Scania 4 Dismantling information Service Manual

00:45-01

Issue 2.3

Dismantling information

Truck

4 series

en

1 712 643

©

Scania CV AB 2010, Sweden

116 883

Work description

General information

This information is aimed at everybody dealing
with reconditioning and scrapping of Scania
vehicles. The information applies to workshops,
dismantling and recycling companies.

The information is applicable to all Scania
models. However, not all parts are covered by
this information booklet. The information is
incomplete.

Draining and removing describes how
environmentally hazardous waste should be
separated from the vehicle (pre-treatment).

Identification of material is to facilitate
identification and sorting of material for
recycling.

Colours and a material code identify polymer
materials. Parts consisting of two plastic
materials are two-coloured. Where there are
more than one variant of a part, the codes of
both materials will be stated.

Drainage and removal

Fluids and materials that are harmful to the environment

The following list is a guide of lubricants, fluids
and parts that are recovered from the truck
during pre-treatment. Volumes are approximate.

IMPORTANT! Avoid spillage and use a
receptacle when handling hazardous fluids.

Engine: Specification Quantity

9 litre engine
11 litre engine
11 and 12 litre engines
14 litre engine
16 litre engine

Oil filter Oil 2 l

Fuel filter Diesel -

Oil 20-34 l

23-30 l
28-38 l
22-30 l
30-38 l

Compressor Oil 0.4 l

Turbocompound unit: Oil 0.3 l

Fuel tank Diesel -

Particulate filter - -

Cooling system: Specification Quantity

9 litre engine
11 litre engine
12 litre engine
14 litre engine
16 litre engine

Electric cooling fan Oil 2 l

Power train: Specification Quantity

Clutch Brake fluid 0.4 l

Torque converter with gear-changing clutch Oil

Manual gearbox Oil 9.5-18.5 l

ZF Transmatic

- Gearbox

- Torque converter with gear-changing clutch

- Retarder

Automatic gearbox ATF oil 30-50 l

Opticruise Oil 0.3 l

Coolant 40 l

50 l
50 l
80 l
80 l

25 l

Coolant

Oil 43 l

3 l

Power take-off Oil 0.5-2.0 l

Power train: Specification Quantity

Scania Retarder Oil 7.5 l

Transfer gearbox Oil 6.5 l

Front axle gear Oil 11-14 l

Rear axle gear Oil 10-18 l

Rear axle, oil filter Oil filter -

Hub reduction gear Oil 0.7-2.0 l

Tag axle lift Oil 3.6-5.0 l

Rear steered tag axles ATF oil 5 l

Compressed air tanks - -

Steering: Specification Quantity

Power steering ATF oil 4 l

Cab: Specification Quantity

Airbag - -

Safety belt with belt pretensioner - -

Cab tilt pump ATF oil 0.8 l

Climate control system Refrigerant R134a 1.5 kg

ACL reservoir Grease 2 kg

Refrigerator Refrigerant -

Washer container Washer fluid 14.5 l

Electrical parts: Specification Quantity

Battery, VPS - -

Starter battery - -

Wheels: Specification Quantity

Balancing weights Lead -

WARNING!

!

Isocyanates are found in some paints,
putties, adhesives and plastic foams,
etc., that are used in motor vehicles.
Inhaling isocyanates in the form of
vapour, dust or aerosols may cause
irritation of mucous membranes causing
asthmatic symptoms from the
respiratory passages and an impaired
function of the lungs. Even brief
exposure to high concentrations can
cause problems of permanent
hypersensitivity.

When products containing isocyanates
in combined form are heated to
temperatures above 150°C, isocyanates
are released. This results in a high
degree of exposure.

This applies for example to grinding,
welding and cutting products to which a
top coat of paint containing isocyanates
has been applied. For this reason, make
sure that there is adequate ventilation in
the areas where the work is carried out.
Personnel carrying out such work
should use protection, such as
respiratory masks with air supply.

Do not take any risks when carrying out
work involving heating materials that
may contain isocyanates; always
presume that the material contains
isocyanates and take the necessary
safety precautions.

WARNING!

!

Where a vehicle is involved in a fire, a
number of substances that are
hazardous to health and the
environment are formed. Smoke and
extinguishing water carry these
substances and to a certain extent they
remain in the vehicle in the form of ash.

When dismantling a vehicle that has
been involved in a fire, the following
should be taken into consideration:

Use protective equipment such as
respiratory protective equipment and
gloves when working on vehicles that
have been involved in a fire. Avoid skin
contact with ashes.

The vehicle may be weakened, which
can have a negative affect on lifting
points. This should also be taken into
consideration when tilting cabs.

Gas dampers that have not been
punctured represent an explosion risk,
as the material they are made of may be
weakened and/or damaged.

Wash the vehicle before starting
dismantling.

Other things to consider:

Do not start dismantling before the
cause of the fire has been fully
investigated.

Power should be disconnected on
vehicles which have been involved in a
fire as soon as possible, by
disconnecting the battery cables. This is
to prevent short circuits, which can
result in a new fire.

Corrosion is accelerated on vehicles
which have been involved in a fire, for
example due to moisture in combination
with ashes and some extinguishing
agents. The vehicle should be
processed as soon as possible, to
minimise the risk of undesirable leakage
of environmentally hazardous fluids and
substances.

Fire damaged vehicles should be
washed in a way that allows the washing
water to be disposed of in an
environmentally responsible way, as it
contains environmentally hazardous
contaminants.

WARNING!

!

When carrying out any type of work
which involves heating products, the
relevant safety regulations for this type
of work should be followed.

WARNING!

!

Cut the power to the vehicle before
starting work.

WARNING!

!

When working with air bellows, the
system must not be pressurised.

Engine

WARNING!

!

Beware of hot oil after driving. Wear
protective gloves and goggles.

1 Drain the engine oil.

2 Remove the oil filter. Also drain the oil

from the centrifugal oil cleaner reservoir.

3 Remove the fuel filter element. Use suction

on the filter housing if necessary.

Note: The fuel system may be pressurised.
Release the pressure before dismantling.

4 Drain the oil from the compressor by

unscrewing the blanking pieces.

5 Drain the oil from the turbocompound unit

by undoing the oil pipe connection.

Fuel tank

Diesel

1 Drain the tank by unscrewing the drain plug.

Particulate filter

WARNING!

!

The particulate filter will be very hot
after driving. Risk of burns. Use a face
mask, protective goggles and gloves
when handling the particulate filter.

1 Remove the side cover and place a jack with

a large plate under the silencer unit where
the particulate filter is located.

2 Remove the upper V-clamp holding the

filter unit in place.

3 Lower and remove the filter unit.

Note: The catalytic converter unit, which is a
part of the silencer unit, contains precious
metals, which should be recycled.

Coolant

WARNING!

!

The cooling system operates with
overpressure. There is a risk that hot
coolant or steam may be emitted if the
system is opened while hot.

Hot coolant can cause burns.

Avoid skin contact with coolant. Skin
contact may cause irritation.

Always wear protective goggles and
rubber gloves when handling coolant.

Scania corrosion inhibitor, ethylene
glycol and other coolant additives can
be fatal if swallowed.

Special tools

Number Denomination Illustration Tool board

99 301 Quick release coupling -

142 231

587 129 Complete unit for coolant -

1 Drain the coolant using coolant draining

unit 587 129.

2 The coolant remaining in the cylinder block

can be drained through the drain plugs
found on certain engine variants.

Note: The coolant volume increases when
components are connected to the coolant
system:

99 301

587 129

307 398

• Retarder + 20 litres

• Oil cooler and hose

• Auxiliary heater Webasto

Electrically controlled cooling fan for gearbox

WARNING!

!

Beware of hot oil after driving. Wear
protective gloves and goggles.

1 Detach the upper hose connection from the

thermostat. Let the oil run out.

2 Remove the oil filter.

Clutch

WARNING!

!

The fluid is toxic if swallowed. Avoid
contact with the skin. Wear protective
gloves and goggles. Hydraulic fluid is
corrosive and can cause permanent eye
damage.

1 Connect a suitable container to the bleed

nipple at the clutch housing.

2 Detach the hose from the connection, and

pump out the brake fluid using the clutch
pedal.

Bleed nipple

Torque converter with gear­changing clutch

WARNING!

!

Beware of hot oil after driving. Wear
protective gloves and goggles.

Special tools

Number Denomination Illustration Tool board

99 309 Turning tool D5

Oil

1 Rotate the flywheel with the turning tool

99 309 to access the drain plug in the torque
converter cover through the opening in the
flywheel housing.

2 Remove the blanking piece on the bottom of

the flywheel housing so that the oil can run
out.

3 Remove the drain plug (10 mm internal

hexagon) in the bottom of the filter housing.
Let the oil run out.

315 099

Bleed nipple

4 Remove the drain plug (6 mm internal

hexagon) in the cover for the torque
converter with gear-changing clutch. Let the
oil run out.

Drain plug

Coolant

1 Remove the drain plug. Allow the

remaining coolant to run out.

Manual gearbox

WARNING!

!

Beware of hot oil after driving. Wear
protective gloves and goggles.

Drain plug

1 Remove the noise shield.

Note: The oil can run onto the exhaust pipe on
vehicles with left-hand mounted exhaust outlet.
Form a piece of metal plate to guide the fluid
past the exhaust pipe and into a receptacle.

2 Remove the drain plug and level plug. Let

the oil run out.

3 Remove the filter.

Noise shield

1 Level plug

2 Drain plug

3 Filter

ZF Transmatic

WARNING!

!

Beware of hot oil after driving. Wear
protective gloves and goggles.

1 Remove the three drain plugs. Let the oil

run out.

Drain plugs

2 Remove the filter in the filter housing.

3 Remove retaining ring 1, washer 2 and

O-ring 3.

4 Remove the taper nut 4. Turn the torque

converter and allow the oil to drain.

308 301

Automatic gearbox

WARNING!

!

Beware of hot oil after driving. Wear
protective gloves and goggles.

1 Put the drive mode selector in position N.

2 Remove the drain plug on the oil sump. Use

a 3/8" square socket spanner. Let the oil run
out.

1 Drain plug 3/8"

2 Filter head

3 Remove the two filter heads, O-rings,

gaskets and filters.

4 Drill around the drain plug to remove oil

that may be trapped by air pockets.
Approximately 1 litre.

Drill a hole at an angle of 45° from below,
close to the torque converter flange. Drill
through the torque converter housing first
and then through the torque converter to
drain it.

Opticruise

1 Remove the longitudinal stroke cylinder and

drain it from oil through the rectangular
opening.

Power take-off

1 Remove the drain plug. Let the oil run out.

315 199

Longitudinal stroke cylinder,
TP gearbox

EK power take-off EG power take-off

Scania Retarder

WARNING!

!

Beware of hot oil after driving. Wear
protective gloves and goggles.

Make sure the compressed air tanks are
empty before starting work. Oil under
pressure or blows from loose parts can
cause personal injury.

Retarder, type 1

Special tools

Number Denomination Illustration Tool board

99 301 Quick release coupling -

142 231

587 129 Complete coolant draining unit -

1 Drain the coolant by connecting quick-fit

coupling 99 301 to the bottom of the
radiator. Remove the radiator cap to make
the coolant drain faster.

99 301

2 Put the retarder lever in position 5 and

switch on the ignition. This empties out
most of the oil volume from the
accumulator so that all the oil ends up in the
retarder sump.

587 129

307 398

3 Remove the oil plug 1 under the planetary

gear section and drain the oil.

4 Disconnect the hoses from the retarder.

5 Remove the oil filter 2.

2

6 Detach the hose 3 from the oil accumulator.

7 Blow out any remaining oil using

compressed air at connection 4.

1

3

4

308 304

308 305

Transfer gearbox

1 Remove the lower and upper drain plug.

2 Let the oil run out.

Front axle gear

Drain plug

1 Lower drain plug

2 Upper drain plug

WARNING!

!

Beware of hot oil after driving. Wear
protective gloves and goggles.

1 Remove the drain plug and level plug. Let

the oil run out.

Drain plug

Level plug

Rear axle gear

WARNING!

!

Beware of hot oil after driving. Wear
protective gloves and goggles.

1 Remove the drain plug and level plug. Let

the oil run out.

2 Remove the oil filter.

3 If the vehicle has two driving rear axles,

remove the oil filter on both driving axles.

1 Oil filter with protective casing

2 Level plug

3 Drain plug

Hub reduction gear

1 Rotate the hub until the drain plug points

straight down.

2 Remove the drain plug and filler plug. Let

the oil run out.

1 Marking line

2 Drain/Filler plug

3 Drain/Filler plug

Tag axle lift

1 Remove the filter plug. Drain the oil from

the reservoir.

2 Detach the hose connections. Drain the oil

from the cylinder.

Rear steered tag axles

WARNING!

!

Before starting work on the hydraulic
system, the pressure must first be
relieved in a controlled manner. The
system has an overpressure of 14 bar,
which means that the oil will be forced
out if a union is opened without relieving
the system. This means there is a risk of
eye injuries, etc. Wear protective
goggles.

The accumulator tank is filled with
nitrogen at an overpressure of
approximately 8.5 bar. This means that
the accumulator tank is pressurised
even if there is no oil in the system.

Hydraulic oil is aggressive; avoid skin
contact at all times. Wear protective
gloves.

IMPORTANT! Handle empty accumulator

tanks in compliance with local regulations.

Relieving the pressure

1 Close the return valve. Unscrew the

pressure limiting valve.

Filling equipment 99 355

1 Pressure connection P

2 Return connection T

3 Pressure limiting valve

4 Return valve

2 Connect the return hose from the filling

equipment return connection to the union
marked Y/Z or L3/L4 on the accumulator as
illustrated.

3 Open the return valve on the filling

equipment. The oil will now be returned to
the filling equipment tank.

4 Oil can be drained from the pipe using

compressed air. The connections on the
master cylinder and centering cylinder must
then be undone.

New marking Previous marking

Y/Z L3/L4

5 Remove the protective cap on the gas side

of the accumulator tank.

6 Undo the plug on the gas side max 2 turns

and allow the gas to seep out.

7 Remove the plug completely.

Compressed air tanks

IMPORTANT! Handle empty compressed air

tanks in compliance with local regulations.

1 Pull the drain valves to depressurise the

tanks.

1 Protective cap

2 Plug

Power steering

1 Undo the engine oil filler pipe and

compressed air pipes from the fluid
reservoir attachment.

2 Detach the hoses from the fluid reservoir.

3 Remove the wheel end lock screw from the

power steering gear lower end plate.

313 150

4 Detach the hoses from the power steering

hydraulic pump.

5 Let the oil run out.

6 Turn the pinion on the power steering gear

to both end positions to drain the oil.

Vehicles with master cylinder

Also detach the outer hose connectors.

Vehicles with double front axles and
auxiliary cylinder

313 052

313 051

Detach the connections at the auxiliary cylinder
before turning the wheel.

Airbag

WARNING!

!

Cut the power to the vehicle before
starting work on the airbag.

Wait at least 10 seconds before you start
working on the airbag.

The airbag contains an explosive
charge. Do not perform any other work
besides that described here.

Carry the airbag with the metal casing
face down.

The airbag must be handled and stored
in compliance with local regulations.

An airbag that has not been activated
contains hazardous substances that can
cause injury if they leak out.

In case of inhalation, provide plenty of
fresh air or, if necessary, oxygen. Seek
medical attention.

In case of skin contact, wash thoroughly
with plenty of soap and water.

In case of eye contact, rinse with water
for at least 15 minutes. Seek medical
attention.

1 Undo the screws securing the airbag. The

screws remain in a special holder.

2 Lift away the airbag.

3 Disconnect the electrical cable from the

airbag.

IMPORTANT! Handle and store the airbag in
compliance with local regulations.

105 925

Safety belt with belt pretensioner

WARNING!

!

Cut the power to the vehicle before
starting work.

The belt pretensioner contains an
explosive charge. Do not perform any
other work besides that described here.

Carry the belt pretensioner with the
mouth of the detonator pipe pointing
downwards. Do not hold your fingers
over the detonator pipe or on the wire
rope.

The belt pretensioner must be handled
and stored in compliance with local
regulations.

Luxury seat

1 Push the upper part of the backrest forward

as far as it will go.

2 Remove the screws from the seat lever.

3 Remove the remaining screws holding the

casings in position.

1 Seat lever

2 Seat lever screws

3 Screws

4 Remove the belt guide including screws.

5 Fold away the upholstery.

6 Disconnect the cable harness under the belt

pretensioner.

7 Remove the screws.

8 Remove the inertia reel and detonator pipe.

IMPORTANT! Handle and store the belt
pretensioner in compliance with local
regulations.

1 Belt guide

2 Screw

3 Screw

4 Screw for belt anchorage

Medium seat

1 Remove the backrest casing.

2 Remove the side casing and the rear lower

casing.

3 Remove the retaining screw from the belt.

4 Disassemble the cable harness.

5 Remove the screw for the inertia reel.

6 Remove the inertia reel and the detonator

pipe.

IMPORTANT! Handle and store the belt
pretensioner in compliance with local
regulations.

1 Belt retaining screw

2 Inertia reel screw

Cab tilt pump

WARNING!

!

If work is to be carried out underneath
the cab later, make sure the cab is in the
lowered position before emptying the
pump.

1 Remove the pump from the vehicle.

2 Drain the oil from the pump.

3 Remove the cab tilt cylinder and cut the oil

pipes.

Climate control system

Refrigerant R134a

Number Denomination Illustration Tool board

588 431 Recycling station

114 045

WARNING!

!

Wear protective gloves and goggles.

Welding, smoking or heating are not
allowed if there is refrigerant present in
the air. Refrigerant generates a very
toxic gas when heated.

1 Remove the protective caps from the

maintenance valves and connect recycling
station 588 431 to the high pressure and low
pressure sides. The maintenance valves for
the high and low pressure sides are of
different dimensions and require different
size quick release couplings.

2 Drain the refrigerant (R134a) slowly.

Refrigerant must not be released into the
atmosphere but must be recycled according
to local regulations.

Components of the AC system:

1 Compressor

2 Condenser

3 Receiver dryer

4 Expansion valve

5 Evaporator

6 Maintenance valve, High pressure DIS

7 Maintenance valve, Low pressure SUC

ACL reservoir

1 Remove the cover on the reservoir and

scrape out the remaining grease.

Refrigerator

1 If a refrigerator is fitted in the cab, it must

be removed and disposed of in compliance
with local regulations.

Washer container

1 Drain the washer fluid from the container.

Xenon lamps

WARNING!

!

Lethal voltage. Power to the bulb must
be turned off when renewing.
Disconnect the electrical connection
from the the bulb unit. Do not touch the
bulb with your fingers.

Wait for at least 3 minutes after
switching off the xenon lamp before you
start working. The pressure inside the
bulb remains high for a while after the
lamp has been switched off, and the
bulb may explode if not handled with
care.

1 Undo the four screws in the headlamp unit.

2 Fold down the wiper arm and take out the

headlamp.

3 Unscrew the two screws holding the cover

inside the lamp unit.

4 Turn the insulator counterclockwise and

remove it from the bulb.

5 Remove the spring holding the bulb, and

remove the bulb.

IMPORTANT! Xenon bulbs contain small
amounts of mercury. Used xenon lamps must be
disposed of in compliance with local
regulations.

1 Cover inside the lamp unit

2 Insulator

Battery, VPS

1 Remove the lower screw for the grab handle

and the M6 screw in the firewall.

2 Lift out the battery and bracket.

3 Dismantle the insulation, bracket and cable

harness.

IMPORTANT! The battery must be handled
and stored in compliance with local regulations.

1 Bracket

2 Battery

3 Insulation

4 Cable harness

Starter battery

WARNING!

!

Wear protective gloves and goggles.
Batteries contain diluted sulphuric acid.
If acid gets into your eyes or onto your
skin or clothes, rinse them immediately
with water. Always seek medical
attention if you get acid in your eyes.

The vehicle batteries contain lead. Lead
is harmful to humans and the
environment. The batteries must
therefore be handled in accordance with
national regulations on environmentally
hazardous substances.

IMPORTANT! Batteries must be handled and

stored in compliance with local regulations.
Within the EU there are producer responsibility
regulations for batteries. This means that all
Scania workshops are obliged to dispose of
batteries responsibly and ensure that they are
recycled correctly.

314 619

1 Detach the ground connection (negative

terminal) first and then any other
connections.

Balancing weights

1 Remove the lead balancing weights on all

wheels.

IMPORTANT! Lead balancing weights should
be disposed of in accordance with local
regulations.

−

−

+

+

100964

Identification of materials

>PC+PBT<

>PE< >PP+EPDM<

>PP-T20<

>PMMA<

>ABS+PC<

16788

>PP<

>PC+PBT<

>PP-GF30<

>TPE-0<>PE<

>PP+EPDM<

>PC+PBT<

>PC+PBT<

>PC+PBT<

>PC+PBT<

116787

>PA+PPE<

>PMMA<

>UP-GF30<

>ASA<

>PP<

>PC+PBT<

>PBT, PMMA, ABS<

>ABS+PC<

>ABS+PC<

>UP-GF30< >PC+PBT<

>PP-M20<

>UP-GF28<

117133

>PP<

>PP-GF30<

>PP<

>HDPE<

>PP+EPDM<

>PP-G20<

>PP-GF30<

>PP-MD40<

>PP-T20<

117131

>HDPE-M30<

116789

>ABS-GB10<

>PP-T20<

>PP-T20+SEBS< >PP-M20<

>PP-T30<

>ABS-GB10<

>ABS<

>PP-T20<

>TPEL<

>TPEL<

>PP-T20<

>PP-M30<

>PP-T20< >PP-T20<

>PP-T20<

>PP-M20<

117134

Colour codes used in the manual

Acrylonitrile butadiene styrene

Polyamide

Polythene

Polymethylmethacrylate

Polypropylene

Polyvinyl chloride

Polyurethane

Other polymeric materials

Dark blue parts without any marking, for
example, rubber parts, should be sorted as other
polymer materials.