Scania DC09 User manual

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
01:02 Issue 6 en-GB 1
Intake system and ventilation
Industrial engines
DC09, DC13, DC16

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
01:02 Issue 6 en-GB 2
Intake air .................................................................................................................. 3
Intake air taken from outside engine compartment............................................. 4
Intake air taken from engine compartment ......................................................... 7
Air cleaners .............................................................................................................. 8
Air cleaners with precleaner................................................................................ 9
Air cleaners without precleaner......................................................................... 10
Crankcase ventilation............................................................................................11
Open crankcase ventilation ............................................................................... 11
Closed crankcase ventilation............................................................................. 12
Connection to turbocharger .................................................................................13
Cleanliness requirement .................................................................................... 13
Charge air pipe .................................................................................................. 13
Stage IV/Tier 4f engines ................................................................................... 14

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Intake air
01:02 Issue 6 en-GB 3
Intake air
If the intake line is located close to exhaust pipes or other hot parts, radiation protec-
tion should be used to limit unnecessary heating of the intake air.
REQUIREMENT!
The temperature of the intake air must not exceed the ambient temperature by more
than 5°C.
If the intake air temperature upstream of the turbocharger continuously exceeds
30°C, then engine power may drop. If the engine is enclosed in some manner, make
sure that there is an adequate flow of intake air.
The dependence of the engine power on intake air temperature is shown in the chart
on the right. 100% engine power is shown under actual test conditions at the factory.
The engine air consumption in kg/min at full power and at different engine speeds is
indicated in the tables showing the air consumption and radiated heat for the relevant
engine type under Technical data in the Installation manual.
100
95
90
%
A
B
10 20 30
25 40 50 °C
340 422
Engine power dependence on intake air temperature. 100% at 25°C, 1,000 mbar, en-
gine power setting not corrected
A = Engine power
B = Intake air temperature

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Intake air
01:02 Issue 6 en-GB 4
Intake air taken from outside engine compartment
In engine systems where the engine intake air comes from outside the engine com-
partment and is led via a fresh air line to the engine, the pressure drop for the intake
system should be measured.
The air intake should be located so that the intake air is as clean as possible and so
that neither the engine exhaust gases nor heated air from the engine compartment can
mix with the intake air.
The intake air must not contain chemical pollutants, such as CFCs.
The air intake should be designed to exclude water, snow and contamination.
Maximum permissible pressure drop is 30 mbar. This value includes the pressure
drop in the new air filter, connected coarse filter and in the fresh air line.

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Intake air
01:02 Issue 6 en-GB 5
The following applies to the fresh air line:
• The fresh air line must not be routed with any sharp bends.
• The inside of the fresh air line must be flat and even.
• If a hose is used as a fresh air line, it must be hard so that it does not collapse onto
itself.
It is not necessary to check the pressure drop in the following cases:
• The intake system comprises air hoses and air pipes from Scania's standard range.
• If the fresh air line is maximum 5 m and has an inside diameter of at least 160 mm
for DC09 or 210 mm for DC13 and DC16, respectively.
If the planned fresh air line is longer than 5 m, the required diameter must be calcu-
lated as illustrated. The vacuum upstream of the turbocharger must then be measured.
The pressure drop measurement is normally made at the vacuum indicator. If the line
between the filter and turbocharger is not a Scania standard line, the pressure drop
should be measured on a straight section as close to the turbocharger as possible.
IMPORTANT!
The total pressure drop with a blocked air filter must not exceed 65 mbar.
Engine damage will not occur up to 100 mbar, but fuel consumption and smoke will
increase. Above 100 mbar there is a risk that the air volume to the engine will be in-
adequate, resulting in breakdowns.
100
200
300
400 25m
5m
10 20 30 40 50
A (mm)
(m /min)
3
B
340 421
Calculation of minimum diameter of the intake line
A = Intake line diameter
B = Air consumption

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Intake air
01:02 Issue 6 en-GB 6
Ventilation of the engine compartment with fresh air line to the
engine
When the intake air to the engine is taken from outside the engine compartment, it is
important to check that the temperature in the engine compartment does not exceed
90°C. If the temperature exceeds this value, there is a risk that the engine's electric
components and control unit will malfunction.
If there is a risk that the temperature will exceed 90°C, the engine compartment must
be ventilated.
When dimensioning the engine compartment ventilation, other air consumers in the
engine compartment must also be considered.
The amount of radiated heat emitted by various engines is indicated under Technical
data in the Installation manual.
The exhaust pipes should be insulated to reduce the radiated heat in the engine com-
partment. See Exhaust system in the Installation manual.

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Intake air
01:02 Issue 6 en-GB 7
Intake air taken from engine compartment
When the engine intake air is taken from the engine compartment, the air intake must
be located in the engine compartment. The opening area should be large enough to
ensure that no vacuum arises in the engine compartment. The air intake should also
be designed and positioned so that it cannot be closed or accidentally blocked by wa-
ter, snow or contaminants.
The air intake should be located so that the intake air is as clean as possible and so
that neither the engine exhaust gases nor heated air from the engine compartment can
mix with the intake air to the engine.
In the chart on the right-hand side, the recommended minimum area for the air intake
can be read from the engine air consumption.
If several engines or other air consumers are located in the same engine compart-
ment, the diameter should be increased correspondingly.
Measure the pressure difference during operation, when the engine or engines have
been running for about 5 minutes at full load. The pressure difference must not ex-
ceed 1 mbar. For engines without a fan, a vacuum of 2 mbar is permissible.
For installations where the engine draws the intake air directly from the engine com-
partment, the engine compartment must normally be equipped with a ventilation sys-
tem. This system should extract the air heated by radiation etc. in order for the
requirement of a low intake air temperature to be met.
If there is a refrigerator compressor in the engine compartment, it is important that
any leakage of refrigerant does not contaminate the intake air.
The radiated heat from the engine exhaust pipe downstream of the engine must also
be taken into account. The heat radiation depends on how much of the line is inside
the engine compartment and how much of it is insulated.
There is also additional heat due to efficiency losses in driven units located in the en-
gine compartment.
10
0,1 0,2 0,3 0,4
20
30
40
50
60
kg/min
m
2
25
o
C
340 420
Calculation of minimum air intake area

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Air cleaners
01:02 Issue 6 en-GB 8
The amount of radiated heat emitted by the engine is indicated in the tables showing
the radiated heat for the relevant engine type under Technical data in the Installation
manual.
Air cleaners
The engines are delivered with air cleaners with paper filter. The air cleaner is avail-
able with or without integrated self-cleaning precleaner.
If the air cleaner has a precleaner, it always has a safety cartridge. This protects the
engine from contamination, for example, if the main filter is damaged or when re-
newing the main filter element. An air cleaner without precleaner is not available
with safety cartridge.
Bear in mind the following when installing an air cleaner:
• The air cleaner must be fitted so that it is easily accessible for cleaning and filter
renewal.
• The vacuum indicator must be positioned so that it can be read easily.
• In order to be able to remove the filter element clearance in the air cleaner exten-
sion is required.
• The intake line between the air cleaner and the turbocharger must be sealed so that
no unfiltered air can be drawn into the engine. The intake line must be designed
in such a way that it cannot collapse onto itself as a result of a large pressure drop.
The intake line should be able to withstand a vacuum of 200 mbar before it col-
lapses onto itself.
• The material and composition of the intake line between the air filter and turbo-
charger must be such that it cannot release rust or objects that could damage the
engine.
An effective self-cleaning prefilter is recommended for particularly dusty environ-
ments. Even engine systems exposed to driving snow can require a special type of
prefilter.

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Air cleaners
01:02 Issue 6 en-GB 9
For such equipment, Scania refers to filter system specialists who can give recom-
mendations about the system which is most suitable for a particular type of engine
installation.
It is also important to make sure that any insulation in the engine compartment and
around the exhaust pipes cannot come loose and be drawn into the intake line.
If a non-Scania air filter is used, engine air consumption and filter element pore size
must be considered.
Air cleaners with precleaner
Air filters with precleaner are available in 3 different sizes: 13 inch, 15 inch and 18
inch.
IMPORTANT!
The air cleaners must be fitted horizontally with the drain pipe pointing downwards.
165
900
340 419
152
340 418

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Air cleaners
01:02 Issue 6 en-GB 10
Air cleaners without precleaner
Air filters without precleaner are available in 2 different sizes: 13 inch and 15 inch.
IMPORTANT!
The air cleaner must be fitted horizontally with the air intake (1) pointing down-
wards. The air cleaner may also be fitted vertically, but only if it is fitted indoors or
in such a way that water cannot get into the air filter.
165
900
1
340 417
152
340 416

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Crankcase ventilation
01:02 Issue 6 en-GB 11
Crankcase ventilation
Open crankcase ventilation
If the engine is located in an enclosed space, crankcase gases should be led out of the
engine compartment.
This is especially important when the engine is equipped with a driving fan since the
crankcase gases will otherwise settle on the radiator, binding dirt and dust, which re-
duces the cooling effect.
The crankcase ventilation pipe (1) has a diameter of 32 mm.
The following points are important for external ventilation of crankcase gases:
• The crankcase gases must not be led to outlet ducts for engine compartment ven-
tilation or exhaust gases.
• The crankcase ventilation lines from multiple engines must not be joined to form
a single pipe.
• The crankcase ventilation line should be made from pipe or oil-resistant hose,
connected to the ventilation pipe on the engine.
• When the crankcase ventilation line is extended in cold environments, it must be
designed to ensure that condensation cannot freeze in the hose. The extension of
a crankcase ventilation line may need to be insulated.
• When the crankcase ventilation line is extended, the extension must be designed
to ensure that no pockets are formed. It must also have a continuous downward
slope so that it can neither freeze nor can oil accumulations form resulting in too
high a pressure in the crankcase.
• Any crankcase ventilation pipe with its outlet outside the engine compartment
must be protected so that no water or contaminants can get into the crankcase.
• If pipe is used, there should be a flexible, oil-resistant line between the engine and
pipe to absorb the engine movements.
• If hose is used, it must be clamped so that no sharp kinks are formed.
AB
11
335 751
Open crankcase ventilation
A. DC09
B. DC13
1
335 753
Open crankcase ventilation, DC16

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Crankcase ventilation
01:02 Issue 6 en-GB 12
• The crankcase ventilation pipe outlet must not be positioned where there is a risk
of it becoming blocked.
Closed crankcase ventilation
For certain engine systems, external ventilation of crankcase gases could be exten-
sive and expensive. This applies, for example, to generator sets in large buildings
where very long evacuation pipes are required.
When there are special requirements for closed crankcase ventilation, e.g. for envi-
ronmental reasons, it is permissible to allow the crankcase gases to be led to the in-
take line between the air filter and the turbocharger.
It is not permissible to lead the crankcase gases to the intake upstream of the engine
air filter.
AB
335 754
Closed crankcase ventilation
A. DC09, DC13
B. DC16

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Connection to turbocharger
01:02 Issue 6 en-GB 13
Connection to turbocharger
Cleanliness requirement
IMPORTANT!
Observe the utmost cleanliness when installing all parts from the air filter up to the
turbocharger. If foreign particles enter the turbocharger, this could quickly lead to
impaired performance and breakdown.
Do not remove the protection from the turbocharger inlet pipes and charge air pipe
before they are connected.
Charge air pipe
The installation of the charge air pipe recommended by Scania is shown in the illus-
tration.
IMPORTANT!
Position a flexible hose as close to the turbocharger connection as possible to reduce
forces and torques.
The weight of the charge air pipe must not put any load on the turbocharger. There-
fore, support the charge air pipe downstream of the turbocharger connection with a
sturdy bracket.
2
1
342
337 360
Recommended installation of charge air pipe
1. Turbocharger
2. Flexible hose
3. Charge air pipe
4. Bracket

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Connection to turbocharger
01:02 Issue 6 en-GB 14
Stage IV/Tier 4f engines
Inlet pipe for connection to turbocharger
The Scania inlet pipes for connection to the turbocharger must be used on all engines
certified according to Stage IV/Tier 4f. The inlet pipes are available in 2 different
versions for DC09 and DC13, and in 1 version for DC16.
Combined sensor T4000 for measuring ambient pressure and temperature is posi-
tioned in each version of the inlet pipe.
Tightening torque for the clamp joint connected to the turbocharger: 20 Nm. Applies
only to DC09 and DC13.
336 772
Inlet pipes for DC09 and DC13
340 413
Inlet pipe for DC16

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Connection to turbocharger
01:02 Issue 6 en-GB 15
Mass flow sensor pipe
All engines certified according to Stage IV/Tier 4f are supplied with an inlet pipe
with a mass flow sensor T126. The mass flow sensor pipes are available in 2 different
versions for DC09 and DC13, and in 1 version for DC16.
The dimensions and air direction for the mass flow sensor pipes are shown in the il-
lustrations below.
Mass flow sensor pipes for DC09 and DC13
389
Ø 126
80
40
Ø 150
4x M10
336 769
271
Ø 126
60
190
40
Ø 150
2x M8
336 770

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Connection to turbocharger
01:02 Issue 6 en-GB 16
In order to get the best possible measured value when measuring the mass flow, the
following recommendations for the installation of all types of mass flow sensor pipes
apply:
• Install the mass flow sensor pipe as near to the turbocharger as possible.
• Use pipes between the turbocharger and the mass flow sensor pipe as far as pos-
sible.
• Make pieces of hose as short as possible.
• Maximum distance between the inlet pipe and mass flow sensor pipe is 800 mm.
This applies to all combinations of inlet pipes and mass flow sensor pipes.
• Use hose which is sturdy enough so that it does not collapse onto itself.
Tightening torque for hose clamps: 5 Nm.
4xM8
M8
340 412
Ø 150
60
Ø 140
220
414
Mass flow sensor pipe for DC16
Max. 800 mm
336 774
Maximum distance between the inlet pipe and mass flow sensor pipe

INSTALLATION
MANUAL
©Scania CV AB 2014, Sweden
Connection to turbocharger
01:02 Issue 6 en-GB 17
• The switch of the mass flow sensor must not be on the underside of the mass flow
sensor pipe where it may come into contact with condensation and dirt. See the
illustration.
• If a pipe bend is installed upstream of the mass flow sensor pipe, the outer radius
of the pipe bend must be on the same side as the measuring body of the mass flow
sensor ±90°. The airflow must hit the measuring body of the mass flow sensor (1).
1
1
336 873
The relationship between the pipe bend and mass flow sensor pipe if a pipe bend is
installed upstream of the mass flow sensor pipe