Function check of temperature Replaces 1-85 12 14 GT CHARGE COOLING Contents Test pressurizing of charge cooling system Connection on DSC9. ... Connection on DSCIT .. Connection on DSC14 Test pressurizing 2Scan © Saab-Scania AB, ScFunction description SCANIA service Function description Charge cooling is available as option on all turbo- charged engine types. In this binder the most significant differences are described compared to corresponding DS engines. There are two principles: = water-to-air for DSI8 up to 1985. ~ air-to-air for DSC engines. The output that can be gained from an engine is, for instance, determined by the quantity of fuel that can be combusted efficiently by the engine. DSI ENGINES - WATER-TO-AIR Cold air is denser and contains more oxygen per volume unit than hot air. There is a temperature increase when the intake air passes the turbo- charger. if the airis cooled it becomes denser and more oxygen is supplied to the engine. This means that more fuel can be combusted This results in higher output and torque. The cooled air reduces combustion temperature and also the temperature of the parts adjacent to the com- bustion chamber, providing for less thermal stress, in spite of the increased output. vase Air path, 0518 Intake manifold The compressed air is cooled by allowing coolant to pass through a cooling package integrated in the intake manifold. The coolant for the charge cooler is taken from the ‘engine block main gallery behind the rearmost core plug. Return coolant passes to the return pipe from the radiator before the oil cooler. © Saab-Scania AB, Scania Owision, Service, (924) 1989 Fuel system The fuel calibration for the injection pump is different. The injectors are adapted to the new fuel calibration by having larger nozzle holes. The pump setting differs from that of present DS. engines. Turbocharger The DSI engine has a special turbocharger with wheels and housings different from the normal DS execution. Externally there are no visible differences between the DSI and DS engine turbochargers. When changing, check part numbers. 1-89.04 30 GTENSCANIA Function description service DSC ENGINES - AIR-TO-AIR head wind, which then passes the radiator. After cooling charge-air is returned to the intake mani- folds which distribute the air to the cylinders. Intake system ‘The DSC engines have pipes that lead the air after On P/R trucks there are two knuckles in the intake the turbocharger to the charge cooler located in. manifolds to enable the charge cooler to follow the front of the radiator. The charge-air is cooled by the radiator when the cab is tilted. Air path, DSC9 and DSC11 e@ == Air path, DSC14 1-89 04.30 GT EN © Saab-Scania AB, Scania Dison, Service, (924) 1989eee eee Function description SCANIA service Temperature controlled charge cooling, psc14 The DSC14 engines on the Nordic market have a thermostat controlled damper (by-pass) that leads the air past the charge cooler. The damper prevents white smoke formation. This happens when vaporized, uncombusted fuel remains in the exhaust gases at the same time as the intake airs, too cold ‘The damper sitsin the charge air pipe under the radiator. it opens and closes the inlet to the charge cooler. The damper is controlled with a compressed air cylinder by the thermostat via a solenoid valve. The thermostat, which senses the air temperature before the damper, is screwed into the charge air Pipe The damper can adopt two different positions: DSC position: DS position * Air passes the charge cooler. * Air does not pass the charge cooler * Compressed air cylinder retracted * Compressed air cylinder extended * High air temperature * Low air temperature * Broken circuit (e.g. blown fuse) * Made circuit (e.g, thermostat stuck in closed position) 4 © Saab-Scania AB, Scania Division, Service, (928) 1989 1-89 04 30GTENSCANIA Function description service Thermostat Damper in DSC position Damper in DS position ‘Compressed air cylinder Solenoid valve yawNS Turbocharger The DSC engine turbocharger has special turbine housing and angled compressor housing. Externally DSC and DS engine turbochargers look alike. When changing, check part numbers. Front section The front of Rand T trucks with DSC engines has been extended to provide space for the charge cooler. The bumper with its drawbeam has been moved forward 50 mm on R truck and 77mm on T truck. Trucks with charge cooling and air conditioning have three cooling packages up front. Front most is. the condenser for the air conditioning 1, behind this sits charge cooler 2 and radiator 3. Cooler package up front 1-89.04 30 GTEN © Saab-Scania AB, Scania Divison, Service, (924) 1989 5Work description SCAN service Work description FUNCTION CHECK OF TEMPERATURE CONTROLLED CHARGE COOLING, BY-PASS, ON DSC14 ENGINES Fuse number 17 (2 series trucks) 8A Fuse number 13 (3 series trucks) 104 1. Check that the compressed air cylinder is retracted and expands when the starter key is. turned on. 2. Unscrew the thermostat with a 30 mm socket. 3. Test compressed air cylinder and thermostat functions by that placing thermostat in warm and then cold water. ‘When the thermostat warms up the damper should open (compressed air cylinder retracts). When the thermostat is cooled down the damper should close (compressed air cylinder expands) z The thermostat must be wired and the starter ai key in on position, The thermostat breaks at rising and makes at falling temperature Three thermostats with different break and make temperatures are available: r ) PartNo Breaks at Makes at 378 141 33+3°C 2544°C 378142 5523°C a7sacc 378 143 50+3°C 4244°C 4. Ifthe damper does not work in above described way, check the thermostat with a test lamp or buzzer. The thermostat should break when it is warmed up in warm water. If the thermostat does not break circuit to set the damper in charge cooling position when the engine is warm, the engine can give off black, sooty exhaust gases and lose output. 6 © Saab-Scania A8, Scania Division, Service, (924) 1989 1-89 04 30 GTENSCANIA Work description service CHANGING OF O-RING IN KNUCKLE - DSC (Applies to R trucks) 1. Loosen hose clamp 1. 2. Remove hose 2. 3. Allow knuckle 4 to remain on charge cooler. 3121 hose onknuckle 4, Remove retaining ring § and teflon ring 6 5, Turn out socket from knuckle. 6. Remove and change O-ring 7. 4 7 65 Note! Head of hose clamp has to be on front or underside (see arrows in figure) of hose to prevent damage to radiator when tilting cab. Assembly is carried out in reverse order. Deena Hose clamp locations Checking Check that pipes are not cracked and that rubber hoses between turbocharger and intake manifolds are intact. 1-89.04 30 GTEN © Saab-Scania AB, Scania Division, Service, (924) 1989 7Work description TEST PRESSURIZING OF CHARGE COOLING ‘SYSTEM Test pressuring kit 98 787, (including seal washer 99 094) Connection on DSC9 SCANIA service Special tool 98 787 92 and 93 trucks: also complementation kit 99 056 Complementation kit 99 056 for 92 and 93 trucks Fit sealing sleeve and plastic plug without hole. Tighten hose clamps. Loosen charge-air pipe nearest the turbo. Fit sealing sleeve and plastic plug with hole Connect measuring equipment to plug, To continue: See page 11 © Saab-Scania AB, Scania Division, Service, (924) 1989 1-89 04 30 GTEN‘CONNECTION ON DSC11 r Work description service DSC11 through engine No. 5 275 560 Loosen hose clamps on front joint. Pull away hose towards radiator. DSC11 through engine No. 5 275 560 Fit large plastic plug in joint, restore hose and tighten hose clamps. DSC11_ from engine No. 5 275 561 manifold. Fit seal washer 094 and tighten to make a tight joint. Loosen connection pipe by flange bolts on intake AILDSC11 engines Loosen hose clamps on rear joint after turbo. Pull away hose. Fit small plastic plug in joint, restore hose and tighten hose clamps. Connect measuring equipment on pipe to charge cooler. To continue: See page 11 1-89 04.30 GTEN © Saab-Scania A8, Scania Division, Service (924) 1989 aion Connection on DSC14 service Loosen hose clamps on front joint, Pull away hose towards radiator. It may be necessary to loosen pipe bracket. Fit large plastic plug in joint, restore hose and tighten hose clamps. Loosen hose clamps on rear joint after turbo. Pull away hose. Fit small plastic plug in joint, restore hose and tighten hose clamps. Connect measuring equipment on pipe to charge cooler. To continue: See page 11 10 © Saab-Scania A8, Scania Division, Serwce (924) 1989 1-89 04 30GTENSCANIA Work description service Test pressurizing Note! Plugs may work loose if poorly fitted or if Pressures too high. Connect air to union and set pressure at 0.7 bar. For excessive pressure drop, find source of fault and During 60 seconds pressure must not drop by more | correct it. than 0.2 bar. Leakage spray may be useful for this 1-89.04 30 GTEN © Saab Scama AB, Scania Division, Service (924) 1989 u