Scania DI9, DC9 with DEC2. Industrial engine. Instruction — part 1
Operator's Instruction
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
PREFACE
This Operator's Instruction 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 in-
line 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
Instruction. 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 instruction before starting to use the engine. Even though you may
be experienced with Scania engines you may find new information in
this Operator's Instruction.
- 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 instruction 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.
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
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
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 (
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
4
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 instruction.
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 Instruction 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.
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 non-
European (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 instruction.
- 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 instruction 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
SAFETY INFORMATION
General
This Operator's Instruction 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.
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
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!
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
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
3
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).
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
4
18
6
3
8
9
10
13
7
17
11
2
1
16
12
14
15
5
19
12
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.
Location of sensors for DEC2 on DI9
Location 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
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
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
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.
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