Scania DC09 Installation Manual
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Scania DC09 Installation Manual

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INSTALLATION
MANUAL
Electrical system
Industrial engines
DC09, DC13, DC16
Marine engines
DI09, DI13, DI16
03:01 Issue 5.0 en-GB
1
©
Scania CV AB 2015, Sweden

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Summary of Contents for Scania DC09

  • Page 1 INSTALLATION MANUAL Electrical system Industrial engines DC09, DC13, DC16 Marine engines DI09, DI13, DI16 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 2: Table Of Contents

    Calculating cable cross-section ................. 11 Splicing and repair .................... 14 Connection to engine ..................... 16 Connection to engine without Scania base system..........16 Current consumption of the electrical system ........... 17 Engine interface....................18 Pin numbering for connectors ................21 Connection of starter motor or alternator............

  • Page 3: Introduction

    There are two different requirements for the electrical installation of S6 and S8: with Battery voltage or without Scania's base system. This installation manual does not describe Scania's Safety during electric welding electrical system. Information about the electrical systems can be found in •...

  • Page 4: Batteries And Alternators

    Connect two 12 V batteries in series for 24 V system voltage. If standard lead acid batteries are used, Scania recommends batteries with a starting capacity of min. 160 Ah and a cold cranking amperage of 800 A for all engine types.

  • Page 5: Battery Cables

    The unbroken lines apply at an ambient temperature of -20°C. stantly exceeds +10°C, the minimum permissible cable cross-section is 50 mm Y = Total cable length in metres X = Cable cross-section in mm² 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 6: Connection Of Batteries

    • Do not bang the battery cable terminals. Terminal posts and cell plates come off easily. • Lubricate battery cable terminals and terminal posts using a thin layer of Vaseline or grease. 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 7: Battery Master Switch

    Status for post-running is sent out in CAN message DLN7. More information is M1 = Starter motor available in the CAN interface installation manual. P1 = Battery P3 = Alternator 1 S6 = Mechanical battery master switch 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 8: Alternator Charging For Marine Engines

    Engine control unit Alternator 2 (only with double alternators) Battery insulator Input to battery insulator Ground Output from battery insulator Output from battery insulator 15 voltage to battery insulator 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 9: Marine Engines With Split Ground System

    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 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 10: Electrical Cables

    • Exhaust pipe, engine and cab heater – 40 mm. • Coolant pipe, engine – 60 mm. A conventional cable harness and CAN cable harness can be routed side by side with- out interference. 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 11: Calculating Cable Cross-Section

    0.0175 x L A = I x The voltage drop for connection points and any joints must be subtracted from the maximum permissible voltage drop before calculating the cable cross-section. 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...
  • Page 12 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. Maximum permissible current and cable length for RK 105°C cable at different cable cross-sections.
  • Page 13 2. For cable lengths above these values the highest permissible voltage drop determines the cable cross-section. 3. The minimum permissible cable cross-section for cables that are routed on the engine is 1.5 mm². 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 14: Splicing And Repair

    The sleeve must be appropriate for the cable cross-section. DIN connectors and jointing sleeves with glue can be ordered from Scania dealers. Position the joint in a well protected location so that it is not subjected to mechanical loading.
  • Page 15 Check that the glue has seeped out all around the cable. Thread the shrinking tubing over the jointing sleeve, and heat the tube until the joint is tight and strong. Test the joint. 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 16: 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 17: Current Consumption Of The Electrical System

    Top value: 4.5 A Exhaust brake actuator Nominal value: 2 A Top value: 5 A Variable geometry turbocharger Nominal value: 2.5 A Top value: 6 A 1. Stage IV/Tier 4f only. 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 18: Engine Interface

    Voltage to SCR system, EGR system and exhaust brake actuator C4022 SCR system, cable harness comes with the engine C4071 Voltage to variable geometry turbocharger and warning lamps for the SCR system DC09, DC13 DC16 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...
  • Page 19 Customer interface to engine control unit C4000 Diagnostics C4002 Customer interface to SCR system or EGR system C4022 SCR system, cable harness comes with the engine 1. Stage III B/Tier 4i only. DC09, DC13 DC16 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...
  • Page 20 Connection to engine Marine engines Pos. Connector Interface C4001 Customer interface to engine control unit C4000 Diagnostics C4002 Connection of limp home mode 2 1 3 A DI09 B DI13 C DI16 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 21: Pin Numbering For Connectors

    Use electrical cables which are twist- ed 40 turns per metre with gold-plat- CAN low ed pins Engine running +24 V Cable area 1.5 mm 1. See instructions in the Engine running signal section. 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...
  • Page 22 Cable area 1.5 mm ductant level +24 V to warning lamp for SCR mal- Cable area 1.5 mm function Ground to warning lamp for SCR er- Cable area 1.5 mm 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...
  • Page 23 1. More information about connection is available in the Connection of limp home mode section. Note: Electrical cables to C4002-2, C4002-3 and C4002-4 must be twisted 35-40 turns per metre. 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...
  • Page 24 Cable area 2.5 mm charger +24 V to warning lamp for low re- Cable area 1.5 mm ductant level +24 V to warning lamp for SCR mal- Cable area 1.5 mm function 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 25: 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 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 26: Connection Of Coolant Level Monitor

    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...
  • Page 27 Resistor 120 ohms Use the following tools for contact housing kit 1 456 342: Resistor 470 ohms • Hand crimping tool 588 206 Coolant level monitor • Dismantling tool 99 591 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...
  • Page 28 On industrial engines the coolant level monitor is connected to 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 03:01 Issue 5.0 en-GB ©...
  • Page 29 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 30: Connection Of Oil Level Sensor

    1 427 160 Cable terminal, round pin 1 347 493 Locking part 1 342 966 Plug Use the following tools: • Hand crimping tool 588 206 • Dismantling tool 99 591 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...
  • Page 31 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 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 32: Connection Of Water Separating Prefilter On Marine Engines (Pde Engines)

    Black (A), ground. Red (B), +12/24 V to prefilter. Yellow (C), signal when the sensor detects the maximum water level in the filter. Fuse, 1 A. Lamp, max. 12 W. Prefilter connectors. 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 33: Engine Control Unit

    The S6 engine control unit has IP class 6K9K when all connectors are connected to the engine control unit. The S6 engine control unit has IP class 40 when the connectors are not connected to the engine control unit. 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 34: Connection Of Limp Home Mode

    1. A fault code is generated if the value from the potentiometer is below 0.1 V or above 4.9 V. Use electrical cables which are twisted 40 turns per metre. Engine control unit for XPI engines 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...
  • Page 35 A2 (PDE) or A6 (XPI): Part No. Designation 1 380 386 Socket 1 380 388 Seal The following tools are required: • Hand crimping tool 588 204 • Dismantling tool 99 592 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 36: 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 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 37: Work Description For Connectors

    Release the secondary locking device by placing tool 588 214 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 5.0 en-GB © Scania CV AB 2015, Sweden...
  • Page 38 Release the primary lock by bending away the plastic tongue securing the cable terminal using tool 588 214 or a small screwdriver. Pull out the cable terminal using the cable. 588 214 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...
  • Page 39 Release the primary lock by bending away the plastic tongue securing the cable terminal using tool 588 214 or a small screwdriver. Pull out the cable terminal using the cable. 588 214 03:01 Issue 5.0 en-GB © Scania CV AB 2015, Sweden...

  • Page 40: 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 5.0 en-GB © Scania CV AB 2015, Sweden...

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