Content      ..     3      4      5      6     ..

Scania DC16 XPI. Industrial engine. Operator’s manual - part 5

Fuel system

To ensure that the filter housings are drained

B

properly, the filter covers must be removed as

follows:

IMPORTANT!

Start with the water separating prefilter (A). Do

not open the main filter cover (B) until the filter

housing for the water separating prefilter is com-

pletely drained.

A

64

Fuel system

1. Make a mark on the water separating prefil-

ter cover (A). Unscrew the cover 3 to 4 turns

with the socket.

IMPORTANT!

A

Do not use an adjustable spanner or other open

tool to remove the filter covers, as the filter cov-

ers may then get damaged.

Wait for at least 2 minutes to allow as much of

the fuel as possible to drain out of the filter hous-

ing.

2. Unscrew the filter cover (A) and lift it up

slowly with the filter element.

3. Make sure the suction tool is completely

drained before starting work. Draw out re-

maining fuel and any particles using the suc-

tion tool or a similar tool.

4. Keep the suction tool hose in the filter hous-

ing for the water separating prefilter (A).

A

65

Fuel system

5. Make a mark on the main filter cover (B).

B

Unscrew the cover 3 to 4 turns with the sock-

et. Draw out fuel which may drain into the

water separating prefilter housing when the

main filter is detached.

IMPORTANT!

Wait for at least 2 minutes to allow as much of

the fuel as possible to drain out of the filter hous-

ing.

6. Unscrew the main filter cover (B) and lift it

up slowly with the filter element.

B

7. Fuel from the main filter housing (B) will

flow into the water separating prefilter hous-

ing (A). Leave the suction tool in the water

separating prefilter housing until it is com-

pletely drained of fuel.

A

66

Fuel system

8. Move the suction tool to the main filter hous-

ing (B). Draw out remaining fuel and parti-

cles.

B

IMPORTANT!

It is important to remove remaining fuel and par-

ticles from the filter housings to prevent fuel sys-

tem contamination.

9. Undo the old filter elements from the covers

by carefully bending them to one side.

Removing the fuel filter if there is no

suction tool

1. Open the bleed nipple on the fuel filter hous-

ing to release any remaining pressure. It may

be difficult to unscrew the filter cover if the

fuel pressure has not fallen sufficiently.

IMPORTANT!

Do not use an adjustable spanner or other open

tool to remove the filter covers, as the filter cov-

ers may then get damaged.

67

Fuel system

To ensure that the filter housings are drained

properly, the filter covers must be removed as

follows:

B

2. On the main filter (B): Make a mark on the

cover. Unscrew the cover 3 to 4 turns with

the socket.

3. Repeat the procedure with the water separat-

ing prefilter (A).

4. Wait at least 2 minutes to ensure the filter

housings have drained properly.

5. On the main filter: Unscrew the filter cover

and lift it up slowly with the filter element.

6. On the water separating prefilter: Unscrew

the filter cover and lift it up slowly with the

filter element.

Remaining fuel will drain out of the fuel fil-

A

ter housings automatically when the filter el-

ements are lifted out.

7. Check that no fuel or particles remain in the

bottom of the filter housings. Draw off re-

maining fuel and any particles.

IMPORTANT!

It is important to remove remaining fuel and par-

ticles from the filter housings to prevent fuel sys-

tem contamination.

8. Undo the old filter element from the cover by

carefully bending it to one side.

68

Fuel system

Bleeding the fuel system

IMPORTANT!

The collected fuel must not be poured back into

the fuel tank.

Environment

Use a suitable container. The fuel collected must

be disposed of as specified in national and inter-

national laws and regulations.

Bleeding the fuel system using a suc-

tion tool

Tool

Description

Illustration

Suction tool

Note:

Scania recommends bleeding the fuel system us-

ing suction tools rather than with a hand pump.

This is a quicker and simpler method, which en-

sures a complete bleeding.

1. Open the bleed nipple on the high pressure

pump and connect the suction tool.

70

Fuel system

2. Hold the suction tool straight and draw out at

least a full container of fuel.

3. Once the fuel coming out of the hose is free

of air bubbles, then bleeding is complete.

4. Close the bleed nipple on the high pressure

pump. Remove the hose and suction tool.

5. Start the engine and check that no leakage

occurs.

Bleeding the fuel system using a

hand pump

1. Attach a clear plastic hose to the bleed nipple

on the fuel filter housing. Let the plastic hose

drop into a container that holds at least 5 li-

tres (1.3 US gallons).

2. Unscrew the hand pump handle on the water

separating prefilter.

3. Open the bleed nipple on the fuel filter hous-

ing and pump until fuel runs out, which will

take around 150 pump strokes. Close the

bleed nipple on the fuel pump and screw

down the hand pump handle.

The main filter has built-in bleeding in the

form of a 0.2 mm restriction valve in which

the fuel continuously flows on to the return

pipe and takes with it any air in the circuit.

4. Start the engine and check that no leakage

occurs.

71

Miscellaneous

Miscellaneous

3

2

Checking the drive belt

5

IMPORTANT!

2

Before starting, make a note of how the drive belt

is fitted. Refit the drive belt with the same direc-

tion of rotation as it had before removal.

4

1. Check the drive belt for cracks. Renew the

drive belt if deep cracks have formed.

1

Note:

Small and shallow cracks are normal and form

Example of a drive belt.

after only a few hours of operation. They do not

1. Crankshaft.

mean that the drive belt needs to be renewed. If

there are many deep cracks, or if parts of the

2. Idler roller.

drive belt have started to come off, the drive belt

3. Alternator.

must then be renewed.

4. Belt tensioner.

5. Coolant pump.

Example of a minor crack in the drive belt. The drive

The drive belt has deep cracks and must be renewed.

belt can be refitted.

72

Miscellaneous

2. Check drive belt wear. Renew the drive belt

if it is too worn.

The drive belt is starting to become worn, but can be

The belt is worn down to the cord. The drive belt

refitted.

must be renewed.

Checking for leaks

IMPORTANT!

If serious leakage occurs, contact your nearest

workshop.

1. Start the engine.

2. Check for oil, coolant, fuel, air or exhaust

leaks.

3. Tighten or renew leaking connections.

Check the overflow holes which show

whether the O-rings between the cylinder

liners and crankcase are leaking.

4. Check whether the drain hole on the coolant

pump is blocked. If there is a leak, renew the

seal in the pump or the complete coolant

pump.

73

Miscellaneous

Checking and adjusting the

valve clearance

Tool

Number

Description

Illustration

99 309

Turning tool for rotating the flywheel from below

2 402 509

Turning tool for rotating the flywheel from above

Other tools

Torque wrench, 0-50 Nm

Waterproof felt-tip pen

0.45 and 0.70 mm feeler gauges

Flash light

Mirror

WARNING!

Block the starting device. If the engine starts un-

expectedly, there is a serious risk of injury.

IMPORTANT!

The engine must be cold when the work is car-

ried out.

Remember to remove the turning tool from the

flywheel after adjustment.

Note:

Carry out the working without pausing, so that

no step is overlooked.

Carry out a check and adjustment of the valve

clearances one more time after the first 500 hours

of operation. After this, adjustment according to

the regular interval takes place, which is every

2,000 operational hours.

74

Miscellaneous

On the flywheel is engraved the reference infor-

mation UP TDC, DOWN TDC and the angle in-

dications listed in the table below. Depending on

the engine installation and type of flywheel

housing, this information is visible in one of the

windows, either furthest up or furthest down on

the flywheel. See illustration.

Valve clearance, specifications

Intake valve

0.45 mm (0.018 in)

Exhaust valve

0.70 mm (0.028 in)

Upper and lower window to read the engraving on

the flywheel.

Tightening torque

Lock nut for valves

35 Nm (26 lb/ft)

Adjust valves according to the table below. Fol-

low the respective column depending on whether

you are reading the engraving on the flywheel in

the lower or the upper window. Start adjustment

at the top of the table.

Reading in the low-

Valve transition on

Adjust intake valve

Adjust exhaust

Reading in the up-

er window

cylinder

on cylinder

valve on cylinder

per window

DOWN TDC (0°)

6

7 and 8

4 and 5

UP TDC (180°)

UP TDC (180°)

7

1 and 5

2 and 6

DOWN TDC (0°)

DOWN TDC (360°)

1

2 and 4

3 and 7

UP TDC (540°)

UP TDC (540°)

4

3 and 6

1 and 8

DOWN TDC (360°)

1

2

3

4

5

6

7

8

Order of cylinders.

75

Miscellaneous

1. Clean the rocker covers and the area around

them.

2. Remove the rocker covers.

3. Use the turning tool appropriate to the instal-

lation of the engine. Tool 99 309 is used to

rotate the flywheel from the underside of the

engine and tool 2 402 509 is used from the

top side.

4. Start adjusting one cylinder according to the

table. Rotate the flywheel until the correct

engraving can be read on the flywheel. It

may be necessary to rotate it more than 1 rev-

olution.

Rotate the flywheel in the rotational direc-

tion of the engine, which is clockwise

viewed from the front of the engine and anti-

clockwise viewed from the back of the en-

gine.

During a valve transition, the exhaust valve

(the long arm) is closing at the same time as

the intake valve is opening.

The UP TDC engraving on the flywheel is

now visible in the window furthest up on the

flywheel. The DOWN TDC engraving is vis-

ible in the lower window.

5. Read the table on the previous page to see

which valve to adjust.

6. Stick the feeler gauge under the pressure pad

of the rocker arm and check the valve clear-

ance.

7. If necessary, adjust the valve clearance by

a) loosening the lock nut on the end of the

3

rocker arm

b) adjusting the valve clearance with the ad-

justing screw

c) tightening the lock nut.

4

8. Mark the rocker arm with the felt-tip pen and

then continue with the next cylinder accord-

ing to the table.

5

1. Adjusting screw

2. Lock nut

3. Rocker arm

4. Valve bridge

5. Feeler gauge

76

Miscellaneous

Renewing the reductant filter

1. Wipe clean around the filter housing to pre-

vent impurities from penetrating it.

3

2. Remove the filter housing. Use a 46 mm

socket.

4

WARNING!

There may be a lot of reductant in the filter hous-

5

ing and it may spill out. Wear protective gloves.

1

6

IMPORTANT!

Always rinse away reductant spillage on connec-

tions and other parts with lukewarm water to pre-

vent corrosion. If reductant seeps into electrical

connections or electrical cables, these must be

renewed.

2

3. Remove the sealing diaphragm.

1. Pump

2. Filter

3. Sealing diaphragm

4. O-ring

5. Antifreeze

6. Filter housing

4. Remove the old reductant filter and fit a new

one.

77

Miscellaneous

5. If the anti-freeze protection in the filter hous-

ing comes loose, wipe both the anti-freeze

protection and filter housing thoroughly so

that they are completely dry before they are

assembled again.

6. Wipe the sealing diaphragm and fit it over

the filter.

Ensure that the edge of the diaphragm is sit-

ting in the groove.

7. Lubricate the sealing diaphragm and threads

with the accompanying spray.

78

Miscellaneous

8. Renew the O-ring. Place the new O-ring in

the filter housing.

9. Refit the filter housing. Use a 46 mm socket.

Tighten to 80 Nm (59 lb-ft).

79

Content      ..     3      4      5      6     ..