Scania DC09 User manual

01:01 Issue 8.0 en-GB
© Scania CV AB 2016, Sweden
Installation manual
Engine
Industrial engines
DC09, DC13, DC16
OC16
333 291

INSTALLATION
MANUAL
© Scania CV AB 2016, Sweden
01:01 Issue 8.0 en-GB 2
Engine suspension....................................................................................................3
Design requirements............................................................................................ 3
Flexible engine suspension.................................................................................. 4
Rigid engine suspension...................................................................................... 5
Permissible installation and operating angles ..................................................... 6
Flywheel housings............................................................................................... 7
Generator set dynamics ....................................................................................... 8
Lifting the engine ................................................................................................ 8
Accessibility for maintenance and repairs ............................................................9
Installation requirements ..................................................................................... 9
Clearances ......................................................................................................... 11
Engine alignment...................................................................................................12
Flexible coupling............................................................................................... 12
Aligning engine and shafts................................................................................ 13
Power transmission ............................................................................................... 18
Flexible coupling............................................................................................... 18
Friction clutch ................................................................................................... 18
Transmission types ................................................................................................ 20
Mechanical transmissions ................................................................................. 20
Belt transmissions ............................................................................................. 20
Power take-offs ...................................................................................................... 22
Front-mounted power take-offs......................................................................... 22
Side-mounted power take-offs .......................................................................... 25
Air compressor ...................................................................................................... 31
Torsional oscillations............................................................................................. 32
Data for torsional oscillation calculation .......................................................... 33
Torsional oscillation calculations from Scania................................................. 34
General tightening torques for screw joints ....................................................... 35
Specification of normal tightening torques....................................................... 35
Tightening torques ............................................................................................ 36
Sticker “Powered by Scania”............................................................................... 39

INSTALLATION
MANUAL
© Scania CV AB 2016, Sweden
Engine suspension
01:01 Issue 8.0 en-GB 3
Engine suspension
Design requirements
The type of engine suspension that is appropriate varies for different engine installa-
tions. In general, the following applies:
• The engine suspension should be designed for the forces it is exposed to, both
continuously and momentarily during operation. Such forces are reaction forces
from the transmitted torque and in some cases longitudinal acceleration, retarda-
tion and reaction forces in the engine.
• Both the engine suspension and the engine bed should be designed so that there
are no resonant oscillations within the engine speed range. They should also be
designed so that annoying vibrations from the engine are not transmitted to the
surroundings.
• The engine bed location and the engine suspension must be designed so that the
permissible angles of inclination for the engine are not exceeded. See the table in
the Permissible installation and operating angles section.
• The engine suspension and engine bed should be designed in a way which allows
access for maintenance and repairs.
IMPORTANT!
If the angles of inclination are exceeded, lubrication system performance will deteri-
orate, which can cause damage to the engine or reduce its service life.
There are two standard engine suspension designs:
• flexible engine suspension
• rigid engine suspension.

INSTALLATION
MANUAL
© Scania CV AB 2016, Sweden
Engine suspension
01:01 Issue 8.0 en-GB 4
Flexible engine suspension
Flexible engine suspension dampens vibrations more effectively than rigid engine
suspension. Flexible engine suspension does not require such careful alignment of
the engine as rigid engine suspension. However, flexible engine suspension does not
absorb longitudinal and lateral forces in the engine to the same extent as rigid engine
suspension.
Insulators
Cushyfloat insulators with hardness 55 or 65 Shore are delivered as standard.
Tightening torque. Hardness marking.
The engine bracket and frame or engine bed should be
parallel.
The vertical centre lines should coincide laterally. The upper and lower parts of the insulators should be
parallel longitudinally.
334 280
Examples of flexible engine suspension.
310 404
160±10 Nm
310 405
55
55
alt. 65
310 407
max 1°
310 408
0°
310 406
0°
55

INSTALLATION
MANUAL
© Scania CV AB 2016, Sweden
Engine suspension
01:01 Issue 8.0 en-GB 5
Rigid engine suspension
A rigid engine suspension can absorb greater forces in all directions than flexible en-
gine suspension. It requires highly accurate alignment of the engine in relation to the
driven unit. On the other hand, it requires no special flexibility in the hoses, pipes and
controls connected to the engine.
A rigid engine suspension can be used in engine installations where vibration causes
no significant problems and where other characteristics make it desirable.
Even with a rigid engine suspension, the transmission of vibration to the engine bed
can be kept low if the masses of the engine bed and connected parts are large in re-
lation to the mass of the engine.
It is also possible to construct flexible engine suspension between the frame and the
engine bed to reduce the transmission of vibration to the engine bed.
344 281
Examples of rigid engine suspension.

INSTALLATION
MANUAL
© Scania CV AB 2016, Sweden
Engine suspension
01:01 Issue 8.0 en-GB 6
Permissible installation and operating angles
Maximum installation angle means maximum permissible installation angle for an
engine relative to the horizontal plane. The angle indicates the limit for engine incli-
nation during continuous operation.
Maximum operating angle means maximum permissible angle of inclination for an
engine in operation and with minimum oil level. The angle may only be used for
short periods. The given maximum forward or rearward operating angles are not ap-
plicable to their full extent if the engine is inclined laterally at the same time.
Engine type Type of oil sump Max. installation angle Max. operating angle Oil capacity (litres)
Inclination rear-
wards and for-
wards
Inclination lat-
erally
Inclination rear-
wards and for-
wards
Inclination lat-
erally
Min. Max.
DC09 Deep front without ladder frame 12° 12° 30° 30° 31 36
DC09 Low 12° 12° 25° 30° 28 35
DC13 Deep front without ladder frame 12° 12° 30° 30° 30 36
DC13 Deep front with ladder frame 12° 12° 30° 30° 39 45
DC13 Low 12° 12° 25° 30° 28 34
DC13 With deep centre part 12° 12° 35° 45° 33 39
DC16, OC16 Deep front without ladder frame 12° 10° 25° 30° 40 48
DC16 Low 12° 10° 25° 30° 29 37

INSTALLATION
MANUAL
© Scania CV AB 2016, Sweden
Engine suspension
01:01 Issue 8.0 en-GB 7
Flywheel housings
Silumin housings are supplied as standard on all industrial engines. The maximum
permissible bending torque for a silumin housing is 10,000 Nm. This presumes that
there are no axial loads from, for example, the propeller shaft, abnormal G forces or
vibration.
For certain engine types, it is also possible to select a nodular iron flywheel housing.
Nodular iron housings can dampen vibrations at certain engine speeds but increase
vibrations at other engine speeds. Nodular iron is stronger than silumin and can there-
fore tolerate greater bending and torsional forces.
The stronger nodular iron housings are recommended in installations where transport
causes serious stress on the flywheel housing, such as in dumper type trucks and gen-
erator sets with high outputs.
If it is difficult to determine the size and nature of the load, contact your nearest Sca-
nia distributor.

INSTALLATION
MANUAL
© Scania CV AB 2016, Sweden
Engine suspension
01:01 Issue 8.0 en-GB 8
Generator set dynamics
If vibration levels in a generator set are too high, it could be due to resonance. This
may be because resonant frequencies of the receiving system are the same as the fre-
quency of the torque and disrupting power pulses that arise during normal operation
of combustion engines with a crankshaft. The resonant frequencies of the system de-
pend in turn on the mass and rigidity of component parts.
It is the responsibility of the installer to check that no resonant frequencies or vibra-
tion levels that could damage component parts are found anywhere in the engine in-
stallation.
The measurement and evaluation of vibrations in static parts is described in interna-
tional standards. See ISO 8528-9.
Lifting the engine
WARNING!
The engine lifting eyes are dimensioned for lifting the engine only, not the engine to-
gether with connected equipment or frame!
5
4
3
2
1
6
6
344 282
Example of generator set.
1. Engine.
2. Flywheel housing.
3. Adapter.
4. Generator.
5. Engine bed.
6. Vibration insulators.

INSTALLATION
MANUAL
© Scania CV AB 2016, Sweden
Accessibility for maintenance and repairs
01:01 Issue 8.0 en-GB 9
Accessibility for maintenance and repairs
Installation requirements
The installer is responsible for ensuring accessibility for maintenance and repairs.
Note:
There must be sufficient space at installation so that standard times for maintenance
and repairs can be attained.
The following requirements for accessibility must be met:
• Canopies and connected components must be designed so that the engine can be
removed and fitted relatively easily.
• In the case of static engine installations, there should be permanent securing
points for lifting devices above the unit.
• The fuel system must be easily accessible for maintenance and bleeding.
• It should be possible to read the graduations on the flywheel when adjusting
valves and unit injectors.
• It should be possible to remove and fit the cylinder head, rocker covers and push-
rods while leaving the engine in place.
• It must be possible to remove the oil sump in order to renew cylinder liners or pis-
tons with the engine in place.

INSTALLATION
MANUAL
© Scania CV AB 2016, Sweden
Accessibility for maintenance and repairs
01:01 Issue 8.0 en-GB 10
• It should be easy to fill and drain oil. In addition, the oil dipstick must be easily
accessible.
• Centrifugal oil cleaners and oil filters must be easy to access for maintenance and
for renewal.
• It should be easy to fill and drain coolant.
• Engine air filters must be located so that they are easy to access for the renewal
of filter elements.
It must also be easy to carry out maintenance on the following components:
• Turbocharger
• Starter motor
• Alternator
• Coolant pump
• Radiator
• Cooling fan
• Clutch
• Batteries
• Crankcase ventilation filter
For gas engines, it must also be easy to carry out maintenance on the following com-
ponents:
• Spark plug
•Flamearrestor
• Gas mixer insert
• Electric throttles
• Gas regulator
• Lambda sensor