Scania D11, DC11, DI11. Industrial engine. Instruction — part 3

1997-11:2

CHANGING BATTERY

Removal

Detach the negative lead (-) from the battery (cable to engine casing).

Detach the positive lead (+) from the battery (cable to starter motor).

Fitting

Connect the positive lead (+) to the battery (cable to starter motor).

Connect the negative lead (-) to the battery (cable to engine casing).

MISCELLANEOUS

22. Every 200 hours:

CHECK/TENSION
V-BELTS

Correctly tensioned drive belts should be possible to depress
about 10 mm with a force of 35-50 N (depending on the
free length of the belt) when pressing on one belt.

Change worn or damaged belts.

Detach the securing screws.

Set the correct tension using the adjusting screw.

Do not over-tighten the belts.

Measurement using belt tension gauge Krikit
(Part. No. 587 495)

Zero the gauge by pressing the measuring arm.

Place the gauge on the V-belt at an equal distance from two pulleys.

Press until the gauge clicks.

Read the gauge.

- Recommended tension in Scania genuine belts

at test is 300 N.

- When changing belts, slightly higher (10-15%) tension should be used.

23. Daily:

LOOK FOR LEAKAGE,
REMEDY AS NECESSARY

- Start the engine.

- Look for leakage of oil, coolant, fuel, air and exhaust.

- Tighten or change leaking connections. Check the overflow holes (1)

which show whether the O-rings between the cylinder liner and crank-
case are leaking, see drawing.

a) If coolant is leaking out, the two upper O-rings are leaking.

b) If oil is leaking out, the lower O-ring is leaking.

- Check that the drain hole (2) on the coolant pump is not blocked, see

drawing. If there is leakage, change the pump seal.

A small amount of leakage from the overflow holes when running in the
engine is normal. (Seals and O-rings are fitted lubricated with soap or
oil).

This leakage normally stops after a time.

If there is a large amount of leakage - contact your nearest Scania
workshop.

1997-11:2

24.

Every 2,400 hours:

CHECK/ADJUST
VALVE CLEARANCE

Checking/adjusting valve clearance can also be done after the first
400 hours of operation.

Valves should be adjusted when the engine is cold, at least 30 minutes after
operation.

Rocker cover gaskets should be changed as necessary. Tightening torque:
25 Nm.

Alternative 1

- Set No. 1 cylinder to TDC by turning the engine in its direction of rota-

tion until both valves are closed.

- Adjust the following valves. Correct valve clearance is indicated on the

instruction plate on one of the rocker covers:

Cylinder 1

Intake and exhaust

- Set No. 6 cylinder to TDC by turning the engine one revolution in its

direction of rotation and adjust the following valves:

Cylinder 2

In and ex

Covers for reading

on flywheel casing

Note

On silumin casings readings can be

taken either from the top or from
underneath, depending on which
flywheel is used.

The cover not being used is covered

with a seal and an instruction
plate.

On cast iron casings readings can

be taken from either the top or
from the side (60

) according to

the accessibility.

FLYWHEEL

TDC

No. 6 cyl

TDC

No. 1 cyl

Intake valve

Exhaust valve

Cylinder numbering

FLYWHEEL

WARNING

Block the starter device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK OF

INJURY

Alternative 2

- Set the No. 1 cylinder to TDC by turning the engine in its direction of

rotation until both valves are closed.

- Adjust both the valves for the No.1 cylinder. Correct valve clearance is

indicated on the instruction plate on one of the rocker covers.

- Repeat this procedure with the remaining cylinders in the order

5 - 3 - 6 - 2 - 4 (firing sequence) by turning the engine 1/3 revolution in
its direction of rotation between each adjustment.

25. Every 2,400 hours:

CHANGING (or CLEANING) VALVE
FOR CLOSED CRANKCASE
VENTILATION

Alternative 1:

Change the valve at the specified interval.

Alternative 2:

- Remove the valve after the specified interval.

- Clean the valve by placing it in a bath of diesel fuel oil overnight.

Then rinse it several times in diesel and let it drip off.

- Refit the valve.

- The valve may be reused (cleaned) a maximum of two times

after the first 2,400 hours of use. Take care to mark the valve
after cleaning it.

1997-11:2

LONG-TERM STORAGE

If the engine is not to be used for a long period of time, special measures
should be taken to protect against corrosion in the cooling system, fuel sys-
tem and combustion chamber and to protect against external corrosion.

The engine can normally stand idle for up to six months. If disuse is longer,
the following measures should be taken, providing protection for about four
years. An alternative to long-term storasge is to start the engine and run it
until warm every 6 months.

Preparing the the engine for long-term storage means:

- Thoroughly cleaning the engine

- Running the engine for a certain time with special preservative fuel, oil

and coolant.

- Otherwise preparing the engine for storage

(filter changes, lubrication etc.).

Preservative coolant

If the engine is to be stored with a full cooling system, use 50% glycol by vol-
ume. If the engine is to be stored with an empty cooling system, use glycol
without nitrite-based inhibitor, such as BASF G48 or BASF D542.

Note!

Only glycol, no water.
Nitrite-based inhibitors in an empty cooling system give rise to
ammonia vapour which can damage brass components such as
monitors and sensors.

Preservative fuel

- Use diesel fuel oil mixed with Lubrizol 560A or equivalent.

- Mix 1 cm

(ml) Lubrizol 560A in 10 dm

(l) fuel.

HANDLING LUBRIZOL 560A

Hazardous!

Contains aromatic hydrocarbons

Use extractors where there is a risk of vapour build-up.

Wear eye protection and protective gloves when handling. Do not use contaminated clothing.

In case of contact with eyes:

Rinse with a gentle stream of water (at least 15 minutes).
Seek medical attention.

In case of contact with skin:

Wash with soap and water

In case of inhalation:

Fresh air, rest and keep warm

Flammable:

Fire class 2A. Flash point + 27 °.

In case of fire: Extinguish using carbon dioxide, powder or foam

Storage:

In well sealed vessel in dry, cool place. Keep out of reach of children.

Preservative oil

Suitable preservative oil can be supplied by most oil companies.

E.g. Dinitrol 40 or equivalent.

Preparations for storage

- Drain and flush the cooling system. Fill with preservative coolant.

- Run the engine until warm with ordinary fuel. Stop the engine and drain

the oil.

- Change fuel filter and turbo filter.

- Fill the engine with preservative oil to the minimum level on the dip-

stick.

- Mix the preservative fuel in a can. Detach the fuel pipe at the feed pump

suction line and connect a hose from the can.

- Detach the fuel pipe at the overflow valve and connect a return hose to

the can.

- Start the engine and run it at about 1,000 rpm (does not apply to single-

speed engines) for 20 - 25 minutes.

- Stop the engine, remove the hoses and connect the normal fuel lines.

- Oil the valve mechanism with plenty of preservative oil.

- Remove the injectors and spray preservative oil into each cylinder

max. 30 cm

(ml).

Crank the engine several revolutions using the starter motor.
Spray a little more into each cylinder.
The engine must not then be cranked. Refit the injectors.

- Drain the preservative oil from the engine. New engine oil can be filled

directly or when taking out of storage.

- Drain the coolant if the engine is not to be stored with a full cooling sys-

tem. Plug and tape over all coolant connections (if the cooling system is
not completely assembled).

- Air cleaner: Clean and change the filter insert.

- Cover air intakes and exhaust pipes.

- Alternator and starter motor:

- Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or equiva-

lent.

- Spray the outside of shiny engine parts, first using penetrating preserva-

tive oil such as Dinitrol 25B and then using Dinitrol 112 or equivalent.

1997-11:2

- Equip the engine with a clear notice giving the date of preservation

and stating that the engine must not be started or cranked.

Batteries

Remove the batteries for maintenance charging in the charging station. (Does
not apply to batteries which, according to the manufacturer, are maintenance-
free). The same applies even for short periods of disuse, even if the engine is
not stored as above.

Storage

After the preparations, the engine should be stored in a dry, warm environ-
ment (room temperature).

Taking out of storage

(action when the engine is taken into operation)

- Remove plugs and tape from coolant connections, air intakes and

exhaust pipes.

- Fill the cooling system with coolant, see page 6.

- Check the oil level in the engine and top up with new oil.

- Crank the engine several revolutions with the injectors removed, oiling

the valve mechanism, pushrods and tappets with plenty of oil.

Important!

The engine must be cranked with the injectors removed so that
excess preservative oil can be forced out of the cylinders.

- Fit the injectors.

- Drain the fuel system’s main filter of preservative fuel.

- Bleed the fuel system.

- Wash off externally applied preservative oil using white spirit.

STORED ENGINE

Date . . . . . . . . . . . .

Must not be started or cranked.

TECHNICAL DATA

GENERAL D11

DC11

DI11

Number of cylinders

6 in line

Cylinder bore

127

Stroke

145

Swept volume

(litres)

11.0

Number of main bearings

Firing sequence

1 - 5 - 3 - 6 - 2 - 4

Compression ratio

15:1

Engine direction of rotation viewed from rear

Anti-clockwise

Fan direction of rotation viewed from the front

Clockwise

Cooling

Fluid

Valve clearance, cold engine

intake valve

exhaust valve

0.45
0.80

Weight, without coolant and oil

*With charge air cooler, radiator,

expansion tank and pipes

930

1020*

950

Output

see “Engine record card”

LUBRICATION SYSTEM

Max. oil pressure

(warm engine at speed above 800 rpm) bar (kp/cm

)

Normal oil pressure

(warm engine at operating speed)

bar (kp/cm

)

3 - 6

Min. oil pressure

(warm engine 800 rpm)

bar (kp/cm

)

0.7

Oil capacity, see page 15

Crankcase pressure with closed crankcase

ventilation

mm VP

-55 - +20

1997-11:2

FUEL SYSTEM

D11

DC11

DI11

Pump setting BTDC

See plate on rocker cover

Injectors, opening pressure

bar (kp/cm

)

300

Low idle

rpm

700

Maximum full load speed

See engine card

Fuel

Diesel fuel oil

Tightening torques:

Socket nut for injectors

Cap nut for delivery pipe

Oil leakage connection

70
20
11

see page 42

COOLING SYSTEM

Number of thermostats

Thermostat, opening temperature

Coolant temperature:

system with atmospheric pressure

system with positive pressure

70 - 93

70 - about 100

Capacity including radiator, engine and expansion tank

and for DSI11 including charge air cooler
with 0.75 m

radiator

(litres)

with 1.00 m

radiator

(litres)

ELECTRICAL SYSTEM

System voltage

Alternator, current

65 or 90

Starter motor power

kW (hp)

6.6 or 6.7 (9.0 or 9.1)

Monitors, alarm values:

oil pressure monitor

bar (kp/cm

)

temperature monitor

°C

0.7

0.15

Stamped on monitor hexagon

FUEL

Diesel fuel oil

The composition of the diesel fuel oil is extremely important for engine and
injection pump function and service life. Even engine output and exhaust
emissions are dependent on fuel quality. The requirements and testing norms
for the most important properties are described in the service instruction in sec-
tions which can be ordered from your Scania dealer or directly from Scania.
The address for Scania is printed on the cover.

The table below shows the requirements for some of the most important prop-
erties:

Environmentally-friendly fuels (low sulphur fuels)

There are three classes of so-called environmentally-friendly fuels. Class 1 is
sulphur-free and class 2 is low in sulphur. Compared with class 3 (normal
fuel), these fuels are less dense and this reduces engine output. Only class 1
fuel should be used with a catalytic converter.

Property Requirement

Viscosity at 40

2.0 - 4.5 mm

/s (cSt)

Density at 15

0.80 - 0.86 kg/dm

Sulphur (concentration by mass)

max 0.3 %

Ignition characteristic
(cetane number)

min 49

flash point

56 °C

1997-11:2

Additives

At low temperatures, paraffin can precipitate and block filters and lines. This
can cause the engine to lose power or stop.

Winter fuel is usually available in cold climates. If necessary, the properties
of this can be improved before operating at low temperatures. However,
extremely low temperatures can cause problems.

The properties of the fuel when cold can be improved by doing one of the fol-
lowing before the temperature drops:

Lamp paraffin or heating oil: Max 50% may be added. Add the paraf-
fin first so that the fuel is blended fully. In a number of countries, the use
of paraffin as an engine fuel is prohibited.

Petrol: Only in emergencies and then no more than 30%. Petrol lowers
the ignition characteristics (cetane number) which can lead to difficulty
starting. There will also be emissions of blue smoke and fuel consump-
tion will be higher. Even very small quantities of petrol will lower the
flash point of the fuel which can mean the risk of fire.

Alcohol: 0.5 - 2% to prevent water in the fuel freezing to form ice.

Light diesel: Can be used for Scania engines in pure form or in the same
way as lamp paraffin to improve the properties of the fuel when cold.
Light diesel is paraffin with a suitable ignition characteristic and with a
lubricating additive. Without this, the injection pump would seize.

Drain fuel tank, drain fuel filter, clean the pre-filter and change
fuel filter regularly.

1997-11:2

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Air cleaner, low pressure indicator . . . . . . . . . 24
Air cleaner, pre-filter . . . . . . . . . . . . . . . . . . . 24
Air cleaner, safety cartridge . . . . . . . . . . . . . . 25
Air filter, insert . . . . . . . . . . . . . . . . . . . . . . . . 24

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Battery, changing . . . . . . . . . . . . . . . . . . . . . . 33
Bleeding, fuel system . . . . . . . . . . . . . . . . . . . 26