Scania DI9, DC9 Operator's Manual

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Operator's Manual

DI9, DC9 with DEC2

Industrial engine

opm96-9adec en 1 588 889

2003-10:1

Industrial & Marine Engines

IMPORTANT INFORMATION

When working on the engine, for example adjusting drive belts, changing the oil or adjusting the

clutch, it is important not to start the engine. The engine may be damaged and there is

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 is reproduced beside those maintenance points where it is

especially important to consider the risk of injury.

COMMISSIONING REPORT - WARRANTY

When the commissioning report has been filled in and sent to Scania, you have a 1-year warranty from the date of commissioning. Also fill in the particulars below as this can make things easier if you need to contact for example a service workshop.

Engine number

Commissioning date

User's name and address

Signature

Engine type

Variant

Engine type and variant are indicated on the engine type plate

2 © Scania Industrial & Marine Engines 2003-10:1

PREFACE

This Operator's Manual describes the handling and maintenance of Scania DC9 and DI9 Industrial Engines with DEC2.

The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder inline diesel type. These engines have turbochargers and charge air coolers: see page 10.

Common applications are as power units in construction machines, generator sets, earth-moving, railway and forestry machines as well as in irrigation systems.

The engines can have different output and speed settings.

The normal output setting of the engine (performance code) is indicated on the type plate, see page 10.

Note: Only standard components are described in the Operator's

Manual. Regarding special equipment, refer to the instructions of the relevant manufacturer.

In order to obtain the best value and service life from your engine, there are several points you should bear in mind:

- Read the manual before starting to use the engine. Even though you may be experienced with Scania engines you may find new information in this Operator's Manual.

- Follow the maintenance instructions. Good working order and service life are ensured if maintenance is carried out according to the instructions.

- In particular, read the safety information starting on page 6.

- Get to know your engine so that you know what it can do and how it works.

- Whenever necessary, always contact an authorised Scania workshop. They have special tools, genuine Scania parts and staff with training and practical experience of Scania engines.

Note: Always use genuine Scania parts during service and repair so as

to keep your engine in the best possible working order.

The information in this manual was correct at the time of going to press. However, we reserve the right to make alterations without prior notice.

Scania CV AB Industrial and Marine Engines

S-151 87 Södertälje, Sweden

During the warranty period,

only genuine Scania parts may

be used during service and

repair otherwise the warranty

will be invalidated.

2003-10:1 © Scania Industrial & Marine Engines 3

CONTENTS

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ENVIRONMENTAL RESPONSIBILITY . . . . . .4

CERTIFIED ENGINES . . . . . . . . . . . . . . . . . . . .5

SAFETY INFORMATION . . . . . . . . . . . . . . . . . .6

Safety precautions for running the engine . . . . 7

Safety precautions for handling materials . . . . .8

Safety precautions for care and maintenance . . 8

TYPE DESIGNATIONS . . . . . . . . . . . . . . . 10

DEC2 CONTROL SYSTEM . . . . . . . . . . . . 12

STARTING AND RUNNING . . . . . . . . . . . 19

AT FIRST START . . . . . . . . . . . . . . . . . . . . . . .19

CHECKS BEFORE RUNNING . . . . . . . . . . . . .21

STARTING THE ENGINE . . . . . . . . . . . . . . . .21

At temperatures below 0°C: . . . . . . . . . . . . . .22

DRIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Rotation speed . . . . . . . . . . . . . . . . . . . . . . . . .23

Coolant temperature . . . . . . . . . . . . . . . . . . . .23

Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .24

STOPPING THE ENGINE . . . . . . . . . . . . . . . . .24

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

CHECKS AFTER RUNNING . . . . . . . . . . . . . .25

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 26

ENGINES WITH FEW OPERATING

HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

MAINTENANCE SCHEDULE . . . . . . . . . . . . .27

LUBRICATING OIL SYSTEM . . . . . . . . . 28

OIL GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . .28

CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . .29

Checking oil level during operation . . . . . . . .29

OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . .29

Maximum angles of inclination during

operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

CLEANING THE OIL CLEANER . . . . . . . . . .30

CHANGING THE OIL FILTER . . . . . . . . . . . .32

COOLING SYSTEM . . . . . . . . . . . . . . . . . . 32

CHECKING COOLANT LEVEL . . . . . . . . . . .32

CHECKING THE COOLANT . . . . . . . . . . . . . .33

Checking protection against corrosion . . . . . . 35

Changing the coolant . . . . . . . . . . . . . . . . . . .35

CLEANING THE COOLING SYSTEM . . . . . . 36

Internal cleaning . . . . . . . . . . . . . . . . . . . . . . .37

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 38

READING THE VACUUM INDICATOR . . . .38

CLEANING THE AIR CLEANER COARSE

CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

CLEANING OR CHANGING THE FILTER

ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

CHANGING THE SAFETY CARTRIDGE . . . .39

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 40

CHECKING THE FUEL LEVEL . . . . . . . . . . . .40

CHANGING THE FUEL FILTER . . . . . . . . . . . 40

CHECKING THE INJECTORS . . . . . . . . . . . . .41

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 42

CHECKING THE ELECTROLYTE LEVEL

IN BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . .42

CHECKING THE STATE OF CHARGE IN

BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

CLEANING BATTERIES . . . . . . . . . . . . . . . . .42

CHECKING THE COOLANT MONITOR . . . .43

CHECKING THE TEMPERATURE

MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

CHECKING THE TEMPERATURE

SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

CHECKING THE OIL PRESSURE

SENSOR/MONITOR . . . . . . . . . . . . . . . . . . . . .45

CHECKING THE OIL PRESSURE MONITOR

FOR DEC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 46

CHECKING THE DRIVE BELT . . . . . . . . . . . . 46

CHECKING FOR LEAKAGE,

NECESSARY ACTION . . . . . . . . . . . . . . . . . . .47

CHECKING/ADJUSTING VALVE

CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . .48

CHANGING (

OR CLEANING) THE CLOSED

CRANKCASE VENTILATION VALVE. . . . . .50

LONG-TERM STORAGE . . . . . . . . . . . . . . 51

Preservative fuel . . . . . . . . . . . . . . . . . . . . . . .51

Preservative oil . . . . . . . . . . . . . . . . . . . . . . . .52

Preparations for storage . . . . . . . . . . . . . . . . .52

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Taking out of storage . . . . . . . . . . . . . . . . . . .53

TECHNICAL DATA . . . . . . . . . . . . . . . . . . 54

ALPHABETICAL INDEX . . . . . . . . . . . . . . 58

4 © Scania Industrial & Marine Engines 2003-10:1

ENVIRONMENTAL RESPONSIBILITY

Scania has always been very much at the leading edge when it comes to developing and producing engines which are as environmentally friendly as possible.

Major progress has been made on reducing harmful exhaust emissions as required to be able to meet the stringent environmental standards stipulated on almost all markets.

At the same time, we have been able to maintain high quality in terms of performance and operating economy for Scania Industrial and Marine Engines.

To preserve these qualities throughout the entire service life of the engine, it is important for the operator/owner to follow the instructions on running, maintenance and the choice of fuel and oil as outlined in the manual.

Other efforts to preserve the environment we all share are possible by ensuring that the person carrying out servicing and maintenance always makes sure that environmentally hazardous waste after servicing and repairs (oil, fuel, coolant, filters, batteries, etc.) is dealt with and disposed of in accordance with applicable environmental standards.

On a number of pages, this Operator's Manual contains specially highlighted text with instructions to help protecting our environment during certain servicing and maintenance work.

See example

Use a container to avoid spillage

when bleeding and changing

components.

2003-10:1 © Scania Industrial & Marine Engines 5

CERTIFIED ENGINES

Emissions-certified engines have been approved in accordance with a special certification standard. The certified engines supplied by Scania meet the most stringent emissions standards which apply on European (EU) and nonEuropean (USA) markets.

Scania guarantees that all the engines it supplies of a certified type are equivalent to the engine approved for certification.

The engine comes with a special certification plate which indicates the certification rules (standard) to which the engine has been approved. See page 10.

The following is required for the certified engine to meet emissions standards once it has been commissioned:

- Servicing and maintenance must be carried out in accordance with the instructions in this manual.

- Only genuine Scania parts are to be used.

- Injection equipment is to be serviced by an authorised Scania workshop.

- The engine must not be modified with equipment not approved by Scania.

- Seals may be broken and setting data edited only once approval has been granted by Scania in Södertälje. Changes may be made by authorised personnel only.

- Changes which affect the exhaust system and intake system must be approved by Scania.

Otherwise, the instructions in the manual in respect of running, care and maintenance of the engine shall apply. The safety precautions described over the next four pages must also be observed.

Important! If servicing and maintenance are not carried out as specified

above, Scania can no longer guarantee that the engine will comply with the certified design, nor can it take responsibility for any damage that occurs.

6 © Scania Industrial & Marine Engines 2003-10:1

SAFETY INFORMATION

General

This Operator's Manual contains safety information which is important so as to avoid both personal injury and damage to the product/other property. See also page 1.

The text highlighted in text boxes on the right of a number of pages is important for engine function and in order to avoid damage to the engine. If these instructions are not followed, your warranty may be invalidated.

See example

Similar text may also appear in the text column, and in this instance it will be marked

Note: or Important

The warning text found in text boxes on the right of a number of pages which is marked with a warning triangle and starts with WARNING is extremely important and warns you of serious engine faults or incorrect handling which may lead to injury.

See example

A list of the safety precautions to be followed when running and maintaining Scania engines can be found on the next three pages. Similar text can often be found at the relevant maintenance points, and here different levels of importance are attached to such text in accordance with the above description.

All points are marked

!, so as to indicate how important it is to read through

each point in this section.

For safety reasons, smoking is not allowed:

• In the vicinity of the engine and in the engine room

• When fuelling and close to the filling station

• When working on the fuel system

• In the vicinity of inflammable or explosive material (fuel, oils, batteries, chemicals, etc.)

Immobilise the starting device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK OF

INJURY

Only use Scania genuine fuel

filter.

2003-10:1 © Scania Industrial & Marine Engines 7

Safety precautions for running the engine

Daily inspection

Always carry out a visual check of the engine and engine room before starting the engine and once you have stopped the engine after running.

This will enable you to easily detect and fuel, oil or coolant leaks, or any other abnormalities which may require rectification.

Refuelling

There is a risk of fire and explosion when refuelling. The engine must be stopped and smoking is not allowed.

Do not overfill the tank due to a risk of expansion, and close the filler cap properly.

Use only fuel recommended in the service literature. Fuel of the wrong quality can cause the engine to malfunction or stop by preventing the injection pump and injectors from operating as they should.

This can cause damage to the engine and, possibly, injury.

Hazardous gases

Start the engine only in a well ventilated area. The exhaust fumes contain carbon monoxide and nitric oxides, which are toxic.

When running the engine in a closed area, there must be an efficient device for dissipating exhaust fumes and crankcase gases.

Starter lock

If the control panel is not fitted with a key operated switch, there should be a lock on the engine room to prevent unauthorised starting of the engine.

Alternatively, a lockable on/off master switch or battery master switch can be used.

Starting spray

Never use starting spray or similar to help you start the engine. This can cause an explosion in the intake manifold and possible injury.

Running

The engine must not be run in environments where there is a risk for explosion as all of the electrical or mechanical components can generate sparks.

Approaching a running engine always poses a safety risk. Parts of the body, clothes or dropped tools can get caught in rotating parts such as the fan and cause injury.

Therefore, all rotating parts and hot surfaces must be shielded as much as possible to aid personal safety.

8 © Scania Industrial & Marine Engines 2003-10:1

Safety precautions for handling materials

Fuel and oil

All fuels and lubricants and many chemicals are inflammable. Always follow the instructions on the relevant packaging.

All work on the fuel system must be done with the engine cold. Fuel leaks and spillage on hot surfaces can cause fire.

Store soaked rags and other inflammable materials safely so as to avoid spontaneous combustion.

Batteries

The batteries contain and emit oxyhydrogen gas, particularly during charging, and this gas is inflammable and highly explosive. Therefore, there must be no smoking, naked flames or sparks near the batteries or the battery compartment.

Incorrect connection of a battery cable or jump lead can cause a spark, which in turn can cause the battery to explode.

Chemicals

Most chemicals such as glycol, corrosion inhibitor, inhibiting oils, degreasing agents, etc. are hazardous to health. Always follow the safety precautions on the relevant packaging.

Some chemicals, such as inhibiting oil, are also inflammable.

Store chemicals and other materials which are hazardous to health in approved containers, marking them clearly and storing them where they are inaccessible to unauthorised persons. Always hand in leftover or used chemicals to an authorised waste disposal contractor.

Safety precautions for care and maintenance

Stop the engine

Always stop the engine before maintenance and servicing unless stated otherwise.

Prevent unwanted starting by taking out the ignition key where applicable and disconnecting the power using the master switch or battery master switch and locking them. Also put up a warning sign somewhere appropriate, indicating that work is in progress on the engine.

Working with a running engine always poses a safety risk. Parts of the body, clothes or dropped tools can get caught in rotating parts and cause injury.

Hot surfaces and fluids

There is always a risk of sustaining burns when an engine is hot. Therefore, take care not to come into contact with manifolds, the turbo, the sump, hot coolant and oil in pipes and hoses.

Lifting the engine

The engine lifting eyes must be used when lifting the engine. Check first that your lifting devices are in good condition and of the correct size to lift the weight.

Extra equipment on the engine can alter the centre of gravity, which is why you may need additional lifting devices to balance the engine correctly and lift it safely.

Never work underneath a suspended engine!

2003-10:1 © Scania Industrial & Marine Engines 9

Batteries

The batteries contain a highly corrosive electrolyte (sulphuric acid). Take care to protect your eyes, skin and clothes when charging or handling batteries. Wear protective gloves and goggles.

If the acid splashes on your skin, wash it off with soap and copious amounts of water. If acid splashes in your eyes, flush them immediately with copious amounts of water and contact a doctor.

Dispose of used batteries through an authorised waste disposal contractor.

Electrical system

The engine must be stopped and the power disconnected using the master switch or battery master switch before working on the electrical system.

External power supplies to extra equipment on the engine must also be disconnected.

Electric welding

When carrying out welding work close to and on the engine, remove the battery leads and the leads to the alternator. Also remove the multi-pin connector to the control unit.

Connect the weld clamp to the component to be welded and close to the welding point, never to the engine or in such a manner that the current can pass over to a mounting.

When you have finished welding, connect the leads to the alternator and control unit before connecting the batteries.

Lubrication system

Hot oil can cause burns and skin irritation. Therefore, avoid skin contact with hot oil.

Make sure that there is no pressure in the lubricating system before starting work on it. Never start or run the engine with the oil filler cap removed, as this may cause oil to be thrown out.

Dispose of used oil through an authorised waste disposal contractor.

Cooling system

Never open the coolant filler cap if the engine is hot. Hot coolant or steam may spray out and cause burns.

If you have to open or remove a cooling system component when the engine is hot, open the cap very carefully and slowly to relieve the system pressure before removing the cap. Wear gloves as the coolant is still very hot.

Dispose of used coolant through an authorised waste disposal contractor.

Fuel system

Always wear gloves when looking for leaks or carrying out any other work on the fuel system. Also wear protective goggles when testing injectors.

Fuel escaping at high pressure can penetrate tissues and cause serious injury.

Never use non-genuine parts in the fuel and electrical systems as genuine parts are designed and manufacture to minimise the risk of fire and explosion.

Before starting

Fit all removed shields before starting the engine again. Check that you have not left any tools or other objects on the engine.

Never start the engine without the air filter fitted. There is a risk of objects being sucked into the impeller or of injury if you come into contact with it.

10 © Scania Industrial & Marine Engines 2003-10:1

TYPE DESIGNATIONS

The engine type designation indicates, in the form of a code, the type of engine, its size and applications, etc.

The type designation and engine serial number are indicated on a type plate affixed to the right-hand side cover behind the oil cleaner. The engine number is also stamped in the top of the engine block in front of the first cylinder head. Refer to the illustration.

Engines which hold certification in respect of smoke and emissions are fitted with a plate which indicates the documents in accordance with which they are certified. This plate is located on rocker cover number two viewed from the front.

DI 9 56 A 06 E

Type

DC Supercharged diesel engine with air-cooled charge air cooler. DI Supercharged diesel engine with liquid-cooled charge air cooler

Displacement in whole dm

Performance and certification code

Indicates, together with the application code, the normal gross engine output. The actual output setting of the engine is indicated on the engine card.

Application

A For general industrial use

Variant 01-99

Type of regulator

E Electronically controlled governor (DEC2).

2003-10:1 © Scania Industrial & Marine Engines 11

The illustrations show a normal version of a DI9 56 engine.

Your engine may have different equipment from that illustrated.

1. Turbocharger

2. Engine number,

stamped into the engine block

3. Thermostat housing with

outlet

4. Type plate

5. Automatic belt tensioner

6. Coolant pump

7. Oil cooler

8. Draining, engine oil

9. Oil filter

10. Charge air cooler

11. Fuel filter

12. Draining, coolant

13. Starter motor

14. Oil cleaner

15. Oil dipstick

16. Extra coolant pump

17. Alternator

18. Injection pump with EDC

19. Connector panel DEC2

12 © Scania Industrial & Marine Engines 2003-10:1

DEC2 CONTROL SYSTEM

This engine has an injection pump with an electromagnetic actuator which adjusts the control rack to give the correct amount of fuel.

The system which controls the pump is called DEC2 (Digital Engine Control, generation 2).

The control unit (DEC2) continuously receives signals from sensors for engine speed, charge air temperature and pressure, coolant temperature, oil pressure, throttle pedal position and control rod travel in the injection pump. Using this input data and a control program, the correct amount of fuel for the current operating conditions can be calculated.

The system's sensors may be used only for DEC2, not for other instruments or other monitoring purposes.

The control unit contains monitoring functions to protect the engine in the event of a fault which would otherwise damage it. Faults and the more important monitoring functions are indicated on the control unit in the form of light emitting diodes. See illustration on page 15 for a description.

In the event of a fault Power - or Shutdown on the control unit comes on as well as the main indicator lamp on the main supply box and instrument panel.

If a fault has been indicated on the main indicator lamp, the operator can determine the cause of the fault with the help of the LEDs on the control unit and the troubleshooting schedule on page 18, and carry out the required investigation and remedy.

Depending on the nature of the fault, the control system can take various steps to protect the engine, reduce its power, allow it to run at a constant low speed or, if a functional fault is detected, the engine will be switched off automatically (Shutdown).

In order to read fault indications on the LEDs, there is a lamp test/fault code switch in the main supply box installed near the control unit.

A PC based program is also available to make it easier for service personnel to detect and rectify faults which may arise and to adjust certain parameters in the driving program.

Only authorised personnel are allowed to carry out diagnostic procedures and program changes.

The locations of the sensors and monitors which send signals to the control unit will be evident from the figures on pages 13 and 14.

There is a description of the functions of the LEDs during normal operation on page 15.

There are descriptions of LED indications when a fault has occurred and the action taken in the case of Power- and Shutdown on page 16.

Troubleshooting and fault code reading are described on pages 17 and 18.

2003-10:1 © Scania Industrial & Marine Engines 13

Location of sensors for DEC2 on DI9Location of sensors for DEC2 on DI9

1. Connection of lead to charge air

pressure sensor

2. Charge air temperature sensor

3. Oil pressure monitor

4. Connector panel

5. Coolant temperature sensor

6. Rotation speed sensors

14 © Scania Industrial & Marine Engines 2003-10:1

Location of sensors for DEC2 on DC9

1. Connection of lead to charge air

pressure sensor

2. Charge air temperature sensor

3. Oil pressure monitor

4. Connector panel

5. Coolant temperature sensor

6. Rotation speed sensors

2003-10:1 © Scania Industrial & Marine Engines 15

LED functions during normal operation

Note: The lamp test/fault code switch should not be

depressed. All LEDs come on briefly when the control unit is powered up.

CONTROL STATUS

< The LED flashes continuously when the control

unit is supplied with current, regardless of whether the engine is running or not.

SHUTDOWN

P The LED is out.

STARTING

< The LED lights up as soon as the engine starts to

rotate during an attempt to start it, follows the programmed starting sequence until it has been completed and then goes out.

RUNNING

< The LED comes on when the engine has started

and the "Starting"-LED goes out. It remains on until the engine is stopped.

TORQUE LIMIT

< The LED comes on when the control unit senses

that the engine has received the maximum permissible quantity of injected fuel according to its power curve. This means 100% power output at the current rpm. If the load increases, engine rpm will decrease.

BOOST LIMIT

< The LED comes on when the control unit's

smoke limiter limits the maximum fuel quantity. Operation of the smoke limiter is dependent on the charge air pressure.

POWER-

P The LED remains out during normal operation

as long as no fault is detected by the control unit. See next page for the procedure to be adopted in the event of a fault.

POWER+

< If the control unit is programmed so that the

engine can be operated with more than one power/torque curve (map), the following applies.

The LED comes on when the engine is operated at more than 100% power output (MAP 2). It goes out when the engine returns to the 100% power output curve (MAP 1) or when the power requirement drops to below 100%.

16 © Scania Industrial & Marine Engines 2003-10:1

Action when a fault arises

LED indications in the event of a fault

Note: It is indicated on the main indicator lamp in

the main supply box and on the instrument panel. The lamp test/fault code switch should not be depressed.

CONTROL STATUS

< The LED continues to flash even if a fault has

occurred as long as the control unit is powered up.

POWER-

< If the LED comes on, the control unit has

detected a fault condition which could result in engine damage if allowed to continue.

The control unit automatically reduces the power to a special level if this function has been selected.

Action: If possible reduce engine speed to idle

and conduct troubleshooting according to instructions on page 17 and the chart on page 18.

SHUTDOWN

< The LED comes on and the engine is switched

off automatically in the event of a fault so

serious that the engine could be damaged if it is still in operation.

Action: Conduct troubleshooting according to instructions on page 17 and the chart on page 18.

If the engine has not stopped, reduce engine speed to idle and carry out troubleshooting.

2003-10:1 © Scania Industrial & Marine Engines 17

Resetting functions with DIP switches in control unit

There are 8 DIP switches in the control unit under the round black rubber cover.

These switches should be in the ON position for normal operation in accordance with the driving program. For single speed engines, it may also be normal for DIP switches 6, 7 and 8 to be in the OFF position.

Shutdown at threshold values for low oil pressure and high coolant temperature can be selected by setting DIP switch 4 to OFF.

With DIP switch 4 in position ON, Power- indication is obtained for these threshold values. Engine power output reduction (LOP) can then be selected to prevent damage to the engine. Changes to the program may be made by authorised personnel only.

Note: The engine should only be used in an

emergency when the Power- indication comes on.

Reading fault codes

Note: If the engine has stopped or lost power but

the main indicator lamp is out and neither POWER- nor SHUTDOWN are on, the fault is outside the control unit's detection area. Probable causes: fuel starvation, temporary overload, mechanical fault.

- Activate the lamp test/fault code switch. In Scania's electrical equipment the main indicator lamp is located in this switch in the main supply box.

- All LEDs will then come on for 2 seconds to indicate that they are intact and in working order. This also applies to the main indicator lamp in the main supply box and on the instrument panel

Make a note of any LED that is defective.

- All LEDs will then go out for approximately 4 seconds.

- Following this, a fault code will be indicated on one of the LEDs for 2 seconds. Note which LED it is.

- The control unit will then automatically return to operating mode.

- After having made a note of the fault code, reset the lamp test/fault code switch and reset the control unit by turning off its power supply momentarily.

- The most probable cause of the fault can then be found in the troubleshooting schedule on the next page.

- When the fault or faults have been rectified the engine can be restarted.

- If the control system still gives an indication on the main indicator lamp, other faults may be registered. The fault codes must then read again as above since the system can only show one fault code at a time.

- The fault or faults will be logged in a special memory in the control unit where the operating time concerned is recorded. Stored faults can be accessed and erased by authorised service personnel.

18 © Scania Industrial & Marine Engines 2003-10:1

READING FAULT CODES

LED INDICATION WHEN THE LAMP TEST/FAULT CODE SWITCH IS ACTIVATED

CONTROL STATUS

SHUTDOWN

STARTING

RUNNING

TORQUE LIMIT

BOOST LIMIT

POWER -

POWER +

Probable cause Action

DEC2 has detected an internal fault in the control unit.

Send in the control unit for repair as soon as

possible.

The engine temperature has reached the threshold level

or the temperature sensor is inoperative.

Check the cooling system. Check the

temperature sensor and cable routing.

The engine has reached the overrevving limit or the

engine speed sensor is inoperative.

Check the wiring and connector. Renew the

engine speed sensor.

Control rack position sensor inoperative. Check connectors and cables to governor.

The intake air temperature has reached the threshold

level or the charge air temperature sensor is

inoperative.

Check the intake system. Check the temperature

sensor and cable routing.

DEC2 detects no charge air pressure.

The charge air pressure sensor is inoperative.

Check the charge air pressure cable. Send in the

control unit if the connection is damaged.

Engine speed potentiometer or the idling safety switch

is inoperative.

Check the cable routing, connectors and cables.

The oil pressure has dropped to the threshold level or

the oil pressure monitor is inoperative.

Check oil level, connector and cable. Renew the

oil pressure monitor.

<= LED is on

2003-10:1 © Scania Industrial & Marine Engines 19

STARTING AND RUNNING

AT FIRST START

When the engine is started for the first time, the maintenance points listed under "First start" in the maintenance schedule should be followed, see page 27.

Since the points are important for satisfactory operation of the engine right from the outset, they are also listed below.

1. Checking the oil level (see page 29).

6. Checking the coolant level (see page 33).

The coolant should contain anti-corrosive to protect the cooling system from corrosion.

If there is a danger of freezing:

- Only anti-freeze glycol should be used in the coolant as protection against corrosion. We recommend only nitrite-free anti-freeze glycol with the following supplier designations:

BASF G48 or BASF D542

- The concentration of glycol should be 30 - 60% by volume depending on the ambient temperature. 30% glycol by volume provides anti-freeze protection down to -16°C. See page 33.

- Never top up with only water or only glycol. Fluid losses must always be replaced with pre-mixed coolant having the same glycol concentration as that in the engine. If the glycol content drops, both anti-freeze protection and protection against corrosion are impaired.

Note: A glycol concentration below 30% by volume will not provide

sufficient protection against corrosion. Glycol concentrations higher than 60% do not improve anti-freeze protection and have a negative effect on engine cooling capacity.

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 Corrosion Inhibitor

(no glycol)

The recommended glycols

should not be mixed with

glycol containing nitrite-based

corrosion inhibitor.

Ethylene glycol and

corrosion inhibitor

are toxic if ingested.

Avoid contact with the skin.

20 © Scania Industrial & Marine Engines 2003-10:1

If there is no danger of freezing:

-Only Scania Corrosion Inhibitor should be used in the coolant as protection against corrosion. The correct concentration of anti-corrosive is 7-12% by volume and this must never drop below 7% by volume. The inhibitor in Scania Corrosion Inhibitor is free of nitrite.

- First filling: Fill up the system with water + 10% by volume Scania

Corrosion Inhibitor. Use drinking water with a pH of 6 - 9.

- Never top up with only water or only anti-corrosive! Fluid losses must always be replaced with blended coolant: water + 10% Scania Corrosion Inhibitor by volume.

Coolant filter (not standard equipment)

Only coolant filter without inhibitor may be used. The use of coolant filters increases the life of the coolant and reduces the risk of deposition corrosion.

12. Checking the fuel level (see page 40).

15. Checking the electrolyte level in batteries (see page 42).

16. Checking the state of charge in batteries (see page 42).

18. Checking the coolant level monitor (see page 43).

19. Checking the temperature monitor (see page 44).

20. Checking the oil pressure monitor (see page 45).

21. Checking transmission tension (see page 46).

Ethylene glycol and corrosion

inhibitor are

toxic if ingested.

Avoid contact with the skin.

Immobilise the starting device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK

OF INJURY.

Overdosing with Scania

Corrosion Inhibitor and mixing

with glycol can cause sludge to

be formed.

If a coolant filter has been fitted

it must not contain inhibitor.

2003-10:1 © Scania Industrial & Marine Engines 21

CHECKS BEFORE RUNNING

Before running, "Daily maintenance" as described in the maintenance schedule should be carried out, see page 27.

STARTING THE ENGINE

If the fuel tank has been run dry or if the engine has not been used for a long time, bleed the fuel system (see page 40).

Out of consideration for our common environment, your new Scania engine has been designed to use a smaller amount of fuel when starting. Using unnecessarily large amounts of fuel when starting the engine always results in the discharge of unburnt fuel.

- Open the fuel cock, if fitted.

- Declutch the engine (not engines with fixed clutch, e.g. generator sets).

- Engines with battery master switch: Switch on the power by means of the battery master switch.

- DEC2: If the main indicator lamp comes on or flashes when the power is turned on, this indicates the presence of a fault in the control system or engine which must be found and rectified before the engine is started. See page 16.

- Start the engine by means of the starter button or starter key.

Starting at low temperatures

Local environmental requirements must be complied with. Starting aids, engine heaters and/or flame start devices should be used to avoid starting problems and white smoke.

To limit white smoke, the engine should be run at low speed and under moderate load. Avoid running it longer than necessary at idling speed.

Start the engine only in a well

ventilated area.

If it is run in a enclosed space,

there should be an effective

device to draw off exhaust gases

and crankcase gases.

Never use starting spray or

similar to help you start the

engine.

An explosion may occur in the

intake manifold with a risk of

personal injury.

22 © Scania Industrial & Marine Engines 2003-10:1

At temperatures below 0°C:

Note: Only use starting aids recommended by Scania.

- The starter motor may only be used for 30 seconds at a time. After that time it must rest for 2 minutes.

If the engine has flame start:

- Operating flame start without timer relay: Press the control button, which also acts as a pre-glow button (maximum 20 seconds). The glow plug continues to glow as long as this button is depressed after the engine has started. Maximum time is 5 minutes.

- Operating flame start with timer relay: Press the pre-glow button (maximum 20 seconds). Release it when the engine starts. The timer relay keeps the glow plug glowing for 5 minutes. If a shorter glow time is required, press the release button. The key must be set to the 0 position if the start attempt fails.

Note: If the engine is equipped with an INTERLOCK switch, this

switch should be depressed and held down until the oil pressure has reached a sufficiently high level.

- Generator sets should be operated under load immediately after starting to avoid the risk of white smoke. This applies in particular to engines that have been installed without aids for heating or applying a basic load.

- Warm up the engine with a moderate load. A light load on a cold engine gives better combustion and faster heating than warming up with no load.

The starter motor may only be

connected for a maximum of

30 seconds.

There is risk of overheating.

Allow the engine to rest for

2 minutes between each

attempt to start it.

2003-10:1 © Scania Industrial & Marine Engines 23

DRIVING

Check instruments and warning lamps at regular intervals.

Rotation speed

The Scania tachometer is divided into sectors of different colours, as follows:

Coolant temperature

Normal coolant temperature when the engine is running should be 70 - 90°C.

DEC2: If the temperature is high, 98°C or higher, it is possible to instruct the control system to reduce the engine power (Power -) in order to lower the temperature. See the DEC section on page 17.

If the temperature continues to rise, the engine will be stopped automatically (Shutdown) at 103°C. See the DEC section on page 17.

Excessively high coolant temperature can damage the engine.

If run for extended periods under an extremely light load, the engine may have difficulty in maintaining normal operating temperature. However, the temperature will rise to a normal level again when the load on the engine is increased.

0 - 500 rpm red area: prohibited engine speed,

passed when stopping and starting.

500 - 700 rpm yellow area: slow idle.

700 - 2200 rpm green area: normal operating speed.

The engine's operating speed range is controlled by the DEC2 control system.

2200 - 2600 rpm yellow/green

striped:

unsuitable operating speed. May occur when switching off and during downhill engine braking

2600 - 3000 rpm red area: prohibited engine speed

WARNING! When driving the vehicle on a steep downhill

slope, or in other installations where the engine can be driven by the vehicle movement, DEC2 will set zero fuel supply to protect against overrevving and will switch off the engine. It must not be disengaged in this position since this can cause important functions such as the steering and brake system to fail when the engine stops rotating.

Cooling systems with Scania

radiators and plastic expansion

tanks must not have excess

pressure in the system, i.e.

pressure caps must not be used

on expansion tanks.

24 © Scania Industrial & Marine Engines 2003-10:1

Oil pressure

Max. oil pressure:

warm engine running at a speed above 800 rpm 6 bar

Normal oil pressure:

warm engine running at an operating speed of 3 - 6 bar

Min. oil pressure:

warm engine running at a speed of 800 rpm 0.7 bar

At speeds below 800 rpm the gauge may show low oil pressure although no fault is present.

Oil pressure below 0.7 bar at speeds above 800 rpm will cause engine damage. The engine must be stopped immediately.

DEC2: The engine is stopped automatically if this function is selected. See the DEC section on page 17.

Charging indicator lamp

If the lamp comes on during operation:

- Check/adjust the alternator drive belts as described under the maintenance point. See page 46.

- If the charging indicator lamp is still on, this could be due to an alternator fault or a fault in the electrical system.

STOPPING THE ENGINE

1. Run the engine without a load for a few minutes if it has been run

continuously with a heavy load.

2. Stop the engine with the stop button. Keep the stop button depressed

until the engine is completely stationary.

3. DEC2: Before switching off, check that the control system's main

indicator lamp is not on or flashing. See page 16 for troubleshooting.

4. Engines with battery master switch: Switch on the power by means of

the battery master switch. (Does not apply to emergency generator sets).

5. Set the control switch to "0". (Does not apply to emergency generator

sets).

High lubricating oil pressure

(above 6 bar) is normal when

starting a cold engine.

High lubricating oil pressure

(above 6 bar) is normal when

starting a cold engine.

There is danger of turbo

damage and post boiling if the

engine is stopped without

cooling.

The power must not be

switched off before the engine

has stopped.

2003-10:1 © Scania Industrial & Marine Engines 25

Clutch

- See the manufacturer's instructions for handling and operating the clutch.

WARNING! If the clutch output shaft is rotating (e.g. in multiple

engine installations where other engines are running), the clutch can, under its own power, be drawn to the engaged position. THIS CAN CAUSE INJURY and engine damage. For this reason, always secure the clutch in the disengaged position if there is a risk of the output shaft starting to rotate.

CHECKS AFTER RUNNING

- Check that the power is cut from the battery master switch and that the control switch is in the "0" position.

- Fill the fuel tank. Make sure that the filler cap and the area round the filler opening are clean to avoid contamination of the fuel.

- If there is a risk of freezing, the cooling system must be drained if it does not contain sufficient glycol, see page 33.

- At temperatures below 0°C: Prepare for the next start by connecting the engine heater.

Topping up with coolant

should be carried out when

the engine is stopped after

the first start.

Immobilise the starting device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK OF

INJURY

26 © Scania Industrial & Marine Engines 2003-10:1

MAINTENANCE

The maintenance programme covers 24 points, divided into the following main groups:

Lubricating oil system . . . . . . . . . . . . . . . . . page 28

Cooling system . . . . . . . . . . . . . . . . . . . . . . .page 32

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . .page 38

Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . .page 40

Electrical system, monitors, batteries, etc. . . page 42

Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . .page 46

The maintenance points are divided into intervals as follows:

Daily maintenance

Maintenance before the first start

Maintenance after the first 400 hours of operation

Periodic maintenance every 200 hours of operation (carried out after 200, 400, 600, 800, etc. hours)

Periodic maintenance every 400 hours of operation (carried out after 400, 800, 1200, 1600, etc. hours)

Periodic maintenance every 1200 hours of operation (carried out after 1200, 2400, 3600, etc. hours)

Periodic maintenance every 2400 hours of operation (carried out after 2400, 4800, etc. hours)

Periodic maintenance every 4800 hours of operation (carried out after 4800, 9600, etc. hours)

Annual Maintenance

Maintenance every 5th year

ENGINES WITH FEW OPERATING HOURS

Emergency generator sets and the like that are not used regularly should be run on test and checked in accordance with the generator set manufacturer's instructions.

Run the engine until it reaches operating temperature and then carry out the maintenance points below:

1. Checking oil level.

5. Checking coolant level.

8. Checking low pressure indicator.

12. Checking fuel level.

15. Checking electrolyte level in batteries.

16. Checking state of charge in batteries.

17. Cleaning batteries.

22. Look for leakage, rectify as necessary

Immobilise the starting device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK OF

INJURY

For engines with few operating

hours that do not receive

periodic maintenance according

to the maintenance schedule on

page 27, maintenance should be

carried out in accordance with

the schedule:

"Annually"

"Every 5th year"

2003-10:1 © Scania Industrial & Marine Engines 27

MAINTENANCE SCHEDULE

1. More often if required

2. For engines with few operating hours, see page 26.

3. Earlier if low pressure indicator shows red.

4. If inhibitor has not been topped up for five years, the coolant should be changed.

Daily

First

time at

Interval At least

First start

400 h

200 h

400 h

1200 h

2400 h

4800 h

Annually

Every 5th year

LUBRICATING OIL SYSTEM, page 28

1. Checking oil level



2. Oil change

1 

3. Cleaning oil cleaner

1 

4. Renewing the oil filter

1 

COOLING SYSTEM, page 32

5. Checking coolant level



6. Checking coolant

 4 

7. Cleaning cooling system

1 

AIR CLEANER, page 38

8. Test reading low pressure indicator



9. Cleaning the coarse cleaner

1 

10. Cleaning or changing filter element

3 

11. Changing safety cartridge

 

FUEL SYSTEM, page 40

12. Checking fuel level

 

13. Changing main filter

1 

14. Checking injectors

 

ELECTRICAL SYSTEM, page 42

15. Checking electrolyte level in batteries

 2 

16. Checking state of charge in batteries

 2 

17. Cleaning batteries

2 

18. Checking level monitor

  

19. Checking temperature monitor

  

20. Checking oil pressure monitor

  

MISCELLANEOUS, page 46

21. Checking drive belt

  

22. Look for leakage, rectify as necessary



23. Checking/adjusting valve clearances

 

24. Changing (or cleaning) valve for closed crankcase ventilation



28 © Scania Industrial & Marine Engines 2003-10:1

LUBRICATING OIL SYSTEM

OIL GRADE

The engine oil must at least meet the requirements for one of the following oil classifications:

- ACEA E3, E4 or E5

- The Total Base Number (TBN) should be minimum 12-13 (ASTM 2896).

- Check with your oil supplier that the oil meets these requirements.

- The specified oil change intervals are applicable provided that the fuel sulphur content does not exceed 0.3% by weight. If the sulphur content is greater than 0.3% but no more than 1.0%, the oil change interval must be halved (200 h).

- Viscosities are shown in the figure below.

- When ambient temperatures are extremely low: Consult your nearest Scania representative to avoid starting difficulties.

Oil analysis

Some oil companies can offer analysis of the engine oil. Such analysis measures the oil's TBN (Total Base Number), TAN (Total Acid Number), fuel dilution, water content, viscosity and the quantity of wear particles and soot in the oil.

The result of a series of analyses is used as the basis for establishing a suitable oil change interval.

If the conditions are changed, a new oil analysis programme must be carried out to establish the new change interval.

Additives must not be used.

The oil should be suitable for

all temperature variations until

the next oil change.

-40 -30 -20 -10 0 10 20 30 40

°C

SAE 10W-30

SAE 20W-30

SAE 30

SAE 40

SAE 50

SAE 5W-30

SAE 15W-40

2003-10:1 © Scania Industrial & Marine Engines 29

1. Daily:

CHECKING OIL LEVEL

Note: Before checking oil level: Allow the engine to remain stationary

for at least 1 minute.

- The correct level is between the marks on the dipstick. Top up when the level is at the lower mark.

- Correct type, see "Oil grade" on page 28.

Checking oil level during operation

On some engines the oil level can be checked during operation.

- Remove the oil filler cap to release the pressure in the crankcase.

- Check the level on the dipstick. Correct oil level: 10 mm below the Min.

or Max. mark.

2. Every 400 hours:

OIL CHANGE

Note: If the engine is used for especially demanding operations,

particularly in a dusty environment or if the deposits in the centrifugal cleaner are thicker than 20 mm: change the oil at more frequent intervals.

- Unscrew the plug and drain the oil when the engine is hot.

- In certain engines the oil is pumped out by means of a bilge pump.

- Clean the magnet on the plug.

- Refit the plug.

- Fill up with oil.

- Check the level on the dipstick.

Max. 27 dm

Min. 20 dm

Max. 20 dm

Min. 16 dm

1 dm3 = 1 litre

Maximum angles of inclination during operation

Maximum permissible angles during operation vary, depending on the type of oil sump, see illustration.

Note: Specified angle may only occur intermittently.

WA R NI N G

The oil may be hot.

Wear protective gloves and

goggles

Max.

Min.

Use a container to avoid

spillage when changing the oil.

Dispose of used oil through an

authorised waste disposal

contractor.

30 © Scania Industrial & Marine Engines 2003-10:1

3. Every 400 hours:

CLEANING THE OIL CLEANER

(at same time as an oil change)

- Unscrew the nut and remove the cover.

- Lift out the rotor and loosen the nut on the rotor bowl three turns.

- If the nut is jammed: Clamp the nut, absolutely not the rotor, in a vice and turn the rotor three turns by hand or with a screwdriver.

- Tap the nut lightly with your hand or a plastic hammer, to detach the rotor bowl from the bottom plate.

- Unscrew the nut and remove the rotor bowl.

- Prize carefully to detach the strainer from the bottom plate.

- Scrape off the deposits from the inside of the rotor bowl. If there are no deposits, this indicates that the cleaner is not working properly.

- If the deposits are thicker than 20 mm: clean more often.

Open the cap carefully. The

oil may be hot.

2003-10:1 © Scania Industrial & Marine Engines 31

- Wash all parts in diesel oil.

- Fit the O-ring in the rotor bowl. Make sure it is not damaged. Change if necessary.

- Assemble the rotor.

- Tighten the rotor nut firmly by hand

- Refit the rotor.

- Make sure that it spins easily.

- Check that the O-ring in the bowl is undamaged. A hardened or damaged O-ring must be changed.

- Screw the bowl down hard by hand

If the nut is tightened with a tool, the rotor shaft, nut or bowl may be damaged.

Functional inspection

The rotor rotates very fast and should continue to rotate when the engine has stopped.

- Stop the engine when it is warm.

- Listen for a whirring sound from the rotor or feel whether the cleaner housing is vibrating.

The rotor normally continues spinning for 30 - 60 seconds after the engine has stopped.

If it does not: dismantle it and inspect the component parts.

32 © Scania Industrial & Marine Engines 2003-10:1

4. Every 400 hours:

CHANGING THE OIL FILTER

(at same time as an oil change)

- Remove the old filter.

- Oil the rubber gasket and fit a new genuine Scania filter.

- Tighten the filter by hand.

Never use tools for this. The filter could sustain damage, obstructing circulation.

- Start the engine and check for leaks.

Important! If the deposits in the centrifugal cleaner are more than 20 mm

thick, the oil filter has to be replaced more often. The same is true for cleaning the centrifugal filter and changing the oil.

COOLING SYSTEM

5. Daily:

CHECKING COOLANT LEVEL

- Open the expansion tank filler cap and check the coolant level.

- Correct level: (Scania plastic expansion tank)

- Cold engine: The coolant should be level with the bottom of the filler neck.

- Hot engine: The coolant should be about 25 mm above the lower edge of the filler hole.

- Other types of expansion tank according to the instructions of the fitter.

- Top up the coolant as necessary, see point 6.

Note: When filling large amounts of coolant:

Never pour cold coolant into a hot engine. This could crack the cylinder block and cylinder head.

Always top up with ready mixed

coolant.

Open the cap carefully.

Water and steam may

spray out.

Use a container to avoid spillage

when changing the filter.

Dispose of used filters through

an authorised waste disposal

contractor.

2003-10:1 © Scania Industrial & Marine Engines 33

6. Every 2400 hours:

CHECKING THE COOLANT

Coolant should be checked as follows:

a) Check the appearance of the coolant.

b) Coolant with glycol only: check the glycol content.

c) Coolant with Scania Corrosion Inhibitor only:

Check the anti-corrosive content.

The composition of the coolant is described in more detail under

"Starting and running"

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 it.

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

- Use drinking water with a pH of 6 - 9.

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.

- 30% glycol by volume provides protection against freezing to -16°C. If additional protection against freezing is required, see the table on the next page to help you calculate how much glycol you need.

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: The coolant should be changed when the cooling system is

cleaned: every 4800 hours or at least every 5th year.

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 Corrosion Inhibitor

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

corrosion inhibitor.

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 © Scania Industrial & Marine Engines 2003-10:1

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,

Ice slush starts

to form at °C

-6 -9 -12 -16 -22 -27 -36 -46 -55

Glycol dm

(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 formation starts (ice slush)

Curve B: Temperature at which there is a risk of

damage by freezing

1. Safe area

2. Malfunctions may occur (ice slush)

Characteristics 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

Anti-freeze glycol, % by volume

2003-10:1 © Scania Industrial & Marine Engines 35

Checking protection against corrosion

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 Corrosion Inhibitor should be used in the coolant.

The inhibitor in Scania Corrosion Inhibitor is free of nitrite.

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

- Topping up with 1.0% Scania Corrosion Inhibitor 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 blended coolant: water + 10% Scania Corrosion Inhibitor by volume.

Note: The coolant should be changed when the cooling system is

cleaned: every 4800 hours or at least every 5th year.

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 drain taps.

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

Mix coolant as described on page 33.

Use a container to avoid spillage

when changing the coolant.

Dispose of used coolant through

an authorised waste disposal

contractor.

If a coolant filter has been fitted

it must not

contain inhibitor.

Mixing with glycol or the use of

too much corrosion inhibitor can lead to build up of sludge and reduced cooling capacity.

It is highly dangerous to

consume corrosion inhibitor.

Avoid contact with the skin.

36 © Scania Industrial & Marine Engines 2003-10:1

Charge air cooler (DI engine)

Drain the coolant from the engine, see "Changing the coolant".

2. Detach the intake manifold from the turbo.

3. Detach the charge air cooler inlet and outlet connections for the coolant.

4. Remove the upper intake manifold.

Take care not to damage the element's water connections.

5. Remove the bolts holding the element and remove the element.

6. Clean the outside of the element. Use a paraffin-based engine cleaner.

7. Fit a new gasket to the lower part of the intake manifold.

8. Screw the element into the lower part. Tighten the bolts to 26 Nm.

9. Fit new V-ring seals to the inlet and outlet connections of the element

and fit the upper part of the intake manifold. Tighten the bolts to 50 Nm.

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

11. Refit the delivery pipe clamps.

12. Connect the intake manifold from the turbo.

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

1. Intake

manifold, upper part

2. V-ring seal

3. Element

4. Gasket

5. Intake

manifold, lower part

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.

2003-10:1 © Scania Industrial & Marine Engines 37

Internal cleaning

Removing oil and grease

- If possible, run the engine until it has reached operating temperature and then drain the cooling system.

- Remove the thermostats.

- Fill the system with clean, hot water mixed with liquid dishwasher detergent designed 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 about 20-30 minutes.

- Drain the water from the system.

- Refit the thermostats.

- Top up the system 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 thermostats.

- Fill the system with clean, hot water mixed with one of the commercially available radiator cleaners 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 about 20-30 minutes.

- Drain the water from the system.

- Refit the thermostats.

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

Handling cleaning agents for

the cooling system:

Read the warning label on the

container.

Use a collecting vessel in order

to avoid spillages when

changing the coolant.

Dispose of used coolant through

an authorised waste disposal

contractor.

38 © Scania Industrial & Marine Engines 2003-10:1

AIR CLEANER

8. Daily:

READING THE VACUUM INDICATOR

If the red indicator telltale is entirely visible, change or clean the air cleaner filter element, point 10. This is particularly important if the engine is run at high loads and high 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 cleaner as shown in the figure and screw the cover in

place.

1. Filter element

2. Coarse cleaner

3. Cover

4. Vacuum indicator

Air cleaner with coarse cleaner

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 only be cleaned a maximum of four times. After cleaning, it has poorer dust 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.

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 without

the air filter.

There is a risk of injury or

serious engine damage.

2003-10:1 © Scania Industrial & Marine Engines 39

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:

CHANGING 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. Change or clean the filter element, see point 10.

6. Assemble the air cleaner.

1. Safety cartridge

Air cleaner with safety cartridge

Do not remove the safety

cartridge unnecessarily.

Never clean the safety cartridge

40 © Scania Industrial & Marine Engines 2003-10:1

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, see point 13.

13. Every 1200 hours:

CHANGING 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. Discard the filter according to environmental requirements.

- Fit the new filter and tighten it by hand.

Never use tools for this. 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

- Open the bleed screw 1 on the main filter.

- Pump with the hand pump 2 until the fuel flowing out by the bleed screw is free from air.

- Close the bleed screw. Pump a few more strokes with the hand pump.

If there are starting difficulties after bleeding . . . . .

- Unscrew the injection pump overflow valve 3 half a turn and make another attempt at starting.

If the engine will still not start . . . . . . .

- Pump with the hand pump until the fuel coming through the overflow valve is free from bubbles.

- Tighten the overflow valve when the engine has started.

Use a container to avoid spillage

when bleeding and changing

components.

Only use Scania genuine fuel

filter.

Observe the utmost cleanliness

when working on the fuel

system.

There is a risk of engine

malfunction and damage to the

injection equipment.

2003-10:1 © Scania Industrial & Marine Engines 41

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 round 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 sealing washer 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 a nozzle tester.

Correct opening pressure, see Technical data, page 54.

Fitting

1. Check that there is no old sealing washer in place and fit a new sealing

washer in the bottom of the injector seat.

2. Fit a new O-ring in the threaded socket nut and a new sealing ring 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 cap nuts to 20 Nm (2.0 kpm). Fit

clamps and brackets.

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. Sealing washer

1. Delivery pipe

2. Cap nut

3. Washer

4. Cone

5. Connection on injector or

injection pump

The delivery pipes must not be

bent.

All clamps must be refitted.

Also wear protective goggles

when testing injectors.

A jet from the injector can

penetrate tissue and cause

serious injury.

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 battery. This will damage the battery in the long run.

17. Every 200 hours:

CLEANING 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 protective goggles when charging and

handling batteries

The batteries contain a highly

corrosive acid.

Do not connect the terminals up

incorrectly.

This can cause serious damage

to the electrical system.

If the terminals are shorted,

sparking will occur.

Avoid naked flames or sparks

near the batteries.

When the batteries are

charged, oxyhydrogen gas is

formed which is inflammable

and explosive.

18. Every 1200 hours:

CHECKING THE COOLANT MONITOR

(optional equipment)

1. Start the engine.

2. Lower the coolant level in the expansion tank.

3. Automatic stop in case of fault: Engine stops, indicator lamp is on, and

buzzer sounds if there is no fault in the level monitor.

4. No automatic stop in case of fault: Indicator lamp is on, buzzer sounds

if there is no fault in the level monitor.

5. Top up coolant to the correct level, see page 32.

2-pin level monitor installed in the

expansion tank for radiators

supplied by Scania

Use a container to avoid spillage

when draining the coolant.

Dispose of used coolant through

an authorised waste disposal

contractor.

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) on the monitor.

5. Submerge the monitor sensor body in water. Heat the water slowly

(about 1° per minute) using an immersion heater, for example.

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

(about 1° per minute) using an immersion heater, for example.

6. Check the resistance at the temperatures given below.

7. The sensor should give the following readings:

temp.

°C

Resistance ΩTolerance

°C

60 134 ± 13,5

±4

90 51,2 ± 4,3

±3

100 38,5 ± 3

±3

2-pin temperature sensor

C = Common connection

1 = Connection C -1 closes at the

stamped temperature

2 = Connection C -2 switches off

at the stamped temperature

2-pin temperature monitor

Use a container to avoid spillage

when draining the coolant.

Dispose of used coolant through

an authorised waste disposal

contractor.

20. Every 1200 hours:

CHECKING THE OIL PRESSURE SENSOR/MONITOR

Sensor function

Measure the output voltage from the sensor (pin 3) at different oil pressures. The sensor should give the following readings:

0.85-1.15 bar = 2.45 volts

1.80-2.20 bar = 3.70 volts

2.75-3.25 bar = 4.50 volts

3.79-4.20 bar = 5.20 volts

4.55-5.45 bar = 5.70 volts

5.40-6.6 bar = 6.10 volts

The tolerance values apply at +30°C - 110°C. The tolerance range increases at lower temperatures, e.g. 0°C = x 1.4.

Monitor function

Connect a test lamp to oil pressure monitor pin 4 (- earth) and check that the monitor closes at the correct pressure when the engine is started and stopped. The monitor should close at 0.7 ± 0.15 bar when the engine is stopped.

Important The sensor/monitor must be supplied with voltage when

measuring. Max. load 4 W from test lamp.

CHECKING THE OIL PRESSURE MONITOR FOR DEC 2

Connect an ohmmeter or test lamp to the oil pressure monitor and check that the monitor opens/closes at the correct pressure when the engine is started and stopped. The monitor should open at 1.1 ± 0.15 bar when the engine is started and close at 0.7 ± 0.15 bar when the engine is stopped.

CHANGING THE BATTERY

Removal

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

earth).

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

starter motor).

Fitting

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

2. Connect the negative cable (-) to the battery (cable connected to earth).

MISCELLANEOUS

21. Every 1200 hours:

CHECKING THE DRIVE BELT

If the drive belt (1), which is a poly-V belt, is worn or damaged it must be changed.

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

The extra coolant pump is driven with a V-belt (3) via a pulley on the crankshaft. This V-belt should be tensioned with the aid of the pump attachment until it can be pressed down a maximum of 10 mm with a pressure of 35-50 N.

Do not connect the terminals

up incorrectly.

This can cause serious damage

to the electrical system.

If the terminals are shorted,

sparking will occur.

Dispose of used batteries

through an authorised waste

disposal contractor.

22. Daily:

CHECKING FOR LEAKAGE, NECESSARY ACTION

- Start the engine.

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

- Tighten or change leaking connections. Check the overflow holes (1) in the block which show whether the O-rings between the cylinder liners and crankcase are leaking, see figure.

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

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

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.

Take care to ensure that any leaks do not cause pollution.

If serious leakage occurs,

contact your nearest Scania

workshop.

23. Every 2400 hours:

CHECKING/ADJUSTING VALVE CLEARANCES

Note: Checking/adjusting valve clearances 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 torque: 26 Nm.

Intake valve clearance: 0.45 mm. Exhaust valve clearance: 0.80 mm.

Alternative 1

- Set No. 1 cylinder to TDC by turning the engine in its direction of rotation until all four valves are closed.

- Adjust the following valves. Correct valve clearances are also given on the instruction plate on one of the rocker covers:

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

Cylinder numbering

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.

Alternative 2

- Set No. 1 cylinder to TDC by turning the engine in its direction of rotation until all four valves are closed.

- Adjust all valves for No. 1 cylinder. Correct valve clearances are indicated on the instruction plate on one of the rocker covers.

- Repeat this procedure with the other cylinders in the order 5 - 3 - 6 - 2 - 4 (firing order) by turning the engine 1/3 revolution in its direction of rotation between each adjustment.

Note:

Readings can be taken from the flywheel through covers in the flywheel housing either from above or underneath depending on access when fitting.

It says up or down on the flywheel

Both covers are fitted with a cover at delivery.

Covers for reading

on the flywheel housing

24. Every 2400 hours:

CHANGING (or CLEANING) THE CLOSED CRANKCASE VENTILATION VA LV E

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 allow it to drip dry.

- Refit the valve.

- The valve may be reused (cleaned), but not more than twice after the first 2400 hours of use. Take care to mark the valve after cleaning it.

LONG-TERM STORAGE

If the engine is not to be used for a lengthy period of time, special measures should be taken to protect the cooling system, fuel system and combustion chamber from corrosion and the exterior from rusting.

The engine can normally stand idle for up to six months. If it remains unused for longer than this the following measures, which provide protection for about four years, should be adopted. An alternative to preparing the engine for long-term storage is to start the engine and warm it up every 6 months.

Preparing the engine for long-term storage means:

- Thoroughly cleaning the engine

- Running the engine for a certain time using 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 coolant containing 50% glycol by volume. Glycol without nitrite-based inhibitor should be used. For example BASF G48 or BASF D542.

Preservative fuel

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

-Mix 1 cm

(ml) Lubrizol 560A in 10 dm3 (l) of fuel.

HANDLING LUBRIZOL 560A

Hazardous!

Contains aromatic hydrocarbons

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

Wear protective gloves and goggles when handling Lubrizol. Do not use contaminated clothing.

If it gets in your eyes: Rinse with a gentle stream of water (at least 15 minutes). Seek medical attention.

If it gets on your skin: Wash the affected area with soap and water

If inhaled: Fresh air, rest and warmth

Inflammable: Fire class 2A. Flashpoint + 27.

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

Storage: In well-sealed receptacle in a dry, cool place. Keep out of reach of children.

Ethylene glycol is

toxic if ingested.

Avoid contact with the skin.

Preservative oil

Suitable preservative oil can be supplied by most petroleum companies.

E.g. Dinitrol 40 or the equivalent.

Preparations for storage

- Drain and flush the cooling system. Top up with preservative coolant.

- Warm up the engine on regular fuel. Stop the engine and drain the oil.

- Change the fuel filter and turbo filter.

- Fill the engine with preservative oil up to the minimum level on the dipstick.

- Mix 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 1000 rpm (not single-speed engines) for 20-25 minutes.

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

- Oil the valve mechanism generously with preservative oil.

- Remove the injectors and spray preservative oil into each cylinder,

max 30 cm

(ml).

Turn the engine over a few times using the starter motor. Spray a small amount of oil additionally into each cylinder. After this the engine must not be cranked. Refit the injectors.

- Drain the preservative oil from the engine. Fresh engine oil can be filled directly or when the engine is taken out of storage.

- Drain the coolant if the engine is not to be stored with a full cooling system. Plug and tape over all coolant connections (if the cooling system is not completely assembled).

- Air cleaner: Clean or change the filter element.

- Cover air intakes and exhaust pipes.

- Alternator and starter motor:

- Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or the equivalent.

- Spray the outside of bright engine parts, first with penetrating preservative oil such as Dinitrol 25B and then with Dinitrol 112 or the equivalent.

Use a container to avoid spillage

when draining the oil and

coolant.

Dispose of used oil and coolant

through an authorised waste

disposal contractor.

- Attach a label to the engine showing the date of preservation and clearly stating that it must not be started or cranked.

Batteries

Remove the batteries for trickle charging at the battery charging station. (Does not apply to batteries which according to the manufacturer do not require any maintenance). The same is applicable for short-term storage if the engine has not been prepared for storage as above.

Storage

After the preparations, the engine should be stored in a dry and warm place (room temperature).

Taking out of storage

(Procedure when the engine is to be put into operation)

- Remove plugs and tape from coolant connections, air intakes and exhaust pipes.

- Fill the system with coolant, see page 19.

- Check the oil level in the engine or fill up with fresh motor oil.

- Turn the engine over a few times with the injectors removed, at the same time copiously oiling the valve mechanism with pushrods and tappets.

Important!The engine must be turned over with the injectors removed so

that surplus preservative oil will be pressed out of the cylinders.

- Fit the injectors.

- Empty the fuel system's main filter of preservative oil.

- Bleed the fuel system, see page 40.

- Wash off any externally applied preservative oil, using white spirit.

STORED ENGINE

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

Do not start or crank!

Wear gloves and protective

goggles when charging and

handling batteries

The batteries contain a highly

corrosive acid.

TECHNICAL DATA

GENERAL DC9 DI9

Number of cylinders

6 in line

Cylinder diameter mm

115

Stroke mm

144

Capacity dm

(litres)

9,0

No. of main bearings

Firing order

1 - 5 - 3 - 6 - 2 - 4

Compression ratio

17:1

Engine direction of rotation viewed from rear

Anti-clockwise

Fan direction of rotation viewed from front

Clockwise

Cooling

Liquid

Valve clearances, cold engine

intake valve mm exhaust valve mm

0,45 0,80

Weight, without coolant or oil kg *With charge air cooler, radiator,

expansion tank and pipes

890* 840

Power

see engine card, "Engine record card"

LUBRICATION SYSTEM

Max. oil pressure

(hot engine at engine speeds above 800 rpm bar (kp/cm

)

Normal oil pressure

(hot engine at operating speeds) bar (kp/cm

)

3 - 6

Min. oil pressure

(hot engine 800 rpm) bar (kp/cm

)

0,7

Oil capacity, see page 29

Crankcase pressure with

closed crankcase ventilation mm VP

-55 - +20

FUEL SYSTEM DC9 DI9

Pump setting BTDC

See plate on rocker cover

Injector, opening pressure bar (kp/cm

)

300

Low idle speed rpm

700

Maximum full load speed

See engine card

Fuel

Diesel fuel oil

Tightening torques:

Threaded socket nut for injectors Nm Cap nut for delivery pipe Nm Oil leakage connection Nm

70 20 11

see page 56

COOLING SYSTEM

Number of thermostats 1

Thermostat, opening temperature

°C79

Coolant temperature:

system at atmospheric pressure

°C

system at overpressure

°C

70 - 93

70 - approx. 100

Volume, incl 0.75 m

radiator and

expansion tank dm

(litres)

50 53

ELECTRICAL SYSTEM

System voltage V

Alternator, current A

65 or 90

Starter motor output kW (hp)

4,0 (5,4)

Monitors, alarm values:

oil pressure monitor bar (kp/cm

)

temperature monitor °C

0,7

± 0,15

Stamped on hexagonal part of monitor

FUEL

Diesel fuel oil

The composition of the diesel fuel oil has a great influence on the functioning and the service life of the engine and the injection pump. The engine output and exhaust emissions are also dependent on the fuel quality. The requirements and testing standards for the most important properties are described in the service manual in sections which can be ordered from Scania dealers or directly from Scania. The address of Scania is printed on the cover.

The diesel fuel must meet European standard EN 590.

The table below shows the requirements for some of the most important properties:

Environmentally favourable fuels (low sulphur fuels)

There are three classes of so called environmentally favourable fuels (SS155435). 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 power output. Only class 1 fuel should be used with a catalytic converter.

Short term use of fuel with a higher sulphur content than 0.05% by weight will not cause permanent damage to the catalytic converter.

The catalytic converter may, however, require fuel with low sulphur content for some time after this to regain its normal efficiency.

Property Requirement

Viscosity at 40°C 2.0 - 4.5 mm2/s (cSt)

Density at 15

°C 0.82 - 0.86 kg/dm

Sulphur (concentration by mass) max. 0.3%

Ignitability (CET rating) min. 49

Flashpoint 56°C

Temperature dependence of diesel fuel

At temperatures lower than those specified for the diesel fuel, paraffin wax may precipitate from the fuel and block filters and pipes. The engine can then lose power or stop.

The diesel fuel is adapted for use in the specific climate of each country. If a vehicle or an engine is to be operated in a temperature zone with lower temperature than normal, first identify the temperature properties of the fuel concerned.

The properties of the fuel when cold can be improved by adopting one of the following measures before the temperature drops:

- If the fuel concerned cannot cope with the expected temperatures, and diesel fuel is not available with the correct temperature properties, we recommend that an electric fuel heater is installed as a preventative

measure.

- The low temperature properties of diesel fuel may be improved by adding kerosene as a preventative measure. A maximum of 20% may be added. When refuelling, the kerosene should be added first, so that it mixes thoroughly with the diesel fuel.

Note: It is prohibited to use kerosene in engine fuel in

some countries.

- To prevent water in the fuel from freezing and forming ice, a maximum of 0.5-2% alcohol (isopropanol) may be added.

Drain fuel tanks and drain or change fuel filters regularly.

It is not permitted to mix kerosene with diesel fuel that is already adapted for the climate concerned. The injection pump

may be damaged. All use of

paraffin other than kerosene is

forbidden, as it causes engine

damage.

It is not permissible to mix

petrol with diesel fuel. In the

long term, petrol may cause

wear to the injection pump and

at worst it may also cause

damage to the engine.

ALPHABETICAL INDEX

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Air cleaner, prefilter . . . . . . . . . . . . . . . . . . . . 38

Air cleaner, safety cartridge . . . . . . . . . . . . . . 39

Air cleaner, vacuum indicator . . . . . . . . . . . . 38

Air filter, element . . . . . . . . . . . . . . . . . . . . . . 38

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Bleeding, fuel system . . . . . . . . . . . . . . . . . . . 40

Certified engines . . . . . . . . . . . . . . . . . . . . . . . . 5

Changing the battery . . . . . . . . . . . . . . . . . . . 46

Changing the fuel filter . . . . . . . . . . . . . . . . . . 40

Checks after running . . . . . . . . . . . . . . . . . . . 25

Checks before running . . . . . . . . . . . . . . . . . . 21

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Coolant level monitor . . . . . . . . . . . . . . . . . . . 43

Coolant temperature . . . . . . . . . . . . . . . . . . . . 23

Coolant temperature monitor . . . . . . . . . . . . . 44

Coolant temperature sensor . . . . . . . . . . . . . . 44

Coolant, changing . . . . . . . . . . . . . . . . . . . . . . 35

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 32

Cooling system, cleaning . . . . . . . . . . . . . . . . 36

Corrosion inhibitor . . . . . . . . . . . . . . . . . . . . . 35

DEC2 Control system . . . . . . . . . . . . . . . . . . . 12

DEC2 fault codes . . . . . . . . . . . . . . . . . . . . . . 17

DEC2 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Electrical system . . . . . . . . . . . . . . . . . . . . . . . 42

Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Environmental responsibility . . . . . . . . . . . . . . 4

Filter, air cleaner . . . . . . . . . . . . . . . . . . . . . . . 38

Filter, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

First start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Fuel specifications . . . . . . . . . . . . . . . . . . . . . 56

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Fuel system, bleeding . . . . . . . . . . . . . . . . . . . 40

Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

LED functions . . . . . . . . . . . . . . . . . . . . . . . . . 15

Lubricating oil system . . . . . . . . . . . . . . . . . . 28

Lubrication oil pressure sensor/monitor . . . . . 45

Lubrication pressure . . . . . . . . . . . . . . . . . . . . 24

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Maintenance Schedule . . . . . . . . . . . . . . . . . . 27

Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Oil pressure monitor, DEC2 . . . . . . . . . . . . . . 45

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Prefilter, air cleaner . . . . . . . . . . . . . . . . . . . . 38

Preparations for storage . . . . . . . . . . . . . . . . . 51

Safety cartridge, air cleaner . . . . . . . . . . . . . . 39

Safety information . . . . . . . . . . . . . . . . . . . . . . 6

Safety precautions for care and maintenance . . 8

Safety precautions for handling materials . . . . 8

Safety precautions for running the engine . . . . 7

Starting the engine . . . . . . . . . . . . . . . . . . . . . 21

Stopping the engine . . . . . . . . . . . . . . . . . . . . 24

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Taking out of storage . . . . . . . . . . . . . . . . . . . 53

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 54

Temperature monitor . . . . . . . . . . . . . . . . . . . 44

Troubleshooting DEC2 . . . . . . . . . . . . . . . . . . 16

Type designations . . . . . . . . . . . . . . . . . . . . . . 10

Vacuum indicator . . . . . . . . . . . . . . . . . . . . . . 38

Valve clearances . . . . . . . . . . . . . . . . . . . . . . . 48

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Scania DI9, DC9 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual