Scania DI9, DC9 with DEC2. Industrial engine. Instruction — part 4

2003-10:1

49

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

50

24. 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 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.

2003-10:1

51

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

3

(ml) Lubrizol 560A in 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.

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.

52

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

3

(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.

2003-10:1

53

- 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.

54

TECHNICAL DATA

GENERAL

DC9

DI9

Number of cylinders

6 in line

Cylinder diameter

mm

115

Stroke

mm

144

Capacity

dm

3

(litres)

9,0

No. of main bearings

7

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

2

)

6

Normal oil pressure

(hot engine at operating speeds)

bar (kp/cm

2

)

3 - 6

Min. oil pressure

(hot engine 800 rpm)

bar (kp/cm

2

)

0,7

Oil capacity, see page 29

Crankcase pressure with

closed crankcase ventilation

mm VP

-55 - +20

2003-10:1

FUEL SYSTEM

DC9

DI9

Pump setting BTDC

See plate on rocker cover

Injector, opening pressure

bar (kp/cm

2

)

300

Low idle speed

rpm

700

Maximum full load speed

See engine card

Fuel

Diesel fuel oil

1

Tightening torques:

Threaded socket nut for injectors

Nm

Cap nut for delivery pipe

Nm

Oil leakage connection

Nm

70

20

11

1

see page 56

COOLING SYSTEM

Number of thermostats

1

Thermostat, opening temperature

°

C

79

Coolant temperature:

system at atmospheric pressure

°

C

system at overpressure

°

C

70 - 93

70 - approx. 100

Volume, incl 0.75 m

2

radiator and

expansion tank

dm

3

(litres)

50

53

ELECTRICAL SYSTEM

System voltage

V

24

Alternator, current

A

65 or 90

Starter motor output

kW (hp)

4,0 (5,4)

Monitors, alarm values:

oil pressure monitor

bar (kp/cm

2

)

temperature monitor

°C

0,7

±

0,15

Stamped on hexagonal part of monitor

56

2003-10:1

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 instruction 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

(SS15 54 35).

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 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

2003-10:1

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.

58

2003-10:1

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