Scania DC09 Installation Manual
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Scania DC09 Installation Manual

Exhaust gas aftertreatment. industrial engines
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Installation manual
Exhaust gas aftertreatment
Industrial engines
DC09, DC13, DC16
01:07 Issue 17 en-GB
© Scania CV AB 2018, Sweden

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Summary of Contents for Scania DC09

  • Page 1 Installation manual Exhaust gas aftertreatment Industrial engines DC09, DC13, DC16 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 2: Table Of Contents

    Evaporator ......................26 Hydrolysis catalytic converter................29 SCR catalytic converter..................31 Exhaust gas temperature sensor ................ 32 NOx sensor......................32 Reductant tank ...................... 35 Tank volumes ....................36 Dimensions......................37 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 3: Changes From The Previous Issue

    Resonant frequencies under 300 Hz must be avoided. Scania refers to ISO standard 16750 for more infor- In order for the emission control to meet the emission requirements set by the public mation on vibrations.

  • Page 4: System Overview - Stage V

    12. Coolant hose for heating the reductant tank and pump. 13. Coolant hose, return from heating the reductant tank and reductant pump. 1. 90° exhaust pipe bend and exhaust brake is available as an option. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 5: System Overview Of Electrics

    Exhaust gas temperature sensor T4012. Exhaust gas temperature sensor T4010. Differential pressure sensor T141. Exhaust gas temperature sensor T113. Reductant doser V117. sensor T115 with control unit. Engine control unit. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 6: Exhaust Pipe

    There is then a great risk that the engine will go into heating mode, which can in- crease fuel consumption. The maximum permitted exhaust gas temperature reduc- tion is indicated in 01:04 Exhaust system. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 7 T115. Note: The requirement for pipe length D applies only if a 90° pipe bend is connected di- rectly downstream of the SCR unit. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 8 MANUAL System overview – Stage V Pipe material Scania recommends that the exhaust pipe between the particulate filter unit and SCR unit be made from stainless metal type 1.4301 or 1.4509, US grade 316L or equiva- lent. Other instructions on exhaust system shape and fitting are available in 01:04 Exhaust system.

  • Page 9: Components - Stage V

    The positioning of the particulate filter unit is also limited by the inclination of the differential pressure sensor. See Differential pressure sensor. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 10 The particulate filter unit is supplied with 2 retaining straps with brackets. Attach the 4xØ13 brackets with flange screw M12 or a common screw of a suitable length. Use an M12 flange nut if necessary. Tightening torques 70 Nm Retaining strap 39 Nm 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 11 Purpose Renewing particulate filter. Renew particulate filter with vertically installed bracket. In order to renew the particulate filter, screw 1 must be undone. Renew particulate filter with horizontally installed bracket. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 12: Differential Pressure Sensor

    The differential pressure sensor must not be inclined when compared to the horizon- tal plane. There must be a continuous inclination in pipes and hoses in order to pre- vent water from collecting in them and freezing. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 13 The differential pressure sensor must be slightly inclined when compared to the ver- tical plane, so that condensation can run off it. Maximum installation angle is 30° rel- ative to the vertical plane. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 14: Scr Unit

    SCR catalytic converter. Dimensions The SCR unit is available in 2 versions. Engine L1 (mm) L2 (mm) DC09 and DC13 up to 331 kW 763.5 DC13 over 331 kW 840.5 The tolerance for dimension L1 is ±3 mm. 01:07 Issue 17 en-GB...
  • Page 15 IMPORTANT! Maximum permitted ambient temperature at the reductant doser is 115°C. On the SCR unit, there is a drain hole for emptying flush water (1). Scania recom- mends that the SCR unit is positioned with the drain hole facing down.
  • Page 16 SCR unit can be maintained and repaired in a simple way. Purpose Gaining access to the reductant doser and exhaust gas tem- perature sensor, flushing clean the evaporator. Checking the SCR catalytic converter using an endoscope, draining flush water. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 17 To ensure sufficient flow, hoses must not have any sharp bends and there must be no spots where they are at risk of being pinched. The maximum bend radius for the hos- es is 50 mm. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 18: Exhaust Gas Temperature Sensor

    • T115, which must be fitted in the supplied NO adapter on the SCR unit outlet side. Length of the electrical cable be- Tightening torques tween NO sensor and control unit 910 mm 50 ±10 Nm NOx sensor. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 19 Maximum installation angle is 80° relative to the ver- tical plane. This applies regardless of whether the exhaust pipe is installed horizon- tally or vertically. max 80 max 80 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 20: System Overview - Stage Iv/Tier 4F And Stage Iii B/Tier 4I

    1. Hydrolysis catalytic converter is used for DC16 Stage III B/Tier 4i. 2. Only Stage IV/Tier 4f. 3. Stage IV/Tier 4f only. Not DC13 085A and DC16. 4. Customer option. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 21: System Overview Of Electrics

    Electrical cable for reductant doser Electrical cable for exhaust gas temperature sensor Electrical cable for NO sensor on the outlet side of the SCR catalytic converter 1. Only Stage IV/Tier 4f. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 22: Exhaust Pipe

    3.5 metres. There is then a great risk that the engine will go into heating mode, which can increase fuel consumption. The maximum permitted exhaust gas temperature reduction is indicated in 01:04 Exhaust system. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 23 The exhaust pipe between the evaporator or hydrolysis catalytic converter and the SCR catalytic converter must be made from stainless metal type 1.4301 or 1.4509, US grade 316L or equivalent. Scania also recommends that this material is used for Oxidation catalytic converter.
  • Page 24 The tightening torques for the V-clamps in the SCR system are indicated in the illus- trations to the right. IMPORTANT! Scania recommends that the V-clamps in the SCR system are retightened after the engine has reached operating temperature for the first time. Carry out the retighten- ing when the engine has cooled down again.

  • Page 25: Components - Stage Iv/Tier 4F And Stage Iii B/Tier 4I

    The oxidation catalytic converter is supplied with 2 retaining straps with brackets. The attachment holes have a diameter of 11 mm. Attach the brackets with M10 hex- agon socket screws. Tightening torques 39 Nm Retaining strap 20 Nm 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 26: Evaporator

    Stage IV/Tier 4f: Evaporator for DC09 and DC13. DC16. Stage IIIB/Tier 4i 530.5 For engines certified according to Stage III B/Tier 4i, an evaporator is used for DC09 and DC13. For DC16, see Hydrolysis catalytic converter. The illustration shows the dimensions of the evaporator.
  • Page 27 13 mm. Attach the brackets with flange screw M12 or a common screw of a suitable length. Use an M12 flange nut if necessary. Tightening torques 70 Nm Retaining strap 39 Nm 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 28 To ensure sufficient flow, hoses must not have any sharp bends and there must be no spots where they are at risk of being pinched. The maximum bend radius for the hos- es is 50 mm. Reductant doser. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 29: Hydrolysis Catalytic Converter

    The hydrolysis catalytic converter must be fitted in the direction of the exhaust gases as illustrated. The hydrolysis catalytic converter should be positioned in a space where the ventilation is as good as possible. Maximum permitted ambient tempera- ture 115°C. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 30 13 mm. Attach the bracket with flange screw M12 or a common screw of a suitable length. Use an M12 flange nut if necessary. Tightening torques 70 Nm Retaining strap 39 Nm 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 31: Scr Catalytic Converter

    13 mm. Attach the brackets with flange screw M12 or a common screw of a suitable length. Use an M12 flange nut if necessary. Tightening torques 70 Nm Retaining strap 39 Nm 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 32: Exhaust Gas Temperature Sensor

    • SCR systems according to Stage IIIB/Tier 4i have 1 NO sensor: T115, which is fitted as described on the following page. Electrical cable length (mm) Tightening torque (Nm) 50 ±10 NOx sensor T131 and T115. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 33 SCR system. The tightening torque for the V-clamp be- tween the SCR catalytic converter outlet and the NO adapter is 20 Nm. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 34 This applies regardless of whether the exhaust pipe is installed horizon- tally or vertically. The illustration shows an example of NO sensor installation in a vertical exhaust pipe. max 80 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 35: Reductant Tank

    The reductant pump and EEC3 control unit are located on the reductant tank. The re- ductant tank is heated via the engine cooling system. 38 litres. Scania advises against manufacturing your own reductant tank. 60 litres. The reductant tank and reductant pick-up unit are designed to withstand freezing.

  • Page 36: Tank Volumes

    Reductant tank A Expansion volume (l) B Fill volume (l) C Reserve volume (l) Total volume (l) Volume for first filling 52.5 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 37: Dimensions

    Dimension A (mm) Stage V/Stage IV/Tier 4f Stage III B/Tier 4i Dimensions for 60 litre reductant tank Emission class Dimension A (mm) Stage V/Stage IV/Tier 4f 788.3 Stage III B/Tier 4i 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 38: 01:07 Issue 17 En-Gb

    INSTALLATION MANUAL Reductant tank Dimensions for 45 litre reductant tank Dimensions for 63 litre reductant tank Dimensions for 70 litre reductant tank 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 39: Position

    Refer to 01:08 Measuring instructions for installation inspection. IMPORTANT! The reductant tank must not be twisted or tipped in relation to the lode line when it is installed. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 40 The location of the drain hole for different reductant tanks is shown in the illustra- tions. The tanks are shown from below. The holes have M18 threads. 38 litre tank. 60 litre tank. 45 litre tank. 63 litre tank. 70 litre tank. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 41: Mounting

    The reductant tanks with a capacity of 38 and 60 litres are fitted using six M14 studs. The bracket is threaded so that screws without nuts can be used if the studs are re- moved. Bracket for the 38 and 60 litre reductant tanks. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 42 In this case use at least six of the eight nuts. It also is possible 2x16 to fit the bracket using 6 holes with a diameter of 14 mm. 40,2 70,2 234,7 264,7 2x631 121,4 343,5 389,2 429,2 459,2 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 43 MANUAL Reductant tank Attaching the 70 litre tank The reductant tank with a volume of 70 litres is fitted using the 6 holes with a diam- eter of 15 mm. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 44: Connecting The Reductant Tank

    Union, Ø 16 mm 10. Pressure hose for reductant to reduct- SAE J2044, Ø 6.30 mm. ant doser 11. Return hose for reductant to reductant SAE J2044, Ø 7.89 mm. tank 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 45 SAE J2044, Ø 6.30 mm. ant doser Coolant from engine Union, Ø 16 mm C4051 sensor upstream of the catalytic converter (T131). Note: Only applies to Stage IV/ Tier 4f and Stage V. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 46 (T115). 10. Coolant return to engine Union, Ø 16 mm 11. Return hose for reductant to reductant SAE J2044, Ø 7.89 mm. tank 12. Ventilation hose. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...
  • Page 47 Note: Only applies to Stage V. 10. Coolant return to engine Union, Ø 16 mm 11. Return hose for reductant to reductant SAE J2044, Ø 7.89 mm. tank 12. Ventilation hose 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 48: Ventilation

    The filter should be positioned as high as possible, but at least 400 mm above the re- ductant tank. The filter should be positioned so that it is protected from rain. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 49: Available Lengths Of Reductant Hoses

    Hose length which is unavailable for installation, between the reductant pump and the marking. 38 litre tank: 0.8 m. 60 litre tank: 0.9 m. 45 litre tank: 0.7 m. 63 litre tank: 1.1 m. 70 litre tank: 0.8 m. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 50: Coolant Connections On The Engine

    To ensure sufficient flow, hoses must not have any sharp bends and there must be no spots where they are at risk of being pinched. A. DC09 and DC13. B. DC16. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 51: Warnings And Torque Reduction For Stage V

    Malfunction Indicator in section DLN7 in 03:05 CAN interface. There are no specific requirements for how other warnings should be displayed. However, Scania recommends that the warning lamps described on the following pages are used. For all warnings, a fault code is generated via DM1 which describes in detail the component affected by the fault and the type of fault.

  • Page 52: Reaction At Low Reductant Level

    The system reacts to a low reductant level via the CAN message DLN8. For further information on connection, see 03:05 CAN interface. To indicate low reductant level, Scania recommends that the warning lamp according to ISO 7000 - 2946 is used in accordance with the strategy below.

  • Page 53: Reaction To Faults In The Exhaust Gas Aftertreatment System

    The system reacts to faults in the exhaust gas aftertreatment system via the CAN message DLN8. For further information on connection, see 03:05 CAN interface. To indicate faults in the exhaust gas aftertreatment system, Scania recommends that the warning lamp according to ISO 7000 - 2596 is used in accordance with the strat- egy below.

  • Page 54: Regeneration Of The Particulate Filter

    To indicate that the particulate filter is full and needs to be regenerated manually, the CAN message DPFC1 is used. See 03:05 CAN interface. In order to indicate that the particulate filter needs to be regenerated manually, Scania recommends that the symbol for particulate filter regeneration according to ISO 7000 - 2433 is used.

  • Page 55: Warnings And Torque Reduction For Stage Iiib/Iv/Tier 4I/Tier 4F

    They must be installed correctly in the vehicle or machine. The warn- ing lamps can be ordered via Scania and also accompany the Scania EMS display. If the installer uses neither Scania warning lamps nor the Scania EMS display, then the lamps used must have the same functionality and symbols.

  • Page 56: Reaction To Fault In Scr System

    If a new fault occurs within 40 hours of operation since the first fault, the warning lamp will come on. After 30 minutes of operation, the warning lamp will flash rap- idly and torque will be reduced to 0% (low idling) within 30 minutes. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 57: Periodic Hydrocarbon Evaporation For Stage Iv/V/Tier 4F Engines

    Periodic hydrocarbon evaporation can be selected with two different settings: • Only warning. • Warning and engine shutdown. Scania recommends that this setting is used for unmanned applications. If the engine is started again after an engine shutdown due to accumulated hydrocar- bons, and is idling without load, the engine is switched off again after five minutes.

  • Page 58: Engines Without Exhaust Brake

    Below are some examples of conditions: • Gearbox in neutral position to prevent the vehicle from moving. • There are no active bodywork systems or power take-offs. 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

  • Page 59: Important Data

    Highest permitted reductant temperature 55°C Maximum permitted ambient temperature at the SCR unit, evaporator or hydrolysis catalytic 115°C converter Maximum permitted ambient temperature at the NO sensor control units 90°C 01:07 Issue 17 en-GB © Scania CV AB 2018, Sweden...

This manual is also suitable for:

Dc13Dc16

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