Scania P, G, R, Dismantling information Service Manual

December 2017, en-GB

Dismantling information

P, G, R and S series

Table of contents

General............................................................................................................................. 1

Dismantling information ..................................................................................................1

Exchange components ...................................................................................................3

Hazardous substances and materials...............................................................................4

Identification of plastics ...................................................................................................9

Lifting and supporting on stands ....................................................................................27

Engine ............................................................................................................................ 38

Engine.........................................................................................................................38

Oil filter .......................................................................................................................41

Rotor ...........................................................................................................................43

Engine oil.....................................................................................................................45

Cooling system ............................................................................................................. 46

Coolant........................................................................................................................46

Fuel and exhaust systems ........................................................................................... 50

Dismantling the silencer ................................................................................................ 50

Reductant tank .............................................................................................................54

Fuel tank......................................................................................................................57

Coupling......................................................................................................................... 60

Connection and operation .............................................................................................60

Gearbox.......................................................................................................................... 63

Gearbox ...................................................................................................................... 63

Brakes - Pneumatic system ......................................................................................... 65

Compressed air tanks ..................................................................................................65

Spring brake chamber...................................................................................................66

Suspension.................................................................................................................... 68

Air suspension .............................................................................................................68

Steering.......................................................................................................................... 71

Removal - Airbag.......................................................................................................... 71

Electrical system........................................................................................................... 75

Chassis central electric unit ..........................................................................................75

Removal - Curtain airbag...............................................................................................77

Batteries ......................................................................................................................81

Instrument...................................................................................................................... 83

Removal - Instrument panel...........................................................................................83

Cab - Body - Canopy..................................................................................................... 93

Cab tilt system ............................................................................................................. 93

U4, Refrigerator............................................................................................................95

A/C compressor ...........................................................................................................97

Working with refrigerant ................................................................................................99

Compressor - auxiliary cab cooler (E114) .....................................................................101

General - Dismantling information

General

Dismantling information

General

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 new 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 materials 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 twocoloured. Where there are more than one variant of a part, the codes of both materials will be stated.

Scania and the environment

Scania works continuously towards products, processes and services with reduced impact on the environment. The environmental work therefore focuses on doing the right thing from the beginning, and reducing the consumption of resources such as base materials and energy.

By including environmental aspects in the product development from an early stage, the product's impact on the environment can be reduced during the whole life cycle - from research and development, via production and usage, to end-of-life treatment. Lower fuel consumption and reduced exhaust emissions are always in focus. An environmentally appropriate end-of-life treatment can be made possible by adapting the design solutions, by choosing materials with little environmental impact, and by avoiding hazardous materials.

A more environmentally friendly production is obtained by, among other things, reducing the consumption of water, chemicals, base materials and energy. Residual products such as chips and scrap are utilised.

Scania supports its customers in choosing the right vehicle for a certain transport task. This reduces both fuel consumption and wear. Scania can also assist with driver training and inspection programmes. Correct maintenance is important in order to maintain the environmental characteristics of the vehicle. About 1,500 Scania workshops are found around the world to provide this.

Dismantling information and correct marking of components and materials facilitate end-of-life treatment.

End-of-life treatment of vehicles

With the ever increasing global population and economical development, efficient usage of the resources is becoming more and more important. Material reuse and recycling are two ways to contribute to efficient usage of resources.

Scania's involvement in end-of-life treatment issues aims for responsible, environmentally responsible and resource-efficient after-life management of Scania vehicles.

End-of-life treatment comprises a number of procedures that the vehicle must undergo, for example:

• Pre-treatment: E.g. draining fluids, emptying climate control systems and removing batteries

• Re-use: Parts, reconditioned or non-reconditioned, are being re-used after removal. Scania has its own service exchange system.

December 2017, en-GB © Scania CV AB

General - Dismantling information

• Recycling: The material is re-used in the production of new products with the same or a lower quality rating.

• Energy recovery: Combustion with energy recovery.

Only disposal remains if none of the above alternatives is possible.

General - Exchange components

Exchange components

General

As part of its efforts to be environmentally-friendly, Scania offers a wide range of Service Exchange components. Units that have been returned are reconditioned so as to have the same technical status as a new part. Scania Service Exchange is a sustainable way of reducing harmful carbon dioxide emissions, energy use and consumption of raw materials.

Exchange components have the same warranty as other spare parts.

Ordering exchange components

Exchange components are ordered from Scania in the same way as other spare parts. Orders for spare parts and exchange components can be placed on the same order.

Scania service exchange system

For more information about the Scania service exchange system, you can contact a Scania dealer or a Scania workshop.

December 2017, en-GB © Scania CV AB

General - Hazardous substances and materials

Hazardous substances and materials

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

ENVIRONMENT

Avoid spillage and use a receptacle when handling hazardous fluids

Engine:

7-9 litre engine

D9/13 XPI Fuel filter housing, diesel

D9/13/16 XPI

13 litre engine

D16 XPI

D13 PDE

16 litre engine

Cooling system: Specification: Quantity:

7-9 litre engine

13 litre engine

16 litre engine

Chassis: Specification: Quantity:

Fuel tank Diesel

Specification: Quantity:

Oil

High pressure fuel pump, oil

Oil

Fuel filter housing, engine, diesel

Fuel filter housing

Oil

Coolant

27 - 38 litres

0.4 l

0.3 l

40 - 44 litres

0.2 l

0.3 l

32 - 47 litres

30-52 litres

40-62 litres

45-102 litres

Steering: Specification: Quantity:

Steering axle

Gearbox: Specification: Quantity:

Gearbox Oil

Transfer gearbox

Opticruise, longitudinal stroke damper

Retarder

M33 electric machine

Transmission oil, ATF 2.2 litres

13-50 litres

Oil

6.5 litres

0.09 litres

approx. 7.5 litres

5.5 litres

General - Hazardous substances and materials

Axle gear:

Axle gear

Axle gear with bogie gear

Portal axle (ZF) Oil

Hub:

Hub reduction gears

ZF hub

Specification: Quantity:

Oil

9-13 litres

11-12 litres

19.5 litres

Specification: Quantity:

Oil

2 litres

0.7 litres

Cab: Specification: Quantity:

Refrigerator Refrigerant R134a

Auxiliary cab cooler

A/C

Airbag (H14)

Safety belt with belt pretensioner

Refrigerant R134a

- -

30-47 g

approx. 1,200 g

(H16, H17)

Side curtain airbags (H30, H31)

- -

Cab tilt system: Specification Quantity

Pump and cylinder Pentosin oil 1.7-2 l

Electrical parts:

Battery, VPS

Starter battery

Battery cable terminals Lead, brass

Wheel

Balancing weights

Specification Quantity

- -

Specification Quantity

- -

December 2017, en-GB © Scania CV AB

General - Hazardous substances and materials

Isocyanates

WARNING!

Isocyanates are found in some paints, putty, adhesive and plastic foams 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.

Vehicle fires

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 water carry these substances and to a certain extent they remain in the vehicle (ashes).

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.

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

General - Hazardous substances and materials

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 which have not been punctured represent an explosion risk, as the material they are made of may be weakened or damaged.

Wash the vehicle before starting dismantling.

Keep the following in mind:

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

December 2017, en-GB © Scania CV AB

General - Hazardous substances and materials

IMPORTANT!

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

Cut the power to the vehicle before starting work.

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

General - Identification of plastics

Identification of plastics

Plastics are divided into 2 main groups; meltable (thermoplastics) and non-meltable (thermosets).

Thermoplastics are cast or injection moulded and unlike thermosets they lack bonds between the plastic molecules. Thermoplastics can be recycled with good results.

Thermoplastic recycling is a good way to conserve base materials and save money. There are different types of thermoplastics and it is important to keep them separate during recycling work so that the mechanical properties of the recycled material are not impaired. Certain material combinations can be compensated using additives that make the plastics miscible. Mixing in new base material can also improve the properties.

Parts made of thermoplastic

Parts made of thermosets

December 2017, en-GB © Scania CV AB

General - Identification of plastics

Examples of plastics that are not suitable for mixing are listed in the table below:

Base material

ABS

PA B A B

PBT A B A A A A B B B

PC +ABS

Mixing material

+PBT

PMMA A B B A A A B A B B

PVC

Compatible

Compatible in purer mixtures (<5%)

Incompatible

A B A A A A

A B A A A A B A B

PA PBT

C C C C C

A A A A B A B

C C C C

PC PC

+ABSPC+PBT

C C C

C C

PE PMM-APP

B B B

B A B A

A B

PVC

Painting thermoplastics is disadvantageous with respect to recycling even though there are methods of separating the paint. Plastics age and become brittle. Take a random sample for measuring the melting index to see how far degradation has advanced. See ISO 1133.

Pure plastic that does not contain a high degree of other material (maximum 5% of another plastic), and has not degraded due to long periods of damp or heat treatment can be classified as new plastic, though with reduced properties.

Mixed material or material with molecules degraded to short chains can only be reshaped to very simple products or used for energy recovery.

Thermosets are plastic prepared with hardeners which bind the plastic molecules to each other. Thermosets are strong and rigid but brittle. Therefore it is often reinforced with for example glass fibre mat.

Thermosetting plastics are more difficult to recycle as it is not possible to melt and reshape them. The methods of recycling available today are energy recovery and, to a certain degree, pulverisation for filling.

Marking of plastics

Scania marks all its plastics (where there is space for a mark) in compliance with Scania Standard STD 387, which in turn is based on ISO 11469 - Generic identification and marking of plastic products.

The marks consists of international designations according to the following standards:

ISO 1043 Plastics - Symbols and abbreviations

ISO 1433 Vulcanised rubber - Choice of required properties

ISO 1629

Rubber and latex -Terminology

General - Identification of plastics

The marks start and finish with the arrow symbols > and <.

The following is a brief description of the thermoplastics most commonly used by Scania. Plastics are designated by 2 to 4 capital letters (e.g. >ABS<) and sometimes a mixture of 2 materials (e.g. >ABS +PC<).

There are often fillers (T for Talcum powder, M for Mineral and G for Glass) and the amount of filler as a percentage (e.g. >ABS-T20<, which means ABS with 20% talcum powder).

Part numbers are necessary for identification of parts in production as well as for maintenance and spare parts. Part numbers comprise a five, six or seven digit serial number, e.g. 1234567-LH (part number - lefthand).

The marked date refers to the date of manufacture. The marked date often comprises a date and a time or just a date field.

Plastics designations

>ABS<

Acrylonitrile butadiene styrene:

ABS is easy to recycle and can be mixed with PC to form PC+ABS after recycling, which is advantageous since pure ABS can loose impact resistance when remelted.

>ASA<

Acrylonitrile styrene acrylate:

Used for A-pillar panels, windscreen wiper panels, hinge covers, rear view mirror holders and roof hatch panels. Weather and colour resistant. Easy to recycle.

>EPDM<

Ethylene propylene diene monomer (rubber).

>HDPE<

High density polyethylene.

Nitrile rubber.

>PA<

Polyamide:

The designation is often followed by one of the figures 6, 6.6, 11 or 12. Used primarily for engine compartment components, compressed air and fuel pipes. Recycling is limited by the availability of material. Material properties are not impaired to any significant degree as long as the recycling process takes into account the problems of moisture.

>PBT<

Polybutyleneterephthalate:

Recycling is limited by the relatively small amounts of material available and the lack of material data collected from recycled material.

General - Identification of plastics

>PMMA<

Polymethylmethacrylate:

Better known as plexiglas. Used primarily for covers for lighting and instruments. Easy to recycle.

>PC<

Polycarbonate:

At Scania, we use PC in exterior sun visors and as lenses. PC is often used in combination with ABS, PBT, PETor ASA.

>PC+PBT<

A mixture of PC and PBT, combining the best characteristics from both materials. It is sensitive to moisture and high temperatures during manufacturing.

Recycling is difficult to assess as the material degrades at high temperatures and after exposure to moisture for long periods.

>PC+ABS<

A mixture of PC and ABS. Recycling is easier than PC+PBTand works well for material for simpler products.

>PE<

Polyethylene:

Several designations can occur depending on the density:

• PE - LD where LD means Low Density

• PE - HD where HD means High Density

Used for certain fuel tanks, etc. Polythene is the most recycled material in the world. The material absorbs fuel which later, and if recycled, emits odour. Material from fuel tanks should therefore undergo special treatment and be used for energy recovery.

>PP<

Polypropylene:

Normally used for interiors, in low temperature applications around the engine and even externally in some cases. PP is easy to recycle.

>PUR<

Polyurethane (Thermosets):

Used in squab cushions, armrests and noise reduction mats. This material is difficult to recycle at present.

>PVC<

Polyvinyl chloride:

Used for cable insulation, for example. This material is difficult to recycle as it is sensitive to impurities. It also forms hydrochloric acid during incineration.

>TPE<

Thermoplastic elastomer (rubber).

General - Identification of plastics

>UP<

Unsaturated polyester (Thermosets):

At Scania, UP is used mostly as pressed SMC - Sheet Moulding Compound. SMC is a semi-finished product comprising fibres (usually glass fibres) and UP mixed with filling, release agent, hardener and sometimes paint. Used most often for air deflector kits and exterior panels.

Overview illustrations

Colour codes

"other" = other polymer materials