Opm 0000239 01
Opm 0000239 01
Opm 0000239 01
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
D9 DI9
Marine engine
opm96-9m en 1 588 295
2001-05:1
Engine number
Start-up date
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
D9 and DI9 marine engines. The instructions apply to engines in program 96,
starting with engine number 5 119 902.
The engines are of direct-injection, liquid-cooled, four-stroke, 6-cylinder in
line diesel type. The engines are available with or without charge air cooler,
see page 10.
The engines may have two different cooling systems, a heat exchanger which
is cooled by sea water or keel cooling which has cooling coils on the keel in
which the engine coolant is cooled.
Common areas of usage include propulsion engines in boats like patrol boats
and fishing boats, larger pleasure craft or propulsion engines or aggregate
engines on board ships.
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
During the warranty period,
practical experience of Scania engines. only use genuine Scania parts in
Note: Always use genuine Scania parts in service and repair to keep the service and repair for the
engine operating correctly. warranty to be valid.
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
©
2001-05:1 Scania Industrial & Marine Engines 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.
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
Refer to example control, there is a
SERIOUS RISK
OF INJURY.
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-
pand, and close the fuel filler cap properly. Operation
Only use fuel recommended in the service The engine should not be operated in environ-
literature. Fuel of an incorrect grade may cause ments with surrounding explosive materials
malfunctions or stoppage by interfering with the since electrical or mechanical components of
operation of the fuel injection pump and the in- the engine may emit sparks.
jectors. It is always a safety hazard to be near an en-
This could cause engine damage and possibly gine that is running. Body parts or clothing, or a
personal injury. dropped tool may get stuck in rotating parts,
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.
Chemicals
Lifting the engine
Most chemicals, such as glycol, corrosion in-
hibitors, preservation oils, degreasers etc. are Use the engine lifting eyes when lifting the
hazardous. Always follow the safety precau- engine. First check that the lifting equipment is
tions stated on the container. in proper condition and has sufficient lift capac-
ity rating.
Some chemicals, e.g. preservative oil, are
flammable. Auxiliary equipment fitted to the engine may
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
persons. Always dispose of superfluous or Never work below a suspended engine!
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.
DI 9 44 M 31 S LR
Type
D Turbocharged diesel engine
DI Turbocharged diesel engine with liquid-cooled charge air cooler
Application
M For marine use
Variant 01-99
Governor type
D Electronically controlled auxiliary governor
S RSV, all-speed and single-speed governor
T RQ, single-speed governor
K RQV-K, all-speed governor
17 3
6 5 19 7 1
2
9
13
14
10 4 7 11 12
The drawings illustrate a common type of DI9 engine.
Your engine may have other equipment not shown here.
Engine speed
The Scania tachometer is divided into sectors of different colours, as follows.
Coolant temperature
Correct coolant temperature during operation:
70 - 93 °C for system at atmospheric pressure.
70 - about 100 °C for system with positive pressure.
High coolant temperature leads to engine damage. Reduce the load on the
engine in order to lower the temperature. If the temperature does not drop,
stop the engine and look for the fault.
During long periods of operation with very low power take-off, the engine
may have difficulty in reaching 70 °C. However, if the load is increased, tem-
perature will rise.
2. Stop the engine using the stop control. Engines with a stop solenoid and
fuel shut-off valve are stopped using the stop button. Hold the stop but- There is danger of turbo damage
ton depressed until the engine has fully stopped.
and post boiling if the engine is
3. Engines with battery master switch: Cut the power using the battery stopped without cooling.
master switch. (Does not apply to emergency power back-up units).
4. Set the control switch to 0. (Does not apply to emergency power back-
up units).
The power must not be switched
Emergency stop off before the engine has
The stop solenoid linkage system has a knob marked ”STOP”. Pull the lin- stopped.
kage system to the stop position using this knob if it is not possible to stop the
engine using the stop solenoid.
Annually
1200 h
2400 h
4800 h
400 h
200 h
400 h
Daily
LUBRICATION OIL SYSTEM, page 20
1. Checking oil level l l
2. Oil change l1 l
3. Cleaning the lubrication oil cleaner l1 l
4. Changing the turbo filter l1 l
COOLING SYSTEM, page 24
5. Checking coolant level l
6. Checking corrosion protection rods 4) l5 l
7. Checking seawater pump impeller 4) l5 l
8. Checking coolant l l6 l6
9. Cleaning cooling system l1 l
AIR CLEANER, page 32
10. Test reading low pressure indicator l
11. Cleaning coarse cleaner l1 l
12. Cleaning or changing filter insert l3 l
13. Changing safety cartridge l l
FUEL SYSTEM, page 35
14. Checking fuel level l l
15. Changing main filter l1 l
16. Checking injectors l l
ELECTRICAL SYSTEM, page 37
17. Checking electrolyte level in batteries l l2 l
18. Checking charge state of batteries l l2 l
19. Cleaning batteries l2 l
20. Checking level monitor l l l
21. Checking temperature monitor l l l
22. Checking oil pressure monitor l l l
23. Checking stop function l l l
MISCELLANEOUS, page 42
24. Checking transmission belt l l l
25. Look for leaks. Remedy as necessary l
26. Checking/adjusting valve clearance. l l
27. Changing (or cleaning) valve for closed crankcase l
ventilation
Oil analysis
Some oil companies can offer analysis of the engine oil. Such analysis
measures the oil TBN (Total Base Number), TAN (Total Acid Number), fuel
dilution, water content, viscosity and the quantity of friction particles and
soot in the oil.
The result of a series of analyses is used as the basis for establishing a
suitable oil change interval.
If the conditions are changed, a new oil analysis programme must be carried
out to establish the new change interval.
SAE 20W-30
SAE 30
SAE 40
SAE 50
SAE 5W-30
SAE 10W-30
SAE 15W-40
- Lift out the rotor and slacken the rotor bowl retaining nut three turns.
- Tap the nut lightly with your hand or a plastic hammer, to detach the
rotor bowl from the bottom plate.
- Scrape off the deposits from the inside of the rotor bowl. If there are no
deposits, this indicates that the cleaner is not working properly.
- If the deposits are thicker than 20 mm: clean more often.
- Fit the O-ring in the rotor bowl. Make sure it is not damaged.
Change if necessary.
Functional test
The rotor spins very fast and should continue to rotate when the engine has
stopped.
- Stop the engine when it is warm.
- Listen for a whirring sound from the rotor or feel whether the cleaner
housing is vibrating.
The rotor normally continues spinning for 30 - 60 seconds after the engine
has stopped.
If not: dismantle it and inspect.
COOLING SYSTEM
5. Daily:
CHECKING COOLANT LEVEL
- Open the expansion tank filler cap and check the coolant level.
Carefully open the cap.
- Correct level: (integrated expansion tank in heat exchanger)
Hot water and steam
- Cold engine: Coolant level should reach the lowest part of the may blow out.
filler pipe.
- Warm engine: Coolant level should be between 10-20 mm above the
lowest part of the filler pipe.
- Other types of expansion tank according to the installer’s instructions.
- Top up the coolant as necessary, see point 6.
Always top up with ready mixed
Note When filling large amounts of coolant: coolant.
Never pour cold coolant into a hot engine.
This could cause cracks in the cylinder block and the cylinder
head.
b)
Checking the glycol content
If there is a danger of freezing, use only glycol as an anti-corrosive in the
coolant.
- Cooling systems with glycol should contain at least 30% glycol by Ethylene glycol is highly
volume to provide acceptable protection against corrosion. dangerous if ingested and can
- A content of 30% glycol by volume protects against freezing down to prove fatal.
-16°C. If further protection is needed, refer to the table on the next page Avoid skin contact with glycol.
for calculating the required amount of glycol.
We recommend only nitrite-free anti-freeze glycol with the following sup-
plier designations:
BASF G48 or BASF D542
- Always top up the anti-freeze if its glycol content drops below 30% by The coolant should be ready
volume. A glycol content above 60% by volume will not provide greater mixed when it is poured into the
protection against freezing. cooling system.
- The table shows the temperature at which ice starts to form. The engine Never top up with only water or
will freeze and fracture at appreciably lower temperatures, see diagram. only glycol.
- Ice forming in the coolant often causes malfunctioning without any risk
of damage. The engine should not be subjected to heavy loads when ice
starts to form.
Note Change the coolant when cleaning the cooling system: Every 4800
hours or minimum every 5 years. The recommended glycol must
not be mixed with glycol having
Important If a coolant filter is used in the cooling system, it must not nitrite-based anti-corrosive.
contain an inhibitor.
Risk for build up of sludge and
reduced cooling capacity.
A
% glycol by
15 20 25 30 35 40 45 50
Cooling 60
volume
system
Ice slush starts 3
-6 -9 -12 -16 -22 -27 -36 -46 -55 capacity, dm
to form at °C
5 6 8 9 11 12 14 15 18 30
6 8 10 12 14 16 18 20 24 40
8 10 13 15 18 20 23 25 30 50
9 12 15 18 21 24 27 30 36 60
11 14 18 21 25 28 32 35 42 70
12 16 20 24 28 32 36 40 48 80
14 18 23 27 32 36 41 45 54 90
15 20 25 30 35 40 45 50 60 100
Glycol dm3 17 22 28 33 39 44 50 55 66 110
(litres) 18 24 30 36 42 48 54 60 72 120
20 26 33 39 46 52 59 65 78 130
21 28 35 42 49 56 63 70 84 140
23 30 38 45 53 60 68 75 90 150
24 32 40 48 56 64 72 80 96 160
26 34 43 51 60 68 77 85 102 170
27 36 45 54 63 72 81 90 108 180
29 38 48 57 67 76 86 95 114 190
30 40 50 60 70 80 90 100 120 200
A= Area to be avoided. Only for calculating glycol mix.
Coolant freezing temperature when ice starts to form at different glycol mixes
1. Cover
2. O-ring
3. Flange
4. Heat exchanger
5. Heat exchanger
element
6. Cover
1. Spacer
2. O-ring
3. Flange
4. Charge air cooler hous-
ing
5. Charge air element
6. Cover
7. Heat exchanger
1. Pour the cleaning solution into the element outlet at the same time as
turning the element so that the cleaning solution pours through the
element against the direction of the air flow.
2. Leave the element in the cleaning solution for 5 minutes and then take it
out so that all the cleaning solution drains away.
3. Rinse the element with ca 30 litres clean water at 30 - 40 °C. Pour the
rinsing water into the element in the same way as the cleaning solution.
4. Take out the element and allow the rinsing water to drain off.
5. Repeat the procedure until the rinsing water is clean.
6. Leave the element to dry in a warm place for a few days.
3 2 1
Important Take care to fit the delivery pipe without tension and make sure
that the cone on it is correctly positioned in the connection.
6. Fit the leak-off fuel line. Tighten the bolts to 11 Nm (1.1 kpm).
1. Delivery pipes
2. Cap nut
3. Washer
4. Cone
5. Connector on injector or
injection pump
90 51.2 ± 4.3 ±3
100 38.5 ± 3 ±3
Important Stop solenoids with a timer module may be activated for start
and stop a maximum of 3 times per minute. Otherwise, the
timer module may be damaged and the stop feature cease.
Important The stop solenoid must not be activated more than 3 times per Installation “Pull to stop”
minute as the timer module can be damaged.
Important The stop solenoid must not be activated more than 3 times per
minute as the timer module can be damaged.
MISCELLANEOUS
24. Every 1200 hours:
CHECKING THE DRIVE BELT
Replace the drive belt (1) (poly V-belt) if worn or damaged. 2
Also check that the automatic belt tensioner (2) is working and keeps the
drive belt correctly tensioned. 1
A small amount of leakage from the overflow holes during the engine
running-in period is normal. (Seals and O-rings are lubricated with soap In case of major leakage,
or oil when fitted). contact the nearest Scania
This leakage normally stops after a time. workshop.
Note
Readings can either be taken
from underneath or from
above, depending on which
flywheel is used.
The cover not being used is
covered with a seal and an
instruction plate.
FLYWHEEL
Preservative coolant
If the engine is to be stored with a full cooling system, use coolant containing Ethylene glycol, if swallowed
50% glycol by volume. Glycol without nitrite-based inhibitor must be used. can be fatal.
E.g. BASF G48 or BASF D542. Avoid contact with the skin.
Preservative fuel
- Use diesel fuel mixed with Lubrizol 560A or equal.
- Mix 1 cm3 (ml) of Lubrizol 560A with 10 dm3 (l) of fuel.
In case of splashes in the eye: Rinse with moderate water spray (for min. 15 minutes). Seek medical attention.
In case of skin contact: Wash affected areas with soap and water.
If you inhale it: Fresh air, rest and warmth
Flammable: Fire class 2A. Flash point + 27°.
In case of fire: Extinguish using carbonic acid, powder or foam
Storage: In properly sealed container in a dry, cool place. Keep out of reach of children.
STORED ENGINE
Date . . . . . . . . . . .
Do not start or crank!
Batteries
Remove the batteries for trickle charging at a charging station. (This does not
apply to batteries which, according to the manufacturer, are maintenance Wear gloves and eye protection
free.) The same is applicable for short-term storage if the engine has not been
prepared for storage as above. when charging and handling
batteries.
Storage Batteries contain a highly
After the preparations, the engine should be stored in a dry and warm place corrosive acid.
(room temperature).
LUBRICATION SYSTEM
Max. oil pressure
(warm engine at speeds above 800 rpm) bar (kp/cm2) 6
Normal oil pressure
(warm engine at operating speed) bar (kp/cm2) 3-6
Min. oil pressure
(warm engine 800 rpm) bar (kp/cm2) 0.7
Oil capacity, see page 21
COOLING SYSTEM
Number of thermostats 2
Thermostat, opening temperature °C 79
Coolant temperature:
system with atmospheric pressure °C 70 - 93
system with positive pressure °C 70 - about 100
Capacity
with heat exchanger dm3 (litres) 40
without heat exchanger
(keel-cooling engine) dm3 (litres) 25
ELECTRICAL SYSTEM
System voltage V 24
Alternator, current A 65 or 90
Starter motor power kW (hp) 4.0 (5.4)
Monitors, settings:
Oil pressure monitor bar (kp/cm2) 2-pole: 0.7 ± 0.15
Temperature monitor °C Stamped on monitor hexagon
Property Requirement
Viscosity at 40°C 2.0 - 4.5 mm2/s (cSt)
Flashpoint 56°C
Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Long-term storage . . . . . . . . . . . . . . . . . . . . . . 46