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  Operation and Maintenance Manual SC9DF Series Diesel Engine Shanghai Diesel Engine Co., Ltd. March, 2010…
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  7. Notices for repair and replacement of the diesel engine parts: Users shall follow the Repair & Maintenance Manual of SC9DF Series Diesel Engine in the process of repair; Please purchase the parts subject to the specifications of parts catalogue of the diesel engine, and only adopt the products approved by our original equipment manufacturer in order to ensure performance, reliability and service life of the diesel engine.
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  Users also have to read the Repair & Maintenance Manual of SC9DF Series Diesel Engine for removal, installation and repair of the diesel engine, and purchase relevant parts in terms of Parts Catalogue of SC9DF Series Diesel Engine.
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  Operation and Maintenance Instruction of SC9DF Series Diesel Engine Contents General Model identification of SC9DF series diesel engine Acronym and abbreviation definitions Nameplate of the diesel engine Outline drawing of SC9DFQ3 diesel engine Main technical and performance specification of the diesel engine…
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  Diesel engine emission (L) Shangcai Power Example: SC9DF375Q represents 114 series 9-liter electronic-controlled four-valve vehicle diesel engine of 375 HP compliant with China III made by Shanghai Diesel Engine Co., Ltd. 1.2 Acronym and abbreviation definitions Electronic-controlled High Pressure Common-rail System…
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  1.3 Nameplate of the diesel engine The nameplate of the diesel engine lists the special information of the diesel engine, which serves as the main basis for the user to purchase the maintenance parts and for our company to conduct after-sale technical service.
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  Air Bleeding joint Engine water outlet Warm water outlet Output pulley Engine water inlet Starting motor Flywheel Oil filter Water housing drain Oil temp. sensor joint M15 Oil drain plug Exhaust side view Compressor inlet Compressor air outlet Water filter control Turbine outlet Oil filler…
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  Chapter II Main Technical & Performance Specifications for Diesel Engine 2.1 Main technical specifications Four stroke, water-cooled, in-line, charged and Type inter-cooled intake air Number of cylinders Number of valves per cylinder Bore × stroke, mm 114×144 Displacement, L 8.82 Fuel injection equipment High-pressure common rail Compression ratio…
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  2.3 Main technical parameters Engine model SC9DFQ3 Technical parameters Valve clearance (cold state) Intake valve, mm 0.30 Exhaust valve, mm 0.50 Intake valve opening: 22.5°CA BTDC Valve timing (°) crankshaft angle Intake valve closing: 42.5°CA ABDC (Valve clearance: when intake is 0.30 mm Exhaust valve opening:69.5°CA BBDC and exhaust is 0.55 mm) Exhaust valve closing: 34.5°CA ATDC…
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  Max absorption vacuum of fuel transfer pump, kPa Max fuel return resistance, kPa Fuel inlet flow temperature, ℃ 35-45 Electrical system Min. battery capacity recommended 24V system: * Cold start current at -18°C , A (320) (Reserve capacity current, A)** Cold start current at 0°C, A (240) (Reserve capacity current , A)**…
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  /s or above during the diesel engine is working. 2.4.2 Lube oil As per the specification, SC9DF series diesel engine shall apply the special oil for D6114 diesel engine provided by Shanghai Diesel Engine Company or the oil above CF level.
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  2.4.3 Coolant The coolant for SC9DF series diesel engine shall be the composite liquor mixed by certain ratio of antifreeze and DCA4 chemical additive. As the antifreeze can prevent the coolant from freezing and increase the boiling point of coolant, we require the antifreeze be used under any weather conditions.
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  Name Thread spec. Final torque (Nm) Tightening method 125±5 N·m First: 50 N·m Main bearing cap bolts M16-4h6h Final angle Second: 120-130 N·m 210°±5° Third: angle 210°±5° First: 50N·m 115±5 N·m Cylinder head bolts Second: 110～120 N·m M14-4h6h Final angle 240°±5°…
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  Fuel pump fuel inlet banjo 18±2 N·m bolt High pressure common rail 16±2 N·m fuel return banjo bolt Fuel filter sensor 20±3 N·m Lifting plate bolts 77±6 N·m Oil filter head 40±10 N·m Oil drain plug 80±4 N·m Heater plug in oil sump 80±4 N·m Oil pressure regulating 80±4 N·m…
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  Table 3 Recommended tightening torque for tapered screw plug Specification of screw plug Torque N⋅m Effective thread (outer Thread Cast iron or steel Aluminum diameter) 1/16 10.4 13.7 17.3 21.6 26.7 33.5 42.2 48.3 Table 4 Recommended tightening torque for pipe banjo bolt Specification M8×1 M10×1…
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  Turn the electrical key from ON position to START position to start the diesel engine when the indicator lamp blinks and goes off. △Caution: SC9DF series electrically controlled diesel engine can usually be started quickly and run smoothly even in a very low temperature environment. For those machines to be stopped outside, the winter protections and specific warm-up time shall be provided.
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  Rotate crankshaft by the starter motor until the oil pressure gauge reads the pressure. Open the throttle. Start the diesel engine as per the start procedures specified in 3.1.1 (Normal start) or 3.1.2 (Low temperature starting). Discharge the air in the fuel system according to descriptions in article 4.4.2. 3.2 Running the diesel engine 3.2.1 New diesel engine running-in New diesel engines or those after overhaul can be put into full-load service only after a specific period of…
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  3.3 Operation and control of diesel engine brake Some of SC9DF series diesel engines are equipped with in-cylinder braking system, which can be used to reduce the loads on the vehicle braking system effectively, so that you can decrease and control the vehicle speed without pressing down the accelerator pedal, especially when driving down the slope, and avoid overheating of breaking drum to ensure driving and life safety, as well to reduce vehicle running &…
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  Chapter IV Repair & Maintenance of Diesel Engine 4.1 Repair and Maintenance schedule It is recommended to maintain the SC9DF series electronically controlled diesel engine according to the «Repair and Maintenance Procedures» specified in this Section. The maintenance interval shall be shortened appropriately in case of the diesel engine is always operating at the ambient temperature lower than -18℃…
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  The preventative maintenance work on diesel engine starts with understanding daily working conditions of diesel engine itself and its systems. Daily maintenance shall be made before starting: Check the oil level Check the coolant level Check whether the belt is worn or damaged. Check the drive system of the fan Check the oil and water separator Visually check for leakage…
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  Caution: The water filler cap or inspection port choke plug of the cooler can be unscrewed only after the diesel engine coolant temperature falls below 50°C. If unscrewed operation is done immediately after the engine stops running, this can cause injuries due to suddenly spraying-out of high temperature water and steam! It is required to unscrew them slowly until the pressure of cooling system is gradually reduced.
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  Check the belt tension. Measure the deflection of the belt at its maximum span. The maximum deflection shall not more than 9.-12.7mm. It’s also allowed to measure the tensile force at the maximum span of the belt if an instrument for measuring the belt tensile force can be available;…
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  Check air intake intercooler; Check wiring harness of the electric control system; Sensor 4.3.1 Replace oil filter cartridge and oil The oil and oil filter cartridge shall be replaced periodically to remove the pollutants suspended in the oil, that’s because the used oil will become dirty and the oil additives will decrease after the diesel engine has been put into service.
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  Replace oil filter cartridge Stop the diesel engine when the water temperature reaches 60℃, and then clear stains around the oil filter assembly. Use matching socket to remove the rotary type oil filter cover (the cover will be damaged if using common spanners), and then draw out the oil filter cartridge.
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  4.3.2 Check air filter Air filter units shall be replaced if the resistance exceeds the following values: Supercharger and supercharged intercooling models: 6.2kPa; △Caution: The air filter resistance shall be checked under the rated condition of the diesel engine. Make periodical checks if the air filter is equipped with maintenance indicator;…
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  Check the intercooler pipes, radiating fins and welding seams to see whether there are cracks, loose welds or other defects. If the oil or rubbish is found to pass into the air intake intercooler due to supercharger failure or other causes, remove the intercooler from the machine for water cleaning.
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  4.4.1 Replace the fuel filter Clean surroundings of the fuel filter seat. Remove the fuel filter and clean sealing surface of the filter seat. Fill new fuel filter with clean diesel and lubricate the rubber seal ring with clean oil. Install fuel filter according to the instruction printed on the surface of the fuel filter.
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  4.4.3 Check for concentrations of anti-freeze fluid and coolant additive Use ice point apparatus to check anti-freeze fluid concentration under any climatic condition, it’s necessary to add anti-freeze coolant, that’s because it can increase boiling point of the coolant and decrease condensation point meanwhile, so that the operation temperature range of the diesel engine coolant is expanded.
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  Check adjust specified valve clearances according to Step A at the piston TDC of the cylinder 1 (I represents air inlet; E represents air outlet). The clearance values shall not be changed during rechecking of all valves clearance after tightening the rocker arm locknuts.
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  Rotate the fan to check whether there is something wrong with the rotation axle bearing. △Caution: Rotating the fan shall be free of vibration without significant axle float. 4.6 Maintenance content every 80000 km, 2000 h or 2 years The following maintenance items shall be completed in Water Water temperature…
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  Check whether the belt has been damaged and the clamp loosened or damaged, and replace them if necessary. Check if there exists leakage, damage and dust stratification. Clean and repair them if necessary. Fill the diesel engine cooling system with sodium carbonate detergent.
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  Fill the cooling system with clean water Diesel engine inlet △caution: intercooler must be exhausted out to ensure it is full of the coolant. Do not install water inlet cover of the radiator nor does new cooling water filter. Start the diesel engine and run it for 5 min with the Start coolant temperature higher than 80℃.
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  4.6.2 Check the crankshaft torsional vibration damper Check whether the scribed lines (A) on inner ring (B) and outer ring (C) of torsional vibration damper move, and replace the damper if misplacement of the above two scribed lines exceeds 1.6 mm. Check whether the damper rubber components have aged or not.
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  Measure total thickness of carbon deposit layer Internal diameter of inside the exhaust pipe inner hole of the air exhaust pipe compressor, and if the total thickness (× ＋ ×) exceeds 2 mm, clean and check air compressor cylinder head, valve assembly and exhaust pipe. Replace them if necessary.
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  Apply the anti-seizure agent on the outer surface of the unloading valve bonnet. Apply the 15W-40 clean oil on the outer surface of the unloading valve O ring. Install the unloading valve components on the air compressor cylinder head, and tighten the compression bolt of the unloading valve body.
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  Chapter 5 Troubleshooting Guidelines Only when correct operation and regular maintenance is done as required in this manual can the failure be eliminated effectively. Any abnormal condition during operation on diesel engine shall deserve attention and timely be reported to the Maintenance Department, so that the troubleshooting methods can be available.
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  5.2 Diesel Engine Suddenly flames out Possible Causes Troubleshooting methods The fuel is contaminated Replace with clean and qualified fuel The air enters the fuel system Deflate the fuel system high-pressure pipe Check for leakage, tighten/replace relative parts if necessary leakage Check channel and filter element, clean coarse strainer and filter The fuel pipe or filter is blocked…
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  5.4 Fuel Consumption is too high Possible causes Troubleshooting methods The fuel is leakage Check for pipe tightness of fuel system, please tighten it if it is loose The fuel quality is poor Use the qualified fuel as recommended Additional load is produced due to Check auxiliary devices and vehicle parts (refer to the failure of auxiliary device specification of vehicle manufacturer)
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  5.6 Diesel engine is overheating Possible causes Troubleshooting methods Check the coolant for leakage, add coolant and discharge air The coolant is insufficient completely Radiator pressure cap has failure Check the radiator cap The diesel engine is overloaded Operate it after reducing engine load radiator covered with…
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  5.8 Oil pressure is too low Possible causes Troubleshooting methods The oil level is too low Adjust the oil level The oil is incorrect in specification, Check for/replace with qualified oil or its viscosity is too low Oil pipeline joint is loose or oil duct Check for oil leakage cock separates The oil is diluted with water…
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  5.10 Diesel engine’s coolant temperature is too low Possible causes Troubleshooting methods Too much cold air flow through the Check the fan and fan clutch, refer to instructions of radiator manufacturer The radiator shutter is stuck at Check the shutter and replace it if necessary maximum opening Temperature sensor is failed Check/calibrate the sensor…
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  Possible causes Troubleshooting methods battery connector becomes Clean/tighten the battery connector loose or Corroded The engine belt slips Check/replace the belt and tension pulley The instrument or indicator lamp is Check/replace the instrument or indicator lamp malfunction The engine wire becomes loose or Repair the wire damaged The generator is failed…
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  Appendix 1 Repair and Maintenance Records Repair and Maintenance Records Diesel Engine No. Vehicle VIN No. Diesel Engine Model User Name Plant Name/Number Km (hrs) Actual Date Maintenance Content Maintainer Remark: Mileage Or Time Interval…