Workshop Manual DC09

00:23-02
Issue 7.0 en-GB
Maintenance instructions
DC09 industrial engine with XPI
E2011
336 504
©
Scania CV AB 2016, Sweden
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Checking the oil level . . . . . . . . . . . . . . . . . . . 8
Changing the oil . . . . . . . . . . . . . . . . . . . . . . . 9
Labels for top-up engine oil grade . . . . . . . . 11
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cleaning the centrifugal oil cleaner . . . . . . . 12
Operational testing . . . . . . . . . . . . . . . . . . . . 16
Renewing the oil filter. . . . . . . . . . . . . . . . . . 17
Air cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Reading the air cleaner vacuum indicator. . . 18
Renewing the air cleaner filter element . . . . 18
Renewing the air cleaner safety cartridge . . . 19
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . 20
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Checking the coolant level . . . . . . . . . . . . . . 24
Checking coolant antifreeze and corrosion pro-
tection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Changing the coolant and cleaning the cooling
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cleanliness requirements. . . . . . . . . . . . . . . . . 35
Checking the fuel level . . . . . . . . . . . . . . . . . 36
Renewing the fuel filter with draining nipple 37
Renewing the fuel filter using a suction tool 40
Bleeding the fuel system using a suction tool 44
Bleeding the fuel system using a hand pump 44
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Checking the drive belt . . . . . . . . . . . . . . . . . 45
Checking for leaks . . . . . . . . . . . . . . . . . . . . 46
Checking and adjusting the valve clearance . 47
Renewing the reductant filter . . . . . . . . . . . . 50
Cleaning the reductant tank filler filter . . . . . 52
Cleaning the reductant tank ventilation filter 52
00:23-02 en-GB 2
© Scania CV AB 2016, Sweden
Maintenance
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 cleaners • extend the service life of the engine
• Fuel system • maximise the long-term emission perfor-
mance of the engine
• Other
• 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.
There is always a risk of sustaining burns when
an engine is hot. Particularly hot parts are turbo-
chargers, oil sumps, hot coolant and oil in pipes
and hoses.
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
00:23-02 en-GB 3
Maintenance
Cleaning the engine
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.
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.
314 905
Clean within the marked area.
00:23-02 en-GB 4
Maintenance
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 the oil level.
2. Checking the coolant level.
3. Checking the vacuum indicator.
4. Checking the fuel level.
5. Check for engine leaks.
00:23-02 en-GB 5
Maintenance
Maintenance interval
Daily First time at Interval (hours) At least

first start 500 500 1,000 2,000 6,000 annu- every
R S M L XL ally 5
years
Lubrication system
Checking the oil level X X
Changing the oil X X X X X X
Cleaning the centrifugal oil
X X X X X X
cleaner
Renewing the oil filter X X X X X X
Cooling system
Checking the coolant level X X X X X X X
Checking coolant antifreeze and
X X X X
corrosion protection
Changing the coolant and clean-
X X
ing the cooling system
Air cleaners
Reading the air cleaner vacuum
X X X X X X
indicator
Renewing the air cleaner filter
X X X
element
Renewing the air cleaner safety
X X X
cartridge
Fuel system
Checking the fuel level X X
Renewing the fuel filter X X X X
Other
Checking the drive belt X X X X X
Checking for leaks X X X X X
Checking and adjusting the
X X X
valve clearance
Renewing the reductant filter X X X X
Cleaning the reductant tank filler
X X X X
filter
Cleaning the reductant tank ven-
X X X
tilation filter
00:23-02 en-GB 6
Lubrication system
Lubrication system
Oil grade
Scania LDF stands for the Scania Long Drain
Field test standard. Scania LDF oils have been
carefully selected after extensive testing. The ap-
proval is only granted to the highest quality en-
gine oils available on the market.
Recommended oil
Scania Oil LDF-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 engines not run on low-sulphur fuel, the
TBN (Total Base Number) should be at least
12 (ASTM 2896).
• 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)
00:23-02 en-GB 7
Lubrication system
Oil analysis
To be able to extend the oil change intervals us-
ing an oil analysis, Scania LDF-2 and LDF-3 oils
must be used. Oil companies can offer analysis
of the engine oil.
The following conditions must remain fulfilled
when the oil is changed.
• Viscosity at 100°C (212°F): max. ±20% of
original value of the fresh oil.
• TBN (in accordance with ASTM D4739): >
3.5
• TBN (in accordance with ASTM D4739): >
TAN (in accordance with ASTM D664)
• Soot (DIN 51452): < 3%
Such analysis measures the oil's TBN (Total

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

Checking the oil level with the engine 2
switched off
Note:
Leave the engine off for at least 7 minutes 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.
312 506
2. Fill with more oil (2) when the oil level is at

or below the lower mark.
For information on the correct oil type, see the

Oil grade section.
00:23-02 en-GB 8
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 pres-
sure 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.
314 600
Change oil more often if the engine is subjected
to particularly demanding operation, such as a
dusty environment, or if deposits in the centrifu- Deep front, without ladder frame:
gal oil cleaner are thicker than 28 mm (1.1 in).
Min. 31 litres (8.2 US gallons).
Max. 36 litres (9.5 US gallons).
Environment
Use a container to avoid spillage. Used oil must

be disposed of as specified in national and inter-
national laws and regulations.
1. Unscrew the oil plug and drain the oil when

the engine is hot. In certain engines the oil is
pumped out by means of a bilge pump.
When draining with the valve, the oil should
be hot. Alternatively, use a pump. This is so
that draining occurs more quickly.
2. Clean the magnet on the oil plug.
314 601
3. Refit the oil plug.

4. Fill with oil.
5. Check the level on the oil dipstick. Low, without ladder frame:
Min. 28 litres (7.4 US gallons).
Max. 35 litres (9.2 US gallons).
00:23-02 en-GB 9
Lubrication system
Maximum angles of inclination during opera-

tion
30°
Maximum permissible angles during operation
vary, depending on the type of oil sump; see il- 30°
lustration. 30° 30°
25°
343 838
25° 30° 30°
00:23-02 en-GB 10
Lubrication system
Labels for top-up engine oil

grade
When changing oil it is important to use the cor-
rect engine oil grade.
The oil filler cap must be clearly marked with a
label showing the top-up oil grade. If the label is
missing or if the engine oil grade is changed, a
new label must be fitted.
336 492
Filling label in the cylinder block.
353 114
Filling label in the rocker cover.

Parts
Oil grade Colour Part No. Part No.

Filling in the cylinder Filling in the rocker cover
block
Scania LDF-2 Blue 2 132 424 2 296 064
Scania LDF-3 Red 2 132 426 2 296 066
Scania LDF Grey 2 269 345 2 296 071
ACEA E7 White 2 132 425 2 296 065
Scania Low Ash Green 2 132 427 2 296 067
Scania Bioethanol Black 2 132 428 2 296 068
Scania BEO-2 Orange 2 258 841 2 296 070
ACEA E9 - 2 132 429 2 296 069
00:23-02 en-GB 11
Lubrication system
Cleaning the centrifugal oil

cleaner
WARNING!
The oil may be hot. Carefully remove the cover

from the centrifugal oil cleaner.
Tools Illustration
Torque wrench 2-20 Nm with exchangeable ratchet head
364 731
Ratchet head
364 729
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 ro-
tor cover is clean, in other words the rotor is not
working, the cause must be established immedi-
ately.
If the dirt deposits exceed 28 mm (1.1 in) at the
recommended intervals, the rotor cover should x 1.5
be cleaned more often.
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
protect the bearing.
Note:
133 315
Take care not to damage the rotor shaft.
00:23-02 en-GB 12
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 il-
lustration. M20
IMPORTANT!
The rotor must not be put in a vice. Never strike

the rotor cover. This may cause damage resulting
in imbalance.
x 1.5
133 316
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.
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.
133 317
00:23-02 en-GB 13
Lubrication system
7. Remove the paper insert and scrape away

any remaining dirt deposits inside the rotor
cover. If the deposits are thicker than 28 mm
(1.1 in), the centrifugal oil cleaner must be
cleaned more often.
333 044
8. Wash the parts.
9. Check 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. Re-
new damaged bearings.
333 037
1
11. Fit a new paper insert inside the rotor cover.
2 3 4
337 178
00:23-02 en-GB 14
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. Tighten the rotor nut by hand.
16. Check that the rotor shaft is not damaged or
loose.
If the rotor 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 check

that it rotates easily.
127 882
00:23-02 en-GB 15
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.
Note:
A torque wrench together with a ratchet head is
suitable for use during maintenance of the cen-
333 043
trifugal oil cleaner.
Operational testing
Operational testing need only be carried out if it
is suspected that the centrifugal oil cleaner is
malfunctioning. For example, if the dirt deposit
is abnormally small given the distance driven.
The rotor rotates very fast and should continue to
turn when the engine has stopped.
1. Run the engine until it reaches normal oper-
ating temperature.
2. Turn off the engine and listen for the sound
from the rotor. Use your hand to feel if the
filter housing is vibrating.
3. If the filter housing is not vibrating, disman-
333 039
tle and check the centrifugal oil cleaner.
00:23-02 en-GB 16
Lubrication system
Renewing the oil filter
Designation Illustration
Hexagon socket, drive 1/2", 36 mm
118 268
IMPORTANT!
Clean the centrifugal oil cleaner at the same time

as you change the oil filter. Otherwise, the oil fil-
ter 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 with-
out being filtered.
1. Unscrew the filter cover using the socket.
IMPORTANT!
Do not use an adjustable spanner or other open

tool as there is risk of damaging the filter cover.
312 503
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
00:23-02 en-GB 17
Air cleaners
Air cleaners
A B
Reading the air cleaner vacu-
um indicator
If the indicator's red plunger is fully visible, re-
new the air cleaner filter element following the
instructions below.
Renewing the air cleaner filter
336 100
element
This procedure applies if the engine has an air A Vacuum indicator.
cleaner with a filter element from Scania. B Filter element.
WARNING!
Never start the engine without the air filter being

in place. If you do, this could cause injury and se-
vere engine damage.
Note:
Renew the filter element earlier than the mainte-
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.
1. Remove the cover from the air cleaner.

2. Renew the filter element.
3. Insert a torch into the element and check
326 671
from the outside that there are no holes or

cracks in the filter paper.
Resetting the vacuum indicator.
4. Assemble the air cleaner.
5. Reset the vacuum indicator by pressing the
button.
00:23-02 en-GB 18
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 being

in place. If you do, this could cause injury and se-
vere 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 car-
tridge unnecessarily.
1. Remove the cover from the air cleaner.

4
2. Remove the filter element.
3. Remove the safety cartridge.
2
4. Fit a new safety cartridge from Scania.
5. Renew or clean the filter element.
6. Check the condition of the O-ring. Renew
the O-ring if it is damaged or hard. 3
7. Assemble the air cleaner. Ensure that the O- 1
ring is not outside the edges.
361 380
Air cleaner.
1 Cover.
2 Filter element.
3 Safety cartridge.
4 O-ring.
00:23-02 en-GB 19
Cooling system
Cooling system Coolant resistance to cold

The following example shows coolant properties
Coolant with 30 percent by volume of antifreeze and cor-
rosion inhibitor:
WARNING! • Ice slush starts to form at -16°C (3°F).

• At -30°C (-22°F), there is a risk of cooling
Ethylene glycol can be fatal if ingested and can system malfunction.
cause skin irritation and eye damage. • There is no risk of damage by freezing with a
minimum antifreeze and corrosion inhibitor
content of 35 percent by volume.
Note:
The coolant should be changed when the cooling 0 10 20 30 40 50 %
system is cleaned: every 6,000 hours or at least 0
every 5 years. See Changing the coolant and
cleaning the cooling system. -10
-16 1
-20
The coolant has several characteristics which are
-30
important for the operation of the cooling sys-
3 2
tem: -40
• Corrosion protection
312 505
-50
• Frost protection
• Increases the boiling point °C B A
Scania recommends that the coolant used is a

mixture of water with antifreeze and corrosion
protection (ethylene glycol). The coolant should The chart depicts coolant properties at different
always contain 35-55% by volume of antifreeze percents of antifreeze and corrosion inhibitor
and corrosion inhibitor so that the coolant has the concentration by volume.
correct properties for the cooling system to work.
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: There is risk of damage by freezing
00:23-02 en-GB 20
Cooling system
Antifreeze and corrosion inhibitor con-

centration 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 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.
col is 45% by volume (freezing point -30°C).
According to the table, 18 litres of ethylene
glycol are required in the cooling system.
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).
Adequate protection against corrosion

Volume of ethylene glycol Cooling system
(%) 35 40 45 50 60 volume (litres)
Ice slush forms (°C) -21 -24 -30 -38 -50
11 12 14 15 18 30
14 16 18 20 24 40
18 20 23 25 30 50
21 24 27 30 36 60
25 28 32 35 42 70
28 32 36 40 48 80
32 36 41 45 54 90
35 40 45 50 60 100
Volume of ethylene glycol (li- 39 44 50 55 66 110
tres) 42 48 54 60 72 120
46 52 59 65 78 130
49 56 63 70 84 140
53 60 68 75 90 150
56 64 72 80 96 160
60 68 77 85 102 170
63 72 81 90 108 180
67 76 86 95 114 190
70 80 90 100 120 200
00:23-02 en-GB 21
Cooling system
Antifreeze and corrosion inhibitor con-

centration 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.
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.
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).
Adequate protection against corrosion

Volume of ethylene glycol Cooling system
(%) 35 40 45 50 60 volume (US gal-
Ice slush forms (°F) -6 -11 -22 -36 -58 lons)
2.9 3.2 3.7 4 4.8 7.9
3.7 4.2 4.8 5.3 6.3 10.6
4.8 5.3 6.1 6.6 7.9 13.2
5.5 6.3 7.1 7.9 9.5 15.9
6.6 7.4 8.5 9.2 11.1 18.5
7.4 8.5 9.5 10.6 12.7 21.1
8.5 9.5 10.8 11.9 14.3 23.8
9.2 10.6 11.9 13.2 15.9 26.4
Volume of ethylene glycol 10.3 11.6 13.2 14.5 17.4 29.1
(US gallons) 11.1 12.7 14.3 15.9 19 31.7
12.2 13.7 15.6 17.2 20.6 34.3
12.9 14.8 16.6 18.5 22.2 37
14 15.9 18 19.8 23.8 39.6
14.8 16.9 19 21.1 25.4 42.3
15.9 18 20.3 22.5 26.9 44.9
16.6 19 21.4 23.8 28.5 47.6
17.7 20.1 22.7 25.1 30.1 50.2
18.5 21.1 23.8 26.4 31.7 52.8
00:23-02 en-GB 22
Cooling system
Antifreeze and corrosion protection

products
Only Scania coolant or other products that Scan-
ia has tested to provide proper antifreeze and cor-
rosion protection, may be used in Scania
engines. Products that do not satisfy the require-
ments 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 inap-
propriate coolant.
The antifreeze and corrosion protection products
used in Scania engines should be of the ethylene
glycol type.
Scania concentrate
Coolant with antifreeze and corrosion protection.
Part No. Volume Volume

litres US gallons
1 894 323 5 1.3
1 894 324 20 5.3
1 894 325 210 55
1 894 326 1,000 264
Scania Ready Mix

Ready mixed coolant with antifreeze and corro-
sion protection.
Part No. Volume Volume

litres US gallons
1 921 955 5 1.3
1 921 956 20 5.3
1 921 957 210 55
1 896 695 1,000 264
00:23-02 en-GB 23
Cooling system
Checking the coolant level
WARNING!
Do not open the coolant filler cap in the expan-

sion 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 care-
fully 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. Filling via the ex-
pansion tank leads to air pockets in the cooling
system which can lead to e.g. damage to the cool-
ant pump shaft seal. If a large amount of coolant
must be added, follow the instructions in the sec-
tion Filling coolant.
Never fill a large amount of cold coolant in a hot
engine. There is great risk of cracks forming in
the cylinder block and cylinder heads.
Only pour pre-mixed coolant into the cooling
system.
1. Open the expansion tank cap and check the

coolant level.
– The right coolant level on a cold engine is
even with the lower edge of the filler neck.
– The right coolant level on a hot engine is
approximately 25 mm (1 in) over the low-
er edge of the filler neck.
2. Top up with coolant as necessary.
00:23-02 en-GB 24
Cooling system
Checking coolant antifreeze

and corrosion protection
Note:
Use only pure fresh water that is free from parti-
cles, sludge and other impurities.
Tools Illustration
Refractometer
305 523
138008
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 inhibi-
tor content with a refractometer.
The following rules apply to ethylene glycol-
based coolant:
• The antifreeze and corrosion inhibitor content
must be minimum 35 percent by volume for
corrosion protection to be sufficient.
• An antifreeze and corrosion inhibitor content
greater than 55 percent by volume impairs the
ability to protect against frost.
• If ice forms in the coolant, there are disrup-
tions initially, but there is no immediate risk
of damage. The engine should not be subject-
ed to heavy loads when ice starts to form.
00:23-02 en-GB 25
Cooling system
Changing the coolant and

cleaning the cooling system
Draining coolant
Special tools
Number, designation
2 443 679, coolant
pump
360 625
WARNING!

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 irrita-
tion if it comes in contact with the skin. Hot cool-
ant can also cause scalding.
Environment
Use a suitable container. Used coolant must be

disposed of as specified in national and interna-
tional laws and regulations.
1. Open the expansion tank cap.

2. Place the hose of the coolant pump in an
empty container.
352 794
3. Connect the pump to the draining nipple in

the cylinder block. See illustration.
4. Connect the pump's 2 cable terminals to the

battery's negative and positive terminal.
Make sure that the drainage starts. If the
drainage does not start: Change the position
of the cable terminals.
00:23-02 en-GB 26
Cooling system
5. Repeat the procedure at the cooling system's

lowest drainage point. The location of the
lowest drainage point on the engine may dif-
fer depending on engine application.
00:23-02 en-GB 27
Cooling system
Draining coolant with coolant trolley
WARNING!

If the cap has to be opened do it slowly to release
the pressure before removing the cap.
Environment
Use a suitable container. Used coolant must be

disposed of as specified in national and interna-
tional laws and regulations.
Designation
Coolant trolley
333 980
1. Remove the filler cap on the expansion tank.

2. Drain the coolant at the following two
points:
– Lowest point of the cylinder block.
– Lowest point of the cooling system.
3. Close the drain taps.
00:23-02 en-GB 28
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
Number, designation Illustration

2 443 679, coolant
pump
360 625
WARNING!

IMPORTANT!
It is not permissible to fill large amounts of cool-

ant via the expansion tank. Filling via the expan-
sion tank leads to air pockets in the cooling
system which can lead to damage to the coolant
pump shaft seal for example.
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.
Fill the cooling system only with ready-mixed
coolant. Mix the coolant as specified in the sec-
tion headed Coolant.
Do not start the engine until the correct coolant
level has been obtained. If the engine is started
with a coolant level that is too low, the coolant
pump shaft seal may be damaged, which can re-
sult in leaks.
00:23-02 en-GB 29
Cooling system
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 ca-
ble terminals.
4. Start the engine and run it at idling for
15 minutes.
IMPORTANT!
It is very important that the engine is idling. En-
352 794
gine overspeed could damage the coolant pump
shaft seal, which leads to coolant leakage.
5. Switch off the engine and fill with coolant to

the maximum level through the expansion
tank.
Air pockets may still be left in the cooling
system. These will disappear after the engine
has been operated for a period of time.
Therefore, the coolant may need topping up
at a later stage.
00:23-02 en-GB 30
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!

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.
IMPORTANT!
Mix the coolant as specified under the section

Coolant.
IMPORTANT!
Do not start the engine until the correct coolant

level has been obtained. If the engine is started
with a coolant level that is too low, the coolant
pump shaft seal may be damaged, which can re-
sult in leaks.
00:23-02 en-GB 31
Cooling system
Designation
Coolant trolley
333 980
1. Connect the hose from the coolant trolley to
the engine drain valve, see illustration.
2. Ensure that the cooling system bleed pipes
are not blocked or damaged.
4. Fill with coolant using coolant trolley to
pump up to the maximum level of the expan-
sion tank.
5. Disconnect coolant trolley.
352 794
00:23-02 en-GB 32
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. Stop the engine and fill with coolant to the
maximum level through the expansion tank.
8. It is possible that a small amount of air may
be left as air pockets in the cooling system.
Therefore, always fill the expansion tank af-
ter the engine has warmed up and the ther-
mostat has opened. It is necessary to run the
engine for some time before all air will have
disappeared from the cooling system, which
may involve topping up at a later stage.
00:23-02 en-GB 33
Cooling system
Internal: Removing oil and grease Internal: Removing deposits
Environment Environment
Use a suitable container. Used coolant must be Use a suitable container. Used coolant must be
disposed of as specified in national and interna- disposed of as specified in national and interna-
tional laws and regulations. tional laws and regulations.
1. Run the engine until it has reached operating 1. Run the engine until it has reached operating
temperature if possible and then drain the temperature if possible and then drain the
cooling system following the previous de- cooling system following the previous de-
scription. scription.
2. Remove the thermostats. 2. Remove the thermostats.
3. Fill the cooling system with clean, hot water 3. Fill the cooling system with clean, hot water
mixed with liquid dishwasher detergent for mixed with radiator detergent which is based
household machines. Concentration 1% (0.1/ on sulphamic acid and contains dispersing
10 litres). agents. Follow the manufacturer's instruc-
4. Run the engine until it has reached operating tions for the concentration and cleaning peri-
temperature for approximately 20-30 min- od.
utes. Remember to switch on the cab heating 4. Run the engine for the specified time. Re-
system, if one is installed. member to switch on the cab heating system,
5. Drain the cooling system. if one is installed.
6. Fill the cooling system with clean, hot water 5. Drain the cooling system.
and run the engine for about 20-30 minutes. 6. Fill the cooling system with clean, hot water
7. Drain the water from the cooling system. and run the engine for about 20-30 minutes.
8. Refit the thermostats. 7. Drain the water from the cooling system.
9. Fill the cooling system with new coolant as 8. Refit the thermostats.
described in the next section. 9. Fill the cooling system with new coolant as
described in the next section.
00:23-02 en-GB 34
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.
It is strictly forbidden to carry out any machining
work or work with compressed air near an open
fuel system.
Be extra careful and always use clean, lint-free
and dust-free clothes and disposable gloves
when working on the fuel system. Scania recom-
mends use of Tegera 848 gloves.
Clean tools before they are used and do not use
any worn or chrome-plated tools. Material and
flakes of chrome may come off.
Clean connections and the surrounding area be-
fore removal. When cleaning, cloths or paper
which shed fibres must not be used. Use clean
and lint free cloths, part number 588 879.
Plug or cover the connections during removal.
Also clean the connections before the compo-
nents are fitted. Place removed components on a
thoroughly cleaned, dust-free surface. Scania
recommends using a stainless steel bench top,
part number 2 403 296. Cover the components
with a lint-free cloth.
00:23-02 en-GB 35
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 sys-
tem. See the sections Bleeding the fuel system
using a hand pump or Bleeding the fuel system
using a suction tool.
00:23-02 en-GB 36
Fuel system
Renewing the fuel filter with

draining nipple
Removal
118 268
Environment
Avoid spillage and use a suitable container. Used

fuel must be disposed of as specified in national
and international law.
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. 1
On certain engines, there is a draining nipple (1)
on the fuel filter housing. If there is no draining
351 550
nipple, see Renewing the fuel filter using a suc-
tion tool or Renewing the fuel filter if there is no
suction tool.
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

cover. Unscrew the cover 3 to 4 turns, use the A B
socket.
• On the water separating suction filter: Make a
mark on the cover. Unscrew the cover 3 to 4
turns, use the socket.
329 083
A Water separating suction filter.

B Pressure filter.
00:23-02 en-GB 37
Fuel system
• 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.
00:23-02 en-GB 38
Fuel system
Fitting
118 268
IMPORTANT!
Check that there is no remaining packaging ma-

terial stuck to the new filter elements.
Fit the filter elements in the filter covers before
placing them in the fuel filter housings or the fil-
ter 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. Lubricate the

O-ring with O-ring grease.
2. Press the filter elements into the snap fasten-
ers on the covers.
3. Check that the filter housing is clean before
fitting. Use lint free cloths.
4. Press down the filter elements into the fuel
filter housings with the filter covers.
5. Screw down the filter covers until the cover
seals are in contact with the filter housings.
Use the socket.
6. Tighten the filter housings to 25 Nm (18 lbf
ft).
7. Bleed the fuel system, see Bleeding the fuel
system using a hand pump or Bleeding the
fuel system using a suction tool.
8. Start the engine and check that there is no
fuel leakage between the filter covers and fil-
ter housings. If there is leakage, undo the fil-
ter covers and start again from step 4.
00:23-02 en-GB 39
Fuel system
Renewing the fuel filter using

a suction tool
Removal
118 268
Suction tool
337 296
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
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.
00:23-02 en-GB 40
Fuel system
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, use the socket.
329 084
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

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 the suc-
tion tool 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, use the sock-
et. Draw out fuel which may drain into the
water separating suction filter housing when B
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
housing.
329 086
00:23-02 en-GB 41
Fuel system
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)
until it is completely drained of fuel.
A
329 087
8. Move the suction tool to the pressure filter
housing (B). Draw out remaining fuel and
particles.
IMPORTANT! B
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

by carefully bending them to one side.
329 088
00:23-02 en-GB 42
Fuel system
Fitting
118 268
IMPORTANT!
Check that there is no remaining packaging ma-

terial stuck to the new filter elements.
Fit the filter elements in the filter covers before
placing them in the fuel filter housings or the fil-
ter 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. Lubricate the

O-ring with O-ring grease.
2. Press the filter elements into the snap fasten-
ers on the covers.
3. Check that the filter housing is clean before
fitting. Use lint free cloths.
4. Press down the filter elements into the fuel
filter housings with the filter covers.
5. Screw down the filter covers until the cover
seals are in contact with the filter housings.
Use the socket.
6. Tighten the filter housings to 25 Nm (18 lbf
ft).
7. Bleed the fuel system, see Bleeding the fuel
system using a hand pump or Bleeding the
fuel system using a suction tool.
8. Start the engine and check that there is no
fuel leakage between the filter covers and fil-
ter housings. If there is leakage, undo the fil-
ter covers and start again from step 4.
00:23-02 en-GB 43
Fuel system
Bleeding the fuel system us-

ing a suction tool
Suction tool
337 296
1. Open the bleed nipple at the high pressure
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.
329 119
Bleeding the fuel system us-
ing a hand pump
1. Attach a clear plastic hose to the bleed nipple
on the fuel filter housing. Let the plastic hose
drop into a container that holds at least 5 li-
tres.
2. Loosen the hand pump handle.
3. Open the bleed nipple and pump until fuel
runs out, which will take around 100 pump
strokes. Close the bleed nipple.
4. Start the engine and open the bleed nipple
carefully. Approximately 3 litres will run out
into the container before the fuel coming out
will be free of air.
00:23-02 en-GB 44
Other
Other
Checking the drive belt
IMPORTANT!
Refit the drive belt with the same direction of ro-

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

at the idler rollers.
312158
Example of a drive belt.
2. Check the drive belt for cracks. Renew the

drive belt if cracks have formed.
106 229
Example of a crack in the drive belt.
00:23-02 en-GB 45
Other
3. Check drive belt wear. Renew the drive belt

if it is too worn. See the illustrations.
112 931
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.
Check the overflow holes which show
whether the O-rings between the cylinder
liners and crankcase are leaking.
00:23-02 en-GB 46
Other
Checking and adjusting the

valve clearance
WARNING!
Block the starting device. If the engine starts un-

expectedly, there is a serious risk of injury.
Special tools
Number Designation Illustration

99 309 Turning tool for rotating the flywheel from below.
142 238
99 109 Turning tool for rotating the flywheel from above.
312 733
Tools
Torque screwdriver.
341 423
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.
00:23-02 en-GB 47
Other
Specifications
Valve clearance, intake 0.45 mm (0.018 in)
valve
Valve clearance, ex- 0.70 mm (0.028 in)
haust valve
Max. clearance between two valves under the

same valve bridge is 0.2 mm.
346 529
Tightening torque
Lock nut for valves 35 Nm (26 lbf/ft)
1. Read the mark on the flywheel in one of the

following ways:
– Turn the flywheel in the direction of rota-
tion of the engine using turning tool
99 309. Read the mark on the flywheel in
the lower window of the flywheel hous-
ing.
– Engines fitted with flywheels marked
TDC UP: Fit turning tool 99 109 in fly-
wheel housing holes of the upper window.
Press the pinion into the external ring gear
and turn the flywheel with a ratchet handle
and a 14 mm socket. Read the mark in the
310 343
upper window of the flywheel housing.

2. Adjust the valves according to Table for
valve adjustment. It is a good idea to mark
the rocker arm with a pen after adjustment to Window for reading the valve clearance.
keep track of what has already been adjusted.
Note:
Remember to remove the turning tool from the
flywheel after adjustment.
00:23-02 en-GB 48
Other
Table for valve adjustment
Reading the mark on Revolution Valve transition Adjust intake Reading the mark on
the flywheel in the low- on cylinder and exhaust the flywheel in the up-
er window valves on cylin- per window
der
TDC down 1 1 TDC up
72/432 1 5 252/612
144/504 1 2 324/684
216/576 1 3 36/396
288/648 1 4 108/468
TDC down 2 1 TDC up
72/432 2 5 252/612
144/504 2 2 324/684
216/576 2 3 36/396
288/648 2 4 108/468
• 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
319 704
Cylinder location.
00:23-02 en-GB 49
Other
Renewing the reductant filter

Hexagon socket, 1/2" drive, 46 mm
118 268
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 the socket.
4. Remove the filter cover and O-ring.
326 565
00:23-02 en-GB 50
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 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.
00:23-02 en-GB 51
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 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
00:23-02 en-GB 52

Workshop Manual DC09

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What are the main sections covered in the maintenance program?

What are the main sections covered in the maintenance program?

What safety precautions should be taken when working on the engine?

What safety precautions should be taken when working on the engine?

00:23-02

Issue 7.0 en-GB

Block the starting device when working on the

The maintenance programme includes the fol-

During a period, the sequence is S-M-S-L-S-M-

Cleaning the engine

Beware of hot water! Use suitable protective

The washing water must be disposed of in com-

The engine must be cleaned before starting work.

Engines with few hours of op-

On engines with few hours of operation, mainte-

Stand-by generator sets and the like that are not

Daily First time at Interval (hours) At least

The engine oil must fulfil the following quality

Check with your oil supplier that the oil meets

Viscosity class Outdoor temperature

Such analysis measures the oil's TBN (Total

Checking the oil level

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

2. Fill with more oil (2) when the oil level is at

For information on the correct oil type, see the

Changing the oil

Hot oil can cause burns and skin irritation. Wear

Use a container to avoid spillage. Used oil must

1. Unscrew the oil plug and drain the oil when

3. Refit the oil plug.

Maximum angles of inclination during opera-

Labels for top-up engine oil

Filling label in the rocker cover.

Oil grade Colour Part No. Part No.

Cleaning the centrifugal oil

The oil may be hot. Carefully remove the cover

1. Clean the cover. Unscrew the nut securing

Take care not to damage the rotor shaft.

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

The rotor must not be put in a vice. Never strike

6. Remove the strainer from the rotor cover. If

7. Remove the paper insert and scrape away

9. Check the 2 nozzles on the rotor. Ensure that

11. Fit a new paper insert inside the rotor cover.

12. Fit the strainer onto the rotor.

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

18. Fit a new O-ring in the cover. Refit the cover

To reduce the risk of oil leakage it is important to

From engine serial number 6 841 928:

tle and check the centrifugal oil cleaner.

Renewing the oil filter

Clean the centrifugal oil cleaner at the same time

1. Unscrew the filter cover using the socket.

Do not use an adjustable spanner or other open

4. Fit the new filter and tighten the filter cover

Renewing the air cleaner filter

Never start the engine without the air filter being

1. Remove the cover from the air cleaner.

from the outside that there are no holes or

Renewing the air cleaner