Scania DC9 EMS with S6/PDE. Industrial engine. Instruction — part 4
49
Mark on flywheel
(reading taken
through the lower
opening)
Revolution
Valve
overlap on
cylinder
Adjust the
valves on
cylinder
TDC Down (0°)
1
-
1
2
1
-
144°
1
-
2
504°
2
2
-
288°
1
-
4
648°
2
4
-
72°
1
5
-
432°
2
-
5
216°
1
3
-
576°
2
-
3
Flywheel seen from the rear of the engine.
*Direction of rotation when adjusting.
The solid line shows the order for angles on the first rotation and the
broken line the order for rotation 2.
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 openings are fitted with a
cover at delivery.
Openings for taking readings
on the flywheel housing
50
21. Every 2,400 hours
Checking and adjusting the unit
injector rocker arms
Note:
Checking and adjusting the unit injector rocker arms should
also be done together with the valve clearance check and
adjustment after the first 400 hours of operation.
Important! The unit injectors are adjusted using setting tool 99 414
or a digital sliding calliper.
This adjustment is essential as a fault in the position of
the unit injector can result in poor performance and
possible breakdown.
Order of adjustment
The table below applies when readings are taken through the lower opening.
If readings can only be taken through the upper cover and not from
underneath: Turn the flywheel until valve overlap on cylinder 1, which
corresponds to TDC down (0°) in the lower window. Turn the flywheel
counterclockwise, 144° at a time and note the valve overlap. The injectors
can then be adjusted according to the table below.
Mark on flywheel
(reading taken
through the lower
opening)
Revolution
Valve
overlap on
cylinder
Adjust unit
injector
rocker arm
on cylinder
TDC Down (0°)
1
-
2
2
1
-
144°
1
-
4
504°
2
2
-
288°
1
-
5
648°
2
4
-
72°
1
5
-
432°
2
-
3
216°
1
3
-
576°
2
-
1
Measurement A=
PDE32: 69.9 ±0.1 mm
Measurement B=
PDE32: 38.8 mm
51
PDE32:
1.
See page 50 for a description of how the engine should be turned to
access TDC down (0°) to be able start checking and adjusting the
injectors.
2.
You are now on the first revolution and can check/adjust the injectors as
specified in the table on the previous page.
3.
Firstly, measure the distance (A) between plane (a) and the top edge of
the valve spring washer on the PDE injector using a digital sliding
calliper. See figure.
4.
Dimension (A) should be 69.9 mm for PDE31 (dimension B=38.8 mm).
5.
The dimension is adjusted by undoing the lock nut and screwing the
rocker arm adjusting screw (1) to the correct measurement.
WARNING! Take care when carrying out the adjustment if the
dimension is well outside the adjustment dimension. The
spring is pre-tensioned and can cause personal injury if it is
released.
6.
Position setting tool 99 442 with the metal plate around the injector
spring.
7.
Finely adjust dimension (A ) by simultaneously using a finger to sense
that the small piston (2) is level with the flat upper surface of the tool. It
is possible to feel differences of less than a tenth of a millimetre.
8.
If the setting tool is not available, a digital sliding calliper can also be
used for fine adjustment. The rocker position is adjusted using the
adjusting screw to 69.9 +/-0.1 mm as stated above.
9.
Tighten the adjusting screw lock nut to 39 Nm and remove the tool.
10.
Continue to turn the flywheel counterclockwise so that the marking on
the flywheel is visible in the lower window on the flywheel housing and
adjust the valves as shown in the table on the previous page.
Piston level with the flat surface.
Adjustment is correct.
Piston above or below the flat
surface. Adjustment necessary.
69.9
99 442
52
Preparing the engine for
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 for 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 renewal, lubrication,
etc.).
Preservative coolant
If the engine is being stored with coolant in the system, the coolant should
contain 50% glycol by volume. Use glycol without nitrite-based inhibitors,
such as BASF G48 or BASF D542.
Preservative fuel
- Use diesel fuel oil mixed with Lubrizol 560H or equivalent.
- Mix 1 cm
3
(ml) Lubrizol 560H in 10 dm
3
(l) of fuel.
Ethylene glycol is highly
dangerous if imbibed and can
prove fatal.
Avoid contact with the skin.
HANDLING LUBRIZOL 560H
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
Flammable:
Fire class 2A. Flashpoint +27°. In the event 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.
!
WARNING
!
53
Preservative oil
Suitable preservative oils are available from most oil companies.
For Example Dinitrol 40 or equivalent.
Preparations for storage
- Drain and flush the cooling system. Top up with preservative coolant.
- Warm up the engine on normal fuel. Stop the engine and drain the oil.
- Renew the fuel 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 1,000 rpm for 20-25 minutes.
- Stop the engine, remove the hoses and connect the normal fuel pipes.
- Remove the rocker covers and lubricate the valve mechanisms and unit
injector mechanisms with preservative oil. Refit the rocker covers.
Note:
The unit injectors are not to be removed.
- 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 coolant in the
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 the
equivalent.
- Spray the outside of bright engine parts with penetrating preservative
oil, for example Dinitrol 25B, and then with Dinitrol 112 or equivalent.
Use a container to avoid spills
when draining the oil and
coolant.
Dispose of used oil and coolant
through an authorised waste
disposal contractor.
Help protect our
environment!
54
- Attach a label to the engine, clearly stating the storage preparation date
and that the engine must not be started or cranked.
ENGINE PREPARED FOR
LONG-TERM STORAGE
Date. . . . . . . . . . . .
Do not start or crank!
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 applies to short-term storage, even 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 for taking the engine into operation)
- Remove plugs and tape from coolant connections, air intakes and
exhaust pipes.
- Fill the system with coolant, see page 22.
- Check the oil level in the engine or fill up with fresh motor oil.
- Lubricate the valve mechanisms and their pushrods and valve tappets as
well as the unit injector mechanisms.
- Drain the preservative fuel from the fuel manifold and fuel filter.
- Connect and bleed the fuel system, see page 43.
- Wash off any externally applied preservative oil using white spirit.
Wear gloves and protective
goggles when charging and
handling batteries.
The batteries contain a highly
corrosive acid.
WARNING
!
55
Technical data
General
DC9 EMS
Number of cylinders
5 in line
Cylinder diameter
mm
127
Piston stroke
mm
140
Displacement
dm
3
(litres)
8.87
No. of main bearings
6
Firing order
1 - 2 - 4 - 5 - 3
Compression ratio
18:1
Engine direction of rotation viewed from rear
Counterclockwise
Fan direction of rotation viewed from front
Clockwise
Cooling
Liquid
Valve clearances, cold engine
intake valve
mm
outlet valve
mm
0.45
0.70
Weight, without coolant or oil
kg
*With charge air cooler, radiator, expansion tank
and pipes
887
Lubrication system
Maximum oil pressure
(warm engine at a speed above
1,000 rpm
bar (kp/cm
2
)
6
Normal oil pressure:
hot engine at operating speed
bar (kp/cm
2
)
3-6
Minimum oil pressure:
hot engine under 1,000 rpm
bar (kp/cm
2
)
hot engine above 1,000 rpm
bar (kp/cm
2
)
0.7
2.3
Oil capacity, see page 31
Crankcase pressure with closed crankcase
ventilation
mm VP
-55 - +20
56
Fuel system
DC9 EMS
Low idling
rpm
700 (adjustable 500-800)
Maximum full load speed
See engine card
Fuel
Diesel fuel oil
1
1
see page 57
Cooling system
Number of thermostats
1 (dual thermostat)
Thermostat, opening temperature
°C
83
Coolant temperature:
system at atmospheric pressure
°C
system at overpressure
°C
83-95
83 - approximately 100
Volume, including radiator, engine and
expansion tank with 1.0 m
2
radiator
dm
3
(litres)
57
Electrical system
System voltage
V
24
Alternator, current
A
80 or 100
Starter motor output
kW (hp)
5.5 (7.5)
Monitors, threshold values:
oil pressure monitor
bar (kp/cm
2
)
temperature monitor
°C
1.0
±
0.15
Programmed in S6
57
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 system. 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 workshop instruction in sections which can be ordered from
Scania dealers or directly from Scania. Scania’s address is printed on the
cover.
Diesel fuel must comply with the following standard: EN 590 (European
standard).
The table below shows the requirements for some of the most important
properties.
Environmentally friendly fuels (low sulphur fuels)
There are three classes of environmentally friendly 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
Requirements
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
58
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. Maximum 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 renew fuel filters regularly.
It is not permitted to mix
kerosene with diesel fuel that is
already adapted for the climate
concerned. The injection
equipment 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 unit injectors and at
worst it may also cause damage
to the engine.
Important
!
WARNING
!
59
Alphabetical index
Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Vacuum indicator . . . . . . . . . . . . . . . . . . . . . . 36
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . 44
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
60
Scania Assistance
Wherever you are you can always get assistance from our service
organization, Scania Assistance. All day, every day of the year. Using Scania
Assistance is free, but the cost of repairs, spare parts and help from
mechanics will be debited.
Always call your own country!
Other countries: +46 8 52 24 24 24
Note:
Calls will be recorded for training purposes.
AR
0800 999 722 642
IE
+353 71 9634000
AT
+43 1 256 44 11
IT
+39 0461 996 222
AU
1300 SCANIA
KR
+82 1588 6575
1300 722642
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+32 226 400 000
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+32 2 264 00 00
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+34 91 678 92 13
BG
+359 886 660001
MX
01 800 4SCANIA
BR
0800 019 42 24
NL
+31 70 4182666
CH
+41 800 55 24 00
NO
+47 223 217 00
CL
188 800 722 642
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+48 602 622 465
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+420 225 020 225
PT
+48 91 678 9247
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+49 261 887 8888
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+40 723 27 27 26
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+45 333 270 44
SE
+46 42 100 100
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+34 91 678 80 58
SK
+421 903 722 048
FI
+358 10 555 24
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+90 212 335 04 40
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+33 2 414 132 32
TZ
+255 78 472 2642
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0 800 800 660
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0800 8351
+44 1274 301260
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0800 005 798
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