Scania 4 Dismantling information Service Manual

00:45-01

Issue 2.3

Dismantling information

Truck

4 series

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.

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