Scania DC09 Installation Manual
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Scania DC09 Installation Manual

Electrical systems
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See also: Installation Manual
Installation manual
Electrical systems
Industrial engines
DC09, DC13, DC16, OC16
Marine engines
DI09, DI13, DI16
03:01 Issue 11 en-GB
© Scania CV AB 2018, Sweden

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Summary of Contents for Scania DC09

  • Page 1 Installation manual Electrical systems Industrial engines DC09, DC13, DC16, OC16 Marine engines DI09, DI13, DI16 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 2: Table Of Contents

    Calculating cable cross-section ................. 11 Splicing and repair .................... 13 Connection to engine ..................... 14 Connection to engine without Scania base system..........14 Current consumption of the electrical system ........... 15 Engine interface....................16 Pin numbering for harness-to-harness connectors ..........20 Starting and shutdown procedure for gas engines..........

  • Page 3: Introduction

    There are two different requirements for the electrical installation of S6 and S8: with The terms in the table below are used to describe different types of voltage. Unless or without Scania's base system. This installation manual does not describe Scania's otherwise specified, always +24 V.

  • Page 4: Safety During Electric Welding

    Connect two 12 V batteries in series for 24 V system voltage. The welding clamp must not be connected to the engine, or so that the current can If standard lead acid batteries are used, Scania recommends batteries with a starting cross a bearing.

  • Page 5: Connection Of Batteries

    (once a month) for approx. 1 hour or using a battery charger and timer. Boost charge and continuous trickle charge shorten the service life of the batteries. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 6: Battery Cables

    The dotted lines apply at a constant ambient temperature of more than 10°C. The unbroken lines apply at an ambient temperature of -20°C. Y = Total cable length in metres. X = Cable cross-section in mm² 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 7: Battery Master Switch

    Status for post-running is sent out in CAN message DLN7. More information is available in section DLN7 in 03:05 CAN interface. Mechanical battery master switch. M1 = Starter motor. P1 = Battery. P3 = Alternator 1. S6 = Mechanical battery master switch. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 8: Alternator Charging For Marine Engines

    When double alternators controlled from the engine control unit charge different bat- tery groups, the battery negative terminals must be connected together. Otherwise, a fault code is generated. Engine control unit Ground connection between batteries 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 9: Ground Connection On Gas Engines

    The term control unit ground refers to pins 2 and 5 in the C4001 harness-to-harness connector. See also C4001: Harness-to-harness connector for engine control unit. Engine ground refers to the ground screw on the starter motor. Ground connection, OC16. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 10: Electrical Cables

    The cables must not touch any sharp edges, radius < 0.5 mm, e.g. sharp edges or ends of threaded screws. When the cables are clamped to rubber hoses, the cable must not interfere with the movement of the hose. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 11: Calculating Cable Cross-Section

    The minimum permissible cable cross-section for a specific load also depends on which type of electrical cable is used. Scania recommends the use of PVC 105°C electrical cable type RK. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 12 2. For cable lengths above these values the highest permissible voltage drop determines the cross-section. 3. The minimum permissible cable cross-section for electrical cables routed to the engine is 1.5 mm² for single-core cables, and 1.0 mm for multicore cables. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 13: Splicing And Repair

    Use shrinking tubing. The length of the shrinking tubing should be at least three times the length of the jointing sleeve. Cut a length of shrinking tubing and slide it onto the cable. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 14: Connection To Engine

    CAN bus. The Scania coordinator has no integrated resistor. Therefore, position a resistor of 120 ohms as close to the other end of the CAN net- work as possible. The Scania base system has an integrated resistor of 120 ohms. As a result, a resistor is not necessary.

  • Page 15: Current Consumption Of The Electrical System

    Nominal value: 1.5 A Gas engines only. Top value: 2.5 A Ignition coils Nominal value: 2 A Gas engines only. The values are for 1 ignition coil. Top value: 8 A 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 16: Engine Interface

    C4022 SCR system, cable harness supplied with the engine. C4126 C4071 Voltage to variable geometry turbocharger and warning lamps for the SCR system. C4125 Scania Communicator. C4126 Throttle control. DC16. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 17 Industrial engines, gas C4000 C4001 Harness-to-har- Interface ness connector C4094 C4000 Diagnostics. C4001 Customer interface to engine control unit. C4094 Voltage to ignition coils and throttle actuator at gas mixer. OC16. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 18 Marine engines without SCR system C4001 Harness-to-har- Interface C4000 C4002 ness connector C4000 Diagnostics. C4001 Customer interface to engine control unit. C4002 Connection of limp home mode. DI19, DI13. C4000 C4001 C4002 DI16. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 19 M4001. Cable harness supplied with the engine. C4000 C4091 Connection to exhaust routing valve harness-to-harness con- C4090 nector M4002. Cable harness supplied with the engine. DI13. C4000 C4091 C4001 C4089 C4090 C4022 DI16. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 20: Pin Numbering For Harness-To-Harness Connectors

    1 547 479 Harness-to-harness con- 8-pin nector 1 504 108 Cable terminal 2.5 mm 1 427 166 Cable terminal, round 1.1-2.0 mm socket 1 547 480 Locking part 8-pin green 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 21 Ground connection for exhaust gas Cable cross-section 2.5 mm aftertreatment management system 15 voltage to exhaust gas aftertreat- Cable cross-section 1.5 mm , fuse ment management system 10 A Not used To be plugged 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 22 15 voltage to EGR system Cable cross-section 1.5 mm , fuse 10 A Ground Cable cross-section 1.5 mm Not used To be plugged Not used To be plugged Not used To be plugged 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 23 INSTALLATION MANUAL Connection to engine Task Note Not used To be plugged 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 24 2 110 930. Use hand crimping tool 588 206 and dismantling tool 99 591 for the contact housing kit. Contact housing kit 2 110 930 contains the following components: Qty Part No. Designation Note 1 505 950 Contact housing 6-pin black 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 25 591 for the contact housing kit. Contact housing kit 2 151 234 contains the following components: Qty Part No. Designation Note 1 528 286 Contact housing 4-pin 1 529 440 Locking part 4-pin green 1 427 166 Cable terminal, round 1.1-2.0 mm socket 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 26 INSTALLATION MANUAL Connection to engine Qty Part No. Designation Note 1 504 108 Cable terminal 2.5 mm 1 779 819 Boot 4-pin black 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 27 20 A Not used To be plugged Ground connection for SCR system Cable cross-section 2.5 mm 1. For further information on connection, see the section Connection of limp home mode. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 28 C4109 is connected using contact housing kit 2 599 614, alternatively cable harness 2 587 366 can be used. The positioning of the harness-to-harness connector is shown in 02:07 SCR-system. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 29 • The electrical cables must not be spliced. Junction boxes must not be used. Power supply to the ignition coils should come from a stable power source, such as a battery, and not an alternator. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 30 Cable cross-section 1 mm Not used To be plugged C4126 is connected with a 6.2 m pre-assembled electrical cable. harness-to-harness connector C4126 on the engine viewed from the electrical cable input side. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 31: Starting And Shutdown Procedure For Gas Engines

    45 seconds or until the engine speed exceeds 500 rpm. at least 2 minutes. Run the engine under load. The connection of C4001 and C4094 is described in more detail in the section numbering for harness-to-harness connectors. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 32 C4001-3 or C4094-4, with or without delay. 30 voltage to the engine control unit is deactivated via C4001-1 and C4001- 4. Delay at least 30 s. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 33: Connection Of Starter Motor Or Alternator

    Alternator 100A Battery positive Alternator 150A Battery positive Starter motor Battery positive Ground connection near starter motor Marine engines Alternator Battery positive Battery negative Starter motor Battery positive Battery negative 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 34 If several battery groups are to be connected to the alternator and separated, battery voltage is required on the positive terminal in order for the alternator to start charg- ing. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 35: Connection Of Coolant Level Monitor

    MANUAL Connection to engine Connection of coolant level monitor Scania recommends that the cooling system be fitted with a coolant level monitor to warn when the coolant drops below a specific level. REQUIREMENT! If the cooling system temperature monitor has an alarm temperature above 100°C, a coolant level monitor must be installed.
  • Page 36 1 383 572 Sleeve Resistor 330 ohms. Signal. 1 349 112 Locking part Resistor 120 ohms. 1 361 119 Cable terminal, round pin Resistor 470 ohms. 0 V. Coolant level monitor. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 37 On industrial engines the coolant level monitor is connected to harness-to-harness connector T8, which is positioned as shown in the figures. Connecting a coolant level monitor on a DC09 and DC13. Connecting a coolant level monitor on a DC16 and OC16.
  • Page 38 Dl16 Engines with keel cooling can be supplied with or without coolant level monitor. If the Scania coolant level monitor is not used, Scania recommends that the cooling sys- tem be fitted with a coolant level monitor from another manufacturer.

  • Page 39: Connection Of Oil Level Sensor

    1 757 720 Contact housing 1 427 160 Cable terminal, round pin 1 347 493 Locking part 1 342 966 Plug Use hand crimping tool 588 206 and dismantling tool 99 591. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 40 Limit value Voltage (V) Level (mm) Min. alarm level 29.1 Min. level 48.3 Max. level 78.4 Max. alarm level 95.5 The measuring range of the oil level sensor is 0.2-4.8 V. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 41: Engine Control Unit

    The S6 engine control unit has an IP rating of 6K9K when all harness-to-harness con- nectors are connected to the engine control unit. S6 has an IP rating of 40 when the harness-to-harness connectors are not connected to the engine control unit. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 42: Connection Of Limp Home Mode

    The following parts are needed in order to connect a backup accelerator pedal to the Engine control unit for XPI engines. engine control unit harness-to-harness connector A2 (PDE) or A6 (XPI): 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 43: Engine Running Signal

    – 5.6 kohms provides a voltage of approximately 3.0 V. – 4.7 kohms provides a voltage of approximately 2.5 V. – 3.3 kohms provides a voltage of approximately 1.85 V. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 44: Connecting Auxiliary Equipment

    Cable terminal x 2: 1 507 723 (1062-12-1066) 2-4 mm Example of fuel heater connection. Shrinking tubing between harness-to-component connector and cable: Raychem type Fuse, 20 A. HTAT, size 24/6. Relay. Fuel heater. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 45: Installation Of The Supply Connector For Engine Heater

    See illustration. Also open the lower of the two weakenings so that condensation water can drain out of the connector. This applies both at to recessed and separate fitting. See illustration. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 46 Drill a Ø 29 mm hole through the template. Drill carefully so that the existing components, electrical cables, etc. are not damaged. ø 29 File a Ø 4 mm guide groove at the lower edge of the hole. ø 4 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 47 Connecting auxiliary equipment Fit the expander screw into the hole. Thread the electrical cable through. Insert the female part into the male part and tighten the expander screw using the female. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 48 Before the heat source is connected, lubricate the O-ring with oil. The connection is pressed in when the gap between the connectors (male and female) is 0 to 0.5 mm. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 49: Work Description For Harness-To-Harness Connectors

    Release the secondary locking device by placing tool 99 591 in the slot in the contact housing. Note: The locking device may be stuck. Be careful not to lose the locking device. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 50 Release the primary lock by bending away the plastic tongue securing the cable terminal using tool 99 591 or a small screwdriver. Pull out the cable terminal using the cable. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...
  • Page 51 Release the primary lock by bending away the plastic tongue securing the cable terminal using tool 99 591 or a small screwdriver. Pull out the cable terminal using the cable. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

  • Page 52: Harness-To-Harness Connector For Engine Control Unit

    B. The rear section of the seal should be aligned with the housing after assembly. C. The rear section of the seal must be aligned with the edge of the insulation. 03:01 Issue 11 en-GB © Scania CV AB 2018, Sweden...

This manual is also suitable for:

Dc13Dc16Di09, di13, di16Oc16

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