Scania D9, DI9. Marine engine. Operator’s manual

2001-05:1

Clutch

- See the manufacturer’s instructions for handling and operating the

clutch.

WARNING

If the clutch output shaft is rotating (e.g. in multiple

engine installations where other engines are running), the clutch
can, under its own power, be drawn to the engaged position.
THIS CAN CAUSE PERSONAL INJURY and engine damage.
For this reason, always secure the clutch in the disengaged posi-
tion if there is a risk of the output shaft starting to rotate.

CHECKS AFTER RUNNING

- Check that the power is cut from the battery master switch and that the

control switch is in the "0" position.

- Fill the fuel tank. Make sure that the filler cap and the area round the

filler opening are clean to avoid contamination of the fuel.

- If there is a risk of freezing, the cooling system must be drained if it

does not contain a sufficient amount of glycol, refer to page 26.

- Close inlet valve for the sea water system (if fitted).

- If there is danger of freezing, the sea water system must be emptied.

- At temperatures below 0 °C: Prepare for the next start by connecting the

engine heater (if fitted).

Top up engine coolant when the

engine has been stopped after

being started for the first time.

Immobilise the starting device

when working on the engine.

If the engine starts out of

control, there is a

SERIOUS RISK

OF INJURY.

MAINTENANCE

The maintenance programme covers 27 points, divided into the following
main groups:

Lubrication oil system  . . . . . . . . . . . . . . . . . page 20
Cooling system . . . . . . . . . . . . . . . . . . . . . . . page 24
Air cleaner  . . . . . . . . . . . . . . . . . . . . . . . . . . page 32
Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . page 35
Electrical system, monitors, batteries etc.  . . page 37
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . page 42

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

Periodic maintenance after every 1,200 hours of operation (carried out after
1,200, 2,400, 3,600 etc. hours)

Periodic maintenance after every 2,400 hours of operation (carried out after
2,400, 4,800 etc. hours)

Periodic maintenance after every 4,800 hours of operation (carried out after
4,800, 9,600 etc. hours)

Annual Maintenance

Maintenance every 5th year

ENGINES WITH FEW HOURS
OF OPERATION

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

1. Checking oil level.

5. Checking coolant level.

10. Checking low pressure indicator.

14. Checking fuel level.

17. Checking electrolyte level in batteries.

18. Checking state of charge in batteries.

19. Cleaning batteries.

25. Look 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

2001-05:1

MAINTENANCE SCHEDULE

More often if required.

For engines with few operating hours, see page 18.

Earlier if low pressure indicator shows red.

Applies only to M engines with sea water pump.

Reference value

. Varies depending on the composition of the sea water.

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

Dail

First

time at

Interval At

least

t fi

t s

400 h

200 h

400 h

1200

2400

4800

Annual

Ever

y 5t

h ye

LUBRICATION OIL SYSTEM, page 20

1. Checking oil level

2. Oil change

3. Cleaning the lubrication oil cleaner

4. Changing the turbo filter

COOLING SYSTEM, page 24

5. Checking coolant level

6. Checking corrosion protection rods 4)

7. Checking seawater pump impeller 4)

8. Checking coolant

9. Cleaning cooling system

AIR CLEANER, page 32

10. Test reading low pressure indicator

11. Cleaning coarse cleaner

12. Cleaning or changing filter insert

13. Changing safety cartridge

FUEL SYSTEM, page 35

14. Checking fuel level

15. Changing main filter

16. Checking injectors

ELECTRICAL SYSTEM, page 37

17. Checking electrolyte level in batteries

18. Checking charge state of batteries

19. Cleaning batteries

20. Checking level monitor

21. Checking temperature monitor

22. Checking oil pressure monitor

23. Checking stop function

MISCELLANEOUS, page 42

24. Checking transmission belt

25. Look for leaks. Remedy as necessary

26. Checking/adjusting valve clearance.

27. Changing (or cleaning) valve for closed crankcase

ventilation

LUBRICATION 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 0 10 20 30 40

°C

SAE 10W-30

SAE 20W-30

SAE 30

SAE 40

SAE 5W-30

SAE 15W-40

SAE 50

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.

- Pump out the oil with the oil bilge pump when the engine is warm.

- Fill up with new oil.

- Check the level on the dipstick.

Max 25 dm

Min 20 dm

Max 20 dm

Min 16 dm

1 dm

= 1 litre

Maximum angles of inclination during operation

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

Note

Specified angle 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.

4. Every 400 hours:

CHANGING THE TURBO FILTER

(at the 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, obstruc-
ting circulation.

- Start the engine and check for leaks.

Important

If the deposits in the centrifugal cleaner exceed 20 mm the oil
filter must be changed at more frequent intervals, at the same
time as the centrifugal filter is cleaned and the oil changed.

COOLING SYSTEM

5. Daily:

CHECKING COOLANT LEVEL

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

- Correct level: (integrated expansion tank in heat exchanger)

- Cold engine: Coolant level should reach the lowest part of the

filler pipe.

- Warm engine: Coolant level should be between 10-20 mm above the

lowest part of the filler pipe.

- Other types of expansion tank according to the installer’s instructions.

- 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 400 hours:

CHECKING CORROSION BARS

(Only engines with heat exchanger)

- Empty the sea water circuit and check the corrosion bars (protection

anodes). Located as illustrated.

- Scrape off all loose material on the anode.

- Change if less than half the bar is left.

A new bar is 55 mm long with a diameter of 17 mm

Important

If the corrosion bars are very corroded they need to be
checked more often, for example every 200 hours.

7. Every 400 hours:

CHECKING THE SEAWATER PUMP
IMPELLER

(Only engines with heat exchanger)

- Close the bottom valve if the seawater pump is below the water line.

- Empty the sea water circuit.

- Take off the seawater pump cap.

- Check that the impeller vanes are not worn or damaged.

Important

If the impeller must be changed frequently, the cleaning of
the sea water must be improved.

Changing the impeller

- Pull out the impeller with puller 98 482 (Scania Special Tools).

- Fit new impeller and cap. Check that the cap seal is not hard or dam-

aged.

Note

A spare impeller should be kept on board.

- The impeller can be deformed at longer periods of inactivity. Change

before or remove the impeller before longer periods of stoppage. Also
see "Preparations of storage".

8. 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 Scania Anti-corrosive:
Check the

anti-corrosive content.

The composition of the coolant is also described under
“Starting and running”

Checking the appearance of the coolant

- Fill a

receptacle 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.

- 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 sup-
plier 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 fracture 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
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 Anti-corrosive

Ethylene glycol is highly

dangerous if ingested and can

prove fatal.

Avoid skin contact with glycol.

The coolant should be ready

mixed when it is poured into the

cooling system.

Never top up with only water or

only 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.

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)

100

110

120

130

140

150

160

102

170

108

180

114

190

100 120

200

% Glycol by volume

Curve A: Ice formation starts (slush)
Curve B: Temperature at which damage due to

freezing can occur

Safe range

2. Malfunctions may occur (ice slush)
3. Risk of damage by freezing

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

Checking protection against corrosion

There must always be sufficient anti-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.

The inhibitor in Scania Anti-corrosive is

nitrite-free.

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
cleaned: 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 as illustrated

- the ”lowest point” of the engine block, see drawing.

- the ”lowest point” of the cooling system.

Close the valves.

Top up with coolant through the expansion tank filler hole

Mix coolant as described on page 26.

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

Every 4800 hours:

CLEANING THE COOLING SYSTEM

Note

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

External cleaning

Heat exchanger

Drain the coolant from the engine, see “Changing coolant”.

Drain the seawater circuit.

Detach the heat exchanger hose and pipe connections.

Dismantle the heat exchanger as illustrated. DI9: Start by removing the
charge air cooler.

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

Any deposit on the inside of the pipes is removed mechanically using a
round rod.

Change the O-rings and assemble the heat exchanger.
DI9: See “Charge air cooler”.

Refit hose and pipe connections.

Fill the system with coolant as described on page 26.

Cover

O-ring

Flange

Heat exchanger

Heat exchanger
element

Cover

The cooling system must never

be cleaned with caustic soda.

There is a risk of damage to

aluminium parts.

Charge air cooler (DI engine)

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

Drain the seawater circuit.

Detach the connections to the turbo and the intake manifold.

Detach the water connection from the charge air cooler’s outlet.

Remove the complete charge air cooler and dismantle it as illustrated.

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

Any deposit on the inside of the pipes is removed mechanically using a
round file.

Change the O-rings and assemble the charge air cooler.

Refit the charge air cooler to the heat exchanger.

10.

Refit the hose connections to the turbo and intake manifold and the con-
nection to the charge air cooler cover.

11.

Fill the system with coolant
as described on page 26.

12.

Connect the intake manifold from the
turbo.

Spacer

O-ring

Flange

Charge air cooler hous-
ing

Charge air element

Cover

Heat exchanger

Engines without heat exchanger (keel-cooling)

Check cooling elements/cooling pipes on the inside and outside of the
keel.

If necessary, clean with paraffin-based engine cleaner, or carefully
scrape off deposits on external pipes.

Take care not to damage the cooling element or cooling pipe

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 oils and greases

- If possible, run the engine until it has reached the 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 it has reached operating temperature 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 coolant according to the specification on

page 26.

Removing deposits

- If possible, run the engine until it has reached the 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 coolant according to the specification on

page 26.

Always collect fluid in a suitable
container to avoid spillage when

draining coolant.

Dispose of used coolant through

an authorized waste disposal

contractor.

Handling cleaning agents for

the cooling system:

Read the warning label on the

container.

AIR CLEANER

10. Daily:

READING THE
LOW PRESSURE INDICATOR

If the indicator’s red plunger is fully visible, change or clean the air cleaner
filter element, point 12.

11. 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

12. Every 1200 hours:

CLEANING OR CHANGING THE
FILTER ELEMENT

Note

Earlier if the

vacuum indicator shows red.

Disassembly

Remove and clean the coarse cleaner, see point 11.

Undo the nut securing the filter element and remove it.

Change or clean the element.

Note

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

Pre-filter with cover

Filter insert

Low pressure indicator

Safety cartridge

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.

The coarse cleaner should be

fitted with the marking ”TOP”

facing up.

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