COOLING SYSTEM — INDUSTRIAL ENGINES Function description 2a General Circulation, 9 engines Circulation, 11 engines . Circulation, 14 engines . Radiator with expansion tank Coolant filter . Fan oo... Thermostat and thermostat hor Coolant pump, 11 engines .... Coolant pump, 14 engines .... Level indicator Charge cooler .... SSmmomvuauauwn PS EFIB3. © Saab-Scania AB, Scania Division Service (917) 1989 1Function description GENERAL The cooling system maintains the engine working temperature on a suitable level when loading the engine, which is very important to the operating ‘economy and service life of the engine. The cooling system operates with overpressure and this allows the boiling point of the coolant to be higher. To ensure that there is no loss of coolant because of the increase in volume when heated, there is an ‘expansion tank which also operates asa vent in the cooling system. The cooling system consists of: Radiator with expansion tank and pressure cap Oil cooler for engine lubrication oil ‘Temperature gauge and level indicator (not standard) . Fan and coolant pump. Coolant jacket in cylinder block and cylinder heads Thermostat housing with thermostat and by- passline Coolant filter Lines (pipes and hoses) External heaters (i.e. cab heater) connected to cooling system Engine heater (not standard) 1. Expansion tank Radiator Coolant pump 4. Fan 5. Thermostat housing with thermostat 6 Fansing 7. Staticline & Level indicator : 9. Venting line 10. Drain tap Scania cooling system for industrial engines 2 «© Saab-Scania AB, Scania Dwision Service, (917) 1989 2-890427MENCIRCULATION IN 9 ENGINES: The coolant pump, oil cooler and coolant filter are integrated as one unit fitted to the right side of the ‘engine. From the oil cooler the coolant enters the coolant gallery of the cylinder block, up round the each cylinder head to an external coolant manifold with its front end connected to the thermostat housing. With liquid cooled exhaust manifold the entire coolant flow is routed from the coolant manifold to and through the exhaust manifold and then to the thermostat housing, which is then fitted to the front end of the liquid cooled exhaust manifold. service 2-890427 MEN Coolant filter Oil cooler Coolant pump For electric engine heater By pass line and static line Froom cooler 7. Inlet to engine NORAWNS Girculation through coolant pump, oil cooler and coolant filter in 9 engine © Saab-Scania AB, Scania Dision Service, (917) 1989CIRCULATION IN 11 ENGINES From the pump the coolant is ducted via the cylinder block distribution passage to holes in the cylinder block to cool the cylinder liners and then upwards into the cylinder heads. Coolant is also pumped direct to the cylinder heads from the distribution passage via passages directed towards injectors and exhaust valves. From the rear cylinder head coolant flows forward tothe front and out from the engine direct into the thermostat housing on the right side of the front cylinder head. With liquid cooled exhaust manifold the coolant flow in the engine is to the rear only and the entire coolant flow is ducted to the exhaust manifold from the rear cylinder head. Coolant then flows forward in the coolant jacket of the exhaust manifold to the thermostat housing, which is fitted to the front part of the exhaust manifold. SETVICE On DSI engines coolant is taken out from the block just after the coolant pump and is ducted to the charge cooler where it flows rearwards in the upper part and then forward in the lower part before it is returned to pump sucti coolant from the cooler. n side and mixes with Coolant circulation in 11 engine 1. Pressure cap 2. Expansion tank 3. Static line 4. Bypassline 5. Thermostat housing with thermostat 6. To charge cooler 7. Charge cooler &. From charge cooler 8. Oil cooler (full flow) 10. Coolant pump 11, Fan 12. Radiator 13, Venting line Coolant circulation for DSI11 engine © Saab-Scamia AB, Scania Diwsion Service, (917) 1989 2-89 0427 MENOo ie service CIRCULATION IN 14 ENGINES The coolant pump supplies coolant to the cylinder ‘On DSt engines coolant is taken out fromthe front block distribution passages channels in the of the block just after the coolant pump and is jing gear housing. ducted to the charge coolers , where it flows to the rear in the lower part and then forward in the From the distribution passages coolant flows into upper part before it returns and mixes with coolant the cylinder block to cool the cylinder liners and from the engine before the thermostathousing. then further upwards into the cylinder heads. In the cylinder head the coolant is directed for effective cooling of the exhaust valve. From the cylinder heads the coolant is directed to the centre of the engine into two pipes to be ducted forward to passages housing and out from the engine through the thermostat housing on the right side of the timing gear housing front. With liquid cooled exhaust manifold part of the coolant flow in the engine is ducted to the side pipe and cross pipe of the exhaust manifold. The coolant ted forward in the side pipes and back tothe suction side of the coolant pump together with coolant from the cross pipe. is then dit 2-890427M EN the timing gear 1. Pressure cap 8 Outlet from charge cooler 2. Expansion tank 9. Fan 3. Static line 10. By-pass 4. Outlet to charge cooler 11. Thermostat housing with 5. Coolant pump thermostat 6. Charge cooler 12. Radiator 7. Oil cooler (partial flow) 13, Venting line Coolant circulation for DSI14 engine © Saab-Scania AB, Scania Division Service, (917) 1989 5RADIATOR WITH EXPANSION TANK ‘The radiator consists of a core between two vertical tanks. ‘The radiator core consists of horizontal thin-wall brass tubes in three rows. The tubes are inserted through fins of thin copper plate to make the heat dissipation ability of the radiator as good as possible. The right radiator tank (radiator inlet) is connected to the engine thermostat housing, For location of ‘thermostat housing, see pages 4 and 5. The left radiator tank (radiator outlet) is, together with the by-pass line, connected to the coolant pump suction side. ‘The expansion tank is located above the ra ‘and has a filler pipe with cap. The cap has valve that opens at a certain overpressure. When the engine cools off after it has been stopped and the pressure has dropped the valve opens at a certain underpressure to equalize the pressure difference. ;nsion tank has also a direct connection, ic line, with the coolant pump suction side. This line provides for reduced underpressure in the jet and thereby reduces the risk of cavi- tation in the pump. When the thermostat opens, coolant is ducted to. ‘the lower right part of the radiator to then flow upwards and horizontally through the radiator 1. Expansion tank 2. Radiator core 3. Drain tap 4. Outlet from radiator 5. Inlet to radiator 6 Radiator tank 7. Venting Radiator with expansion tank 6 © Saab-Scania AB, Scania Division Service, (917) 1989 2-890427M EN‘COOLANT FILTER The cooling system may be equipped with a filter that cleans the coolant and adds anti-corrosive. The 9-litre engine is equipped with coolant filter as standard, The filter consists of a mantle, filter insert and corrosion inhibitors made of pressed powder (anti- corrosive). Coolant flows into the container between the ‘mantle and filter, through the filter and past the corrosion inhibitors which are dissolved by the coolant and carried out in the cooling system, thereby protecting the engine against corrosion. FAN The engines are available with two different types of fan, either suction or pressure type. There are four standard sizes. With a suction type fan better distribution over the radiator core is obtained with a short distance (100- 150 mm) between fan and radiator. This also results in higher cooling efficiency than with the pressure type fan. The cooling capacity of a pressure type fan can be improved by increasing the distance between fan and radiator. Air flow through radiator with pressure type fan 2-890427MEN service © Saab-Scania AB ScaraDwison Service $17) 1989 1. Container 2 Filter insert 3.Corrosion inhibitor Coolant filter To increase the efficiency of the fan a close-fitting fan ring can be installed round the fan. There is also a fan cowling between the radiator and fan ring to force air to the fan to pass through the radiator. Radiator capacity is affected by radiator size, fan diameter and speed. The size of the fan and speed also affects the power requirement and noise level. ig] Air flow through radiator with suction type fan 7‘COOLANT PUMP, 11 ENGINES The coolant pump is located at the front of the engine and is driven by drive belts from the crank- shaft pulley. ‘The pump is of centrifugal type and consists of a spiral shaped pump housing with an impeller direct, ‘on the drive shaft. The shaft has two permanently lubricated ball bearings. The pump shaft bearing is sealed against coolant witha spring loaded axial seal. COOLANT PUMP, 14 ENGINES The coolant pump is fitted on the timing gear housing of the engine. Itis driven via a gear from the camshaft gear. The pump is of centrifugal type and consists of a spiral shaped pump housing with an impeller direct ‘on the drive shaft. The shaft runsin two ball bearings which are splash lubricated from the ‘timing gear housing. ‘The pump shaft bearing is sealed against coolant with a spring loaded axial seal. THERMOSTAT AND THERMOSTAT HOUSING Industrial engines without liquid cooled exhaust manifold have double thermostats. The thermostat housing is fitted on the front part of the engine: engine: ‘The thermostat housing is placed horizontally on top of the timing gear housing and has external connections only. L1engine: The thermostat housing is connected to the coolant, outlet in the front cylinder head with an internal bby.pass to the suction side of the pump. 8 © Saab-Scame AB, Scania Division Service, (917) 1989. — SA KX iN 1. Outlet to engine 2. Fromradiator 3. Bypass Coolant pump, 11 engine Outlet to engine From radiator Outlet to engine By-pass Static line awh Coolant pump, 14 engine 14engine: The thermostat housing is fitted on the right part of the timing gear housing and is connected to the coolant manifold outlet via ducts in the timing gear housing. Itis also connected via an internal by-pass in the timing gear housing direct to the suction side of the pump. 9 engines and 11 engines with liquid cooled exhaust manifold have only one thermostat of slide ‘type and the thermostat housing is then placed in the front part of the exhaust manifold. 14 engines can also have an external thermostat, housing with thermostat of slide type. 2-890427 MENservice When double thermostats are used they have If the coolant temperature is higher than the different opening temperatures. The thermostats ‘temperature required for a fully opened ‘use wax as thermo-sensitive medium. thermostat, all coolant flows through the thermostat and through the radiator. ‘ At coolant temperature below that of the thermo- If there is temperature balance within the control stat opening nearly all coolant circulates between ange, i.e. between the temperature limits for the engine coolant passages and coolant pump fully closed and fully open thermostat, the without passing the radiator. ‘thermostat valves will adopt a corresponding intermediate position. Some of the coolant is then ducted to the coolant pump without cooling and the remainder is ducted to the radiator. 2068 2:00 1. Return from engine ® 2. Bypass 3. Outlet to radiator losed thermostat - return to engine via by-pass B = open thermostat - full flow to radiator Thermostat housing with thermostats on 11 engine (similar for 9 engines but with horizontal position) 1. Venting hale 2. Return from engine 3. By-pass ® 4. Outlet to radiator A = dosed thermostat - return to engine via by-pass B = open thermostat full flow to radiator Thermostat housing with thermostats on 14 engine 2-890427M EN © Saab-Scania AB, Scania Division Service, (917) 1989 9LEVEL INDICATOR Alevel indicator gives a warning when the coolant level is too low. The indicator consists of a level sensor fitted in the right radiator tank when 1-pole and externally between expansion tank and radiator when 2-pole, see figure. Itis connected via a relay to a warning light on the instrument panel. If the coolant level has dropped that much that the level sensor is not surrounded by coolant, the relay switches on the warning light. Lpole level indicator: The relay has some delay to avoid that the light flashes when the coolant surges in the radiator. How the level indicator is wired is described in the installation instructions for the electrics. ee ee ee ee eee ee Sr ee fee e Location for 1-pole level sensor Location for 2-pole level sensor 10 © Saab-Scania AB, Scania Diusion Service, (917) 1989 2-890427 MENCHARGE COOLER turbocharged engines. This feature operates according to either of two principles: (see type designation) DSI: coolant to air (not available for 9 engine) air to air (9 engines only in truck and bus execution) Dsc: The power that may be utilized from the engine is determined, for instance, by the amount of air and fuel supplied to the engine. Cold air is denser and contains more oxygen per volumetric unit. The charge air temperatire is raised when it passes the turbocharger. If the airis subsequently chilled in a charge cooler, the air becomes denser and more oxygen is supplied to the engine. This allows more fuel to be combusted. The sum total of this is boosted output and torque. The chilled air reduces the combustion temperature and also the temperature of the parts affected by the combustion, resulting in less thermal stresses and strains in spite of increased output. DSI engines - COOLANT TO AIR By making the coolant pass an integral cooler package in the intake manifold the compressed air is chilled. S111: Coolant to the charge cooler is taken from the block just after the coolant pump and is ducted to the upper part of the charge cooler. Coolant flows through the cooler to the rear and then forward and out through the bottom connection. ‘The return line is connected to the line between the cil cooler and suction side of the pump. DS114: Coolant to the charge cooler is taken from ‘the front of the block just after the coolant pump and is ducted via a common line to the charge coolers where it flows through the coolers to the rear and then forward in a common line to the by-pass in the timing gear housing. 1. Airintake manifold 2. Charge air cooler Charge air path, DSI(11 engine shown) 2-89.04 27 MEN © Saab-Scania AB, Scania Division Service, (917) 1989 "1DSC engines AIR TO AIR The DSC engines have a pipe that ducts the air from the turbocharger to the charge cooler between engine and the radiator. After having been chilled the charge air is ducted bback to the intake manifold for distribution to the cylinders. 1. Charge cooler 2. Radiator 3. Airintake manifold Charge air path, DSC(14 engine shown) © Saab-Scama AB, Scania Dwision Service, (917) 1989 2-89 04 27 MEN @ Pitan Owen by Nowa Grate