Scania DI9 55 User manual

Operator’s Manual
DI9 55 - DI9 59
Marine engine
opm99-9m en 1 588 713
2001-05:1
Industrial&MarineEngines
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
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.
!
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2 © Scania Industrial & Marine Engines 2001-05:1
FOREWORD
This operator’s manual describes the operation andmaintenance 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
works.
- Whenever necessary, always contact an authorised Scania workshop.
They have special tools, genuine Scania parts and trained staff with
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
During the warranty period,
only use genuine Scania parts in
service and repair for the
warranty to be valid.
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2001-05:1 © Scania Industrial & Marine Engines 3
CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENVIRONMENTAL RESPONSIBILITY . . . . . .4
CERTIFIED ENGINES . . . . . . . . . . . . . . . . . . . .5
SAFETY DETAILS . . . . . . . . . . . . . . . . . . . . . . .6
Safety precautions for operation . . . . . . . . . . . .7
Safety precautions for handling materials . . . . .8
Safety precautions for care and maintenance . .8
TYPE DESIGNATIONS . . . . . . . . . . . . . . . 10
DEC2 CONTROL SYSTEM . . . . . . . . . . . . 12
STARTING AND RUNNING . . . . . . . . . . . 18
AT FIRST START . . . . . . . . . . . . . . . . . . . . . . .18
CHECKS BEFORE RUNNING . . . . . . . . . . . . .19
STARTING THE ENGINE . . . . . . . . . . . . . . . .19
At temperatures below 0 °C: . . . . . . . . . . . . . .20
RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . .21
Coolant temperature . . . . . . . . . . . . . . . . . . . .21
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .22
STOPPING THE ENGINE . . . . . . . . . . . . . . . . .22
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
CHECKS AFTER RUNNING . . . . . . . . . . . . . .23
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 24
ENGINES WITH FEW HOURS
OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . .24
MAINTENANCE SCHEDULE . . . . . . . . . . . . .25
LUBRICATING OIL SYSTEM . . . . . . . . . 26
OIL GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Oil analysis . . . . . . . . . . . . . . . . . . . . . . . . . . .26
CHECKING THE OIL LEVEL . . . . . . . . . . . . .27
OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . .27
Maximum angles of inclination during
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
CLEANING THE OIL CLEANER . . . . . . . . . .28
CHANGING THE OIL FILTER . . . . . . . . . . . .30
COOLING SYSTEM . . . . . . . . . . . . . . . . . . 30
CHECKING COOLANT LEVEL . . . . . . . . . . .30
CHECKING CORROSION BARS . . . . . . . . . . .31
CHECKING THE SEA WATER PUMP
IMPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
CHECKING THE COOLANT . . . . . . . . . . . . . .32
Changing the coolant . . . . . . . . . . . . . . . . . . .34
CLEANING THE COOLING SYSTEM . . . . . .35
Internal cleaning . . . . . . . . . . . . . . . . . . . . . . .37
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 38
READING THE VACUUM INDICATOR . . . .38
CLEANING THE AIR CLEANER
COARSE CLEANER . . . . . . . . . . . . . . . . . . . . .38
CLEANING OR CHANGING THE
FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . .38
CHANGING SAFETY CARTRIDGE . . . . . . . .40
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 41
CHECKING FUEL LEVEL . . . . . . . . . . . . . . . .41
CHANGING THE FUEL FILTER . . . . . . . . . . .41
CHECKING INJECTORS . . . . . . . . . . . . . . . . .42
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . 43
CHECKING THE
ELECTROLYTE LEVEL IN BATTERIES . . . .43
CHECKING THE STATE OF CHARGE
IN BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . .43
CLEANING BATTERIES . . . . . . . . . . . . . . . . .43
CHECKING THE COOLANT LEVEL
MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
CHECKING THE
TEMPERATURE MONITOR . . . . . . . . . . . . . .45
CHECKING THE TEMPERATURE SENSOR .45
CHECKING THE OIL PRESSURE SEN-
SOR/MONITOR . . . . . . . . . . . . . . . . . . . . . . . . .46
CHECKING THE OIL PRESSURE MONITOR
FOR DEC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
CHANGING THE BATTERY . . . . . . . . . . 47
MISCELLANEOUS . . . . . . . . . . . . . . . . . . . 47
CHECKING THE DRIVE BELT . . . . . . . . . . . .47
CHECKING FOR LEAKAGE, RECTIFY
AS NECESSARY . . . . . . . . . . . . . . . . . . . . . . . .48
CHECKING/ADJUSTING VALVE
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .49
CHANGING (OR CLEANING) THE CLOSED
CRANKCASE VENTILATION VALVE . . . . .50
LONG-TERM STORAGE . . . . . . . . . . . . . . 51
Preservative fuel . . . . . . . . . . . . . . . . . . . . . . .51
Preservative oil . . . . . . . . . . . . . . . . . . . . . . . .52
Preparations for storage . . . . . . . . . . . . . . . . .52
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Taking out of storage . . . . . . . . . . . . . . . . . . .53
TECHNICAL DATA . . . . . . . . . . . . . . . . . . 54
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
ALPHABETIC INDEX . . . . . . . . . . . . . . . . 58
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4 © Scania Industrial & Marine Engines 2001-05:1
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.
Refer to example
Always use suitable containers
to avoid spillage when bleeding
systems or renewing
components.
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2001-05:1 © Scania Industrial & Marine Engines 5
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.
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6 © Scania Industrial & Marine Engines 2001-05:1
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
for the proper operation of the engine and to avoid damage to the engine.
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
of serious defects to the engine or improper handling that may lead to
personal injury.
Refer to example
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.)
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK
OF INJURY.
Only use Scania genuine fuel
filter.
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2001-05:1 © Scania Industrial & Marine Engines 7
Safety precautions for operation
Daily inspection
Always perform visual inspection of the engine
andenginebaybeforetheengineisstartedand
when the engine has been stopped after oper-
ation.
This will make it easy to detect any leakage of
fuel, oil or coolant or any other abnormal condi-
tion that may require remedial action.
Refuelling
When refuelling, there is a risk of fire and explo-
sion.The enginemustbestoppedandsmoking
is not allowed.
Do not overfill the tank, since the fuel may ex-
pand, and close the fuel filler cap properly.
Only use fuel recommended in the service
literature.Fuelofanincorrectgrade maycause
malfunctionsorstoppagebyinterferingwiththe
operation of the fuel injection pump and the in-
jectors.
This could cause engine damage and possibly
personal injury.
Harmful gases
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.
Starter lock
If the control panel is not fitted with a key
switch, the engine bay should be fitted with a
lock to prevent unauthorized starting of the en-
gine.
Alternatively, a lockable main switch or battery
master switch may be used.
Starting spray
Never use starting spray or similaras a starting
aid. An explosion may occur in the intake pipe,
which could cause personal injury.
Operation
The engine should not be operated in environ-
ments with surrounding explosive materials
since electrical or mechanical components of
the engine may emit sparks.
It is always a safety hazard to be near an en-
gine thatis running. Body parts or clothing, or a
dropped tool may get stuck in rotating parts,
such as the fan, causing bodily injury.
Alwayscoverrotatingpartsandhot surfacesas
much as possible to ensure personal safety.
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8 © Scania Industrial & Marine Engines 2001-05:1
Safety precautions for handling
materials
Fuel and lubrication oil
All fuels and lubricants as well as many chemi-
cals are flammable. Always follow the instruc-
tions stated on the container.
All work on the fuel system must be performed
when the engine is cold. Fuel leakage and spill-
age on hot surfaces may cause fire.
Store drenched rags and other flammable ma-
terials in a safe way to avoid spontaneous com-
bustion.
Batteries
Batteries, particularly when being recharged,
emit highly flammable fumes that can explode.
Do not smoke or let openflame or sparks come
near the batteries or the battery compartment.
Incorrect connection of a battery cable or jump
startcablemaycauseaspark,whichintunmay
cause the battery to explode.
Chemicals
Most chemicals, such as glycol, corrosion in-
hibitors, preservation oils, degreasers etc. are
hazardous. Always follow the safety precau-
tions stated on the container.
Some chemicals, e.g. preservative oil, are
flammable.
Always store chemicals and other hazardous
materials in approved and distinctly marked
containers and out of reach of unauthorized
persons. Always dispose of superfluous or
used chemicals through an authorized waste
disposal contractor.
Safety precautions for care and
maintenance
Stop the engine
Always stop the engine before any mainte-
nance and service work unless otherwise
stated.
Prevent unauthorized starting by removing the
starter key and turning off the power by the
main switch or the battery disconnect switch,
locking it in the off position. Also attach a warn-
ing tag, stating that work on the engine is in
progress, at a suitable location.
It is always a safety hazard to work on an en-
gine that is running. Parts of your body or cloth-
ing, or a dropped tool may get stuck in rotating
parts, causing bodily injury.
Hot surfaces and fluids
Ahotenginealwayspresentsariskofscalding.
Always take care not to touch the exhaust
manifold, turbocharger, oil pan, hotcoolantand
oil in pipes and hoses.
Lifting the engine
Use the engine lifting eyes when lifting the
engine. First check that the lifting equipment is
in proper condition and has sufficient lift capac-
ity rating.
Auxiliary equipment fitted to the engine may
cause the centre of gravity to be displaced.
Thus, additional lift devices may be required in
order to provide proper balance and a safe lift.
Never work below a suspended engine!
Batteries
Batteries contain a highly corrosive electrolyte
(sulphuric acid). Always take care to protect
youreyes,skinandclothingwhenchargingand
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,
rinseeyes immediatelywithplentyofwaterand
seek medical attention.
Dispose of used batteries through an author-
ized waste disposal contractor.
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2001-05:1 © Scania Industrial & Marine Engines 9
Electrical system
Before work is performed on the electrical sys-
tem,turnoffthepowerbythemainswitchorthe
battery disconnect switch.
Also disconnect any external power supply to
auxiliary equipment on the engine.
Arc Welding
Before welding near or on the engine, remove
the battery and alternator cables. Also remove
the control unit connector.
Connecttheweldclamptothecomponenttobe
welded, close to the weld location. Never con-
nect it to the engine or in such a way that the
current can pass through a bearing.
After the welding is completed, connect the ca-
blesto the alternatorand thecontrolunitbefore
connecting the batteries.
Lubrication system
Hot oil may cause scalding and skin irritation.
Avoid skin contact with hot oil.
Make sure that the pressure in the lubrication
system is relieved before work is carried out.
Never startor operatethe engine with the oilfill-
er cap removed since oil will be ejected force-
fully.
Dispose of used oil through an authorized
waste disposal contractor.
Cooling system
Never open the coolant filler cap while the en-
gine is hot. Steam and hot coolant can come
out forcefully and cause scalding.
If the cooling system must still opened or disas-
sembled while the engine is hot, open the filler
cap very cautiously and slowly to release the
pressure before the cap is removed. Use
gloves since the coolant is still very hot.
Dispose of used coolant through an authorized
waste disposal contractor.
Fuel system
Always use gloves when checking for leaks in
or performing other work on the fuel system. Al-
ways wear eye protection when testing injec-
tors.
Fuel escaping under high pressure can pene-
trate body tissue and cause serious injury.
Neveruse non-genuineparts inthefuelsystem
and the electrical system. Genuine parts are
designed and manufactured to minimize fire
and explosion hazard.
Before starting
Install any guards that have been removed be-
fore the engine is started. Check to ensure that
no tools or other objects have been left on the
engine.
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.
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10 © Scania Industrial & Marine Engines 2001-05:1
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
MFor marine use
Variant code for equipment options 01-99
Governor type
EElectronically 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
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
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2001-05:1 © Scania Industrial & Marine Engines 11
1. Type plate
2. Engine number,
stamped in engine block
3. Oil cooler
4. Oil dipstick
5. Oil cleaner
6. Protective anode
7. Draining, engine oil
8. Coolant pump
9. Turbo charger
10. Injection pump
11. Fuel filter
12. Starter motor
13. Alternator
14. Draining, coolant
15. Oil filling
16. Sea water pump
17. Heat exchanger
18. Charge air cooler
19. Turbo filter
The drawings illustrate a common type of DI9 engine.
Your engine may have other equipment not shown here.
6 5 1
15
9
11
10
2
4 7
14
12
13
3
8
7
16
17
18
19
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12 © Scania Industrial & Marine Engines 2001-05:1
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 © Scania Industrial & Marine Engines 13
Location of sensors for DEC2 on DI9
5
2
4
3
1
6
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
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14 © Scania Industrial & Marine Engines 2001-05:1
LED functions during normal operation
Note The lamp test/fault code switch should not
be depressed. All LEDs come on briefly
when the control unit is powered up.
CONTROL STATUS
✹The LED flashes continuously when the control
unit is supplied with current, regardless of
whether the engine is running or not.
SHUTDOWN
❍The LED is out.
STARTING
✹The LED lightsup as soon as the engine starts to
rotate during an attempt to start it and follows
the programmed starting sequence until it has
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.
POWER-
❍The LED remains out during normal operation
as long as no fault is detected by the control
unit. See next page for the procedure to be adop-
ted in the event of a fault.
POWER+
✹If the control unit is programmed to allow the
engine to be operated according to more than
one power/torque curve (map), the following
applies.
The LED comes on when the engine is run at
more than 100% power output (MAP 2). It goes
out when the engine returns to the 100% power
output curve (MAP 1) or when the power output
required is less than 100%.
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2001-05:1 © Scania Industrial & Marine Engines 15
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.
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16 © Scania Industrial & Marine Engines 2001-05:1
Changing functions using the DIP
switches in the control unit
There are 8 DIP switches in the control unit under the
round black rubber cover.
These switches shall be in the ON position to obtain
normal functions according to the operating program.
However, for single-speed engines, the normal
position of DIP switches 6, 7, and 8 may also be OFF
Shutdown at threshold values for low oil pressure and
high coolant temperature can be selected by setting
DIP switch 4to OFF
With DIP switch 4in position ON, Power- indication
is obtained for these threshold values. Engine output
reduction (LOP) can be selected to prevent damage to
the engine. Changes to the program must only be
performed by authorized personnel.
Note Do not operate the engine with a Power-
indication except for in emergencies.
Readout of fault codes
Note If the engine has stopped or lost power but
the main indicator lamp is out and neither
POWER- nor SHUTDOWN are on, the
fault is outside the control unit detection
range. Probable causes: fuel shortage,
temporary overload, mechanical fault.
- Activate the lamp test/fault code switch. In
Scania electrical equipment the main indicator
lamp is located in this switch on the main supply
box.
- All LEDs will then come on for 2 seconds to
indicate that they are intact and in working order.
This also applies to the main indicator lamp in the
main supply box and the instrument panel.Make
a note of any LED that is defective.
- All LEDs will then be out for approximately 4
seconds.
- Following this, a fault code will be indicated on
one of the LEDs for 2 seconds. Note which LED
it is.
- The control unit then resumes the operating mode
automatically.
- After having made a note of the fault code, reset
the lamp test/fault code switch and reset the
control unit by turning off its power supply
momentarily.
- The most probable cause of the fault can then be
found in the trouble shooting schedule on the next
page.
- When the fault or faults have been rectified the
engine can be restarted.
- If the control system continues to indicate a fault
by way of the main indicator lamp, further faults
may have been recorded. The fault code readout
must then be repeated as per above since the
system can only display one fault code at a time.
- The fault(s) will be stored in a special memory in
the control unit along with information about the
operating time when it(they) occurred. Stored
faults can be accessed and erased by authorised
service personnel.
DIP switches are shown in the ON position
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2001-05:1 © Scania Industrial & Marine Engines 17
READOUT OF FAULT CODES
LED INDICATION WHEN THE LAMP TEST/FAULT CODE SWITCH IS ACTIVATED
CONTROL STATUS
SHUTDOWN
STARTING
RUNNING
TORQUE LIMIT
BOOST LIMIT
POWER -
POWER +
Probable cause Action
✹DEC2 has detected an internal fault in the control unit. Send in the control unit for repair as soon as
possible.
✹The engine temperature has reached the threshold level
or the temperature sensor is inoperative. Check the cooling system. Check the temperature
sensor and cable routing.
✹The engine has reached the overrevving limit or the
engine speed sensor is inoperative. Check the wiring and connector.
Renew the engine speed sensor.
✹Control rack position sensor inoperative. Check connectors and cables to governor.
✹The intake air temperature has reached the threshold
level or the charge air temperature sensor is inoperative. Check the intake system. Check the temperature
sensor and cable routing.
✹DEC2 detects no charge air pressure.
The charge air pressure sensor is inoperative. Check the charge air pressure hose. Send in the
control unit for repair if the connection is damaged.
✹Engine speed potentiometer or the idling safety switch
is inoperative. Check the cable routing, connectors and cables.
✹The oil pressure has dropped to the threshold level or
the oil pressure monitor is inoperative. Check oil level, connector and cable.
Renew the oil pressure monitor.
✹=LED on
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18 ©Scania Industrial & Marine Engines 2001-05:1
STARTING AND RUNNING
AT FIRST START
When the engine is started for the first time, follow the maintenance points
listed under "First start" in the maintenance schedule, see page 25.
Since the points are important for satisfactory operation of the engine right
from the outset, they are also listed below.
1. Checking the oil level (see page 27).
8. Checking the coolant (see page 32).
The coolant should contain corrosion inhibitor to protect the cooling
system from corrosion.
If there is a danger of freezing:
- Only anti-freeze glycol should be used in the coolant as protection
against corrosion. We recommend only nitrite-free anti-freeze glycol
with the following supplier designations:
BASF G48 or BASF D542
-The concentration of glycol should be 30 - 60% by volume depending
on the ambient temperature. A content of 30 % by volume provides
protection down to -16 °C. See page 32.
-Never top up with only water or only glycol. Fluid losses must always
be replaced with pre-mixed coolant having the same glycol
concentration as that in the engine. If the glycol content drops, both
anti-freeze protection and protection against corrosion are impaired.
Note A glycol concentration below 30% by volume will not provide
sufficient protection against corrosion. Glycol concentrations
higher than 60% do not improve anti-freeze protection and have
a negative effect on engine cooling capacity.
If there is no danger of freezing:
- Only Scania Anti-corrosive should be used in the coolant as protection
against corrosion. The correct concentration of anti-corrosive is 7-12%
by volume and this must never drop below 7% by volume. The inhibitor
in Scania Anti-corrosive is nitrite-free.
- First top up: Top up with Scania Anti-corrosive as indicated on the
packaging.
-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.
Coolant filter (not standard equipment)
Only coolant filter without inhibitor may be used. The use of coolant filters
increases the life of the coolant and reduces the risk of deposition corrosion.
The recommended glycol must
not be mixed with glycol having
nitrite-based anti-corrosive.
The use of too much Scania
Anti-corrosive as mixed with
glycol may cause deposits.
If a coolant filter has been fitted
it must not contain 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
(no glycol)
Ethylene glycol and corrosion
inhibitor, if swallowed can be
fatal.
Avoid contact with the skin.
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2001-05:1 ©Scania Industrial & Marine Engines 19
14. Checking the fuel level (see page 41).
17. Checking the electrolyte level in batteries (see page 43).
18. Checking the state of charge in batteries (see page 43).
20. Checking the coolant level monitor (see page 44) (if fitted).
21. Checking the temperature monitor (see page 45).
22. Checking the oil pressure monitor (see page 46).
23. Checking transmission tension (see page 47).
CHECKS BEFORE RUNNING
Before running, "Daily maintenance" as described in the maintenance
schedule should be carried out, see page 25.
STARTING THE ENGINE
If the fuel tank has been run dry or if the engine has not been used for a long
time, bleed the fuel system (see page 41).
Out of consideration for our common environment, your new Scania engine
has been designed to use a smaller amount of fuel when starting. Using
unnecessarily large amounts of fuel when starting the engine always results in
the discharge of unburnt fuel.
- Open the fuel cock, if fitted.
- Declutch the engine.
- Engines with battery master switch: Switch on the power by means of
the battery master switch.
- DEC2: If the main indicator lamp comes on or flashes when the power is
turned on, this indicates the presence of a fault in the control system or
engine which must be found and rectified before the engine is started.
See page 15.
- Start the engine by means of the starter button or starter key.
Starting at low temperatures
Local environmental requirements must be complied with. Starting aids,
engine heaters and/or flame start devices should be used to avoid starting
problems and white smoke.
To limit white smoke, the engine should be run at low speed and under
moderate load. Avoid running it longer than necessary at idling speed.
Immobilise the starting device
when working on the engine.
If the engine starts out of
control, there is a
SERIOUS RISK
OF INJURY.
Only start the engine in a
properly ventilated area.
When operating the engine in
an enclosed area, an effective
extraction device for exhaust
gases and crankcase gases
must be used.
Never use starting spray or
similar as a starting aid.
An explosion may occur in the
intake pipe, which could cause
personal injury.
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20 ©Scania Industrial & Marine Engines 2001-05:1
At temperatures below 0 °C:
Note Only use starting aids recommended by Scania.
- The starter motor may only be used for 30 seconds at a time. After that
time it must cool for 2 minutes.
If the engine has flame start:
- Operating flame start without timer relay: Press the control button,
which also acts as a pre-glow button (max. 20 seconds). The glow plug
continues to glow as long as this button is depressed after the engine has
started. Maximum time is 5 minutes.
- Operating flame start with timer relay: Press the pre-glow button
(a maximum of 20 seconds). Release it when the engine starts. Thetimer
relay keeps the glow plug glowing for 5 minutes. If a shorter glow time
is required, press the release button. The key must be set to the
0 position if the start attempt fails.
Note If the engine is equipped with an INTERLOCK switch, this
switch should be depressed and held down until the oil pressure
has reached a sufficiently high level.
- Warm up the engine with a light load. A light load on a cold engine
gives better combustion and faster heating than warming up with no
load.
Maximum starter engagement
time is 30 seconds. Risk of
overheating. Allow starter to
cool for 2 minutes after a
starting attempt before
cranking again.
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