00:23-03 Issue 5.
E2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engines with few hours of operation . . . . . . . 5 Cleaning the engine. . . . . . . . . . . . . . . . . . . . . 5 Inspection intervals . . . . . . . . . . . . . . . . . . . . . 6 Lubrication system . . . . . . . . . . . . . . . . . . . . . . 7 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Oil analysis . . . . . . . . . . . . . . . . . .
Inspection Inspection The inspection programme covers a number of points that are divided into the following sections: • • • • • Lubrication system Cooling system Air cleaner Fuel system Miscellaneous WARNING! Block the starting device when working on the engine. If the engine starts unexpectedly, there is a serious risk of injury. The inspection programme includes the following inspections: • S inspection: Minimum basic inspection. • M inspection: More extensive inspection.
Inspection • give the best possible operating economy.
Inspection Engines with few hours of operation IMPORTANT! On engines with few hours of operation, inspection must be carried out annually or every 5 years. Stand-by generator sets and the like that are not used regularly should be test run and checked in accordance with the manufacturer's instructions. The following inspection points must be carried out once the engine has been warmed up to operating temperature. 1. Checking the oil level. 2. Checking the coolant level. 3. Checking the vacuum indicator. 4.
Inspection Inspection intervals Daily Lubrication system Checking the oil level Changing the oil X First time at first start 500 X Cleaning the centrifugal oil cleaner Renewing the oil filter Cooling system Checking the coolant level Checking coolant antifreeze or corrosion protection Cleaning the cooling system and changing coolant Air cleaner Reading the vacuum indicator Renewing the filter element X Interval (hours) Minimum 500 1,000 2,000 6,000 annu- every ally 5 S M L XL years X1 X1 X1 X1
Lubrication system Lubrication system Oil grade What is Scania LDF? Scania LDF stands for the Scania Long Drain Field test standard. Approved Scania LDF oils have been carefully selected after extensive testing. The approval is only granted to the highest quality engine oils available on the market.
Lubrication system Oil analysis To be able to extend the oil change intervals using 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.
Lubrication system Changing the oil Note: Renew the oil filter and clean the centrifugal oil cleaner when changing oil. 314 603 WARNING! • Hot oil can cause burns and skin irritation. Wear protective gloves and goggles when changing hot oil. • Make sure that there is no pressure in the lubrication system before starting work on it. • The oil filler cap must always be in place when starting and running the engine to prevent oil being ejected. Max. 45 litres (11.9 US gallons) Min. 39 litres (10.
Lubrication system Maximum angles of inclination during operation 30° Maximum permissible angles during operation vary, depending on the type of oil sump; see illustration. 30° 30° 30° 25° 30° 30° 343 843 25° Labels for top-up engine oil grade When changing oil it is important to use the correct engine oil grade. The oil filler cap must be clearly marked with a label showing the top-up oil grade. 336 492 If the label is missing or the engine oil grade is changed, a new label must be fitted.
Lubrication system Cleaning the centrifugal oil cleaner When cleaning the centrifugal oil cleaner there will be some dirt deposits in the rotor cover. If this is the case, this indicates that the rotor is working. If it is not working, the cause must be established immediately. If the dirt deposit exceeds 28 mm at the recommended intervals, the rotor cover should be cleaned more often. WARNING! x 1.5 The oil may be hot. Carefully remove the cover from the centrifugal oil cleaner. 1. Clean the cover.
Lubrication system 5. Remove the rotor cover by holding the rotor 133 317 in both hands and tapping the rotor nut against the table. Never strike the rotor directly as this may damage its bearings. 6. Remove the strainer from the rotor cover. If 127 878 the strainer is stuck, insert a screwdriver between the rotor cover and strainer and carefully prise them apart.
Lubrication system 7. Remove the paper insert and scrape away 333 044 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. 8. Wash the parts. 9. Check the 2 nozzles on the rotor. Ensure that 333 037 they are not blocked or damaged. Renew any damaged nozzles. 10. Check that the bearings are undamaged.
Lubrication system 11. Fit a new paper insert on the inside of the ro- tor cover. Fit the strainer onto the rotor. 1 3 4 337 178 2 12. Fit the strainer onto the rotor. 13. Fit a new O-ring by sliding it over the strain- er. 14. Refit the rotor cover. Make sure that the Oring sits correctly on the inside. 15. Screw the rotor nut back on by hand. 16. Check that the shaft is not loose. Secure with thread-locking fluid 561 200 if it is loose. First clean thoroughly using a suitable solvent.
Lubrication system 17. Refit the rotor and rotate it by hand to make 127 882 sure it rotates easily. 18. Renew the O-ring on the cover of the oil cleaner housing and fit the cover. Tighten the lock nut to 15 Nm.
Lubrication system Operational testing A functional inspection need only be carried out if it is suspected that the centrifugal oil cleaner is not working properly. For example, if there is an abnormally small amount of deposit in the centrifugal 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. 333 039 2. Stop the engine and listen for the rotor.
Lubrication system Renewing the oil filter IMPORTANT! Clean the centrifugal oil cleaner when renewing the oil filter. 312 503 Otherwise, the oil filter will be blocked and resistance 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.
Cooling system Cooling system Coolant WARNING! Ethylene glycol can be fatal if ingested and can cause skin irritation and eye damage. The coolant recommended by Scania is a mixture of water with antifreeze and corrosion inhibitor (ethylene glycol).
Cooling system Antifreeze and corrosion inhibitor concentration table 35% by volume of 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 glycol is 35% by volume (freezing point -21 °C). According to the table, there are 14 litres of ethylene glycol in the cooling system. 3.
Cooling system Antifreeze and corrosion inhibitor concentration table 35% by volume of 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 glycol is 35% by volume (freezing point -6°F). According to the table there are 3.7 US gallons of ethylene glycol in the cooling system. 3.
Cooling system Checking the coolant level Daily The following instructions apply to Scania expansion tanks. For other types of expansion tanks, follow the manufacturer's instructions. WARNING! Never open the coolant filler cap when the engine is hot. Hot coolant and steam may spray out and cause burns. If the cap has to be opened do it slowly and carefully to release the pressure before removing the cap. Wear gloves as the coolant is still very hot. 1.
Cooling system Checking antifreeze and corrosion inhibitor Note: Use only pure fresh water that is free from particles, sludge and other impurities. 1. Pour a small amount of coolant into a con- tainer and check that the coolant is pure and clear. 2. Change the coolant if it is contaminated or cloudy. 3. Measure the content of antifreeze and corrosion inhibitor with one of the following instruments: Part No.
Cooling system Antifreeze and corrosion inhibitor Only the product Scania coolant, or other products 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 engine 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.
Cooling system Changing coolant Environment Avoid spillage and use a suitable container. Used coolant must be disposed of as specified in national and international law. IMPORTANT! Mix the coolant as specified under the section Coolant. 1. Remove the filler cap on the expansion tank. 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 taps.
Cooling system Filling coolant 1. Connect the hose from unit 588 540 to the 307 399 engine's drain valve. 2. Ensure that the cooling system bleed pipes are not blocked or damaged. There are bleed pipes from the radiator, engine and expansion 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 expansion tank. 5. Disconnect the hose. 6. Set the heating control to maximum heating and start the engine.
Cooling system Cleaning the cooling system Note: Clean the cooling system more often than specified in the inspection programme if necessary. IMPORTANT! Do not use caustic soda or other alkaline detergent as this could damage the aluminium. External: Cleaning the radiator and charge air cooler 1. Check that the radiator and the charge air cooler are not clogged on the air side and that the cooling fins are not damaged. 2. Carefully scrape away any deposits from the radiator cooling fins.
Cooling system Internal: Removing oil and grease 1. Run the engine until it has reached operating temperature and then drain the cooling system. 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 minutes. Remember to switch on the cab heating system, if one is installed. 5. Drain the cooling system. 6.
Cooling system Internal: Removing deposits 1. Run the engine until it has reached operating temperature and then drain the cooling system. 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 concentration and cleaning period. 4. Run the engine for the specified time.
Air cleaner Air cleaner Reading the vacuum indicator 326 671 If the indicator's red plunger is fully visible, renew or clean the air cleaner filter element following the instructions. Renewing the filter element Note: Renew the filter element earlier than the inspection interval if the indicator shows red. A B There is always a risk that the filter element will be damaged when it is cleaned. The filter element must not be cleaned in water or be blown clean with compressed air.
Air cleaner 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 cartridge 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.
Fuel system 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 fuel system IMPORTANT! The fuel system is very sensitive to dirt. It is therefore important that everything is as clean as possible when work is carried out on the fuel system.
Fuel system Renewing the fuel filter Engines with XPI have dual fuel filters in the form of a water separating suction filter and a pressure filter. Removing Designation 588 475 Socket 588 793 Suction tool Illustration 337 297 118 268 Tool No. Environment Avoid spillage and use a suitable container. Used fuel must be disposed of as specified in national and international law.
Fuel system IMPORTANT! A Do not use an adjustable spanner or other open tool to undo the filter covers, as this risks damaging the filter covers. 1. Make a mark on the water separating suction 329 084 filter cover (A). Unscrew the cover 3 to 4 turns using a socket wrench with hexagon 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. 2.
Fuel system 5. Make a mark on the pressure filter cover (B). Unscrew the cover 3 to 4 turns using a socket wrench with hexagon driver, e.g. 588 475. Draw out fuel which may drain into the water separating suction filter housing when the pressure filter is detached. B IMPORTANT! 329 086 Wait a minimum of 2 minutes to allow as much of the fuel as possible to drain out of the filter housing. B 6. Unscrew the pressure filter cover (B) and lift it up slowly with the filter element. 7.
Fuel system Fitting Designation Socket Illustration 118 268 Tool No. 588 475 1. Unpack the new filter elements and the sup- plied O-rings. IMPORTANT! Check that there is no remaining packaging material stuck to the new filter elements. 2. Fit the new O-rings to the covers. Lubricate the O-rings with O-ring grease 2 002 537. 3. Press the filter elements into the snap fasteners on the covers.
Fuel system Bleeding the fuel system Designation Suction tool Illustration 337 297 Tool No. 588 793 1. Open the bleed nipple at the high pressure 329 119 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.
Miscellaneous Miscellaneous Checking the drive belt IMPORTANT! Refit the drive belt with the same direction of rotation as it had before removal. 312158 Check the drive belt thoroughly, particularly at the idler rollers. 106 229 Check the drive belt for cracks. The drive belt must be renewed if it has cracks.
Miscellaneous 112 931 Check drive belt wear. 112 932 The drive belt is starting to become worn, but can be refitted. The belt is worn down to the cord. The drive belt must be renewed.
Miscellaneous Checking for leaks 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.
Miscellaneous Option 1 Special tool 99 309 is used when turning from below. Special tool 99 109 is used when turning from above. From below Valve transition TDC down 120/480 240/600 TDC down 120/480 240/600 6 2 4 1 5 3 Valve adjustment 1 5 3 6 2 4 From above TDC up 300/660 60/420 TDC up 300/600 60/420 1. Turn in the engine's direction of rotation so that TDC down or TDC up is visible in the flywheel housing window. 2. Check the valve transition and start adjusting as indicated in the table.
Miscellaneous Option 2 Set cylinder 1 exactly at TDC after the compression stroke. Adjust the following valves: Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. 5 Intake and exhaust Intake Exhaust Intake Exhaust Turn the crankshaft exactly one revolution. Adjust the following valves: Exhaust Intake Exhaust Intake Intake and exhaust 00:23-03 en-GB 1 2 3 4 5 6 319 705 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. 5 Cyl.
Miscellaneous Renewing the reductant filter 1. Remove the cover on the rear of the reduct- 316 163 ant tank. 2. Place a suitable container underneath. 3. Unscrew the filter cover. Use a 46 mm sock- 326 565 et. 4. Remove the filter cover and O-ring.
Miscellaneous 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 cover. 12. Fit the new cover and tighten to 80 Nm (59 lbf/ft).
Miscellaneous Cleaning the reductant tank filler filter Make sure that the filler filter is clean. If it is dirty: Clean the filler filter with clean water and refit it. Cleaning the reductant tank ventilation filter Make sure that the ventilation filter is clean. If it is dirty: Clean the ventilation filter with clean water and refit it.
