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

MAINTENANCE

The maintenance programme covers 25 points, divided into the following
main groups:

Lubricating oil system  . . . . . . . . . . . . . . . . . .  sid 20
Cooling system . . . . . . . . . . . . . . . . . . . . . . . .  sid 24
Air cleaner  . . . . . . . . . . . . . . . . . . . . . . . . . . .  sid 30
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . .  sid 32
Electrical system, monitors, batteries etc.  . . .  sid 34
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . .  sid 39

The maintenance points are divided into intervals as follows:

Daily maintenance

Maintenance before first start

Maintenance after the first 400 hours of operation

Periodic maintenance every 200 hours of operation (carried out after 200,
400, 600, 800, etc. hours)

Periodic maintenance every 400 hours of operation (carried out after 400,
800, 1200, 1600, etc. hours)

Periodic maintenance every 1200 hours of operation (carried out after 1200,
2400, 3600, etc. hours)

Periodic maintenance every 2400 hours of operation (carried out after 2400,
4800 etc. hours)

Periodic maintenance every 4800 hours of operation (carried out after 4800,
9600, etc. hours)

Annual Maintenance

Maintenance every 5th year

ENGINES WITH FEW HOURS OF
OPERATION

Emergency generator sets and the like that are not used regularly should be
run on test and checked in accordance with the generator set manufacturer’s
instructions.

Run the engine until it reaches operating temperature and then carry out the
maintenance points below:

1. Checking the oil level.

5. Checking the coolant level.

8. Checking the vacuum indicator.

12. Checking the fuel level.

15. Checking the electrolyte level in batteries.

16. Checking the state of charge in batteries.

17. Cleaning the batteries.

23. Checking for leakage, rectify as necessary

For engines with few operating

hours that are not subject to

periodic maintenance according

to the maintenance schedule on

page 19, maintenance should be

carried out in accordance with

the schedule:

"Every year"

"Every 5 years"

Immobilise the starting device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK

OF INJURY

MAINTENANCE SCHEDULE

More often if required

For engines with few operating hours, see page 18.

Earlier if vacuum indicator shows red.

If inhibitor has not been topped up for five years, the coolant should be changed.

Dail

First

time at

Interval

At least

Firs

t sta

400 h

200 h

400 h

1200

2400

4800

Annual

Ever

y 5t

h ye

LUBRICATING OIL SYSTEM, page 20

1. Checking the oil level

2. Oil change

3. Cleaning the oil cleaner

4. Renewing the oil filter

COOLING SYSTEM, page 24

5. Checking the coolant level

6. Checking the coolant

7. Cleaning the cooling system

AIR CLEANER, page 30

8. Checking the vacuum sensor

9. Cleaning the coarse cleaner

10. Cleaning or renewing filter element

11. Renewing the safety cartridge

FUEL SYSTEM, page 32

12. Checking the fuel level

13. Renewing the main filter

14. Checking the injectors

ELECTRICAL SYSTEM, page 34

15. Checking the electrolyte level in batteries

16. Checking the state of charge in batteries

17. Cleaning the batteries

18. Checking the level monitor

19. Checking the temperature monitor

20. Checking the oil pressure monitor

21. Checking the stop function

MISCELLANEOUS, page 39

22. Checking the drive belt

23. Checking for leakage, rectify as necessary

24. Checking/adjusting valve clearance

25. Renewing (or cleaning) the valve for closed crankcase

ventilation

2001-05:1

LUBRICATING OIL SYSTEM

OIL GRADE

The engine oil must at least meet the requirements for one of the following
oil classifications:

-ACEA E3, E4 or E5

- The Total Base Number (TBN) should be minimum 12-13

(ASTM 2896).

- Check with your oil supplier that the oil meets these requirements.

- The specified oil change intervals apply provided that the fuel sulphur

content does not exceed 0.3% by weight. If the sulphur content exceeds
0.3 % but is maximum 1.0%, the oil change intervals must be halved
(200 h).

- Viscosities as illustrated below.

- For operation at extremely low ambient temperature: Consult your

nearest Scania representative on how to avoid starting difficulties.

Oil analysis

Some oil companies can offer analysis of the engine oil. Such analysis
measures the oil TBN (Total Base Number), TAN (Total Acid Number), fuel
dilution, water content, viscosity and the quantity of friction particles and
soot in the oil.

The result of a series of analyses is used as the basis for establishing a
suitable oil change interval.

If the conditions are changed, a new oil analysis programme must be carried
out to establish the new change interval.

-40

-30

-20

-10

40 °C

SAE 10W-30

SAE 20W-30

SAE 30

SAE 40

SAE 50

SAE 5W-30

SAE 15W-40

Additives must not be used.

The oil should be suitable for all
temperature variations until the

next oil change.

2001-05:1

1. Daily:

CHECKING THE OIL LEVEL

Note

Before checking oil level: Allow the engine to remain stopped for
at least 1 minute.

- The correct level is between the marks on the dipstick. Top up when the

level is at the lower mark.

- Correct type, see "Oil grade" on page 20.

Note!

Checking of oil level during operation can not be performed on
engines with standard oil sump, see picture.

2. Every 400 hours:

OIL CHANGE

Note

Under extremely severe operating conditions, especially in dusty
environment or if the deposits in the centrifugal cleaner are
thicker than 20 mm: change oil more frequently.

- Unscrew the plug and drain the oil when the engine is hot.

- In certain engines the oil is pumped out by means of a bilge pump.

- Clean the magnet on the plug.

- Refit the plug.

- Fill up with oil.

- Check the level on the dipstick.

Max 27 dm

Min 20 dm

Max 20 dm

Min 16 dm

1 dm

= 1 liter

Maximum angles of inclination during operation

Maximum permissible angles during operation vary, depending on the type
of oil sump, see illustration.

Note

Specified angles may only occur intermittently.

WARNING

The oil may be hot.

Wear protective gloves and

goggles

Always use a suitable container

to avoid spillage when

changing oil.

Dispose of used oil through an

authorized waste disposal

contractor.

2001-05:1

4. Var 400:e timme:

RENEWING THE TURBO 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 a tool for tightening. The filter could be damaged,
obstructing circulation.

- Start the engine and check for leaks.

Important

If the deposits in the centrifugal cleaner are thicker than 20
mm the oil filter should be renewed more frequently. This
includes cleaning the centrifugal filter and changing oil.

COOLING SYSTEM

5. Daily:

CHECKING THE COOLANT LEVEL

- Open the expansion tank filler cap and check the coolant level.

- Correct level: (Scania plastic expansion tank)

- Cold engine: The coolant should be level with the lower edge of the

filler neck.

- Hot engine:

The coolant should be approximately 25 mm above the

lower edge of the filler neck.

- Other types of expansion tank according to the instructions of the fitter.

- Top up the coolant as necessary, see point 6.

Note

When filling large amounts of coolant:
Never pour cold coolant into a hot engine.
This could cause cracks in the cylinder block and the cylinder
head.

Always collect oil in a suitable

container to avoid spillage when

renewing the oil filter.

Dispose of used filters through

an authorized waste disposal

contractor.

Always top up with ready mixed

coolant.

Carefully open the cap.

Hot water and steam

may blow out.

2001-05:1

6. Every 2400 hours:

CHECKING THE COOLANT

Coolant should be checked as follows:

Check the appearance of the coolant.

Coolant with only glycol: Check the glycol content.

Coolant with only Scania Anti-corrosive:
Check the corrosion inhibitor.

The composition of the coolant is described in detail under
"Starting and running"

Checking the appearance of the coolant

- Fill a container with a little coolant and check that it is clean and clear.

- If the coolant is contaminated or cloudy: consider changing the coolant

- Water added to the coolant should be clean and free from dirt of any

kind.

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

Checking the glycol content

If there is a danger of freezing, use only glycol as an anti-corrosive in the
coolant.

- Cooling systems with glycol should contain at least 30% glycol by

volume to provide acceptable protection against corrosion.

- A content of 30% glycol by volume protects against freezing down to

-16°C. If further protection is needed, refer to the table on the next page
for calculating the required amount of glycol.

We recommend only nitrite-free anti-freeze glycol with the following
supplier designations:

BASF G48 or BASF D542

- Always top up the anti-freeze if its glycol content drops below 30% by

volume. A glycol content above 60% by volume will not provide greater
protection against freezing.

- The table shows the temperature at which ice starts to form. The engine

will freeze and break at appreciably lower temperatures, see diagram.

- Ice forming in the coolant often causes malfunctioning without any risk

of damage. The engine should not be subjected to heavy loads when ice
starts to form.

Note

Change the coolant when cleaning the cooling system: every 4800
hours or minimum every 5 years.

Important

If a coolant filter is used in the cooling system it must not con-
tain an inhibitor.

The coolant should be ready

mixed when it is poured into the

cooling system.

Never top up with only water or

only glycol.

Ethylene glycol is highly

dangerous if ingested and can

prove fatal.

Avoid skin contact with glycol.

The recommended glycol must

not be mixed with glycol having

nitrite-based anti-corrosive.

Risk for build up of sludge and

reduced cooling capacity.

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 Anti-corrosive

2001-05:1

A= Area to be avoided. Only for calculating glycol mix.

Coolant freezing temperature when ice starts to form at different glycol mixes

% glycol by

volume

Cooling

system

capacity, dm

Ice slush starts

to form at °C

-6

-9

-12

-16 -22 -27 -36 -46 -55

Glycol dm

(litres)

11 12 14 15 18

12 14 16 18 20 24

10 13

15 18 20 23 25 30

12 15

18 21 24 27 30 36

11 14 18

21 25 28 32 35 42

12 16 20

24 28 32 36 40 48

14 18 23

27 32 36 41 45 54

15 20 25

30 35 40 45 50 60

100

17 22 28

33 39 44 50 55 66

110

18 24 30

36 42 48 54 60 72

120

20 26 33

39 46 52 59 65 78

130

21 28 35

42 49 56 63 70 84

140

23 30 38

45 53 60 68 75 90

150

24 32 40

48 56 64 72 80 96

160

26 34 43

51 60 68 77 85 102

170

27 36 45

54 63 72 81 90 108

180

29 38 48

57 67 76 86 95 114

190

30 40 50

60 70 80 90 100 120

200

Curve A: Ice build up starts (slush)

Curve B: Temperature at which damage due to

freezing can occur

1. Safe range

2. Malfunctions may occur (ice slush)

3. Risk of damage by freezing

% glycol by volume

Properties of glycol at low temperatures:

- Example with 30% glycol by volume

- Ice slush starts to form at -16°C.

- There is risk for malfunctions at -30°C

- No risk of damage by freezing with a

minimum content of 30% glycol by volume

2001-05:1

Checking the corrosion inhibitor

There must always be sufficient corrosive inhibitor in the coolant to protect
the cooling system against corrosion.

If there is no danger of freezing, only Scania Anti-corrosive should be used
in the coolant.

The inhibitor in Scania Anti-corrosive is free of nitrite.

The correct proportion of anti-corrosive is 7-12% by volume.

- Topping up with 1.0% Scania Anti-corrosive by volume should be done

after every 2400 hours of operation.

- 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 Anti-corrosive.

Note

The coolant should be changed when the cooling system is clea-
ned: every 4800 hours or minimum every 5 years.

Changing the coolant

Remove the filler cap from the expansion tank.

The coolant is drained at two points:

- the "lowest point" of the engine block, see illustration.

- the "lowest point" of the cooling system.

Close the cocks.

Fill up with coolant through the expansion tank’s filler hole.

Mix coolant as described on page 25.

If a coolant filter has been fitted

it must not contain inhibitor.

Mixing corrosion inhibitor with

glycol or adding too much

corrosion inhibitor may cause

deposits and reduced cooling

capacity.

Corrosion inhibitor, if

swallowed can be fatal.

Avoid contact with the skin.

Always collect fluid in a suitable
container to avoid spillage when

changing coolant.

Dispose of used coolant through

an authorized waste disposal

contractor.

2001-05:1

7. Every 4800 hours:

CLEANING THE COOLING SYSTEM

Note

If necessary, the cooling system should be cleaned more often.

External cleaning

Radiator

- Check that the radiator is not clogged on the air side and that the cooling

fins are not damaged.

- Carefully scrape the deposit off the radiator’s cooling fins. If necessary,

a paraffin-based engine cleaner can be used.

- Bent fins can be straightened using a wire brush, for example, and exer-

cising care.

Charge air cooler (DI engine)

Drain the coolant from the engine, refer to "Changing the coolant".

Detach the intake manifold from the turbo.

Detach the charge air cooler inlet and outlet connections.

Unbolt the charge air cooler assembly from the intake manifold. The
charge air element is integrated into the housing.
Be careful - do not damage the core water connections.

Clean the outside of the element. This is especially important if the eng-
ine is equipped with closed crankcase ventilation. Use a paraffin-based
engine cleaner.

Clean and degrease the sealing surfaces on the core and the air intake
pipe with a spirit based cleaner.

Apply sealant (silicone 816 064) in a uniform bead, approximately
2-3 mm, on the sealing surface of the air intake pipe.

Tighten the charge air cooler by means of the clamp rails.
Install the charge air cooler within 15 minutes of applying the sealant.
Torque tighten the bolts to 50 Nm.

Refit the inlet and outlet connections with new O rings.

10.

Connect the intake manifold from the turbo.

11.

Fill up with coolant according to the specification
on page 25.

Important

Allow the sealant to cure for minimum
24 hours before the engine is used.

Clamp rail

Charge cooler hous-
ing with element

O-ring

Sealant 816 064

Intake manifold

The cooling system must never

be cleaned with caustic soda.

There is a risk of damage to

aluminium parts.

2001-05:1

Internal cleaning

Removing oil and grease

- If possible, run the engine until it has reached the operating temperature

and then drain the cooling system.

- Remove the thermostat.

- Fill the system with clean, hot water mixed with liquid dishwasher

detergent intended for household use.
Concentration 1% (0.1/10 l).

- Run the engine until warm for about 20-30 minutes. Do not forget the

cab heating system (if fitted).

- Drain the cooling system.

- Fill the system again using clean, hot water and run the engine for

approximately 20-30 minutes.

- Drain the water from the system.

- Refit the thermostat.

- Fill up with new coolant according to the specification on page 25.

Removing deposits

- If possible, run the engine until it has reached operating temperature and

then drain the cooling system.

- Remove the thermostat.

- Fill the system with clean, hot water mixed with a commercially

available radiator cleaner based on sulphamic acid and containing
dispersing agents. Follow the manufacturer’s instructions for mixing
proportions and cleaning times.

- Run the engine for the specified time and then drain the cooling system.

- Refill the system with hot water and run the engine for approximately

20-30 minutes.

- Drain the water from the system.

- Refit the thermostat.

- Fill up with new coolant according to the specification on page 25.

Handling cleaning agents for

the cooling system:

Read the warning label on the

container.

Always collect fluid in a suitable
container to avoid spillage when

draining coolant.

Dispose of used coolant through

an authorized waste disposal

contractor.

2001-05:1

AIR CLEANER

8. Daily:

CHECKING THE VACUUM INDICATOR

If the indicator’s red plunger is fully visible, change or clean the air cleaner
filter insert, point 10.

9. Every 200 hours:

CLEANING THE AIR CLEANER
COARSE CLEANER

Detach the eccentric catch and remove the coarse cleaner.

Remove the plastic cover from the coarse cleaner and clean the parts.

Check that the plastic cover is intact and that it makes a seal against the
air cleaner housing during assembly.

Assemble the air cleaner.

Pre-filter with cover

Filter insert

Low pressure indicator

Safety cartridge

Air cleaner with pre-filter

The coarse cleaner should be

fitted with the marking ”TOP”

facing up.

10. Every 1200 hours:

CLEANING OR CHANGING THE
FILTER ELEMENT

Note

Earlier if the vacuum indicator shows red

Dismantling

Remove and clean the coarse cleaner, see point 9.

Undo the nut securing the filter insert and remove it.

Change or clean the insert.

Note

Cleaning the element always entails a risk of damaging it. The
element should only be cleaned four times a year at most. After
cleaning, it has poorer dust capacity than a new element.

Mark the filter when it has been cleaned.

Cleaning the element

- Carefully blow the filter element clean using dry compressed air from

the inside.

Note

This filter element must not be washed with water.

Only use Scania genuine air

filter. Change the filter element

if it is damaged.

Danger of engine damage if the

filter element is damaged.

Never start the engine unless

the air filter is installed.

Danger of personal injury or

engine damage.

2001-05:1

FUEL SYSTEM

12. Daily:

CHECKING THE FUEL LEVEL

- Top up with fuel if necessary.

- If the tank has been run dry, bleed the fuel system, refer to paragraph 13.

13. Every 1200 hours:

RENEWING THE FUEL FILTER

Fuel tanks

- Drain any water from the fuel tanks.

Filter

The filter consists of a filter unit.

- Wash the outside of the filter and unscrew it. Discard the filter according

to environmental requirements.

- Tighten the new filter by hand.

Never use a tool for tightening. The filters can be damaged,
obstructing circulation.

- Bleed the fuel system as described below.

- Start the engine and check for leaks.

Bleeding the fuel system

- Open the bleed screw 1 on the main filter.

- Pump the hand pump 2 until air-free fuel flows out at the main

bleed screw.

- Close the bleed screw. Pump a few times using the hand pump.

If the engine is difficult to start after bleeding . . . . .

- Slacken the injection pump overflow valve 3 one half turn

and try starting again.

If the engine fails to start after bleeding . . . . . . .

- Pump the hand pump until bubble-free fuel flows from the overflow

valve.

- Tighten the overflow valve when the engine has started.

Always collect fuel in a suitable

container to avoid spillage when

bleeding system or renewing

components.

Only use Scania genuine fuel

filter.

Observe the utmost cleanliness

when working on the fuel

system.

Malfunctions could easily occur

and the injection equipment

could be damaged.

Scania D9, DI9, DC9. Industrial engine. Operator’s manual - part 2