Scania DI9, DC9 with DEC2. Industrial engine. Instruction — part 2

2003-10:1

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

READING F

A

UL

T CODES

LED INDICA

TION WHEN THE LAMP

TES

T

/F

AUL

T

CODE SWITCH IS ACTIV

A

TED

CONTROL STA

TUS

SHUTDOWN

STAR

TING

RUNNING

TO

RQUE LIMIT

BOOST LIMIT

POWER -

POWER +

Pr

obabl

e cause

A

ction

<

D

E

C2 has de

tected an

intern

al fault in the control

unit.

Se

nd i

n the

control unit for repair as soon as

possible.

<

The e

ngine

te

mperature has

re

ached the

thres

hold level

or the

temperature sensor is inoperative.

Check the cooling

system. Check the

te

mperature sensor and cable routing.

<

Th

e en

gin

e ha

s reac

he

d the

o

ve

rrev

vin

g limit or th

e

engine

speed sensor is inoperative.

Che

ck the wiring and connector.

R

ene

w the

eng

ine

spe

ed se

ns

or.

<

Control rack position sensor

inoperative.

Ch

eck connectors and

ca

bl

es to governor.

<

The inta

ke a

ir tempe

rature

has

re

ached

the thre

shold

le

vel or

the charge air tempera

ture se

nsor is

inoperat

ive.

Che

ck the inta

ke

sys

te

m

. Check the te

mperature

senso

r an

d

cabl

e ro

uti

ng.

<

D

E

C2 detects no charge air pre

ssure.

The charge air pre

ssure sensor is inoperative.

Che

ck the charge

air pres

sure

ca

ble. Se

nd

in

the

control unit if

the connect

ion

is damaged.

<

Engine speed potentiometer

or the idling safety

switch

is inoperat

ive.

Che

ck the cable routing,

co

nne

ctors

a

nd cables.

<

The oil pressure has dropped

to the

threshold level or

the oil pressure monitor is inope

ra

tive.

Check oi

l level,

connector and cable.

Renew t

he

oil pressure monitor.

<

= LED is on

2003-10:1

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

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

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

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

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

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

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

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

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

Firs

t sta

rt

40

0 h

20

0 h

40

0 h

12

00

h

24

00

h

48

00

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

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

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

3

Min. 20 dm

3

Max. 20 dm

3

Min. 16 dm

3

1 dm

3

= 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.

WARNING

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

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

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

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.