Scania Service

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  • 8/18/2019 Scania Service


    © Scania CV AB 2010, Sweden1 712 643

    00:45-01Issue 2.3 en

    Dismantling information


    4 series

    1 1 6

    8 8 3

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    Work description

    General informationThis information is aimed at everybody dealingwith reconditioning and scrapping of Scaniavehicles. The information applies to workshops,dismantling and recycling companies.

    The information is applicable to all Scaniamodels. However, not all parts are covered bythis information booklet. The information isincomplete.

    Draining and removing describes howenvironmentally hazardous waste should beseparated from the vehicle (pre-treatment).

    Identification of material is to facilitateidentification and sorting of material forrecycling.

    Colours and a material code identify polymermaterials. Parts consisting of two plasticmaterials are two-coloured. Where there aremore than one variant of a part, the codes of

    both materials will be stated.

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    Drainage and removal

    Fluids and materials that areharmful to the environment

    The following list is a guide of lubricants, fluidsand parts that are recovered from the truckduring pre-treatment. Volumes are approximate.

    IMPORTANT! Avoid spillage and use areceptacle when handling hazardous fluids.

    Engine: Specification Quantity9 litre engine 11 litre engine 11 and 12 litre engines 14 litre engine 16 litre engine

    Oil 20-34 l 23-30 l 28-38 l 22-30 l 30-38 l

    Oil filter Oil 2 lFuel filter Diesel -Compressor Oil 0.4 lTurbocompound unit: Oil 0.3 lFuel tank Diesel -

    Particulate filter - -

    Cooling system: Specification Quantity9 litre engine 11 litre engine 12 litre engine 14 litre engine 16 litre engine

    Coolant 40 l 50 l 50 l 80 l 80 l

    Electric cooling fan Oil 2 l

    Power train: Specification QuantityClutch Brake fluid 0.4 lTorque converter with gear-changing clutch Oil

    Coolant25 l3 l

    Manual gearbox Oil 9.5-18.5 lZF Transmatic- Gearbox - Torque converter with gear-changing clutch - Retarder

    Oil 43 l

    Automatic gearbox ATF oil 30-50 l

    Opticruise Oil 0.3 lPower take-off Oil 0.5-2.0 l

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    Scania Retarder Oil 7.5 lTransfer gearbox Oil 6.5 lFront axle gear Oil 11-14 l

    Rear axle gear Oil 10-18 lRear axle, oil filter Oil filter -Hub reduction gear Oil 0.7-2.0 lTag axle lift Oil 3.6-5.0 lRear steered tag axles ATF oil 5 lCompressed air tanks - -

    Steering: Specification QuantityPower steering ATF oil 4 l

    Cab: Specification QuantityAirbag - -Safety belt with belt pretensioner - -Cab tilt pump ATF oil 0.8 lClimate control system Refrigerant R134a 1.5 kgACL reservoir Grease 2 kgRefrigerator Refrigerant -Washer container Washer fluid 14.5 l

    Electrical parts: Specification QuantityBattery, VPS - -Starter battery - -

    Wheels: Specification QuantityBalancing weights Lead -

    Power train: Specification Quantity

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    ! WARNING!Isocyanates are found in some paints,putties, adhesives and plastic foams,

    etc., that are used in motor vehicles.Inhaling isocyanates in the form ofvapour, dust or aerosols may causeirritation of mucous membranes causingasthmatic symptoms from therespiratory passages and an impairedfunction of the lungs. Even briefexposure to high concentrations cancause problems of permanenthypersensitivity.

    When products containing isocyanates

    in combined form are heated totemperatures above 150°C, isocyanatesare released. This results in a highdegree of exposure.

    This applies for example to grinding,welding and cutting products to which atop coat of paint containing isocyanateshas been applied. For this reason, makesure that there is adequate ventilation inthe areas where the work is carried out.

    Personnel carrying out such workshould use protection, such asrespiratory masks with air supply.

    Do not take any risks when carrying outwork involving heating materials thatmay contain isocyanates; alwayspresume that the material containsisocyanates and take the necessarysafety precautions.

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    ! WARNING!Where a vehicle is involved in a fire, anumber of substances that are

    hazardous to health and theenvironment are formed. Smoke andextinguishing water carry thesesubstances and to a certain extent theyremain in the vehicle in the form of ash.

    When dismantling a vehicle that hasbeen involved in a fire, the followingshould be taken into consideration:

    Use protective equipment such asrespiratory protective equipment and

    gloves when working on vehicles thathave been involved in a fire. Avoid skincontact with ashes.

    The vehicle may be weakened, whichcan have a negative affect on liftingpoints. This should also be taken intoconsideration when tilting cabs.

    Gas dampers that have not beenpunctured represent an explosion risk,as the material they are made of may beweakened and/or damaged.

    Wash the vehicle before startingdismantling.

    Other things to consider:

    Do not start dismantling before thecause of the fire has been fullyinvestigated.

    Power should be disconnected onvehicles which have been involved in afire as soon as possible, bydisconnecting the battery cables. This isto prevent short circuits, which canresult in a new fire.

    Corrosion is accelerated on vehicleswhich have been involved in a fire, forexample due to moisture in combinationwith ashes and some extinguishingagents. The vehicle should be

    processed as soon as possible, tominimise the risk of undesirable leakageof environmentally hazardous fluids andsubstances.

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    Fire damaged vehicles should bewashed in a way that allows the washingwater to be disposed of in anenvironmentally responsible way, as itcontains environmentally hazardous


    ! WARNING!When carrying out any type of workwhich involves heating products, therelevant safety regulations for this typeof work should be followed.

    ! WARNING!Cut the power to the vehicle beforestarting work.

    ! WARNING!When working with air bellows, thesystem must not be pressurised.

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    ! WARNING!Beware of hot oil after driving. Wearprotective gloves and goggles.

    1 Drain the engine oil.

    2 Remove the oil filter. Also drain the oilfrom 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 byunscrewing the blanking pieces.

    5 Drain the oil from the turbocompound unit by undoing the oil pipe connection.

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    Fuel tank


    1 Drain the tank by unscrewing the drain plug.

    Particulate filter

    ! WARNING!The particulate filter will be very hotafter driving. Risk of burns. Use a facemask, protective goggles and gloveswhen handling the particulate filter.

    1 Remove the side cover and place a jack witha large plate under the silencer unit wherethe particulate filter is located.

    2 Remove the upper V-clamp holding thefilter unit in place.

    3 Lower and remove the filter unit.

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

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    ! WARNING!The cooling system operates withoverpressure. There is a risk that hotcoolant or steam may be emitted if thesystem is opened while hot.

    Hot coolant can cause burns.

    Avoid skin contact with coolant. Skincontact may cause irritation.

    Always wear protective goggles andrubber gloves when handling coolant.

    Scania corrosion inhibitor, ethyleneglycol and other coolant additives canbe fatal if swallowed.

    Special tools

    1 Drain the coolant using coolant drainingunit 587 129.

    2 The coolant remaining in the cylinder blockcan be drained through the drain plugsfound on certain engine variants.

    Note: The coolant volume increases whencomponents are connected to the coolantsystem:

    • Retarder + 20 litres

    • Oil cooler and hose• Auxiliary heater Webasto

    Number Denomination Illustration Tool board

    99 301 Quick release coupling -

    587 129 Complete unit for coolant -

    1 4 2

    2 3 1

    587 129

    99 301 3 0 7

    3 9 8

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    Electrically controlled cooling fanfor gearbox

    ! WARNING!Beware of hot oil after driving. Wearprotective gloves and goggles.

    1 Detach the upper hose connection from thethermostat. Let the oil run out.

    2 Remove the oil filter.


    ! WARNING!The fluid is toxic if swallowed. Avoidcontact with the skin. Wear protectivegloves and goggles. Hydraulic fluid iscorrosive and can cause permanent eye


    1 Connect a suitable container to the bleednipple at the clutch housing.

    2 Detach the hose from the connection, and pump out the brake fluid using the clutch pedal.

    Bleed nipple

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    Torque converter with gear-changing clutch

    ! WARNING!Beware of hot oil after driving. Wearprotective gloves and goggles.

    Special tools


    1 Rotate the flywheel with the turning tool99 309 to access the drain plug in the torqueconverter cover through the opening in theflywheel housing.

    2 Remove the blanking piece on the bottom ofthe flywheel housing so that the oil can runout.

    3 Remove the drain plug (10 mm internal

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

    4 Remove the drain plug (6 mm internalhexagon) in the cover for the torqueconverter with gear-changing clutch. Let theoil run out.

    Number Denomination Illustration Tool board

    99 309 Turning tool D5

    Bleed nipple

    Drain plug

    3 1 5

    0 9 9

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    1 Remove the drain plug. Allow theremaining coolant to run out.

    Manual gearbox

    ! WARNING!Beware of hot oil after driving. Wearprotective gloves and goggles.

    1 Remove the noise shield.

    Note: The oil can run onto the exhaust pipe onvehicles 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. Letthe oil run out.

    3 Remove the filter.

    Drain plug

    Noise shield

    1 Level plug 2 Drain plug 3 Filter

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    Automatic gearbox

    ! WARNING!Beware of hot oil after driving. Wearprotective gloves and goggles.

    1 Put the drive mode selector in position N.

    2 Remove the drain plug on the oil sump. Usea 3/8" square socket spanner. Let the oil runout.

    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. Drillthrough the torque converter housing firstand then through the torque converter todrain it.

    1 Drain plug 3/8" 2 Filter head

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    1 Remove the longitudinal stroke cylinder anddrain it from oil through the rectangularopening.

    Power take-off

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

    Longitudinal stroke cylinder,TP gearbox

    EK power take-off EG power take-off

    3 1 5

    1 9 9

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    Scania Retarder

    ! WARNING!Beware of hot oil after driving. Wearprotective gloves and goggles.

    Make sure the compressed air tanks areempty before starting work. Oil underpressure or blows from loose parts cancause personal injury.

    Retarder, type 1

    Special tools

    1 Drain the coolant by connecting quick-fitcoupling 99 301 to the bottom of theradiator. Remove the radiator cap to makethe coolant drain faster.

    2 Put the retarder lever in position 5 andswitch on the ignition. This empties outmost of the oil volume from theaccumulator so that all the oil ends up in theretarder sump.

    Number Denomination Illustration Tool board

    99 301 Quick release coupling -

    587 129 Complete coolant draining unit -

    1 4 2 2 3 1

    587 129

    99 301 3 0 7 3 9 8

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    3 Remove the oil plug 1 under the planetarygear section and drain the oil.

    4 Disconnect the hoses from the retarder.

    5 Remove the oil filter 2.

    6 Detach the hose 3 from the oil accumulator.

    7 Blow out any remaining oil usingcompressed air at connection 4.


    1 3 0 8

    3 0 4

    3 0 8

    3 0 5



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    Rear axle gear

    ! WARNING!Beware of hot oil after driving. Wearprotective gloves and goggles.

    1 Remove the drain plug and level plug. Letthe 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.

    Hub reduction gear

    1 Rotate the hub until the drain plug pointsstraight down.

    2 Remove the drain plug and filler plug. Letthe oil run out.

    1 Oil filter with protective casing 2 Level plug 3 Drain plug

    1 Marking line2 Drain/Filler plug 3 Drain/Filler plug

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    Tag axle lift

    1 Remove the filter plug. Drain the oil fromthe reservoir.

    2 Detach the hose connections. Drain the oilfrom the cylinder.

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    Rear steered tag axles

    ! WARNING!Before starting work on the hydraulicsystem, the pressure must first berelieved in a controlled manner. Thesystem has an overpressure of 14 bar,which means that the oil will be forcedout if a union is opened without relievingthe system. This means there is a risk ofeye injuries, etc. Wear protectivegoggles.

    The accumulator tank is filled with

    nitrogen at an overpressure ofapproximately 8.5 bar. This means thatthe accumulator tank is pressurisedeven if there is no oil in the system.

    Hydraulic oil is aggressive; avoid skincontact at all times. Wear protectivegloves.

    IMPORTANT! Handle empty accumulatortanks in compliance with local regulations.

    Relieving the pressure

    1 Close the return valve. Unscrew the pressure limiting valve.

    Filling equipment 99 3551 Pressure connection P 2 Return connection T 3 Pressure limiting valve4 Return valve

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    2 Connect the return hose from the fillingequipment return connection to the unionmarked Y/Z or L3/L4 on the accumulator asillustrated.

    3 Open the return valve on the fillingequipment. The oil will now be returned tothe filling equipment tank.

    4 Oil can be drained from the pipe usingcompressed air. The connections on themaster cylinder and centering cylinder mustthen be undone.

    5 Remove the protective cap on the gas sideof the accumulator tank.

    6 Undo the plug on the gas side max 2 turnsand allow the gas to seep out.

    7 Remove the plug completely.

    Compressed air tanks

    IMPORTANT! Handle empty compressed airtanks in compliance with local regulations.

    1 Pull the drain valves to depressurise thetanks.

    New marking Previous markingY/Z L3/L4

    1 Protective cap2 Plug

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    Power steering

    1 Undo the engine oil filler pipe andcompressed air pipes from the fluidreservoir attachment.

    2 Detach the hoses from the fluid reservoir.

    3 Remove the wheel end lock screw from the power steering gear lower end plate.

    4 Detach the hoses from the power steeringhydraulic 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 andauxiliary cylinder

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

    3 1 3

    1 5 0

    3 1 3

    0 5 2

    3 1 3 0 5 1

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    Safety belt with belt pretensioner

    ! WARNING!Cut the power to the vehicle beforestarting work.

    The belt pretensioner contains anexplosive charge. Do not perform anyother work besides that described here.

    Carry the belt pretensioner with themouth of the detonator pipe pointingdownwards. Do not hold your fingersover the detonator pipe or on the wire

    rope.The belt pretensioner must be handledand stored in compliance with localregulations.

    Luxury seat

    1 Push the upper part of the backrest forwardas far as it will go.

    2 Remove the screws from the seat lever.

    3 Remove the remaining screws holding thecasings in position.

    1 Seat lever 2 Seat lever screws3 Screws

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    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 localregulations.

    Medium seat

    1 Remove the backrest casing.

    2 Remove the side casing and the rear lowercasing.

    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 localregulations.

    1 Belt guide2 Screw3 Screw4 Screw for belt anchorage

    1 Belt retaining screw2 Inertia reel screw

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    Cab tilt pump

    ! WARNING!If work is to be carried out underneaththe cab later, make sure the cab is in thelowered position before emptying thepump.

    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.

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    Climate control system

    Refrigerant R134a

    ! WARNING!Wear protective gloves and goggles.

    Welding, smoking or heating are notallowed if there is refrigerant present inthe air. Refrigerant generates a verytoxic gas when heated.

    1 Remove the protective caps from themaintenance valves and connect recyclingstation 588 431 to the high pressure and low

    pressure sides. The maintenance valves forthe high and low pressure sides are ofdifferent dimensions and require differentsize quick release couplings.

    2 Drain the refrigerant (R134a) slowly.Refrigerant must not be released into theatmosphere but must be recycled accordingto local regulations.

    Number Denomination Illustration Tool board

    588 431 Recycling station

    Components of the AC system:1 Compressor 2

    Condenser 3 Receiver dryer 4 Expansion valve5 Evaporator 6 Maintenance valve, High pressure DIS 7 Maintenance valve, Low pressure SUC

    1 1 4

    0 4 5

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    ACL reservoir

    1 Remove the cover on the reservoir andscrape out the remaining grease.


    1 If a refrigerator is fitted in the cab, it must be removed and disposed of in compliancewith local regulations.

    Washer container

    1 Drain the washer fluid from the container.

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    Xenon lamps

    ! WARNING!Lethal voltage. Power to the bulb mustbe turned off when renewing.Disconnect the electrical connectionfrom the the bulb unit. Do not touch thebulb with your fingers.

    Wait for at least 3 minutes afterswitching off the xenon lamp before youstart working. The pressure inside thebulb remains high for a while after thelamp has been switched off, and the

    bulb may explode if not handled withcare.

    1 Undo the four screws in the headlamp unit.

    2 Fold down the wiper arm and take out theheadlamp.

    3 Unscrew the two screws holding the coverinside the lamp unit.

    4 Turn the insulator counterclockwise andremove it from the bulb.

    5 Remove the spring holding the bulb, andremove the bulb.

    IMPORTANT! Xenon bulbs contain smallamounts of mercury. Used xenon lamps must bedisposed of in compliance with localregulations.

    1 Cover inside the lamp unit 2 Insulator

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    Battery, VPS

    1 Remove the lower screw for the grab handleand the M6 screw in the firewall.

    2 Lift out the battery and bracket.

    3 Dismantle the insulation, bracket and cableharness.

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

    1 Bracket 2 Battery3 Insulation4 Cable harness

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    Starter battery

    ! WARNING!Wear protective gloves and goggles.Batteries contain diluted sulphuric acid.If acid gets into your eyes or onto yourskin or clothes, rinse them immediatelywith water. Always seek medicalattention if you get acid in your eyes.

    The vehicle batteries contain lead. Leadis harmful to humans and theenvironment. The batteries musttherefore be handled in accordance with

    national regulations on environmentallyhazardous substances.

    IMPORTANT! Batteries must be handled andstored in compliance with local regulations.Within the EU there are producer responsibilityregulations for batteries. This means that allScania workshops are obliged to dispose of

    batteries responsibly and ensure that they arerecycled correctly.

    1 Detach the ground connection (negativeterminal) first and then any otherconnections.

    Balancing weights

    1 Remove the lead balancing weights on allwheels.

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

    3 1 4

    6 1 9

    − +− +

    1 0 0 9 6 4

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    Identification of materials

    1 1 6 7 8




    >PE< >PP+EPDM<



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    1 1 6 7 8 7










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    1 1 7 1 3 3






    >UP-GF30< >PC+PBT<






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    1 1 7 1 3 1









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    1 1 6

    7 8 9


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    1 1 7 1 3 4




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





    >PP-T20< >PP-T20<





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    Colour codes used in the manual

    Dark blue parts without any marking, forexample, rubber parts, should be sorted as other

    polymer materials.

    Acrylonitrile butadiene styrenePolyamidePolythenePolymethylmethacrylatePolypropylenePolyvinyl chloridePolyurethaneOther polymeric materials