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FUEL SYSTEM

Description of operation

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© Scania CV AB 1995-10
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 Contents

Contents

Design ........................................................................ 4

Fuel tanks and lines ........................................................................ 6

Fuel valve Function ......................................................... 7

Open fuel valve .............................................. 7
Closed fuel valve ........................................... 8

Feed pumps General ........................................................... 9

Single action feed pump .............................. 10
Dual action feed pump ................................. 12

Fuel filter ...................................................................... 14

Injection pumps Conventional in-line pumps ......................... 15

In-line pumps with adjustable
injection timing ............................................ 16
Pump element and delivery valve
mode of operation ........................................ 17
Pump settings ............................................... 19
Injection quantities ....................................... 19

Delivery pipes, injectors .............................. 20

© Scania CV AB 1995
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Design

Design

The fuel system consists of fuel tank with fuel

pick-up unit, fuel lines, feed pump, fuel filter,
injection pump with fuel valve and overflow
valve as well as injectors and return lines.
The feed pump sucks fuel through the tank filter
and then forces it through the fuel filters on to
the injection pump.
The injection pump distributes the fuel via the
delivery pipes and injectors to the engine cylin-
ders at the correct moment and in a quantity
which corresponds to the power output of the
engine.
Excess fuel, which is returned from the over-
flow valve, and leak-off fuel from the injectors
is returned to the tank via the leak-off fuel and
return lines.

© Scania CV AB 1995
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 Design

6 11 8 12

10

2 1

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Fuel to injectors
Feed fuel to injection pump
Return fuel

1 Suction line with strainer 7 Fuel valve

2 Fuel tank 8 Delivery pipe
3 Fuel level sensor 9 Injector
4 Feed pump 10 Return line
5 Fuel filter 11 Overflow valve
6 Injection pump 12 Leak-off fuel pipe

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Fuel tanks and lines

Fuel tanks and lines

Scania trucks are supplied with one or two fuel

tanks. The fuel line to the engine is connected to
the right-hand tank. Trucks with two tanks
therefore have a plastic connection pipe between
the two tanks.

There is a fuel pick-up unit in the fuel tank with

suction and return lines to the injection pump

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and auxiliary heater. There is also a float and
sensor to the fuel level gauge. The return pipe
from the injection pump is angled towards the
strainer at the bottom of the fuel pick-up unit so 1 Suction pipe for fuel to injection pump
that the warm return fuel can help to prevent
2 Suction pipe for fuel to auxiliary heater
waxing in cold weather.
3 Return pipe for fuel from injection pump
4 Return pipe for fuel from auxiliary heater
5 Switch for fuel level sensor
6 Fuel level sensor
7 Strainer
The float actuates the slip ring connector via the 8 Float
float arm and causes it to move on the coil and, 9 Float arm
via increased or decreased resistance, enables
the fuel level gauge to show what quantity of
fuel remains in the tank.
A plastic fuel line runs from the suction pipe and
follows the frame side member from the towards
the engine.
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N.B. The plastic pipe must be protected against

intense heat when e.g. welding.
1 Slip ring connector
2 Coil

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 Fuel valve

Fuel valve

Function
The fuel valve is a solenoid valve which opens
and closes the fuel supply to the engine. The
route of the fuel through the valve depends on
whether it is open or closed.
The fuel valve is open when the power is

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switched on. This is why power should always
be on when bleeding the fuel system.
Fuel valve and overflow valve
When power is switched off, the valve closes.
The feed pump then draws fuel from the injec-
tion pump instead of supplying it. The engine
stops due to vacuum.

Open fuel valve

The feed pump draws fuel from the tank through
the fuel valve. It then pushes the fuel through
the filter and the fuel valve on to the injection
pump.
Excess fuel from the injection pump flows back
to the tank via the fuel valve and overflow
valve. Fuel leak-off from the injectors is
returned via a connection on the overflow valve.
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© Scania CV AB 1995
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Fuel valve

Closed fuel valve

The feed pump draws fuel from the injection

pump through the fuel valve. It then forces the
fuel through the filter and fuel valve, on to the
tank.

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© Scania CV AB 1995
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 Feed pumps

Feed pumps

General
The function of the feed pump is to suck fuel
from the tank and to push it on through the sys-
tem to the injection pump.

The feed pump is a mechanical piston-type

pump, attached to the injection pump. It is pow-
ered from the injection pump camshaft which
has two lobes to drive the feed pump.

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Therefore, the single action feed pump pumps
fuel twice for each camshaft revolution and the
dual action feed pump four times.

Camshaft, lobes for feed pump

There is a hand pump on the feed pump for
priming after service work.

The capacity of the feed pump is sized so that

fuel quantity considerably exceeds engine
requirements.

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Feed pumps

Single action feed pump

The single action feed pump consists of two

chambers, separated by a piston. The piston 10
is actuated partly by the tappet 14 and the push-
rod 9, partly by piston spring 11.

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1 Pump housing 10 Piston
2 Suction valve 11 Piston spring
3 Delivery valve 12 Gasket
4 Hand pump 13 Plug
5 Gasket 14 Tappet
6 Valve spring 15 Tappet roller
7 Plug 16 Tappet shaft
8 O-ring 17 Guide
9 Pushrod 18 Spring ring

Suction stroke
(Induction of fuel)

The pump piston is forced in by the piston

spring, fuel is sucked in, passes the suction
valve and fills the outer pump chamber.
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Induction of fuel

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 Feed pumps

Intermediate stroke
(Pumping between outer and inner pump cham-
bers)

When the cam pushes the pump piston back, the

suction valve closes and the fuel is force through
the delivery valve into the pump chamber.

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Pumping between outer and inner pump chambers

Pump stroke

(Pumping fuel to injection pump)

When the cam returns to its lower position, the

piston is pushed in by the piston spring and the
fuel in the pump chamber is pushed to the outlet.
At the same time, new fuel is sucked in to the
outer pump chamber.
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Pumping fuel to injection pump

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Feed pumps

Dual action feed pump

The dual action feed pump has four check

valves (the single action pump has two).

This means that the chambers are combined

pump and suction chambers. At each stroke, fuel
is sucked in to one chamber and forced out of
the other chamber.

Drive is using the same method as for the single

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action feed pump.

1 Pump housing 10 Piston

2 Suction valve 11 Piston spring
3 Delivery valve 12 Gasket
4 Hand pump 13 Plug
5 Gasket 14 Tappet
6 Valve spring 15 Tappet roller
7 Plug 16 Tappet shaft
8 O-ring 17 Guide
9 Pushrod 18 Spring

Stroke in

The pump piston is forced in by the piston

spring and fuel is sucked in through the suction
chamber, passes the suction valve and fills the
pump chamber.
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Stroke in

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 Feed pumps

Stroke out

The camshaft forces the piston out and sucks

fuel, this time to the other pump chamber. At the
same time, the fuel in the first pump chamber is
forced through the supply chamber to the outlet.
When the dual action feed pump repeats its
stroke in, the fuel is forced from the second
pump chamber to the outlet.

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Stroke out

! WARNING!

Never block the outlet from the feed

pump. Pressure becomes damagingly
high.

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Fuel filter

Fuel filter

The fuel filter is located on a filter retainer

which is bolted to the engine.

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The filter consists of a metal retainer with spi-
rally wound paper inserts. It cannot be disman-
tled and must be changed as a complete unit.

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 Injection pumps

Injection pumps

Conventional in-line pumps 3 4 5

The injection pump is driven from the engine

timing gear. The injection pump camshaft has a
hub with a gear wheel. Exchange ratio is such
that the injection pump is driven at half engine
speed.

Injection pump bearings, camshaft and tappets 2

are lubricated with oil from the engine lubricat-
ing system. The pump element is lubricated with 1
fuel.

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1 Pulse wheel
The injection pump has one pump element for
each cylinder. The pump elements always have 2 Main engine speed sensor
the same stroke. Injection quantity is determined
by how much the plunger in the pump element is 3 Setting solenoid
turned. The pump plunger is turned by the con-
trol rack which is controlled by the governor. 4 Return spring
5 Control rack

All plungers are turned at the same time and by

the same amount. Injection starts when the
pump plunger closes the inlet and spill ports in
the pump element.

a
a

The pump plunger has a diagonal helix edge.

Injection ceases when this helix edge passes the
spill port in the barrel.
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a = quantity of fuel
Pump element and control rack

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Injection pumps

Above each pump element, there is a delivery

valve which consists of valve housing and valve
plunger. The valve plunger is held against its
seat by a spring.
The delivery valve opens and releases fuel into
the delivery pipe when opening pressure is
achieved in the pump element. When fuel pres-
sure drops after injection, the valve plunger is
forced back against its seat by the spring.
When the delivery valve plunger has closed, the
available volume for the fuel in the delivery pipe
increases. This lowers the pressure in the deliv-
ery pipe and injectors, decreasing the risk of
dropping from the injector.
The change in capacity is adapted to the length
of the delivery pipe and this length must never
be changed.
The delivery valve is held in the pump housing
by the delivery valve holder, which is bolted
into the housing from above.

6 4 3

In-line pumps with adjustable 2

5
injection timing
7
In-line pumps with adjustable injection timing
have a sliding ”sleeve” on the pump plunger 8
which allows adjustment of prestroke in order to
alter the start of feed and injection. Injection
quantity is controlled in the same way, as on a
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conventional pump.

1 Setting solenoid, injection timing

2 Return spring
3 Prestroke shaft
4 Return spring
5 Setting solenoid, fuel supply
6 Control rack
7 Stroke position sleeve
8 Pump plunger

© Scania CV AB 1995
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 Injection pumps

Principle of operation of pump

element and delivery valve

First phase of piston stroke: inlet port is exposed

and fuel flows in.

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Lower dead centre, fuel supply

Second phase of piston stroke: from bottom

dead centre until the upper edge of the piston
closes the inlet.
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Prestroke

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Injection pumps

Third phase of piston stroke: from when the

upper edge of the plunger has closed the inlet
port until the spill port is opened by the helix
edge. When inlet port is opened, delivery valve
is closed.

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Delivery stroke

Fourth phase of piston stroke: from when the

spill port opens to top dead centre.

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Prestroke

The axial groove is aligned with the port. In this

position, there is no fuel delivery. The plunger is
turned to this position in order to stop the
engine.
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Non-delivery

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 Injection pumps

Pump settings
The injection pump must be set so that the cor-
rect quantity of fuel is injected into each cylin-
der at the correct moment during the work cycle.

Injection pump setting in degrees from top dead

centre is given on a plate on the engine rocker

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cover or intake manifold. See ”Fuel system,
work description”.
99 316
Lock pin 99 316 is used to check and set injec-
tion timing.

Injection quantities
In order to achieve specified power and torque
from the engine, the injection pump and gover-
nor must be correctly set.

Only workshops which have the special equip-

ment and trained personnel may work on pump
and governors. When testing, pumps and gover-
nors should be run according to Scania testing
tables.

The testing tables are not part of the Workshop

and can be found in ”Injection system” a special
issue of the Workshop Manual.

The testing tables have been worked out for

each particular combination of engine, pump,
governor etc. This is given in the testing tables.

All setting devices on the pump and governor

should be sealed in order to prevent them being
set by unqualified persons.

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Delivery pipe, injectors

Delivery pipe
Delivery pipes are manufactured from steel pip-
ing, with cones and cap nuts at each end.
The delivery pipes are attached with clips in
order to damp vibrations in the pipe, reducing
the risk of it breaking.
Broken, or otherwise damaged delivery pipes,
must not be repaired by soldering or welding,

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but should be changed.
Delivery pipes must not be switched between
different types or designs of engine as diameter 1 Delivery pipe
and length depend on which engine type the 2 Cap nut
pipe fits. 3 Washer
4 Cone shaped end of pipe
5 Connection

Delivery pipe union

Injectors
1
The fuel is forced through the delivery pipes to
the injectors. The injector atomizes the fuel in 2
the combustion chamber.
3
An edge filter is pressed into the pipe union on
4
the injector. The fuel is forced through a passage
in the edge filter to the nozzle. 5

The movement of the nozzle needle is controlled

by fuel pressure and spring force.
When fuel from the injection pump reaches a
certain pressure (opening pressure), the nozzle 6
needle lifts (start of injection). The fuel is then
sprayed in atomized form into the engine com-
bustion chamber through five accurately cali-
brated holes.
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The fuel that leaks between the nozzle needle

and nozzle housing is routed back to the fuel
tank via the leak-off line which is connected to 1 Delivery pipe from pump
the injector. 2 Cap nut
3 Edge filter
4 Leak-off fuel line
5 Spring
6 Nozzle needle

Injectors, function

© Scania CV AB 1995
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