00:23-03 Issue 7.
E2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cleaning the engine. . . . . . . . . . . . . . . . . . . . . 4 Engines with few hours of operation . . . . . . . 5 Maintenance interval. . . . . . . . . . . . . . . . . . . . 6 Lubrication system . . . . . . . . . . . . . . . . . . . . . . 7 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Oil analysis . . . . . . . . . . . . . . . . . . . . .
Maintenance Maintenance IMPORTANT! The maintenance programme covers a number of points that are divided into the following sections: • • • • • On delivery a Scania engine is optimised for its application. However, regular maintenance is necessary to: Lubrication system Cooling system Air cleaners Fuel system Other • prevent unplanned stops • extend the service life of the engine • maximise the long-term emission performance of the engine • give the best possible operating economy.
Maintenance Cleaning the engine WARNING! Beware of hot water. Use suitable protective equipment. Environment The washing water must be disposed of in compliance with the relevant national and international regulations. The engine must be cleaned before starting work. 312 152 Clean the engine with hot water. Also use a degreasing agent, if necessary. Avoid spraying water on the engine control unit, see illustration. Clean within the marked area.
Maintenance Engines with few hours of operation IMPORTANT! On engines with few hours of operation, maintenance 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 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.
Maintenance Maintenance interval Daily First time at first start 500 R Lubrication system Checking the oil level Changing the oil Cleaning the centrifugal oil cleaner Renewing the oil filter Cooling system Checking the coolant level Checking coolant antifreeze and corrosion protection Changing the coolant and cleaning the cooling system Air cleaners Reading the air cleaner vacuum indicator Renewing the air cleaner filter element Renewing the air cleaner safety cartridge Fuel system Checking the fuel leve
Lubrication system Lubrication system Oil grade 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. Recommended oil Scania Oil LDF-3 Scania Oil LDF-2 Scania Oil LDF Scania Oil E7 The engine oil must fulfil the following quality requirements: • ACEA E5/API CI-4 • ACEA E7/API CI-4+ for fuel with maximum 15 ppm sulphur content (0.
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 WARNING! Hot oil can cause burns and skin irritation. Wear protective gloves and eye protection 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. Note: Renew the oil filter and clean the centrifugal oil cleaner when changing oil.
Lubrication system Maximum angles of inclination during operation 30° Maximum permissible angles during operation vary, depending on the type of oil sump; see illustration.
Lubrication system Labels for top-up engine oil grade When changing oil it is important to use the correct engine oil grade. 336 492 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. 353 114 Filling label in the cylinder block. Filling label in the rocker cover.
Lubrication system Cleaning the centrifugal oil cleaner WARNING! The oil may be hot. Carefully remove the cover from the centrifugal oil cleaner. Illustration 364 731 Tools Torque wrench 2-20 Nm with exchangeable ratchet head 364 729 Ratchet head When the centrifugal oil cleaner is cleaned, there should be some dirt deposits in the rotor cover. This indicates that the rotor is working. If the rotor cover is clean, in other words the rotor is not working, the cause must be established immediately.
Lubrication system 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 anti-clockwise 1.5 turns by hand or use an M20 nut, see illustration. M20 IMPORTANT! The rotor must not be put in a vice. Never strike the rotor cover. This may cause damage resulting in imbalance. 133 316 x 1.5 5. Remove the rotor cover by holding the rotor 133 317 in both hands and tapping the rotor nut against the table.
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 (1.1 in), 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. Renew damaged bearings. 11. Fit a new paper insert inside the rotor cover.
Lubrication system 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 edges. 15. Screw the rotor nut back on by hand. 16. Check that the shaft is not damaged or loose. If the shaft is damaged or loose, see Workshop Manual 01-20. Note: Take care not to damage the rotor shaft. 17. Refit the rotor and rotate it by hand to make 127 882 sure it rotates easily.
Lubrication system 18. Fit a new O-ring in the cover. Refit the cover and tighten the lock nut. IMPORTANT! To reduce the risk of oil leakage it is important to tighten the cover to the correct tightening torque. From engine serial number 6 841 928: Tightening torque 20 Nm. Older engine serial number: Tightening torque 15 Nm. 333 043 Note: A torque wrench together with a ratchet head is suitable for use during maintenance of the centrifugal oil cleaner.
Lubrication system Renewing the oil filter Designation Illustration 118 268 Hexagon socket, drive 1/2", 36 mm IMPORTANT! Clean the centrifugal oil cleaner at the same time as you change the oil filter. Otherwise, the oil filter will be blocked and resistance in the filter will increase. If this happens, an overflow valve in the filter retainer opens and lets the oil pass without being filtered. 1. Unscrew the filter cover using the socket.
Air cleaners Air cleaners Reading the air cleaner vacuum indicator If the indicator's red plunger is fully visible, renew the air cleaner filter element following the instructions below. Renewing the air cleaner filter element A B This procedure applies if the engine has an air cleaner with a filter element from Scania. WARNING! 336 100 Never start the engine without the air filter as this could cause injury and severe engine damage.
Air cleaners Renewing the air cleaner safety cartridge This procedure applies if the engine has an air cleaner with a filter element from Scania. WARNING! Never start the engine without the air filter as this could cause injury and severe engine damage. IMPORTANT! When you renew 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. 4 1. Remove the cover from the air cleaner. 2. Remove the filter element.
Cooling system Cooling system Coolant resistance to cold The following example shows coolant properties with 30 percent by volume of antifreeze and corrosion inhibitor: Coolant • Ice slush starts to form at -16°C (3°F). • At -30°C (-22°F), there is a risk of cooling system malfunction. • There is no risk of damage by freezing with a minimum antifreeze and corrosion inhibitor content of 35 percent by volume. WARNING! Ethylene glycol can be fatal if ingested and can cause skin irritation and eye damage.
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. The measured concentration of ethylene glycol is 45% by volume (freezing point -30°C).
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. The measured concentration of ethylene glycol is 45% by volume (freezing point -22°F).
Cooling system Antifreeze and corrosion protection products Only Scania coolant or other products that Scania has tested to provide proper antifreeze and corrosion protection, 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 Checking the coolant level WARNING! Do not open the coolant filler cap in the expansion tank if 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. IMPORTANT! It is not permissible to top up large amounts of coolant via the expansion tank.
Cooling system Checking coolant antifreeze and corrosion protection Note: Use only pure fresh water that is free from particles, sludge and other impurities. Illustration 138008 305 523 Tools Refractometer 1. Pour a small amount of coolant into a con- tainer and check that the coolant is pure and clear. 2. Change the coolant if it is contaminated or cloudy. 3. Measure the antifreeze and corrosion inhibitor content with a refractometer.
Cooling system Changing the coolant and cleaning the cooling system Draining coolant with pump Special tools 360 625 Number, designation 2 443 679, coolant pump WARNING! Do not open the coolant filler cap in the expansion tank if the engine is hot. Hot coolant and steam may spray out and cause burns. If the cap has to be opened do it slowly to release the pressure before removing the cap. Use protective gloves as coolant can cause irritation if it comes in contact with the skin.
Cooling system Make sure that the drainage starts. If the drainage does not start: Change the position of the cable terminals. 5. Repeat the procedure at the cooling system's lowest drainage point. The location of the lowest drainage point on the engine may differ depending on engine application.
Cooling system Draining coolant with coolant trolley WARNING! Do not open the coolant filler cap in the expansion tank if the engine is hot. Hot coolant and steam may spray out and cause burns. If the cap has to be opened do it slowly to release the pressure before removing the cap. Use protective gloves as coolant can cause irritation if it comes in contact with the skin. Hot coolant can also cause scalding. Environment Use a suitable container.
Cooling system Refilling coolant with pump This procedure applies when the cooling system has been drained and needs to be filled with a large amount of coolant. Special tools 360 625 Number, designation Illustration 2 443 679, coolant pump WARNING! Use protective gloves as coolant can cause irritation if it comes in contact with the skin. Hot coolant can also cause scalding. IMPORTANT! It is not permissible to fill large amounts of coolant via the expansion tank.
Cooling system 1. Open the expansion tank cap. 2. Connect the coolant pump to the filler nipple in the cylinder block. 3. Connect the pump's 2 cable terminals to the battery's negative and positive terminal. Make sure that the filling starts. If the filling does not start: Change the position of the cable terminals. 4. Start the engine and run it at idling for 15 minutes. IMPORTANT! 352 794 It is very important that the engine is idling.
Cooling system Refilling coolant with coolant trolley This procedure applies when the cooling system has been drained and needs to be filled with a large amount of coolant. WARNING! Use protective gloves as coolant can cause irritation if it comes in contact with the skin. Hot coolant can also cause scalding. IMPORTANT! When it is necessary to fill a large quantity of coolant, it must be pumped in from underneath.
Cooling system 333 980 Designation Coolant trolley 1. Connect the hose from the coolant trolley to 352 794 the engine drain valve, see illustration. 2. Ensure that the cooling system bleed pipes are not blocked or damaged. 3. Open the expansion tank cap. 4. Fill with coolant using coolant trolley to pump up to the maximum level of the expansion tank. 5. Disconnect coolant trolley.
Cooling system Note: Idling speed must not exceed 600 rpm. Engine overspeed could damage the coolant pump shaft seal, which leads to coolant leakage. For certain applications for Scania Engines it is not possible to reduce the idling speed to 600 rpm with the Scania settings. In these cases the engine must be run at the idling speed specified by the factory settings. 6. Start the engine and run it at idling speed for 15 minutes. 7.
Cooling system External: Cleaning the radiator and charge air cooler IMPORTANT! Do not use caustic soda or other alkaline detergent as this could damage the aluminium. WARNING! To ensure proper handling of detergent, study the warning text on the packaging concerned. 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 Internal: Removing deposits Environment Environment Avoid spillage and use a suitable container. Used coolant must be disposed of as specified in national and international laws and regulations. Avoid spillage and use a suitable container. Used coolant must be disposed of as specified in national and international laws and regulations. 1. Run the engine until it has reached operating 1.
Fuel system Fuel system Cleanliness requirements IMPORTANT! The whole fuel system is very sensitive to dirt and also very small particles. Foreign particles in the system can cause serious malfunctions. It is therefore very important that everything is as clean as possible when work is carried out on the fuel system. Wash the engine before carrying out repair work. If possible, a hot wash should be used.
Fuel system Checking the fuel level • Check the fuel level and top up with fuel as necessary. Note: If the tank has been run dry or if the engine has not been used for a long time, bleed the fuel system. See the sections Bleeding the fuel system using a hand pump or Bleeding the fuel system using a suction tool.
Fuel system Renewing the fuel filter with draining nipple Removal Designation Illustration 118 268 Hexagon socket, drive 1/2", 36 mm Environment Avoid spillage and use a suitable container. Used fuel must be disposed of as specified in national and international laws and regulations. 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.
Fuel system • Wait at least 2 minutes to ensure the filter housings have drained properly. • On the pressure filter: Unscrew the filter cover and lift it up slowly with the filter element. • On the water separating suction filter: Unscrew 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.
Fuel system Fitting Designation Illustration 118 268 Hexagon socket, drive 1/2", 36 mm IMPORTANT! Check that there is no remaining packaging material stuck to the new filter elements. Fit the filter elements in the filter covers before placing them in the fuel filter housings or the filter elements may be damaged. In order to prevent back pressure in the filter housings when the filter elements are screwed on, the bleed nipple should be open. 1. Fit a new O-ring to the cover.
Fuel system Renewing the fuel filter using a suction tool Removal Designation Illustration 118 268 Hexagon socket, drive 1/2", 36 mm 337 296 Suction tool Environment Avoid spillage and use a suitable container. Used fuel must be disposed of as specified in national and international laws and regulations. To ensure that the filter housings are drained properly, the filter covers must be removed as follows: IMPORTANT! A B 329 083 Start with the water separating suction filter (A).
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, use the socket. IMPORTANT! Wait a minimum of 2 minutes to allow as much of the fuel as possible to drain out of the filter housing. 2. Unscrew the filter cover (A) and lift it up A 329 085 slowly with the filter element. 3.
Fuel system 6. Unscrew the pressure filter cover (B) and lift B it up slowly with the filter element. 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) until it is completely drained of fuel. 329 087 A 8. Move the suction tool to the pressure filter housing (B). Draw out remaining fuel and particles.
Fuel system Fitting Designation Illustration 118 268 Hexagon socket, drive 1/2", 36 mm IMPORTANT! Check that there is no remaining packaging material stuck to the new filter elements. Fit the filter elements in the filter covers before placing them in the fuel filter housings or the filter elements may be damaged. In order to prevent back pressure in the filter housings when the filter elements are screwed on, the bleed nipple should be open. 1. Fit a new O-ring to the cover.
Fuel system Bleeding the fuel system using a suction tool Illustration 337 296 Designation Suction tool 1. Open the bleed nipple at the high pressure 329 119 pump and connect a clear plastic hose from the suction tool 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. Bleeding the fuel system using a hand pump 1. Attach a clear plastic hose to the bleed nipple on the fuel filter housing.
Other Other Checking the drive belt IMPORTANT! Refit the drive belt with the same direction of rotation as it had before removal. 1. Check the drive belt thoroughly, particularly 312158 at the idler rollers. Example of a drive belt. 2. Check the drive belt for cracks. Renew the 106 229 drive belt if cracks have formed. Example of a crack in the drive belt.
Other 3. Check drive belt wear. Renew the drive belt 112 931 if it is too worn. See the illustrations. The drive belt is starting to become worn, but can be refitted. 112 932 Checking for leaks The belt is worn down to the cord. The drive belt must be renewed. IMPORTANT! If serious leakage occurs, contact your nearest Scania workshop. 1. Start the engine. 2. Check for leaks in the lubrication, coolant, fuel, intake or exhaust system. 3. Tighten or renew leaking connections.
Other Checking and adjusting the valve clearance Adjusting may be carried out in one of two ways. Either by setting TDC on the flywheel or by following the tables showing which valves can be adjusted. Or by following the tables showing which flywheel position to set to adjust all valves on a cylinder. WARNING! Block the starting device when working on the engine. If the engine starts unexpectedly, there is a serious risk of injury.
Other Note: Checking and adjusting valve clearances should also be carried out one more time after the first 500 hours of operation. Then, the normal interval follows every 2,000 hours. Valve transition occurs when the cylinder switches from exhaust stroke to intake stroke. The exhaust valve is closing while the intake valve is opening. Carry out the adjustment on a cold engine.
Other Specifications Valve clearance, intake valve Valve clearance, exhaust valve 0.45 mm (0.018 in) 0.70 mm (0.028 in) Tightening torque Lock nut for valves 346 529 Max. clearance between two valves under the same valve bridge is 0.2 mm. 35 Nm (26 lbf/ft) 1. Read the mark on the flywheel in one of the following ways: 310 343 – Turn the flywheel in the direction of rotation of the engine using turning tool 99 309. Read the mark on the flywheel in the lower window of the flywheel housing.
Other Table for valve adjustment Reading the mark on the fly- Valve transition on wheel in the lower window cylinder TDC down 120/480 240/600 TDC down 120/480 240/600 6 2 4 1 5 3 Adjust intake and Reading the mark on the flyexhaust valves on wheel in the upper window cylinder 1 TDC up 5 300/660 3 60/420 6 TDC up 2 300/660 4 60/420 2 3 4 5 6 319 705 1 Cylinder location.
Other Adjustment using TDC 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 valve and exhaust valve Intake valve Exhaust valve Intake valve Exhaust valve 1 2 3 4 3 4 6 5 O Intake valve. X Exhaust valve. Turn the crankshaft exactly one revolution. Adjust the following valves: Cyl. 2 Cyl. 3 Cyl. 4 Cyl. 5 Cyl.
Other Renewing the reductant filter Illustration 118 268 Designation Hexagon socket, drive 1/2”, 3/4”, 46 mm 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 the socket. 326 565 4. Remove the filter cover and O-ring.
Other 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). B C D 336 879 E A Pump. B Filter. C Frost protection device. D O-ring. E Cover.
Other 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 refit it. 350 114 1 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.
