Scania D9, DI9, DC9. Industrial engine. Instruction — part 3
14. Every 2400 hours:
CHECKING THE INJECTORS
Injectors should be inspected by trained personnel with access to the neces-
sary equipment. Inspection should be carried out at least once a year or every
2400 hours.
Removal
1.
Clean around the injectors and connections, including clamps and
brackets.
2.
Detach the delivery pipe bundle and leak-off fuel lines.
3.
Unscrew the injector.
4.
Fit protective plugs on the injector and delivery pipe.
5.
Lift up the seal from the bottom of the injector seat if it does not come
out together with the injector.
6.
Fit a core plug in the injector seat in the cylinder head.
7.
Clean the injectors and check/adjust in a nozzle tester.
Correct opening pressure, see Technical data, page 46.
Fitting
1.
Check that there is no old seal in place and fit a new seal in the bottom
of the injector seat.
2.
Fit a new O-ring in the socket nut and a new seal under the socket nut.
3.
Fit the injector.
4.
Tighten the socket nut to 70 Nm (7.0 kpm).
5.
Fit the delivery pipe and tighten the union nuts to 20 Nm (2.0 kpm). Fit
clamps and brackets.
Important
Take care to fit the delivery pipe without tension and make sure
that the cone on it is correctly positioned in the connection.
6.
Fit the leak-off fuel line. Tighten the bolts to 11 Nm (1.1 kpm).
1.
Delivery pipes
2.
Cap nut
3.
Washer
4.
Cone
5.
Connector on injector or
injection pump
1.
Socket nut
2.
O-ring
3.
O-ring
4.
Stop ring
5.
Guide pin
6.
Seal
The delivery pipes must
not be bent.
All clamps must be refitted.
Always wear gloves and eye
protection when testing
injectors.
Fuel escaping under high
pressure can penetrate body
tissue and cause serious injury.
34
ELECTRICAL SYSTEM
15. Every 200 hours:
CHECKING THE ELECTROLYTE
LEVEL IN BATTERIES
1.
Unscrew the plugs and check the electrolyte level in all cells.
2.
Top up with distilled water until the level is 10-15 mm above the plates.
16. Every 200 hours:
CHECKING THE STATE OF CHARGE IN
BATTERIES
Note
Every 200 hours applies to generator sets and the like. Other
installations every 1200 hours.
- Check the density with an acid tester.
In a fully-charged battery it should be:
1.280 at +20 °C
1.294 at 0°
1.308 at -20 °C
- If the density is below 1.20, the battery must be charged. A discharged
battery freezes at -5 °C.
Do not rapid-charge the batteries. This will damage the battery in the
long run.
17. Every 200 hours:
CLEANING THE BATTERIES
Note:
Every 200 hours applies to generator sets and the like. Other
installations every 1200 hours.
1.
Clean batteries, cables and cable terminals.
2.
Check that all cable terminals are firmly tightened.
3.
Grease battery terminal posts and cable terminals with vaseline.
Wear gloves and eye protection
when charging and
handling batteries.
Batteries contain a highly
corrosive acid.
Do not connect the cables to the
wrong terminals.
This could cause serious
damage to the electrical system.
If the terminals are
shortcircuited, sparks
will be generated.
Do not let open flame or sparks
come near the batteries.
When batteries are charged,
they emit highly flammable
fumes that can explode.
18. Every 1200 hours:
CHECKING THE COOLANT LEVEL
MONITOR
(optional equipment)
1.
Start the engine.
2.
Lower the coolant level in the expansion tank.
3.
Automatic stop in case of fault: The engine stops, the indicator lamp
comes on and the buzzer sounds if the level monitor is OK.
4.
Without automatic stop in case of fault: The indicator lamp comes on
and the buzzer sounds if the level monitor is OK.
5.
Top up coolant to the correct level, refer to page 24.
2-pole level monitor installed
in expansion tank for radiator
supplied by Scania
Always use a suitable container
to avoid spillage when
draining coolant.
Dispose of used coolant through
an authorized waste disposal
contractor.
36
19. Every 1200 hours:
CHECKING THE TEMPERATURE
MONITOR
1.
Drain the coolant, allowing the temperature monitor to be removed.
2.
Remove the temperature monitor cable(s).
3.
Unscrew the monitor.
4.
Refit the cable(s) to the monitor.
5.
Submerge the monitor sensor body in water. Heat the water slowly
(approx. 1° minute) using e.g. an immersion heater.
6.
Set the control switch to "ON". Use a thermometer to check that the
warning lamp comes on or that an alarm is initiated at the correct
temperature.
The correct temperature is stamped on the hexagonal part of the
monitor.
The monitor tolerance is
±
3°.
CHECKING THE TEMPERATURE
SENSOR
1.
Drain the coolant, allowing the temperature sensor to be removed.
2.
Remove the temperature sensor cable(s).
3.
Unscrew the sensor.
4.
Connect an ohmmeter to the temperature sensor.
5.
Submerge the sensor body in water. Heat the water slowly
(approximately 1° per minute) using e.g. an immersion heater.
6.
Check the resistance at the temperatures given below.
7.
The sensor should give the following readings:
At temp. °C
Resistance
Ω
Tolerance °C
60
134
±
13.5
±
4
90
51.2
±
4.3
±
3
100
38.5
±
3
±
3
2-pole temperature sensor
C =Common connection
1 = Connection C -1 closes at
stamped temperature
2 = Connection C -2 opens at
stamped temperature
2-pole temperature monitor
Always use a suitable container
to avoid spillage when
draining coolant.
Dispose of used coolant through
an authorized waste disposal
contractor.
20. Every 1200 hours:
CHECKING THE OIL PRESSURE
SENSOR/MONITOR
Sensor function
Measure the sensor output voltage (pin 3) at different oil pressures. The
sensor output voltage shall be as follows:
0.85-1.15 bar = 2.45 volt
1.80-2.20 bar = 3.70 volt
2.75-3.25 bar = 4.50 volt
3.79-4.20 bar = 5.20 volt
4.55-5.45 bar = 5.70 volt
5.40-6.6 bar
= 6.10 volt
The tolerances apply at +30°C - 110°C. At lower temperatures the tolerance
range is wider, e.g. 0°C = x 1.4.
Monitor function
Connect a test lamp to the oil pressure monitor, pin 4 (
-
ground), and check
that the monitor switches on at the correct pressure when the engine is started
and stopped. The monitor shall switch on at 0.7
±
0.15 bar when the engine is
stopped.
Important
The sensor/monitor must be supplied with voltage during the
measurement. Maximum 4 W load from a test lamp.
Monitor connected for automatic stop in case of a fault:
1.
Start the engine.
1.
Check on the oil pressure gauge that oil pressure rises.
2.
Stop the engine instructionly (using the emergency stop).
3.
Check on the oil pressure gauge at what pressure the stop solenoid oper-
ates and the monitor opens. Correct pressure: 0.7
±
0.15 bar.
Monitor connected to buzzer:
1.
Main power switch in operating position, check that buzzer sounds.
2.
With the engine running, check that the buzzer falls silent when the oil
pressure is above 1.1
±
0.15 bar and the monitor closes.
21. Every 400 hours:
CHECKING THE STOP FEATURE
Check that the stop solenoid is activated and stops the engine when the stop
signal is given by the button, temperature monitor, coolant level monitor and
oil pressure monitor if these are coupled for automatic stop in the case of
fault.
Important
Stop solenoids with a timer module may be activated for start
and stop a maximum of 3 times per minute. Otherwise, the
timer module may be damaged and the stop feature cease.
4
1
3
2
38
CHECKING STOP SOLENOID STOP POSITION
When changing the stop solenoid, or if the stop feature is not satisfactory, the
following should be done (the figures show the stop control with the engine
in stop position):
Stop position at “Pull to stop”.
- Check and/or set the length of the link rod so that the distance between
the locknuts (nut height 5.2 mm) is 21.0
±
0.1 mm when the nuts are
tightened.
- Fit the stop solenoid in the bracket as in the figure.
- Connect the stop solenoid electrically, red to battery
+
and black to
battery
-
, and activate it so that it is fully pulled.
Note:
Pole reversal
will damage the timer module.
- Screw the clevis onto the stop lever using the link pin and check, in stop
position, that there is a small clearance (0.2-0.3 mm) between the stop
lever and the operating point on the governor
- Check the stop feature by starting the engine and then stopping it by
activating the stop solenoid.
Important
The stop solenoid must not be activated more than 3 times per
minute as the timer module can be damaged.
Installation “Pulled during
operation”
Installation “Pull to stop”
Stop position at “Pulled during operation”.
- Check and/or set the length of the link rod so that the distance between
the locknuts (nut height 5.2 mm) is 26.0
±
0.1 mm when the nuts are
tightened.
- Fit the stop solenoid in the bracket as in the figure.
- Connect the stop solenoid electrically, red to
+
and black to
-
and acti-
vate it so that it is fully pulled. Note: The timer module is damaged if
the poles are reversed.
- Turn the stop lever to operating position and screw the clevis onto the
stop lever using the link pin and check, in operating position, that there
is a small clearance (0.2-0.3 mm) between the stop lever and the operat-
ing point on the governor
- Activete the stop solenoid and start the engine. Stop the engine by cut-
ting the power to the stop solenoid.
Important
The stop solenoid must not be activated more than 3 times per
minute as the timer module can be damaged.
RENEWING THE BATTERY
Removal
1.
Disconnect the negative cable (-) from the battery (cable connected to
ground).
2.
Disconnect the positive cable (+) from the battery (cable connected to
starter motor).
Fitting
1.
Connect the positive cable (+) to the battery (cable connected to starter
motor).
2.
Connect the negative cable (-) to the battery (cable connected to
ground).
MISCELLANEOUS
22. Every 1200 hours:
CHECKING THE DRIVE BELT
Replace the drive belt (1) (poly V-belt) if worn or damaged.
Also check that the automatic belt tensioner (2) is working and keeps the
drive belt correctly tensioned.
1
2
Do not connect the cables to the
wrong terminals.
This could cause serious
damage to the electrical system.
If the terminals are short-
circuited, sparks will be
generated.
Dispose of used batteries
through an authorized waste
disposal contractor.
40
23. Daily:
CHECKING FOR LEAKAGE, RECTIFY
AS NECESSARY
- Start the engine.
- Check for oil, coolant, fuel, air and exhaust leakage.
- Tighten or change leaking connections. Check the overflow holes (1)
which show whether the O rings between the cylinder liners and crank-
case are leaking, refer to illustration.
a) If coolant is leaking out, the two upper O-rings are leaking.
b) If oil is leaking out, the lower O-ring is leaking.
A small amount of leakage from the overflow holes during the engine
running-in period is normal. (Seals and O-rings to be lubricated with
soap or oil when fitted).
This leakage normally stops after a time.
1
Ensure that any leakage does
not pollute the environment.
In case of major leakage,
contact the nearest Scania
workshop.
24. Every 2400 hours:
CHECKING/ADJUSTING VALVE
CLEARANCE
Note
Checking/adjusting valve clearance should also be done after the
first 400 hours of operation.
Valve clearances should be adjusted when the engine is cold, at least 30 min-
utes after running.
The rocker cover gaskets should be changed as necessary. Tightening torque:
20 Nm.
Intake valve clearance: 0,45 mm.
Outlet valve clearance: 0,80 mm.
Alternative 1
- Set No. 1 cylinder to TDC by turning the engine in its direction of rota-
tion until both valves are closed.
- Adjust the following valves. Correct valve clearance is indicated on the
instruction plate on one of the rocker covers:
- 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 exhaust
2
In
3
Ex
4
In
5
Ex
Cylinder 2
Ex
3
In
4
Ex
5
In
6
In and Ex
Covers for reading
on flywheel casing
Note
Readings can either be taken
from underneath or from
above, depending on which
flywheel is used.
The cover not being used is
covered with a seal and an
instruction plate.
TDC
No. 6 cyl
TDC
No. 1 cyl
Intake valve
Exhaust valve
5
4
3
2
1
6
Cylinder numbering
FLYWHEEL
FLYWHEEL
WARNING
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK
OF INJURY.
42
Alternative 2
- Set the No. 1 cylinder to TDC by turning the engine in its direction of
rotation until both valves are closed.
- Adjust both the valves for the No.1 cylinder. Correct valve clearance is
indicated on the instruction plate on one of the rocker covers.
- Repeat this procedure with the remaining cylinders in the order
5 - 3 - 6 - 2 - 4 (firing sequence) by turning the engine 1/3 revolution in
its direction of rotation between each adjustment.
25. Every 2400 hours:
CHANGING (or CLEANING) THE
CLOSED CRANKCASE VENTILATION
VALVE
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 oil overnight. Then rinse
it several times in diesel oil and allow it to drip dry.
- Refit the valve.
- The valve may be reused (cleaned), maximum twice after the initial
2400 hours of operation. 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
- To run the engine for a period of time with preservative fuel,
preservative oil and preservative 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 must be used.
E.g. BASF G48 or BASF D542.
Preservative fuel
- Use diesel fuel mixed with Lubrizol 560A or equal.
- Mix 1 cm
3
(ml) of Lubrizol 560A with 10 dm
3
(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.
In case of splashes in the eye: Rinse with moderate water spray (for min. 15 minutes). Seek medical attention.
In case of skin contact:
Wash affected areas with soap and water.
If you inhale it:
Fresh air, rest and warmth
Flammable:
Fire class 2A. Flash point + 27°.
In case of fire: Extinguish using carbonic acid, powder or foam
Storage:
In properly sealed container in a dry, cool place. Keep out of reach of children.
!
Ethylene glycol, if swallowed
can be fatal.
Avoid contact with the skin.
44
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 approximately 1000 rpm (not single-speed
engines) for 20-25 minutes.
- Stop the engine, remove the hoses and connect the normal fuel lines.
- Oil the valve mechanism generously with preservative oil.
- Remove the injectors and spray preservative oil into each cylinder,
maximum 30 cm
3
(ml).
Turn the engine over a few revolutions using the starter motor. Spray an
additional small amount of oil 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 renew the filter element.
- Cover air intakes and exhaust pipes.
- Alternator and starter motor:
- Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or equal.
- Spray the outside of bright metal engine parts, first with penetrating pre-
servative oil such as Dinitrol 25B and then with Dinitrol 112 or equal.
Always use suitable containers
to avoid spillage when
draining oil and coolant.
Dispose of used oil and coolant
through an authorized 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 a charging station. (Does not
apply to batteries, which the manufacturer specifies to be maintenance free).
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 cooling system with coolant, refer to page 12.
- 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 cranked 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.
- Wash off any externally applied preservative oil, using white spirit.
STORED ENGINE
Date . . . . . . . . . . .
Do not start or crank!
Wear gloves and eye protection
when charging and handling
batteries.
Batteries contain a highly
corrosive acid.
46
TECHNICAL DATA
GENERAL D9
DI9
DC9
Number of cylinders
6 in line
Cylinder bore
mm
115
Stroke
mm
144
Displacement
dm
3
(litres)
9,0
Number of main bearings
7
Firing sequence
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 the front
Clockwise
Cooling
Fluid
Valve clearance, cold engine
intake valve
mm
exhaust valve
mm
0,45
0,80
Weight, without coolant and oil
*With charge air cooler, radiator,
kg
expansion tank and pipes
825
835
890*
Output
see “Engine record card”
LUBRICATION SYSTEM
Max. oil pressure
(warm engine at speed above 800 rpm) bar (kp/cm
2
)
6
Normal oil pressure
(warm engine at operating speed)
bar (kp/cm
2
)
3 - 6
Min. oil pressure
(warm engine 800 rpm)
bar (kp/cm
2
)
0,7
Oil capacity, see page 21
Crankcase pressure with closed crankcase
mm VP
ventilation
-55 - +20
FUEL SYSTEM
D9
DI9
DC9
Pump setting BTDC
See plate on rocker cover
Injectors, opening pressure
bar (kp/cm
2
)
300
Low idle
rpm
700
Maximum full load speed
See engine card
Fuel
Diesel fuel oil
1
Tightening torques:
Socket nut for injectors
Nm
Cap nut for delivery pipe
Nm
Oil leakage connection
Nm
70
20
11
1
see page 48
COOLING SYSTEM
Number of thermostats
1
Thermostat, opening temperature
°
C
79
Coolant temperature:
system with atmospheric pressure
°
C
system with positive pressure
°
C
70 - 93
70 - about 100
Capacity including 0.75 m
2
radiator and
expansion tank
dm
3
(litres)
50
53
50
ELECTRICAL SYSTEM
System voltage
V
24
Alternator, current
A
65 alt. 90
Starter motor power
kW (hp)
4,0 (5,4)
Monitors, settings:
Oil pressure monitor
bar (kp/cm
2
)
Temperature monitor
°C
<
2-pole:1.0
±
0.15
Stamped on monitor hexagon
48
FUEL
Diesel fuel
The composition of the diesel fuel is vitally important to the operation and
life of the engine and the fuel injection pump. The engine power output and
the exhaust emissions are also dependent on the fuel quality. The
requirements and the test standards for the most important properties are
described in the workshop manual in sections that can be ordered from your
Scania dealer or directly from Scania. The address of Scania is printed on the
cover.
The diesel fuel shall comply with the following standard: EN 590 (European
standard).
The table below shows the requirements for some of the most important
properties:
Environmentally favourable fuels (low sulphur fuels)
There are three different grades of so called environmentally favorable fuels
(SS15 54 35). Grade 1 is sulphur-free and grade 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 mm
2
/s (cSt)
Density at 15
°
C
0.82 - 0.86 kg/dm
3
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
loose 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 is not intended for the expected temperature and no
diesel fuel with the correct temperature properties is available, we
recommend that an electric fuel heater be 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, maximum
0.5-2% alcohol (isopropanol) may be added.
Drain fuel tanks and drain or renew fuel filters at regular intervals.
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. Petrol
may cause wear to the fuel
injection pump and it may also
cause damage to the engine.
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