Scania D9, DI9, DC9. Industrial engine. Operator’s manual — part 2
Clutch
- See the manufacturer’s instructions for handling and operating the
clutch.
VARNING!
If the clutch output shaft is rotating (e.g. in multiple engine
installations where other engines are running), the clutch can,
under its own power, be drawn to the engaged position.
THIS MAY CAUSE PERSONAL INJURY and engine damage.
For this reason, always secure the clutch in the disengaged posi-
tion if there is a risk of the output shaft starting to rotate.
CHECKS AFTER RUNNING
- Check that the power is cut from the battery master switch and that the
control switch is in the ”0” position.
- Fill the fuel tank. Make sure that the filler cap and the area round the
filler opening are clean to avoid contamination of the fuel.
- If there is a risk of freezing, the cooling system must be drained if it
does not contain a sufficient amount of glycol, refer to page 25
- Vid temperatur under 0 °C: Förbered nästa start genom att koppla in ev.
motorvärmare.
Top up engine coolant when the
engine has been stopped after
being started for the first time.
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK
OF INJURY.
18
MAINTENANCE
The maintenance programme covers 25 points, divided into the following
main groups:
Lubricating oil system . . . . . . . . . . . . . . . . . . sid 20
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . sid 24
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . sid 30
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . sid 32
Electrical system, monitors, batteries etc. . . . sid 34
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . sid 39
The maintenance points are divided into intervals as follows:
Daily maintenance
Maintenance before first start
Maintenance after the first 400 hours of operation
Periodic maintenance every 200 hours of operation (carried out after 200,
400, 600, 800, etc. hours)
Periodic maintenance every 400 hours of operation (carried out after 400,
800, 1200, 1600, etc. hours)
Periodic maintenance every 1200 hours of operation (carried out after 1200,
2400, 3600, etc. hours)
Periodic maintenance every 2400 hours of operation (carried out after 2400,
4800 etc. hours)
Periodic maintenance every 4800 hours of operation (carried out after 4800,
9600, etc. hours)
Annual Maintenance
Maintenance every 5th year
ENGINES WITH FEW HOURS OF
OPERATION
Emergency generator sets and the like that are not used regularly should be
run on test and checked in accordance with the generator set manufacturer’s
instructions.
Run the engine until it reaches operating temperature and then carry out the
maintenance points below:
1. Checking the oil level.
5. Checking the coolant level.
8. Checking the vacuum indicator.
12. Checking the fuel level.
15. Checking the electrolyte level in batteries.
16. Checking the state of charge in batteries.
17. Cleaning the batteries.
23. Checking for leakage, rectify as necessary
For engines with few operating
hours that are not subject to
periodic maintenance according
to the maintenance schedule on
page 19, maintenance should be
carried out in accordance with
the schedule:
"Every year"
"Every 5 years"
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK
OF INJURY
MAINTENANCE SCHEDULE
1.
More often if required
2.
For engines with few operating hours, see page 18.
3.
Earlier if vacuum indicator shows red.
4.
If inhibitor has not been topped up for five years, the coolant should be changed.
Dail
y
First
time at
Interval
At least
Firs
t sta
rt
400 h
200 h
400 h
1200
h
2400
h
4800
h
Annual
ly
Ever
y 5t
h ye
ar
LUBRICATING OIL SYSTEM, page 20
1. Checking the oil level
l
l
2. Oil change
l1
l
3. Cleaning the oil cleaner
l1
l
4. Renewing the oil filter
l1
l
COOLING SYSTEM, page 24
5. Checking the coolant level
l
6. Checking the coolant
l
l4
l
7. Cleaning the cooling system
l1
l
AIR CLEANER, page 30
8. Checking the vacuum sensor
l
9. Cleaning the coarse cleaner
l1
l
10. Cleaning or renewing filter element
l3
l
11. Renewing the safety cartridge
l
l
FUEL SYSTEM, page 32
12. Checking the fuel level
l
l
13. Renewing the main filter
l1
l
14. Checking the injectors
l
l
ELECTRICAL SYSTEM, page 34
15. Checking the electrolyte level in batteries
l
l2
l
16. Checking the state of charge in batteries
l
l2
l
17. Cleaning the batteries
l2
l
18. Checking the level monitor
l
l
l
19. Checking the temperature monitor
l
l
l
20. Checking the oil pressure monitor
l
l
l
21. Checking the stop function
l
l
l
MISCELLANEOUS, page 39
22. Checking the drive belt
l
l
l
23. Checking for leakage, rectify as necessary
l
24. Checking/adjusting valve clearance
l
l
25. Renewing (or cleaning) the valve for closed crankcase
ventilation
l
20
LUBRICATING OIL SYSTEM
OIL GRADE
The engine oil must at least meet the requirements for one of the following
oil classifications:
-ACEA E3, E4 or E5
- The Total Base Number (TBN) should be minimum 12-13
(ASTM 2896).
- Check with your oil supplier that the oil meets these requirements.
- The specified oil change intervals apply provided that the fuel sulphur
content does not exceed 0.3% by weight. If the sulphur content exceeds
0.3 % but is maximum 1.0%, the oil change intervals must be halved
(200 h).
- Viscosities as illustrated 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 oil TBN (Total Base Number), TAN (Total Acid Number), fuel
dilution, water content, viscosity and the quantity of friction 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.
-40
-30
-20
-10
0
10
20
30
40 В°C
SAE 10W-30
SAE 20W-30
SAE 30
SAE 40
SAE 50
SAE 5W-30
SAE 15W-40
Additives must not be used.
The oil should be suitable for all
temperature variations until the
next oil change.
1. Daily:
CHECKING THE OIL LEVEL
Note
Before checking oil level: Allow the engine to remain stopped for
at least 1 minute.
- The correct level is between the marks on the dipstick. Top up when the
level is at the lower mark.
- Correct type, see "Oil grade" on page 20.
Note!
Checking of oil level during operation can not be performed on
engines with standard oil sump, see picture.
2. Every 400 hours:
OIL CHANGE
Note
Under extremely severe operating conditions, especially in dusty
environment or if the deposits in the centrifugal cleaner are
thicker than 20 mm: change oil more frequently.
- Unscrew the plug and drain the oil when the engine is hot.
- In certain engines the oil is pumped out by means of a bilge pump.
- Clean the magnet on the plug.
- Refit the plug.
- Fill up with oil.
- Check the level on the dipstick.
Max 27 dm
3
Min 20 dm
3
Max 20 dm
3
Min 16 dm
3
1 dm
3
= 1 liter
Maximum angles of inclination during operation
Maximum permissible angles during operation vary, depending on the type
of oil sump, see illustration.
Note
Specified angles may only occur intermittently.
WARNING
The oil may be hot.
Wear protective gloves and
goggles
Always use a suitable container
to avoid spillage when
changing oil.
Dispose of used oil through an
authorized waste disposal
contractor.
22
3. Every 400 hours:
CLEANING THE OIL CLEANER
(at same time as an oil change)
- Unscrew the nut and remove the cover.
- Lift out the rotor and loosen the nut on the rotor bowl three turns.
- If the nut is jammed:
Clamp the nut, not the rotor, in a vise and turn the rotor three
revolutions by hand or using a screwdriver.
- Tap the nut lightly with your hand or a plastic hammer, to detach the
rotor bowl from the bottom plate.
- Unscrew the nut and remove the rotor bowl.
- Prize carefully to detach the strainer from the bottom plate.
- Scrape off the deposits from the inside of the rotor bowl. If there are no
deposits, this indicates that the cleaner is not working properly.
- If the deposits are thicker than 20 mm: clean more frequently.
Open the cap carefully. The
oil may be hot.
- Rinse all parts in diesel fuel.
- Fit the O-ring in the rotor bowl. Make sure it is not damaged.
Renew parts if necessary.
- Assemble the rotor.
- Tighten the rotor nut firmly by hand
- Refit the rotor.
- Make sure that it spins easily.
- Check that the O-ring in the bowl is undamaged.
Renew the O-ring if hard or damaged.
- Secure the bowl firmly, tightening the nut
If the nut is tightened with a tool, the rotor shaft, nut or bowl may be
damaged.
Operational test
The rotor rotates very fast and should continue to turn 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 inspect.
24
4. Var 400:e timme:
RENEWING THE TURBO FILTER
(at same time as an oil change)
- Remove the old filter.
- Oil the rubber gasket and fit a new genuine Scania filter.
- Tighten the filter by hand.
Never use a tool for tightening. The filter could be damaged,
obstructing circulation.
- Start the engine and check for leaks.
Important
If the deposits in the centrifugal cleaner are thicker than 20
mm the oil filter should be renewed more frequently. This
includes cleaning the centrifugal filter and changing oil.
COOLING SYSTEM
5. Daily:
CHECKING THE 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 lower edge of the
filler neck.
- Hot engine:
The coolant should be approximately 25 mm above the
lower edge of the filler neck.
- Other types of expansion tank according to the instructions of the fitter.
- Top up the coolant as necessary, see point 6.
Note
When filling large amounts of coolant:
Never pour cold coolant into a hot engine.
This could cause cracks in the cylinder block and the cylinder
head.
Always collect oil in a suitable
container to avoid spillage when
renewing the oil filter.
Dispose of used filters through
an authorized waste disposal
contractor.
Always top up with ready mixed
coolant.
Carefully open the cap.
Hot water and steam
may blow out.
6. Every 2400 hours:
CHECKING THE COOLANT
Coolant should be checked as follows:
a)
Check the appearance of the coolant.
b)
Coolant with only glycol: Check the glycol content.
c)
Coolant with only Scania Anti-corrosive:
Check the corrosion inhibitor.
The composition of the coolant is described in detail under
"Starting and running"
a)
Checking the appearance of the coolant
- Fill a container with a little coolant and check that it is clean and clear.
- If the coolant is contaminated or cloudy: consider changing the coolant
- Water added to the coolant should be clean and free from dirt of any
kind.
- Use drinkable water with a pH value 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.
- A content of 30% glycol by volume protects against freezing down to
-16В°C. If further protection is needed, refer to the table on the next page
for calculating the required amount of glycol.
We recommend only nitrite-free anti-freeze glycol with the following
supplier designations:
BASF G48 or BASF D542
- Always top up the anti-freeze if its 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
Change the coolant when cleaning the cooling system: every 4800
hours or minimum every 5 years.
Important
If a coolant filter is used in the cooling system it must not con-
tain an inhibitor.
The coolant should be ready
mixed when it is poured into the
cooling system.
Never top up with only water or
only glycol.
Ethylene glycol is highly
dangerous if ingested and can
prove fatal.
Avoid skin contact with glycol.
The recommended glycol must
not be mixed with glycol having
nitrite-based anti-corrosive.
Risk for build up of sludge and
reduced cooling capacity.
Coolant composition:
If there is a danger of freezing:
minimum 30% glycol by
volume
maximum 60% glycol by
volume
If there is no danger of freezing:
7-12% by volume
Scania Anti-corrosive
26
A
A= Area to be avoided. Only for calculating glycol mix.
Coolant freezing temperature when ice starts to form at different glycol mixes
% glycol by
volume
15
20
25
30
35
40
45
50
60
Cooling
system
capacity, 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
Curve A: Ice build up starts (slush)
Curve B: Temperature at which damage due to
freezing can occur
1. Safe range
2. Malfunctions may occur (ice slush)
3. Risk of damage by freezing
% glycol by volume
Properties of glycol at low temperatures:
- Example with 30% glycol by volume
- Ice slush starts to form at -16В°C.
- There is risk for malfunctions at -30В°C
- No risk of damage by freezing with a
minimum content of 30% glycol by volume
c)
Checking the corrosion inhibitor
There must always be sufficient corrosive inhibitor in the coolant to protect
the cooling system against corrosion.
If there is no danger of freezing, only Scania Anti-corrosive should be used
in the coolant.
The inhibitor in Scania Anti-corrosive is free of nitrite.
The correct proportion of anti-corrosive is 7-12% by volume.
- Topping up with 1.0% Scania Anti-corrosive by volume should be done
after every 2400 hours of operation.
- Never top up with only water or only anti-corrosive!
Fluid losses must always be replaced with premixed coolant:
water + 10% by volume of Scania Anti-corrosive.
Note
The coolant should be changed when the cooling system is clea-
ned: every 4800 hours or minimum every 5 years.
Changing the coolant
1.
Remove the filler cap from the expansion tank.
2.
The coolant is drained at two points:
- the "lowest point" of the engine block, see illustration.
- the "lowest point" of the cooling system.
3.
Close the cocks.
4.
Fill up with coolant through the expansion tank’s filler hole.
Mix coolant as described on page 25.
If a coolant filter has been fitted
it must not contain inhibitor.
Mixing corrosion inhibitor with
glycol or adding too much
corrosion inhibitor may cause
deposits and reduced cooling
capacity.
Corrosion inhibitor, if
swallowed can be fatal.
Avoid contact with the skin.
Always collect fluid in a suitable
container to avoid spillage when
changing coolant.
Dispose of used coolant through
an authorized waste disposal
contractor.
28
7. Every 4800 hours:
CLEANING THE COOLING SYSTEM
Note
If necessary, the cooling system should be cleaned more often.
External cleaning
Radiator
- Check that the radiator is 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 exer-
cising care.
Charge air cooler (DI engine)
1.
Drain the coolant from the engine, refer to "Changing the coolant".
2.
Detach the intake manifold from the turbo.
3.
Detach the charge air cooler inlet and outlet connections.
4.
Unbolt the charge air cooler assembly from the intake manifold. The
charge air element is integrated into the housing.
Be careful - do not damage the core water connections.
5.
Clean the outside of the element. This is especially important if the eng-
ine is equipped with closed crankcase ventilation. Use a paraffin-based
engine cleaner.
6.
Clean and degrease the sealing surfaces on the core and the air intake
pipe with a spirit based cleaner.
7.
Apply sealant (silicone 816 064) in a uniform bead, approximately
2-3 mm, on the sealing surface of the air intake pipe.
8.
Tighten the charge air cooler by means of the clamp rails.
Install the charge air cooler within 15 minutes of applying the sealant.
Torque tighten the bolts to 50 Nm.
9.
Refit the inlet and outlet connections with new O rings.
10.
Connect the intake manifold from the turbo.
11.
Fill up with coolant according to the specification
on page 25.
Important
Allow the sealant to cure for minimum
24 hours before the engine is used.
1.
Clamp rail
2.
Charge cooler hous-
ing with element
3.
O-ring
4.
Sealant 816 064
5.
Intake manifold
1
3
4
5
1
2
1
The cooling system must never
be cleaned with caustic soda.
There is a risk of damage to
aluminium parts.
Internal cleaning
Removing oil and grease
- If possible, run the engine until it has reached the operating temperature
and then drain the cooling system.
- Remove the thermostat.
- Fill the system with clean, hot water mixed with liquid dishwasher
detergent intended 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.
- Fill the system again using clean, hot water and run the engine for
approximately 20-30 minutes.
- Drain the water from the system.
- Refit the thermostat.
- Fill up with new coolant according to the specification on page 25.
Removing deposits
- If possible, run the engine until it has reached operating temperature and
then drain the cooling system.
- Remove the thermostat.
- Fill the system with clean, hot water mixed with a commercially
available radiator cleaner based on sulphamic acid and containing
dispersing agents. Follow the manufacturer’s instructions for mixing
proportions and cleaning times.
- Run the engine for the specified time and then drain the cooling system.
- Refill the system with hot water and run the engine for approximately
20-30 minutes.
- Drain the water from the system.
- Refit the thermostat.
- Fill up with new coolant according to the specification on page 25.
Handling cleaning agents for
the cooling system:
Read the warning label on the
container.
Always collect fluid in a suitable
container to avoid spillage when
draining coolant.
Dispose of used coolant through
an authorized waste disposal
contractor.
30
AIR CLEANER
8. Daily:
CHECKING THE VACUUM INDICATOR
If the indicator’s red plunger is fully visible, change or clean the air cleaner
filter insert, point 10.
9. Every 200 hours:
CLEANING THE AIR CLEANER
COARSE CLEANER
1.
Detach the eccentric catch and remove the coarse cleaner.
2.
Remove the plastic cover from the coarse cleaner and clean the parts.
3.
Check that the plastic cover is intact and that it makes a seal against the
air cleaner housing during assembly.
4.
Assemble the air cleaner.
1.
Pre-filter with cover
2.
Filter insert
3.
Low pressure indicator
4.
Safety cartridge
Air cleaner with pre-filter
The coarse cleaner should be
fitted with the marking ”TOP”
facing up.
10. Every 1200 hours:
CLEANING OR CHANGING THE
FILTER ELEMENT
Note
Earlier if the vacuum indicator shows red
Dismantling
1.
Remove and clean the coarse cleaner, see point 9.
2.
Undo the nut securing the filter insert and remove it.
3.
Change or clean the insert.
Note
Cleaning the element always entails a risk of damaging it. The
element should only be cleaned four times a year at most. After
cleaning, it has poorer dust capacity than a new element.
4.
Mark the filter when it has been cleaned.
Cleaning the element
- Carefully blow the filter element clean using dry compressed air from
the inside.
Note
This filter element must not be washed with water.
Only use Scania genuine air
filter. Change the filter element
if it is damaged.
Danger of engine damage if the
filter element is damaged.
Never start the engine unless
the air filter is installed.
Danger of personal injury or
engine damage.
Checking
- Insert a torch into the element and check from the outside that there are
no holes or cracks in the filter paper.
- Change 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 red plunger in the vacuum indicator by depressing the button.
11. Every 2400 hours:
RENEWING THE SAFETY CARTRIDGE
1.
Remove and clean the coarse cleaner, see point 9.
2.
Undo the nut securing the filter element and remove it.
3.
Change or clean the filter element, see point 10.
4.
Undo the nut securing the safety cartridge and remove it.
5.
Fit a new Scania genuine safety cartridge.
6.
Assemble the air cleaner.
1.
Pre-filter with cover
2.
Filter insert
3.
Low pressure indicator
4.
Safety cartridge
Air cleaner with pre-filter
Do not remove the safety
cartridge unnecessarily.
Never clean the safety cartridge
32
FUEL SYSTEM
12. Daily:
CHECKING THE FUEL LEVEL
- Top up with fuel if necessary.
- If the tank has been run dry, bleed the fuel system, refer to paragraph 13.
13. Every 1200 hours:
RENEWING THE FUEL FILTER
Fuel tanks
- Drain any water from the fuel tanks.
Filter
The filter consists of a filter unit.
- Wash the outside of the filter and unscrew it. Discard the filter according
to environmental requirements.
- Tighten the new filter by hand.
Never use a tool for tightening. The filters can be damaged,
obstructing circulation.
- Bleed the fuel system as described below.
- Start the engine and check for leaks.
Bleeding the fuel system
- Open the bleed screw 1 on the main filter.
- Pump the hand pump 2 until air-free fuel flows out at the main
bleed screw.
- Close the bleed screw. Pump a few times using the hand pump.
If the engine is difficult to start after bleeding . . . . .
- Slacken the injection pump overflow valve 3 one half turn
and try starting again.
If the engine fails to start after bleeding . . . . . . .
- Pump the hand pump until bubble-free fuel flows from the overflow
valve.
- Tighten the overflow valve when the engine has started.
Always collect fuel in a suitable
container to avoid spillage when
bleeding system or renewing
components.
Only use Scania genuine fuel
filter.
Observe the utmost cleanliness
when working on the fuel
system.
Malfunctions could easily occur
and the injection equipment
could be damaged.
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