Scania DC09 XPI. Industrial engine en-GB 2 824 008. Operator’s manual - part 3
Starting and running
Coolant temperature
IMPORTANT!
An excessive coolant temperature can cause en-
gine damage.
Normal coolant temperature during operation is
90 to 95°C (194 to 203°F).
The alarm levels are set in the engine control
unit. The default setting for the lowest and high-
est limit values for high coolant temperature are
95°C/203°F and 105°C/221°F respectively. The
following function is standard as alarm for high
coolant temperature:
• Alarm and torque reduction at the lowest lim-
it value.
Depending on the engine configuration, the fol-
lowing alarm functions may also be available:
• Alarm only.
• Alarm and engine shutdown at the highest
limit value.
• Alarm, torque reduction at the lowest limit
value and engine shutdown at the highest lim-
it value.
• Alarm and engine shutdown at the highest
limit value with the possibility of engine shut-
down override control.
• Alarm, torque reduction at the lowest limit
value and engine shutdown at the highest lim-
it value, with the possibility of engine shut-
down override control.
If run for extended periods under an extremely
light load, the engine may have difficulty in
maintaining the coolant temperature. At an in-
creased load the coolant temperature rises to the
normal value.
32
Starting and running
Oil pressure
Normal oil pressure during operation is 3-6 bar
(43.5-87 psi). The lowest permitted oil pressure
when idling is 0.7 bar (10.2 psi).
The engine management system issues an alarm
at the following levels:
• At an engine speed below 1,000 rpm and an
oil pressure below 0.7 bar (10.2 psi).
• At an engine speed above 1,000 rpm and an
oil pressure below 2.5 bar (36.3 psi) for
longer than 3 seconds.
The following function is standard as alarm for
incorrect oil pressure:
• Alarm and torque reduction by 30%.
Depending on the engine configuration, the fol-
lowing alarm functions may also be available:
• Alarm only.
• Alarm and engine shutdown.
• Alarm and engine shutdown override control.
Note:
High oil pressure (above 6 bar/87 psi) is normal
if the engine is cold when started.
Charging indicator lamp
If the lamp comes on during operation: Check
and adjust the alternator drive belt according to
the instructions in the section Checking the drive
belt.
If the charging indicator lamp is still on, this
could be due to an alternator fault or a fault in the
electrical system.
33
Starting and running
Belt transmission
When the belt transmission is new, it may make
a squeaking noise when running. This noise is
normal and disappears after 50-100 hours of op-
eration. The noise does not affect the service life
of the belt transmission.
Raised idling rotational speed for en-
gines with SCR system
If the engine is run without load for an extended
period of time, the SCR system needs to be heat-
ed by raising the idling speed. The function is
called periodic hydrocarbon evaporation and is
used to avoid damaging the SCR catalytic con-
verter.
Periodic hydrocarbon evaporation functions dif-
ferently depending on how the engine is
equipped. A warning is output for all engines if
the engine needs to be warmed up. The warning
is output after approx. eight hours if the engine is
idling without load and the outdoor temperature
is 20°C (68°F). The time is reduced as the out-
door temperature becomes colder.
For some engines, a request for automatic raising
of the idling speed is also output after the warn-
ing. If the request is confirmed, the idling speed
is raised automatically. The function is active for
45 minutes or less and is deactivated automati-
cally. If the request is not confirmed, the engine
is switched off after approx. 45 minutes, if the
engine has been configured with engine shut-
down.
Note:
During hydrocarbon evaporation, the engine
speed can rise to 1,500 rpm for all-speed engines.
For engines configured as single-speed, all hy-
drocarbon evaporation occurs at the selected ro-
tational speed.
34
Starting and running
Engine shutdown
IMPORTANT!
There is risk of post boiling and of damage to the
turbocharger if the engine is switched off with-
out cooling. The power must not be switched off
before the engine has stopped.
If the engine is equipped with a battery master
switch and an SCR system, the SCR system must
run for a while after the engine has been switched
off to allow it to cool down. During this period
the power must not be cut using the battery mas-
ter switch.
Note:
The battery voltage must remain on for a few
seconds after the 15 voltage is switched off so
that the control units can store the values and
switch to standby mode.
10 prohibited engine shutdowns will cause a
torque reduction (70% of fuel volume). Reset the
engine by switching it off correctly once.
1. Run the engine without a load for a few min-
utes if it has been run continuously with a
heavy load.
2. Switch off the engine.
35
Starting and running
Checks after running
Transporting engines
WARNING!
IMPORTANT!
Block the starting device when working on the
When transporting engines or machines, the ex-
engine. If the engine starts unexpectedly, there is
haust outlet must be protected from water and
a serious risk of injury.
debris. The exhaust gas aftertreatment may be
damaged if there is water or debris intrusion.
There is always a risk of sustaining burns when
an engine is hot. Particularly hot parts are engine
Ensure that the transport protection is in place
manifolds, turbochargers, oil sumps, as well as
and remains there throughout the transport.
hot coolant and oil in pipes and hoses.
IMPORTANT!
Check the coolant level following the first start.
Top up with coolant as necessary.
1. Check that the power supply has been cut.
2. Top up the fuel tank. Make sure that the filler
cap and the area round the filler opening are
clean to avoid contamination of the fuel.
3. If the engine is equipped with an SCR sys-
tem: Top up the reductant tank. Make sure
that the filler cap and the area round the filler
opening are clean to avoid contamination of
the reductant.
4. If there is a risk of freezing, the cooling sys-
tem must contain enough glycol. See the sec-
tion Risk of freezing.
5. If the temperature is below 0°C (32°F): Pre-
pare for the next start by connecting the en-
gine heater (if fitted).
36
Maintenance
Maintenance
IMPORTANT!
The maintenance programme covers a number of
points that are divided into the following sec-
On delivery a Scania engine is optimised for its
tions:
application. However, regular maintenance is
necessary to:
• Lubrication system
•
prevent unplanned stops
• Air cleaner
•
extend the service life of the engine
• Cooling system
•
maximise the long-term emission perfor-
• Fuel system
mance of the engine
• Other
•
give the best possible operating economy.
WARNING!
Block the starting device when working on the
engine. If the engine starts unexpectedly, there is
a serious risk of injury.
There is always a risk of sustaining burns when
an engine is hot. Particularly hot parts are engine
manifolds, turbochargers, oil sumps, as well as
hot coolant and oil in pipes and hoses.
The maintenance programme includes the fol-
lowing:
• R maintenance: One event when taken into
service.
• S maintenance: Minimum basic maintenance.
• M maintenance: More extensive mainte-
nance.
• L maintenance: Includes nearly all mainte-
nance items in the form.
• XL maintenance: Includes all maintenance
items in the form.
During a period, the sequence is S-M-S-L-S-M-
S-L-S-M-S-XL.
XL
L
L
M
M
M
S
S
S
S
S
S
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
37
Maintenance
Cleaning the engine
Engines with few hours of op-
eration
WARNING!
IMPORTANT!
Beware of hot washing water. Wear eye protec-
tion, protective clothes and protective gloves.
On engines with few hours of operation, mainte-
nance must be carried out annually or every 5
years.
Environment
Stand-by generator sets and the like that are not
Dispose of the washing water in compliance with
used regularly should be test run and checked in
relevant national or local regulations.
accordance with the manufacturer's instructions.
The following maintenance items must be car-
Engines and engine compartments are cleaned
ried out once the engine has been warmed up to
with hot water. Be careful when using high pres-
operating temperature.
sure hose systems. Avoid spraying electrical
1. Checking oil level.
components such as the starter motor, alternator,
etc.
2. Checking coolant level.
3. Checking vacuum indicator.
4. Checking fuel level.
5. Check for engine leaks.
38
Maintenance
Maintenance interval
Daily
First time at
Interval (hours)
Minimum
first start
500
500
1,000
2,000
6,000
annu-
every
ally
5
S
M
L
XL
R
years
Lubrication system
Checking the oil level
X
X
X
X
X
X
X
X
Oil change1
Renewing/cleaning rotor in cen-
X2
X3
X
X
trifugal oil cleaner
Renewing the oil filter
X
X
X
X
X
X
Air cleaner
Reading the vacuum indicator
X
X
X
X
X
X
Renewing the filter element
X
X
X
Renewing the safety cartridge
X
X
X
Cooling system
Checking coolant level
X
X
X
X
X
X
X
Checking the coolant's anti-
X
X
X
X
freeze and corrosion protection
Changing the coolant and clean-
X
X
ing the cooling system
Fuel system
Checking the fuel level
X
X
Renewing the fuel filter
X
X
X
X
Other
Checking the drive belt
X
X
X
X
X
Checking for leaks
X
X
X
X
X
Checking and adjusting the
X
X
X
valve clearance
Renewing the reductant filter
X
X
X
X
Cleaning the reductant tank filler
X
X
X
X
filter
Cleaning the reductant tank ven-
X
X
X
X
X
tilation filter
Checking/renewing the particu-
4
4,500 hours
late filter
1. For engines that comply with Stage 5, see Stage 5 table.
2. XPI engines where Stage3/Tier3 or lower emissions legislation applies.
3. XPI engines where Stage4/Tier4 or higher emissions legislation applies.
4. Change interval is highly dependent on medium load and type of application. See section Maintenance interval for particulate filter
on the next page.
39
Maintenance
Particulate filter maintenance inter-
vals
IMPORTANT!
Scania recommends using Scania LDF-4 engine
oil. The graph can only be used if this condition
is met.
h
16000
= A
14000
12000
= B
10000
= C
8000
6000
4000
2000
0
0
5
10
15
20
25
30
35 40
45
50
55
60
65
70
75 l/h
The graphs in the diagram show calculated driving time before particulate filter renewal must be carried out
on engines with the following 3 types of dynamic load:
• A = High dynamic load, for example excavator and wheel loader.
• B = Semi-dynamic load, for example stone crushing plant and dumper truck.
• C = Low dynamic load, for example generator set.
Note:
The Y axis shows the driving time and the X axis
shows the average fuel consumption.
40
Lubrication system
Lubrication system
Oil grade
Scania LDF stands for the Scania Long Drain
Field test standard. Scania LDF oils have been
carefully selected after extensive testing. The ap-
proval is only granted to the highest quality en-
gine oils available on the market.
Recommended engine oils: Scania’s LDF and
Scania E7 oils.
IMPORTANT!
Regarding particulate filters, the information in
this document is not valid if an engine oil other
than Scania LDF-4 is used.
Particulate filter
Oil grade
LDF-4
LDF-3
LDF-2
LDF
No
Scania Oil E7
ACEA E7
ACEA E5
API CI-4
API CI-4+
LDF-4
ACEA E6
Yes
ACEA E9
API CK-4
with ash content < 1%
For fuels with high sulphur content, the Total
Base Number (TBN) must be at least 12.
41
Lubrication system
If Scania LDF-4 is not used, the oil must be of a
viscosity class suitable for the outdoor tempera-
ture in the area where the engine is used.
The illustration describes the ambient temperature in °C that each viscosity class can handle for Scania-ap-
proved and market approved oil grades. Note that the Scania-approved oil grades have a greater temperature
range than market approved oil grades.
The temperature range that the market approved oil grades, for example ACEA Exx and API
= Cxx, can handle.
The temperature range that the Scania-approved oil grades, for example the Scania LDF
= oils and Scania Low Ash, can handle beside the market approved oils.
42
Lubrication system
Stage 5 table
Table of oil change intervals for engines that
comply with stage 5. A 500-hour service interval
applies for other engines.
Oil
Oil change intervals
Medium load (l/h)
<25
<28
>28
LDF-4
750 h
500 h
500 h
Other
500 h
500 h
400 h
The table does not apply for engines that:
• occasionally have much higher consumption
• idling percentage > 15%
• if the engine is used at high coolant tempera-
tures
For operation at extremely low outdoor tempera-
tures: Consult your nearest Scania representative
on how to avoid starting difficulties.
If the engine is used in areas of the world where
engine oil with ACEA or API classification is
not available, the oil grade must be measured in
actual operation. In this case contact the nearest
Scania workshop.
43
Lubrication system
Filled engine oil grade label
When changing oil it is important to use the cor-
rect engine oil grade. The oil filler cap must be
clearly marked with a label showing the filled oil
grade. However, there are only labels for oils
from Scania and oil grade ACEA E9.
Stick on a new label if the oil type or oil grade is
changed in favour of any of the oil types above.
Replace the label if it is missing.
If the oil grades below are used, it is possible to
order labels for the oil filler cap from Scania.
Oil filler label in the cylinder block.
Oil filler label in rocker cover.
Oil grade
Colour
Part no.
Part no.
Filling in the cylinder block
Filling in the rocker cover
Scania LDF-4
Blue
2 602 886
Scania LDF-4
Yellow
2 602 885
Scania LDF-3
Red
2 132 426
2 427 133
Scania LDF-2
Blue
2 132 424
-
Scania LDF
Grey
2 269 345
-
ACEA E9
-
2 132 429
44
Lubrication system
Oil analysis
To be able to extend the oil change intervals us-
ing an oil analysis, Scania LDF-4 oils must be
used. Certain laboratories offer engine oil analy-
sis.
The following conditions must remain fulfilled
when the oil is changed:
• Viscosity at 100°C (212°F): max. ±20% of
the original value of the fresh oil.
• TBN (in accordance with ASTM D4739):
>3.5
• TBN (in accordance with ASTM D4739):
>TAN (in accordance with ASTM D664).
• Oil oxidation (in accordance with
DIN 51453) > 10.
During analysis, the oil’s TBN (Total Base Num-
ber), TAN (Total Acid Number), fuel dilution,
water content and viscosity are measured, as well
as the quantity of particles in the oil.
The result of a series of analyses is used as the
basis for establishing a suitable oil change inter-
val.
If the conditions are changed, a new oil analysis
programme must be carried out to establish new
oil change intervals. Work out the new oil
change interval for the engine in conjunction
with the workshop.
REQUIREMENT!
Only Scania LDF-4 oils may be used in conjunc-
tion with oil analysis and a possible extended oil
change interval.
Depending on the market, the warranty condi-
tions may also change if the oil change intervals
differ from the recommended Scania timetable.
45
Lubrication system
Checking the oil level
Note:
1
Leave the engine off for at least 7 minutes before
you check the oil level.
2
1. Remove the oil dipstick and check the oil
level. The correct level is between the mini-
mum and maximum marks on the oil dip-
stick.
2. Top up with more oil via the oil filler if the
oil level is at or below the minimum mark.
1. Oil dipstick.
For information on the correct oil grade, see the
2. Oil filler.
section Oil grade.
Maximum angles of inclina-
tion during operation
Maximum permissible angles of inclination dur-
30°
ing operation vary, depending on the type of oil
sump. See illustration.
30°
30°
30°
25°
25°
30°
30°
46
Lubrication system
Changing the oil
WARNING!
Hot oil can cause burns and skin irritation. Wear
protective gloves and eye protection when
changing hot oil. Make sure that there is no pres-
sure in the lubrication system before changing
the oil. The oil filler cap must always be in place
when starting and running the engine to prevent
oil being ejected.
Note:
Change oil more often if the engine is subjected
to particularly demanding operation, such as a
Oil volume for oil sumps with deep front: Max. 36 li-
dusty environment, or if deposits in the centrifu-
tres (9.5 US gallons) Min. 31 litres (8.2 US gallons)
gal oil cleaner are thicker than 28 mm (1.1 in).
Renew the oil filter and clean the centrifugal oil
cleaner when changing oil.
Environment
Use a suitable container. Used oil must be dis-
posed of as specified in national and internation-
al laws and regulations.
1. Unscrew the oil plug and drain the oil when
the engine is hot. In certain engine types the
oil is pumped out by means of a bilge pump.
If the engine is drained via the valve, the oil
should be hot. Alternatively, use a pump.
This so that draining occurs more quickly.
2. Wipe off the magnet on the oil plug.
Oil volume for low oil sump: Min. 28 litres (7.4 US
3. Renew the gasket on the oil plug.
gallons) Max 35 litres (9.2 US gallons)
4. Refit the oil plug.
5. Fill with the amount of oil specified for the
oil sump.
6. Wait at least seven minutes.
7. Check the level on the oil dipstick.
47