Scania DI9, DC9 with DEC2. Industrial engine. Operator’s manual

2003-10:1

6. Every 2400 hours:

CHECKING THE COOLANT

Coolant should be checked as follows:

Check the appearance of the coolant.

Coolant with glycol only: check the glycol content.

Coolant with Scania Corrosion Inhibitor only:

Check the anti-corrosive content.

The composition of the coolant is described in more detail under

"Starting and running"

a)
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 it.
- Water added to the coolant should be clean and free from dirt of any

kind.

- Use drinking water with a pH of 6 - 9.

b)
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.

- 30% glycol by volume provides protection against freezing to -16°C. If

additional protection against freezing is required, see the table on the

next page to help you calculate how much glycol you need.

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:

The coolant should be changed when the cooling system is

cleaned: every 4800 hours or at least every 5th year.

Important!

If a coolant filter is used in the cooling system it must not

contain an inhibitor.

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

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

corrosion inhibitor.

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.

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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,

Ice slush starts

to form at °C

-6

-9

-12 -16 -22 -27 -36 -46 -55

Glycol dm

(litres)

100

110

120

130

140

150

160

85 102

170

90 108

180

95 114

190

90 100 120

200

Curve A: Ice formation starts (ice slush)
Curve B: Temperature at which there is a risk of

damage by freezing

1. Safe area
2. Malfunctions may occur (ice slush)

Characteristics 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

Anti-freeze glycol, % by volume

2003-10:1

Checking protection against corrosion

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 Corrosion Inhibitor should be

used in the coolant.
The inhibitor in Scania Corrosion Inhibitor is free of nitrite.
The correct proportion of anti-corrosive is 7-12% by volume.

- Topping up with 1.0% Scania Corrosion Inhibitor 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 blended coolant:

water + 10% Scania Corrosion Inhibitor by volume.

Note:

The coolant should be changed when the cooling system is

cleaned:

every 4800 hours or at least every 5th year.

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 drain taps.

Fill up with coolant through the expansion tank's filler hole.
Mix coolant as described on page 33.

Use a container to avoid spillage

when changing the coolant.

Dispose of used coolant through

an authorised waste disposal

contractor.

If a coolant filter has been fitted

it must not contain inhibitor.

Mixing with glycol or the use of

too much corrosion inhibitor

can lead to build up of sludge

and reduced cooling capacity.

It is highly dangerous to

consume corrosion inhibitor.

Avoid contact with the skin.

2003-10:1

Charge air cooler (DI engine)

Drain the coolant from the engine, see "Changing the coolant".

Detach the intake manifold from the turbo.

Detach the charge air cooler inlet and outlet connections for the coolant.

Remove the upper intake manifold.

Take care not to damage the element's water connections.

Remove the bolts holding the element and remove the element.

Clean the outside of the element. Use a paraffin-based engine cleaner.

Fit a new gasket to the lower part of the intake manifold.

Screw the element into the lower part. Tighten the bolts to 26 Nm.

Fit new V-ring seals to the inlet and outlet connections of the element

and fit the upper part of the intake manifold. Tighten the bolts to 50 Nm.

10.

Refit the inlet and outlet connections with new O-rings.

11.

Refit the delivery pipe clamps.

12.

Connect the intake manifold from the turbo.

13.

Fill up with coolant according to the specification on page 33.

Intake

manifold,

upper part

V-ring seal

Element

Gasket

Intake

manifold,

lower part

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

exercising care.

The cooling system must never

be cleaned with caustic soda.

There is a risk of damage to

aluminium parts.

2003-10:1

Internal cleaning

Removing oil and grease

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

then drain the cooling system.

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

detergent designed 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 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.

Removing deposits

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

then drain the cooling system.

- Remove the thermostats.
- Fill the system with clean, hot water mixed with one of the

commercially available radiator cleaners 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 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.

Handling cleaning agents for

the cooling system:

Read the warning label on the

container.

Use a collecting vessel in order

to avoid spillages when

changing the coolant.

Dispose of used coolant through

an authorised waste disposal

contractor.

AIR CLEANER

8. Daily:

READING THE VACUUM INDICATOR

If the red indicator telltale is entirely visible, change or clean the air cleaner

filter element, point 10. This is particularly important if the engine is run at

high loads and high speed.

9. Every 200 hours:

CLEANING THE AIR CLEANER

COARSE CLEANER

Remove the cover from coarse cleaner 2.

Remove the conical coarse separator. Empty out the particles of dirt and

clean it.

Fit the coarse cleaner as shown in the figure and screw the cover in

place.

Filter element

Coarse cleaner

Cover

Vacuum indicator

Air cleaner with coarse cleaner

The coarse cleaner must always

be fitted in an upright position.

10. Every 1200 hours:
CLEANING OR CHANGING THE

FILTER ELEMENT

Note:

Earlier if the vacuum indicator shows red

Dismantling

Remove the side cover from the air cleaner.

Change or clean the element.

Note:

Cleaning the element always entails a risk of damaging it. The

element can only be cleaned a maximum of four times. 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.

Cover

Filter element

Filter housing

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 without

the air filter.

There is a risk of injury or

serious engine damage.

2003-10:1

Checking

- Insert a torch into the element and check from the outside that there are

no holes or cracks in the filter paper.

- Change the filter element if it has the slightest damage. Danger of

engine damage.

Assembly

Assemble the air cleaner in reverse order.

Reset the red plunger in the vacuum indicator by depressing the button.

11. Every 2400 hours:

CHANGING THE SAFETY CARTRIDGE

Note:

Not all filters are equipped with a safety cartridge. When

changing the safety cartridge, take great care to ensure that no

dirt or other impurities can get into the engine.

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

Air cleaner with safety cartridge

Do not remove the safety

cartridge unnecessarily.

Never clean the

safety cartridge

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, see point 13.

13. Every 1200 hours:
CHANGING 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.

- Fit the new filter and tighten it by hand.

Never use tools for this. 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 with the hand pump 2 until the fuel flowing out by the bleed

screw is free from air.

- Close the bleed screw. Pump a few more strokes with the hand pump.

If there are starting difficulties after bleeding . . . . .

- Unscrew the injection pump overflow valve 3 half a turn and make

another attempt at starting.

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.

Use a container to avoid spillage

when bleeding and changing

components.

Only use Scania genuine fuel

filter.

Observe the utmost cleanliness

when working on the fuel

system.

There is a risk of engine

malfunction and damage to the

injection equipment.

2003-10:1

14. Every 2400 hours:
CHECKING THE INJECTORS

Injectors should be inspected by trained personnel with access to the

necessary equipment. Inspection should be carried out at least once a year or

every 2400 hours.

Removal

Clean round the injectors and connections, including clamps and

brackets.

Detach the delivery pipe bundle and leak-off fuel lines.

Unscrew the injector.

Fit protective plugs on the injector and delivery pipe.

Lift up the sealing washer from the bottom of the injector seat if it does

not come out together with the injector.

Fit a core plug in the injector seat in the cylinder head.

Clean the injectors and check/adjust a nozzle tester.

Correct opening pressure, see Technical data, page 54.

Fitting

Check that there is no old sealing washer in place and fit a new sealing

washer in the bottom of the injector seat.

Fit a new O-ring in the threaded socket nut and a new sealing ring under

the socket nut.

Fit the injector.

Tighten the socket nut to 70 Nm (7.0 kpm).

Fit the delivery pipe and tighten the cap nuts to 20 Nm (2.0 kpm). Fit

clamps and brackets.
Take care to fit the delivery pipe without tension and make sure that

the cone on it is correctly positioned in the connection.

Fit the leak-off fuel line. Tighten the bolts to 11 Nm (1.1 kpm).

Threaded

socket nut

O-ring

Stop ring

Guide pin

Sealing washer

Delivery pipe

Cap nut

Washer

Cone

Connection on injector or

injection pump

The delivery pipes must not be

bent.

All clamps must be refitted.

Also wear protective goggles

when testing injectors.

A jet from the injector can

penetrate tissue and cause

serious injury.

ELECTRICAL SYSTEM

15. Every 200 hours:
CHECKING THE ELECTROLYTE

LEVEL IN BATTERIES

Unscrew the plugs and check the electrolyte level in all cells.

Top up with distilled water until the level is 10-15 mm above the plates.

16. Every 200 hours:
CHECKING THE STATE OF CHARGE IN

BATTERIES

Note:

Every 200 hours applies to generator sets and the like. Other

installations every 1200 hours.

- Check the density with an acid tester.

In a fully-charged battery it should be:

1.280 at +20°C

1.294 at 0°

1.308 at -20°C

- If the density is below 1.20, the battery must be charged. A discharged

battery freezes at -5°C.
Do not rapid-charge the battery. This will damage the battery in the

long run.

17. Every 200 hours:
CLEANING BATTERIES

Note:

Every 200 hours applies to generator sets and the like. Other

installations every 1200 hours.

Clean batteries, cables and cable terminals.

Check that all cable terminals are firmly tightened.

Grease battery terminal posts and cable terminals with vaseline.

Wear gloves and protective
goggles when charging and

handling batteries

The batteries contain a highly

corrosive acid.

Do not connect the terminals up

incorrectly.

This can cause serious damage

to the electrical system.

If the terminals are shorted,

sparking will occur.

Avoid naked flames or sparks

near the batteries.

When the batteries are

charged, oxyhydrogen gas is

formed which is inflammable

and explosive.

19. Every 1200 hours:
CHECKING THE TEMPERATURE

MONITOR

Drain the coolant, allowing the temperature monitor to be removed.

Remove the temperature monitor cable(s).

Unscrew the monitor.

Refit the cable(s) on the monitor.

Submerge the monitor sensor body in water. Heat the water slowly

(about 1° per minute) using an immersion heater, for example.

Set the control switch to "ON". Use a thermometer to check that the

warning lamp comes on or that an alarm is initiated at the correct

temperature.
The correct temperature is stamped on the hexagonal part of the

monitor.
The monitor tolerance is

± 3°.

CHECKING THE TEMPERATURE

SENSOR

Drain the coolant, allowing the temperature sensor to be removed.

Remove the temperature sensor cable(s).

Unscrew the sensor.

Connect an ohmmeter to the temperature sensor.

Submerge the sensor body in water. Heat the water slowly

(about 1° per minute) using an immersion heater, for example.

Check the resistance at the temperatures given below.

The sensor should give the following readings:

temp.

°C

Resistance

Ω

Tolerance

°C

134

± 13,5

±4

51,2

± 4,3

±3

100

38,5

± 3

±3

2-pin temperature sensor

C = Common connection
1 = Connection C -1 closes at the

stamped temperature

2 = Connection C -2 switches off

at the stamped temperature

2-pin temperature monitor

Use a container to avoid spillage

when draining the coolant.

Dispose of used coolant through

an authorised waste disposal

contractor.

2003-10:1

20. Every 1200 hours:
CHECKING THE OIL PRESSURE

SENSOR/MONITOR

Sensor function

Measure the output voltage from the sensor (pin 3) at different oil pressures.

The sensor should give the following readings:

0.85-1.15 bar = 2.45 volts

1.80-2.20 bar = 3.70 volts

2.75-3.25 bar = 4.50 volts

3.79-4.20 bar = 5.20 volts

4.55-5.45 bar = 5.70 volts

5.40-6.6 bar

= 6.10 volts

The tolerance values apply at +30°C - 110°C. The tolerance range increases

at lower temperatures, e.g. 0°C = x 1.4.

Monitor function

Connect a test lamp to oil pressure monitor pin 4 (

earth) and check that the

monitor closes at the correct pressure when the engine is started and stopped.

The monitor should close at 0.7

± 0.15 bar when the engine is stopped.

Important

The sensor/monitor must be supplied with voltage when

measuring. Max. load 4 W from test lamp.

CHECKING THE OIL PRESSURE

MONITOR FOR DEC 2

Connect an ohmmeter or test lamp to the oil pressure monitor and check that

the monitor opens/closes at the correct pressure when the engine is started

and stopped. 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.

CHANGING THE BATTERY

Removal

Disconnect the negative cable (-) from the battery (cable connected to

earth).

Disconnect the positive cable (+) from the battery (cable connected to

starter motor).

Fitting

Connect the positive cable (+) to the battery (cable connected to starter

motor).

Connect the negative cable (-) to the battery (cable connected to earth).

MISCELLANEOUS

21. Every 1200 hours:
CHECKING THE DRIVE BELT

If the drive belt (1), which is a poly-V belt, is worn or damaged it must be

changed.
Also check that the automatic belt tensioner (2) is in proper working order

and keeps the drive belt correctly tensioned.

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.

Do not connect the terminals

up incorrectly.

This can cause serious damage

to the electrical system.

If the terminals are shorted,

sparking will occur.

Dispose of used batteries

through an authorised waste

disposal contractor.

23. Every 2400 hours:
CHECKING/ADJUSTING

VALVE CLEARANCES

Note:

Checking/adjusting valve clearances should also be done after the

first 400 hours of operation.

Valve clearances should be adjusted when the engine is cold, at least 30

minutes after running.
The rocker cover gaskets should be changed as necessary. Tightening torque:

26 Nm.
Intake valve clearance: 0.45 mm.

Exhaust valve clearance: 0.80 mm.

Alternative 1

- Set No. 1 cylinder to TDC by turning the engine in its direction of

rotation until all four valves are closed.

- Adjust the following valves. Correct valve clearances are also given on

the instruction plate on one of the rocker covers:

- Set No. 6 cylinder to TDC by turning the engine one revolution in its

direction of rotation and adjust the following valves:

Cylinder

Intake and outlet

Intake

Outlet

Intake

Outlet

Cylinder

Outlet

Intake

Outlet

Intake

Intake and outlet

TDC

no. 6 cylinder

TDC

no. 1 cylinder

Intake valve

Exhaust valve

Cylinder numbering

FLYWHEEL

WARNING

Immobilise the starting device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK

OF INJURY.

Scania DI9, DC9 with DEC2. Industrial engine. Operator’s manual - part 3