Scania DI09 PDE Operator's Manual
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Scania DI09 PDE Operator's Manual

Scania DI09 PDE Operator's Manual

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Important information
Serious risk of injury
When working on the engine, e.g. when adjusting the drive belts and clutch, or when changing oil, it is im-
portant not to start the engine. The engine could be damaged, but more importantly there is a serious risk of
injury.
For this reason, always secure the starting device or disconnect a battery cable before working on the engine.
This is especially important if the engine has a remote starter or automatic starting.
WARNING!
This warning symbol and text can be found next to those maintenance items where it is particularly impor-
tant to bear in mind the risk of injury.
Operator's manual
DI09 PDE Marine engine
en-GB 3 169 156
Issue 13.0

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Summary of Contents for Scania DI09 PDE

  • Page 1 WARNING! This warning symbol and text can be found next to those maintenance items where it is particularly impor- tant to bear in mind the risk of injury. Operator's manual DI09 PDE Marine engine en-GB 3 169 156 Issue 13.0...

  • Page 2: Table Of Contents

    Hose clamps ......81 Scania Assistance ..... . .82 Renewing the oil filter.

  • Page 3: Start Of Warranty

    The more we know about you, your company and your equipment, the more effectively we can adapt our services to you. If you have started to use a new Scania engine, it is very important that you send in the war- ranty start report to us immediately.

  • Page 4: Introduction

    The information in this Operator's manual was only once approval has been granted by Sca- correct at the time of going to press. Scania re- nia. Modifications may be made by author- serves the right to make alterations without prior ised personnel only.

  • Page 5: Power Classes

    The engine serial numbers and power classes for the engines that are used in this installation should be listed below: You can find the power class of your engine in the engine type data sheet on the Scania website, www.scania.com.

  • Page 6: Environment And Safety

    Environmental liability a particular hazardous substance must communi- cate this to the EU Chemicals Agency (ECHA). Scania develops and produces engines that are as environmentally-friendly as possible. Scania has Scania supplies individual notification numbers made major investments in the reduction of in SCIP for affected vehicles.
  • Page 7 Advisories preceded by Note: refer to informa- tion important to ensure the best possible opera- tion and functionality. Example: Note: Leave the engine off for at least 7 minutes before you check the oil level. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 8: Warnings And Advisories

    This inspection should be done to detect fuel, oil there must be an effective device to extract ex- or coolant leaks, or anything else that may re- haust gases and crankcase gases. quire corrective action. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 9 Parts of the body, clothes or dropped tools can get caught in rotating parts such as the fan and cause injury. For personal safety all ro- tating parts and hot surfaces must be fitted with guards. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 10 There is always a risk of sustaining burns when an engine is hot. Particularly hot parts are branch pipes, turbochargers, oil sumps, and hot coolant and oil in pipes and hoses. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 11 Hot oil can cause burns and skin irritation. Wear Maintenance and repairs of injection equipment protective gloves and eye protection when are to be carried out by an authorised Scania changing hot oil. workshop. Make sure that there is no pressure in the lubri- Always use Scania spare parts for the fuel and cation system before starting work on it.
  • Page 12 Wash with soap and plenty of water. If it gets in your eyes: Rinse immediately with plenty of wa- ter and seek medical attention. Environment Used batteries must be disposed of as specified in national and international laws and regula- tions. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 13: Engine Data Plate

    Performance and certification code. The code indicates, together with the applica- tion code, the normal gross engine output. Code for application. M means for marine use. Example of an engine data plate OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 14: Component Identification

    Expansion tank. Filling coolant. Level glass for checking coolant level. Oil filter. Sacrificial anodes (2 pcs). Nipple for draining and filling coolant. Centrifugal oil cleaner. Sea water intake. Sea water pump. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 15: Starting And Driving

    30 seconds at a time. After that, it must rest for at least 5 minutes before the next attempt to start it. checks before driving For environmental reasons the Scania engine has been developed to be started with a low fuel feed. Carry out daily maintenance as described in the Using unnecessarily large amounts of fuel when maintenance schedule prior to operation.

  • Page 16: Driving

    The nomi- more than 1,000 metres. nal engine speed is indicated on the engine data plate. Low idling can be set between 500 and • Contact Scania if the operating conditions de- 1,050 rpm. viate from these. OPM 150 en-GB ©...
  • Page 17 50-100 hours of op- creased load the coolant temperature rises to the eration. The noise does not affect the service life normal value. of the belt transmission. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 18: Engine Shutdown

    See the sec- tion Risk of freezing. If the temperature is below 0°C (32°F): Pre- pare for the next start by connecting the en- gine heater (if fitted). OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 19: Maintenance

    Maintenance Maintenance IMPORTANT! The maintenance programme covers a number of On delivery a Scania engine is optimised for its points that are divided into the following sec- tions: application. However, regular maintenance is necessary to: • Lubrication system. • prevent unplanned stops •...

  • Page 20: Maintenance Interval

    Checking the fuel level Draining the water separating prefilter Renewing the fuel filters Other Checking the drive belt Checking for leakage Checking and adjusting the valve clearance and unit injec- tors OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 21: Lubrication System

    For operation at extremely low outdoor tempera- tures: Consult your nearest workshop in order to avoid starting difficulties. Oil grade Scania LDF stands for the Scania Long Drain Viscosity Outdoor temperature in °C Field test standard. Scania LDF oils have been class carefully selected after extensive testing.
  • Page 22 However, there are only labels for oils with Scania LDF approval and oil grade ACEA E7. Stick on a new label if the oil type or oil grade is changed in favour of any of the oil types above.

  • Page 23: Oil Analysis

    Lubrication system Oil analysis To be able to extend the oil change intervals us- ing an oil analysis, Scania LDF-3 and LDF-2 oils must be used. Certain laboratories offer engine oil analysis. The following requirements must remain satis- fied when the oil is changed: •...

  • Page 24: Checking The Oil Level

    For information on the correct oil type, see the section grade. Maximum angles of inclina- tion during operation Maximum permissible angles of inclination dur- ing operation vary, depending on the type of oil sump. See illustration. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 25: Changing The Oil

    Min. 25 litres (6.6 US gallons). Fill with the amount of oil specified for the Max. 32 litres (8.4 US gallons). oil sump. Wait at least 7 minutes. Check the level on the oil dipstick. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 26: Cleaning The Centrifugal Oil Cleaner

    Let the oil run out from the rotor. Lift out the rotor. Wipe off the outside. Loosen the rotor nut and unscrew it about 1.5 turns. Note: Take care not to damage the rotor shaft. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 27 Remove the strainer from the rotor cover. If the strainer is stuck, insert a screwdriver be- tween the rotor cover and strainer and care- fully prise them apart. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 28 Renew any damaged nozzles. Check that the bearings are undamaged. Renew damaged bearings. Fold and fit a new paper insert on the inside of the rotor cover as illustrated. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 29 Screw the rotor nut back on by hand. Check that the shaft is not damaged or loose. Contact a Scania workshop if the rotor shaft needs renewing. Note: Take care not to damage the rotor shaft.

  • Page 30: Operational Testing Of The Centrifugal Oil Cleaner

    Use your hand to feel if the filter housing is vibrating. If the filter housing is not vibrating, disman- tle and check the centrifugal oil cleaner. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 31: Renewing The Oil Filter

    Turn screw a further half turn by hand. Turn the rotary control 90° to the left so that the rotary control points towards filter A. Then renew filter B in the same way as filter OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 32: Air Cleaner

    If the vacuum indicator's red plunger is fully vis- ible, renew the air cleaner filter element in ac- cordance with the following section. Air cleaner without safety cartridge. 1. Filter element. 2. Vacuum indicator. 3. O-ring. 4. Cover. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 33: Renewing The Air Cleaner Filter Element And Safety Cartridge

    Renew the O-ring if it is damaged or hard. Assemble the air cleaner. Ensure that the O-ring is not outside the edg- Reset the vacuum indicator by pressing in the button marked in the illustration. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 34: Cooling System

    The coolant should be changed when the cooling functioning antifreeze and corrosion protection system is cleaned: every 6,000 hours or at least may be used in Scania engines. Products not ful- every 5 years. See Changing the coolant and filling the demands in this section may lead to cleaning the cooling system.
  • Page 35 There is no risk of damage by freezing if the content of Scania antifreeze and corrosion protection, or an equivalent mixture of a similar product, is at least 35% by volume.
  • Page 36 In order to retain the corrosion protection and the Scania Ready Mix 50/50 higher boiling point, it is essential to use coolant Scania Ready Mix 50/50 is a ready-mixed cool- consisting of water mixed with antifreeze and ant containing 50% antifreeze (ethylene glycol) corrosion protection (ethylene glycol).
  • Page 37 Cooling system Antifreeze and corrosion protection concentration table, litres 35% by volume of Scania antifreeze provides sufficient corrosion protection. Example: • The total volume of the cooling system is 40 litres. • The measured concentration of ethylene gly- col is 35% by volume (freezing point -21°C).
  • Page 38 15.9 19.8 23.8 39.6 14.8 16.9 21.1 25.4 42.3 15.9 20.3 22.5 26.9 44.9 16.6 21.4 23.8 28.5 47.6 17.7 20.1 22.7 25.1 30.1 50.2 18.5 21.1 23.8 26.4 31.7 52.8 OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 39: Checking The Coolant Level

    Filling coolant. Only pour pre-mixed coolant into the cooling system. The following instructions apply to Scania ex- pansion tanks. For other types of expansion tanks, follow the manufacturer’s instructions. Check the coolant level through the sight glass on the expansion tank.

  • Page 40: Checking The Coolant's Antifreeze And Corrosion Protection

    • If ice forms in the coolant, there are disrup- tions initially, but there is no immediate risk of damage. The engine should not be subject- ed to heavy loads when ice starts to form. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 41: Checking The Sacrificial Anodes

    If the sacrificial anodes are very corroded, they often come loose entirely. Renew the gasket when fitting. 1. New sacrificial anode. 2. Approx. 3/4 remains. 3. Approx. 1/4 remains. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 42: Checking The Sea Water Pump Impeller

    Fit a new impeller and cap. Check that the cap seal is not hard or damaged. IMPORTANT! When fitting the new impeller, bend the vanes in the same direction as on the old one. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 43: Changing The Coolant And Cleaning The Cooling

    Repeat the procedure at the cooling system's Drain nipple. lowest drainage point. The location of the lowest drainage point on the engine may dif- fer depending on engine application. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 44 Remove the water pipe (4) of the charge air cooler. Release the hose clamp and remove the sea water hose (5) between the charge air cooler and the heat exchanger. Remove the charge air cooler (6). OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 45 Renew the O-rings (2) and assemble the charge air cooler. Tighten the M8 screws on the covers to 15 Nm (11 lb-ft). 1. Cover. 2. O-rings. 3. Charge air cooler housing. 4. Cooler core. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 46 (4) in the 2 brackets. Slacken the screws holding the heat ex- changer bracket (5) in the cylinder block suf- ficiently to allow the heat exchanger to be removed. Remove the heat exchanger. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 47 Renew the O-rings (2) and assemble the heat exchanger. Tighten the M8 screws on the covers to 15 Nm (11 lb-ft). 1. Cover. 2. O-rings. 3. Heat exchanger housing. 4. Cooler core. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 48 Fit the inlet and outlet coolant pipes and the sea water pipe from the heat exchanger (2). Fit the hose (1) between the heat exchanger and the water-cooled exhaust pipe bend and tighten the V-clamp. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 49 Check that the charge air pipe is properly fitted. Fit the protective plate (1) to the charge air cooler. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 50 Run the engine until it has reached operating cleaning of the expansion tank will suffice. temperature if possible and then drain the cooling system following the previous de- scription. Remove the thermostat. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 51 Do not start the engine until the correct coolant level has been obtained. If the engine is started with engine coolant level low, it can damage the coolant pump shaft seal, which leads to coolant leakage. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 52 Open the sea cock on the sea water inlet. Start the engine and check that there are no leaks. Check the coolant level and top up if neces- sary via the expansion tank. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 53: Fuel System

    Be extra careful and always use clean, lint-free and dust-free clothes and gloves when working on the fuel system. Scania recommends using Tegera 848 gloves. Clean tools before they are used and do not use any worn or chrome-plated tools. Material and flakes of chrome may come off.

  • Page 54: Draining And Renewing The Single Water Separat- Ing Prefilter (Option)

    Screw the sensor cable in the contact housing onto the filter bracket. Bleed the fuel system according to the in- structions in the Bleeding the fuel system section. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 55 Be careful that the valve does not pass the closed position when the engine is in operation. A closed position can result in the engine stopping. Remove the cover from the filter housing. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 56 Fuel system Undo the drain plug. Tighten the drain plug when all the water has emptied. Fill the filter housing with clean fuel. Fit the cover. Tighten the cover screw by hand. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 57 A closed position can result in the engine stopping. Clean the filter housing externally with a cleaning cloth. Remove the cover from the filter housing. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 58 Remove the filter and fit the new filter. Renew the O-rings in the cover. Lubricate the O-rings with engine oil. Fill the filter housing with clean fuel. Fit the cover. Tighten the cover screw by hand. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 59: Renewing The Fuel Filter

    Screw the filter into place by hand until it makes contact. Screw a further half turn by hand. Bleed the fuel system according to the in- structions in the Bleeding the fuel system section. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 60: Renewing And Venting Reversible Fuel Filters

    Turn the rotary control 90° to the left so that the rotary control points towards filter A. Fil- ter B can now be renewed in the same way as filter A. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 61: Bleeding The Fuel System

    Once the fuel coming out of the hose is free of air bubbles, then venting is complete. Bleed nipple Close the bleed nipple. Remove the hose and suction tool. Start the engine and check that there are no leaks. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 62 Start the motor. The motor should be easy to start. If the fuel filter has been renewed, check that no fuel is leaking from the filter. Further tighten the filter if it is leaking. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 63: Other

    5. Coolant pump. Example of a minor crack in the drive belt. The drive The drive belt has deep cracks and must be renewed. belt can be refitted. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 64: Checking For Leakage

    Check whether the drain hole on the coolant pump is blocked. If there is leakage, renew the seal in the pump or the complete coolant pump assembly. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 65: Checking And Adjusting The Valve Clearance And Unit Injectors

    The engine must be cold when the work is car- ried out. Remember to remove the turning tool from the flywheel following adjustment. Note: Carry out the working without pausing, so that no step is overlooked. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 66 DOWN TDC UP TDC 72/432 252/612 144/504 324/684 216/576 36/396 288/648 108/468 DOWN TDC UP TDC 72/432 252/612 144/504 324/684 216/576 36/396 288/648 108/468 OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 67 Mark the rocker arm with the felt-tip pen and 3. Rocker arm. adjust the unit injector according to the next section. Then continue on to the next cylin- 4. Valve bridge. der according to the table. 5. Feeler gauge. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 68 (3) tightening the lock nut. IMPORTANT! Remove the setting tool when the adjustment is done. Mark the injector with the felt-tip pen and continue adjustment according to the table. OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 69 The setting tool piston is above or below the flat The setting tool piston is level with the flat upper upper surface of the tool. Adjust the unit injector. surface of the tool. The unit injector is correctly adjusted. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 70: Quality Requirements For Fuel

    The operator is responsible for using the correct of fuel are described in the Workshop Manual. type of diesel to ensure that local laws are com- This can be ordered from Scania dealers or di- plied with. rectly from Scania.
  • Page 71 Oil analysis in this Opera- tor’s manual. Bear in mind that the emission limit for the cur- rent engine type may limit the maximum permit- ted sulphur content of the diesel. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 72: Biodiesel (Fame)

    Biodiesel (FAME) Storage of biodiesel Use of biodiesel IMPORTANT! Scania uses the term biodiesel to refer to a re- Biodiesel must not be stored for more than 6 newable diesel made from greases or oils and months. methanol. The biodiesel should conform to the requirements of European standard EN 14214 or Brazilian standard ANP-45.

  • Page 73: Renewable Diesel (Hvo)

    To the user, HVO is reminiscent of diesel in accordance with EN590, apart from HVO having a somewhat lower density. Scania approves the use of up to 100% HVO for all engines in accordance with the European standard EN 15940.

  • Page 74: Preparing The Engine For Storage

    • Otherwise prepare the engine for storage (fil- ter renewal, lubrication, etc.). Preservative products Preservative oil Use a normal engine oil that meets the require- ments in the Oil grade section. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 75: Preparations For Storage

    Spray the outside of the alternator and starter motor with water-repellent anti-corrosive oil: CRC 226, LPS1 or equivalent. Spray the outside of smooth engine parts, first with penetrating preservative oil such as OPM 150 en-GB © Scania CV AB 2023, Sweden...
  • Page 76 Refit the rocker covers. Drain the preservative fuel from the fuel manifold. Connect and bleed the fuel system. Wash off any preservative oil on the outside using white spirit. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 77: Technical Data

    Oil pressure (bar/psi) Normal with the engine at operating temperature, operating speed 3-6/43.5-87 Minimum permitted at idling speed 0.7/10.2 Crankcase pressure with closed crankcase ventilation (mbar/psi) -5.4 to 2.0/-0.08 to 0.03 OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 78: Intake System

    Water separating prefilter Paper filter from Scania Electrical system Type 1-pin, 24 V, DC Starter motor, standard equipment 1-pin, 24 V, 6 kW Alternator, standard equipment 1-pin, 28 V, 100 A OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 79: Material Content

    Re-use if possible; otherwise hand in to an authorised waste disposal contrac- tor. Fuel filter and oil filter Hand in to an authorised waste disposal contractor. Colour No known recycling methods. Electronics Hand in to an authorised waste disposal contractor. OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 80: Tightening Torque For Screw Joint

    Torx screws, hexagon nuts Metric thread. Strength class 8.8/8. Tightening torque Thread Lb-ft Flange screws with hexagonal head and hexagonal flange nuts Metric thread. Strength class 8.8/8. Tightening torque Thread Lb-ft 10.2 OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 81: Hose Clamps

    Specifications in the tables show tightening torque when tightening by hand. Note: The maximum tightening torque for a new unfit- ted hose clamp is 1 Nm (0.7 lb-ft). A = width Tightening torque (mm) Lb-ft 7.5-9 OPM 150 en-GB © Scania CV AB 2023, Sweden...

  • Page 82: Scania Assistance

    Scania Assistance Scania Assistance Wherever you are, you can always get assistance from Scania's service organisation, Scania Assis- tance, 24 hours a day, every day of the year. Always call the contact for your country. Country Tel. Country Tel. Austria...

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