Scania DI12, DC12. Industrial engine. Operator’s manual - part 3

 

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Scania DI12, DC12. Industrial engine. Operator’s manual - part 3

 

 

2001-05:1

33

6. Every 2400 hours:

CHECKING THE COOLANT

Coolant should be checked as follows:

a)

Check the appearance of the coolant.

b)

Coolant with only glycol: Check the glycol content.

c)

Coolant with only Scania Anti-corrosive:
Check the corrosion inhibitor.

The composition of the coolant is described in detail under 
"Starting and running"

a)

Checking the appearance of the coolant

- Fill a container with a little coolant and check that it is clean and clear.

- If the coolant is contaminated or cloudy: consider changing the coolant

- Water added to the coolant should be clean and free from dirt of any 

kind.

- Use drinkable water with a pH value of 6 - 9.

b)

Checking the glycol content

If there is a danger of freezing, use only glycol as an anti-corrosive in the 
coolant.

- Cooling systems with glycol should contain at least 30% glycol by 

volume to provide acceptable protection against corrosion.

- A content of 30% glycol by volume protects against freezing down to 

-16°C. If further protection is needed, refer to the table on the next page 
for calculating the required amount of glycol.

We recommend only nitrite-free anti-freeze glycol with the following 
supplier designations:

BASF G48 or BASF D542

- Always top up the anti-freeze if its glycol content drops below 30% by 

volume. A glycol content above 60% by volume will not provide greater 
protection against freezing.

- The table shows the temperature at which ice starts to form. The engine 

will freeze and break at appreciably lower temperatures, see diagram.

- Ice forming in the coolant often causes malfunctioning without any risk 

of damage. The engine should not be subjected to heavy loads when ice 
starts to form.

Note:

Change the coolant when cleaning the cooling system: every 4800 
hours or minimum every 5 years.

Important!

If a coolant filter is used in the cooling system it must not 

contain an inhibitor.

Coolant composition:

If there is a danger of freezing:

minimum 30% glycol by 

volume

maximum 60% glycol by 

volume

If there is no danger of freezing:

7-12% by volume

Scania Anti-corrosive

The coolant should be ready 

mixed when it is poured into the 

cooling system.

Never top up with only water or 

only glycol.

Ethylene glycol is highly 

dangerous if ingested and can 

prove fatal.

Avoid skin contact with glycol.

The recommended glycol must 

not be mixed with glycol having 

nitrite-based anti-corrosive.

Risk for build up of sludge and 

reduced cooling capacity.

34

2001-05:1

A

A= Area to be avoided. Only for calculating glycol mix.

Coolant freezing temperature when ice starts to form at different glycol mixes

% glycol by 

volume

15

20

25

30

35

40

45

50

60

Cooling 

system

capacity, dm

3

Ice slush starts 

to form at °C

-6

-9

-12

-16 -22 -27 -36 -46 -55

Glycol dm

3

(litres)

5

6

8

9

11 12 14 15 18

30

6

8

10

12 14 16 18 20 24

40

8

10 13

15 18 20 23 25 30

50

9

12 15

18 21 24 27 30 36

60

11 14 18

21 25 28 32 35 42

70

12 16 20

24 28 32 36 40 48

80

14 18 23

27 32 36 41 45 54

90

15 20 25

30 35 40 45 50 60

100

17 22 28

33 39 44 50 55 66

110

18 24 30

36 42 48 54 60 72

120

20 26 33

39 46 52 59 65 78

130

21 28 35

42 49 56 63 70 84

140

23 30 38

45 53 60 68 75 90

150

24 32 40

48 56 64 72 80 96

160

26 34 43

51 60 68 77 85 102

170

27 36 45

54 63 72 81 90 108

180

29 38 48

57 67 76 86 95 114

190

30 40 50

60 70 80 90 100 120

200

Curve A: Ice build up starts (slush)

Curve B: Temperature at which damage due to 

freezing can occur

1. Safe range

2. Malfunctions may occur (ice slush)

3. Risk of damage by freezing

Properties of glycol at low temperatures:

- Example with 30% glycol by volume

- Ice slush starts to form at -16°C.

- There is risk for malfunctions at -30°C

- No risk of damage by freezing with a 

minimum content of 30% glycol by volume

% glycol by volume

2001-05:1

35

c)

Checking the corrosion inhibitor

There must always be sufficient corrosive inhibitor in the coolant to protect 
the cooling system against corrosion.

If there is no danger of freezing, only Scania Anti-corrosive should be used 
in the coolant.

The inhibitor in Scania Anti-corrosive is free of nitrite.

The correct proportion of anti-corrosive is 7-12% by volume

- Topping up with 1.0% Scania Anti-corrosive by volume should be done 

after every 2400 hours of operation.

- Never top up with only water or only anti-corrosive!

Fluid losses must always be replaced with premixed coolant:
water + 10% by volume of Scania Anti-corrosive.

Note:

The coolant should be changed when the cooling system is 
cleaned: every 4800 hours or minimum every 5 years.

Changing the coolant

1.

Remove the filler cap from the expansion tank.

2.

The coolant is drained at two points:

- the "lowest point" of the engine block, see illustration.

- the "lowest point" of the cooling system. 

3.

Close the cocks.

4.

Fill up with coolant through the expansion tank’s filler hole.

Mix coolant as described on page  33.

Always collect fluid in a suitable 
container to avoid spillage when 

changing coolant.

Dispose of used coolant through 

an authorized waste disposal 

contractor.

If a coolant filter has been fitted 

it must not contain inhibitor.

Mixing corrosion inhibitor with 

glycol or adding too much 

corrosion inhibitor may cause 

deposits and reduced cooling 

capacity.

Corrosion inhibitor, if 

swallowed can be fatal.

Avoid contact with the skin.

36

2001-05:1

7. Every 4800 hours:

CLEANING THE COOLING SYSTEM

Note!

If necessary, the cooling system should be cleaned more often.

External cleaning

Radiator

- Check that the radiator is not clogged on the air side and that the cooling 

fins are not damaged.

- Carefully scrape the deposit off the radiator’s cooling fins. If necessary, 

a paraffin-based engine cleaner can be used.

- Bent fins can be straightened using a wire brush, for example, and 

exercising care.

The cooling system must never 

be cleaned with caustic soda.

There is a risk of damage to 

aluminium parts.

Charge air cooler (DI engine)

1.

Drain the coolant from the engine, refer to "Changing the coolant".

2.

Detach the intake manifold from the turbo.

3.

Detach the charge air cooler inlet and outlet connections.

4.

Unbolt the charge air cooler assembly from the intake manifold. The 
charge air element is integrated into the housing.
Be careful - do not damage the core water connections.

5.

Clean the outside of the element. This is especially important if the 
engine is equipped with closed crankcase ventilation. Use a paraffin-
based engine cleaner.

6.

Clean and degrease the sealing surfaces on the core and the air intake 
pipe with a spirit based cleaner. 

7.

Apply sealant (silicone 816 064) in a uniform bead, approximately 
2-3 mm, on the sealing surface of the air intake pipe.

8.

Install the charge air cooler within 15 minutes of applying the sealant. 
Torque tighten the bolts to 26 Nm.

9.

Refit the inlet and outlet connections with new O rings..

10.

Refit the delivery pipe clamps.

11.

Connect the intake manifold from the turbo.

12.

Fill up with coolant according to the specification 
on page 33.

Important

Allow the sealant to cure for minimum
24 hours before the engine is used.

1.

Charge air 
cooler housing 
with core

2.

O-ring

3.

Sealant 816 064

4.

Air intake pipe

1

2

3

4

2001-05:1

37

Internal cleaning

Removing oil and grease

- If possible, run the engine until it has reached the operating temperature 

and then drain the cooling system.

- Remove the thermostat.

- Fill the system with clean, hot water mixed with liquid dishwasher 

detergent intended for household use.
Concentration 1% (0.1/10 l).

- Run the engine until warm for about 20-30 minutes. Do not forget the 

cab heating system (if fitted).

- Drain the cooling system.

- Fill the system again using clean, hot water and run the engine for 

approximately 20-30 minutes.

- Drain the water from the system.

- Refit the thermostat.

- Fill up with new coolant according to the specification on page 33.

Removing deposits

- If possible, run the engine until it has reached operating temperature and 

then drain the cooling system.

- Remove the thermostat.

- Fill the system with clean, hot water mixed with a commercially 

available radiator cleaner based on sulphamic acid and containing 
dispersing agents. Follow the manufacturer’s instructions for mixing 
proportions and cleaning times.

- Run the engine for the specified time and then drain the cooling system.

- Refill the system with hot water and run the engine for approximately 

20-30 minutes.

- Drain the water from the system.

- Refit the thermostat.

- Fill up with new coolant according to the specification on page 33.

Handling cleaning agents for 

the cooling system:

Read the warning label on the 

container.

Always collect fluid in a suitable 
container to avoid spillage when 

draining coolant.

Dispose of used coolant through 

an authorized waste disposal 

contractor.

38

2001-05:1

AIR CLEANER

8. Daily:

CHECKING THE VACUUM INDICATOR

If the entire red plunger of the indicator is visible, renew or clean the air filter 
element, paragraph 10. This is especially important if the engine is operated 
under heavy load and at high engine speed.

9. Every 200 hours:

CLEANING THE AIR CLEANER 
COARSE CLEANER

1.

Remove the cover from coarse cleaner 2.

2.

Remove the conical coarse separator. Empty out the particles of dirt and 
clean it.

3.

Fit the coarse separator as shown in the figure and screw the cover in 
place.

4

3

2

1

1.

Filter element

2.

Coarse cleaner

3.

Cover

4.

Vacuum sensor

Air cleaner with safety cartridge

The coarse cleaner must always 

be fitted in an upright position.

10. Every 1200 hours:

CLEANING OR CHANGING THE
FILTER ELEMENT

Note:

Earlier if the vacuum indicator shows red

Dismantling

1.

Remove the side cover from the air cleaner.

2.

Change or clean the element.

Note

Cleaning the element always entails a risk of damaging it. The 
element can be cleaned a maximum of four times
After cleaning, 
it has less dust separation capacity than a new element.

3.

Mark the filter when it has been cleaned.

Cleaning the element

- Carefully blow the filter element clean using dry compressed air from 

the inside.

Note

This filter element must not be washed with water.

1.

Cover

2.

Filter element

3.

Filter housing

Only use Scania genuine air 

filter. Change the filter element 

if it is damaged.

Danger of engine damage if the 

filter element is damaged.

Never start the engine unless 

the air filter is installed.

Danger of personal injury or 

engine damage.

1

2

3

2001-05:1

Checking

- Insert a torch into the element and check from the outside that there are 

no holes or cracks in the filter paper.

- Change the filter element if it has the slightest damage. Danger of 

engine damage.

Assembly

1.

Assemble the air cleaner in reverse order.

2.

Reset the red plunger in the vacuum indicator by depressing the button.

11. Every 2400 hours:

RENEWING THE SAFETY CARTRIDGE

Note

Not all filters are equipped with a safety cartridge. When 
changing the safety cartridge, take great care to ensure that no 
dirt or other impurities can get into the engine.

1.

Remove the side cover from the air cleaner.

2.

Remove the filter element.

3.

Remove the safety cartridge.

4.

Fit a new genuine Scania safety cartridge.

5.

Renew or clean the filter element, refer to paragraph 10.

6.

Assemble the air cleaner.

1. Safety cartridge

Air cleaner with safety cartridge

1

Do not remove the safety 

cartridge unnecessarily.

Never clean the safety cartridge

40

2001-05:1

FUEL SYSTEM

12. Daily:

CHECKING THE FUEL LEVEL

- Top up with fuel if necessary.

- If the tank has been run dry, bleed the fuel system, refer to paragraph 13.

13. Every 1200 hours:

RENEWING THE FUEL FILTER

Fuel tanks

- Drain any water from the fuel tanks.

Filter

The filter consists of a filter unit.

- Wash the outside of the filter and unscrew it. 

- Tighten the new filter by hand.

Never use a tool for tightening. The filters can be damaged,
obstructing circulation.

- Bleed the fuel system as described below.

- Start the engine and check for leaks.

Bleeding the fuel system

- Turn on the power so that the fuel shut-off valve opens.

- Undo the connection on fuel filter outlet 1 (upwards).

- Pump hand pump 3 until fuel without air bubbles flows out of the 

opened connection.

- Tighten the connection on the filter.

- Undo the overflow valve 2 at the fuel shut-off valve outlet.

- Pump with the hand pump until the fuel coming out of the open 

overflow valve is free of air bubbles.

- Tighten the overflow valve and pump the hand pump an additional 10 

strokes.

If the engine fails to start after bleeding. . . . . . .

- Open the overflow valve again and pump the hand pump until fuel 

without air bubbles flows out.

- Close the overflow valve firmly and start the engine.

1

3

2

Always collect fuel in a suitable 

container to avoid spillage when 

bleeding system or renewing 

components.

Only use Scania genuine fuel 

filter.

Observe the utmost cleanliness 

when working on the fuel 

system.

Malfunctions could easily occur 

and the injection equipment 

could be damaged.

2001-05:1

14. Every 2400 hours:

CHECKING THE INJECTORS

Injectors should be inspected by trained personnel with access to the 
necessary equipment. Inspection should be carried out at least once a year or 
every 2400 hours.

Removal

1.

Clean around the injectors and connections, including clamps and 
brackets.

2.

Detach the delivery pipe bundle and leak-off fuel lines.

3.

Unscrew the injector.

4.

Fit protective plugs on the injector and delivery pipe.

5.

Lift up the seal from the bottom of the injector seat if it does not come 
out together with the injector.

6.

Fit a core plug in the injector seat in the cylinder head.

7.

Clean the injectors and check/adjust in a nozzle tester.

Correct opening pressure, see Technical data, page 54.

Fitting

1.

Check that there is no old seal in place and fit a new seal in the bottom 
of the injector seat.

2.

Fit a new O-ring in the socket nut and a new seal under the socket nut.

3.

Fit the injector.

4.

Tighten the socket nut to 70 Nm (7.0 kpm).

5.

Fit the delivery pipe and tighten the union nuts to 20 Nm (2.0 kpm). Fit 
clamps and brackets.

Important

Take care to fit the delivery pipe without tension and make sure 
that the cone on it is correctly positioned in the connection. 

6.

Fit the leak-off fuel line. Tighten the bolts to 11 Nm (1.1 kpm).

1.

Threaded 
socket nut

2.

O-ring

3.

O-ring

4.

Stop ring

5.

Guide pin

6.

Seal

1.

Delivery pipe

2.

Union nut

3.

Washer

4.

Cone

5.

Connection on injector or 
injection pump

The delivery pipes must

not be bent.

All clamps must be refitted.

Always wear gloves and eye 

protection when testing 

injectors.

Fuel escaping under high 

pressure can penetrate body 

tissue and cause serious injury.

42

ELECTRICAL SYSTEM

15. Every 200 hours:

CHECKING THE ELECTROLYTE 
LEVEL IN BATTERIES

1.

Unscrew the plugs and check the electrolyte level in all cells.

2.

Top up with distilled water until the level is 10-15 mm above the plates.

16. Every 200 hours:

CHECKING THE STATE OF CHARGE IN 
BATTERIES

Note:

Every 200 hours applies to generator sets and the like. Other 
installations every 1200 hours.

- Check the density with an acid tester.

In a fully-charged battery it should be:

1.280 at +20°C

1.294 at 0°

1.308 at -20°C

- If the density is below 1.20, the battery must be charged. A discharged 

battery freezes at -5°C.

Do not rapid-charge the batteries. This will damage the battery in the 
long run.

17. Every 200 hours:

CLEANING THE BATTERIES

Note:

Every 200 hours applies to generator sets and the like. Other 
installations every 1200 hours.

1.

Clean batteries, cables and cable terminals.

2.

Check that all cable terminals are firmly tightened.

3.

Grease battery terminal posts and cable terminals with vaseline.

Wear gloves and eye protection 

when charging and

handling batteries.

Batteries contain a highly 

corrosive acid.

Do not connect the cables to the 

wrong terminals.

This could cause serious 

damage to the electrical system.

If the terminals are

shortcircuited, sparks

will be generated. 

Do not let open flame or sparks 

come near the batteries.

When batteries are charged, 

they emit highly flammable 

fumes that can explode.

Do not let open flame or sparks 

come near the batteries.

When batteries are charged, 

they emit highly flammable 

fumes that can explode.

2001-05:1

43

18. Every 1200 hours:

CHECKING THE COOLANT LEVEL 
MONITOR

(optional equipment)

1.

Start the engine.

2.

Lower the coolant level in the expansion tank.

3.

Automatic stop in case of fault: The engine stops, the indicator lamp 
comes on and the buzzer sounds if the level monitor is OK. 

4.

Without automatic stop in case of fault: The indicator lamp comes on 
and the buzzer sounds if the level monitor is OK.

5.

Top up coolant to the correct level, refer to page 32.

2-pin level monitor installed in 

coolant expansion tank delivered 

by Scania

Always use a suitable container 

to avoid spillage when

draining coolant.

Dispose of used coolant through 

an authorized waste disposal 

contractor.

44

19. Every 1200 hours:

CHECKING THE TEMPERATURE 
MONITOR

1.

Drain the coolant, allowing the temperature monitor to be removed.

2.

Remove the temperature monitor cable(s).

3.

Unscrew the monitor.

4.

Refit the cable(s) to the monitor.

5.

Submerge the monitor sensor body in water. Heat the water slowly 
(approx. 1° minute) using e.g. an immersion heater.

6.

Set the control switch to "ON". Use a thermometer to check that the 
warning lamp comes on or that an alarm is initiated at the correct 
temperature.

The correct temperature is stamped on the hexagonal part of the 
monitor.

The monitor tolerance is 

±

3°.

CHECKING THE TEMPERATURE 
SENSOR

1.

Drain the coolant, allowing the temperature sensor to be removed.

2.

Remove the temperature sensor cable(s).

3.

Unscrew the sensor.

4.

Connect an ohmmeter to the temperature sensor.

5.

Submerge the sensor body in water. Heat the water slowly 
(approximately 1° per minute) using e.g. an immersion heater.

6.

Check the resistance at the temperatures given below.

7.

The sensor should give the following readings:

At temp. °C

Resistance 

Tolerance °C

60

134 

±

 13.5

±

4

90

51.2 

±

 4.3

±

3

100

38.5 

±

 3

±

3

2-pole temperature sensor

C =Common connection

1 = Connection C -1 closes at the 

stamped temperature

2 =Connection C -2 opens at the 

stamped temperature

2-pole temperature monitor

Always use a suitable container 

to avoid spillage when

draining coolant.

Dispose of used coolant through 

an authorized waste disposal 

contractor.

2001-05:1

20. Every 1200 hours:

CHECKING THE OIL PRESSURE 
SENSOR/MONITOR

Sensor function

Measure the sensor output voltage (pin 3) at different oil pressures. The 
sensor output voltage shall be as follows:

0.85-1.15 bar = 2.45 volt
1.80-2.20 bar = 3.70 volt
2.75-3.25 bar = 4.50 volt
3.79-4.20 bar = 5.20 volt
4.55-5.45 bar = 5.70 volt
5.40-6.6 bar

= 6.10 volt

The tolerances apply at +30°C - 110°C. At lower temperatures the tolerance 
range is wider, e.g. 0°C = x 1.4.

Monitor function

Connect a test lamp to the oil pressure monitor, pin 4 (

-

 ground), and check 

that the monitor switches on at the correct pressure when the engine is started 
and stopped. The monitor shall switch on at 0.7 

±

 0.15 bar when the engine is 

stopped.

Important

The sensor/monitor must be supplied with voltage during the 
measurement. Maximum 4 W load from a test lamp.

CHECKING THE OIL PRESSURE 
MONITOR FOR DEC 2

Connect an ohmmeter or a test lamp to the oil pressure monitor and check 
that the monitor switches off/on at the correct pressure when the engine is 
started and stopped. The monitor shall switch off at 1.1 

±

 0.15 bar when the 

engine is started and switch on at 0.7 

±

 0.15 bar when the engine is stopped.

4

1

3

2

46

RENEWING THE BATTERY

Removal

1.

Disconnect the negative cable (-) from the battery (cable connected to 
ground).

2.

Disconnect the positive cable (+) from the battery (cable connected to 
starter motor).

Fitting

1.

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

2.

Connect the negative cable (-) to the battery (cable connected to 
ground).

MISCELLANEOUS

21. Every 1200 hours:

CHECKING THE DRIVE BELT

Replace the drive belt (1) (poly V-belt) if worn or damaged.

Also check that the automatic belt tensioner (2) is working and keeps the 
drive belt correctly tensioned.

On installations with dual belt circuits, the second belt circuit has a drive belt 
with manual belt tensioner. 

This drive belt should be tensioned to 15-20 Nm as shown in the figure.

Do not connect the cables to the 

wrong terminals.

This could cause serious 

damage to the electrical system.

If the terminals are short-

circuited, sparks will be 

generated. 

Dispose of used batteries 

through an authorized waste 

disposal contractor.

2001-05:1

47

22. Daily:

CHECKING FOR LEAKAGE, RECTIFY 
AS NECESSARY

- Start the engine.

- Check for oil, coolant, fuel, air and exhaust leakage.

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

(below the side covers) which show whether the O rings between the 
cylinder liners and crankcase are leaking, refer to illustration.

a) If coolant is evident, the O-ring is leaking.

b) If oil is running out, the liner shelf is leaking.

- Check that the coolant pump drain hole (2) is not clogged, refer to 

illustration. If there is leakage, renew the pump seal or the coolant pump 
assembly.

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

This leakage normally stops after a time.

Ensure that any leakage does 

not pollute the environment. 

In case of major leakage, 

contact the nearest Scania 

workshop.

48

23. Every 2400 hours:

CHECKING/ADJUSTING VALVE 
CLEARANCE

Note:

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

Valve clearances should be adjusted when the engine is cold, at least 30 
minutes after running.

The rocker cover gaskets should be changed as necessary. Tightening 
torques: 26 Nm.

Intake valve clearance: 0.45 mm
Outlet valve clearance: 0.70 mm.

Alternative 1

- Position No. 1 cylinder at TDC by turning the crankshaft in its normal 

direction of rotation until all four valves are closed.

- Adjust the following valves. The correct valve clearance is also stated 

on the instruction plate on one of the valve covers:

- Position No. 6 cylinder at TDC by turning the crankshaft one revolution 

in its normal direction of rotation and adjust the following valves:

Cylinder

1

Intake and outlet

2

Intake

3

Outlet

4

Intake 

5

Outlet

Cylinder

2

Outlet

3

Intake

4

Outlet

5

Intake

6

Intake and outlet

TDC

no. 6 cylinder

TDC

no. 1 cylinder

Intake valve

exhaust valve

5

4

3

2

1

6

Cylinder numeration

FLYWHEEL

FLYWHEEL

WARNING

Immobilise the starting device 

when working on the engine.

If the engine starts out of 

control, there is a

SERIOUS RISK 

OF INJURY.

 

 

 

 

 

 

 

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