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Scania Dismantling Manual

Dec 21, 2015

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Scania trucks dismantling

  • Scania1 712 643

    00:45-01

    116 CV AB 2005, Sweden 883Issue 2.2 en

    Dismantling information

    Truck

    4 series

  • 2ContentsContentsGeneral General ..................................................................... 3

    Drainage and removal Fluids and materials that are harmful to the environment .............................................................. 4Engine....................................................................... 8Fuel tank ................................................................... 9Particle filter ............................................................. 9Coolant ................................................................... 10Electric cooling fan for gearbox ............................. 11Clutch ..................................................................... 12Torque converter ..................................................... 12Manual gearbox ...................................................... 14ZF Transmatic......................................................... 15Automatic gearbox ................................................. 16Opticruise ............................................................... 17Power take-off ........................................................ 17Scania Retarder....................................................... 18Transfer box............................................................ 18Front axle gear ........................................................ 19Rear axle gear ......................................................... 19Hub reduction gear ................................................. 20Tag axle lift ............................................................. 20Rear steering tag axles............................................ 21Compressed air tanks.............................................. 23Power steering ........................................................ 24Airbag ..................................................................... 25Seat belt with belt tensioner ................................... 27Cab tilt pump .......................................................... 29Climate control system........................................... 30ACL reservoir ......................................................... 31Refrigerator............................................................. 31Washer fluid reservoir ............................................ 31Battery, VPS ........................................................... 32Starter battery ......................................................... 33Balancing weights .................................................. 33

    Illustrations ................................................................................ 34Colour codes........................................................... 48 Scania CV AB 2005, Sweden 00:45-01

  • GeneralWork description

    General

    This information is aimed at all people dealing with reconditioning and scrapping of Scania vehicles. The information applies to workshops as well as 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 by no means complete.

    The first section describes how hazardous waste is to be separated from the vehicle (environmental disposal).The purpose of the second section is to facilitate identification and sorting of material for recycling.

    Colours and a material code identify polymer materials. With parts that consist of two plastic materials each material has a different colour. Where there are more than one variant of a part, the codes of both materials will be stated.

    On the last page there is a colour map of the common types of plastic.00:45-01 Scania CV AB 2005, Sweden 3

  • 4 to the environment

    tion Quantity Page20-34 l23-30 l28-38 l22-30 l30-38 l

    8

    - 8- 80,4 l 80,3 l 8- 9- 9

    tion Quantity Page40 l50 l50 l80 l80 l

    10

    2 l 11

    tion Quantity Pageid 0,4 l 12

    25 l3 l

    12

    9,5-18,5 l 1443 l 15

    Drainage and removalOpticruise Oil 0,3 l 17Power take-off Oil 0,5-2,0 l 17- Gearbox- Torque converter- RetarderAutomatic gearbox ATF oil 30-50 l 16Drainage and removal

    Fluids and materials that are harmful

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

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

    Engine: Specifica9 litre engine11 litre engine11 and 12 litre engines14 litre engine16 litre engine

    Oil

    Oil filter OilFuel filter DieselCompressor OilTurbo compound OilFuel tank DieselParticle filter -

    Cooling system: Specifica9 litre engine11 litre engine12 litre engine14 litre engine16-liters motor

    Coolant

    Electric cooling fan Oil

    Power train: SpecificaClutch Brake fluTorque converter Oil

    CoolantManual gearbox OilZF Transmatic Oil Scania CV AB 2005, Sweden 00:45-01

  • 7,5 l 186,5 l 1811-14 l 1910-18 l 19- 19, 200,7-2,0 l 203,6-5,0 l 205 l 21- 23

    tion Quantity Page4 l 24

    tion Quantity Page- 25- 270,8 l 29

    nt R134a 1,5 kg 302 kg 31

    nt - 31luid 14,5 l 31

    tion Quantity Page- 32- 33

    tion Quantity Page- 33

    tion Quantity Page

    Drainage and removalScania Retarder OilTransfer box OilFront axle gear OilRear axle gear OilRear axle, oil filter Oil filterHub reduction gear OilTag axle lift OilRear steering tag axles ATF oilCompressed air tanks -

    Steering: SpecificaPower steering ATF oil

    Cab: SpecificaAirbag -Seat belt with belt tensioner -Cab tilt pump ATF oilClimate control system RefrigeraACL reservoir GreaseRefrigerator RefrigeraWasher fluid reservoir Washer f

    Electrics: SpecificaBattery, VPS -Starter battery -

    Wheels: SpecificaBalancing weights Lead

    Power train: Specifica00:45-01 Scania CV AB 2005, Sweden 5

  • 6Drainage and removal! 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 150C, isocyanates are set free. 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 working with heated materials that might contain isocyanates; always presume that the material contains isocyanates and take necessary safety precautions. Scania CV AB 2005, Sweden 00:45-01

  • Drainage and removal! WARNING!Where a vehicle is involved in a fire, a number of substances which 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 (ashes).When dismantling a vehicle which 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 which 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 which 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.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, 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.00:45-01 Scania CV AB 2Washing of burnt vehicles should be carried out in a way that allows the washing water to be disposed of in an environmental way, as it contains environmentally hazardous contaminants.

    ! WARNING!When carrying out all forms of hot work, the relevant safety regulations for this type of work should be followed005, Sweden 7

  • 8Drainage and removal4 Drain the oil from the compressor by unscrewing the covers.

    5 Drain the oil from the turbo compound unit by undoing the oil pipe connection. Scania CV AB 2005, Sweden3 Remove the fuel filter.1 Drain the engine oil.

    2 Remove the oil filter. Drain the oil also from the centrifugal oil cleaner reservoir.Engine

    ! WARNING!Beware of hot oil after driving. Wear protective gloves and goggles.00:45-01

  • Fuel tank

    Drainage and removal00:45-01 Scania CV AB 2005, Swe1 Drain the tank by unscrewing the drain plug.

    Particle filter

    ! WARNING!The particle filter will be very hot after driving. Risk of burn injuries. Use a face mask, protective goggles and gloves when handling the particle filter.

    1 Remove the side cover and place a jack with a large plate under the silencer un

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