 32 36 41 45 54 90
15 20 25 30 35 40 45 50 60 100
Glycol dm3 17 22 28 33 39 44 50 55 66 110
(litres) 18 24 30 36 42 48 54 60 72 120
20 26 33 39 46 52 59 65 78 130
21 28 35 42 49 56 63 70 84 140
23 30 38 45 53 60 68 75 90 150
24 32 40 48 56 64 72 80 96 160
26 34 43 51 60 68 77 85 102 170
27 36 45 54 63 72 81 90 108 180
29 38 48 57 67 76 86 95 114 190
30 40 50 60 70 80 90 100 120 200
A= Area to be avoided. Only for calculating glycol mix.
Coolant freezing temperature when ice starts to form at different glycol mixes

2001-05:1 © Scania Industrial & Marine Engines 33

c)
Checking protection against corrosion
There must always be sufficient corrosive inhibitor in the coolant to protect
the cooling system against corrosion.
Corrosion inhibitor, if
If there is no danger of freezing, only Scania Anti-corrosive should be used. swallowed can be fatal.
The inhibitor in Scania Anti-corrosive is nitrite-free. Avoid contact with the skin.
The correct proportion of anti-corrosive is 7-12% by volume.
- Topping up with 1.0% Scania Anti-corrosive by volume should be done
after every 2400 hours of operation.
- Never top up with only water or only anti-corrosive! Mixing corrosion inhibitor with
Fluid losses must always be replaced with premixed coolant: glycol or adding too much
water + 10% by volume of Scania Anti-corrosive.
corrosion inhibitor may cause
Note The coolant should be changed when the cooling system is deposits and reduced cooling
cleaned: every 4800 hours or minimum every 5 years. capacity.

If a coolant filter has been fitted

it must not contain inhibitor.

Changing the coolant

1. Remove the filler cap from the expansion tank.
2. The coolant is drained at two points as illustrated:
- from the underside of the heat exchanger by removing two plugs.
- through a valve in the unit.
3. Close the valve and refit the plugs.
4. Top up with coolant through the expansion tank filler hole.
Mix coolant as described on page 32.

Always collect fluid in a suitable

container to avoid spillage when
changing coolant.
Dispose of used coolant through
an authorized waste disposal
contractor.

34 © Scania Industrial & Marine Engines 2001-05:1

 9. Every 4800 hours:
CLEANING THE COOLING SYSTEM
Note If necessary, the cooling system should be cleaned more often.
External cleaning
Heat exchanger The cooling system must never
be cleaned with caustic soda.
1. Drain the coolant from the engine, see “Changing coolant”. There is a risk of damage to
2. Drain the seawater circuit. aluminium parts.
3. Detach the heat exchanger hose and pipe connections.
4. Start by removing the charge air cooler and then dismantle the heat
exchanger as illustrated.
5. Clean the outside of the element. Use a paraffin-based engine cleaner.
6. Any deposit on the inside of the pipes is removed mechanically using a
round file.
7. Change the O-rings and assemble the heat exchanger
See “Charge air cooler”.
8. Refit hose and pipe connections.
9. Fill the system with coolant as described on page 32.

1. Cover
2. O-ring
3. Flange
4. Heat exchanger
5. Heat exchanger ele-
ment
6. Cover

2001-05:1 © Scania Industrial & Marine Engines 35

Charge air cooler
1. Drain the coolant from the engine, see "Changing the coolant".
2. Drain the seawater circuit.
3. Detach the connections to the turbo and the intake manifold.
4. Detach the water connection from the charge air cooler’s outlet.
5. Remove the complete charge air cooler and dismantle it as illustrated.
6. Clean the outside of the element. Use a paraffin-based engine cleaner.
7. Any deposit on the inside of the pipes is removed mechanically using a
round file.
8. Change the O-rings and assemble the charge air cooler. The cooling system must never
be cleaned with caustic soda.
9. Refit the charge air cooler to the heat exchanger.
There is a risk of damage to
10. Refit the hose connections to the turbo and intake manifold and the con- aluminium parts.
nection to the charge air cooler cover.
11. Fill the system with coolant as described on page 32.
12. Connect the intake manifold from the turbo.

1. Spacer
2. O-ring
3. Flange
4. Charge air cooler hou-
sing
5. Charge air element
6. Cover
7. Heat exchanger

36 © Scania Industrial & Marine Engines 2001-05:1

Internal cleaning
Removing oils and greases
- If possible, run the engine until it has reached the operating
temperature and then drain the cooling system.
- Remove the thermostats.
- Fill the system with clean, hot water mixed with liquid dishwasher
detergent designed for household use.
Concentration 1% (0.1/10 l). Handling cleaning agents for
the cooling system:
- Run the engine until it has reached operating temperature for about
20-30 minutes. Do not forget the cab heating system (if fitted). Read the warning label on the
container.
- Drain the cooling system.
- Fill the system again using clean, hot water and run the engine for
about 20-30 minutes.
- Drain the water from the system.
- Refit the thermostats.
- Top up the system with coolant according to the specification on page
32.

Removing deposits Always collect fluid in a suitable

- If possible, run the engine until it has reached the operating temperature container to avoid spillage when
and then drain the cooling system. draining coolant.
- Remove the thermostats. Dispose of used coolant through
- Fill the system with clean, hot water mixed with one of the an authorized waste disposal
commercially available radiator cleaners based on sulphamic acid and contractor.
containing dispersing agents. Follow the manufacturer’s instructions for
mixing proportions and cleaning times.
- Run the engine for the specified time and then drain the cooling system.
- Refill the system with hot water and run the engine for about 20-30
minutes.
- Drain the water from the system.
- Refit the thermostats.
- Top up the system with coolant according to the specification on page
32.

2001-05:1 © Scania Industrial & Marine Engines 37

AIR CLEANER
10. Daily:
READING THE VACUUM INDICATOR
If the entire red plunger of the indicator is visible, renew or clean the air filter
element, paragraph 12. This is especially important if the engine is operated
under heavy load and at high engine speed.

11. Every 200 hours:

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

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

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

12. Every 1200 hours:

CLEANING OR CHANGING THE 1. Pre-filter with cover
FILTER ELEMENT 2. Filter insert
3. Low pressure indicator
Note Earlier if the low pressure indicator shows red. 4. Safety cartridge

Disassembly
1. Remove and clean the coarse cleaner, see point 11.
2. Undo the nut securing the filter element and remove it.
3. Change or clean the element. Only use Scania genuine air
filter. Change the filter element
Note Cleaning the element always entails a risk of damaging it. The if it is damaged.
element can only be cleaned a maximum of four times. After
cleaning, it has poorer dust capacity than a new element. Danger of engine damage if the
4. Mark the filter when it has been cleaned. filter element is damaged.

Cleaning the element

- Carefully blow the filter element clean using dry compressed air from
the inside.
Note This filter element must not be washed with water. Never start the engine unless
the air filter is installed.
Danger of personal injury or
engine damage.

38 © Scania Industrial & Marine Engines 2001-05:1

Checking
- Insert a flashlamp into the insert and check from the outside that there
are no holes or cracks in the filter paper.
- Change the filter insert if there is any damage at all. Danger of engine
damage.

Assembly
1. Assemble the air cleaner in reverse order.
2. Reset the red plunger in the low pressure indicator by pressing in the
button

Filter with a non-changeable element (unit cleaner)

Cleaning
- The filter may be cleaned a maximum of 3 times. Mark the filter after
each time it has been cleaned.
- Use a cleaning solution consisting of water mixed with approx. 1% mild
detergent.

1. Pour the cleaning solution into the element outlet at the same time as
turning the element so that the cleaning solution pours through the
element against the direction of the air flow.
2. Leave the element in the cleaning solution for 5 minutes and then take it
out so that all the cleaning solution drains away.
3. Rinse the element with ca 30 litres clean water at 30 - 40 °C. Pour the
rinsing water into the element in the same way as the cleaning solution.
4. Take out the element and allow the rinsing water to drain off.
5. Repeat the procedure until the rinsing water is clean.
6. Leave the element to dry in a warm place for a few days.

Note The element must not be dried with compressed air.

2001-05:1 © Scania Industrial & Marine Engines 39

13. Every 2400 hours:
CHANGING SAFETY CARTRIDGE Do not remove the safety
1. Remove and clean the coarse cleaner, see point 11. cartridge unnecessarily.
2. Undo the nut securing the filter insert and remove it.
3. Change or clean the filter insert, see point 12.
4. Undo the nut securing the safety cartridge and remove it.
5. Fit a new Scania genuine safety cartridge.
6. Assemble the air cleaner.

1. Pre-filter with cover

2. Filter insert
3. Low pressure indicator
4. Safety cartridge

Air cleaner with pre-filter

Never clean the safety cartridge

40 © Scania Industrial & Marine Engines 2001-05:1

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

15. Every 1200 hours:

CHANGING THE FUEL FILTER
Fuel tanks
- Drain any water from the fuel tanks.

Main filter
The filter consists of a filter unit.
- Wash the outside of the filter and unscrew it.
- Fit the new filter and tighten it by hand.
Never use a tool for tightening. The filters can be damaged,
obstructing circulation.

- Bleed the fuel system as described below.

- Start the engine and check for leaks. Only use Scania genuine fuel
filter.
Bleeding the fuel system
- Turn on the power so that the fuel shut-off valve opens.
- Undo the connection on fuel filter outlet 1 (upwards).
- Pump hand pump 3 until fuel without air bubbles flows out of the Always collect fuel in a suitable
opened connection. container to avoid spillage when
- Tighten the connection on the filter.
bleeding system or renewing
components.
- Undo the overflow valve 2 at the fuel shut-off valve outlet.
- Pump with the hand pump until the fuel coming out of the open 3 2 1
overflow valve is free of air bubbles.
- Tighten the overflow valve and pump the hand pump an additional
10 strokes.
If the engine fails to start after bleeding. . . . . . .
- Open the overflow valve again and pump the hand pump until fuel
without air bubbles flows out.
- Close the overflow valve firmly and start the engine.

2001-05:1 © Scania Industrial & Marine Engines 41

16. Every 2400 hours:
CHECKING INJECTORS 1. Socket nut
Injectors should be inspected by trained personnel with access to the neces- 2. O-ring
sary equipment. Inspection should be carried out at least once a year or every 3. O-ring
2400 hours. 4. Stop ring
5. Guide pin
Removal 6. Seal
1. Clean round the injectors and connections, including clamps and
brackets.
2. Detach the delivery pipe bundle and leak-off fuel lines.
3. Unscrew the injector.
4. Fit protective plugs on the injector and delivery pipe.
5. Lift up the seal from the bottom of the injector seat if it does not come
out together with the injector. The delivery pipes must
6. Fit a core plug in the injector seat in the cylinder head. not be bent.
7. Clean the injectors and check/adjust in a nozzle tester. All clamps must be refitted.
Correct opening pressure, see Technical data, page 54.

Fitting
1. Check that there is no old seal in place and fit a new seal in the bottom
of the injector seat. Always wear gloves and eye
2. Fit a new O-ring in the threaded socket nut and a new seal under the protection when testing
socket nut. injectors.
3. Fit the injector. Fuel escaping under high
4. Tighten the socket nut to 70 Nm (7.0 kpm). pressure can penetrate body
tissue and cause serious injury.
5. Fit the delivery pipe and tighten the cap nut to 20 Nm (2.0 kpm). Fit
clamps and brackets.

Important Take care to fit the delivery pipe without tension and make sure
that the cone on it is correctly positioned in the connection.

6. Fit the leak-off fuel line. Tighten the bolts to 11 Nm (1.1 kpm).

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

Delivery pipe connection

42 © Scania Industrial & Marine Engines 2001-05:1

ELECTRICAL SYSTEM
17. Every 200 hours:
Do not let open flame or sparks
CHECKING THE come near the batteries.
ELECTROLYTE LEVEL IN BATTERIES When batteries are charged,
they emit highly flammable
1. Unscrew the plugs and check the electrolyte level in all cells.
fumes that can explode.
2. Top up with distilled water until the level is 10-15 mm above the plates.

18. Every 1200 hours:

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

19. Every 1200 hours:

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

©
2001-05:1 Scania Industrial & Marine Engines 43
20. Every 1200 hours:
CHECKING THE COOLANT LEVEL
MONITOR
(optional equipment)
Note Check the coolant level monitor when the engine is cold.
1. Loosen the coolant level monitor cable clamps towards the cable
cluster and disconnect the connector.
2. Put a container under the heat exchanger and unscrew the monitor.
Immediately insert a threaded plug M18x1.5 in the hole for the
monitor. Avoid contact with the skin when handling coolant.
3. Connect the monitor connector and put the control switch in the "ON"
position.
4. Check that the warning lamp remains on and that the buzzer sounds
(if fitted).
5. Lower the monitor into a metal container (steel) with liquid. It is
important that the monitor body is in contact with the metal.
6. After approximately 2 seconds the warning lamp should go out.
7. Remove the monitor from the liquid. After approximately 7 seconds
the warning lamp will come on and the buzzer sound (if fitted).
8. Disconnect the monitor connector and screw on the monitor again.
9. Clamp the monitor cable as before and connect the connector.
10. Top up the system with coolant according to the specification on
page 32.

©
44 Scania Industrial & Marine Engines 2001-05:1
21. Every 1200 hours:
CHECKING THE
TEMPERATURE MONITOR
1. Drain the coolant, allowing the temperature monitor to be removed.
2. Remove the temperature monitor cable(s).
3. Unscrew the monitor.
C = Common connection
4. Refit the cable(s) on the monitor.
1 = Connection C -1 closes at
5. Submerge the monitor sensor body in water. Heat the water slowly the stamped temperature
(about 1° per minute) with for example an immersion heater.
2 = Connection C -2 opens at the
6. Set the control switch to "ON". Use a thermometer to check that the stamped temperature
warning lamp comes on or that an alarm is initiated at the correct
temperature. 2-pole temperature monitor
The correct temperature is stamped on the hexagonal part of the
monitor.
The temperature tolerance is ± 3°.
Always use a suitable container
to avoid spillage when
draining coolant.
Dispose of used coolant through
CHECKING THE TEMPERATURE an authorized waste disposal
contractor.
SENSOR
1. Drain the coolant, allowing the temperature sensor to be removed.
2. Remove the temperature sensor cable(s).
3. Unscrew the sensor.
4. Connect an ohmmeter to the temperature sensor.
5. Submerge the sensor body in water. Heat the water slowly 2-pole temperature sensor
(about 1° per minute) with for example an immersion heater.
6. Check the resistance at the temperatures given below.
7. The sensor should give the following readings:

At temp. °C Resistance Ω Tolerance °C

60 134 ± 13.5 ±4

90 51.2 ± 4.3 ±3

100 38.5 ± 3 ±3

©
2001-05:1 Scania Industrial & Marine Engines 45
22. Every 1,200 hours:
CHECKING THE OIL PRESSURE
SENSOR/MONITOR
Sensor function
Measure the sensor output voltage (pin 3) at different oil pressures. The
sensor output voltage shall be as follows:
0.85-1.15 bar = 2.45 volt
1.80-2.20 bar = 3.70 volt
2.75-3.25 bar = 4.50 volt
3.79-4.20 bar = 5.20 volt
4.55-5.45 bar = 5.70 volt
5.40-6.6 bar = 6.10 volt
The tolerances apply at +30°C - 110°C. At lower temperatures the tolerance
range is wider, e.g. 0°C = x 1.4. 1 4
Monitor function
Connect a test lamp to the oil pressure monitor, pin 4 (- ground), and check
that the monitor switches on at the correct pressure when the engine is started
and stopped. The monitor shall switch on at 0.7 ± 0.15 bar when the engine is
stopped. 3
2
Important The sensor/monitor must be supplied with voltage during the
measurement. Maximum 4 W load from a test lamp.

CHECKING THE OIL PRESSURE

MONITOR FOR DEC 2
Connect an ohmmeter or a test lamp to the oil pressure monitor and check
that the monitor switches off/on at the correct pressure when the engine is
started and stopped. The monitor shall switch off at 1.1 ± 0.15 bar when the
engine is started and switch on at 0.7 ± 0.15 bar when the engine is stopped.

©
46 Scania Industrial & Marine Engines 2001-05:1
CHANGING THE BATTERY
Removal Do not connect the cables to the
wrong terminals.
1. Disconnect the negative cable (-) from the battery (cable connected to
earth). This could cause serious
damage to the electrical system.
2. Disconnect the positive cable (+) from the battery (cable connected to
starter motor). If the terminals are short-
circuited, sparks will be
Fitting
generated.
1. Connect the positive cable (+) to the battery (cable connected to starter
motor).
2. Connect the negative cable (-) to the battery (cable connected to earth).
Dispose of used batteries
through an authorized waste
disposal contractor.

MISCELLANEOUS
23. Every 1200 hours:
CHECKING THE DRIVE BELT
Replace the drive belt (1) (poly V-belt) if worn or damaged.
2
Also check that the automatic belt tensioner (2) is working and keeps the
drive belt correctly tensioned.
1

©
2001-05:1 Scania Industrial & Marine Engines 47
24. Daily:
CHECKING FOR LEAKAGE, RECTIFY
AS NECESSARY
- Start the engine.
- Check for oil, coolant, fuel, air and exhaust leakages.
- Tighten or change leaking connections. Check the overflow holes (1)
which show whether the O-rings between the cylinder liner and crank-
case are leaking, see drawing.
a) If coolant is leaking out, the two upper O-rings are leaking.
Ensure that any leakage does
b) If oil is leaking out, the lower O-ring is leaking. not pollute the environment.

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

48 © Scania Industrial & Marine Engines 2001-05:1

25. Every 2400 hours:
CHECKING/ADJUSTING VALVE WARNING
CLEARANCE Immobilise the starting device
when working on the engine.
Note Checking/adjusting valve clearance should also be done after the If the engine starts out of
first 400 hours of operation. control, there is a
Valves clearances should be adjusted when the engine is cold, at least 30 SERIOUS RISK
minutes after running. OF INJURY.
Rocker cover gaskets should be changed as necessary. Tightening torque:
25 Nm.
Intake valve clearance: 0.45 mm
Outlet valve clearance: 0.80 mm.
1
Alternative 1
- Set No. 1 cylinder to TDC by turning the engine in its direction of rota- 2
tion until both valves are closed.
- Adjust the following valves. Correct valve clearance is indicated on the 3
instruction plate on one of the rocker covers:
Cylinder 1 Intake and exhaust 4
2 In
3 Ex
4 In 5
5 Ex
- Set No. 6 cylinder to TDC by turning the engine one revolution in its 6
direction of rotation.
FLYWHEEL
- Adjust the following valves:
Cylinder 2 Ex
3 In
4 Ex TDC TDC
5 In No. 6 cyl No. 1 cyl
6 In and ex

Note
Readings can either be taken
from underneath or from
above, depending on which
flywheel is used.
The cover not being used is
covered with a seal and an
instruction plate.

FLYWHEEL

Covers for reading Intake valve

on flywheel casing Exhaust valve

2001-05:1 © Scania Industrial & Marine Engines 49

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

26. Every 2,400 hours:

CHANGING (or CLEANING) THE
CLOSED CRANKCASE VENTILATION
VALVE
Alternative 1:
Change the valve at the specified interval.
Alternative 2:
- Remove the valve after the specified interval.
- Clean the valve by placing it in a bath of diesel fuel oil overnight. Then
rinse it several times in diesel and allow it to drip dry.
- Refit the valve.
- The valve may be reused (cleaned), maximum twice after the initial
2400 hours of operation. Take care to mark the valve after cleaning it.

50 © Scania Industrial & Marine Engines 2001-05:1

LONG-TERM STORAGE
If the engine is not to be used for a lengthy period of time, special measures
should be taken to protect the cooling system, fuel system and combustion
chamber from corrosion and the exterior from rusting.
The engine can normally stand idle for up to six months. If it remains unused
for longer than this the following measures, which provide protection for
about four years, should be adopted. An alternative to preparing the engine
for long-term storage is to start the engine and warm it up every 6 months.
Preparing the engine for long-term storage means:
- Thoroughly cleaning the engine
- To run the engine for a period of time with preservative fuel,
preservative oil and preservative coolant.
- Otherwise preparing the engine for storage (filter changes, lubrication,
etc.).

Preservative coolant
If the engine is to be stored with a full cooling system, use coolant containing Ethylene glycol, if swallowed
50% glycol by volume. Glycol without nitrite-based inhibitor must be used. can be fatal.
E.g. BASF G48 or BASF D542. Avoid contact with the skin.

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

! HANDLING LUBRIZOL 560A

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

In case of splashes in the eye: Rinse with moderate water spray (for min. 15 minutes). Seek medical attention.
In case of skin contact: Wash affected areas with soap and water.
If you inhale it: Fresh air, rest and warmth
Flammable: Fire class 2A. Flash point + 27°.
In case of fire: Extinguish using carbonic acid, powder or foam
Storage: In properly sealed container in a dry, cool place. Keep out of reach of children.

2001-05:1 © Scania Industrial & Marine Engines 51

Preservative oil
Suitable preservative oil can be supplied by most petroleum companies.
For example: Dinitrol 40 or the equivalent.

Preparations for storage

- Drain and flush the cooling system. Top up with preservative coolant.
- Warm up the engine on regular fuel. Stop the engine and drain the oil.
- Change the fuel filter and turbo filter. Always use suitable containers
to avoid spillage when
- Fill the engine with preservative oil up to the minimum level on the
dipstick. draining oil and coolant.
Dispose of used oil and coolant
- Mix preservative fuel in a can. Detach the fuel pipe at the feed pump
suction line and connect a hose from the can. through an authorized waste
disposal contractor.
- Detach the fuel pipe at the overflow valve and connect a return hose to
the can.
- Start the engine and run it at about 1000 rpm (not single-speed engines)
for 20-25 minutes.
- Stop the engine, remove the hoses and connect the regular fuel lines.
- Oil the valve mechanism generously with preservative oil.
- Remove the injectors and spray preservative oil into each cylinder,
max 30 cm3 (ml).
Turn the engine over a few times using the starter motor. Spray a small
amount of oil additionally into each cylinder.
After this the engine must not be cranked. Refit the injectors.
- Drain the preservative oil from the engine. Fresh engine oil can be filled
directly or when the engine is taken out of storage.
- Drain the coolant if the engine is not to be stored with a full cooling
system. Plug and tape over all coolant connections (if the cooling system
is not completely assembled).
- Air cleaner: Clean or change the filter element.
- Cover air intakes and exhaust pipes.
- Alternator and starter motor:
- Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or the
equivalent.
- Spray the outside of bright engine parts, first with penetrating preserva-
tive oil such as Dinitrol 25B and then with Dinitrol 112 or the equiva-
lent.
Winter storage
- In order to minmize the risk of condensation water in the fuel tank
during a winter stop, it should be filled with fuel.

52 © Scania Industrial & Marine Engines 2001-05:1

 - Attach a label to the engine showing the date of preservation and
clearly stating that it must not be started or cranked.

STORED ENGINE
Date . . . . . . . . . . .
Do not start or crank!

Batteries
Remove the batteries for trickle charging at a charging station. (This does not
apply to batteries which, according to the manufacturer, are maintenance
free.) The same is applicable for short-term storage if the engine has not been Wear gloves and eye protection
prepared for storage as above.
when charging and handling
Storage batteries.
Batteries contain a highly
After the preparations, the engine should be stored in a dry and warm place
corrosive acid.
(room temperature).

Taking out of storage

(Procedure when the engine is to be put into operation)
- Remove plugs and tape from coolant connections, air intakes and
exhaust pipes.
- Fill the system with coolant, see page 18.
- Check the oil level in the engine or top up with new motor oil. Always use suitable containers
- Turn the engine over a few times with the injectors removed, at the same to avoid spillage when
time copiously oiling the valve mechanism with pushrods and tappets. draining oil and coolant.
Dispose of used oil and coolant
Important The engine must be cranked with the injectors removed so that through an authorized waste
surplus preservative oil will be pressed out of the cylinders.
disposal contractor.
- Fit the injectors.
- Empty the fuel system main filter of preservative oil.
- Bleed the fuel system.
- Wash off any externally applied preservative oil, using white spirit.

2001-05:1 © Scania Industrial & Marine Engines 53

TECHNICAL DATA
GENERAL DI9
Number of cylinders 6 in line
Cylinder bore mm 115
Stroke mm 144
Displacement dm3 (litres) 9.0
Number of main bearings 7
Firing sequence 1-5-3-6-2-4
Compression ratio 15:1
Engine direction of rotation viewed from rear Anti-clockwise
Fan direction of rotation viewed from the front Clockwise
Cooling Fluid
Valve clearance, cold engine
intake valve mm 0.45
exhaust valve mm 0.80
Weight (without coolant and oil)
engine with heat exchanger kg 905
Output see “Engine record card”

LUBRICATION SYSTEM
Max. oil pressure
(warm engine at speeds above 800 rpm) bar (kp/cm2) 6
Normal oil pressure
(warm engine at operating speed) bar (kp/cm2) 3-6
Min. oil pressure
(warm engine 800 rpm) bar (kp/cm2) 0.7
Oil capacity, see page 27

Crankcase pressure with closed crankcase

ventilation mm VP -55 - +20

54 © Scania Industrial & Marine Engines 2001-05:1

 FUEL SYSTEM DI9
Pump setting BTDC See plate on rocker cover
Injectors, opening pressure bar (kp/cm2) 300
Low idle
with RSV governor rpm 700
Maximum full load speed See engine card
Fuel Diesel fuel oil1
Tightening torques:
Socket nut for injectors Nm 70
Cap nut for delivery pipe Nm 20
Oil leakage connection Nm 11
1
see page 56

COOLING SYSTEM
Number of thermostats 2
Thermostat, opening temperature °C 79
Coolant temperature:
system with atmospheric pressure °C 70 - 93
system with positive pressure °C 70 - about 100
Capacity with heat exchanger dm3 (litre) 40

ELECTRICAL SYSTEM
System voltage V 24
Alternator, current A 65 or 90
Starter motor power kW (hp) 4.0 (5.4)
Monitors, settings:
Oil pressure monitor bar (kp/cm2) 2-pole: 0.7 ± 0.15
Temperature monitor °C Stamped on monitor hexagon

2001-05:1 © Scania Industrial & Marine Engines 55

FUEL
Diesel fuel
The composition of the diesel fuel is vitally important to the operation and
life of the engine and the fuel injection pump. The engine power output and
the exhaust emissions are also dependent on the fuel quality.
The requirements and the test standards for the most important properties are
described in the workshop manual in sections that can be ordered from your
Scania dealer or directly from Scania. The address of Scania is printed on the
cover.
The diesel fuel shall comply with the following standard:
EN 590 (European standard).
The table below shows the requirements for some of the most important
properties:

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

Density at 15°C 0.82 - 0.86 kg/dm3

Sulphur (concentration by mass) max. 0.3%

Ignitability (CET rating) min. 49

Flashpoint 56°C

Environmentally favourable fuels (low sulphur fuels)

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

56 © Scania Industrial & Marine Engines 2001-05:1

Temperature dependence of diesel fuel
At temperatures lower than those specified for the diesel fuel, paraffin wax
may precipitate from the fuel and block filters and pipes. The engine can then
loose power or stop.
The diesel fuel is adapted for use in the specific climate of each country. It is not permitted to mix
If a vehicle or an engine is to be operated in a temperature zone with lower kerosene with diesel fuel that is
temperature than normal, first identify the temperature properties of the
fuel concerned. already adapted for the climate
concerned. The injection pump
The properties of the fuel when cold can be improved by adopting one of the may be damaged. All use of
following measures before the temperature drops:
paraffin other than kerosene is
- If the fuel concerned is not intended for the expected temperature and no forbidden, as it causes
diesel fuel with the correct temperature properties is available, we engine damage.
recommend that an electric fuel heater be installed as a preventative
measure.
- The low temperature properties of diesel fuel may be improved by
adding kerosene as a preventative measure. A maximum of 20% may
be added. When refuelling, the kerosene should be added first, so that it
mixes thoroughly with the diesel fuel.
Note: It is prohibited to use kerosene in engine fuel in some countries. It is not permissible to mix
petrol with diesel fuel. Petrol
- To prevent water in the fuel from freezing and forming ice, maximum may cause wear to the fuel
0.5-2% alcohol (isopropanol) may be added. injection pump and it may also
Drain fuel tanks and drain or renew fuel filters at regular intervals. cause damage to the engine.

2001-05:1 © Scania Industrial & Marine Engines 57

 ALPHABETIC INDEX

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Air cleaner, filter element . . . . . . . . . . . . . . . . 38 LED functions . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air cleaner, low pressure indicator . . . . . . . . . 38 Long-term storage . . . . . . . . . . . . . . . . . . . . . . 51
Air cleaner, pre-filter . . . . . . . . . . . . . . . . . . . 38 Low pressure indicator . . . . . . . . . . . . . . . . . . 38
Air cleaner, safety cartridge . . . . . . . . . . . . . . 40 Lubricating oil pressure . . . . . . . . . . . . . . . . . 22
Lubricating oil pressure monitor . . . . . . . . . . 46
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Lubricating oil system . . . . . . . . . . . . . . . . . . 26
Battery, changing . . . . . . . . . . . . . . . . . . . . . . 47
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Certified engines . . . . . . . . . . . . . . . . . . . . . . . . 5 Maintenance Schedule . . . . . . . . . . . . . . . . . . 25
Checks after running . . . . . . . . . . . . . . . . . . . 23
Checks before running . . . . . . . . . . . . . . . . . . 19 Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Coolant level monitor . . . . . . . . . . . . . . . . . . . 44 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Coolant temperature . . . . . . . . . . . . . . . . . . . . 21 Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Coolant temperature monitor . . . . . . . . . . . . . 45 Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Coolant, changing . . . . . . . . . . . . . . . . . . . . . . 34 Oil pressure monitor . . . . . . . . . . . . . . . . . . . . 46
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 30 Oil pressure monitor, DEC2 . . . . . . . . . . . . . . 46
Cooling system, cleaning . . . . . . . . . . . . . . . . 35
Corrosion inhibitor . . . . . . . . . . . . . . . . . . . . . 34 Pre-filter, air cleaner . . . . . . . . . . . . . . . . . . . . 38

DEC2 Control system . . . . . . . . . . . . . . . . . . . 12 Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

DEC2 sensors . . . . . . . . . . . . . . . . . . . . . . . . . 13
Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Safety cartridge, air cleaner . . . . . . . . . . . . . . 40
Safety details . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical system . . . . . . . . . . . . . . . . . . . . . . . 43 Safety precautions for care and maintenance . . 8
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Safety precautions for handling materials . . . . 8
Environmental responsibility . . . . . . . . . . . . . . 4 Safety precautions for operation . . . . . . . . . . . . 7
Starting the engine . . . . . . . . . . . . . . . . . . . . . 19
Fault codes DEC2 . . . . . . . . . . . . . . . . . . . . . . 16 Start-up report . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Filter, air cleaner . . . . . . . . . . . . . . . . . . . . . . . 38 Stopping the engine . . . . . . . . . . . . . . . . . . . . 22
Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel filter, changing . . . . . . . . . . . . . . . . . . . . 41 Taking out of storage . . . . . . . . . . . . . . . . . . . 53
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fuel specifications . . . . . . . . . . . . . . . . . . . . . 56 Temperature monitor . . . . . . . . . . . . . . . . . . . 45
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Turbo filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel system, bleeding . . . . . . . . . . . . . . . . . . . 41 Type designations . . . . . . . . . . . . . . . . . . . . . . 10

Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . 49

Venting, fuel system . . . . . . . . . . . . . . . . . . . . 41
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

58 © Scania Industrial & Marine Engines 2001-05:1