pre-delivery inspection: instructions general information

Pre-delivery inspection: Instructions
General information
More information is found in the following documents:

• Pre-delivery inspection: Checklist• Declaration of Conformity• Use and responsibility• BCI – Bodywork Communication Interface

General informationIn order for Scania’s warranties to remain valid for the chassis, the bodywork must be completed according to Scania’s bodywork instructions. The instructions in this document have been prepared as a support for the bodybuilder to carry out bodywork in a way that ensures high quality, high operational reliability and minimal risk of personal injuries and material damage during the entire service life of the vehicle.

A quality and safety check is mandatory.

1. Print 2 copies of the following document:

– Pre-delivery inspection: Checklist

2. Fill them out

3. Fill out the following document on the Scania Truck Bodybuilder website:

– Declaration of Conformity

4. Print 2 copies of the document.

5. Place one original of each document in the cab close to the Driver’s Manual. The Driver’s Manual is usually placed under the bunk or in one of the storage com-partments in the cab.

6. Keep one original of each document at the bodybuilder’s.

When a vehicle breakdown is caused by something in the interface between the chas-sis and bodywork, the following connections and components are often involved:

• Hydraulic connections

• Hot components

• Electrical components

• Electrical connections

The check points in this document are mainly about these connections and compo-nents.

Scania Truck Bodybuilder 22:10-556 Issue 3 2017-03-22© Scania CV AB 2017, Sweden 1 (21)

Check points


Check pointsThe instructions in this document have been developed as an aid to the bodybuilder when filling out the document Pre-delivery inspection: Checklist.

Check point 1The following documents for the bodywork must be supplied with the vehicle:

• Pre-delivery inspection: Checklist

• Declaration of Conformity

• Manual that describes the safe operation and handling of the bodywork functions

• Instructions on care and maintenance of the bodywork

• Protocol from test drive and leakage test

• A description of the BICT diagrams used


Check points


Check point 2For vehicles and markets that are covered by the machinery directive 2006/42/EC, it is mandatory that the equipment is CE marked and that the following documentation is supplied together with the vehicle:

• Document showing CE marked products

• Protocol from leakage test and operational testing of overflow valves

Scania recommends that the corresponding documentation is delivered with the bod-ywork for markets outside the EU.

More information on the Machinery directive and CE marking is found in the docu-ment Legal requirements.

Check point 3The vehicle must be clean with no remains left from the bodybuilding such as drill swarf, cable clippings and footprints.

Check point 4The surface between the bodywork and the chassis frame must be clean and smooth. No swarf or bumps may exist. If the subframe is joined of several parts, the surface to the chassis frame must be smooth.

Check point 5No parts of the bodywork may prevent moving parts on the chassis from being able to move fully to their end positions.


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Examples of when the bodywork is designed so that it prevents filling of reductant.

Check point 6The bodywork must be designed so as not to hinder or make impossible the mainte-nance and repair of the chassis or bodywork, see illustration.

More information is found in the document Limitations for work with the chassis.

Check point 7A manufacturer’s plate with information on the bodywork must be attached to the bodywork.

The manufacturer’s plate must include the following:

• Bodybuilder’s name

• Bodywork model

• Serial number

• Year of manufacture


Check points


3060 A

1530 A

3

4

2

1

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1. Main central electric unit P2.2. Bodywork central electric unit P9.3. Stickers in cover for bodywork central electric unit P9.4. Stickers in cover for main central electric unit P2.

Check point 8The central electric units must be marked with complementary information on retro-fitted electrical equipment and the marking of fuses. Preferably, complete the exist-ing stickers, see illustration.

IMPORTANT!

Inadequate information can lead to unnecessary work when troubleshooting or incor-rect handling of fuses which may lead to overheating.


Check points


Check point 9Electrical cables must have well adjusted lengths and planned clamping in order to achieve the following:

• That the fuse panel can be folded out without stretching any electrical cables.

• Reduced risk of wear or chafing of electrical cables.

IMPORTANT!

• Stretched electrical cables can damage the connections, which may lead to loss of functionality.

• Wear and chafing can damage the electrical cables resulting in short circuit.

• Heavy electrical components may need a more robust attachment, for example us-ing screws.

More information on the central electric units is found in the following documents:

• Working with the main central electric unit• Working with the bodywork central electric unit• Working on the vehicle electrical system• Central electric units

Check point 10Electrical cables must be marked and colour-coded to simplify troubleshooting.


Check points


Check point 11Cable harnesses that can be subject to rain, dirt, snow and ice demand extra good at-tachment and that the components have the correct encapsulation class. This also ap-plies to cables fitted low, where there is a risk that the cables are subject to foreign objects on the road.

IMPORTANT!

Cables which become detached can result in short circuit and reduced function.

Check point 12Cables must not be installed closer than 100 mm from hot components, for example, the exhaust system. Components regarded as hot are those that have a temperature higher than 250°C.

Please use the table with recommended safety clearances, which is found in the doc-ument Risk of fire and damage in connection with hot components.

WARNING!Overheating can cause fire.


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Check point 13The chassis ground connections must be located in the left-hand frame side member. Pre-defined positions should mainly be used. If other electrical ground points are re-quired, new ground screws must be fitted, see illustration.

WARNING!Ground connections are only reliable in the left-hand frame side member. Other frame parts may be well grounded, but they are technically inferior due to the con-struction of the chassis frame. Poor ground connections can cause overheating and fire.

More information on ground connections is found in the document Grounding and power supply.


Check points


G65 G64

G3

G1

G2

G70

Ground connections on the chassis frame and in the cab.

Check point 14Ground connections in the cab must be placed in G1, G2, G3, G64, G65 or G70, see illustration.


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3

4

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1. Main central electric unit P2.2. Bodywork central electric unit P9.3. Chassis central electric unit P11.4. Chassis central electric unit P8.

Check point 15The power supply must be taken from one of the central electric units:

• Bodywork central electric unit P9:

– 15 voltage (highest load 30 A with starter lock in drive position).– 30 voltage (highest load 60 A, direct from the battery).

• Chassis central electric unit P11:

– 30 voltage (highest load 150 A, direct from the battery) must be taken from the chassis central electric unit behind the left-hand front wheel (24 V).

• Work should be avoided in the main central electric unit P2, but there is access to a 12 V supply.

WARNING!Any circuits without fuses connected to the battery positive terminal (+24 V) can cause fire in case of chafing or short circuit.

IMPORTANT!

It is not permitted to connect to only one battery in order to draw 12 V as this results in a charging imbalance, which reduces the service life of the batteries.


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Example of cable protection.

Check point 16All electrical connections outside the cab must be well protected against moisture, e.g. switches, connectors, cable splices and junction boxes. Use a classification ac-cording to IP6K9K, i.e. they must withstand high pressure washers, see illustration.

Do not use junction blocks outside the cab.

WARNING!Poor moisture protection will quickly result in malfunctions and, in worst case, over-heating.

Check point 17Pipes, hoses and cable harnesses must be clamped at a distance of max. 900 mm be-tween clamping points.


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1

2

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Location of compressed air outlets for bodywork.1. Location of the compressed air outlet at the third crossmember.2. Solenoid valves at the rear end of the chassis.

Check point 18The compressed air to the bodywork must be taken from the intended compressed air outlet, which is located at the third crossmember from the front (1), or via solenoid valves at the rear end of the chassis (2).

More information on pneumatic systems is found in the following documents:

• General information about the pneumatic system.• Modifying the pneumatic system.


Check points


2 3

4

1

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Check point 19Coolant outlet from the vehicle’s cooling system must be connected to the engine’s connection for that purpose.

Location for connector for inline engine (1), see illustration.

Locations for V-engines (2) (3) and (4), see illustration.

More information is found in the document Coolant outlet for external heating.


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Check point 20Coolant return to the vehicle’s cooling system must be connected to the return con-nection,see illustration.

More information is found in the document Coolant outlet for external heating.


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Steel pipes.

Check point 21Steel pipes must primarily be used for hydraulic installations. When hydraulic hoses must be used, select the correct type of hose with regard to the application and envi-ronment.

Document the selection of hydraulic hose in the document Pre-delivery inspection: Checklist.

More information is found in the document Power take-off driven hydraulic systems.


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1

3

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1. Heat shield above the exhaust pipe behind the cab.2. Heat shield between the exhaust pipe and hydraulic pump for power take-off with hoses.3. Heat shield between engine and bodywork.

Check point 22If plastic or rubber parts must be fitted less than 100 mm from hot components, metal heat shields must be used. The distance must be minimum 15 mm between the hot surface and the heat shield, see illustration.

WARNING!• Plastic and rubber hoses that come in contact with or are too close to hot compo-

nents can melt.

• Hydraulic oil that leaks and comes in contact with hot components can cause fire.

Check point 23Hydraulic pumps must be protected from high heat. A pump fitted to an engine power take-off on a 16 litre engine must have a heat shield.

IMPORTANT!

Hydraulic oil loses its properties permanently at excessive heating.


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Check the necessary clearance.

Check point 24Hydraulic hoses must be installed in a way that ensures minimal risk of chafing.

If necessary, use chafing covers made of spiral plastic, for example polyamide.

IMPORTANT!

Chafing can cause leakage.

Check point 25Ensure there is necessary clearance between the components in the hydraulic system and components attached to the chassis, see illustration. This is also applicable to the most extreme operating conditions, for example the following:

• Longest suspension travel

• Maximum steering lock

• Engine movement


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Example of clamping.

Check point 26Hoses and pipes must be fitted in a way that provides a good strain relief. Mechani-cally weak components require tighter clamping than mechanically strong compo-nents.

Load relief and clamping must be made close to couplings to avoid undesired break-ing forces. Load relief must be made max. 200-300 mm from couplings.

IMPORTANT!

Heavy couplings such as T-unions give higher breaking forces and should therefore have load relief. The breaking forces may also increase from snow, ice, dirt and poor road conditions. Insufficient relief of the breaking forces can cause fractures in the couplings.


Check points


Check point 27Avoid placing hydraulic equipment with couplings (for example tanks, valves and connections) above hot components with temperatures higher than 250°C, for exam-ple parts of the exhaust system.

If this is not possible, drip protection must be fitted to prevent leaking oil from drip-ping onto hot components.

WARNING!Hydraulic oil that leaks and comes in contact with hot components can cause fire.


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Check point 28The area for the exhaust outlet must not come in contact with any flammable mate-rial. Particularly critical components are plastic and rubber hoses that convey fuel and hydraulic fluids for the steering and brakes.

Bear in mind that very large amounts of heat flow from the exhaust outlet during op-eration, even when the vehicle is stationary, e.g. during crane work. The exhaust gas volume is often 5-15 m³/min and the exhaust gas temperature can reach temperatures higher than 500°C.

WARNING!An incorrectly constructed exhaust outlet can lead to impaired function and perfor-mance and cause a fire.

More information on exhaust systems is found in the document Modifying the exhaust system.


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Example of fluid reservoir.

Check point 29Flammable loads and other material, for example from loading and unloading, must not be allowed to collect close or next to hot components. Flammable cargo spillage must not get any closer than 300 mm from hot components, depending on the air cir-culation.

More information on safety distances is found in the document Risk of fire and dam-age in connection with hot components.

WARNING!Collection of flammable material close to hot components can cause a fire.

Check point 30Fluid reservoirs must be marked with the name of the intended type of fluid, see il-lustration.

Check point 31The Max and Min levels on fluid reservoirs must be easy to read, with sight glass, dipstick or similar.

IMPORTANT!

The correct type and quantity of fluid must be used for the system to work correctly.


pre-delivery inspection: instructions general information

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