Scania DC09 XPI. Industrial engine en-GB 2 824 008. Operator’s manual - part 1


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Scania DC09 XPI. Industrial engine en-GB 2 824 008. Operator’s manual - part 1



Important information
Serious risk of injury
When working on the engine, for example when adjusting drive belts and the clutch, or when changing the
oil, it is important not to start the engine. The engine could be damaged, but more importantly there is a
serious risk of injury.
For this reason, always secure the starting device or disconnect a battery cable before working on the engine.
This is especially important if the engine has a remote starter or automatic starting.
This warning symbol and text can be found next to those maintenance items where it is particularly impor-
tant to bear in mind the risk of injury.
Operator's manual
DC09 XPI Industrial engine
en-GB 2 824 008
Issue 9.0
The owner is responsible for making sure that maintenance is carried out on time and in accordance with
the instructions.
The owner must entrust the maintenance, renewal and repair of emission-related components and systems
to a qualified workshop or person.
Start of warranty
Cooling system
Scania Engines engine warranty for industrial
Checking coolant level
Emission control systems warranty
Checking the coolant's antifreeze and corrosion
Emission control system warranty statement . 4
California emission control warranty statement
Changing the coolant and cleaning the cooling
Your warranty rights and obligations
Fuel system
Manufacturer's warranty coverage
Cleanliness requirements
Owner's warranty responsibilities
Checking the fuel level
SCR catalytic converter
Renewing the fuel filters
Bleeding the fuel system
Power classes
Checking the drive belt
Environment and safety
Checking for leaks
Environmental responsibility
Checking and adjusting the valve clearance .84
Renewing the reductant filter
Warnings and advisories
Cleaning the reductant tank filler filter
Engine data plate
Cleaning the reductant tank ventilation filter.90
Component identification
Renewing the particulate filter
Quality requirements for fuel
Exhaust gas aftertreatment management system
Biodiesel (FAME)
Starting and running
Checks before first start
Checks before running
Reductant for SCR
Starting the engine
Preparing the engine for storage
Preservative products
Engine shutdown
Preparations for storage
Checks after running
Technical data
Transporting engines
General data
Lubrication system
Cleaning the engine
Intake system
Engines with few hours of operation
Cooling system
Maintenance interval
Fuel system
Lubrication system
Electrical system
Oil grade
Scania Assistance
Oil analysis
General tightening torques for screw joints .108
Checking the oil level
Hexagon screws, hexagon socket screws, Torx
Maximum angles of inclination during operation
screws, hexagon nuts
Flange screws with hexagonal head and hexago-
Changing the oil
nal flange nuts
Cleaning upwards-moving centrifugal oil clean-
Hose clamps
Operational testing of the centrifugal oil cleaner
Renewing the rotor in downwards-moving cen-
trifugal oil cleaner
Renewing the oil filter
Air cleaner
Reading the vacuum indicator
Renewing the air cleaner filter element and safe-
ty cartridge
Start of warranty
Start of warranty
The more we know about you, your company and your equipment, the more effectively we can adapt our
services to you. If you have started to use a new Scania engine, it is very important that you send in the war-
ranty start report to us immediately. Quite simply, we need to register all the details on engine ownership
etc., so we can monitor it for you.
You can report the start of the warranty on the Scania website:
If you do not send in the warranty report, the engine is not covered by the accompanying Scania warranty.
Also fill in below the details you enter in the warranty report. These details can facilitate contact with a
workshop, for example. The engine serial number is on the engine data plate and is also engraved on the
cylinder block.
Engine serial number (e.g. 1111111)
Ship ID (for example MMSI 111111111 or IMO 1111111)
Start date (yyyy-mm-dd)
Company name
Contact person
Telephone number
E-mail address
Post code
Postal town
Scania Engines engine warranty for industrial engines
in the engine manufacturer's application for
Scania Engines engine war-
ranty for industrial engines
Where a warrantable condition exists, Scania
will repair your heavy-duty off-road engine at no
Emission control systems
cost to You including diagnosis, parts, and labor.
Warranty period
Only applicable to engines used in the U.S.A.
This warranty shall apply for one of the follow-
ing periods, whichever occurs first:
3,000 hours of operation as determined by a
Table of Contents
device to measure hours of use, or
General warranty provisions
• Five years
Warranty period
Each engine is equipped with a device to meas-
Parts covered by the Warranty
ure hours of use. If that device fails to account for
hours of use due to defects in materials or work-
General warranty limitations
manship, the engine shall be warranted for a pe-
Specific warranty exclusions
riod of five years. The warranty period shall
Customer support
begin on the date the engine is delivered to the
first ultimate purchaser who, in good faith, pur-
chases the engine for purposes other than immi-
nent resale.
Emission control system war-
ranty statement
The Warranty on emission-related
General warranty provisions
parts shall be interpreted as follows:
The emission control systems of your new Scan-
1. Any warranted part which is not scheduled
ia Engines (“Scania”) industrial diesel engine
for replacement as required maintenance in
were designed, built and tested using genuine
Scania's written instructions for maintenance
parts, and were certified as being in conformity
and use of the engine by owner shall be war-
with federal emission control regulations. Scania
ranted for the warranty period defined above.
warrants to the original owner, and to each sub-
If any such part fails during the period of
sequent owner, of a new Scania industrial diesel
warranty coverage, it shall be repaired or re-
engine (“You”) that the engine:
placed by the engine manufacturer according
to Subsection (4) below. Any such part re-
1. Was designed, built and equipped so as to
paired or replaced under the Warranty shall
conform at the time of sale with all applica-
be warranted for the remaining warranty pe-
ble regulations under Section 213 of the
Clean Air Act, 42 U.S.C. § 7547, for their
2. Any warranted part which is scheduled only
full useful life and designed, built and
for regular inspection in Scania's written in-
equipped so as to conform with all applicable
structions for maintenance and use of the en-
regulations adopted by the California Air Re-
gine by owner shall be warranted for the
sources Board pursuant to its authority under
warranty period defined above. A statement
Chapters 1 and 2, Part 5, Division 26 of the
in such written instructions to the effect of
California Health and Safety Code, and;
“repair or replace as necessary” shall not re-
2. Is free from defects in material and work-
duce the period of warranty coverage. Any
manship which would cause such engine to
such part repaired or replaced under warran-
fail to conform to applicable regulations for
ty shall be warranted for the remaining war-
its warranty period or otherwise cause the
ranty period.
failure of a warranted part to be identical in
all material respects to the part as described
Scania Engines engine warranty for industrial engines
3. Any warranted part which is scheduled for
shall not be liable under this article to war-
replacement as required maintenance in Sca-
rant failures of warranted parts caused by the
nia's written instructions for maintenance
use of a non-exempted add-on or modified
and use of the engine by owner shall be war-
ranted for the period of time prior to the first
11. The Executive Officer of the California Air
scheduled replacement point for that part. If
Resources Board may request, and in such
the part fails prior to the first scheduled re-
case, the engine manufacturer shall provide,
placement, the part shall be repaired or re-
any documents which describe that manufac-
placed by the engine manufacturer according
turer's warranty procedures or policies.
to Subsection (4) below. Any such part re-
paired or replaced under warranty shall be
warranted for the remainder of the period
prior to the first scheduled replacement point
Parts covered by the Warranty
for the part.
The following is a list of parts considered to be
4. Repair or replacement of any warranted part
part of the Emission Control Systems covered by
under the warranty provisions of this article
the Emission Warranty for Scania industrial en-
shall be performed at no charge to the owner
gines which were built to conform to federal and
at a warranty station.
California emission control regulations:
5. Notwithstanding the provisions of Subsec-
tion (4) above, warranty services or repairs
1. Fuel injection system.
shall be provided at all manufacturer distri-
2. Air induction system.
bution centers that are franchised to serve the
3. Exhaust manifold system.
subject engines.
4. Smoke puff limiter (included in ECU).
6. The owner shall not be charged for diagnos-
tic labor that leads to the determination that a
5. Oil filler cap.
warranted part is in fact defective, provided
6. EGR system (when applicable):
that such diagnostic work is performed at a
a) Cooler.
warranty station.
b) EGR valve.
7. The engine manufacturer shall be liable for
7. Exhaust brake (when applicable).
damages to other engine components proxi-
mately caused by a failure under warranty of
8. NOx sensors:
any warranted part.
a) NOx sensor, engine out.
8. Throughout the engine's warranty period de-
b) NOx sensor, tail pipe.
fined above, the engine manufacturer shall
9. DOC (when applicable).
maintain a supply of warranted parts suffi-
10. SCR system:
cient to meet the expected demand for such
a) DEF tank.
b) DEF tank level, temperature and quality
9. Any replacement part, as defined in Section
1900(b), Title 13 of the California Code of
c) DEF hose.
Regulations, may be used in the performance
d) DEF injector.
of any maintenance or repairs and must be
e) DEF injector pressure and temperature
provided without charge to the owner. It is
not necessary for replacement parts to be the
f) Evaporator.
same brand or by the same manufacturer as
g) SCR catalyst inlet temperature sensor.
the original part sold with the engine. Such
h) SCR catalyst including the ammonia-slip
use shall not reduce the warranty obligations
of the engine manufacturer.
i) SCR control unit (EEC3).
10. Add-on or modified parts, as defined in Sec-
tion 1900(b), Title 13 of the California Code
of Regulations, that are not exempted by the
California Air Resources Board may not be
used. The use of any non-exempted add-on
or modified parts shall be grounds for disal-
lowing a warranty claim made in accordance
with this article. The engine manufacturer
Scania Engines engine warranty for industrial engines
11. Miscellaneous items used in the above sys-
Receipts covering the performance of regular
maintenance should be retained in the event
questions arise concerning maintenance. The re-
a) Electronic control unit (ECU), sensors,
ceipts should be transferred to each subsequent
wiring harnesses.
owner of the engine with the emission warranted
b) Hoses, belts, connectors, assemblies,
engine. Scania cannot, however, deny warranty
clamps, fittings tubing, sealing gaskets or
solely for the lack of receipts or for your failure
devices and mounting hardware.
to ensure the performance of all scheduled main-
c) Pulleys, belts and idlers.
d) Emission control information label.
The Warranty covers the cost of diagnosis, repair
and replacement parts and services of warranted
components and systems performed by an au-
This list does not include all expendable mainte-
thorized Scania distributor or dealer using genu-
nance parts.
ine Scania parts. You may elect to have
maintenance, replacement or repair of these
• Expendable emission related parts requiring
components and systems performed by any re-
scheduled maintenance are warranted until
pair establishment or individual without invali-
their first scheduled replacement point.
dating the Warranty.
• Emission related parts scheduled for inspec-
The use of other than Scania replacement parts
tion and replacement only as necessary are
also does not invalidate the warranty on other
not considered expendable and if repaired or
components unless such parts cause damage to
replaced under warranty shall be warranted
warranted parts. However, the cost of such ser-
for the remaining warranty period.
vices or parts will not be covered by the Warran-
See Specific Warranty Exclusions below.
You are responsible for initiating the warranty
process. The California Air Resources Board
suggests that You present your heavy-duty off-
road engine to an authorized Scania dealer as
General warranty limitations
soon as a problem exists. The warranty repairs
should be completed by the dealer as expedi-
To retain the dependability of the exhaust emis-
tiously as possible.
sion control originally built into your Scania in-
dustrial diesel engine, it is essential that the
engine is installed according to Scania installa-
tion instructions and emission certificates. Your
engine is designed to operate on diesel fuel only.
Use of replacement parts which are not of equiv-
Use of any other fuel may result in your engine
alent quality may impair the effectiveness of
no longer operating in compliance with state or
emission control systems. Accordingly, it is rec-
federal emissions requirements. The use of alter-
ommended that only Scania repair or replace-
native fuels shall not void the warranties on any
ment parts be used for maintenance, repair or
engine certified to use such fuel.
replacement of emission control systems.
In addition, as the engine owner, You are respon-
If other than Scania parts are used for mainte-
sible for the performance of all scheduled main-
nance, repair or replacement, the owner should
tenance listed in your owner's manual, and all
obtain assurance that such parts are warranted by
necessary repairs, on your new Scania industrial
their manufacturer to be equivalent to genuine
diesel engine. Scania may deny a warranty claim
Scania parts.
if the engine or part has failed due to abuse, ne-
glect, improper maintenance or unapproved
Scania Engines engine warranty for industrial engines
Specific warranty exclusions
Customer support
This warranty does not cover:
In the event that You do not receive the warranty
service to which You believe You are entitled
1. Malfunctions in any part caused by any of
under the Warranty, or if You need additional
the following: misuse, abuse, improper ad-
support or information concerning the Warranty,
justments, modifications, alteration, tamper-
please contact:
ing, disconnection, improper or inadequate
maintenance, or use of fuels not recommend-
Scania USA, Inc.
ed for the engine as described in the Opera-
Address: 121 Interpark Blvd, suite 1002, 78216,
tor’s Manual.
San Antonio, Texas
2. Engine installation, including cooling sys-
tem, intake system and exhaust system in-
Mailing address: 121 Interpark Blvd, suite
stallation, that is not completed in
1002, 78216, San Antonio, Texas
accordance with the Scania installation in-
Telephone: +1 210 403 0007
structions and emissions certificate for this
engine type.
Fax: +1 210 403 0211
3. Damage resulting from accidents, acts of na-
ture or other events beyond the control of
California customers shall also be furnished a
4. The replacement of expendable maintenance
copy of the California Emission Control Warran-
items such as filters, hoses, belts, oil, ther-
ty Statement applicable to each new Scania en-
mostat, exhaust system and coolant made in
gine purchased.
connection with scheduled maintenance ser-
vices once these parts have been replaced.
5. Replacement items which are not genuine
Scania parts or not authorized by Scania.
6. Inconvenience, loss of use of the engine or
commercial loss.
7. Any engine on which the actual use cannot
be accurately determined due to a failure of
the device to track hours of use unrelated to
defects in materials or workmanship.
8. Any engine operating outside the United
California emission control warranty statement
California emission control
Owner's warranty responsi-
warranty statement
As the off-road engine owner, you are respon-
Your warranty rights and obli-
sible for the performance of the required
maintenance listed in your owner's manual.
Scania CV AB recommends that you retain
The California Air Resources Board is pleased to
all receipts covering maintenance on your
explain the emission control system warranty on
off-road engine, but Scania CV AB cannot
your 2019 engine. In California, new heavy-duty
deny warranty solely for the lack of receipts
off-road engines must be designed, built and
or for your failure to ensure the performance
equipped to meet the State's stringent anti-smog
of all scheduled maintenance.
standards. Scania CV AB must warrant the
As the off-road engine owner, you should
emission control system on your engine for the
however be aware that Scania CV AB may
periods of time listed below provided there has
deny you warranty coverage if your off-road
been no abuse, neglect or improper maintenance
engine or a part has failed due to abuse, ne-
of your engine.
glect, improper maintenance or unapproved
Your emission control system may include parts
such as the fuel injection system and the air in-
Your engine is designed to operate on ultra
duction system. Also included may be hoses,
low-sulfur diesel fuel only. Use of any other
belts, connectors and other emission-related as-
fuel may result in your engine no longer oper-
ating in compliance with California's emis-
sions requirements.
Where a warrantable condition exists,
You are responsible for initiating the warran-
Scania CV AB will repair your heavy-duty off-
ty process. The ARB suggests that you pres-
road engine at no cost to you including diagno-
ent your off-road engine to a Scania CV AB
sis, parts and labor.
dealer as soon as a problem exists. The war-
ranty repairs should be completed by the
dealer as expeditiously as possible.
Manufacturer's warranty cov-
If you have any questions regarding your war-
ranty rights and responsibilities, you should con-
tact Scania U.S.A. Inc +1-210-403-0007.
The 2019 heavy-duty off-road engines are war-
ranted for a period of five years or 3,000 hours,
whichever occurs first. If any emission-related
part on your engine is defective, the part will be
repaired or replaced by Scania CV AB.
SCR catalytic converter
Environmental protection measures
SCR catalytic converter
The SCR catalytic converter is a manufac-
tured article that contains vanadium pentox-
ide, a hazardous substance. Before disposing
of, or scrapping, a spent SCR catalytic con-
The SCR catalytic converter contains vanadium
verter, it should be tested for any hazardous
pentoxide, a chemical known to the State of Cal-
characteristics (ignitability, corrosivity, reac-
ifornia to cause cancer.
tivity, acute hazardousness, and toxicity), as
those categories are described in 22 CCR §
66261.30. If the spent SCR catalytic convert-
The SCR catalytic converter is fitted in the si-
er exhibits hazardous characteristics and is
lencer and does not constitute a health hazard
being disposed of, it will be considered by the
during normal use and handling.
State of California to be a hazardous waste
When carrying out work on the SCR catalytic
subject to Title 22, California Code of Regu-
converter which may result in exposure to dust,
lations. Before disposing of hazardous waste,
safety precautions must be taken. Such work in-
review and follow all pertinent federal and
cludes, for example, opening the silencer ma-
California requirements.
chining and scrapping the SCR catalytic
Vanadium pentoxide is a listed commercial
chemical product - P120 - pursuant to 22
CCR § 66261.33(e). According to the State of
Safety precautions when working on the SCR
California, commercial chemical products
that are discarded or intended to be discarded
• Inhalation: If dust is inhaled, the person
are hazardous wastes and are subject to all
should be provided with fresh air immediate-
provisions of Title 22, California Code of
ly. Seek medical attention.
Regulations. Before disposing of vanadium
pentoxide, review and follow all pertinent
• Eye contact: Rinse eyes with water immedi-
federal and California requirements.
ately. If irritation persists, seek medical atten-
If the SCR catalytic converter is opened for
maintenance, any dust spillages from the cat-
• Skin contact: Wash with water and soap. Re-
alyst should be collected and tested for the
move contaminated clothes.
presence of vanadium pentoxide prior to
• Ingestion: If large amounts have been ingest-
proper disposal. Dust spillages should also be
ed, drink plenty of water and induce vomit-
tested for any hazardous characteristics (ig-
ing. Seek medical attention
nitability, corrosivity, reactivity, acute haz-
ardousness, and toxicity), as those categories
Environmental hazards
are described in 22 CCR § 66261.30, prior to
• Vanadium pentoxide is toxic to water organ-
proper disposal. If the dust contains either va-
isms and can cause detrimental long term ef-
nadium pentoxide or exhibits hazardous char-
fects to water environment.
acteristics and is being disposed of, it will be
considered by the State of California to be a
hazardous waste subject to Title 22, Califor-
nia Code of Regulations. Before disposing of
hazardous waste, review and follow all perti-
nent federal and California requirements.
SCR catalytic converter
• Do not dispose of the spent SCR catalytic
Any dust from the SCR catalytic converter
converter or its constituent parts into any wa-
should be removed using a vacuum cleaner
terways, storm drains or sanitary sewers.
with microfilter to minimize exposure.
Make sure that the work surface is cleaned af-
ter completed work; Vacuum first then swab.
Make sure you clean your hands after work-
ing with SCR catalytic converter to avoid in-
The SCR catalytic converter contains vanadium
pentoxide, a chemical known to the State of Cal-
ifornia to cause cancer.
Work done on the SCR catalytic converter
may generate waste considered by the State
of California to be a hazardous waste subject
Additional considerations when working on the
to Title 22, California Code of Regulations.
SCR system
Before disposing of hazardous waste, review
and follow all pertinent federal and California
Carry out work on the SCR catalytic convert-
er in a well ventilated area. Use protective
goggles and gloves if there is any risk of
splashing or spraying of reductant or coolant.
When engine is running, the exhaust system
parts can reach such high temperatures that
there is a risk of personal injury. Make sure
that the exhaust system temperature has de-
creased to a suitable level before starting to
The SCR system is heated by water from the
engine cooling system. The cooling system
runs at overpressure and when the engine is
hot the coolant is hot. Do not open any hoses
without first stopping the coolant flow in the
A P3 type respirator/filter mask or a type
FFP3 fine dust musk, protective goggles and
gloves should be used for any work where
there is a risk of exposure to dust from the
SCR catalytic converter.
Use a disposable overall and dispose of it
properly after machining.
Eating, drinking or smoking while working is
not permitted.
This Operator's manual describes the operation
and maintenance of Scania industrial engines.
The engines are direct-injection, liquid-cooled,
For Scania to guarantee that the engine corre-
four-stroke turbocharged diesel engines. Certain
sponds to its certified configuration, and take re-
engines are also equipped with exhaust gas after-
sponsibility for any damage and injuries that
treatment management systems.
occur, maintenance must be carried out in ac-
cordance with the instructions in this Operator's
The engines are available with different output
and engine speed settings. Engine power for the
engine ordered is indicated on a plate located on
the engine control unit.
An emissions certified engine fulfils the emis-
sions requirements for a particular range of ap-
Only standard components are described in the
operator's manual. Information about special
On each emissions certified engine there is a la-
equipment is contained in instructions from the
bel which shows which requirements the engine
various manufacturers.
fulfils. Scania guarantees that each such engine
fulfils the emissions requirements for the range
of application for which it is certified.
To ensure the maximum performance and the
The following are required for the certified en-
longest service life for the engine remember the
gine to fulfil the emissions requirements once it
has been taken into service:
• Read through the Operator's manual before
• Maintenance is to be carried out in accord-
starting to use the engine. Even regular users
ance with the instructions in this Operator's
of Scania engines will get new information
from the Operator's manual.
• Maintenance and repairs of injection equip-
• Always follow the maintenance instructions.
ment are to be carried out by an authorised
• Read the section on safety carefully.
Scania workshop.
• Get to know your engine so that you know
• The engine may only be modified with equip-
what it can do and how it works.
ment that has been approved by Scania.
• Always contact a workshop with qualified
• Seals may be broken and setting data edited
personnel for maintenance and repair.
only once approval has been granted by Sca-
nia. Modifications may be made by author-
The information in this Operator's manual was
ised personnel only.
correct at the time of going to press. Scania re-
serves the right to make alterations without prior
• Modifications affecting the exhaust and in-
take systems must be approved by Scania.
Otherwise, the instructions in the Operator's
manual for the running and maintenance of the
engine shall apply. Follow the safety precautions
on the following pages.
Power classes
Power classes
Scania supplies engines in four different power
ICFN, Continuous service: Intended for contin-
uous use and an unlimited number of operational
hours per year at a total load factor of 100%.
IFN, Intermittent service: Intended for periodic
use, where the rated power is available for one
hour per three-hour period. The total load factor
must not exceed 80% of the rated power. Unlim-
ited number of operational hours per year.
PRP, Prime power: Intended for continuous use
and an unlimited number of operational hours
with varying loads. The average load factor must
not exceed 70% of the rated power in a 24-hour
period. Accumulated overload 110% for one
hour per 12-hour period. This power class ap-
plies to single-speed engines.
COP, Continuous power: Intended for continu-
al use with a non-varying load and an unlimited
number of operational hours.
The engine serial numbers and power classes for
the engines that are used in this installation
should be listed below: You can find the power
class of your engine in the engine type data sheet
on the Scania website,
Engine serial no.:
Engine type:
Engine power:
kW at
ICFN, Continuous service
IFN, Intermittent service
PRP, Prime power
COP, Continuous Power
Environment and safety
Different types of advisory
Environment and safety
Environmental responsibility
All advisories preceded by Warning! are very
Scania develops and produces engines that are as
important. They warn of serious faults and incor-
environmentally-friendly as possible. Scania has
rect operation that could lead to personal injury.
made major investments in the reduction of
harmful exhaust emissions in order to fulfil the
environmental requirements in force in almost
every market.
At the same time, we have been able to maintain
Block the starting device when working on the
a high level of performance quality and operat-
engine. If the engine starts unexpectedly, there is
ing economy for Scania engines. To maintain
a serious risk of injury.
these throughout the entire service life of the en-
gine, it is important for the user to follow the in-
structions on running, maintenance and fuel,
lubricating oil and coolant as outlined in the Op-
Advisories preceded by Important! warn of
erator's manual.
faults and incorrect operation that could lead to
Other green initiatives taken include ensuring
equipment being damaged. Example:
that, following maintenance and repair, waste
that is harmful to the environment (for example
oil, fuel, coolant, filters and batteries) is disposed
of accordance with the applicable environmental
An excessive coolant temperature can cause en-
gine damage.
The following pages contain a summary of the
Advisories preceded by Note: refer to informa-
safety precautions to be complied with when op-
tion important to ensure the best possible opera-
erating and maintaining Scania engines. The
tion and functionality. Example:
equivalent text can also be found under the rele-
vant maintenance item.
Leave the engine off for at least 7 minutes before
To prevent damage to the engine and to ensure
you check the oil level.
that it runs optimally, follow the instructions in
the warnings and advisories.
If the instructions are not followed, the warranty
can cease to apply.
Environment and safety
This Operator’s manual contains specially high-
lighted text with instructions to help protect the
environment during maintenance. Example:
The wrong fuel grade can cause breakdowns or
stoppages by causing the injection system to
malfunction. This can cause damage to the en-
gine and, possibly, personal injury.
Use a suitable container. The fuel collected must
be disposed of as specified in national and inter-
national laws and regulations.
Use only fuel which fulfils the requirements in
the Quality requirements for fuel section.
Warnings and advisories
Smoking is prohibited
During refuelling there is a risk of fire and explo-
• in the vicinity of flammable or explosive ma-
sion. The engine must be switched off and smok-
terial, e.g. fuel, oils, batteries, chemicals
ing is prohibited.
• when refuelling and in the vicinity of the fill-
Never overfill the tank as the fuel needs space to
ing station
expand. Make sure that the filler cap is fully
• when working on the fuel system
Safety precautions for running the
Hazardous gases
Daily maintenance
Always carry out a visual inspection of the en-
Only start the engine in a well-ventilated area.
gine and engine compartment before starting the
The exhaust gases contain carbon monoxide and
engine or when the engine has been switched off
nitrogen oxides, which are toxic.
after operation.
When the engine is run in an enclosed space,
This inspection should be done to detect fuel, oil
there must be an effective device to extract ex-
or coolant leaks, or anything else that may re-
haust gases and crankcase gases.
quire corrective action.
Environment and safety
Starter lock
Safety precautions for handling ma-
Fuel and lubricating oil
If the instrument panel is not fitted with a starter
lock, the engine compartment should be locked
to prevent unauthorised personnel from starting
the engine. Alternatively, a lockable master
All fuels and lubricants as well as many chemi-
switch or battery master switch can be used.
cals are flammable. Always follow the instruc-
tions on the relevant packaging.
The work must be carried out on a cold engine.
Starter gas
Fuel leaks and spillages on hot surfaces can
cause fire.
Store used rags and other flammable materials
safely so as to avoid spontaneous combustion.
Never use starter gas or similar agents to help
start the engine. This can cause an explosion in
the intake manifold and possible injury.
The batteries contain and form oxyhydrogen gas,
particularly during charging. Oxyhydrogen gas
is flammable and highly explosive.
The engine must not be run in environments
where there is a risk of explosion, as all of the
There must be no smoking, naked flames or
electrical or mechanical components can gener-
sparks near the batteries or the battery compart-
ate sparks.
ment. Incorrect connection of a battery cable or
jump lead can cause a spark, which can cause the
Approaching a running engine always poses a
battery to explode.
safety risk. Parts of the body, clothes or dropped
tools can get caught in rotating parts such as the
fan and cause injury. For personal safety all ro-
tating parts and hot surfaces must be fitted with








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