Scania DC16 XPI en-GB 2 826 309. Industrial engine. Operator’s manual - part 4
Cooling system
Antifreeze and corrosion protection
Cooling system
The antifreeze and corrosion protection used in
Scania engines should be antifreeze (ethylene
Coolant
glycol) and corrosion inhibitor.
Note:
Only Scania coolant or another product with
The coolant should be changed when the cooling
functioning antifreeze and corrosion protection
system is cleaned: every 6,000 hours or at least
may be used in Scania engines. Products not ful-
every five years. See Changing the coolant and
filling the demands in this section may lead to
cleaning the cooling system.
faults and damage occurring in the cooling sys-
tem. This can lead to the invalidation of Scania's
warranty for faults and damage caused by the use
The coolant recommended by Scania is a mix-
of inappropriate coolant.
ture of water with antifreeze (ethylene glycol)
and corrosion inhibitor. The coolant has several
Addition of antifreeze and corrosion
characteristics which are important for the oper-
inhibitor to water
ation of the cooling system:
The coolant should contain 35-55% by volume
• Corrosion protection.
antifreeze (ethylene glycol) and corrosion inhib-
itor. The percentage varies depending on the
• Antifreeze.
need for antifreeze.
• Increases the boiling point.
A minimum of 35% by volume of Scania anti-
Water
freeze and corrosion protection is needed to pro-
vide sufficient protection against corrosion.
Use only pure fresh water that is free of particles,
sludge and other impurities. If there is uncertain-
Note:
ty about the quality of the water, Scania recom-
Too high a dose of antifreeze and corrosion in-
mends use of Scania ready-mixed coolants. See
hibitor will increase the amount of sludge and
the section Recommended Scania products.
blockages accumulating in the radiator. Too low
a concentration can lead to corrosion of the cool-
ing system and ice formation at low tempera-
tures.
Measure the ethylene glycol content (antifreeze
and corrosion protection) with a refractometer
following the instructions in the Checking the
coolant's antifreeze and corrosion protection sec-
tion.
48
Cooling system
Risk of freezing
IMPORTANT!
The engine should not be subjected to heavy
loads if ice starts to form in the cooling system.
If the coolant starts to freeze, the water in the
coolant starts to crystallise and the ethylene gly-
col content in the coolant increases. If freezing
produces a great increase in the amount of ice,
circulation problems could arise. There is no risk
of damage by freezing if the content of Scania
antifreeze and corrosion inhibitor, or an equiva-
lent mixture of a similar product, is at least 35%
by volume.
Minimal ice formation in the coolant sometimes
causes minor problems without any risk of dam-
age. For example, the auxiliary heater may not
work for up to one hour after the engine has been
started.
10
20
30
40
50
60%
The chart depicts coolant properties at different
o
percents of antifreeze and corrosion inhibitor
-10
C
concentration by volume.
o
-16
C
1
o
-20
C
Curve A: Ice formation starts (ice slush)
o
-30
C
Curve B: Damage by freezing
3
2
o
Area 1: Safe area
-40
C
Area 2: Malfunctions may occur (ice
o
-50
C
slush)
o
Area 3: Risk of damage by freezing
-60
C
B
A
The following example shows coolant properties
with 30 percent by volume of antifreeze and cor-
rosion inhibitor:
• Ice slush starts to form at -16°C (3°F).
• At -30°C (-22°F), there is a risk of cooling
system malfunction.
• There is no risk of damage by freezing with a
minimum antifreeze and corrosion inhibitor
content of 35 percent by volume.
Example: If the temperature is -16°C (3°F), there
is a risk of damage by freezing if the percentage
of antifreeze and corrosion inhibitor is 20% by
volume. At 30% antifreeze and corrosion protec-
tion by volume the coolant will not contain any
ice.
49
Cooling system
Warm climates
Recommended Scania products
In order to retain the corrosion protection and the
Scania Ready Mix 50/50
higher boiling point, it is essential to use coolant
consisting of water mixed with antifreeze and
Scania Ready Mix 50/50 is a ready-mixed cool-
corrosion inhibitor (ethylene glycol). This also
ant containing 50% antifreeze (ethylene glycol)
applies in countries where the temperature never
and corrosion protection and 50% water. It
drops below 0°C (32°C).
should be used in cold countries where there is a
risk of freezing in the cooling system.
The coolant should always contain 35-55% by
volume of antifreeze and corrosion inhibitor so
that the coolant properties ensure that the coolant
Part no.
Volume
Volume
works correctly.
litres
US gallons
1 921 955
5
1.3
Topping up
1 921 956
20
5.3
Coolant must only be topped up with pre-mixed
coolant. The pre-mixed coolant can either be
1 921 957
210
55
concentrate mixed with clean freshwater or pre-
1 896 695
1,000
264
mixed coolant from the factory. Use only pure
fresh water that is free of particles, sludge and
Scania Ready Mix 35/65
other impurities.
Scania Ready Mix 35/65 is a ready-mixed cool-
ant containing 35% antifreeze (ethylene glycol)
IMPORTANT!
and corrosion protection and 65% water. It
should be used in warm countries where there is
no risk of freezing in the cooling system.
Containers, which are used for mixing coolant,
must be intended for the purpose and free from
any dirt or contaminants. When the containers
Part no.
Volume
Volume
not in use they must be kept closed to avoid col-
litres
US gallons
lecting dirt and dust.
2 186 291
5
1.3
2 186 292
20
5.3
Note:
2 186 293
210
55
Within the coolant change interval, coolant may
2 186 294
1,000
264
only be reused if it has been cleaned of dirt,
sludge and particles. If the coolant is contaminat-
Scania concentrate
ed with oil or fuel, it must not be reused.
Scania also produces coolant with antifreeze and
corrosion inhibitor in the form of a concentrate.
Part no.
Volume
Volume
litres
US gallons
1 894 323
5
1.3
1 894 324
20
5.3
1 894 325
210
55
1 894 326
1,000
264
50
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
51
Cooling system
Antifreeze and corrosion protection
concentration table, US gallons
35% by volume of antifreeze provides sufficient
corrosion protection.
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
ethylene 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
52
Cooling system
Checking coolant level
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.
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
the coolant pump shaft seal. If a large amount of
coolant needs to be added, follow the instruc-
tions in the section Filling coolant.
Only pour pre-mixed coolant into the cooling
system.
The following instructions apply to Scania ex-
pansion tanks. For other types of expansion
tanks, follow the manufacturer's instructions.
1. Open the expansion tank cap and check the
coolant level.
- The right coolant level on a cold engine is
even with the lower edge of the filler neck.
- The right coolant level on a hot engine is
approximately 25 mm (1 in) over the low-
er edge of the filler neck.
2. Top up with coolant as necessary.
53
Cooling system
Checking the coolant's anti-
freeze and corrosion protec-
tion
Tools
Designation
Illustration
Refractometer
WARNING!
Avoid skin contact with coolant as this may
cause irritation to the skin. Wear protective gog-
gles and gloves when handling coolant.
IMPORTANT!
Use only pure fresh water that is free of particles,
sludge and other impurities.
1. Pour a small amount of coolant into a con-
tainer and check that the coolant is pure and
clear.
2. Change the coolant if it is contaminated or
cloudy.
3. Measure the antifreeze and corrosion inhibi-
tor content with the refractometer.
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 if ice starts to form.
54
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
Tools
Number, designation
Illustration
2 443 679, coolant pump
1. Open the expansion tank cap.
55
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 two cable terminals to
the battery’s negative and positive terminals.
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
Tools
Designation
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.
56
Cooling system
Cleaning the cooling system
Internal cleaning: Removing oil and
grease in the cooling system
Note:
Clean the cooling system more often than speci-
Environment
fied in the maintenance interval if necessary.
Use a suitable container. Used coolant must be
disposed of as specified in national and interna-
External cleaning: Cleaning the radiator
tional laws and regulations.
and charge air cooler
IMPORTANT!
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
Do not use caustic soda or other alkaline deter-
equipped with a coolant filter, also renew this fil-
gent as this could damage the aluminium.
ter.
Read the warning text on the detergent packag-
It may be necessary to wash it multiple times if
ing.
the cooling system is very dirty. One cause of
contamination can be that oil is lying on top of
1. Check that the radiator and the charge air
the coolant and collecting high up in the cooling
cooler are not clogged on the air side and that
system. If several rinses are needed, this is not
the cooling fins are not damaged.
necessarily because work has been carried out
incorrectly. Oil residues often need to be rinsed
2. Carefully scrape away any deposits from the
repeatedly from the expansion tank and the ex-
radiator cooling fins. Use a paraffin-based
ternal heating system to be completely clean.
engine cleaner if necessary.
3. Carefully straighten bent cooling fins using a
Repeated washing is more effective and prefera-
steel brush or the like.
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.
57
Cooling system
3. Fill the cooling system with clean hot water
Internal cleaning: Removing deposits in
mixed with detergent 2 479 017. Detergent
the cooling system
2 479 017 must make up 5-10% (depending
on the degree of dirt) of the total coolant vol-
Environment
ume.
If detergent 2 479 017 is not available, use a
Use a suitable container. Used coolant must be
dishwasher detergent for household dish-
disposed of as specified in national and interna-
washers that does not foam. Concentration
tional laws and regulations.
1%.
4. Run the engine until it has reached operating
1. Run the engine until it has reached operating
temperature for approximately 20-30 min-
temperature and then drain the cooling sys-
utes. Remember to switch on the cab heating
tem following the previous description.
system, if one is installed.
2. Remove the thermostats.
5. Drain the cooling system.
3. Fill the cooling system with clean, hot water
6. Fill the cooling system with clean, hot water
mixed with radiator detergent which is based
and run the engine for about 20-30 minutes.
on sulphamic acid and contains dispersing
7. Repeat steps 3-6 if the cooling system is not
agents. Follow the manufacturer's instruc-
clean.
tions for the concentration and cleaning peri-
8. Drain the water from the cooling system.
od.
9. If necessary, clean the expansion tank by de-
4. Run the engine for the specified time. Re-
taching all hoses and rinsing and cleaning
member to switch on the cab heating system,
with a degreasing agent and a dishwashing
if one is installed.
brush.
5. Drain the cooling system.
Alternatively, dismantle the expansion tank
6. Fill the cooling system with clean, hot water
and clean it with water with 10% of detergent
and run the engine for about 20-30 minutes.
2 479 017. Fill the expansion tank with the
7. Drain the water from the cooling system.
mixture, shake it and drain it. Renew the cov-
er of the expansion tank.
8. Refit the thermostats.
10. Fit a new thermostat.
9. Fill the cooling system with new coolant as
described in the next section.
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.
58
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.
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.
59
Cooling system
Filling coolant with coolant pump
Tools
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.
60
Cooling system
Refilling coolant with coolant trolley
Tools
Designation
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.
61
Fuel system
Fuel system
Checking the fuel level
Check the fuel level and top up with fuel as nec-
Cleanliness requirements
essary.
Note:
IMPORTANT!
If the fuel tank has been run dry or if the engine
has not been used for a long time, bleed the fuel
The whole fuel system is very sensitive to dirt
system. See the section Bleeding the fuel system.
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.
62
Fuel system
Renewing the fuel filters
Tools
Designation
Illustration
Hexagon socket, 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 suc-
tion tool
Tools
Designation
Illustration
Suction tool
63