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Scania DC09 XPI Service & Operator Manual - EN

Scania DC09 XPI Service & Operator manual_EN

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محمد حسن

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100% found this document useful (5 votes)

2K views80 pages

Scania DC09 XPI Service & Operator Manual - EN

Scania DC09 XPI Service & Operator manual_EN

Uploaded by

محمد حسن

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Important information

Serious risk of injury

When working on the engine, for example when adjusting drive belts and the clutch, or when changing the
oil, it is important not to start the engine. The engine could be damaged, but more importantly there is a
serious risk of injury.
For this reason, always secure the starting device or disconnect a battery cable before working on the engine.
This is especially important if the engine has a remote starter or automatic starting.

WARNING!

This warning symbol and text can be found next to those maintenance items where it is particularly impor-
tant to bear in mind the risk of injury.

Operator's manual
DC09
XPI
Industrial engine
en-GB 2 398 932
Issue 3.0

IMPORTANT!

The owner is responsible for making sure that maintenance is carried out on time and in accordance with
the instructions.

The owner must entrust the maintenance, renewal and repair of emission-related components and systems
to a qualified workshop or person.
Start-up Report – Warranty
The warranty starts when the start-up report has been filled in and sent to Scania. The normal warranty pe-
riod is 1 year, but other conditions can apply.
Fill in the particulars in the start-up report below as well. This can make things easier if you need to contact
a workshop, for example.

Engine serial number

Date of entry into service
User's name and address

Signature
Engine type
Variant

Engine type and variant are indicated on the engine data plate.

OPM 100 en-GB 2

© Scania CV AB 2015, Sweden
Start-up Report – Warranty . . . . . . . . . . . . . . . 2 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General information on the XPI system. . . . .57
Environment and safety . . . . . . . . . . . . . . . . . . 5 Checking fuel level . . . . . . . . . . . . . . . . . . . .57
Environmental responsibility . . . . . . . . . . . . . 5 Renewing the fuel filter with draining nipple 58
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Renewing the fuel filter using a suction tool .60
Warnings and advisories . . . . . . . . . . . . . . . . . 6 Bleeding the fuel system using a suction tool 63
Certification . . . . . . . . . . . . . . . . . . . . . . . . . 11 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . .64
Scania engines engine warranty for industrial Checking the drive belt . . . . . . . . . . . . . . . . .64
engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Checking for leaks . . . . . . . . . . . . . . . . . . . . .65
Emission control systems warranty. . . . . . . . 12 Checking and adjusting the valve clearance .66
Emission control system warranty statement 12 Renewing the reductant filter . . . . . . . . . . . . .68
California emission control warranty statement Cleaning the reductant tank filler filter . . . . .70
16 Cleaning the reductant tank ventilation filter.70
Your warranty rights and obligations . . . . . . 16 Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Manufacturer's warranty coverage . . . . . . . . 16 Composition of the fuel . . . . . . . . . . . . . . . . .71
Owner's warranty responsibilities . . . . . . . . . 16 Sulphur content of fuel. . . . . . . . . . . . . . . . . .71
SCR catalytic converter . . . . . . . . . . . . . . . . . 17 Temperature dependency of the fuel . . . . . . .73
Engine data plate . . . . . . . . . . . . . . . . . . . . . . . 19 Reductant for SCR . . . . . . . . . . . . . . . . . . . . . .74
Component identification . . . . . . . . . . . . . . . . 20 Responsibility and quality requirements . . . .74
SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Starting and running . . . . . . . . . . . . . . . . . . . . 23 Preparing the engine for storage . . . . . . . . . . .75
Checks before running . . . . . . . . . . . . . . . . . 23 Handling the engine . . . . . . . . . . . . . . . . . . . .75
Reductant pump . . . . . . . . . . . . . . . . . . . . . . 24 Preservative coolant . . . . . . . . . . . . . . . . . . . .75
Starting the engine . . . . . . . . . . . . . . . . . . . . 25 Preservative fuel. . . . . . . . . . . . . . . . . . . . . . .75
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Preservative oil. . . . . . . . . . . . . . . . . . . . . . . .76
Engine shutdown. . . . . . . . . . . . . . . . . . . . . . 29 Preparations for storage . . . . . . . . . . . . . . . . .76
Checks after running . . . . . . . . . . . . . . . . . . . 29 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . .78
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 General data . . . . . . . . . . . . . . . . . . . . . . . . . .78
Engines with few hours of operation . . . . . . 31 Lubrication system . . . . . . . . . . . . . . . . . . . . .78
Cleaning the engine. . . . . . . . . . . . . . . . . . . . 31 Injection system . . . . . . . . . . . . . . . . . . . . . . .79
Maintenance intervals . . . . . . . . . . . . . . . . . . 32 Cooling system. . . . . . . . . . . . . . . . . . . . . . . .79
Biodiesel (FAME). . . . . . . . . . . . . . . . . . . . . 33 Intake system . . . . . . . . . . . . . . . . . . . . . . . . .79
Lubrication system . . . . . . . . . . . . . . . . . . . . . 34 Electrical system . . . . . . . . . . . . . . . . . . . . . .79
Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Scania Assistance . . . . . . . . . . . . . . . . . . . . . . .80
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Checking oil level . . . . . . . . . . . . . . . . . . . . . 35
Changing the oil . . . . . . . . . . . . . . . . . . . . . . 36
Labels for top-up engine oil grade . . . . . . . . 37
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cleaning the centrifugal oil cleaner . . . . . . . 38
Operational testing . . . . . . . . . . . . . . . . . . . . 44
Renewing the oil filter. . . . . . . . . . . . . . . . . . 45
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 46
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Checking coolant level . . . . . . . . . . . . . . . . . 49
Checking antifreeze and corrosion inhibitor . 49
Antifreeze and corrosion inhibitor . . . . . . . . 50
Changing coolant . . . . . . . . . . . . . . . . . . . . . 51
Cleaning the cooling system . . . . . . . . . . . . . 53
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Reading the vacuum indicator. . . . . . . . . . . . 55
Renewing the filter element . . . . . . . . . . . . . 55
Renewing the safety cartridge. . . . . . . . . . . . 56

OPM 100 en-GB 3

Introduction
This Operator's manual describes the operation
and maintenance of Scania industrial engines.
The engines are direct-injection, liquid-cooled,
four-stroke, turbocharged diesel engines. Certain
engines are also equipped with an SCR system
for emission control.
The engines are available with different output
and engine speed settings. Engine power for the
engine ordered is indicated on a plate located on
the engine control unit.

Note:
Only standard components are described in the
operator's manual. Information about special
equipment is contained in instructions from the
various manufacturers.

To ensure the maximum performance and the

longest service life for the engine remember the
following:
• Read through the Operator's Manual before
starting to use the engine. Even regular users
of Scania engines will get new information
from the Operator's Manual.
• Always follow the maintenance instructions.
• Read the section on safety carefully.
• Get to know your engine so that you know
what it can do and how it works.
• Always contact a workshop with qualified
personnel for maintenance and repair.

The information in this manual was correct at the

time of going to press. Scania reserves the right
to make alterations without prior notice.

OPM 100 en-GB 4

Environment and safety Different types of advisory

Warning!
Environmental responsibility All advisories preceded by Warning! are very
Scania develops and produces engines that are as important. They warn of serious faults and incor-
environmentally-friendly as possible. Scania has rect operation that could lead to personal injury.
made major investments in the reduction of Example:
harmful exhaust emissions in order to fulfil the
environmental requirements in force in almost
every market. WARNING!

At the same time, we have been able to maintain Block the starting device when working on the
a high level of performance and operating econ- engine. If the engine starts unexpectedly, there is
omy for Scania Industrial and Marine Engines. a serious risk of injury.
To maintain these throughout the entire service
life of the engine, it is important for the user to
follow the instructions on running, maintenance
and fuel and lubricating oil as outlined in the Op-
erator's manual. Important!
Other green initiatives taken include ensuring Advisories preceded by Important! warn of
that, following maintenance and repair, waste faults and incorrect operation that could lead to
that is harmful to the environment (for example equipment being damaged. Example:
oil, fuel, coolant, filters and batteries) is disposed
of accordance with the applicable environmental IMPORTANT!
requirements.
For Scania to guarantee that the engine corre-
sponds to its certified configuration, and take re-
Safety sponsibility for any damage and injuries that
occur, maintenance must be carried out as above.
The following pages contain a summary of the
safety precautions to be complied with when op-
erating and maintaining Scania engines. The
equivalent text can also be found under the rele-
vant maintenance item.
To prevent damage to the engine and to ensure
that it runs optimally, follow the instructions in
the warnings and advisories.
If the instructions are not followed, the warranty
can cease to apply.

OPM 100 en-GB 5

Note: Safety precautions for running the

Advisories preceded by Note: refer to informa- engine
tion important to ensure the best possible opera- Daily maintenance
tion and functionality. Example:
Always carry out a visual inspection of the en-
Note: gine and engine compartment before starting the
Leave the engine off for at least 1 minute before engine or when the engine has been switched off
checking the oil level. after operation.
This inspection should be done to detect fuel, oil
or coolant leaks, or anything else that may re-
quire corrective action.
Environment
This Operator’s manual contains specially high-
lighted text with instructions to help protect the Fuel
environment during maintenance. Example: Use only fuel recommended in the workshop
manual.
Environment
WARNING!
Use a container to avoid spillage.
The wrong fuel grade can cause breakdowns or
stoppages by causing the injection system to
malfunction. This can cause damage to the en-
gine and, possibly, personal injury.
Warnings and advisories
Smoking
Refuelling
WARNING!
Never overfill the fuel tank as the fuel needs
Smoking is prohibited space to expand. Also ensure that the filler cap is
properly closed.
• in the vicinity of flammable or explosive ma-
terial, e.g. fuel, oils, batteries, chemicals
WARNING!
• when refuelling and in the vicinity of the fill-
ing station
During refuelling there is a risk of fire and explo-
• when working on the fuel system sion. The engine must be switched off and smok-
ing is prohibited.

OPM 100 en-GB 6

Hazardous gases Running

WARNING! WARNING!

Only start the engine in a well ventilated area. The engine must not be run in environments
The exhaust gases contain carbon monoxide and where there is a risk of explosion, as all of the
nitrogen oxides, which are toxic. electrical or mechanical components can gener-
ate sparks.
If it is run in an enclosed space, there should be
an effective device to extract exhaust gases and Approaching a running engine always poses a
crankcase gases. safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts such as the
fan and cause injury. For personal safety all ro-
tating parts and hot surfaces must be fitted with
guards.
Starter lock

IMPORTANT!

If the control panel is not fitted with a starter Safety precautions for handling ma-
terials
lock, the engine compartment should be locked
to prevent unauthorised personnel from starting Fuel and lubricating oil
the engine. Alternatively, a lockable master
switch or battery master switch can be used.
WARNING!

All fuels and lubricants as well as many chemi-

cals are flammable. Always follow the instruc-
Starter gas tions on the relevant packaging.
The work must be carried out on a cold engine.
WARNING!
Fuel leaks and spillage on hot surfaces can cause
fire.
Never use starter gas or similar agents to help
start the engine. This can cause an explosion in Store used rags and other flammable materials
the intake manifold and possible injury. safely so as to avoid spontaneous combustion.

OPM 100 en-GB 7

Batteries Reductant

WARNING! WARNING!

The batteries contain and form oxyhydrogen gas, Reductant (AdBlue/DEF) is used in the reductant
particularly during charging. Oxyhydrogen gas tank on engines equipped with an SCR system.
is flammable and highly explosive. Avoid contact with the skin.
There must be no smoking, naked flames or If reductant comes in contact with the skin: Wash
sparks near the batteries or the battery compart- with soap and plenty of water. If reductant
ment. Incorrect connection of a battery cable or splashes in the eyes: Rinse immediately with
jump lead can cause a spark, which can cause the plenty of water. Contact a doctor if it is ingested
battery to explode. or causes skin irritations.

Chemicals Safety precautions for maintenance

and repair
WARNING! Switch off the engine
Always switch off the engine before carrying out
Most chemicals such as glycol, anti-corrosive
maintenance and repairs, unless otherwise indi-
agents, preservative oils and degreasing agents,
cated.
are hazardous to health.
Make it impossible to start the engine: Remove
Some chemicals, such as preservative oil, are
any starter key, or cut the power using the main
also flammable.
power switch or battery master switch and lock
Always follow the safety precautions on the rel- them.
evant packaging.
Fix a warning plate somewhere appropriate,
Store chemicals and other materials which are showing that work is being carried out on the en-
hazardous to health in approved containers, gine.
marking them clearly and storing them where
they are inaccessible to unauthorised persons.
WARNING!

Working with a running engine always poses a

Environment safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts and cause
Always hand in leftover and used chemicals to injury.
an authorised waste disposal contractor.

OPM 100 en-GB 8

Hot surfaces and fluids Batteries

WARNING! WARNING!

There is always a risk of sustaining burns when The batteries contain highly corrosive sulphuric
an engine is hot. Particularly hot parts are ex- acid. Take care to protect your eyes, skin and
haust manifolds, turbochargers, oil sumps, hot clothes when charging or handling batteries.
coolant and oil in pipes and hoses. Wear protective gloves and goggles.
If sulphuric acid comes in contact with the skin:
Wash with soap and plenty of water. If it gets in
your eyes: Rinse immediately with plenty of wa-
Lift the engine out ter and seek medical attention.
Always use the engine lifting eyes. Always
check that lifting devices are in good condition
and are designed to lift the weight. Environment
Optional equipment on the engine can change
the centre of gravity. This means that it may be Always hand in used batteries to an authorised
necessary to use additional lifting devices to bal- waste disposal contractor.
ance the engine correctly and lift it safely.

WARNING!
Electrical system
Never work underneath a suspended engine! The engine must be switched off and the power
disconnected using the master switch or battery
master switch before working on the electrical
system. External power supplies to extra equip-
ment on the engine must also be disconnected.

IMPORTANT!

Scania recommends that Scania spare parts are

used for the fuel and electrical systems. Scania
spare parts are designed to minimise the risk of
fire and explosion.

OPM 100 en-GB 9

Electric welding Cooling system

IMPORTANT! WARNING!

When carrying out welding work on and near the Never open the coolant filler cap when the en-
engine, disconnect the battery and alternator gine is hot. Hot coolant and steam may spray out
leads. Pull out the multi-pin connector for the en- and cause burns.
gine control unit as well.
If the cap has to be opened do it slowly and care-
Connect the welding clamp close to the compo- fully to release the pressure before removing the
nent to be welded. The welding clamp must not cap. Wear gloves as the coolant is still very hot.
be connected to the engine, or so that the current
can cross a bearing.
When welding is finished: Environment
1. Connect the alternator and control unit ca-
bles first. Always hand in used coolant to an authorised
waste disposal contractor.
2. Then connect the batteries.

Fuel system
Lubrication system

WARNING!
WARNING!
Always wear protective goggles when testing in-
Hot oil can cause burns and skin irritation. Wear jectors. Fuel escaping at high pressure can pene-
protective gloves and goggles when changing trate tissues and cause serious injury.
hot oil.
Scania recommends that Scania spare parts are
Make sure that there is no pressure in the lubri- used for the fuel and electrical systems. Scania
cation system before starting work on it. spare parts are designed to minimise the risk of
The oil filler cap must always be in place when fire and explosion.
starting and running the engine to prevent oil be-
ing ejected.

Environment

Always hand in used oil to an authorised waste

disposal contractor.

OPM 100 en-GB 10

Before starting Certification

Ensure that all guards are in place before starting An emissions certified engine fulfils the emis-
the engine. Ensure that no tools or other objects sions requirements for a particular range of ap-
have been left on the engine. plication.
On each emissions certified engine there is a la-
WARNING! bel which shows which requirements the engine
fulfils. Scania guarantees that each such engine
The air filter must be fitted before starting the en- fulfils the emissions requirements for the range
gine. Otherwise there is a risk of objects being of application for which it is certified.
sucked into the compressor impeller or of injury
if you come into contact with the air filter. The following are required for the certified en-
gine to fulfil the emissions requirements once it
has been taken into service:
• Maintenance is to be carried out in accord-
ance with the instructions in this Operator's
manual.
• The maintenance and repair of injection
equipment are to be carried out by a qualified
workshop or person.
• The engine may only be modified with equip-
ment that has been approved by Scania.
• Seals may be broken and setting data edited
only once approval has been granted by Sca-
nia. Modifications may be made by author-
ised personnel only.
• Modifications affecting the exhaust and in-
take systems must be approved by Scania.

Otherwise, the instructions in the Operator's

manual for the running and maintenance of the
engine shall apply. The safety precautions
should be observed.

IMPORTANT!

For Scania to guarantee that the engine corre-

sponds to its certified configuration, and take re-
sponsibility for any damage and injuries that
occur, maintenance must be carried out as above.

OPM 100 en-GB 11

Scania engines engine war- in the engine manufacturer's application for

ranty for industrial engines
certification.

Where a warrantable condition exists, Scania

Emission control systems will repair your heavy-duty off-road engine at no
cost to You including diagnosis, parts, and labor.
warranty

IMPORTANT!
Warranty period
Only applicable to engines used in the U.S.A. This warranty shall apply for one of the follow-
ing periods, whichever occurs first:
• 3,000 hours of operation as determined by a
Table of Contents device to measure hours of use, or
General warranty provisions 12 • Five years
Warranty period 12 Each engine is equipped with a device to meas-
Parts covered by the Warranty 13 ure hours of use. If that device fails to account for
General warranty limitations 14 hours of use due to defects in materials or work-
manship, the engine shall be warranted for a pe-
Specific warranty exclusions 15 riod of five years. The warranty period shall
Customer support 15 begin on the date the engine is delivered to the
first ultimate purchaser who, in good faith, pur-
chases the engine for purposes other than immi-
nent resale.
Emission control system war-
ranty statement
The Warranty on emission-related
General warranty provisions parts shall be interpreted as follows:
The emission control systems of your new Scan- 1. Any warranted part which is not scheduled
ia Engines (“Scania”) industrial diesel engine for replacement as required maintenance in
were designed, built and tested using genuine Scania's written instructions for maintenance
parts, and were certified as being in conformity and use of the engine by owner shall be war-
with federal emission control regulations. Scania ranted for the warranty period defined above.
warrants to the original owner, and to each sub- If any such part fails during the period of
sequent owner, of a new Scania industrial diesel warranty coverage, it shall be repaired or re-
engine (“You”) that the engine: placed by the engine manufacturer according
to Subsection (4) below. Any such part re-
1. Was designed, built and equipped so as to paired or replaced under the Warranty shall
conform at the time of sale with all applica- be warranted for the remaining warranty pe-
ble regulations under Section 213 of the riod.
Clean Air Act, 42 U.S.C. § 7547, for their
full useful life and designed, built and 2. Any warranted part which is scheduled only
equipped so as to conform with all applicable for regular inspection in Scania's written in-
regulations adopted by the California Air Re- structions for maintenance and use of the en-
sources Board pursuant to its authority under gine by owner shall be warranted for the
Chapters 1 and 2, Part 5, Division 26 of the warranty period defined above. A statement
California Health and Safety Code, and; in such written instructions to the effect of
“repair or replace as necessary” shall not re-
2. Is free from defects in material and work- duce the period of warranty coverage. Any
manship which would cause such engine to such part repaired or replaced under warran-
fail to conform to applicable regulations for ty shall be warranted for the remaining war-
its warranty period or otherwise cause the ranty period.
failure of a warranted part to be identical in
all material respects to the part as described

OPM 100 en-GB 12

3. Any warranted part which is scheduled for shall not be liable under this article to war-
replacement as required maintenance in Sca- rant failures of warranted parts caused by the
nia's written instructions for maintenance use of a non-exempted add-on or modified
and use of the engine by owner shall be war- part.
ranted for the period of time prior to the first 11. The Executive Officer of the California Air
scheduled replacement point for that part. If Resources Board may request, and in such
the part fails prior to the first scheduled re- case, the engine manufacturer shall provide,
placement, the part shall be repaired or re- any documents which describe that manufac-
placed by the engine manufacturer according turer's warranty procedures or policies.
to Subsection (4) below. Any such part re-
paired or replaced under warranty shall be
warranted for the remainder of the period
prior to the first scheduled replacement point
for the part. Parts covered by the Warranty
4. Repair or replacement of any warranted part The following is a list of parts considered to be
under the warranty provisions of this article part of the Emission Control Systems covered by
shall be performed at no charge to the owner the Emission Warranty for Scania industrial en-
at a warranty station. gines which were built to conform to federal and
California emission control regulations:
5. Notwithstanding the provisions of Subsec-
tion (4) above, warranty services or repairs 1. Fuel injection system.
shall be provided at all manufacturer distri- 2. Air induction system.
bution centers that are franchised to serve the
subject engines. 3. Exhaust manifold system.
6. The owner shall not be charged for diagnos- 4. Smoke puff limiter (included in ECU).
tic labor that leadsto the determination that a 5. Oil filler cap.
warranted part is in fact defective, provided 6. EGR system (when applicable):
that such diagnostic work is performed at a
warranty station. a) Cooler.
b) EGR valve.
7. The engine manufacturer shall be liable for
damages to other engine components proxi- 7. Exhaust brake (when applicable).
mately caused by a failure under warranty of 8. NOx sensors:
any warranted part. a) NOx sensor, engine out.
8. Throughout the engine's warranty period de- b) NOx sensor, tail pipe.
fined above, the engine manufacturer shall 9. DOC (when applicable).
maintain a supply of warranted parts suffi-
cient to meet the expected demand for such 10. SCR system:
parts. a) DEF tank.
9. Any replacement part, as defined in Section b) DEF tank level, temperature and quality
1900(b), Title 13 of the California Code of sensors.
Regulations, may be used in the performance c) DEF hose.
of any maintenance or repairs and must be d) DEF injector.
provided without charge to the owner. It is e) DEF injector pressure and temperature
not necessary for replacement parts to be the sensors.
same brand or by the same manufacturer as f) Evaporator.
the original part sold with the engine. Such g) SCR catalyst inlet temperature sensor.
use shall not reduce the warranty obligations h) SCR catalyst including the ammonia-slip
of the engine manufacturer. catalyst.
i) SCR control unit (EEC3).
10. Add-on or modified parts, as defined in Sec-
tion 1900(b), Title 13 of the California Code
of Regulations, that are not exempted by the
California Air Resources Board may not be
used. The use of any non-exempted add-on
or modified parts shall be grounds for disal-
lowing a warranty claim made in accordance
with this article. The engine manufacturer

OPM 100 en-GB 13

11. Miscellaneous items used in the above sys- Receipts covering the performance of regular
tem: maintenance should be retained in the event
a) Electronic control unit (ECU), sensors, questions arise concerning maintenance. The re-
wiring harnesses. ceipts should be transferred to each subsequent
b) Hoses, belts, connectors, assemblies, owner of the engine with the emission warranted
clamps, fittings tubing, sealing gaskets or engine. Scania cannot, however, deny warranty
devices and mounting hardware. solely for the lack of receipts or for your failure
c) Pulleys, belts and idlers. to ensure the performance of all scheduled main-
d) Emission control information label. tenance.
The Warranty covers the cost of diagnosis, repair
IMPORTANT! and replacement parts and services of warranted
components and systems performed by an au-
This list does not include all expendable mainte- thorized Scania distributor or dealer using genu-
nance parts. ine Scania parts. You may elect to have
maintenance, replacement or repair of these
• Expendable emission related parts requiring components and systems performed by any re-
scheduled maintenance are warranted until pair establishment or individual without invali-
their first scheduled replacement point. dating the Warranty.
• Emission related parts scheduled for inspec-
tion and replacement only as necessary are The use of other than Scania replacement parts
not considered expendable and if repaired or also does not invalidate the warranty on other
replaced under warranty shall be warranted components unless such parts cause damage to
for the remaining warranty period. warranted parts. However, the cost of such ser-
vices or parts will not be covered by the Warran-
See Specific Warranty Exclusions below. ty.
You are responsible for initiating the warranty
process. The California Air Resources Board
suggests that You present your heavy-duty off-
road engine to an authorized Scania dealer as
General warranty limitations soon as a problem exists. The warranty repairs
To retain the dependability of the exhaust emis- should be completed by the dealer as expedi-
sion control originally built into your Scania in- tiously as possible.
dustrial diesel engine, it is essential that the
engine is installed according to Scania installa-
WARNING!
tion instructions and emission certificates. Your
engine is designed to operate on diesel fuel only.
Use of any other fuel may result in your engine Use of replacement parts which are not of equiv-
no longer operating in compliance with state or alent quality may impair the effectiveness of
federal emissions requirements. The use of alter- emission control systems. Accordingly, it is rec-
native fuels shall not void the warranties on any ommended that only Scania repair or replace-
engine certified to use such fuel. ment parts be used for maintenance, repair or
replacement of emission control systems.
In addition, as the engine owner, You are respon-
sible for the performance of all scheduled main- If other than Scania parts are used for mainte-
tenance listed in your owner's manual, and all nance, repair or replacement, the owner should
necessary repairs, on your new Scania industrial obtain assurance that such parts are warranted by
diesel engine. Scania may deny a warranty claim their manufacturer to be equivalent to genuine
if the engine or part has failed due to abuse, ne- Scania parts.
glect, improper maintenance or unapproved
modifications.

OPM 100 en-GB 14

Specific warranty exclusions Customer support

This warranty does not cover: In the event that You do not receive the warranty
service to which You believe You are entitled
1. .Malfunctions in any part caused by any of under the Warranty, or if You need additional
the following: misuse, abuse, improper ad- support or information concerning the Warranty,
justments, modifications, alteration, tamper- please contact:
ing, disconnection, improper or inadequate
maintenance, or use of fuels not recommend- Scania USA, Inc.
ed for the engine as described in the Opera-
tor's Manual. Address: 121 Interpark Blvd, suite 1002, 78216,
San Antonio, Texas
2. Engine installation, including cooling sys-
tem, intake system and exhaust system in- Mailing address: 121 Interpark Blvd, suite
stallation, that is not completed in 1002, 78216, San Antonio, Texas
accordance with the Scania installation in-
structions and emissions certificate for this Telephone: +1 210 403 0007
engine type. Fax: +1 210 403 0211
3. Damage resulting from accidents, acts of na-
ture or other events beyond the control of E-mail: [email protected]
Scania. California customers shall also be furnished a
4. The replacement of expendable maintenance copy of the California Emission Control Warran-
items such as filters, hoses, belts, oil, ther- ty Statement applicable to each new Scania en-
mostat, exhaust system and coolant made in gine purchased.
connection with scheduled maintenance ser-
vices once these parts have been replaced.
5. Replacement items which are not genuine
Scania parts or not authorized by Scania.
6. Inconvenience, loss of use of the engine or
commercial loss.
7. Any engine on which the actual use cannot
be accurately determined due to a failure of
the device to track hours of use unrelated to
defects in materials or workmanship.
8. Any engine operating outside the United
States.

OPM 100 en-GB 15

California emission control Owner's warranty responsi-

warranty statement bilities
• As the off-road engine owner, you are respon-
Your warranty rights and obli- sible for the performance of the required
gations maintenance listed in your owner's manual.
Scania CV AB recommends that you retain
The California Air Resources Board is pleased to all receipts covering maintenance on your
explain the emission control system warranty on off-road engine, but Scania CV AB cannot
your 2015 engine. In California, new heavy-duty deny warranty solely for the lack of receipts
off-road engines must be designed, built and or for your failure to ensure the performance
equipped to meet the State's stringent anti-smog of all scheduled maintenance.
standards. Scania CV AB must warrant the • As the off-road engine owner, you should
emission control system on your engine for the however be aware that Scania CV AB may
periods of time listed below provided there has deny you warranty coverage if your off-road
been no abuse, neglect or improper maintenance engine or a part has failed due to abuse, ne-
of your engine. glect, improper maintenance or unapproved
Your emission control system may include parts modifications.
such as the fuel injection system and the air in- • Your engine is designed to operate on ultra
duction system. Also included may be hoses, low-sulfur diesel fuel only. Use of any other
belts, connectors and other emission-related as- fuel may result in your engine no longer oper-
semblies. ating in compliance with California's emis-
sions requirements.
Where a warrantable condition exists,
Scania CV AB will repair your heavy-duty off- • You are responsible for initiating the warran-
road engine at no cost to you including diagno- ty process. The ARB suggests that you pres-
sis, parts and labor. ent your off-road engine to a Scania CV AB
dealer as soon as a problem exists. The war-
ranty repairs should be completed by the
dealer as expeditiously as possible.

Manufacturer's warranty cov- If you have any questions regarding your war-
erage ranty rights and responsibilities, you should con-
tact Scania U.S.A. Inc +1-210-403-0007.
The 2015 heavy-duty off-road engines are war-
ranted for a period of five years or 3,000 hours,
whichever occurs first. If any emission-related
part on your engine is defective, the part will be
repaired or replaced by Scania CV AB.

OPM 100 en-GB 16

SCR catalytic converter Environmental protection measures

• The SCR catalytic converter is a manufac-
tured article that contains vanadium pentox-
WARNING!
ide, a hazardous substance. Before disposing
of, or scrapping, a spent SCR catalytic con-
The SCR catalytic converter contains vanadium verter, it should be tested for any hazardous
pentoxide, a chemical known to the State of Cal- characteristics (ignitability, corrosivity, reac-
ifornia to cause cancer. tivity, acute hazardousness, and toxicity), as
those categories are described in 22 CCR §
66261.30. If the spent SCR catalytic convert-
The SCR catalytic converter is fitted in the si- er exhibits hazardous characteristics and is
lencer and does not constitute a health hazard being disposed of, it will be considered by the
during normal use and handling. State of California to be a hazardous waste
When carrying out work on the SCR catalytic subject to Title 22, California Code of Regu-
converter which may result in exposure to dust, lations. Before disposing of hazardous waste,
safety precautions must be taken. Such work in- review and follow all pertinent federal and
cludes, for example, opening the silencer ma- California requirements.
chining and scrapping the SCR catalytic • Vanadium pentoxide is a listed commercial
converter. chemical product - P120 - pursuant to 22
CCR § 66261.33(e). According to the State of
Safety precautions when working on the SCR California, commercial chemical products
system. that are discarded or intended to be discarded
• Inhalation: If dust is inhaled, the person are hazardous wastes and are subject to all
should be provided with fresh air immediate- provisions of Title 22, California Code of
ly. Seek medical attention Regulations. Before disposing of vanadium
pentoxide, review and follow all pertinent
• Eye contact: Rinse eyes with water immedi- federal and California requirements.
ately. If irritation persists, seek medical atten-
tion. • If the SCR catalytic converter is opened for
maintenance, any dust spillages from the cat-
• Skin contact: Wash with water and soap. Re- alyst should be collected and tested for the
move contaminated clothes. presence of vanadium pentoxide prior to
• Ingestion: If large amounts have been ingest- proper disposal. Dust spillages should also be
ed, drink plenty of water and induce vomit- tested for any hazardous characteristics (ig-
ing. Seek medical attention nitability, corrosivity, reactivity, acute haz-
ardousness, and toxicity), as those categories
Environmental hazards are described in 22 CCR § 66261.30, prior to
• Vanadium pentoxide is toxic to water organ- proper disposal. If the dust contains either va-
isms and can cause detrimental long term ef- nadium pentoxide or exhibits hazardous char-
fects to water environment. acteristics and is being disposed of, it will be
considered by the State of California to be a
hazardous waste subject to Title 22, Califor-
nia Code of Regulations. Before disposing of
hazardous waste, review and follow all perti-
nent federal and California requirements.

OPM 100 en-GB 17

• Do not dispose of the spent SCR catalytic • Any dust from the SCR catalytic converter
converter or its constituent parts into any wa- should be removed using a vacuum cleaner
terways, storm drains or sanitary sewers. with microfilter to minimize exposure.
• Make sure that the work surface is cleaned af-
ter completed work; Vacuum first then swab.
WARNING!
• Make sure you clean your hands after work-
ing with SCR catalytic converter to avoid in-
The SCR catalytic converter contains vanadium
gestion.
pentoxide, a chemical known to the State of Cal-
ifornia to cause cancer. • Work done on the SCR catalytic converter
may generate waste considered by the State
of California to be a hazardous waste subject
Additional considerations when working on the to Title 22, California Code of Regulations.
SCR system Before disposing of hazardous waste, review
and follow all pertinent federal and California
• Carry out work on the SCR catalytic convert- requirements.
er in all well ventilated area. Use protective
goggles and gloves if there is any risk of
splashing or spraying of reductant or coolant.
• When engine is running, the exhaust system
parts can reach such high temperatures that
there is a risk of personal injury. Make sure
that the exhaust system temperature has de-
creased to a suitable level before starting to
work.
• The SCR system is heated by water from the
engine cooling system. The cooling system
runs at overpressure and when the engine is
hot the coolant is hot. Do not open any hoses
without first stopping the coolant flow in the
hose.
• A P3 type respirator/filter mask or a type
FFP3 fine dust musk, protective goggles and
gloves should be used for any work where
there is a risk of exposure to dust from the
SCR catalytic converter.
• Use a disposable overall and dispose of it
properly after machining.
• Eating, drinking or smoking while working is
not permitted.

OPM 100 en-GB 18

Engine data plate

The engine data plate indicates, in the form of a
code, the engine type, its size and applications. It
also indicates the engine type power range and
operating speed. The engine EU type approval
for exhaust emissions is indicated under Output,
where applicable.
The engine power is stated on a plate which is lo-
cated on the engine control unit.
The engine serial number is stamped onto the top
of the cylinder block at the front right.

Example: DC09 085A

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

Made b y

Type DC09 085A

Engine No 6950106
Output. 232-257 kW 2100 r pm.
348 325

Example of an engine data plate

OPM 100 en-GB 19

Component identification

1 2 3 4 5 6 7 8 9 15 16 17 13

12
14

348 424
13 20 19 18
The illustration shows a normal version of a DC09 engine. The engine ordered may have different equipment

1. Engine data plate 11. Draining coolant

2. EGR valve 12. Centrifugal oil cleaner
3. Actuator 13. Oil filler
4. Exhaust brake 14. Engine control unit
5. Turbocharger 15. Water separating prefilter for fuel
6. EGR cooler 16. Hand pump for fuel
7. Oil cooler 17. Fuel filter
8. Oil filter 18. Starter motor
9. Engine serial number on the cylinder 19. Oil dipstick
block 20. Oil plug
10. Coolant pump

OPM 100 en-GB 20

SCR system
The illustration provides an overview of SCR
system components.

1 2

4
3 6

14 7
13

12 11
10

336 907
1. Evaporator 8. Coolant hose, return from tank and pump heating
2. Pressure line for reductant 9. NOx sensor with control unit1
3. Coolant hose for tank and pump heating 10. Oxidation catalytic converter1
4. Coolant valve 11. Exhaust gas temperature sensor
5. Reductant return line 12. SCR catalytic converter
6. Reductant tank 13. NOx sensor with control unit
7. Reductant pump and control unit 14. Reductant doser

1. DC09 084/085/086/087/089A only.

OPM 100 en-GB 21

Reductant tank

Reductant tanks come in 4 different sizes. The

volumes indicated for each tank are filling vol-
umes.
A filler filter with magnet is fitted in the reduct-
ant tank to prevent the reductant from becoming
contaminated when topping up. The filler filter

348 425
with magnet is used when topping up at a filling
station.
38 litres (10 US gallons)
A filler filter without a magnet is also supplied
for use when manually topping up reductant.

348 422
60 litres (15.8 US gallons)

348 421

69 litres (18.2 US gallons)

348 426

70 litres (18.5 US gallons)

OPM 100 en-GB 22

Starting and running

Note:
Before the engine is started for the first time, car-
ry out the maintenance items listed under First
start in the maintenance schedule. See the Main-
tenance section.

Always check the following before running:

• oil level
• coolant
• fuel level
• electrolyte level in batteries
• state of charge of the batteries
• condition of the drive belt
• the level in the reductant tank, if the engine is
equipped with an SCR system.

WARNING!

Running the engine without reductant in the re-

ductant tank violates emissions legislation and
will damage the SCR system.

Checks before running

Carry out daily maintenance as described in the
maintenance schedule prior to operation. See the
Maintenance section.

WARNING!

Block the starting device when working on the

engine. If the engine starts unexpectedly, there is
a serious risk of injury.

OPM 100 en-GB 23

Reductant pump
When the reductant pump is new, the check
valves may need to be slackened.

IMPORTANT!

Blow the reductant pump suction nipple with

compressed air (approx. 6 bar) for at least 3 sec-
onds before starting the engine for the first time.

336 838
Reductant pump

OPM 100 en-GB 24

Starting the engine Starting at low temperatures and at

high altitudes
For environmental reasons the Scania engine has
Take the local environmental requirements into
been developed to be started with a low fuel feed.
account. Use a fuel heater and engine heater to
Using unnecessarily large amounts of fuel when
avoid starting problems and white smoke.
starting the engine always results in emissions of
unburnt fuel. Scania recommends that an engine heater should
be used if the engine will be used at temperatures
1. Open the fuel cock if fitted.
below -10°C or at an altitude of more than 2,000
2. Disengage the engine. metres.
3. If the engine has a battery master switch:
A low engine speed and a moderate load on a
Switch on the power by means of the battery
cold engine limits white smoke, gives better
master switch.
combustion and warms up the engine more
4. Start the engine. quickly than warming it up with no load.
If the fuel tank has been run dry or if the engine Avoid running it longer than necessary at idling
has not been used for a long time, bleed the fuel speed.
system.

WARNING!

Never use starter gas or similar agents to help

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

IMPORTANT!

The starter motor must only be cranked twice for

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

OPM 100 en-GB 25

Running
Check instruments and warning lamps at regular
intervals.

Engine speed range

600-750 rpm Low idling. Engine idling is controlled by the engine management system.
Low idling up to 2,100 rpm Engine operating speed range. Controlled by the engine management sys-
tem.
2,100-2,600 rpm Unsuitable operating speed, but a slightly higher engine speed than the nor-
mal maximum operating speed may occur when load is low or negative.
2,600-3,000 rpm Prohibited engine speed.

Emission control
The system provides a warning if there are faults
on the SCR system or if the level of reductant in
the reductant tank is too low. In the case of some
faults, for example if doser cooling is not work-
ing, the torque is reduced.

Reaction at low reductant level

Reductant Warning Torque reduction1

level lamp
20% Constant
light
10% Flashing Torque is reduced by
1% per minute to
70% of the highest
319 562

torque
0% Flashing rap- Torque is reduced to Symbol for low reductant level
idly 0% (low idling)
within 2-10 minutes
1. Applies only to engines that are certified according to Tier
4.

The engine resumes normal torque after reduct-

ant has been filled to a level of at least 20%.

OPM 100 en-GB 26

Reaction to fault in SCR system

Time Warning Torque reduction1

lamp
Fault detect- Constant
ed light
After 30 Flashing Torque is reduced by
minutes 1% per minute to
70% of the highest

319 563
torque
After 4 hours Flashing rap- Torque is reduced to
idly 0% (low idling) Symbol for fault in SCR system
within 2-10 minutes
1. Applies only to engines that are certified according to Tier
4.

Once the fault has been remedied and the engine

control unit has received an indication that it is
working, torque returns to the normal level.
If a new fault occurs within 40 hours of operation
since the first fault, the warning lamp will come
on. After 30 minutes of operation, the warning
lamp will flash rapidly and torque will be re-
duced to 0% (low idling) within 30 minutes.

IMPORTANT!

If the torque has been reduced to 0% (low

idling), the engine control unit does not detect
that the SCR system is functioning again. A ser-
vice technician must then reset the system so that
the torque returns to the normal level.

Note:
The torque reduction applies only to engines that
are certified according to Tier 4.

OPM 100 en-GB 27

Coolant temperature Oil pressure

Normal coolant temperature during operation is Information about the normal oil pressure and
80-90°C/176-194°F. lowest permitted oil pressure is contained in the
section headed Technical Data.
Alarm levels are set in the engine control unit.
The default setting for the lowest and highest The engine management system has the follow-
limit values for high coolant temperature are ing alarm levels:
95°C/203°F and 105°C/221°F respectively.
• At an engine speed below 1,000 rpm and an
The following function is standard as alarm for oil pressure below 0.7 bar/10.2 psi.
high coolant temperature: • At an engine speed above 1,000 rpm and an
• Alarm and torque reduction at the lowest lim- oil pressure below 2.5 bar/36.3 psi for longer
it value. than 3 seconds.

Depending on the engine configuration, the fol- The following function is standard as alarm for
lowing alarm functions may also be available: incorrect oil pressure:

• Alarm only. • Alarm and torque reduction by 30%.

• Alarm and engine shutdown at the highest Depending on the engine configuration, the fol-
limit value. lowing alarm functions may also be available:
• Alarm, torque reduction at the lowest limit
• Alarm only.
value and engine shutdown at the highest lim-
it value. • Alarm and engine shutdown.
• Alarm and engine shutdown at the highest • Alarm and engine shutdown override control.
limit value with the possibility of engine shut-
down override control. Note:
• Alarm, torque reduction at the lowest limit High oil pressure (above 6 bar/87 psi) is normal
value and engine shutdown at the highest lim- when starting a cold engine.
it value, with the possibility of engine shut-
down override control.
Charging indicator lamp
If run for extended periods under an extremely
light load, the engine may have difficulty in If the lamp comes on during operation:
maintaining the coolant temperature. At an in- • Check and adjust the alternator drive belts as
creased load the coolant temperature rises to the described under the corresponding mainte-
normal value. nance item. See the Maintenance section.
If the charging indicator lamp is still on, this
IMPORTANT!
could be due to an alternator fault or a fault in the
electrical system.
An excessively high coolant temperature can
damage the engine. Belt transmission
When the belt transmission is new, it may make
a squeaking noise when running. The noise is
normal and disappears after 50-100 hours of op-
eration.
The noise does not affect the service life of the
belt transmission.

OPM 100 en-GB 28

Engine shutdown Checks after running

1. Run the engine without a load for a few min-
utes if it has been run continuously with a WARNING!
heavy load.
2. Switch off the engine. Block the starting device when working on the
engine. If the engine starts unexpectedly, there is
Note: a serious risk of injury.
The battery voltage must remain on for a few There is always a risk of sustaining burns when
seconds after the 15 voltage is switched off so an engine is hot. Particularly hot parts are ex-
that the control units can store the values and haust manifolds, turbochargers, oil sumps, hot
switch to standby mode. coolant and oil in pipes and hoses.
10 prohibited engine shutdowns will cause a
torque reduction (70% of fuel quantity). Reset 1. Check that the power supply has been cut.
the engine by switching it off correctly once.
2. Top up the fuel tank. Make sure that the filler
cap and the area round the filler opening are
clean to avoid contamination of the fuel.
IMPORTANT! 3. Top up the reductant tank. Make sure that the
filler cap and the area round the filler open-
There is risk of post boiling and of damage to the ing are clean to avoid contamination of the
turbocharger if the engine is switched off with- reductant.
out cooling.
4. If there is a risk of freezing, the cooling sys-
The power must not be switched off before the tem must contain enough glycol.
engine has stopped. 5. If the temperature is below 0°C/32°F: Pre-
pare for the next start by connecting the en-
If the engine is equipped with a battery master
gine heater (if fitted).
switch and an SCR system, the SCR system must
run for a while after the ignition has been
switched off to allow it to cool down. During this IMPORTANT!
period the power must not be cut using the bat-
tery master switch. Check the coolant level following the first start.
Top up if necessary.

OPM 100 en-GB 29

Maintenance
IMPORTANT!
The maintenance programme covers a number of
points that are divided into the following sec- On delivery a Scania engine is optimised for its
tions: application. However, regular maintenance is
necessary to:
• Lubrication system
• Cooling system • prevent unplanned stops
• Air cleaner • extend the service life of the engine
• Fuel system • maximise the long-term emission perfor-
mance of the engine
• Miscellaneous
• give the best possible operating economy.

WARNING!

Block the starting device when working on the

engine. If the engine starts unexpectedly, there is
a serious risk of injury.

The maintenance programme includes the fol-

lowing:
• S maintenance: Minimum basic maintenance.
• M maintenance: More extensive mainte-
nance.
• L maintenance: Includes nearly all mainte-
nance items.
• XL maintenance: Includes all maintenance
items.
During a period, the sequence is S-M-S-L-S-M-
S-L-S-M-S-XL.

XL
L L
M M M
S S S S S S

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000
313 153

OPM 100 en-GB 30

Engines with few hours of op-

eration

IMPORTANT!

On engines with few hours of operation, mainte-

nance must be carried out annually or every 5
years.

Stand-by generator sets and the like that are not

used regularly should be test run and checked in
accordance with the manufacturer's instructions.
The following maintenance items must be car-
ried out once the engine has been warmed up to
operating temperature.
1. Checking oil level.
2. Checking coolant level.
3. Checking vacuum indicator.
4. Checking fuel level.
5. Checking for engine leaks.

Cleaning the engine

The engine must be cleaned before starting work.
Clean the engine with hot water. Also use a de-
greasing agent, if necessary.
Avoid spraying water on the engine control unit,
see illustration.

WARNING!

Beware of hot water! Use suitable protective

equipment.

Environment

The washing water must be disposed of in com-

pliance with the relevant national and interna-
tional regulations.
314 905

Clean within the marked area.

OPM 100 en-GB 31

Maintenance intervals

Daily First time at Interval (hours) At least

first start 500 500 1,000 2,000 6,000 annu- every
ally 5
S M L XL years
Lubrication system
Checking oil level X X
Changing the oil X1 X1 X1 X1 X
Cleaning the centrifugal oil
cleaner X1 X1 X1 X1 X

Renewing the oil filter X1 X1 X1 X1 X

Cooling system
Checking coolant level X X
Checking coolant antifreeze or
X X X X
corrosion protection
Cleaning the cooling system and
changing coolant X1 X

Air cleaner
Reading the vacuum indicator X
Renewing the filter element X1 X
Renewing the safety cartridge X X X
Fuel system
Checking fuel level X X
Renewing the fuel filter X1 X1 X1 X
Miscellaneous
Checking the drive belt X X X X X
Checking for leaks X X X
Checking and adjusting the
X X X
valve clearance
Renewing the reductant filter X X X
Cleaning the reductant tank filler
filter X1 X1 X1 X1
Cleaning the reductant tank ven-
tilation filter X1 X1 X1

1 More often if required.

OPM 100 en-GB 32

Biodiesel (FAME)
Scania uses the term biodiesel according to the
EN 14214 standard to refer to a renewable diesel
made from greases or oils and methanol. The
biodiesel should conform to the requirements of
European standard EN 14214. For biodiesel EN
14214 the term FAME is commonly used.
Scania XPI engines are approved for diesel ac-
cording to the EN 590 standard. EN 590 contains
up to 7% biodiesel in accordance with EN
14214.

OPM 100 en-GB 33

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

Recommended oil
Scania Oil LDF
Scania Oil LDF-2
Scania Oil LDF-3
Scania Oil E7

The engine oil must fulfil the following quality

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

Check with your oil supplier that the oil meets

these requirements.
If the engine is used in areas of the world where
lubricating oil with ACEA or API classification
is not available, the oil grade must be measured
in actual operation. In this case contact the near-
est Scania workshop.
For operation at extremely low outdoor tempera-
tures: Consult your nearest Scania representative
on how to avoid starting difficulties.

Viscosity class Outdoor temperature

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

OPM 100 en-GB 34

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

Such analysis measures the oil's TBN (Total

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

Checking oil level

Checking the oil level with the engine 2

switched off
Note:
Leave the engine off for at least 1 minute before
checking the oil level. 1

1. Remove the oil dipstick (1) and check the oil

level. The correct level is between the mini-
mum and maximum marks on the oil dip-
stick.
2. Top up with more oil (2) when the oil level is
312 506

at or below the lower mark.

Information on the correct oil type is found under

the heading Oil grade.

OPM 100 en-GB 35

Changing the oil

Note:
Renew the oil filter and clean the centrifugal oil
cleaner when changing oil.

WARNING!

Hot oil can cause burns and skin irritation. Wear

protective gloves and goggles when changing
hot oil.

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

Environment

Use a container to avoid spillage. Used oil must

be disposed of as specified in national and inter-
national law.

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

1. Unscrew the oil plug and drain the oil when

the engine is hot.
In certain engines the oil is pumped out by Max. 34 litres (9 US gallons).
means of a bilge pump. Min. 29 litres (7.7 US gallons).
2. Clean the magnet on the oil plug.
3. Refit the oil plug.
4. Top up with oil.
5. Check the level on the oil dipstick.

OPM 100 en-GB 36

Maximum angles of inclination during opera-

tion
Maximum permissible angles during operation
vary, depending on the type of oil sump; see il- 30°
lustration.
30°
30° 30°

25°

343 838
30° 30°

Labels for top-up engine oil

grade
When changing oil it is important to use the cor-
rect engine oil grade.
The oil filler cap must be clearly marked with a
label showing the top-up oil grade.
If the label is missing or if the engine oil grade is
changed, a new label must be fitted.

336 492
Label for oil grade Scania LDF-2

Parts

Oil grade Colour Part No.

Scania LDF-2 Blue 2 132 424
Scania LDF-3 Red 2 132 426
Scania LDF Grey 2 269 345
ACEA E7 White 2 132 425

OPM 100 en-GB 37

Cleaning the centrifugal oil

cleaner
When cleaning the centrifugal oil cleaner there
will be some dirt deposits in the rotor cover. If
this is the case, this indicates that the rotor is
working. If it is clean and not working, the cause
must be established immediately.
If the dirt deposit exceeds 28 mm at the recom-
mended intervals, the rotor cover should be
cleaned more often.

WARNING!

The oil may be hot. Carefully remove the cover x 1.5

from the centrifugal oil cleaner.

1. Clean the cover. Unscrew the nut securing

the outer cover.
2. Let the oil run out from the rotor.
3. Lift out the rotor. Wipe off the outside. Undo
the rotor nut and unscrew it about 1.5 turns to

133 315
protect the bearing.

Note:
Take care not to damage the rotor shaft.

4. If the rotor nut is difficult to get loose, turn

the rotor upside down and fasten the rotor nut
in a vice. Turn the rotor counterclockwise
M20
1.5 turns by hand or use an M20 nut, see il-
lustration.

IMPORTANT! x 1.5
The rotor must not be put in a vice. Never strike
the rotor cover. This may cause damage resulting
in imbalance.
133 316

OPM 100 en-GB 38

5. Remove the rotor cover by holding the rotor

in both hands and tapping the rotor nut
against the table. Never strike the rotor di-
rectly as this may damage its bearings.

133 317
6. Remove the strainer from the rotor cover. If
the strainer is stuck, insert a screwdriver be-
tween the rotor cover and strainer and care-
fully prise them apart.

127 878

OPM 100 en-GB 39

7. Remove the paper insert and scrape away

any remaining dirt deposits inside the rotor
cover. If the deposits are thicker than 28 mm,
the centrifugal oil cleaner must be cleaned
more often.

333 044
8. Wash the parts.
9. Inspect the 2 nozzles on the rotor. Ensure that
they are not blocked or damaged. Renew any
damaged nozzles.
10. Check that the bearings are undamaged.

333 037

OPM 100 en-GB 40

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

tor cover.

2 3 4

337 178

OPM 100 en-GB 41

12. Fit the strainer onto the rotor.

13. Fit a new O-ring by sliding it over the strain-
er.
14. Refit the rotor cover. Ensure that the O-ring
is not outside the cover.
15. Screw the rotor nut back on by hand.
16. Check that the shaft is not damaged or loose.
If the shaft is damaged, it should be renewed.
Secure the shaft with thread-locking fluid
561 200 if it is loose. First clean thoroughly
using a suitable solvent. Tighten the rotor
shaft using socket wrench 99 520.

127 881
Tightening torque
Up to engine serial number 6 841 927: 27
Nm.
From engine serial number 6 841 928: 45
Nm.
Tool 588 651 or 2 259 530 together with a
ratchet head is suitable for use during main-
tenance.
Note:
Take care not to damage the rotor shaft.

OPM 100 en-GB 42

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

sure it rotates easily.

127 882
18. Fit a new O-ring in the cover. Refit the cover
and tighten the lock nut. Tightening torque
20 Nm.

IMPORTANT!

To reduce the risk of oil leakage it is important to

tighten the cover to the correct tightening torque.

Note:
Tool 588 651 or 2 259 530 together with a ratch-
et head is suitable for use during centrifugal oil
cleaner maintenance.
333 043

OPM 100 en-GB 43

Operational testing
Operational testing need only be carried out if it
is suspected that the centrifugal oil cleaner is not
working properly. For example, if there is an ab-
normally small amount of deposit in the centrif-
ugal oil cleaner in relation to the distance driven.
The rotor rotates very fast and should continue to
turn when the engine has stopped.
1. Run the engine until it is warm.
2. Stop the engine and listen for noise coming
from the rotor. Use your hand to feel if the

333 039
filter housing is vibrating.
3. If the filter housing is not vibrating, disman-
tle and check the centrifugal oil cleaner.

OPM 100 en-GB 44

Renewing the oil filter

IMPORTANT!

Clean the centrifugal oil cleaner when renewing

the oil filter.
Otherwise, the oil filter will be blocked and re-
sistance in the filter will increase. If this happens,
an overflow valve in the filter retainer opens and
lets the oil pass without being filtered.

1. Unscrew the filter cover with a socket

wrench with hexagon driver e.g. 36 mm
socket 588 475.

312 503
IMPORTANT!

Do not use an adjustable spanner or other open

tool as there is risk of damaging the filter cover.

2. Lift out the filter housing cover with filter el-

ement. The filter housing will drain automat-
ically once the filter has been removed.

3. Detach the old filter from the cover by hold-

ing the cover and carefully tapping the entire
filter element against something hard. Re-
member that there will be oil splashes.

4. Fit the new filter and tighten the filter cover

to 25 Nm (18 lbf ft).
312 502

OPM 100 en-GB 45

Cooling system
Coolant

WARNING!

Ethylene glycol can be fatal if ingested and can

cause skin irritation and eye damage.

The coolant recommended by Scania is a mix-

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

The coolant should always contain 35-55% by

volume of antifreeze and corrosion inhibitor so
that the coolant properties ensure that the coolant
works correctly.

Note:
The coolant should be changed when the cooling
system is cleaned: every 6,000 hours or at least
every 5 years. Refer to Changing coolant.

Coolant resistance to cold

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

content of 35 percent by volume. -50

°C B A
The chart depicts coolant properties at different
percents of antifreeze and corrosion inhibitor
concentration by volume.

Curve A: Ice formation starts (ice slush)

Curve B: Damage by freezing occurs
Area 1: Safe area
Area 2: Malfunctions may occur (ice slush)
Area 3: Risk of damage by freezing

OPM 100 en-GB 46

Antifreeze and corrosion inhibitor con-

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

For calculation Adequate protection against corrosion

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

OPM 100 en-GB 47

Antifreeze and corrosion inhibitor con-

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

For calculation Adequate protection against corrosion

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

OPM 100 en-GB 48

Checking coolant level Checking antifreeze and cor-

The following instructions apply to Scania ex- rosion inhibitor
pansion tanks. For other types of expansion
Note:
tanks, follow the manufacturer's instructions.
Use only pure fresh water that is free from parti-
cles, sludge and other impurities.
WARNING!

Never open the coolant filler cap when the en- 1. Pour a small amount of coolant into a con-
gine is hot. Hot coolant and steam may spray out tainer and check that the coolant is pure and
and cause burns. clear.
2. Change the coolant if it is contaminated or
If the cap has to be opened do it slowly and care- cloudy.
fully to release the pressure before removing the
cap. Wear gloves as the coolant is still very hot. 3. Measure the content of antifreeze and corro-
sion inhibitor with one of the following in-
struments:
1. Open the expansion tank cap and check the
coolant level.
Part No. Designation
– The right coolant level on a cold engine is
even with the lower edge of the filler neck. 588 805 Refractometer
– The right coolant level on a hot engine is 588 226 Refractometer
approximately 25 mm (1 in) over the low-
er edge of the filler neck.
2. Top up with coolant as necessary. The following rules apply to ethylene glycol-
based coolant:
IMPORTANT! • The antifreeze and corrosion inhibitor content
must be minimum 35 percent by volume for
Do not top up large quantities of coolant through corrosion protection to be sufficient.
the expansion tank. Top up in accordance with • An antifreeze and corrosion inhibitor content
the instructions in the section headed Changing greater than 55 percent by volume impairs the
coolant instead. ability to protect against frost.
• If ice forms in the coolant, there are disrup-
tions initially, but there is no immediate risk
IMPORTANT! of damage. The engine should not be subject-
ed to heavy loads when ice starts to form.
Never fill a large amount of cold coolant in a hot
engine. There is great risk of cracks forming in
the cylinder block and cylinder heads.

IMPORTANT!

Only pour pre-mixed coolant into the cooling

system.

OPM 100 en-GB 49

Antifreeze and corrosion in-

hibitor
Only the product Scania coolant, or other prod-
ucts that are tested to provide proper antifreeze
and protection against corrosion for Scania, may
be used in Scania engines. Products that do not
satisfy the requirements for use in a Scania en-
gine can result in faults in and damage to the
cooling system. This can lead to the invalidation
of Scania's warranty for faults and damage
caused by the use of inappropriate coolant.
The antifreeze and corrosion inhibitor used in
Scania engines should be of the ethylene glycol
type.

Scania concentrate
Designation Contents Part No. Vol- Volume
ume
(litres) (US gallons)
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 323 5 1.3
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 324 20 5.3
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 325 210 55
Coolant Antifreeze and corrosion inhibitor (concentrate) 1 894 326 1,000 264

Scania Ready Mix

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

OPM 100 en-GB 50

Changing coolant

Environment

Avoid spillage and use a suitable container. Used

coolant must be disposed of as specified in na-
tional and international law.

IMPORTANT!

Mix the coolant as specified under the section

Coolant.

1. Remove the expansion tank cap.

2. Drain the coolant at the following two
points:
– Lowest point of the cylinder block.
– The lowest point of the cooling system.
3. Close the drain taps.

OPM 100 en-GB 51

Filling coolant
1. Connect the hose from unit 588 540 to the
engine's drain valve.
2. Ensure that the cooling system bleed pipes
are not blocked or damaged. There are bleed

307 399
pipes from the radiator, engine and expan-
sion tank.
Unit 588 540
3. Open the expansion tank cap.
4. Pump in coolant using coolant unit 588 540.
Fill with coolant to the max. level of the ex-
pansion tank.
5. Disconnect the hose.
6. Set the heating control to maximum heating
and start the engine. Idling speed must not
exceed 600 rpm. Leave the engine idling for
15 minutes.
7. Stop the engine and top up with coolant to
the maximum level through the expansion
tank.
8. Air pockets may still be left in the cooling
system, which will disappear after the engine
has been operated for a period of time. It
may, therefore, need some topping up to start
with.

IMPORTANT!

When it is necessary to fill a large quantity of

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

OPM 100 en-GB 52

Cleaning the cooling system Internal: Removing oil and grease

1. Run the engine until it has reached operating
Note: temperature and then drain the cooling sys-
Clean the cooling system more often than speci- tem.
fied in the maintenance interval if necessary. 2. Remove the thermostats.
3. Fill the system with clean, hot water mixed
with liquid dishwasher detergent intended
for household machines. Concentration 1%
(0.1/10 l).
4. Warm up the engine for approximately 20-30
IMPORTANT! minutes. Remember to switch on the cab
heating system, if one is installed.
Do not use caustic soda or other alkaline deter-
gent as this could damage the aluminium. 5. Drain the cooling system.
6. Fill the system with clean, hot water and run
the engine for about 20-30 minutes.
7. Drain the water from the cooling system.
8. Refit the thermostats.

External: Cleaning the radiator and 9. Fill the cooling system with new coolant fol-
charge air cooler lowing the specification under Coolants ear-
lier in the document.
1. Check that the radiator and the charge air
cooler are not clogged on the air side and that
the cooling fins are not damaged.
2. Carefully scrape away any deposits from the
radiator cooling fins. Use a paraffin-based
engine cleaner if necessary. Environment
3. Carefully straighten bent cooling fins using a
Avoid spillage and use a suitable container. Used
steel brush or the like.
coolant must be disposed of as specified in na-
tional and international law.

WARNING!

To ensure proper handling of cooling system de-

tergent, study the warning text on the package.

OPM 100 en-GB 53

Internal: Removing deposits

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

Environment

Avoid spillage and use a suitable container. Used

coolant must be disposed of as specified in na-
tional and international law.

OPM 100 en-GB 54

Air cleaner

Reading the vacuum indicator

If the indicator's red plunger is fully visible, re-
new or clean the air cleaner filter element follow-
ing the instructions.

Renewing the filter element

326 671
Note:
Renew the filter element earlier than the mainte- A B
nance interval if the indicator shows red.

There is always a risk that the filter element will

be damaged when it is cleaned.
The filter element must not be cleaned in water
or be blown clean with compressed air.

WARNING!

336 100
Never start the engine without the air filter as this A Vacuum indicator
could cause injury and severe engine damage. B Filter element

1. Remove the cover from the air cleaner.

2. Renew the filter element.
3. Carry out a check by inserting an inspection
lamp into the element and checking from the
outside that there are no holes or cracks in the
filter paper.
4. Assemble the air cleaner.
5. Reset the vacuum indicator by pressing the
button.

OPM 100 en-GB 55

Renewing the safety cartridge

IMPORTANT!

When renewing the safety cartridge, take great

care to ensure that no dirt or other impurities get
into the engine. Do not remove the safety car-
tridge unnecessarily.

1. Remove the cover from the air cleaner.

2. Remove the filter element.
3. Remove the safety cartridge.
4. Fit a new safety cartridge.
5. Renew or clean the filter element.
6. Assemble the air cleaner.

OPM 100 en-GB 56

Fuel system
Sulphur content in fuel and its effect on oil
change interval
• A sulphur content of 0-500 ppm in the fuel
gives an oil change interval of up to 500
hours.

Note:
More than 15 ppm sulphur content must only be
used where Stage 3A/Tier 3 or less restrictive
emission laws apply.

General information on the

XPI system

WARNING!

The fuel system is very sensitive to dirt. It is

therefore very important that everything is as
clean as possible when work is carried out on the
fuel system.
• Do not use compressed air to blow compo-
nents in the fuel system clean.
• Use lint-free cloths for cleaning.
• Clean tools before use.
• Do not use worn chrome-plated tools as
flakes of chrome may come off.
• Plug or tape connections on components
which are removed.

Checking fuel level

• Check the fuel level and top up with fuel as
necessary.

Note:
The fuel system must be bled if the tank has been
run dry. Refer to the Bleeding the fuel system
section.

OPM 100 en-GB 57

Renewing the fuel filter with

draining nipple

Tool No. Designation Illustration

588 475 Socket

118 268
On certain engines, there is a draining nipple (1)
on the fuel filter housing. If there is no draining
nipple, see Renewing the fuel filter using a suc-
tion tool or Renewing the fuel filter if there is no
suction tool.
If the fuel tank is positioned higher than the fuel
filter housing, the shut-off valve between the fuel
tank and the fuel filter housing must be closed.
This is to prevent fuel running into the fuel filter
housing.

Environment 1
Avoid spillage and use a suitable container. Used
fuel must be disposed of as specified in national

351 550
and international law.

1. Open the draining nipple (1).

2. To ensure that the filter housings are drained
properly, the filter covers must be removed
as follows:

• On the pressure filter: Make a mark on the A B

cover. Unscrew the cover 3 to 4 turns using a
closed tool with hexagon driver, e.g. 588 475.
• On the water separating suction filter: Make a
mark on the cover. Unscrew the cover 3 to 4
turns using a closed tool with hexagon driver,
e.g. 588 475.
329 083

A Water separating suction filter.

B Pressure filter.

OPM 100 en-GB 58

• Wait at least 2 minutes to ensure the filter

housings have drained properly.
• On the pressure filter: Unscrew the filter cov-
er and lift it up slowly with the filter element.
• On the water separating suction filter: Un-
screw the filter cover and lift it up slowly with
the filter element.

The remaining fuel will drain out of fuel filter

housing automatically once the filter elements
have been removed.
3. Check that no fuel or particles remain in the
bottom of the filter housings. Draw off re-
maining fuel and any particles.

IMPORTANT!

It is important to remove remaining fuel and par-

ticles from the filter housings to prevent fuel sys-
tem contamination.

4. Undo the old filter elements from the covers

by carefully bending them to one side.
5. Close the draining nipple.
6. Open the shut-off valve between the fuel
tank and the fuel filter housing if it has been
closed.

OPM 100 en-GB 59

Renewing the fuel filter using

a suction tool
Removing

Tool No. Designation Illustration

588 475 Socket

118 268
588 793 Suction tool

337 296
Environment

Avoid spillage and use a suitable container. Used

fuel must be disposed of as specified in national
and international law.

To ensure that the filter housings are drained

properly, the filter covers must be removed as
follows:

IMPORTANT! A B
Start with the water separating suction filter (A)!
Do not open the pressure filter cover (B) until the
filter housing for the water separating filter (A) is
completely drained.
329 083

A Water separating suction filter.

B Pressure filter.

OPM 100 en-GB 60

IMPORTANT! A

Do not use an adjustable spanner or other open

tool to undo the filter covers, as this risks damag-
ing the filter covers.

1. Make a mark on the water separating suction

filter cover (A). Unscrew the cover 3 to 4
turns using a socket wrench with hexagon

329 084
driver, e.g. 588 475.

IMPORTANT!

Wait a minimum of 2 minutes to allow as much

of the fuel as possible to drain out of the filter
housing.

A
2. Unscrew the filter cover (A) and lift it up
slowly with the filter element.
3. Make sure the suction tool is completely
drained before starting work. Draw out re-
maining fuel and any particles using suction
tool 588 793 or a similar tool.
4. Keep the suction tool hose in the filter hous-
ing for the water separating suction filter (A).

329 085
5. Make a mark on the pressure filter cover (B).
Unscrew the cover 3 to 4 turns, using a sock-
et wrench with hexagon driver, e.g. 588 475.
Draw out fuel which may drain into the water B
separating suction filter housing when the
pressure filter is detached.

IMPORTANT!

Wait a minimum of 2 minutes to allow as much

of the fuel as possible to drain out of the filter
329 086

housing.

OPM 100 en-GB 61

6. Unscrew the pressure filter cover (B) and lift

it up slowly with the filter element. B
7. Fuel from the pressure filter housing (B) will
flow into the water separating suction filter
housing (A). Leave the suction tool in the
water separating suction filter housing (A)
A
until it is completely drained of fuel.

329 087
8. Move the suction tool to the pressure filter
housing (B). Draw out remaining fuel and
particles.

B
IMPORTANT!

It is important to remove remaining fuel and par-

ticles from the filter housings to prevent fuel sys-
tem contamination.

9. Undo the old filter elements from the covers

329 088
by carefully bending them to one side.

OPM 100 en-GB 62

Bleeding the fuel system us-

ing a suction tool
Tool No. Designation Illustration
588 793 Suction tool

337 296
1. Open the bleed nipple at the high pressure
pump and connect a clear plastic hose from
suction tool 588 793 or similar tool.
2. Drain the suction tool. Hold the suction tool
straight and draw out a full container of fuel.
Bleeding is now complete.
3. Start the engine.

329 119

OPM 100 en-GB 63

Miscellaneous
Checking the drive belt

IMPORTANT!

Refit the drive belt with the same direction of ro-

tation as it had before removal.

Check the drive belt thoroughly, particularly at

the idler rollers.

312158
Check the drive belt for cracks.

106 229

The drive belt must be renewed if it has cracks.

OPM 100 en-GB 64

Check drive belt wear.

112 931
The drive belt is starting to become worn, but can be
refitted.

112 932
The belt is worn down to the cord. The drive belt
Checking for leaks must be renewed.
1. Start the engine.
2. Check for oil, coolant, fuel, air or exhaust
leaks.
3. Tighten or renew leaking connections.
Check the overflow holes which show
whether the O-rings between the cylinder
liners and crankcase are leaking.
4. Check whether the drain hole on the coolant
pump is blocked. If there is a leak, renew the
seal in the pump or the complete coolant
pump.

IMPORTANT!

If serious leakage occurs, contact your nearest

workshop.

OPM 100 en-GB 65

Checking and adjusting the

valve clearance
Note:
Checking and adjusting valve clearances should
also be done one more time after the first 500
hours of operation. Then the normal interval will
follow (every 2,000 hours).

Valve clearances should be adjusted when the

engine is cold, at least 30 minutes after running.

WARNING!

Block the starting device when working on the

engine. If the engine starts unexpectedly, there is
a serious risk of injury.

Intake valve clearance 0.45 mm (0.018 in)

Exhaust valve clearance 0.70 mm (0.028 in)

Readings can be taken from the flywheel through

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

Openings for taking readings on the flywheel hous-

ing.

OPM 100 en-GB 66

312 879
Special tool 99 309 is used when turning from be-
low.

312 878
Special tool 99 109 is used when turning from
above.

From below Valve transition Valve adjust- From above

ment
TDC down 1 TDC up
72/432 5 252/612
144/504 2 324/684
216/576 3 36/396
288/648 4 108/468
TDC down 1 TDC up
72/432 5 252/612
144/504 2 324/684
216/576 3 36/396
288/648 4 108/468

• Turn the flywheel in the engine's direction of

rotation so that TDC up or TDC down is vis-
ible in the flywheel housing window.

• If there is valve clearance on cylinder 1, start

valve adjustment as indicated in the table.
• If there is valve transition on cylinder 1, work
should start at row six of the table. 1 2 3 4 5
Tightening torque for lock nut 35 Nm (26 lbf ft).
319 704

OPM 100 en-GB 67

Renewing the reductant filter

1. Remove the cover on the rear of the reduct-
ant tank.

316 163
2. Place a suitable container underneath.
3. Unscrew the filter cover. Use a 46 mm sock-
et.
4. Remove the filter cover and O-ring.

326 565

OPM 100 en-GB 68

5. Remove the frost protection device (C) and

the filter (B).

6. Wipe the pump clean (A).

7. Fit the new filter (B).
8. Fit the new frost protection device (C).
9. Lubricate the threads with the spray.
A
10. Fit the new O-ring (D) in the new cover (E).
11. Check that the frost protection device and
valve ring are correctly fitted in the new cov-
er.
12. Fit the new cover and tighten to 80 Nm (59 B
lbf/ft).

336 879
A Pump
B Filter
C Frost protection device
D O-ring
E Cover

OPM 100 en-GB 69

Cleaning the reductant tank

filler filter
Make sure that the filler filter (1) is clean. If it is
dirty: Clean the filler filter with clean water and 1
refit it.

350 114
Cleaning the reductant tank
ventilation filter
Make sure that the ventilation filter (2) is clean.
If it is dirty: Clean the ventilation filter with
clean water and refit it. 2

352 009

OPM 100 en-GB 70

Diesel Sulphur content of fuel

Composition of the fuel It is important to use low-sulphur fuel

It is important for sulphur-free or ultra-low sul-
The composition of the fuel is extremely impor- phur fuel to be used on engines with SCR sys-
tant for the operation and service life of the en- tems certified in accordance with Stage III B/
gine and injection system. The engine output and Tier 4i and Stage IV/Tier 4f to ensure that the
exhaust gases are also dependent on the fuel engine operates correctly. Use of the wrong fuel
grade. grade can cause damage to the engine and the ex-
The requirements and testing standards for the haust gas aftertreatment system.
most important characteristics are described in From January 2011 legislation in the USA and
the Workshop Manual which can be ordered Europe requires all diesel engines not used on the
from Scania dealers or directly from Scania. road to be run on sulphur-free or ultra-low sul-
The table shows some of the key properties. phur fuel.

Property Requirements REQUIREMENT!

Viscosity at 40°C 2.0-4.5 cSt In Europe, the fuel should be sulphur-free ac-
(104°F) cording to standard EN 590. This means that the
Density at 15°C (59°F) 0.82-0.86 cSt sulphur content must not exceed 10 ppm.
Ignitability (CET rating) minimum 49 In the USA the fuel must be an ultra-low sulphur
Flashpoint 56°C (132°F) fuel in accordance with standard ASTM D975.
Particulate contamina- ISO 11500, This means that the sulphur content may not ex-
tion level ceed 15 ppm.
class 22/20/17

Responsibility

IMPORTANT!

The machine operator is responsible for using

the correct type of fuel to ensure that local laws
are complied with.

OPM 100 en-GB 71

Permitted sulphur content in fuel

Engine type Max. sulphur content in fuel for Note

unaffected oil change intervals
Engines without EGR and SCR Up to 2,000 ppm (0.2%) If the sulphur content is higher than
2,000 ppm, the oil change intervals
must be halved. A higher sulphur
content than 4,000 ppm is not per-
mitted, since this will result in en-
gine damage.
Engines with SCR only Up to 500 ppm (0.05%) A higher sulphur content than 15
ppm may only be used where
Stage III A/Tier 3 or less restrictive
emission laws apply.
Engines with both EGR and SCR Up to 350 ppm (0.035%) A higher sulphur content than 15
ppm may only be used where
Stage III A/Tier 3 or less restrictive
emission laws apply. A higher sul-
phur content than 350 ppm is not
permitted, since this will result in
engine damage.

Fuel with a higher sulphur content

than 15 ppm for engines with SCR
systems
If fuel with a higher sulphur content that that
specified in the standard is used on a short-term
basis, this will not cause permanent damage to a
catalytic converter. The catalytic converter may,
however, require fuel with a low sulphur content
for some time after this to regain its normal effi-
ciency.
If fuel with too high a sulphur content is used for
a prolonged period, there is a risk that the cata-
lytic converter will not operate correctly, which
will result in a reduction in engine torque.

OPM 100 en-GB 72

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

IMPORTANT!

Mixing kerosene or other paraffins with the fuel

is prohibited. The injectors may be damaged.
Mixing petrol with the fuel is prohibited. In the
long term petrol can cause wear in the injectors
and engine.

OPM 100 en-GB 73

Reductant for SCR Properties

Reductant is a urea solution normally known as Reductant in accordance with ISO 22241 is a
AdBlue, DEF or ARLA 32 depending on the solution consisting of urea and water containing
market. With SCR, the reductant is added to the 32.5% by weight of urea. The solution will
exhaust gases before the catalytic converter. This freeze at approx. -11°C. When the solution freez-
reduces nitrogen oxide emissions. es, ice and urea always maintain the same con-
centration. Always store reductant at a
temperature between -11°C and 30°C.

Responsibility and quality re- Rec. % by weight of Limit value according

quirements urea to ISO 22241
32.5% 31.8-33.2%
IMPORTANT!
Reductant is normally colourless if no dye has
The machine operator is responsible for using been added. It is not harmful to the skin. Nor is it
the correct type of reductant to ensure that local toxic in small quantities, but it tastes very un-
laws are complied with. pleasant.
Reductant has a low surface tension and rapidly
spreads over large areas, which then become
very slippery. Reductant is extremely corrosive,
REQUIREMENT! especially to aluminium and copper. Therefore,
wash off any spillages on metal and electrical
In order for the emission control to meet the connections as soon as possible. Water works
emission requirements set by the public authori- very well for cleaning purposes. Please use hot
ties, the reductant should be specified in accord- water.
ance with ISO 22241.
Reductant can dry out and form white or greyish
brown crystals or deposits. Dense deposits which
have been formed as a result of heat may need to
be scraped off or heated to more than 500°C.

OPM 100 en-GB 74

Preparing the engine for Preservative coolant

storage If the engine is to be stored with a full cooling
system, use coolant containing 50 percent glycol
If the engine is not being used for an extended by volume. Glycol without nitrite-based inhibi-
period its cooling system, fuel system and com- tor should be used. Example: BASF G48 or
bustion chamber and outside must be protected BASF D542.
against rust.
An alternative to preparing the engine for long- WARNING!
term storage is to start the engine and warm it up
every 6 months.
Ethylene glycol can be fatal if ingested. Avoid
contact with the skin.

Handling the engine

The engine can normally stand idle for up to 6
months without preparation. For longer periods Preservative fuel
of downtime, the following measures should be
taken. These measures provide protection for ap- Use diesel mixed with Lubrizol 560H or the
proximately 4 years. equivalent. Mix 1 cm3 (ml)/0.06 in3 Lubrizol
560H in 10 dm3/2.3 US gallons of fuel.
Preparations for storage:
1. Thoroughly clean the engine. WARNING!
2. Run the engine for a specific period using
special preservative fuel, oil and coolant. Lubrizol 560H contains aromatic hydrocarbons
3. Otherwise prepare the engine for storage (fil- which are hazardous to health.
ter renewal, lubrication, etc.).
• Use spot extractors where there is a danger of
If the engine is equipped with an SCR system: vapour build-up.
The reductant in the SCR system is perishable. If • Wear protective goggles and gloves when
it is not used, its quality can deteriorate over handling the fuel.
time. The reductant tank and the system should • Do not use contaminated clothing.
be drained if there are longer periods of down-
time. • If it gets in your eyes: Flush with a gentle jet
of water for at least 15 minutes and contact a
doctor.
IMPORTANT! • If it gets on your skin: Wash with soap and
water.
Reductant is a highly corrosive fluid which must
not come into contact with materials which are • If you inhale it: Fresh air, rest and warmth.
sensitive to corrosion. • Store in well-sealed containers in a dry, cool,
place out of the reach of children.
Rinse off reductant spillages with plenty of wa-
ter. Lubrizol is flammable and has a 2A fire rating.
The flashpoint is 27 °C/81°F. In case of fire: Ex-
If reductant seeps into electrical connections or tinguish with carbon dioxide, powder or foam.
electrical cables, these must be renewed.

OPM 100 en-GB 75

Preservative oil 10. Drain the preservative oil from the engine.
Fill with new engine oil immediately or
Suitable preservative oils are supplied by most when the engine is to be reused.
oil companies. Example: Dinitrol 40 or equiva-
11. Drain the coolant if the engine is not to be
lent.
stored with coolant in the system. Plug and
tape all coolant connections if the engine is
to be stored without a cooling system.
Preparations for storage 12. Air cleaner: Clean or renew the filter ele-
ment.
Environment 13. Cover air intakes and exhaust pipes.
14. Alternator and starter motor: Spray with wa-
Use a container to avoid spillage when draining ter-repellent anti-corrosive oil, CRC 226,
the oil, coolant and reductant. Dispose of used LPS1 or the equivalent.
fluids through an authorised waste disposal con- 15. Spray the outside of bright engine parts, first
tractor. with penetrating preservative oil such as
Dinitrol 25B and then with Dinitrol 112 or
1. Drain and flush the cooling system. Top up
the equivalent.
with preservative coolant. Clearly mark the engine with the storage prepa-
2. Warm up the engine on normal fuel. Stop the ration date, and state that the engine must not be
engine and drain the oil. started or cranked.
3. Renew the fuel filter. If the engine is to stand idle for more than a year:
4. Fill the engine with preservative oil up to the
minimum level on the oil dipstick. 16. Drain the reductant from the reductant tank.
5. Mix preservative fuel in a can. Detach the
fuel pipe at the feed pump suction line and
connect a hose from the can. Batteries
6. Detach the fuel pipe at the overflow valve Remove the batteries and trickle charge them at
and connect a return hose to the can. the battery charging station. This does not apply
7. Start the engine and run it at about 1,000 rpm to batteries specified as maintenance-free by the
for 20-25 minutes. manufacturer.
8. Stop the engine, remove the hoses and con- The same applies to short-term storage, even if
nect the normal fuel pipes. the engine has not been prepared for storage as
9. Remove the rocker covers and lubricate the above.
valve mechanisms with plenty of preserva-
tive oil. Refit the rocker covers. WARNING!
Note:
Wear gloves and protective goggles when charg-
Do not remove the injectors. ing and handling batteries. The batteries contain
a highly corrosive acid.

OPM 100 en-GB 76

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

When the engine is to be taken into

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

If the engine is equipped with an SCR system

which has been drained and cleaned:
8. Fill the reductant tank with reductant.

OPM 100 en-GB 77

Technical data
General data

Number of cylinders and configuration 5, straight

Working principle 4-stroke engine
Cylinder diameter (mm/in) 130/5.12
Piston stroke (mm/in) 140/5.51
Displacement (dm3/in3) 9.3/567.5
Firing sequence 1-2-4-5-3
Compression ratio
DC09 076/078/080A 18:1
DC09 084/085/086/087/089A 17:1
Other engine types 16:1
Engine direction of rotation viewed from rear Anti-clockwise
Fan direction of rotation viewed from front Clockwise
Cooling Coolant
Valve clearances, cold engine
Intake valve (mm/in) 0.45/0.018
Exhaust valve (mm/in) 0.70/0.028
Number of teeth on the flywheel 158
Low idling speed (rpm) 600-750
Maximum full-load speed (rpm) 2,100
Fuel Diesel
Approximate weight, without coolant and oil (kg/lb)
DC09 084/085/086/087/089A 975/2,150
Other engine types 950/2,094

Lubrication system

Oil volume See Maintenance

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

OPM 100 en-GB 78

Injection system

Type XPI (Extra High Pressure Injec-

tion)
Engine management system EMS
Fuel filter Paper filter from Scania
Fuel filter with water separator Paper filter from Scania

Cooling system

Coolant volume, excluding radiator (dm3/US gallons)

DC09 084/085/086/087/089/384/385/386/387/389A 16/4.2
Other engine types 15/4.0
Coolant volume including 1.1 m2 radiator (dm3/US gallons)
DC09 084/085/086/087/089/384/385/386/387/389A 38/10.0
Other engine types 37/9.8
Coolant temperature (°C/°F) 90-95/194-203
Number of thermostats 1
Thermostat opening temperature (°C/°F) 80/176 and 87/189

Intake system

Permissible pressure drop in the intake system with cleaned or new 30

filter (mbar)
Permissible pressure drop in the intake system with blocked (dirty) 65
filter (mbar)

Electrical system

Type 1-pin, 24 V, DC
Starter motor, standard equipment 1-pin, 24 V, 6 kW
Alternator, standard equipment 1-pin, 28 V, 100 A

OPM 100 en-GB 79

Scania Assistance
Wherever you are, you can always get assistance
from the Scania service organisation, Scania As-
sistance, all day, every day of the year.
Always call the contact for your country.

AR 0800 999 722 642 IE +353 71 9634000

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

Other countries: +46 8 52 24 24 24

Note:
Calls will be recorded for training purposes.

OPM 100 en-GB 80

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