Table of Contents
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When working on the engine, for example adjusting drive belts, changing the oil or adjusting the
clutch, it is important not to start the engine. The engine may be damaged and there is
!
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.
This warning symbol and text is reproduced beside those maintenance points where it is
When the commissioning report has been filled in and sent to Scania, you have a 1-year warranty from the date
of commissioning.
Also fill in the particulars below as this can make things easier if you need to contact for example a service
workshop.
Engine number
Commissioning date
User's name and address
Signature
Engine type
Variant
Engine type and variant are indicated on the engine type plate
Industrial & Marine Engines
IMPORTANT INFORMATION
SERIOUS RISK OF INJURY.
especially important to consider the risk of injury.
Operator's Manual
DI9, DC9 with DEC2
Industrial engine
opm96-9adec en
COMMISSIONING REPORT - WARRANTY
1 588 889
2003-10:1
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Table of Contents
Related Manuals for Scania DI9
Summary of Contents for Scania DI9
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Page 1: Important Information
2003-10:1 COMMISSIONING REPORT - WARRANTY When the commissioning report has been filled in and sent to Scania, you have a 1-year warranty from the date of commissioning. Also fill in the particulars below as this can make things easier if you need to contact for example a service workshop. -
Page 2: Preface
During the warranty period, - Whenever necessary, always contact an authorised Scania workshop. They have special tools, genuine Scania parts and staff with training and only genuine Scania parts may practical experience of Scania engines. be used during service and... -
Page 3: Table Of Contents
CLEANING THE COOLING SYSTEM ..36 Internal cleaning ..... . .37 2003-10:1 © Scania Industrial & Marine Engines... -
Page 4: Environmental Responsibility
ENVIRONMENTAL RESPONSIBILITY Scania has always been very much at the leading edge when it comes to developing and producing engines which are as environmentally friendly as possible. Major progress has been made on reducing harmful exhaust emissions as required to be able to meet the stringent environmental standards stipulated on almost all markets. -
Page 5: Certified Engines
European (EU) and non- European (USA) markets. Scania guarantees that all the engines it supplies of a certified type are equivalent to the engine approved for certification. The engine comes with a special certification plate which indicates the certification rules (standard) to which the engine has been approved. -
Page 6: Safety Information
INJURY A list of the safety precautions to be followed when running and maintaining Scania engines can be found on the next three pages. Similar text can often be found at the relevant maintenance points, and here different levels of importance are attached to such text in accordance with the above description. -
Page 7: Safety Precautions For Running The Engine
The exhaust fumes contain carbon monoxide and nitric oxides, which are toxic. When running the engine in a closed area, there must be an efficient device for dissipating exhaust fumes and crankcase gases. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 8: Safety Precautions For Handling Materials
Always hand in leftover or used chemicals to an authorised waste disposal contractor. 2003-10:1 © Scania Industrial & Marine Engines... - Page 9 Never start or run the engine with the oil filler cap removed, as this may cause oil to be thrown out. Dispose of used oil through an authorised waste disposal contractor. 2003-10:1 © Scania Industrial & Marine Engines...
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Page 10: Type Designations
Indicates, together with the application code, the normal gross engine output. The actual output setting of the engine is indicated on the engine card. Application For general industrial use Variant 01-99 Type of regulator Electronically controlled governor (DEC2). © Scania Industrial & Marine Engines 2003-10:1... - Page 11 The illustrations show a normal version of a DI9 56 engine. Your engine may have different equipment from that illustrated. Turbocharger Coolant pump Oil cleaner Engine number, Oil cooler Oil dipstick stamped into the engine Draining, engine oil Extra coolant pump...
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Page 12: Dec2 Control System
There are descriptions of LED indications when a fault has occurred and the action taken in the case of Power- and Shutdown on page 16. Troubleshooting and fault code reading are described on pages 17 and 18. © Scania Industrial & Marine Engines 2003-10:1... - Page 13 Location of sensors for DEC2 on DI9 Location of sensors for DEC2 on DI9 Connection of lead to charge air pressure sensor Charge air temperature sensor Oil pressure monitor Connector panel Coolant temperature sensor Rotation speed sensors 2003-10:1 © Scania Industrial & Marine Engines...
- Page 14 Location of sensors for DEC2 on DC9 Connection of lead to charge air pressure sensor Charge air temperature sensor Oil pressure monitor Connector panel Coolant temperature sensor Rotation speed sensors © Scania Industrial & Marine Engines 2003-10:1...
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Page 15: Torque Limit
BOOST LIMIT The LED comes on when the control unit's smoke limiter limits the maximum fuel quantity. Operation of the smoke limiter is dependent on the charge air pressure. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 16: Action When A Fault Arises
Action: Conduct troubleshooting according to instructions on page 17 and the chart on page 18. If the engine has not stopped, reduce engine speed to idle and carry out troubleshooting. © Scania Industrial & Marine Engines 2003-10:1... -
Page 17: Resetting Functions (Dip Switches In Unit)
For single speed engines, it may also be - Activate the lamp test/fault code switch. In normal for DIP switches 6, 7 and 8 to be in the OFF Scania's electrical equipment the main indicator position. lamp is located in this switch in the main supply Shutdown at threshold values for low oil pressure and box. - Page 18 © Scania Industrial & Marine Engines 2003-10:1...
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Page 19: Starting And Running
Glycol concentrations glycol containing nitrite-based higher than 60% do not improve anti-freeze protection and have a negative effect on engine cooling capacity. corrosion inhibitor. 2003-10:1 © Scania Industrial & Marine Engines... - Page 20 Avoid contact with the skin. - First filling: Fill up the system with water + 10% by volume Scania Corrosion Inhibitor. Use drinking water with a pH of 6 - 9. - Never top up with only water or only anti-corrosive! Fluid losses must always be replaced with blended coolant: water + 10% Scania Corrosion Inhibitor by volume.
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Page 21: Checks Before Running
If the fuel tank has been run dry or if the engine has not been used for a long time, bleed the fuel system (see page 40). Out of consideration for our common environment, your new Scania engine Start the engine only in a well has been designed to use a smaller amount of fuel when starting. -
Page 22: At Temperatures Below 0°C
At temperatures below 0°C: Note: Only use starting aids recommended by Scania. - The starter motor may only be used for 30 seconds at a time. After that time it must rest for 2 minutes. The starter motor may only be... -
Page 23: Driving
DRIVING Check instruments and warning lamps at regular intervals. Rotation speed The Scania tachometer is divided into sectors of different colours, as follows: 0 - 500 rpm red area: prohibited engine speed, passed when stopping and starting. 500 - 700 rpm yellow area: slow idle. -
Page 24: Oil Pressure
(Does not apply to emergency generator sets). The power must not be switched off before the engine Set the control switch to "0". (Does not apply to emergency generator has stopped. sets). © Scania Industrial & Marine Engines 2003-10:1... -
Page 25: Clutch
- At temperatures below 0°C: Prepare for the next start by connecting the INJURY engine heater. Topping up with coolant should be carried out when the engine is stopped after the first start. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 26: Maintenance
8. Checking low pressure indicator. "Annually" 12. Checking fuel level. "Every 5th year" 15. Checking electrolyte level in batteries. 16. Checking state of charge in batteries. 17. Cleaning batteries. 22. Look for leakage, rectify as necessary 2003-10:1 © Scania Industrial & Marine Engines... -
Page 27: Maintenance Schedule
More often if required For engines with few operating hours, see page 26. Earlier if low pressure indicator shows red. If inhibitor has not been topped up for five years, the coolant should be changed. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 28: Lubricating Oil System
- Viscosities are shown in the figure below. - When ambient temperatures are extremely low: Consult your nearest Scania representative to avoid starting difficulties. Oil analysis Some oil companies can offer analysis of the engine oil. Such analysis... -
Page 29: Checking Oil Level
Dispose of used oil through an Maximum permissible angles during operation vary, depending on the type of authorised waste disposal oil sump, see illustration. contractor. Note: Specified angle may only occur intermittently. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 30: Cleaning The Oil Cleaner
- 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 often. 2003-10:1 © Scania Industrial & Marine Engines... - Page 31 - 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 it does not: dismantle it and inspect the component parts. 2003-10:1 © Scania Industrial & Marine Engines...
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Page 32: Changing The Oil 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 tools for this. The filter could sustain damage, obstructing circulation. -
Page 33: Checking The Coolant
Coolant should be checked as follows: Check the appearance of the coolant. Coolant with glycol only: check the glycol content. Coolant composition: Coolant with Scania Corrosion Inhibitor only: If there is a danger of freezing: Check the anti-corrosive content. minimum... - Page 34 Glycol dm (litres) 85 102 90 108 95 114 90 100 120 A= Area to be avoided. Only for calculating glycol mix. Coolant freezing temperature when ice starts to form at different glycol mixes 2003-10:1 © Scania Industrial & Marine Engines...
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Page 35: Checking Protection Against Corrosion
It is highly dangerous to the cooling system against corrosion. consume corrosion inhibitor. If there is no danger of freezing, only Scania Corrosion Inhibitor should be Avoid contact with the skin. used in the coolant. The inhibitor in Scania Corrosion Inhibitor is free of nitrite. -
Page 36: Cleaning The Cooling System
Refit the delivery pipe clamps. Connect the intake manifold from the turbo. Fill up with coolant according to the specification on page 33. Intake manifold, upper part V-ring seal Element Gasket Intake manifold, lower part 2003-10:1 © Scania Industrial & Marine Engines... -
Page 37: Internal Cleaning
- Refill the system with hot water and run the engine for about 20-30 minutes. - Drain the water from the system. - Refit the thermostats. - Top up the system with new coolant according to the specification on page 33. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 38: Air Cleaner
Note: This filter element must not be washed with water. Never start the engine without the air filter. There is a risk of injury or serious engine damage. Cover Filter element Filter housing 2003-10:1 © Scania Industrial & Marine Engines... -
Page 39: Changing The Safety Cartridge
Remove the side cover from the air cleaner. Remove the filter element. Remove the safety cartridge. Fit a new genuine Scania safety cartridge. Change or clean the filter element, see point 10. Assemble the air cleaner. 1. Safety cartridge... -
Page 40: Fuel System
If the engine will still not start ..- Pump with the hand pump until the fuel coming through the overflow valve is free from bubbles. - Tighten the overflow valve when the engine has started. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 41: Checking The Injectors
Fit the leak-off fuel line. Tighten the bolts to 11 Nm (1.1 kpm). Delivery pipe Cap nut Washer Cone Connection on injector or injection pump 2003-10:1 © Scania Industrial & Marine Engines... -
Page 42: Electrical System
1200 hours. If the terminals are shorted, Clean batteries, cables and cable terminals. sparking will occur. Check that all cable terminals are firmly tightened. Grease battery terminal posts and cable terminals with vaseline. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 43: Checking The Coolant Monitor
Top up coolant to the correct level, see page 32. supplied by Scania Use a container to avoid spillage when draining the coolant. Dispose of used coolant through an authorised waste disposal contractor. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 44: Checking The Temperature
Check the resistance at the temperatures given below. The sensor should give the following readings: 2-pin temperature sensor Resistance Tolerance temp. Ω °C °C ±4 134 ± 13,5 ±3 51,2 ± 4,3 ±3 38,5 ± 3 2003-10:1 © Scania Industrial & Marine Engines... -
Page 45: Checking The Oil Pressure Sensor/Monitor
The monitor should open at 1.1 ± 0.15 bar when the engine is started and close at 0.7 ± 0.15 bar when the engine is stopped. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 46: Miscellaneous
The extra coolant pump is driven with a V-belt (3) via a pulley on the crankshaft. This V-belt should be tensioned with the aid of the pump attachment until it can be pressed down a maximum of 10 mm with a pressure of 35-50 N. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 47: Checking For Leakage, Necessary Action
A small amount of leakage from the overflow holes during the engine running-in period is normal. (Seals and O-rings are lubricated with soap If serious leakage occurs, or oil when fitted). contact your nearest Scania workshop. This leakage normally stops after a time. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 48: Checking/Adjusting Valve
- Set No. 6 cylinder to TDC by turning the engine one revolution in its direction of rotation and adjust the following valves: Cylinder numbering Cylinder Outlet Intake no. 6 cylinder no. 1 cylinder Outlet Intake Intake and outlet FLYWHEEL Intake valve Exhaust valve 2003-10:1 © Scania Industrial & Marine Engines... - Page 49 It says up or down on the flywheel Both covers are fitted with a cover at delivery. Covers for reading on the flywheel housing 2003-10:1 © Scania Industrial & Marine Engines...
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Page 50: Changing
Then rinse it several times in diesel and allow it to drip dry. - Refit the valve. - The valve may be reused (cleaned), but not more than twice after the first 2400 hours of use. Take care to mark the valve after cleaning it. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 51: Long-Term Storage
Inflammable: Fire class 2A. Flashpoint + 27. In case of fire: Extinguish with carbon dioxide, powder or foam. Storage: In well-sealed receptacle in a dry, cool place. Keep out of reach of children. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 52: Preservative Oil
- Spray with water-repellent anti-corrosive oil, CRC 226, LPS1 or the equivalent. - Spray the outside of bright engine parts, first with penetrating preservative oil such as Dinitrol 25B and then with Dinitrol 112 or the equivalent. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 53: Batteries
- Fit the injectors. - Empty the fuel system's main filter of preservative oil. - Bleed the fuel system, see page 40. - Wash off any externally applied preservative oil, using white spirit. 2003-10:1 © Scania Industrial & Marine Engines... -
Page 54: Technical Data
(hot engine at operating speeds) bar (kp/cm 3 - 6 Min. oil pressure (hot engine 800 rpm) bar (kp/cm Oil capacity, see page 29 Crankcase pressure with -55 - +20 closed crankcase ventilation mm VP 2003-10:1 © Scania Industrial & Marine Engines... - Page 55 System voltage Alternator, current 65 or 90 Starter motor output kW (hp) 4,0 (5,4) Monitors, alarm values: oil pressure monitor bar (kp/cm ± 0,15 temperature monitor °C Stamped on hexagonal part of monitor 2003-10:1 © Scania Industrial & Marine Engines...
- Page 56 Scania dealers or directly from Scania. The address of Scania is printed on the cover. The diesel fuel must meet European standard EN 590.
- Page 57 - To prevent water in the fuel from freezing and forming ice, a maximum of 0.5-2% alcohol (isopropanol) may be added. damage to the engine. Drain fuel tanks and drain or change fuel filters regularly. 2003-10:1 © Scania Industrial & Marine Engines...
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Page 58: Alphabetical Index
Glycol ....... 33 © Scania Industrial & Marine Engines 2003-10:1...
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