Scania DC09 XPI. Industrial engine en-GB 2 824 008. Operator’s manual - part 5

 

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Scania DC09 XPI. Industrial engine en-GB 2 824 008. Operator’s manual - part 5

 

 

Cooling system
Antifreeze and corrosion protection
concentration table, US gallons
Freezing point (°F)
-6
-11
-22
-36
-58
Cooling system volume
Volume of ethylene glycol (%)
35
40
45
50
60
(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
64
Cooling system
Checking coolant level
Checking the coolant's anti-
freeze and corrosion protec-
WARNING!
tion
Tools
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
Designation
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 of particles,
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.
65
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 if ice starts to form.
66
Cooling system
Changing the coolant and
3. Connect the pump to the draining nipple in
the cylinder block. See illustration.
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
4. Connect the pump’s two cable terminals to
Use a suitable container. Used coolant must be
the battery’s negative and positive terminals.
disposed of as specified in national and interna-
Make sure that the drainage starts. If the
tional laws and regulations.
drainage does not start: Change the position
of the cable terminals.
Draining coolant with coolant pump
5. Repeat the procedure at the cooling system's
lowest drainage point. The location of the
Special tool
lowest drainage point on the engine may dif-
fer depending on engine application.
Number, designation
Illustration
2 443 679, coolant
pump
1. Open the expansion tank cap.
2. Position the hose from the coolant pump in
an empty container.
67
Cooling system
Draining coolant with coolant trolley
Tools
Designation
Illustration
588 540 Coolant trolley
99 301 Adapter
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 illustration. The
adapter must be used when using the trolley.
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.
68
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.
69
Cooling system
Internal cleaning: Removing oil and
3. Fill the cooling system with clean hot water
grease in the cooling system
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-
Environment
ume.
Use a suitable container. Used coolant must be
If detergent 2 479 017 is not available, use a
disposed of as specified in national and interna-
dishwasher detergent for household dish-
tional laws and regulations.
washers that does not foam. Concentration
1%.
4. Run the engine until it has reached operating
Always fit a new thermostat and a new cover to
temperature for approximately 20-30 min-
the expansion tank after cleaning, as the oil in the
utes. Remember to switch on the cab heating
cooling system destroys the seals. If the engine is
system, if one is installed.
equipped with a coolant filter, also renew this fil-
5. Drain the cooling system.
ter.
6. Fill the cooling system with clean, hot water
It may be necessary to wash it multiple times if
and run the engine for about 20-30 minutes.
the cooling system is very dirty. One cause of
7. Repeat steps 3-6 if the cooling system is not
contamination can be that oil is lying on top of
clean.
the coolant and collecting high up in the cooling
system. If several rinses are needed, this is not
8. Drain the water from the cooling system.
necessarily because work has been carried out
9. If necessary, clean the expansion tank by de-
incorrectly. Oil residues often need to be rinsed
taching all hoses and rinsing and cleaning
repeatedly from the expansion tank and the ex-
with a degreasing agent and a dishwashing
ternal heating system to be completely clean.
brush.
Repeated washing is more effective and prefera-
Alternatively, dismantle the expansion tank
ble to using higher concentrations of detergent
and clean it with water with 10% of detergent
(max. 10%) or cleaning for a longer period (max
2 479 017. Fill the expansion tank with the
30 minutes).
mixture, shake it and drain it. Renew the cov-
er of the expansion tank.
If only a small amount of dirt has collected in the
10. Fit a new thermostat.
expansion tank after cleaning, one extra rinse
and clean of the expansion tank only is usually
11. Fill the cooling system with new coolant as
sufficient. There is no need to clean the whole
described in the next section.
cooling system again.
12. Check again whether further dirt or oil has
collected in the expansion tank. Decide
1. Run the engine until it has reached operating
whether it it is necessary to carry out another
temperature and then drain the cooling sys-
full cleaning or whether only rinsing or
tem following the previous description.
cleaning of the expansion tank will suffice.
2. Remove the thermostat.
70
Cooling system
Internal cleaning: Removing deposits in
Filling coolant
the cooling system
These procedures apply when the cooling system
has been drained and needs to be filled with a
Environment
large amount of coolant.
Use a suitable container. Used coolant must be
WARNING!
disposed of as specified in national and interna-
tional laws and regulations.
Use protective gloves as coolant can cause irrita-
tion if it comes in contact with the skin. Hot cool-
1. Run the engine until it has reached operating
ant can also cause scalding.
temperature and then drain the cooling sys-
tem following the previous description.
2. Remove the thermostats.
IMPORTANT!
3. Fill the cooling system with clean, hot water
mixed with radiator detergent which is based
Mix the coolant as specified in the section head-
on sulphamic acid and contains dispersing
ed Coolant.
agents. Follow the manufacturer's instruc-
tions for the concentration and cleaning peri-
It is not permissible to top up large amounts of
od.
coolant via the expansion tank. Filling via the ex-
pansion tank leads to air locks in the cooling sys-
4. Run the engine for the specified time. Re-
tem which can lead to e.g. damage to the coolant
member to switch on the cab heating system,
pump shaft seal. If a large amount of coolant
if one is installed.
needs to be added, follow the instructions in the
5. Drain the cooling system.
section Filling coolant.
6. Fill the cooling system with clean, hot water
Never fill a large amount of cold coolant in a hot
and run the engine for about 20-30 minutes.
engine. There is great risk of cracks forming in
7. Drain the water from the cooling system.
the cylinder block and cylinder heads.
8. Refit the thermostats.
Do not start the engine until the correct coolant
9. Fill the cooling system with new coolant as
level has been obtained. If the engine is started
described in the next section.
with an insufficient coolant level, it can damage
the coolant pump shaft seal, which leads to cool-
ant leakage.
71
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.
72
Cooling system
Refilling coolant with coolant trolley
Tools
Designation
Illustration
588 540 Coolant trolley
99 301 Adapter
1. Open the expansion tank cap.
2. Connect the coolant trolley to the filler nip-
ple in the cylinder block. See illustration.
The adapter must be used when using the
trolley.
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.
73
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.
74
Fuel system
Renewing the fuel filters
Tools
Designation
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.
1
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
properly, the filter covers must be removed as
A
B
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. Water separating prefilterB. Main filter
75
Fuel system
4. Wait at least 2 minutes to ensure the filter
housings have drained properly.
5. On the main filter: Unscrew the filter cover
and lift it up slowly with the filter element.
A
B
6. On the water separating prefilter: Unscrew
the filter cover and lift it up slowly with the
filter element.
The remaining fuel will drain out of fuel fil-
ter housing automatically once the filter ele-
ment has been removed.
7. Check that no fuel or particles remain in the
bottom of the filter housings. Draw off re-
maining fuel and any particles.
A. Water separating prefilterB. Main filter
IMPORTANT!
It is important to remove remaining fuel and par-
ticles from the filter housings to prevent fuel sys-
tem contamination.
8. Undo the old filter elements from the covers
by carefully bending them to one side.
9. Close the draining nipple.
76
Fuel system
Removing the fuel filters using a suc-
tion tool
Tools
Designation
Illustration
Suction tool
A
B
To ensure that the filter housings are drained
properly, the filter covers must be removed as
follows:
IMPORTANT!
Start with the water separating prefilter (A). Do
not open the main filter cover (B) until the filter
A. Water separating prefilter
housing for the water separating prefilter is com-
B. Main filter
pletely drained.
1. Make a mark on the water separating prefil-
ter cover (A). Unscrew the cover 3 to 4 turns
A
with the socket.
IMPORTANT!
Do not use an adjustable spanner or other open
tool to remove the filter covers, as the filter cov-
ers may then get damaged.
Wait for at least 2 minutes to allow as much of
the fuel as possible to drain out of the filter hous-
ing.
77
Fuel system
2. Unscrew the filter cover (A) and lift it up
slowly with the filter element.
3. Make sure the suction tool is completely
drained before starting work. Draw out re-
maining fuel and any particles using the suc-
A
tion tool or a similar tool.
4. Keep the suction tool hose in the filter hous-
ing for the water separating prefilter (A).
5. Make a mark on the main filter cover (B).
Unscrew the cover 3 to 4 turns with the sock-
et. Draw out fuel which may drain into the
water separating prefilter housing when the
B
main filter is detached.
IMPORTANT!
Wait for at least 2 minutes to allow as much of
the fuel as possible to drain out of the filter hous-
ing.
6. Unscrew the main filter cover (B) and lift it
B
up slowly with the filter element.
7. Fuel from the main filter housing (B) will
flow into the water separating prefilter hous-
ing (A). Leave the suction tool in the water
separating suction filter housing until it is
A
completely drained of fuel.
78
Fuel system
8. Move the suction tool to the main filter hous-
ing (B). Draw out remaining fuel and parti-
cles.
B
IMPORTANT!
It is important to remove remaining fuel and par-
ticles from the filter housings to prevent fuel sys-
tem contamination.
9. Undo the old filter elements from the covers
by carefully bending them to one side.
Fitting the fuel filters
IMPORTANT!
Check that there is no remaining packaging ma-
terial stuck to the new filter elements. Secure the
filter elements in the filter covers before posi-
tioning them in the fuel filter housings. Other-
wise, the filter elements may break.
In order to prevent back pressure in the filter
housings when the filter elements are screwed
on, the bleed nipple should be open.
1. Fit a new O-ring on the cover. Lubricate the
O-ring with O-ring grease.
2. Press the filter elements into the snap fasten-
ers on the covers.
3. Check that the filter housing is clean before
fitting. Use lint free cloths.
4. Press down the filter elements into the fuel
filter housings with the filter covers.
5. Screw down the filter covers until the cover
seals are in contact with the filter housings.
Use the socket.
6. Tighten the filter housings to 25 Nm (18 lb/
ft).
7. Bleed the fuel system as per the following
section.
8. Start the engine and check that there is no
fuel leakage between the filter covers and fil-
ter housings. If there is leakage, undo the fil-
ter covers and start again from step 4.
79

 

 

 

 

 

 

 

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