Scania DC9 EMS with S6/PDE. Industrial engine. Operator’s manual — part 3
33
- Wash all parts in diesel oil.
- Make sure the nozzles on the rotor are not blocked or damaged.
- Check that the bearings are undamaged. If they are damaged the entire
rotor must be renewed.
- Fit a new O-ring on the rotor and fit the strainer.
- Reassemble the rotor.
- Tighten the rotor nut firmly by hand.
- Check that the shaft is not loose. If it is loose, use locking compound
561 200 and torque tighten the shaft to 34 Nm using tool 98 421.
- In order to tighten the rotor shaft, it is necessary to modify socket
wrench 98 421:
- Drill out the threads from a M20 nut so that it fits on the square drive
of the socket wrench.
- Weld the nut into place.
- Refit the rotor.
- Check that it rotates easily by rotating it manually.
- Fit a new O-ring on the cover and fit the cover.
- Screw the bowl on and tighten the lock nut to 15 Nm.
Tighten the nut carefully so as not to damage the rotor shaft, nut or cover.
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 not: dismantle and check.
34
4. Every 400 hours:
Renewing the oil filter
(in connection with oil change)
- Remove the old filter.
- Fit a new Scania genuine filter. Oil the seal on the filter before fitting.
- Tighten the filter by hand. Never use tools, 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
28 mm thick, the oil filter must be renewed 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 add cold coolant to a hot engine. Risk of cracks forming in
the cylinder block and cylinder head.
Use a container to avoid spillage
when renewing the filter.
Dispose of used filters through
an authorised waste disposal
contractor.
Always top up with pre-mixed
coolant.
Open the cap carefully.
Water and steam can spray out.
Important
!
WARNING
!
Help protect our
environment!
35
6. Every 2,400 hours:
Checking coolant
Coolant should be checked as follows:
a)
Check the appearance of the coolant.
b)
Coolant with glycol only: check the glycol content.
c)
Coolant containing only Scania Corrosion Inhibitor: check the corrosion
inhibitor content.
The composition of the coolant is described in more detail under
"Starting and running".
a)
Checking the appearance of the coolant
- Pour a small amount of coolant in a container, and check that the coolant
is pure and clear.
- If the coolant is contaminated or cloudy: consider changing the coolant.
- Water for the coolant must be clean and free from contamination.
- Use drinking water with a pH of 6-9.
b)
Checking the glycol content
If there is a danger of freezing, use only glycol as an anti-corrosive in the
coolant.
- Cooling systems with glycol should contain at least 30% glycol by
volume to provide acceptable protection against corrosion.
- 30% glycol by volume provides protection against freezing to -16В°C.
If additional protection against freezing is required, see the table on the
next page to help you calculate how much glycol you need.
We recommend only nitrite-free antifreeze glycols with the following
supplier designations:
BASF G48 or BASF D542
- Always add glycol if the glycol content drops below 30% by volume. A
glycol content above 60% by volume will not provide greater protection
against freezing.
- The table shows the temperature at which ice starts to form. The engine
will freeze and break at appreciably lower temperatures; see diagram.
- Ice forming in the coolant often causes malfunctioning without any risk
of damage. The engine should not be subjected to heavy loads when ice
starts to form.
Note:
The coolant should be changed when the cooling system is
cleaned: every 4,800 hours or at least every 5 years.
Important!
If a coolant filter is used in the cooling system it must not
contain an inhibitor.
Coolant composition:
If there is a danger of freezing:
minimum 30% glycol by
volume
maximum 60% glycol by
volume
If there is no danger of freezing:
8-12% by volume
Scania Corrosion Inhibitor
The coolant should be pre-
mixed when it is poured into the
cooling system.
Never top up with only water or
only glycol.
Ethylene glycol is highly
dangerous if imbibed and can
prove fatal.
Avoid skin contact with glycol.
The recommended glycols must
not be mixed with glycol
containing nitrite-based
corrosion inhibitor.
Risk of sludge build-up and
reduced cooling capacity.
Important
!
Important
!
WARNING
!
36
Curve A: Ice formation starts (ice slush)
Curve B: Temperature at which there is a risk of damage by freezing
1. Safe range
2. Malfunctions may occur (ice slush)
3. Risk of damage by freezing
Characteristics of glycol at low temperatures:
- Example with 30% glycol by volume
- Ice slush starts to form at -16В°C.
- There is a risk of malfunctions at -30В°C
- No risk of damage by freezing with a minimum
content of 30% glycol by volume
Antifreeze glycol, % by volume
A
A = Area to be avoided. Only for calculating glycol mix.
Coolant freezing point (when ice starts to form) for different glycol mixes
Glycol % by
volume
15
20
25
30
35
40
45
50
60
Cooling
system
volume, dm
3
Ice slush starts to
form at В°C
-6
-9
-12 -16 -22 -27 -36 -46 -55
Glycol dm
3
(litres)
5
6
8
9
11
12
14
15
18
30
6
8
10
12
14
16
18
20
24
40
8
10
13
15
18
20
23
25
30
50
9
12
15
18
21
24
27
30
36
60
11
14
18
21
25
28
32
35
42
70
12
16
20
24
28
32
36
40
48
80
14
18
23
27
32
36
41
45
54
90
15
20
25
30
35
40
45
50
60
100
17
22
28
33
39
44
50
55
66
110
18
24
30
36
42
48
54
60
72
120
20
26
33
39
46
52
59
65
78
130
21
28
35
42
49
56
63
70
84
140
23
30
38
45
53
60
68
75
90
150
24
32
40
48
56
64
72
80
96
160
26
34
43
51
60
68
77
85
102
170
27
36
45
54
63
72
81
90
108
180
29
38
48
57
67
76
86
95
114
190
30
40
50
60
70
80
90
100 120
200
37
c)
Checking the corrosion inhibitor
There must always be sufficient corrosion protection (inhibitor) in the coolant
to protect the cooling system against corrosion.
If there is no danger of freezing, only Scania Corrosion Inhibitor should be
used in the coolant.
The inhibitor in Scania Corrosion Inhibitor is free of nitrites.
The correct corrosion inhibitor content is 8-12% by volume.
- Topping up with 1.0% Scania Corrosion Inhibitor by volume should be
done after every 2,400 hours of operation.
- 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.
Note:
The coolant should be changed when the cooling system is
cleaned: every 4,800 hours or at least every 5 years.
Changing coolant
1.
Remove the filler cap from the expansion tank.
2.
The coolant is drained at two points:
- the lowest point of the cylinder block; see illustration
- the lowest point of the cooling system.
3.
Close the cocks.
4.
Top up with coolant through the expansion tank’s filler hole.
Mix coolant as described on page 31.
Use a container to avoid spills
when changing the coolant.
Dispose of used coolant through
an authorised waste disposal
contractor.
If a coolant filter has been fitted
it must not contain inhibitor.
Mixing with glycol or the use of
too much corrosion protection
can lead to build up of sludge
and reduced cooling capacity.
Corrosion protection is highly
dangerous if ingested and can
prove fatal.
Avoid contact with the skin.
Important
!
Important
!
WARNING
!
Help protect our
environment!
38
7. Every 4,800 hours:
Cleaning the cooling system
Note:
If necessary, the cooling system should be cleaned more often.
External cleaning
Radiator and charge air cooler
- Check that the radiator and the charge air cooler are not clogged on the
air side and that the cooling fins are not damaged.
- Carefully scrape the deposit off the radiator’s cooling fins. If necessary,
a paraffin-based engine cleaner can be used.
- Bent fins can be straightened using a wire brush, for example, and
exercising care.
The cooling system must never
be cleaned with caustic soda.
There is a risk of damage to
aluminium parts.
Important
!
39
Internal cleaning
Removing oil and grease
- If possible, run the engine until it has reached operating temperature and
then drain the cooling system.
- Remove the thermostats.
- Fill the system with clean, hot water mixed with liquid dishwasher
detergent designed for household use.
Concentration 1% (0.1/10 l).
- Run the engine until warm for about 20-30 minutes. Do not forget the
cab heating system (if fitted).
- Drain the cooling system.
- Refill the system with clean hot water and run the engine for about
20-30 minutes.
- Drain the water from the system.
- Refit the thermostats.
- Top up the system with coolant according to the specification on
page 31.
Removing deposits
- If possible, run the engine until it has reached operating temperature and
then drain the cooling system.
- Remove the thermostats.
- Fill the system with clean, hot water mixed with some of the radiator
cleaning agent available on the market which is based on sulphamic acid
and contains dispersing agents. Follow the manufacturer’s instructions
for the concentration and cleaning period.
- Run the engine for the specified time and then drain the cooling system.
- Refill the system with hot water and run the engine for about
20-30 minutes.
- Drain the water from the system.
- Refit the thermostats.
- Top up the system with coolant according to the specification on
page 31.
When handling cooling system
detergent:
read the warning text on the
containers.
Use a container to avoid spills
when changing the coolant.
Dispose of used coolant through
an authorised waste disposal
contractor.
WARNING
!
Help protect our
environment!
40
9. Every 200 hours:
Cleaning the air cleaner coarse cleaner
1.
Remove the cover from the coarse cleaner (2).
2.
Remove the conical coarse separator. Empty out the particles of dirt and
clean it.
3.
Fit the coarse cleaner as shown in the figure and screw the cover into
place.
10. Every 1,200 hours:
Cleaning or changing filter element
Note:
Clean or renew the filter element earlier if the vacuum indicator
shows red.
Dismantling
1.
Remove the cover (3) from the coarse cleaner.
2.
Renew or clean the filter element.
Note:
There is always a risk that the filter element will be damaged
during cleaning. The element can only be cleaned a maximum of
four times. After cleaning, it has poorer dust capacity than a
new filter element.
3.
Mark the filter when it has been cleaned.
Cleaning the filter element
- Carefully blow the filter element clean using dry compressed air from
the inside.
Note:
The filter element must not be washed with water.
Air cleaner
8. Daily:
Test reading of vacuum indicator
If the indicator’s red plunger is fully visible, change or clean the air cleaner
filter element, point 10. This is especially important if the engine is run with a
heavy load or at high speed.
4
3
2
1
1.
Filter element
2.
Coarse cleaner
3.
Cover
4.
Vacuum indicator
The coarse cleaner must always
be fitted in an upright position.
Only use genuine Scania air
filters.
Renew the filter element if it is
damaged.
Danger of engine damage if the
filter element is damaged.
Never start the engine without
the air filter.
There is a risk of injury or
serious engine damage.
Important
!
Important
!
WARNING
!
41
Check
- Insert a torch into the element and check from the outside that there are
no holes or cracks in the filter paper.
- Renew the filter element if it has the slightest damage. Danger of engine
damage.
Assembly
1.
Assemble the air cleaner in reverse order.
2.
Reset the vacuum indicator by pressing the button.
11. Every 2,400 hours:
Renewing the safety cartridge
Note:
Not all filters are equipped with a safety cartridge. When
changing the safety cartridge, take great care to ensure that no
dirt or other impurities can get into the engine.
1.
Remove the cover from the air cleaner.
2.
Remove the filter element.
3.
Remove the safety cartridge.
4.
Fit a new genuine Scania safety cartridge.
5.
Renew or clean the filter element, see point 10.
6.
Assemble the air cleaner.
1
Do not remove the safety
cartridge unnecessarily.
1. Safety cartridge
Air cleaner with safety cartridge
Never clean the safety cartridge.
Important
!
Important
!
42
Fuel system
12. Daily:
Checking fuel level
- Top up with fuel if necessary.
- If the tank has been run dry, bleed the fuel system, see point 13.
13. Every 1,200 hours:
Renewing the fuel filter
Fuel tanks
- Drain any water from the fuel tanks.
Main filter
- Unscrew the filter cover with a closed tool with hexagon driver, for
example socket 587 637, so as not to damage the filter cover.
- Lift out the filter lid and filter element. At the same time, the filter
housing will drain automatically. This applies only if the fuel tank is
lower than the engine. Otherwise the fuel shut-off cock must be closed
first.
- Remove the filter element from the lid by carefully prying it to one side.
Discard the filter according to environmental requirements.
- Renew the O-ring in the cover. Lubricate the new O-ring with a suitable
grease.
- Check that the filter housing is drained of fuel. Contaminated fuel may
enter the injectors if the drainage does not work.
- Press a new filter element into the snap fastener in the cover.
- Fit the lid with the filter element in the housing. Tighten the cover to
25 +/-5 Nm. Use a closed tool with hexagon driver.
- Bleed the fuel system after changing the water separating filter as
instructed on the next page.
Observe the utmost cleanliness
when working on the fuel
system.
There is a risk of engine
malfunction and damage to the
injection equipment.
Use a container to avoid spillage
when bleeding and renewing
components.
Use only genuine Scania fuel
filters.
Important
!
Important
!
Help protect our
environment!
43
Water separating filter
- Drainage must be carried out when filling fuel.
- The filter must be changed at the same renewal interval as the main
filter.
- Close the cock (1) upstream of the filter.
- Unscrew the container and drain valve (3).
- Unscrew and change the filter (2). Lubricate the seal before tightening
the new filter by hand.
- Screw the container and drain valve into position.
- Open the cock (1).
- Bleed the fuel system after renewing both filters.
Bleeding the fuel system
A
- Attach a clear plastic hose to the bleed nipple (1) on the fuel filter
housing, to lead fuel into a container.
- Open the bleed nipple and pump with the hand pump (2) until fuel
comes out of the hose. When the fuel system is empty, approximately
100 pump strokes will be needed to draw fuel up to the bleed nipple.
- Pump until fuel without air bubbles comes out, approximately 20
strokes.
- Close the bleed nipple and remove the hose.
B
- Transfer the plastic hose to the fuel manifold bleed nipple (3).
- Open the fuel manifold bleed nipple and pump with the hand pump until
the fuel is free from air bubbles (approximately 50 strokes).
- Close the bleed nipple on the fuel manifold and remove the plastic hose.
- Pump approximately 20 hand pump strokes until the overflow valve (4)
opens. You will hear a creaking sound when it opens.
If the engine fails to start after bleeding:
- Open the bleed nipple again and pump the hand pump until fuel without
air bubbles flows out.
- Tighten the bleed nipple. Start the engine and check for leaks.
2
Use a container to avoid spillage
when bleeding and renewing
components.
1.
Shut-off cock
2.
Filter
3.
Drain valve
1
3
4
A
B
Help protect our
environment!
44
Electrical system
14. Every 200 hours:
Checking electrolyte level in batteries
1.
Unscrew the plugs and check the electrolyte level in all cells.
2.
Top up with distilled water until the level is 10-15 mm above the plates.
15. Every 1,200 hours:
Checking state of charge in batteries
- Check the density with an acid tester.
In a fully-charged battery it should be:
1.280 at +20В°C
1.294 at 0В°C
1.308 at -20В°C
- If the density is below 1.20, the battery must be charged. A discharged
battery freezes at -5В°C.
Do not boost charge the battery. This will damage the battery in the long run.
16. Every 1,200 hours:
Cleaning batteries
1.
Clean batteries, cables and cable terminals.
2.
Check that all cable terminals are firmly tightened.
3.
Grease the battery terminal posts and cable terminals with Vaseline.
Wear gloves and protective
goggles when charging and
handling batteries.
The batteries contain a highly
corrosive acid.
Do not connect the terminals
incorrectly.
This can cause serious damage
to the electrical system.
If the terminals are shorted,
sparking will occur.
Avoid naked flames or sparks
near the batteries.
When the batteries are charged,
oxyhydrogen gas is formed
which is flammable and
explosive.
WARNING
!
WARNING
!
WARNING
!
45
Renewing the battery
Removing
1.
Disconnect the negative cable (-) from the battery (cable connected to
earth).
2.
Disconnect the positive cable (+) from the battery (cable connected to
starter motor).
Fitting
1.
Connect the positive cable (+) to the battery (cable connected to starter
motor).
2.
Connect the negative cable (-) to the battery (cable connected to earth).
17. Every 1,200 hours:
Checking coolant level monitor
(optional equipment)
1.
Start the engine.
2.
Lower the coolant level in the expansion tank.
3.
Automatic stop in the event of a fault: The engine stops, fault code, the
indicator lamp comes on and the buzzer (if fitted) sounds if there is no
level monitor fault.
4.
No automatic stop in the event of a fault: The indicator lamp comes on
and the buzzer (if fitted) sounds if there is no fault in the level monitor.
5.
Top up coolant to the correct level, see page 36.
Do not connect the terminals
incorrectly.
This can cause serious damage
to the electrical system.
If the terminals are shorted,
sparking will occur.
Dispose of used batteries
through an authorised waste
disposal contractor.
2-pin level monitor installed in the
expansion tank for radiators
supplied by Scania
Use a container to avoid spills
when draining the coolant.
Dispose of used coolant through
an authorised waste disposal
contractor.
WARNING
!
Help protect our
environment!
Help protect our
environment!
46
Miscellaneous
18. Every 1,200 hours:
Checking drive belt
- If the drive belts (1), which are poly-V belts, are worn or damaged they
must be changed.
- Also check that the automatic belt tensioners (2) are in proper working
order and keep the drive belts correctly tensioned.
47
19. Daily:
Look for leakage, rectify as necessary
- Start the engine.
- Check for oil, coolant, fuel, air and exhaust leaks.
- Tighten or renew leaking connections. Check the overflow holes (1)
(below the side covers) which show whether the O-rings between the
cylinder liners and crankcase are leaking, see figure.
a) If coolant is running out, the O-ring is leaking.
b) If lubricating oil is running out, the liner shelf is leaking.
- Check that the coolant pump drain hole (2) is not clogged, see figure. If
there is a leak, renew the pump seal or the complete coolant pump.
A small amount of leakage from the overflow holes during the engine
running-in period is normal. (Sealing rings and O-rings are lubricated
with soap or oil when fitted).
- This leakage normally stops after a time.
Take care to ensure that any
leaks do not cause pollution.
If serious leakage occurs,
contact your nearest Scania
workshop.
Important
!
Help protect our
environment!
48
Block the starting device when
working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK OF INJURY.
20. Every 2,400 hours:
Checking and adjusting the valve
clearance
Note:
Checking/adjusting valve clearances should also be done after
the first 400 hours of operation.
Valve clearances should be adjusted when the engine is cold, at least
30 minutes after running.
The rocker cover gaskets should be renewed as necessary. Tightening
torques: 26 Nm.
Intake valve clearance: 0.45 mm.
Exhaust valve clearance: 0.70 mm.
Tightening torque for lock nut: 35 Nm.
Order of adjustment
To make sure you adjust on the correct revolution, proceed as follows:
- Rotate the flywheel using tool 99 309 so that the 72В° mark on the
flywheel can be seen in the lower window of the flywheel housing and
there is valve overlap on cylinder 5. Refer to table.
-
Then turn the flywheel clockwise so that it passes TDC down (0В°) by
about 20В° and then turn it anticlockwise until TDC Down (0В°) is visible
in the bottom window on the flywheel housing. The reason for turning
past TDC down (0В°) and then back is to counteract any backlash.
- You are now on the first revolution and can adjust the valves as shown
in the table on the next page.
- Measure the valve clearance using a feeler gauge. Correct valve
clearances are also given on the instruction plate on one of the rocker
covers.
- 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 overleaf.
- Checking and adjustment of the rocker arms for the PDE injectors
should be done together with the valve clearance check/adjustment. See
step 21.
- 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 (0В°) in the lower window. Then turn the flywheel
counterclockwise, 144В° at a time and note the valve overlap. Adjust the
valves according to the table on the next page.
Important!
The flywheel marking is only correct if the reading is taken
through the lower opening.
5
4
3
2
1
Cylinder numbering
FLYWHEEL
WARNING
!
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