Scania DC09 Bedienungsanleitung

INSTALLATION

MANUAL

©Scania CV AB 2016, Sweden

01:05 Issue 8.0 en-GB 1

Cooling system

Industrial engines

DC09, DC13, DC16

333 379

INSTALLATION

MANUAL

©Scania CV AB 2016, Sweden

01:05 Issue 8.0 en-GB 2

Design and dimensioning ........................................................................................3

Expansion tank ........................................................................................................4

Pressure drop and coolant flow..............................................................................5

Radiators and radiator fans ...................................................................................7

Installation of radiator and radiator fan............................................................... 7

Radiator fans ....................................................................................................... 8

Engine-mounted radiators 1.1 m2 and 1.3 m2 .................................................... 9

Cooling capacity................................................................................................ 10

Thermostat ............................................................................................................. 11

Connecting a cab heater........................................................................................12

Transmission oil cooling .......................................................................................13

Connecting a transmission oil cooler ................................................................ 13

Immersion heater ..................................................................................................15

Multi-engine installation with common cooling system..................................... 16

Filling coolant ........................................................................................................18

Installation instructions for the cooling system .................................................. 20

Protective casing for the 1.1 m² cooling package ............................................. 20

Protective casing for the 1.3 m² cooling package ............................................. 21

Pipes and hoses.................................................................................................. 22

INSTALLATION

MANUAL

©Scania CV AB 2016, Sweden

Design and dimensioning

01:05 Issue 8.0 en-GB 3

Design and dimensioning

The design of the cooling system is an important part of the engine installation. It

should therefore be planned carefully when ordering the engine. The cooling require-

ment is dependent on the engine power, engine installation layout and the surround-

ing environment.

If the engine is supplied from Scania without a cooling system, the radiator must have

sufficient capacity for the applicable operating conditions.

Scania accepts no responsibility for the function of cooling systems which are calcu-

lated and installed other than according to Scania's instructions.

Note:

It is the responsibility of the fitter to ensure that the cooling system is dimensioned

and tested so that it works in the applicable operating conditions.

The Data Handbook contains cooling system recommendations for all engines. If the

engine installation and the operating conditions deviate from these recommenda-

tions, the cooling system must be designed for the relevant engine installation.

When dimensioning a cooling system, the following data must be available.

• Heat output that the cooling system must conduct away from the engine. Refer to

01:06 Technical data.

• Fan capacity. Information on the fan capacity of Scania fans is in the Data Hand-

book.

• Pump capacity: Coolant flow as a function of engine speed versus pressure drop.

See Pressure drop and coolant flow.

• The maximum ambient temperature in which the engine is to operate. Scania rec-

ommends dimensioning the cooling system with a margin of at least 5°C to com-

pensate for any clogging of the radiator.

• Alarm limits for the coolant temperature.

The following factors must also be taken into consideration:

• With a pusher fan the cooling air is warmed up when it passes the engine. Heating

is approximately 10°C with Scania standard fans. Other components which gen-

erate heat also contribute to this heating.

• Additional heat from other components connected to the cooling system.

IMPORTANT!

Dimension the cooling system for the entire engine speed range, not just for maxi-

mum engine speed.

INSTALLATION

MANUAL

©Scania CV AB 2016, Sweden

Expansion tank

01:05 Issue 8.0 en-GB 4

Expansion tank

The design of the cooling system must always allow the coolant to expand in an ex-

pansion tank. The expansion tank must be positioned slightly higher than the highest

part in the rest of the cooling system. The volume for expansion (proportion of air)

in the expansion tank should be at least 3% and the reserve volume (proportion of

coolant) should be at least 5% of the total coolant volume.

The expansion tank should be connected to the suction side of the coolant pump with

a static line pipe to reduce the risk of steam build-up and cavitation in the pump. This

connection should have as even a rise as possible to avoid pockets of air.

The outer diameter of the pipe or the inner diameter of the hose should be a minimum

of 25 mm for DC09 and DC13 and a minimum of 32 mm for DC16.

There must always be a bleed pipe between the upper part of the radiator and the ex-

pansion tank to prevent air from entering the cooling system. The inner diameter of

the bleed pipe must not be greater than 8 mm to avoid the flow becoming too great.

There must be a bleed pipe from the vent port on the cylinder heads to the expansion

tank.

If an external heating system is to be connected to the cooling system, Scania recom-

mends positioning the expansion tank higher than the external heating system.

IMPORTANT!

The expansion tank must not be positioned higher than 8.5 m above the coolant pump

intake. This height corresponds to a static pressure of 0.85 bar, the highest pressure

permissible on the suction side of the pump to avoid leakage.

INSTALLATION

MANUAL

©Scania CV AB 2016, Sweden

Pressure drop and coolant flow

01:05 Issue 8.0 en-GB 5

Pressure drop and coolant flow

The coolant pipes and hose connections between engine and radiator must be dimen-

sioned in a manner that prevents reduction of cooling capacity.

An adequate quantity of coolant and cooling air must be able to pass through the

pipes and radiator. Connecting components or restriction valves in the system reduc-

es the amount of coolant passing through the radiator and thereby reduces the cooling

capacity. At the same time, this increases the pressure in thermostat housing, hoses

and cooler.

The diameter of coolant lines should be 57 mm. This measurement refers to the outer

diameter for pipes and the inner diameter for hoses.

The coolant lines should be made of pipe, which is bent and jointed with short

straight hoses. Ribbed hoses can hinder flow.

Maximum permissible pressure drop and minimum coolant flow are depicted in the

diagrams on this and the next page.

If in doubt, check that the pressure drop across the external system does not exceed

permissible values.

The pressure drop is determined by measuring the difference in pressure between the

thermostat housing and the intake to the coolant pump with the thermostats blocked

in the open position (8 mm opening) and with no pressure cap. See the Thermostat-

section.

361 898

The diagram applies to DC09/DC13 with EGR system (Stage IV/Tier 4f and DC09/

DC13 071A).

361 897

The diagram applies to DC09/DC13 without EGR system.

INSTALLATION

MANUAL

©Scania CV AB 2016, Sweden

Pressure drop and coolant flow

01:05 Issue 8.0 en-GB 6

1200 rpm

1500 rpm

1800 rpm

2000 rpm

2200 rpm

MAXIMUM

RESTRICTION

0,25

0,5

0,75

1,25

1,5

1,75

bar

250 300 350 400 450 500 550 600 650

L/min

331 035

The diagram applies to DC16.

INSTALLATION

MANUAL

©Scania CV AB 2016, Sweden

Radiators and radiator fans

01:05 Issue 8.0 en-GB 7

Radiators and radiator fans

Installation of radiator and radiator fan

In order to fully utilise the capacity of the radiator and radiator fan, a fan cover with

fan ring should be placed between the radiator and the radiator fan. In addition there

must be a sufficient distance between the radiator and radiator fan, as well as between

the radiator fan and fan ring, in order for cooling to work effectively.

The optimum distance between radiator fan and radiator is 0.3 x fan diameter. This

is often not possible due to lack of space. 130-150 mm is acceptable as a minimum

distance.

The distance between the fan blade and fan ring should preferably not exceed 6 mm

as shown in the figure.

For engines with flexible engine suspension, engine movements can cause the fan to

come into contact with the fan ring if it is fitted on the radiator. The alternative is to

fit the fan ring on the engine and seal the ring and fan cover with an elastic spacer.

It is important for the air which has passed through the radiator and has been heated

not to be recirculated so that it passes through the radiator again. It may therefore be

necessary to place a shield around the radiator to prevent recirculation.

317 277

Installation of fan ring and fan cover.

A = Distance between fan and radiator. The distance should preferably be 0.3 x fan

diameter, but 130-150 mm is acceptable as a minimum distance.

1. Radiator.

2. Fan cover.

3. Elastic sealing ring.

4. Fan ring.

5. Fan.

INSTALLATION

MANUAL

©Scania CV AB 2016, Sweden

Radiators and radiator fans

01:05 Issue 8.0 en-GB 8

Radiator fans

The engines are available with 2 types of radiator fan – a pusher fan or puller fan.

The significant difference between the two systems is that a puller fan provides a

more even distribution of the air flow through the radiator. See the illustrations.

With a pusher fan, the cooling capacity is also reduced as the cooling air is warmed

when it passes the engine, exhaust pipe and driven unit. A pusher fan also results in

a greater pressure drop across the radiator since the distribution over the surface of

the radiator is not so good.

This means that a particular size of radiator requires a larger volume of air with a

pusher fan to achieve the same cooling capacity.

The fan ring must be correctly located and designed for the fan to achieve maximum

air flow and to ensure that distribution across the radiator is as efficient as possible.

See Installation of radiator and radiator fan.

In order to optimise the cooling capacity, first check that heated air is not being re-

circulated. If it is, a suitable shield must be fitted. The second measure is to increase

the size of the radiator.

It is possible to optimise the fan speed or fan diameter to increase capacity. If the size

of the fan or the fan speed is changed the power requirement and noise level of the

fan increase. Information about permissible combinations can be found in the Data

Handbook.

A pusher fan can help to combat heating of the engine compartment by dissipating

heat radiated by the engine, exhaust pipe and driven unit.

340 450

Air flow through radiator with pusher fan.

340 451

Air flow through radiator with puller fan.

INSTALLATION

MANUAL

©Scania CV AB 2016, Sweden

Radiators and radiator fans

01:05 Issue 8.0 en-GB 9

Engine-mounted radiators 1.1 m2and 1.3 m2

The engine-mounted 1.1 m2radiator has been specially developed for operation in

extremely dusty environments such as stone crushing plants.

The 1.1 m2radiator is intended for DC09 and DC13 engines, with an output of be-

tween 202 kW and 405 W for engines without EGR systems, and between 202 kW

and 331 kW for engines with EGR systems.

The engine-mounted 1.3 m2radiator is intended for operation in normal environ-

ments.

The 1.3 m2radiator is intended for DC13 single-speed engines with a power output

of between 325 kW and 487 kW.

The engine-mounted radiators are installed on the engine using reinforced brackets

that are included in the cooling package. Air and coolant connections are prein-

stalled.

REQUIREMENT!

An engine-mounted radiator must not be allowed to hang freely. A beam should be

placed under the radiator during installation.

338 659

1010

710

DC09: 965,5

DC13: 1129,5 726

400

230

466 949

Engine-mounted radiator 1.1 m² for DC09 and DC13.

338 658

1129,5

265

899

1160

680

496

550 1175

230

Engine-mounted radiator 1.3 m² for DC13 (single-speed engines).

INSTALLATION

MANUAL

©Scania CV AB 2016, Sweden

Radiators and radiator fans

01:05 Issue 8.0 en-GB 10

Cooling capacity

In order to determine the safety margin, the actual coolant temperature (t) must be

measured at the outlet from the thermostat housing when the engine is running at full

power with fully open thermostats. The thermostats should be blocked into the open

position in accordance with the instructions in following section.

Then calculate T max., the highest ambient temperature the engine can work in at

maximum load, using the following formula:

Determine the safety margin by comparing the resulting "T max" with the ambient

temperature for which the engine installation is designed. The margin should always

be greater than 5°C to compensate for radiator clogging.

T max. = L - t + T

where

L = Alarm limit for coolant temperature

T = Ambient temperature during testing

t = Actual coolant temperature at full power.

T max. = Maximum ambient temperature which the engine can work in without an

alarm for high engine temperature.

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