DC 09
DC 09
MANUAL
Cooling system
Industrial engines
DC09, DC13, DC16
333 379
01:05 Issue 8.0 en-GB 1
©
Scania CV AB 2016, Sweden
Thermostat ............................................................................................................. 11
Design and dimensioning The following factors must also be taken into consideration:
The design of the cooling system is an important part of the engine installation. It • With a pusher fan the cooling air is warmed up when it passes the engine. Heating
should therefore be planned carefully when ordering the engine. The cooling require- is approximately 10°C with Scania standard fans. Other components which gen-
ment is dependent on the engine power, engine installation layout and the surround- erate heat also contribute to this heating.
ing environment. • Additional heat from other components connected to the cooling system.
If the engine is supplied from Scania without a cooling system, the radiator must have
sufficient capacity for the applicable operating conditions. IMPORTANT!
Scania accepts no responsibility for the function of cooling systems which are calcu- Dimension the cooling system for the entire engine speed range, not just for maxi-
lated and installed other than according to Scania's instructions. mum engine speed.
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.
• 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.
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.
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.
The diameter of coolant lines should be 57 mm. This measurement refers to the outer
diameter for pipes and the inner diameter for hoses.
361 898
The coolant lines should be made of pipe, which is bent and jointed with short
straight hoses. Ribbed hoses can hinder flow. The diagram applies to DC09/DC13 with EGR system (Stage IV/Tier 4f and DC09/
DC13 071A).
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.
361 897
The diagram applies to DC09/DC13 without EGR system.
Dp
bar
2
MAXIMUM
RESTRICTION
1,75
1
1800 rpm
0,75
1500 rpm
0,5
1200 rpm
0,25
0 L/min
250 300 350 400 450 500 550 600 650
331 035
The diagram applies to DC16.
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.
317 277
The distance between the fan blade and fan ring should preferably not exceed 6 mm
as shown in the figure. Installation of fan ring and fan cover.
For engines with flexible engine suspension, engine movements can cause the fan to
A = Distance between fan and radiator. The distance should preferably be 0.3 x fan
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. diameter, but 130-150 mm is acceptable as a minimum distance.
It is important for the air which has passed through the radiator and has been heated 1. Radiator.
not to be recirculated so that it passes through the radiator again. It may therefore be 2. Fan cover.
necessary to place a shield around the radiator to prevent recirculation. 3. Elastic sealing ring.
4. Fan ring.
5. Fan.
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
340 450
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 through radiator with pusher fan.
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.
340 451
Air flow through radiator with puller fan.
The 1.1 m2 radiator 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
949
and 331 kW for engines with EGR systems.
1010
710
The engine-mounted 1.3 m2 radiator is intended for operation in normal environ-
ments.
230
400
338 659
466
DC09: 965,5
The 1.3 m2 radiator is intended for DC13 single-speed engines with a power output DC13: 1129,5 726
of between 325 kW and 487 kW.
Engine-mounted radiator 1.1 m² for DC09 and DC13.
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!
1175
1160
680
230
265
496
550
48
338 658
1129,5 899
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:
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.
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.
Thermostat
The engines are equipped with a dual thermostat to reduce the risk of pulsation with
large amounts of coolant. The opening temperature for the thermostat that regulates
bypass is 80°C while the temperature for the other thermostat is 87°C. The operating
range of the thermostat, i.e. the difference between a closed and fully open thermo-
stat, is 15°C.
338 569
Thermostat.
338 660
DC09, DC13.
1. M18x1.5 or Ø 16 mm hose.
2. M22x1.5 or Ø 16 mm hose.
1 2
334 280
DC16.
Both the connections: M18x1.5 or Ø 16 mm hose
It is sometimes necessary to route the engine bypass pipe through the external oil
cooler. 3
2
The heat output to be conducted away from the transmission can be quite large and
must therefore be taken into account when designing the engine cooling system. 1
The installation should be constructed with coolant connection lines which are as 4
short as possible. The connection pipes should be dimensioned so that the pressure
drop is kept to a minimum, i.e. sufficient diameter and few sharp bends.
• The oil cooler is connected between the engine's rear coolant pipe and an external
thermostat. This is recommended when the cooling requirement for the oil cooler
is as great or greater than the engine cooling requirement. The retarder oil cooler 5
is an example of this.
340 453
• The oil cooler is connected between the engine radiator and the suction side of the 6
coolant pump. There is then no circulation through the oil cooler before the ther-
mostat has opened, however, by installing an external thermostat and connecting 1. Large retarder type oil cooler (recommended).
the by-pass pipe upstream of the oil cooler this can be avoided. 2. Outlet from engine.
This system is not a primary recommendation, but can be employed when the 3. Outlet to radiator.
cooling requirement for the driven unit is not so great and corresponds to actual 4. Bypass line.
engine output. Hydraulic oil coolers and transmission oil coolers are examples of 5. From radiator.
this. 6. Small oil cooler.
7. Intake to engine.
DC09 and DC13
The figure shows 2 different options for connecting an oil cooler on DC09 and DC13.
DC16
On the DC16 the oil cooler must be connected between the engine's rear coolant pipe
and the engine-mounted external thermostat as shown in the figure. This is the only 4
connection option which ensures a 100% coolant flow irrespective of how much the
thermostat is open.
Note: 1
The engine must be ordered from the factory with an external thermostat.
2
332 920
1. Outlet to radiator.
2. Intake from oil cooler.
3. Intake from radiator.
4. Outlet to oil cooler.
Immersion heater 1 2 3 4
If required, the engines can be supplied with an electric immersion heater. The im-
mersion heater can be selected with or without integrated thermostat. The thermostat
is set to a thoroughly tested temperature to ensure sufficient self-circulation. It also
prevents the temperature from becoming so high that oil film on e.g. the piston and
cylinder liner evaporates or dries.
For DC09 and DC13 both immersion heaters have a power output of 1,500 W and
are available for either 115 V or 230 V electrical power networks.
For DC16, immersion heaters are available with a thermostat with 2 power levels:
500 or 1,500 W. Choice of power depends primarily on how cold it can be around the
engine. The available power supply system can also be a key factor when selecting
power. Immersion heaters are available for either 115 V or 230 V power supply sys-
tems.
335 054
Immersion heater.
1. Without thermostat for DC09 and DC13.
2. With thermostat for DC09 and DC13.
3. Without thermostat for DC16.
4. With thermostat for DC16.
335 014
ume should always be at least 10 litres. 11
• There must be venting at the highest point in the pipe directly downstream of the
thermostat housing and on the venting manifold on the cylinder heads. Outline diagram of cooling system in multi-engine installations.
• There must also be a bleed pipe to the radiator inlet pipe. This must be connected 1. Bleed pipe to expansion tank.
to the pipe at the highest point upstream of the radiator. A static line pipe should 2. Expansion tank.
be routed from the expansion tank to the suction side of the coolant pump. The 3. Bleed pipe from radiator.
outer diameter of the pipe should be a minimum of 25 mm for DC09 and DC13 4. Static line pipe.
and a minimum of 32 mm for DC16. 5. Radiator or heat exchanger.
• All bleed pipes should be connected to the expansion tank below the coolant level. 6. Extra circulation pump. Only on long lines with a large pressure drop.
• The expansion tank must not be placed higher than 8.5 m above the engine cool- 7. Flexible hose.
ant pumps to avoid the pressure in their seals becoming too great. 8. Shut-off valve.
9. Engine coolant pump.
• An extra circulation pump should be installed in the system if there is a risk of a
10. External pipe with check valve. Only for systems with an auxiliary circulation
vacuum greater than 0.1 bar forming on the suction side of the coolant pumps.
pump.
• Circulation pump capacity should be equal to the maximum total flow when all 11. Check valve in the engine intake. Only for systems without an auxiliary circula-
engines are running. tion pump.
• Systems with an extra circulation pump should have an extra external bypass pipe
with a check valve (broken line in diagram) to reduce the coolant flow through an
engine which is not operating.
• Systems without an extra circulation pump should have check valves in the inlet
pipes to the engines to prevent circulation in a stationary engine.
• The connections to the engine may be flexible hoses. However, flexible hoses
should be used as little as possible as they can cause temperature oscillation.
• There should be shut-off valves as shown in the outline diagram to facilitate main-
tenance on the system.
Filling coolant
The fitter must ensure it is possible to top up coolant.
IMPORTANT!
337 371
It is not permissible to fill large amounts of coolant via the expansion tank. Filling
via the expansion tank leads to air pockets in the cooling system, which can damage
the coolant pump shaft seal, among other things. Coolant trolley 588 540.
Never fill a large amount of cold coolant in a hot engine. There is great risk of cracks
forming in the cylinder block and cylinder heads.
When the cooling system has been drained: Use coolant trolley 588 540, coolant
pump 2 443 679 or other suitable equipment, to fill with coolant through the drain
valve on the cylinder block.
Start the engine when the cooling system has been filled. Allow the engine to run for
a while. Then check the coolant level and top up with coolant via the expansion tank
360 625
as necessary.
Coolant pump 2 443 679.
340 455
Drain valve on DC09 and DC13.
340 454
Drain valve on DC16.
362 439
812 502 M6x16 3 Flange screw 6 4
5
8b 2 074 583 Alternator and AC 1 Protection mesh
compressor
812 502 M6x16 4 Flange screw
8c 2 074 584 1 alternator 1 Protection mesh
812 502 M6x16 4 Flange screw
362 438
3
5 4
340 459
12
8 278 474 1 Hose 14 13
816 135 Ø 50-72 mm 2 Hose clamp
1.1 m² radiator for the DC09 and DC13 with EGR and SCR systems
9 1 931 785 1 Bracket
812 516 M8x20 2 Flange screw
340 459
12
14 13
1.1 m² radiator for the DC09 and DC13 with EGR and SCR systems
340 459
12
14 13
1.1 m² radiator for the DC09 and DC13 with EGR and SCR systems
1.1 m² radiator for the DC09 and DC13 with a high turbocharger
and EGR system 1
23 24 25 2
Item Part No. Note Qty Designation 22
368 474
13 12 11
2 043 999 1 Clamp
812 516 M8x20 1 Flange screw 1.1 m² radiator for the DC09 and DC13 with a high turbocharger and EGR system.
8 278 474 1 Hose
816 135 Ø 50-72 mm 2 Hose clamp
368 474
13 12 11
1 927 918 1 U clamp
812 536 DC09, M10x25 2 Flange screw 1.1 m² radiator for the DC09 and DC13 with a high turbocharger and EGR system.
812 516 DC13, M8x20 2 Flange screw
368 474
13 12 11
812 515 M8x16 2 Flange screw
25 1 746 183 1 Charge air pipe 1.1 m² radiator for the DC09 and DC13 with a high turbocharger and EGR system.
368 472
21 20
816 135 Ø 50-72 mm 2 Hose clamp
1.1 m² radiator for the DC09 with a high turbocharger.
23 19
22
368 472
21 20
23 19
22
368 472
21 20
368 476
8 1 930 679 1 Inlet pipe
9 488 368 L = 140 mm 1 Hose
1.1 m² radiator for the DC09 with a low turbocharger.
1 527 869 Ø 88-100 mm 2 Hose clamp
368 476
19 1 746 148 1 Bracket
812 516 M8x20 2 Flange screw
1.1 m² radiator for the DC09 with a low turbocharger.
816 135 Ø 50-72 mm 2 Hose clamp
14
20
19 15
18 17 16
368 476
1.1 m² radiator for the DC09 with a low turbocharger.
14
13
9
368 475
12 11 10
15
14
13
9
368 475
12 11 10
17
7
16 8
15
14
13
9
368 475
12 11 10
368 473
8 1 930 679 1 Inlet pipe
9 488 368 L = 140 mm 1 Hose 1.1 m² radiator for the DC13 with a low turbocharger.
1 527 869 Ø 88-100 mm 2 Hose clamp
368 473
19 1 746 148 1 Bracket
812 516 M8x20 2 Flange screw
1.1 m² radiator for the DC13 with a low turbocharger.
816 135 Ø 50-72 mm 2 Hose clamp
21 13
14
20
19 15
18 17 16
368 473
1.1 m² radiator for the DC13 with a low turbocharger.
334 702
812 516 M8x20 2 Flange screw
816 135 Ø 50-72 mm 2 Hose clamp 1.3 m² radiator for the DC13
13 12 11
334 702
1.3 m² radiator for the DC13
8
16
15 9
14
10
13 12 11
334 702
1.3 m² radiator for the DC13
351 244
816 135 Ø 50-72 mm 2 Hose clamp
13 223 315 L = 100 mm 1 Hose 1.5 m² radiator for the DC16
816 135 Ø 50-72 mm 2 Hose clamp
351 244
1.5 m² radiator for the DC16