Scania D9, DI9, DC9. Industrial engine. Operator’s manual

IMPORTANT INFORMATION

When working on the engine, e.g. when adjusting the belts, changing oil or adjusting the clutch it is

important that the engine does not start. The engine may be damaged but above all there is -

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.

This warning symbol and text is reproduced beside those maintenance points where it is

especially important to consider the risk of injury

Operator’s manual

D9 DI9 DC9

Industrial engine

opm96-9a en

1 588 292

2001-05:1

Industrial & Marine Engines

START-UP REPORT - WARRANTY

When the start-up report has been filled in and sent to Scania there is a 1 year warranty starting from
the start-up date. Also enter the below information since this will facilitate contacts with e.g. service
workshops.

Engine number

Start-up date

User’s name and address

Signature

Engine type

Variant

Engine type and variant are indicated on the engine type plate

FOREWORD

This operator’s manual describes the operation and maintenance of the Scania
D9, DI9 and DC9 industrial engines. The instructions apply to engines in pro-
gram 96, starting with engine number 5 119 902.

The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder in-
line diesel type. The engines are available with or without charge air cooler,
see page 10.

Common applications are as power units in construction machines, generator
sets, earth-moving, railway and forestry machines as well as in irrigation sys-
tems.

The engines are available with different power output and engine speed set-
tings.

The normal output setting of the engine (performance code) is indicated on
the type plate, see page 10

Note

Only standard components are described in the operator’s man-
ual. Regarding special equipment, refer to the instructions of the
relevant manufacturer.

In order to obtain the best value and service life from your engine, there are a
few points to bear in mind:

- Read the manual before starting to use the engine. You will find new

information in this Operator’s Manual even if you have previous
experience of Scania engines.

- Follow the maintenance instructions. Proper maintenance is essential to

keep the engine operating correctly and to increase engine life.

- Pay special attention to the safety information beginning on page 6.

- Get to know your engine so that you know what it can do and how it

works.

- Whenever necessary, always contact an authorised Scania workshop.

They have special tools, genuine Scania parts and trained staff with
practical experience of Scania engines.

Note:

Always use genuine Scania parts in service and repair to keep the
engine operating correctly.

The information in this manual was correct at the time of going to press.
However, we reserve the right to make changes at any time, without prior
notice.

Scania CV AB
Industrial and Marine Engines

S-151 87 Södertälje, Sweden

During the warranty period,

only use genuine Scania parts in

service and repair for the

warranty to be valid.

2001-05:1

ENVIRONMENTAL RESPONSIBILITY

Scania has always been at the forefront in the development and production of
environmentally safe engines.

We have made great progress in reducing harmful exhaust emissions to be
able to meet the stringent emission standards that are mandatory for almost
all markets.

We have done this without compromising the high quality of Scania
industrial and marine engines in terms of performance and cost effective
operation.

To maintain these superior properties throughout the life of the engine it is
important that the operator/owner follows the instructions of this manual as
regards operation, maintenance and choice of fuel and lubricants.

To further contribute to protecting the environment in service, maintenance
and repair, ensure that harmful waste (oil, fuel, coolant, filters, batteries etc.)
is disposed of and destroyed according to applicable local regulations.

This operator’s manual contains highlighted text urging you to protect the
environment in different service and maintenance operations.

Refer to example

Always use suitable containers

to avoid spillage when bleeding

systems or renewing

components.

2001-05:1

CERTIFIED ENGINES

An emission certified engine has been approved according to a specific
certification standard. The certified engines delivered by Scania meet the
most compelling emission standards in the European (EU) and non-European
(USA) markets.

Scania guarantees that all engines of a certified engine type that are delivered,
correspond to the engine approved for certification.

The engine is fitted with a certification plate, stating according to which
certification rules (standard) the engine has been approved. Refer to page 10.

The following is required for the engine to meet the emission standards after
being commissioned:

- Service and maintenance must be performed according to this

Operator’s Manual.

- Only genuine Scania parts must be used.

- Service work on the injection equipment must be performed by an

authorized Scania workshop.

- The engine must not be modified with equipment not approved by

Scania.

- Seals and setting data may only be broken/modified after approval by

Scania, Södertälje. Changes should only be made by qualified
personnel.

- Changes affecting the exhaust system and intake system must be

approved by Scania.

Otherwise, follow the instructions in this manual for operation, care and
maintenance of the engine. Also observe the safety precautions described in
the following four pages.

Important!

If service and maintenance are not performed as stated
above, Scania cannot guarantee that the engine corresponds
to the certified configuration and will not assume liability for
any damage occurring.

2001-05:1

SAFETY DETAILS

General

This Operator’s Manual contains safety information that must be observed in
order to avoid personal injuries and damage to the product or property. Refer
to page 1.

The text boxes to the right on the pages provide information that is important
for the proper operation of the engine and to avoid damage to the engine.
Failure to follow these instructions may void the warranty.

Refer to example.

Corresponding texts may also appear in the text column, headed

Caution!

Important

The warning text in text boxes to the right on the pages provided with a
warning triangle and headed WARNING is extremely important and warns
of serious defects to the engine or improper handling that may lead to
personal injury.

Refer to example

The safety precautions that must be observed in the operation and
maintenance of Scania engines are compiled on the following three pages.
The corresponding text is also often stated next to the maintenance step
concerned, shown with different degrees of significance as described above.

All items are marked with a

to highlight the importance of reading each

item in the section.

A general safety rule is that no smoking is allowed:

•

Near the engine and the engine bay

•

When refuelling and near the filling station

•

When work is performed on the fuel system

•

Near flammable or explosive materials (fuel, oils, batteries, chemicals
etc.)

Immobilise the starting device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK

OF INJURY.

Only use Scania genuine fuel

filter.

2001-05:1

Safety precautions for operation

Daily inspection

Always perform visual inspection of the engine

and engine bay before the engine is started and

when the engine has been stopped after oper-

ation.
This will make it easy to detect any leakage of

fuel, oil or coolant or any other abnormal condi-

tion that may require remedial action.

Refuelling

When refuelling, there is a risk of fire and explo-

sion. The engine must be stopped and smoking

is not allowed.
Do not overfill the tank, since the fuel may ex-

pand, and close the fuel filler cap properly.
Only use fuel recommended in the service

literature. Fuel of an incorrect grade may cause

malfunctions or stoppage by interfering with the

operation of the fuel injection pump and the in-

jectors.
This could cause engine damage and possibly

personal injury.

Harmful gases

Only start the engine in a properly ventilated ar-

ea. The exhaust emissions contain carbon

monoxide and nitrogen oxides that are toxic.
When operating the engine in an enclosed ar-

ea, an effective extraction device for exhaust

gases and crankcase gases must be used.

Starter lock

If the control panel is not fitted with a key

switch, the engine bay should be fitted with a

lock to prevent unauthorized starting of the en-

gine.
Alternatively, a lockable main switch or battery

master switch may be used.

Starting spray

Never use starting spray or similar as a starting

aid. An explosion may occur in the intake pipe,

which could cause personal injury.

Operation

The engine should not be operated in environ-

ments with surrounding explosive materials

since electrical or mechanical components of

the engine may emit sparks.
It is always a safety hazard to be near an en-

gine that is running. Body parts or clothing, or a

dropped tool may get stuck in rotating parts,

such as the fan, causing bodily injury.
Always cover rotating parts and hot surfaces as

much as possible to ensure personal safety.

Fuel and lubrication oil

All fuels and lubricants as well as many chemi-

cals are flammable. Always follow the instruc-

tions stated on the container.
All work on the fuel system must be performed

when the engine is cold. Fuel leakage and spill-

age on hot surfaces may cause fire.
Store drenched rags and other flammable ma-

terials in a safe way to avoid spontaneous com-

bustion.

Batteries

Batteries, particularly when being recharged,

emit highly flammable fumes that can explode.

Do not smoke or let open flame or sparks come

near the batteries or the battery compartment.
Incorrect connection of a battery cable or jump

start cable may cause a spark, which in tun may

cause the battery to explode.

Chemicals

Most chemicals, such as glycol, corrosion in-

hibitors, preservation oils, degreasers etc. are

hazardous. Always follow the safety precau-

tions stated on the container.
Some chemicals, e.g. preservative oil, are

flammable.
Always store chemicals and other hazardous

materials in approved and distinctly marked

containers and out of reach of unauthorized

persons. Always dispose of superfluous or

used chemicals through an authorized waste

disposal contractor.

Safety precautions for care and
maintenance

Stop the engine

Always stop the engine before any mainte-

nance and service work unless otherwise

stated.
Prevent unauthorized starting by removing the

starter key and turning off the power by the

main switch or the battery disconnect switch,

locking it in the off position. Also attach a warn-

ing tag, stating that work on the engine is in

progress, at a suitable location.
It is always a safety hazard to work on an en-

gine that is running. Parts of your body or cloth-

ing, or a dropped tool may get stuck in rotating

parts, causing bodily injury.

Hot surfaces and fluids

A hot engine always presents a risk of scalding.

Always take care not to touch the exhaust

manifold, turbocharger, oil pan, hot coolant and

oil in pipes and hoses.

Lifting the engine

Use the engine lifting eyes when lifting the

engine. First check that the lifting equipment is

in proper condition and has sufficient lift capac-

ity rating.
Auxiliary equipment fitted to the engine may

cause the centre of gravity to be displaced.

Thus, additional lift devices may be required in

order to provide proper balance and a safe lift.
Never work below a suspended engine!

Batteries

Batteries contain a highly corrosive electrolyte

(sulphuric acid). Always take care to protect

your eyes, skin and clothing when charging and

handling batteries. Wear protective gloves and

goggles.
If electrolyte splashes on the skin, wash the

affected part of the body with soap and plenty

of water. If electrolyte splashes into the eyes,

rinse eyes immediately with plenty of water and

seek medical attention.
Dispose of used batteries through an author-

ized waste disposal contractor.

2001-05:1

Electrical system

Before work is performed on the electrical sys-

tem, turn off the power by the main switch or the

battery disconnect switch.
Also disconnect any external power supply to

auxiliary equipment on the engine.

Arc Welding

Before welding near or on the engine, remove

the battery and alternator cables. Also remove

the control unit connector.
Connect the weld clamp to the component to be

welded, close to the weld location. Never con-

nect it to the engine or in such a way that the

current can pass through a bearing.
After the welding is completed, connect the ca-

bles to the alternator and the control unit before

connecting the batteries.

Lubrication system

Hot oil may cause scalding and skin irritation.

Avoid skin contact with hot oil.
Make sure that the pressure in the lubrication

system is relieved before work is carried out.

Never start or operate the engine with the oil fill-

er cap removed since oil will be ejected force-

fully.
Dispose of used oil through an authorized

waste disposal contractor.

Cooling system

Never open the coolant filler cap while the en-

gine is hot. Steam and hot coolant can come

out forcefully and cause scalding.
If the cooling system must still opened or disas-

sembled while the engine is hot, open the filler

cap very cautiously and slowly to release the

pressure before the cap is removed. Use

gloves since the coolant is still very hot.
Dispose of used coolant through an authorized

waste disposal contractor.

Fuel system

Always use gloves when checking for leaks in

or performing other work on the fuel system. Al-

ways wear eye protection when testing injec-

tors.
Fuel escaping under high pressure can pene-

trate body tissue and cause serious injury.
Never use non-genuine parts in the fuel system

and the electrical system. Genuine parts are

designed and manufactured to minimize fire

and explosion hazard.

Before starting

Install any guards that have been removed be-

fore the engine is started. Check to ensure that

no tools or other objects have been left on the

engine.
Never start the engine unless the air filter is in-

stalled. Otherwise there is a risk of objects en-

tering the compressor wheel or a risk of

personal injury from contact with it.

TYPE DESIGNATIONS

The engine designation indicates, as a code, engine type, its size and applica-
tions, etc.

The type designation and engine number are indicated on a type plate which
is located on the right-hand side cover, behind the oil cleaner.
The engine number is also stamped on the top of the engine block, in front of
the first cylinder head.

Engines that are certified regarding smoke and emissions are fitted with a cer-
tification plate specifying the documents they conform to. This plate is
located on the second rocker cover from the front.

DC 9 49 A 31 S

Type

Turbocharged diesel engine

Turbocharged diesel engine with air-cooled charge air cooler.

Turbocharged diesel engine with liquid-cooled charge air cooler.

Displacement

in whole dm

Performance and certification code

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

Governor type

Electronically controlled auxiliary governor

RSV, all-speed and single-speed governor

2001-05:1

Type plate

Engine number,
stamped in engine block

Oil cooler

Oil dipstick

Oil cleaner

Draining, engine oil

Water pump

Turbocharger

Injection pump

10.

Fuel filter

11.

Starter motor

12.

Alternator

13.

Draining, coolant

14.

Oil filling

15.

Charge air cooler

The illustrations show a typical DI9 engine configuration.

Your engine may have different equipment from the one shown.

2001-05:1

STARTING AND RUNNING

AT FIRST START

When the engine is started for the first time, follow the maintenance points
listed under "First start" in the maintenance schedule, see page 19.

Since the points are important for satisfactory operation of the engine right
from the outset, they are also listed below.

1. Checking the oil level (refer to page 21).

6. Checking the coolant (refer to page 25).

The coolant should contain anti-corrosive to protect the cooling system
from corrosion.

If there is a danger of freezing:

- Only anti-freeze glycol should be used in the coolant as protection

against corrosion. We recommend only nitrite-free anti-freeze glycols
with the following supplier designations:

BASF G48 or BASF D542

- The concentration of glycol should be 30 - 60% by volume depending

on the ambient temperature. A content of 30 % by volume provides pro-
tection down to -16 °C. Refer to page 25.

- Never top up with only water or only glycol. Fluid losses must always

be replaced with pre-mixed coolant having the same glycol
concentration as that in the engine. If the glycol content drops, both
anti-freeze protection and protection against corrosion are impaired.

Note

A glycol concentration below 30% by volume will not provide suf-
ficient protection against corrosion. Glycol concentrations higher
than 60 % do not improve anti-freeze protection and have a nega-
tive effect on engine cooling capacity.

If there is no danger of freezing:

- Only Scania Corrosion Inhibitor should be used in the coolant as

protection against corrosion. The correct corrosion inhibitor content is
7-12% by volume and must never be less than 7% by volume. The
inhibitor in Scania Corrosion Inhibitor is free of nitrite.

- First filling: Fill the cooling system with water + 10% by volume of

Scania Corrosion Inhibitor. Use drinkable water with a pH value of
6 - 9.

- Never top up with only water or only anti-corrosive! Fluid losses

must always be replaced with premixed coolant:
water + 10 % by volume of Scania Corrosion Inhibitor.

Coolant filter (not standard equipment)

- Only coolant filter without inhibitor may be used. The use of coolant

filters increases the life of the coolant and reduces the risk of deposition
corrosion.

Coolant composition:

If there is a danger of freezing:

minimum 30% glycol by volume

maximum 60 % glycol by volume

If there is no danger of freezing:

7-12% by volume

Scania Corrosion Inhibitor

(no glycol)

The recommended glycol must

not be mixed with glycol having

nitrite-based anti-corrosive.

Ethylene glycol and corrosion

inhibitor, if swallowed can be

fatal.

Avoid contact with the skin.

The use of too much Scania

Corrosion Inhibitor as mixed

with glycol may cause deposits.

If a coolant filter has been fitted

it must not contain inhibitor.

2001-05:1

12. Checking the fuel level (refer to page 32).

15. Checking the electrolyte level in batteries (refer to page 34).

16. Checking the state of charge in batteries refer to page 34)

18. Checking the coolant level monitor (refer to page 35).

19. Checking the temperature monitor (refer to page 36).

20. Checking the oil pressure monitor (refer to page 37).

21. Checking the stop feature (refer to page 37).

22. Checking the tension of drive belts (refer to page 39).

CHECKS BEFORE RUNNING

Before running, "Daily maintenance" as described in the maintenance sche-
dule should be carried out, see page 19.

STARTING THE ENGINE

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 32.

For environmental reasons, your new Scania engine has been designed to use
a smaller amount of fuel when starting. Using unnecessarily large amounts of
fuel when starting the engine always results in the discharge of unburnt fuel.

- Engines with mechanical stop control: Set the stop control to operating

position.

- Open the fuel cock, if fitted.

- Declutch the engine (not engines with fixed clutch, e.g. generator sets)

- Engines with battery master switch: Switch on the power using the bat-

tery master switch.

- Set the speed control to raised idling. (Does not apply to gensets)

- Start the engine.

Important

A maximum of 3 start attempts per minute may be made when
the stop solenoid is activated at start. The timer module can be
damaged resulting in the loss of the stop feature.

Starting at low temperatures

Local environmental requirements must be complied with. Starting aids,
engine heaters and/or flame start devices should be used to avoid starting
problems and white smoke.

To limit white smoke, the engine should be run at low speed and under mode-
rate load. Avoid running it longer than necessary at idling speed.

Only start the engine in a

properly ventilated area.

When operating the engine in

an enclosed area, an effective

extraction device for exhaust

gases and crankcase gases must

be used.

Never use starting spray or

similar as a starting aid.

An explosion may occur in the

intake pipe, which could cause

personal injury.

Immobilise the starting device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK

OF INJURY.

2001-05:1

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 cool for 2 minutes.

If the engine has flame start:

- Operating flame start without timer relay: Press the control button,

which also acts as a pre-glow button (max. 20 seconds). The glow plug
continues to glow as long as this button is depressed after the engine has
started. Maximum time is 5 minutes.

- Operating flame start with timer relay: Press the pre-glow button (a

maximum of 20 seconds). Release it when the engine starts. The timer
relay keeps the glow plug glowing for 5 minutes. If a shorter glow time
is required, press the release button. The key must be turned to the 0
position if the start attempt fails.

Note:

If the engine is equipped with an INTERLOCK switch, this
switch should be depressed and held until the oil pressure has
reached a sufficiently high level. If the INTERLOCK switch is
released too early, the engine will stop.

- Generator sets should be operated under load immediately after starting

to avoid the risk of white smoke. This applies in particular to engines
that have been installed without aids for heating or applying a basic
load.

- Warm up the engine with a light load. A light load on a cold engine

gives better combustion and faster heating than warming up with no
load.

Maximum starter engagement

time is 30 seconds. Risk of

overheating. Allow starter to

cool for 2 minutes after a

starting attempt before

cranking again.

2001-05:1

OPERATION

Check instruments and warning lamps at regular intervals.

Engine speed

The Scania tachometer is divided into sectors of different colours, as follows:
.

Coolant temperature

Correct coolant temperature during operation:

70 - 93 °C for system at atmospheric pressure.

70 - about 100 °C for system with positive pressure.

High coolant temperature leads to engine damage. Reduce the load on the
engine in order to lower the temperature. If the temperature does not drop,
stop the engine and look for the fault.

During long periods of operation with very low power take-off, the engine
may have difficulty in reaching 70 °C. However, if the load is increased, tem-
perature will rise.

0-500 rpm

red area:

prohibited engine speed,

passed when stopping and

starting.

500-700 rpm

yellow area:

low idle.

700-2200 rpm

green area:

normal operating speed.

Highest torque and lowest

fuel consumption at 1400 -

1600 rpm. Low operating

speed gives less engine

wear.

2200-2600 rpm

yellow/green

striped:

unsuitable operating speed.

May occur when switching

off and during downhill

engine braking

2600-3000 rpm

red area:

prohibited engine speed

Overpressure is not allowed in

cooling systems with Scania

radiators and expansion tanks

made of plastic, i.e. the

expansion tank must not be

fitted with a pressure cap.

2001-05:1

Oil pressure

Max. oil pressure:

warm engine running at a speed above 800 rpm

6 bar

Normal oil pressure:

warm engine running at operating speed

3 - 6 bar

Min. oil pressure:

warm engine running at 800 rpm

0.7 bar

At speeds below 800 rpm, the gauge may show low oil pressure although no
fault is present.

Oil pressure below 0.7 bar at speeds above 800 rpm will cause engine dam-
age. The engine must be stopped immediately.

Charging indicator lamp

If the lamp comes on during operation:

- Check that the alternator drive belt is tensioned. Se page 39

- If the charging indicator lamp is still on, this could be due to an alterna-

tor fault or a fault in the electrical system.

STOPPING THE ENGINE

Run the engine without a load for a few minutes if it has been run con-
tinuously with a heavy load.

Stop the engine using the stop control. Engines with a stop solenoid are
stopped using the stop button. Keep the stop button depressed until the
engine has fully stopped.

Engines with battery master switch: Switch the power off with the bat-
tery master switch. (Does not apply to emergency generator sets).

Set the control switch to ”0”. (Does not apply to emergency generator
sets.)

Emergency stop

The stop solenoid linkage system has a knob marked ”STOP”. Pull the link-
age system to the stop position using this knob if it is not possible to stop the
engine using the stop solenoid.

There is danger of turbo damage

and post boiling if the engine is

stopped without cooling.

The power must not be switched

off before the engine has

stopped.

Scania D9, DI9, DC9. Industrial engine. Operator’s manual - part 1