Scania DI9, DC9 with DEC2. Industrial engine. Instruction — part 3
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"
a)
Checking the appearance of the coolant
- Fill a container with a little coolant and check that it is clean and clear.
- If the coolant is contaminated or cloudy, consider changing 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.
b)
Checking the glycol content
If there is a danger of freezing, use only glycol as an anti-corrosive in the
coolant.
- Cooling systems with glycol should contain at least 30% glycol by
volume to provide acceptable protection against corrosion.
- 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
A
A= Area to be avoided. Only for calculating glycol mix.
Coolant freezing temperature when ice starts to form at different glycol mixes
% glycol by
volume
15
20
25
30
35
40
45
50
60
Cooling
system
capacity,
dm
3
Ice slush starts
to form at °C
-6
-9
-12 -16 -22 -27 -36 -46 -55
Glycol dm
3
(litres)
5
6
8
9
11
12
14
15
18
30
6
8
10
12
14
16
18
20
24
40
8
10
13
15
18
20
23
25
30
50
9
12
15
18
21
24
27
30
36
60
11
14
18
21
25
28
32
35
42
70
12
16
20
24
28
32
36
40
48
80
14
18
23
27
32
36
41
45
54
90
15
20
25
30
35
40
45
50
60
100
17
22
28
33
39
44
50
55
66
110
18
24
30
36
42
48
54
60
72
120
20
26
33
39
46
52
59
65
78
130
21
28
35
42
49
56
63
70
84
140
23
30
38
45
53
60
68
75
90
150
24
32
40
48
56
64
72
80
96
160
26
34
43
51
60
68
77
85 102
170
27
36
45
54
63
72
81
90 108
180
29
38
48
57
67
76
86
95 114
190
30
40
50
60
70
80
90 100 120
200
Curve A: Ice 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
35
c)
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
Charge air cooler (DI engine)
1.
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
1
2
5
3
4
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.
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
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.
4
3
2
1
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.
1
2
3
1.
Cover
2.
Filter element
3.
Filter housing
Only use Scania genuine air
filter.
Change the filter element if it is
damaged.
Danger of engine damage if the
filter element is damaged.
Never start the engine without
the air filter.
There is a risk of injury or
serious engine damage.
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
1
Do not remove the safety
cartridge unnecessarily.
Never clean the
safety cartridge
40
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.
3
Use a container to avoid spillage
when bleeding and changing
components.
Only use Scania genuine fuel
filter.
1
2
Observe the utmost cleanliness
when working on the fuel
system.
There is a risk of engine
malfunction and damage to the
injection equipment.
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.
42
ELECTRICAL SYSTEM
15. Every 200 hours:
CHECKING THE ELECTROLYTE
LEVEL IN BATTERIES
1.
Unscrew the plugs and check the electrolyte level in all cells.
2.
Top up with distilled water until the level is 10-15 mm above the plates.
16. Every 200 hours:
CHECKING THE STATE OF CHARGE IN
BATTERIES
Note:
Every 200 hours applies to generator sets and the like. Other
installations every 1200 hours.
- Check the density with an acid tester.
In a fully-charged battery it should be:
1.280 at +20°C
1.294 at 0°
1.308 at -20°C
- If the density is below 1.20, the battery must be charged. A discharged
battery freezes at -5°C.
Do not rapid-charge the 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.
43
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.
44
19. Every 1200 hours:
CHECKING THE TEMPERATURE
MONITOR
1.
Drain the coolant, allowing the temperature monitor to be removed.
2.
Remove the temperature monitor cable(s).
3.
Unscrew the monitor.
4.
Refit the cable(s) 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:
At
temp.
°C
Resistance
Ω
Tolerance
°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.
45
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.
4
1
3
2
46
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
1.
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.
47
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.
1
Take care to ensure that any
leaks do not cause pollution.
If serious leakage occurs,
contact your nearest Scania
workshop.
48
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
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.
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