Scania DC09 XPI. Industrial engine en-GB 2 824 008. Operator’s manual - part 4

 

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Scania DC09 XPI. Industrial engine en-GB 2 824 008. Operator’s manual - part 4

 

 

Lubrication system
Cleaning upwards-moving
centrifugal oil cleaner
WARNING!
The oil may be hot. Carefully remove the cover
from the centrifugal oil cleaner.
Use eye protection and protective gloves when
working on the centrifugal oil cleaner.
When the centrifugal oil cleaner is cleaned, there
should be some dirt deposits on the paper in the
rotor cover. If the paper is clean, the equipment
is not working as it should. If this is the case, in-
vestigate the cause of this.
Renew the paper more frequently if the dirt de-
posits are thicker than 28 mm (1.1 inches) during
a scheduled oil change.
1. Clean the cover.
2. Unscrew the nut securing the outer cover.
3. Let the oil run out from the rotor.
x 1.5
4. Lift out the rotor. Wipe off the outside.
5. Loosen the rotor nut and unscrew it about
1.5 turns.
Note:
Take care not to damage the rotor shaft.
48
Lubrication system
6. If the rotor nut is jammed: Turn the rotor up-
side down and fasten the rotor nut in a vice.
See illustration.
7. Use protective jaws so as not to damage the
M20
grooves of the rotor nut.
8. Turn the rotor 1.5 turns anti-clockwise by
hand.
9. If this does not work: Screw two nuts togeth-
er with an M20 screw.
10. Position the screw head at the bottom of the
x 1.5
rotor.
11. Position a ring spanner on the lower nut and
turn the rotor 1.5 turns anti-clockwise.
IMPORTANT!
Do not attach the rotor directly to the vice. Never
strike the rotor cover.
12. Remove the rotor cover by holding the rotor
in both hands and tapping the rotor nut
against the table. Never strike the rotor di-
rectly as this may damage its bearings.
13. Remove the strainer from the rotor cover. If
the strainer is stuck, insert a screwdriver be-
tween the rotor cover and strainer and care-
fully prise them apart.
49
Lubrication system
14. Remove the paper insert.
15. Scrape off any remaining dirt deposits from
the inside of the rotor cover. If the deposits
on the paper are thicker than 28 mm (1.1 in),
the centrifugal oil cleaner must be cleaned
more often.
16. Wash the parts according to the applicable
industrial method.
17. Inspect the 2 nozzles on the rotor. Ensure that
they are not blocked or damaged.
Renew any damaged nozzles.
18. Check that the bearings are undamaged.
Renew damaged bearings.
1
19. Fold and fit a new paper insert on the inside
of the rotor cover as illustrated.
2
3
4
50
Lubrication system
20. Fit the strainer onto the rotor.
21. Fit a new O-ring to the foot of the centrifugal
oil cleaner.
22. Refit the rotor cover. Ensure that the O-ring
is not outside the edges, but is in the groove.
23. Screw the rotor nut back on by hand.
24. Check that the shaft is not damaged or loose.
Contact a Scania workshop if the rotor shaft
needs renewing.
Note:
Take care not to damage the rotor shaft.
25. Refit the rotor and rotate it by hand to make
sure it rotates easily.
51
Lubrication system
26. Fit a new O-ring in the cover.
27. Refit the cover and tighten the lock nut.
Tightening torque 20 Nm (15 lb/ft).
IMPORTANT!
To reduce the risk of oil leakage it is important to
tighten the cover to the correct tightening torque.
Operational testing of the
centrifugal oil cleaner
Operational testing need only be carried out if it
is suspected that the centrifugal oil cleaner is
malfunctioning. For example, if there are unusu-
ally few deposits given the distance driven.
1. Run the engine until it reaches normal oper-
ating temperature.
2. Switch off the engine and listen for the sound
from the rotor. It should continue rotating for
a time, even when the engine has stopped.
3. Use your hand to feel if the filter housing is
vibrating.
4. If the filter housing is not vibrating, disman-
tle and check the centrifugal oil cleaner.
52
Lubrication system
Renewing the rotor in down-
wards-moving centrifugal oil
cleaner
Tools
Designation
Illustration
Hexagon socket, drive
1/2", 36 mm
1. Run the engine until it reaches normal oper-
ating temperature.
- Drain the lubrication system as follows:
2. Detach the oil filter cover with specified tool.
See illustration.
3. Allow the system to drain for approximately
2 minutes.
4. Renew the oil filter.
5. Refit the oil filter cover. Tightening torque
for cover: 25 Nm.
6. Clean the area around the centrifugal oil
cleaner.
Environment
Use a waste oil trolley when draining the centrif-
ugal oil cleaner.
WARNING!
Wear protective gloves and goggles. When the
bottom cover is detached, a small amount of oil
will always run out.
7. Unscrew the bottom cover of the centrifugal
oil cleaner 2 turns without removing the cov-
er. See illustration. Start from a mark on the
cover to see the number of turns.
8. Drain the centrifugal oil cleaner for approxi-
mately two minutes.
53
Lubrication system
9. Remove the bottom cover together with the
rotor.
10. Remove the rotor by pulling it straight up
from the cover. See illustration.
IMPORTANT!
Lubricate the threads on the cover and O-rings
with engine oil before they are refitted.
11. Renew the uppermost black O-ring.
12. Renew the 2 lower green O-rings.
54
Lubrication system
13. Press the rotor onto the cover.
14. Refit the cover with rotor in the centrifugal
oil cleaner. Tightening torque: 70 Nm.
55
Lubrication system
Renewing the oil filter
Tools
Designation
Illustration
Hexagon socket, drive
1/2", 36 mm
1. Unscrew the filter cover using the socket.
IMPORTANT!
Do not use an adjustable spanner or other open
tool, as there is a risk of damaging the filter cov-
er.
2. Lift out the filter housing cover with filter el-
ement. The filter housing will drain automat-
ically once the filter has been removed.
3. Detach the old filter from the cover by hold-
ing the cover and carefully tapping the entire
filter element against something hard. Re-
member that there will be oil splashes.
4. Fit the new filter and tighten the filter cover
to 25 Nm (18 lb/ft).
56
Air cleaner
Air cleaner
WARNING!
3
Never start the engine without the air filter in po-
sition. Without the air filter, there is a risk of dirt
2
being sucked into the engine.
1
The engine turbocharger will continue to rotate
and take in air for a time, even after the engine
has stopped. Therefore, wait for a few minutes
before opening the air cleaner.
4
IMPORTANT!
5
Renew the filter element earlier than the mainte-
nance interval if the vacuum indicator shows red.
Air cleaner with safety cartridge.
The filter element must not be cleaned in water
1. Filter element
or be blown clean with compressed air. There is
2. O-ring
always a risk that the filter element will be dam-
aged when it is cleaned.
3. Vacuum indicator
4. Safety cartridge
5. Cover
2
1
Reading the vacuum indicator
If the vacuum indicator's red plunger is fully vis-
ible, renew the air cleaner filter element in ac-
3
cordance with the following section.
4
Air cleaner without safety cartridge.
1. Filter element
2. Vacuum indicator
3. O-ring
4. Cover
57
Air cleaner
Renewing the air cleaner filter
element and safety cartridge
1. Remove the cover from the air cleaner.
2. Renew the filter element.
3. If the air cleaner has a safety cartridge: Re-
move the safety cartridge and fit a new one.
4. Insert a torch into the filter element and
check that the filter paper is free of holes and
cracks.
5. Renew the O-ring if it is damaged or hard.
6. Assemble the air cleaner.
7. Ensure that the O-ring is not outside the edg-
es.
8. Reset the vacuum indicator by pressing in
the button marked in the illustration.
58
Cooling system
Cooling system
Coolant
Note:
The coolant should be changed when the cooling
system is cleaned: every 6,000 hours or at least
every five years. See Changing the coolant and
cleaning the cooling system.
The coolant recommended by Scania is a mix-
ture of water with antifreeze (ethylene glycol)
and corrosion protection. The coolant has several
characteristics which are important for the oper-
ation of the cooling system:
• Corrosion protection
• Antifreeze
• Increases the boiling point
The coolant should always contain 35-55 per
cent by volume of antifreeze and corrosion pro-
tection so that the coolant properties ensure that
the coolant works correctly.
Note:
Too high a dose of antifreeze and corrosion in-
hibitor will increase the amount of sludge and
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.
59
Cooling system
Warm climates
In order to retain the corrosion protection and the
higher boiling point, it is essential to use coolant
consisting of water mixed with antifreeze and
corrosion inhibitor (ethylene glycol). This also
applies in countries where the temperature never
drops below 0°C (32°C).
60
Cooling system
Antifreeze and corrosion protection
Scania Ready Mix 35/65
The antifreeze and corrosion protection used in
Scania engines should be of the antifreeze (eth-
Part no.
Volume
Volume
ylene glycol) and corrosion protection type.
litres
US gallons
Only Scania coolant, or other products tested as
2 186 291
5
1.3
antifreeze and corrosion protection for Scania,
2 186 292
20
5.3
may be used in Scania engines. Products that do
2 186 293
210
55
not satisfy the requirements for use in a Scania
engine may cause faults in and damage to the
2 186 294
1,000
264
cooling system. This may lead to the invalidation
of Scania’s warranty for faults and damage
Scania concentrate
caused by the use of unsuitable coolant.
Scania also produces coolant with antifreeze and
corrosion inhibitor in the form of a concentrate.
Scania Ready Mix coolant is a pre-mixed coolant
consisting of water, antifreeze (ethylene glycol)
and corrosion protection. In warm markets
Part no.
Volume
Volume
where there is no risk of freezing in the cooling
litres
US gallons
system, the concentration of antifreeze and cor-
rosion protection can be lower than in Scania
1
894
323
5
1.3
Ready Mix 50/50. Scania Ready Mix 35/65 is
1
894
324
20
5.3
suitable for these markets.
1
894
325
210
55
Scania Ready Mix 35/65 contains 35% anti-
1
894
326
1,000
264
freeze (ethylene glycol) and corrosion protection
and 65% water.
Water
Use only pure fresh water that is free of particles,
sludge and other impurities. If there is uncertain-
ty about the quality of the water, Scania recom-
mends use of Scania ready-mixed coolants. See
the section Recommended Scania products.
Recommended Scania products
Scania Ready Mix 50/50
Part no.
Volume
Volume
litres
US gallons
1 921 955
5
1.3
1 921 956
20
5.3
1 921 957
210
55
1 896 695
1,000
264
61
Cooling system
Topping up
Addition of antifreeze and corrosion
inhibitor to water
Coolant must only be topped up with pre-mixed
coolant. The pre-mixed coolant can either be
The coolant should contain 35-55% by volume
concentrate mixed with clean freshwater or pre-
antifreeze (ethylene glycol) and corrosion inhib-
mixed coolant from the factory. Use only pure
itor. The percentage varies depending on the
fresh water that is free of particles, sludge and
need for antifreeze.
other impurities.
A minimum of 35% by volume of Scania anti-
freeze and corrosion protection is needed to pro-
IMPORTANT!
vide sufficient protection against corrosion.
Measure the ethylene glycol content (antifreeze
Containers, which are used for mixing coolant,
and corrosion protection) with a refractometer
must be intended for the purpose and free from
following the instructions in the Changing the
any dirt or contaminants. When the containers
coolant and cleaning the cooling system section.
not in use they must be kept closed to avoid col-
lecting dirt and dust.
Risk of freezing
Note:
IMPORTANT!
Within the coolant change interval, coolant may
The engine should not be subjected to heavy
only be reused if it has been cleaned of dirt,
loads if ice starts to form in the cooling system.
sludge and particles. If the coolant is contaminat-
ed with oil or fuel, it must not be reused.
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.
62
Cooling system
Antifreeze and corrosion protection
concentration table, litres
Freezing point (°C)
-21
-24
-30
-38
-50
Cooling system volume
Ethylene glycol (vol. %)
35
40
45
50
60
(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
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
63

 

 

 

 

 

 

 

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