Scania DI9 55 - DI9 59. Marine engine. Operator’s manual - part 1
Industrial & Marine Engines
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
DI9 55 - DI9 59
Marine engine
opm99-9m en
1 588 713
2001-05:1
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
DI9 55 and DI9 59 marine engines. The instructions apply to these engine
types in program 99, starting with engine number 5 134 340.
The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder in
line diesel type. They are supercharged and equipped with a charge air cooler
which is coolant-cooled. See also page 10.
These engines have a cooling system with a heat exchanger, which is cooled
by sea water, in which the engine coolant is cooled.
These engine types have electronic control of the injection system’s governor
to optimize engine performance and such important operating factors as fuel
consumption and exhaust emissions.
The electronic control system is called DEC2 (Digital Electronic Control)
and is described in greater detail on page 12.
A common application is as the propulsion unit in patrol boats (DI9 55) and
in larger pleasure craft (DI9 59).
The engines have different output and speed settings and can be classified in
different classification socities (classed engines must be used in certain
marine installations).
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
During the warranty period,
works.
only use genuine Scania parts in
service and repair for the
- Whenever necessary, always contact an authorised Scania workshop.
They have special tools, genuine Scania parts and trained staff with
warranty to be valid.
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
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2001-05:1
CONTENTS
FOREWORD
2
AIR CLEANER
38
READING THE VACUUM INDICATOR
38
CONTENTS
3
CLEANING THE AIR CLEANER
ENVIRONMENTAL RESPONSIBILITY
4
COARSE CLEANER
38
CERTIFIED ENGINES
5
CLEANING OR CHANGING THE
SAFETY DETAILS
6
FILTER ELEMENT
38
Safety precautions for operation
7
CHANGING SAFETY CARTRIDGE
40
Safety precautions for handling materials
8
FUEL SYSTEM
41
Safety precautions for care and maintenance . .8
CHECKING FUEL LEVEL
41
TYPE DESIGNATIONS
10
CHANGING THE FUEL FILTER
41
CHECKING INJECTORS
42
DEC2 CONTROL SYSTEM
12
ELECTRICAL SYSTEM
43
STARTING AND RUNNING
18
CHECKING THE
AT FIRST START
18
ELECTROLYTE LEVEL IN BATTERIES
43
CHECKS BEFORE RUNNING
19
CHECKING THE STATE OF CHARGE
STARTING THE ENGINE
19
IN BATTERIES
43
At temperatures below 0 °C:
20
CLEANING BATTERIES
43
RUNNING
21
CHECKING THE COOLANT LEVEL
MONITOR
44
Engine speed
21
CHECKING THE
Coolant temperature
21
TEMPERATURE MONITOR
45
Oil pressure
22
CHECKING THE TEMPERATURE SENSOR .45
STOPPING THE ENGINE
22
CHECKING THE OIL PRESSURE SEN-
Clutch
23
SOR/MONITOR
46
CHECKS AFTER RUNNING
23
CHECKING THE OIL PRESSURE MONITOR
FOR DEC 2
46
MAINTENANCE
24
CHANGING THE BATTERY
47
ENGINES WITH FEW HOURS
OF OPERATION
24
MISCELLANEOUS
47
MAINTENANCE SCHEDULE
25
CHECKING THE DRIVE BELT
47
LUBRICATING OIL SYSTEM
26
CHECKING FOR LEAKAGE, RECTIFY
AS NECESSARY
48
OIL GRADE
26
CHECKING/ADJUSTING VALVE
Oil analysis
26
CLEARANCE
49
CHECKING THE OIL LEVEL
27
CHANGING (OR CLEANING) THE CLOSED
OIL CHANGE
27
CRANKCASE VENTILATION VALVE
50
Maximum angles of inclination during
operation
27
LONG-TERM STORAGE
51
CLEANING THE OIL CLEANER
28
Preservative fuel
51
CHANGING THE OIL FILTER
30
Preservative oil
52
Preparations for storage
52
COOLING SYSTEM
30
Batteries
53
CHECKING COOLANT LEVEL
30
Storage
53
CHECKING CORROSION BARS
31
Taking out of storage
53
CHECKING THE SEA WATER PUMP
IMPELLER
31
TECHNICAL DATA
54
CHECKING THE COOLANT
32
FUEL
56
Changing the coolant
34
ALPHABETIC INDEX
58
CLEANING THE COOLING SYSTEM
35
Internal cleaning
37
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3
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.
Always use suitable containers
to avoid spillage when bleeding
Refer to example
systems or renewing
components.
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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
5
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
Only use Scania genuine fuel
for the proper operation of the engine and to avoid damage to the engine.
filter.
Failure to follow these instructions may void the warranty.
Refer to example.
Corresponding texts may also appear in the text column, headed Caution! or
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
Immobilise the starting device
of serious defects to the engine or improper handling that may lead to
when working on the engine.
personal injury.
If the engine starts out of
control, there is a
Refer to example
SERIOUS RISK
OF INJURY.
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.)
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2001-05:1
Safety precautions for operation
Daily inspection
Starter lock
Always perform visual inspection of the engine
If the control panel is not fitted with a key
and engine bay before the engine is started and
switch, the engine bay should be fitted with a
when the engine has been stopped after oper-
lock to prevent unauthorized starting of the en-
ation.
gine.
This will make it easy to detect any leakage of
Alternatively, a lockable main switch or battery
fuel, oil or coolant or any other abnormal condi-
master switch may be used.
tion that may require remedial action.
Starting spray
Refuelling
Never use starting spray or similar as a starting
When refuelling, there is a risk of fire and explo-
aid. An explosion may occur in the intake pipe,
sion. The engine must be stopped and smoking
which could cause personal injury.
is not allowed.
Do not overfill the tank, since the fuel may ex-
Operation
pand, and close the fuel filler cap properly.
The engine should not be operated in environ-
Only use fuel recommended in the service
ments with surrounding explosive materials
literature. Fuel of an incorrect grade may cause
since electrical or mechanical components of
malfunctions or stoppage by interfering with the
the engine may emit sparks.
operation of the fuel injection pump and the in-
jectors.
It is always a safety hazard to be near an en-
gine that is running. Body parts or clothing, or a
This could cause engine damage and possibly
dropped tool may get stuck in rotating parts,
personal injury.
such as the fan, causing bodily injury.
Always cover rotating parts and hot surfaces as
Harmful gases
much as possible to ensure personal safety.
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.
2001-05:1
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Safety precautions for handling
Safety precautions for care and
materials
maintenance
Fuel and lubrication oil
Stop the engine
All fuels and lubricants as well as many chemi-
Always stop the engine before any mainte-
cals are flammable. Always follow the instruc-
nance and service work unless otherwise
tions stated on the container.
stated.
All work on the fuel system must be performed
Prevent unauthorized starting by removing the
when the engine is cold. Fuel leakage and spill-
starter key and turning off the power by the
age on hot surfaces may cause fire.
main switch or the battery disconnect switch,
locking it in the off position. Also attach a warn-
Store drenched rags and other flammable ma-
ing tag, stating that work on the engine is in
terials in a safe way to avoid spontaneous com-
progress, at a suitable location.
bustion.
It is always a safety hazard to work on an en-
gine that is running. Parts of your body or cloth-
Batteries
ing, or a dropped tool may get stuck in rotating
parts, causing bodily injury.
Batteries, particularly when being recharged,
emit highly flammable fumes that can explode.
Do not smoke or let open flame or sparks come
Hot surfaces and fluids
near the batteries or the battery compartment.
A hot engine always presents a risk of scalding.
Incorrect connection of a battery cable or jump
Always take care not to touch the exhaust
start cable may cause a spark, which in tun may
manifold, turbocharger, oil pan, hot coolant and
cause the battery to explode.
oil in pipes and hoses.
Chemicals
Lifting the engine
Most chemicals, such as glycol, corrosion in-
Use the engine lifting eyes when lifting the
hibitors, preservation oils, degreasers etc. are
engine. First check that the lifting equipment is
hazardous. Always follow the safety precau-
in proper condition and has sufficient lift capac-
tions stated on the container.
ity rating.
Some chemicals, e.g. preservative oil, are
Auxiliary equipment fitted to the engine may
flammable.
cause the centre of gravity to be displaced.
Always store chemicals and other hazardous
Thus, additional lift devices may be required in
materials in approved and distinctly marked
order to provide proper balance and a safe lift.
containers and out of reach of unauthorized
Never work below a suspended engine!
persons. Always dispose of superfluous or
used chemicals through an authorized waste
disposal contractor.
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.
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2001-05:1
Electrical system
Cooling system
Before work is performed on the electrical sys-
Never open the coolant filler cap while the en-
tem, turn off the power by the main switch or the
gine is hot. Steam and hot coolant can come
battery disconnect switch.
out forcefully and cause scalding.
Also disconnect any external power supply to
If the cooling system must still opened or disas-
auxiliary equipment on the engine.
sembled while the engine is hot, open the filler
cap very cautiously and slowly to release the
pressure before the cap is removed. Use
Arc Welding
gloves since the coolant is still very hot.
Before welding near or on the engine, remove
Dispose of used coolant through an authorized
the battery and alternator cables. Also remove
waste disposal contractor.
the control unit connector.
Connect the weld clamp to the component to be
Fuel system
welded, close to the weld location. Never con-
nect it to the engine or in such a way that the
Always use gloves when checking for leaks in
current can pass through a bearing.
or performing other work on the fuel system. Al-
ways wear eye protection when testing injec-
After the welding is completed, connect the ca-
tors.
bles to the alternator and the control unit before
connecting the batteries.
Fuel escaping under high pressure can pene-
trate body tissue and cause serious injury.
Never use non-genuine parts in the fuel system
Lubrication system
and the electrical system. Genuine parts are
Hot oil may cause scalding and skin irritation.
designed and manufactured to minimize fire
Avoid skin contact with hot oil.
and explosion hazard.
Make sure that the pressure in the lubrication
system is relieved before work is carried out.
Before starting
Never start or operate the engine with the oil fill-
er cap removed since oil will be ejected force-
Install any guards that have been removed be-
fully.
fore the engine is started. Check to ensure that
no tools or other objects have been left on the
Dispose of used oil through an authorized
engine.
waste disposal contractor.
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.
2001-05:1
9
TYPE DESIGNATIONS
The engine designation indicates, in the form of a code, the type of engine, its
size and intended use, etc.
The type designation and engine serial number are indicated on a type plate
affixed to the right-hand side of the engine. The engine number is also stam-
ped on the top of the engine block beside 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. The plate is fitted
to rocker cover number two as viewed from the front.
DI
9 59 M 31 E LR
Version
DI Turbocharged diesel engine with liquid-cooled charge air cooler
Displacement in whole dm3
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
M For marine use
Variant code for equipment options 01-99
Governor type
E
Electronically controlled governor (DEC2)
Classification society (applies to classed engines)
ABS American Bureau of Shipping
BV Bureau Veritas
GL Germanischer Lloyd
LR Lloyd’s Register of Shipping
DNV Dwt Norske Veritas
RINA Registro Italiano Navale
SjöV Sjöfartsverket
10
2001-05:1
15
16
18
8
17
3
6
5
19
7
1
2
9
13
14
10
4
11
7
12
The drawings illustrate a common type of DI9 engine.
Your engine may have other equipment not shown here.
1. Type plate
7. Draining, engine oil
14. Draining, coolant
2. Engine number,
8. Coolant pump
15. Oil filling
stamped in engine block
9. Turbo charger
16. Sea water pump
3. Oil cooler
10. Injection pump
17. Heat exchanger
4. Oil dipstick
11. Fuel filter
18. Charge air cooler
5. Oil cleaner
12. Starter motor
19. Turbo filter
6. Protective anode
13. Alternator
2001-05:1
11
DEC2 CONTROL SYSTEM
This engine has an injection pump with an electromagnetic actuator which
adjusts the control rack to give the correct amount of fuel.
The system which controls the actuator/pump is called DEC2 (Digital Engine
Control, generation 2).
The control unit (DEC2) continuously receives signals from sensors for
engine speed, charge air temperature and pressure, coolant temperature, oil
pressure, throttle pedal position and control rod travel in the injection pump.
Using this input data and a control program, the correct amount of fuel for the
current operating conditions can be calculated.
The system’s sensors may be used only for DEC2, not for other instruments
or other monitoring purposes.
The control unit contains monitoring functions to protect the engine in the
event of a fault which would otherwise damage it. Faults and the more
important monitoring functions are indicated on the control unit in the form
of light emitting diodes. See illustration on page 13 for a description.
In case of a fault, the Power - or Shutdown indicator on the DEC2 control
unit as well as the main indicator lamp on the main supply box and the
instrument panel will illuminate.
If a fault has been indicated on the main indicator lamp the operator can
determine the cause of the fault with the help of the LEDs on the control unit
and the troubleshooting schedule on page 17, and carry out the required
investigation and remedy.
Depending on the nature of the fault, the control system will take different
actions to protect the engine such as reducing the power output, keeping the
engine running at a constant low speed or, in case of a function impairing
fault, shutting down the engine (Shutdown).
To enable readout of LED fault codes there is a lamp test/fault code switch
located in the main supply box near the control unit.
A PC based program is also available to help service personnel to detect and
rectify faults and to adjust certain parameters in the operating program.
Diagnostics and changes to programs must only be performed by
authorized personnel.
The locations of the sensors and monitors which send signals to the control
unit will be evident from the illustrations on page 13.
There is a description of the functions of the LEDs during normal operation
on page 14.
On page 15 there is a description of the functions of the LEDs in case of a
fault and actions in case of Power- and Shutdown indication.
Troubleshooting and fault code reading are described on pages 16 and 17.
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2001-05:1
Location of sensors for DEC2 on DI9
2
6
3
1
5
4
1. Charge air temperature sensor
2. Connection of lead to charge air
temperature sensor
3. Coolant temperature sensor
4. Engine speed sensor
5. Oil pressure sensor
6. Junction box
2001-05:1
13
LED functions during normal operation
Note The lamp test/fault code switch should not
POWER-
be depressed. All LEDs come on briefly
❍ The LED remains out during normal operation
when the control unit is powered up.
as long as no fault is detected by the control
unit. See next page for the procedure to be adop-
CONTROL STATUS
ted in the event of a fault.
✹ The LED flashes continuously when the control
unit is supplied with current, regardless of
POWER+
whether the engine is running or not.
✹ If the control unit is programmed to allow the
engine to be operated according to more than
SHUTDOWN
one power/torque curve (map), the following
❍ The LED is out.
applies.
The LED comes on when the engine is run at
STARTING
more than 100% power output (MAP 2). It goes
✹ The LED lights up as soon as the engine starts to
out when the engine returns to the 100% power
rotate during an attempt to start it and follows
output curve (MAP 1) or when the power output
the programmed starting sequence until it has
required is less than 100%.
been completed and then goes out.
RUNNING
✹ The LED comes on when the engine has started
and the "Starting"-LED goes out. It remains on
until the engine is stopped.
TORQUE LIMIT
✹ The LED comes on when the control unit
detects that the engine has received the maxi-
mum permissible quantity of injected fuel accor-
ding to its power curve. This means 100%
power output at the current rpm. If the load
increases, engine rpm will decrease.
BOOST LIMIT
✹ The LED comes on when the control unit smoke
limiter restricts the maximum fuel quantity.
Operation of the smoke limiter is dependent on
the charge air pressure.
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2001-05:1
Action in case of a fault
LED indications in case of a fault
Note The main indicator lamp in the main supply
box and at the instrument panel has
indicated a fault. The lamp test/fault code
switch should not be depressed.
CONTROL STATUS
✹ The LED will continue to flash even in case of a
fault as long as voltage is supplied to the control
unit.
POWER -
✹ If the LED comes on, the control unit has
detected a defect that could cause damage to the
engine if operation continues.
The control unit automatically reduces engine
power output to a predefined level if the
corresponding function has been selected.
Action: Reduce engine speed to idle if possible
and conduct troubleshooting according to
instructions on page 16 and the chart on page 17
SHUTDOWN
✹ The LED comes on and the engine is switched
off automatically in case of a severe fault that
could cause damage to the engine if operation
continues.
Action: Conduct troubleshooting according to
instructions on page 16 and the chart on page 17
If the engine has not stopped, reduce engine
speed to idle and conduct troubleshooting.
2001-05:1
15