Scania DC9 EMS with S6/PDE. Industrial engine. OperatorвЂ™s manual — part 2

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Location of sensors for EMS with S6 on DC9

Coolant temperature sensor

Oil pressure sensor

Charge air temperature and pressure sensor

Engine speed sensor (2)

Coolant level monitor (located in the expansion tank)

Troubleshooting using flash codes for the EMS

control unit

вЂў The diagnostics lamp on the instrument panel always comes on for two

seconds when the system is powered up.

вЂў As soon as a fault is detected by the control unit, it is stored in the

EEPROM fault code memory and the diagnostics lamp on the

instrument panel comes on.

вЂў The diagnostic lamp will stay on for as long as a fault is active. Even if

the lamp has gone off and the fault is no longer active, the code can

generally be read off by following the instructions below.

Reading off fault codes for the control unit for

engines with Scania electrical systems

Turn on the ignition.

Activate the diagnostics switch to the left to view the flash codes for the

control unit (EMS).

A fault code will then flash on the diagnostics lamp. This flash code

consists of long flashes (approximately 1 second long) and short flashes

(0.3 seconds long). Long flashes are equivalent to tens and short flashes

to units.

Example: long - short - short = fault code 12.

Repeat this procedure until the first flash code is repeated. This means

that the entire fault code memory has been flashed out. If the fault code

memory is empty, only one long flash approximately 4 seconds long

will be given.

See the flash code table on the next page for a description and to locate

the fault.

In order to obtain further information about the fault code, the PC-based

diagnostics tool or Scania EMS Display must be used. Contact an

authorised Scania workshop.

When a fault has been rectified the fault code can be erased as described

below.

Erasing fault codes for engines with Scania

electrical systems

Switch off the ignition.

Activate the diagnostics switch in the same direction as the flash codes

indicate, i.e. to the right for the coordinator (COO) or to the left for

EMS.

Switch on the ignition and at the same time keep the diagnostics switch

activated, to the right (COO) or to the left (EMS), for 3 seconds.

This will erase passive fault codes which can be read off via flash code

for the relevant system. The rest of the fault codes will remain in the

EEPROM and can only be deleted using the PC tool.

Overview of flash codes for the EMS control unit

Code

Description

Code

Description

No fault detected.

PDE in cylinder 3: The solenoid valve is not

working properly.

Overrevving. One or both engine speed sensors

displays a speed in excess of 3,000 rpm.

PDE in cylinder 4: The solenoid valve is not

working properly.

Engine speed sensor 1 faulty, or incorrect signal.

PDE in cylinder 5: The solenoid valve is not

working properly.

Rotation speed sensor 2 faulty, or incorrect signal.

Incorrect signal in extra analogue input.

Coolant temperature sensor faulty, or incorrect

signal.

Incorrect control unit shutdown.

Charge air temperature sensor faulty, or incorrect

signal.

Shutdown due to coolant level.

Charge air pressure sensor faulty, or incorrect

signal.

Alternator charging incorrectly.

Oil temperature sensor faulty, or incorrect signal.

Starter motor function interrupted or not activated.

Oil pressure sensor faulty, or incorrect signal.

Rotation speed above ref.speed at start.

Coolant level sensor faulty.

Fault in memory circuit (EEPROM) in control

unit.

Internal fault code in the coordinator.

Data transfer to the control unit memory

(EEPROM) has been interrupted.

Accelerator pedal / brake. If the accelerator and

brake pedals have been operated simultaneously.

Incorrect internal temperature in the control unit.

Accelerator pedal sensor / idling switch

Accelerator pedal sensor / kickdown switch

Internal fault in the control unit: Fault in hardware

control.

Engine shutdown bypassed.

Fault in control unit RAM.

Shutdown due to oil pressure.

Internal control unit fault: Memory fault.

Torque limitation due to oil pressure.

Defective seal: Illegal editing of software.

Incorrect parameters for limp home function.

Rotation speed sensors faulty or not connected.

Battery voltage incorrect or no signal.

Shutdown due to high coolant temperature.

Emergency shutdown switch activated in

accordance with CAN message from coordinator.

Torque limitation due to high coolant temperature.

CAN circuit faulty in the control unit.

Incorrect voltage supply to one of the sensors.

Immobiliser function. Starter key code incorrect.

Internal hardware fault in the processor (TPU).

CAN message from the coordinator incorrect or

missing.

Incorrect CAN version in control unit or

coordinator.

PDE in cylinder 1: The solenoid valve is not

working properly.

PDE in cylinder 2: The solenoid valve is not

working properly.

Troubleshooting using flash codes for the EMS

coordinator

вЂў The diagnostics lamp on the instrument panel always comes on for two

seconds when the system is powered up.

вЂў As soon as a fault is detected by the coordinator, it is stored in the

EEPROM fault code memory and the diagnostics lamp on the

instrument panel(s) comes on.

вЂў Even if the lamp has gone off and the fault is no longer active, the code

can generally be read off by following the instructions below.

Reading off fault codes for the coordinator on

engines with Scania electrical systems

Turn on the ignition.

Activate the diagnostics switch to the right for 1 second to view the flash

codes for the coordinator (COO).

A fault code will then flash on the diagnostics lamp. This flash code

consists of long flashes (approximately 1 second long) and short flashes

(0.3 seconds long). Long flashes are equivalent to tens and short flashes

to units.

Example: long - short - short = fault code 12.

Repeat this procedure until the first flash code is repeated. This means

that the entire fault code memory has been flashed out. If the fault code

memory is empty, only one long flash (approximately 4 seconds long)

will be given.

See the flash code table on the next page for a description and to locate

the fault.

In order to obtain further information on the fault code, the PC-based

diagnostics tool or Scania EMS Display must be used. Contact an

authorised Scania workshop.

When a fault has been rectified the fault code can be erased as described
below.

Erasing fault codes for engines with Scania

electrical systems

Switch off the ignition.

Activate the diagnostics switch in the same direction as the flash codes

indicate, i.e. to the right for the coordinator (COO) or to the left for

EMS.

Switch on the ignition and at the same time keep the diagnostics switch

activated, to the right (COO) or to the left (EMS), for 3 seconds.

This will erase passive fault codes which can be read off via flash code

for the relevant system. The rest of the fault codes will remain in the

EEPROM and can only be deleted using the PC tool.

Overview of flash codes for EMS coordinator

1) Single speed engine
2) All-speed engine

Flash code

Fault description

Incorrect signal from the fine adjustment for the nominal engine speed signal.

Incorrect signals from the accelerator pedal sensor.

Incorrect signal from the resistor module for governor setting.

Incorrect signal from the resistor module for idle and fixed speed setting.

No communication with the engine.

Short circuit in the tachometer signal cable.

Faulty atmospheric pressure sensor.

Short circuit in the coolant temperature gauge signal cable.

Short circuit in the oil pressure gauge signal cable.

Short circuit in the oil pressure lamp signal cable.

Different versions of the communications protocol in the coordinator and EMS.

Faulty start switch or short circuit.

The supply voltage is too high.

The supply voltage is too low.

Check value from End of line (EOL) is incorrect.

Road speed sensor signal missing or incorrect.

The signals from the RCB (Remote Control Box) switches are implausible.

Incorrect signals from the droop setting switches.

Faulty remote start switch or short circuit.

No communication from the slave coordinator or the master coordinator.

Short circuit in the signal cable to the coolant temperature warning lamp.

Short circuit in the signal cable to the charge warning lamp.

Incorrect signal from the Fixed speed switches.

Fault in CAN communication.

Starting and driving

First start

When the engine is started for the first time, carry out the maintenance points

listed under "First start" in the maintenance schedule; see page 29.
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 31.
6. Checking the coolant; see page 35.

The coolant must contain corrosion inhibitor to protect the cooling
system from corrosion.

If there is a danger of freezing:

- Only antifreeze glycol should be used in the coolant as protection

against corrosion. We recommend only nitrite-free antifreeze glycols

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 -16В°C. See page 35.

- Never top up with water alone or glycol alone! 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.

If there is no danger of freezing:

- Only Scania Corrosion Inhibitor should be used in the coolant as

protection against corrosion. The correct corrosion inhibitor content is

8-12% by volume, and this must never drop below 8% by volume. The

inhibitor in Scania Corrosion Inhibitor is free of nitrites.

- 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 water alone or corrosion inhibitor alone!

Fluid losses must always be replaced with pre-mixed coolant: water

+ 10% Scania Corrosion Inhibitor by volume.

Coolant filter (not standard equipment)

Only coolant without inhibitor may be used. The use of coolant filters

increases the life of the coolant and reduces the risk of deposit corrosion.

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:

8-12% by volume

Scania Corrosion Inhibitor

(no glycol)

The recommended glycols must

not be mixed with glycol

containing nitrite-based

corrosion inhibitor.

Ethylene glycol and corrosion

protection are highly dangerous

if imbibed.

Avoid contact with the skin.

Overdosing with Scania

Corrosion Protection and mixing

with glycol can cause sludge to

form.

If a coolant filter has been fitted

it must not contain inhibitor.

Important

WARNING

12. Checking the fuel level; see page 42.
14. Checking the electrolyte level in batteries; see page 44.
15. Checking the state of charge in batteries; see page 44.
18. Checking the drive belt tension; see page 46.

Checks before running

Before running, carry out "Daily maintenance" as described in the

maintenance schedule, see page 29.

Engine start

If the fuel tank has been run dry or if the engine has not been used for a long

time, the fuel system must be bled; see page 43.
Out of consideration for our common environment, your Scania engine has

been designed to use less fuel when starting. Using unnecessarily large

amounts of fuel when starting the engine always results in emissions of

unburnt fuel.

- Open the fuel cock, if fitted.
- Disengage the engine.
- Engines with battery master switch: Switch on the power by means of

the battery master switch.

- Start the engine with the key on the control panel (SCP).
- S6: All lamps should go out after around 2 seconds after starting

(applies only to all-speed engines).

Block the starting device when

working on the engine.

If the engine starts accidentally,

there is a

SERIOUS RISK OF INJURY.

Only start the engine 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 starter spray or

similar agents to help start the

engine.

An explosion may occur in the

intake manifold with a risk of

personal injury.

WARNING

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. A moderate load on a cold engine gives better combustion and

faster heating than warming up with no load.
Avoid running it longer than necessary at idling speed.

At temperatures below 0В°C:

- The starter motor must only be cranked for 30 seconds at a time. After

that it must rest for 30 seconds before the next start attempt. Maximum

5 start attempts are permitted. After that the starter motor must rest for

15 minutes before the procedure can be repeated.

Note:

Only use starting aids recommended by Scania.

Running

Check instruments and warning lamps at regular intervals.

Engine speed

The Scania tachometer is divided into different coloured sectors, as follows:

0-500 rpm

Red area

Prohibited engine speed,

passed through when stopping

and starting.

500-700 rpm

Yellow area

Low idling speed. Engine

idling is controlled by the S6

control system. See page 24.

700-2,200 rpm

Green area

Normal operating speed.

The engine operating speed

range is controlled by the S6

control system.

2,200-2,600 rpm

Yellow/green

striped

Unsuitable operating speed.

May occur when switching

off.

2,600-3,000 rpm

Red area

Prohibited engine speed.

The starter motor may only be

cranked for a maximum of

30 seconds. There is risk of

overheating. Let the starter

motor rest for 30 seconds

between each start attempt.

Important

Limp home mode

If there is a fault on the normal accelerator pedal or if CAN communication is

interrupted, the following limp-home option is available:
CAN outage or accelerator pedal malfunction on all-speed engines (both

signal and idling switch):

- The accelerator pedal value is 0% and the engine is running at normal

idling speed.

- The accelerator pedal value is 0% and the engine is running at raised

idling speed (750 rpm) if this function is activated.

Accelerator pedal malfunction but the idling switch is working:

- The accelerator pedal value can be increased slowly between 0% and

50% by using the idling switch.

CAN outage:

- The engine is switched off if the shutdown function is activated.

Coolant temperature

Normal coolant temperature when the engine is running should be 70-90В°C.
The S6 control system has the following alarm levels:

- If the temperature is high, 95В°C-105В°C (standard value, other values can

be programmed), for a certain period (1 second), S6 will send a CAN

message which switches on the warning lamp and diagnostics lamp via

the coordinator.

- If the temperature exceeds 105В°C, the warning lamp and diagnostics

lamps will come on. If torque reduction is activated, the control system

will reduce the fuel quantity to 70%. A fault code is generated in the

control unit.

- At temperatures exceeding 105В°C and with engine shutdown activated,

the warning lamp and diagnostics lamp come on and the engine is

switched off. If the override function is activated, only torque reduction

takes place when this function is activated. A fault code is generated in

the control unit.

After an alarm, approved values should be registered for more than 2 seconds

to reset the alarm.
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.

Oil pressure

Maximum oil pressure:
Warm engine running at a speed above 800 rpm

6 bar

Normal oil pressure:
Warm engine at operating speed

3-6 bar

Minimum oil pressure:
Warm engine above 1,000 rpm

2.3 bar

The control system has the following alarm levels:

- at a speed of less than 1,000 rpm and an oil pressure of less than 1.0 bar
- at a speed of more than 1,000 rpm and an oil pressure of less than 2.3 bar

for longer than 5 seconds.

The following functions are available if there is an alarm:

- Alarm which only switches on the warning lamp and diagnostics lamp.
- Alarm which switches on the warning lamp and diagnostics lamp and

reduces torque if this function is activated (70% of fuel quantity).

A fault code is generated in the control unit.

- Alarm which switches on the warning lamp and diagnostics lamp. The

engine is switched off if engine shutdown is activated. If the override

function is activated, only torque reduction takes place when this

function is activated.

A fault code is generated in the control unit.

After an alarm, approved values should be registered for more than 1 second

to reset the alarm.

High lubricating oil pressure

(above 6 bar) is normal when

starting a cold engine.

Charging indicator lamp

If the lamp comes on during operation:

- Check and 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

Run the engine without a load for a few minutes if it has been run

continuously with a heavy load.

Stop the engine with the stop button or the starter key (depending on

version). Keep the stop button depressed until the engine has stopped

completely.

Set the control switch to the 0 position.

Engines with battery master switch: Switch the power off with the

battery master switch.

Note:

10 prohibited engine stops will cause torque reduction (70% of

fuel quantity). To reset the engine, switch off the engine once in

the prescribed manner.

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 contain enough

glycol. See pages 22 and 37.

- At temperatures below 0В°C: prepare for the next start by connecting the

engine heater (if fitted).

There is danger of turbocharger

damage and post boiling if the

engine is stopped without

cooling.

The power must not be switched

off before the engine has

stopped.

Coolant should be topped up

when the engine is stopped after

the first start.

Block the starting device when

working on the engine.

If the engine starts accidentally,

there is a

SERIOUS RISK OF INJURY.

Hot engine with pressurised

cooling system: Risk of burn

injuries.

Important

WARNING

Maintenance

The maintenance programme covers 20 points, divided into the following

main groups:

Lubricating oil system . . . . . . . . . . . . . . . . . page 26

Cooling system . . . . . . . . . . . . . . . . . . . . . . . page 30

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . page 36

Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . page 38

Electrical system, batteries, etc. . . . . . . . . . . page 40

Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . page 42

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 at 200, 400,

600, 800, etc. hours)
Periodic maintenance every 400 hours of operation (carried out at 400, 800,

1,200, 1,600, etc. hours)
Periodic maintenance every 1,200 hours of operation (carried out at 1,200,

2,400, 3,600, etc. hours)
Periodic maintenance every 2,400 hours of operation (carried out at 2,400,

4,800, etc. hours)
Periodic maintenance every 4,800 hours of operation (carried out at 4,800,

9,600 etc. hours)
Annual maintenance
Maintenance every 5 years

Engines with few hours of operation

Emergency generator sets and the like that are not used regularly should be

test run and checked in accordance with the generator set manufacturerвЂ™s

instructions.
Run the engine until it reaches operating temperature and then carry out the

maintenance points below:

1. Checking the oil level.
5. Checking the coolant level.
8. Checking the vacuum indicator.

12. Checking the fuel level.
14. Checking the electrolyte level in batteries.
15. Checking the state of charge in batteries.
16. Cleaning the batteries.
19. Check for leaks, rectify as necessary.

Block the starting device when

working on the engine.

If the engine starts accidentally,

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 25, maintenance should be

carried out in accordance with

the schedule:

"Annually"

"Every 5th year"

Important

WARNING

Maintenance schedule

More often if required.

Earlier if the vacuum indicator shows red.

If inhibitor has not been topped up for five years, the coolant should be changed.

Dail

First

time at

Interval

At least

Firs

t sta

400 h

200 h

400 h

1,200

2,400

4,800

Annual

Ever

y 5 y

ear

Lubricating oil system, page 26

1. Checking the oil level

2. Oil change

3. Cleaning the lubricating oil cleaner.

4. Renewing the oil filter and filter for crankcase ventilation

Cooling system, page 30

5. Checking the coolant level

6. Checking the coolant

7. Cleaning the cooling system

Air cleaner, page 36

8. Test reading of vacuum indicator

9. Cleaning the coarse cleaner

10. Cleaning or renewing the filter element

11. Renewing the safety cartridge

Fuel system, page 38

12. Checking the fuel level

13. Changing the main filter and water separating filter

Electrical system, page 40

14. Checking the electrolyte level in batteries

15. Checking the state of charge in batteries

16. Cleaning the batteries

17. Checking the coolant level monitor

Miscellaneous, page 42

18. Checking the drive belt

19. Check for leaks, rectify as necessary

20. Checking and adjusting valve clearances

21. Checking and adjusting the unit injector rocker arms

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.
- Specified oil change intervals apply provided that the sulphur content of

the fuel 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.
- For operation at extremely low ambient temperature: Consult your

nearest Scania representative on how to avoid starting difficulties.

Oil analysis

Some oil companies can offer analysis of the engine oil. Such analysis

measures the oilвЂ™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

40 В°C

SAE 10W-30

SAE 20W-30

SAE 30

SAE 40

SAE 50

SAE 5W-30

SAE 15W-40

Important

1. Daily:

Checking the oil level

Note:

Before checking oil level: Leave the engine switched off 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.

- For the correct oil grade, see page 30.

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 more

frequently.

- Unscrew the oil 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 oil plug.
- Refit the oil plug.
- Fill up with oil.
- Check the level on the oil dipstick.

Max. 33 dm

Min. 28 dm

Max. 33 dm

Min 28 dm

1 litre = 1 dm

Maximum angles of inclination during operation

Maximum permissible angles during operation vary, depending on the type

of oil sump, see illustration.

Note:

The specified angles may only occur intermittently.

35В°

25В°

35В°

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.

WARNING

Help protect our

environment!

3. Every 400 hours:

Cleaning the oil cleaner

(At the same time as an oil change)

- Clean the cover. Unscrew the nut and remove the cover.

- Lift out the rotor and wipe the outside. Unscrew the rotor cover nut

about one and a half turns.

- If the rotor nut is jammed:

Turn the rotor upside down and fasten the nut in a vice and turn the rotor

one and a half turns counterclockwise by hand, or use an M20 nut as

illustrated.

Note:

The rotor must never be put in a vice.

- Hold the rotor and tap lightly on the rotor nut with a plastic mallet or

against the workbench, so that the rotor bowl comes loose from the

bottom plate. Never strike on the rotor directly as this may damage the

bearings.

- Unscrew the nut and remove the rotor cover.
- Remove the strainer. If the strainer has seized in the rotor bowl, pry

carefully using a screwdriver between the rotor bowl and the strainer.

- If the strainer has seized in the rotor, pry carefully between the rotor and

the strainer.

- Scrape off the deposits from the inside of the rotor cover. If there are no

deposits, this indicates that the cleaner is not working properly.

- If the deposits are thicker than 28 mm, clean more often.

Open the cover carefully. The

oil may be hot.

WARNING

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Scania DC9 EMS with S6/PDE. Industrial engine. OperatorвЂ™s manual — part 2

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