Scania DC13 XPI. Industrial engine. Operator’s manual - part 5

 

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Scania DC13 XPI. Industrial engine. Operator’s manual - part 5

 

 

Cooling system
Antifreeze and corrosion protection
concentration table, litres
35% by volume of Scania antifreeze provides
sufficient protection against corrosion.
Example:
• The total volume of the cooling system is 40
litres.
• The measured concentration of ethylene gly-
col is 35% by volume (freezing point -21°C).
According to the table there are 14 litres of
ethylene glycol in the cooling system.
• The required concentration of ethylene glycol
is 45% by volume (freezing point -30°C). Ac-
cording to the table, 18 litres of ethylene gly-
col are required in the cooling system.
• Since there are already 14 litres in the cooling
system, 4 litres of ethylene glycol must be
added to the cooling system (18 - 14 = 4 li-
tres).
Adequate protection against corrosion
Volume of ethylene glycol (%)
35
40
45
50
60
Cooling system volume
Ice slush forms (°C)
-21
-24
-30
-38
-50
(litres)
11
12
14
15
18
30
14
16
18
20
24
40
18
20
23
25
30
50
21
24
27
30
36
60
25
28
32
35
42
70
28
32
36
40
48
80
32
36
41
45
54
90
35
40
45
50
60
100
39
44
50
55
66
110
Volume of ethylene glycol (litres)
42
48
54
60
72
120
46
52
59
65
78
130
49
56
63
70
84
140
53
60
68
75
90
150
56
64
72
80
96
160
60
68
77
85
102
170
63
72
81
90
108
180
67
76
86
95
114
190
70
80
90
100
120
200
64
Cooling system
Antifreeze and corrosion protection
concentration table, US gallons
35% by volume of Scania antifreeze provides
sufficient protection against corrosion.
Example:
• The total volume of the cooling system is
10.6 US gallons.
• The measured concentration of ethylene gly-
col is 35% by volume (freezing point -6 °F).
According to the table there are 3.7 US gal-
lons of ethylene glycol in the cooling system.
• The required concentration of ethylene glycol
is 45% by volume (freezing point -22 °F). Ac-
cording to the table, 4.8 US gallons of ethyl-
ene glycol are required in the cooling system.
• Since the cooling system already contains 3.7
US gallons, fill another 1.1 US gallons of eth-
ylene glycol in the cooling system (4.8 - 3.7 =
1.1 US gallons).
Adequate protection against corrosion
Volume of ethylene glycol (%)
35
40
45
50
60
Cooling system volume
Ice slush forms (°F)
-6
-11
-22
-36
-58
(US gallons)
2.9
3.2
3.7
4
4.8
7.9
3.7
4.2
4.8
5.3
6.3
10.6
4.8
5.3
6.1
6.6
7.9
13.2
5.5
6.3
7.1
7.9
9.5
15.9
6.6
7.4
8.5
9.2
11.1
18.5
7.4
8.5
9.5
10.6
12.7
21.1
8.5
9.5
10.8
11.9
14.3
23.8
9.2
10.6
11.9
13.2
15.9
26.4
Volume of ethylene glycol (US gal-
10.3
11.6
13.2
14.5
17.4
29.1
lons)
11.1
12.7
14.3
15.9
19
31.7
12.2
13.7
15.6
17.2
20.6
34.3
12.9
14.8
16.6
18.5
22.2
37
14
15.9
18
19.8
23.8
39.6
14.8
16.9
19
21.1
25.4
42.3
15.9
18
20.3
22.5
26.9
44.9
16.6
19
21.4
23.8
28.5
47.6
17.7
20.1
22.7
25.1
30.1
50.2
18.5
21.1
23.8
26.4
31.7
52.8
65
Cooling system
Checking the coolant level
Checking the coolant's anti-
freeze and corrosion protec-
WARNING!
tion
Tool
Do not open the coolant filler cap in the expan-
sion tank if the engine is hot. Hot coolant and
steam may spray out and cause burns. If the cap
Description
Illustration
has to be opened do it slowly to release the pres-
Refractometer
sure before removing the cap.
Use protective gloves as coolant can cause irrita-
tion if it comes in contact with the skin.
IMPORTANT!
It is not permissible to top up large amounts of
coolant via the expansion tank. Filling via the ex-
pansion tank leads to air locks in the cooling sys-
tem which can lead to e.g. cavitation damage to
WARNING!
the coolant pump shaft seal. If a large amount of
coolant needs to be added, follow the instruc-
Avoid skin contact with coolant as this may
tions in the section Filling coolant.
cause irritation to the skin. Wear protective gog-
gles and gloves when handling coolant.
Only pour pre-mixed coolant into the cooling
system.
IMPORTANT!
The following instructions apply to Scania ex-
pansion tanks. For other types of expansion
tanks, follow the manufacturer's instructions.
Use only pure fresh water that is free from parti-
cles, sludge and other impurities.
1. Open the expansion tank cap and check the
coolant level.
1. Pour a small amount of coolant into a con-
- The right coolant level on a cold engine is
tainer and check that the coolant is pure and
even with the lower edge of the filler neck.
clear.
- The right coolant level on a hot engine is
approximately 25 mm (1 in) over the low-
2. Change the coolant if it is contaminated or
er edge of the filler neck.
cloudy.
2. Top up with coolant as necessary.
3. Measure the antifreeze and corrosion inhibi-
tor content with the refractometer.
66
Cooling system
The following rules apply to ethylene glycol-
based coolant:
• The antifreeze and corrosion inhibitor content
must be minimum 35 percent by volume for
corrosion protection to be sufficient.
• An antifreeze and corrosion inhibitor content
greater than 55 percent by volume impairs the
ability to protect against frost.
• If ice forms in the coolant, there are disrup-
tions initially, but there is no immediate risk
of damage. The engine should not be subject-
ed to heavy loads when ice starts to form.
67
Cooling system
Changing the coolant and
cleaning the cooling system
Draining coolant
WARNING!
Do not open the coolant filler cap in the expan-
sion tank if the engine is hot. Hot coolant and
steam may spray out and cause burns. If the cap
has to be opened do it slowly to release the pres-
sure before removing the cap.
Use protective gloves as coolant can cause irrita-
tion if it comes in contact with the skin.
Environment
Use a suitable container. Used coolant must be
disposed of as specified in national and interna-
tional laws and regulations.
Draining coolant with coolant pump
Special tool
Number, designation
Illustration
2 443 679, coolant
pump
1. Open the expansion tank cap.
68
Cooling system
2. Position the hose from the coolant pump in
an empty container.
3. Connect the pump to the draining nipple in
the cylinder block. See illustration.
4. Connect the pump's 2 cable terminals to the
battery's negative and positive terminal.
Make sure that the drainage starts. If the
drainage does not start: Change the position
of the cable terminals.
5. Repeat the procedure at the cooling system's
lowest drainage point. The location of the
lowest drainage point on the engine may dif-
fer depending on engine application.
Draining coolant with coolant trolley
Tool
Description
Illustration
Coolant trolley
1. Open the expansion tank cap.
2. Position the hose from the coolant trolley in
an empty container.
3. Connect the trolley to the draining nipple in
the cylinder block. See the illustration above.
4. Drain the coolant.
5. Repeat the procedure at the cooling system's
lowest drainage point. The location of the
lowest drainage point on the engine may dif-
fer depending on engine application.
69
Cooling system
Cleaning the cooling system
Note:
Clean the cooling system more often than speci-
fied in the maintenance interval if necessary.
External cleaning: Cleaning the radiator
and charge air cooler
IMPORTANT!
Do not use caustic soda or other alkaline deter-
gent as this could damage the aluminium.
Read the warning text on the detergent packag-
ing.
1. Check that the radiator and the charge air
cooler are not clogged on the air side and that
the cooling fins are not damaged.
2. Carefully scrape away any deposits from the
radiator cooling fins. Use a paraffin-based
engine cleaner if necessary.
3. Carefully straighten bent cooling fins using a
steel brush or the like.
70
Cooling system
Internal cleaning: Removing oil and
grease in the cooling system
Environment
Use a suitable container. Used coolant must be
disposed of as specified in national and interna-
tional laws and regulations.
Always fit a new thermostat and a new cover to
the expansion tank after cleaning, as the oil in the
cooling system destroys the seals. If the engine is
equipped with a coolant filter, also renew this fil-
ter.
It may be necessary to wash it multiple times if
the cooling system is very dirty. One cause of
contamination can be that oil is lying on top of
the coolant and collecting high up in the cooling
system. If several rinses are needed, this is not
necessarily because work has been carried out
incorrectly. Oil residues often need to be rinsed
repeatedly from the expansion tank and the ex-
ternal heating system to be completely clean.
Repeated washing is more effective and prefera-
ble to using higher concentrations of detergent
(max. 10%) or cleaning for a longer period (max
30 minutes).
If only a small amount of dirt has collected in the
expansion tank after cleaning, one extra rinse
and clean of the expansion tank only is usually
sufficient. There is no need to clean the whole
cooling system again.
1. Run the engine until it has reached operating
temperature and then drain the cooling sys-
tem following the previous description.
2. Remove the thermostat.
71
Cooling system
3. Fill the cooling system with clean hot water
mixed with detergent 2 479 017. Detergent
2 479 017 must make up 5-10% (depending
on the degree of dirt) of the total coolant vol-
ume.
If detergent 2 479 017 is not available, use a
dishwasher detergent for household dish-
washers that does not foam. Concentration
1%.
4. Warm up the engine for approximately 20-30
minutes. Remember to switch on the cab
heating system, if one is installed.
5. Drain the cooling system.
6. Fill the cooling system with clean, hot water
and run the engine for about 20-30 minutes.
7. Repeat steps 3-6 if the cooling system is not
clean.
8. Drain the water from the cooling system.
9. If necessary, clean the expansion tank by de-
taching all hoses and rinsing and cleaning
with a degreasing agent and a dishwashing
brush.
Alternatively, dismantle the expansion tank
and clean it with water with 10% of detergent
2 479 017. Fill the expansion tank with the
mixture, shake it and drain it. Renew the cov-
er of the expansion tank.
10. Fit a new thermostat.
11. Fill the cooling system with new coolant as
described in the next section.
12. Check again whether further dirt or oil has
collected in the expansion tank. Decide
whether it it is necessary to carry out another
full cleaning or whether only rinsing or
cleaning of the expansion tank will suffice.
72
Cooling system
Internal cleaning: Removing deposits in
the cooling system
Environment
Use a suitable container. Used coolant must be
disposed of as specified in national and interna-
tional laws and regulations.
1. Run the engine until it has reached operating
temperature and then drain the cooling sys-
tem following the previous description.
2. Remove the thermostats.
3. Fill the cooling system with clean, hot water
mixed with radiator detergent which is based
on sulphamic acid and contains dispersing
agents. Follow the manufacturer's instruc-
tions for the concentration and cleaning peri-
od.
4. Run the engine for the specified time. Re-
member to switch on the cab heating system,
if one is installed.
5. Drain the cooling system.
6. Fill the cooling system with clean, hot water
and run the engine for about 20-30 minutes.
7. Drain the water from the cooling system.
8. Refit the thermostats.
9. Fill the cooling system with new coolant as
described in the next section.
73
Cooling system
Filling coolant
These procedures apply when the cooling system
has been drained and needs to be filled with a
large amount of coolant.
WARNING!
Use protective gloves as coolant can cause irrita-
tion if it comes in contact with the skin. Hot cool-
ant can also cause scalding.
IMPORTANT!
Mix the coolant as specified in the section head-
ed Coolant.
It is not permissible to top up large amounts of
coolant via the expansion tank. Filling via the ex-
pansion tank leads to air locks in the cooling sys-
tem which can lead to e.g. damage to the coolant
pump shaft seal. If a large amount of coolant
needs to be added, follow the instructions in the
section Filling coolant.
Never fill a large amount of cold coolant in a hot
engine. There is great risk of cracks forming in
the cylinder block and cylinder heads.
Do not start the engine until the correct coolant
level has been obtained. If the engine is started
with an insufficient coolant level, it can damage
the coolant pump shaft seal, which leads to cool-
ant leakage.
74
Cooling system
Filling coolant with coolant pump
Special tool
Number, designation
Illustration
2 443 679, coolant
pump
1. Open the expansion tank cap.
2. Connect the coolant pump to the filler nipple
in the cylinder block. See illustration.
3. Connect the pump's 2 cable terminals to the
battery's negative and positive terminal.
Make sure that the filling starts. If the filling
does not start: Change the position of the ca-
ble terminals.
4. Start the engine and run it at idling for
15 minutes.
IMPORTANT!
It is very important that the engine is idling. En-
gine overspeed could damage the coolant pump
shaft seal, which leads to coolant leakage.
5. Switch off the engine and fill with coolant to
the maximum level through the expansion
tank.
Air pockets may still be left in the cooling sys-
tem. These will disappear after the engine has
been operated for a period of time. Therefore, the
coolant may need topping up at a later stage.
75
Cooling system
Refilling coolant with coolant trolley
Tool
Description
Illustration
Coolant trolley
1. Open the expansion tank cap.
2. Connect the coolant trolley to the filler nip-
ple in the cylinder block. See illustration.
3. Fill with coolant using coolant trolley to
pump up to the maximum level of the expan-
sion tank.
4. Disconnect the coolant trolley.
5. Start the engine and run it at idling for
15 minutes.
IMPORTANT!
It is very important that the engine is idling. En-
gine overspeed could damage the coolant pump
shaft seal, which leads to coolant leakage.
6. Switch off the engine and fill with coolant to
the maximum level through the expansion
tank.
Air pockets may still be left in the cooling sys-
tem. These will disappear after the engine has
been operated for a period of time. Therefore, the
coolant may need topping up at a later stage.
After filling, it may be good to start the engine
and check that no coolant leakage occurs.
76
Fuel system
Fuel system
Cleanliness requirements
IMPORTANT!
The whole fuel system is very sensitive to dirt
and even very small particles. Foreign particles
in the system can cause serious malfunctions. It
is therefore very important that everything is as
clean as possible when work is carried out on the
fuel system. Before repair work, the engine must
be washed. If possible, a hot water wash should
be used.
It is strictly forbidden to carry out any machining
work or work with compressed air near an open
fuel system.
Be extra careful and always use clean, lint-free
and dust-free clothes and disposable gloves
when working on the fuel system. Scania recom-
mends using Tegera 848 gloves.
Clean tools before they are used and do not use
any worn or chrome-plated tools. Material and
flakes of chrome may come off.
Clean connections and the surrounding area be-
fore removal. When cleaning, cloths or paper
which shed fibres must not be used. Use clean
and lint free cloths, part number 588 879.
Plug or cover the connections during removal.
Also clean the connections before the compo-
nents are fitted. Place removed components on a
thoroughly cleaned, dust-free surface. Scania
recommends using a stainless steel bench top,
part number 2 403 296. Cover the components
with a lint free cloth.
77
Fuel system
Checking the fuel level
Check the fuel level and top up with fuel as nec-
essary.
Note:
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 the section Bleeding the fuel system.
78
Fuel system
Renewing the fuel filters
Tool
Description
Illustration
Hexagon socket, drive
1/2", 36 mm
Environment
Use a suitable container. The fuel collected must
be disposed of as specified in national and inter-
national laws and regulations.
If the fuel tank is positioned higher than the fuel
filter housing, the shut-off valve between the fuel
tank and the fuel filter housing must be closed.
This is to prevent fuel running into the fuel filter
housing.
Removing the fuel filters using a
draining nipple
On certain engines, there is a draining nipple (1)
on the fuel filter housing. If there is no draining
nipple, see the following section.
1. Open the draining nipple.
To ensure that the filter housings are drained
1
properly, the filter covers must be removed as
follows:
2. On the main filter (B): Make a mark on the
cover. Unscrew the cover 3 to 4 turns with a
socket.
3. Repeat the procedure with the water separat-
ing prefilter (A).
A
B
A. Water separating prefilter
B. Main filter
79

 

 

 

 

 

 

 

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