Moving fuel tanks General notes on moving fuel tanks
General notes on moving fuel tanks It is sometimes necessary to move one or more fuel tanks to make room for bodywork components. VARNING! • The fuel system is pressurised. Wear eye protection when removing pipes and connectors. • The return fuel may be very hot in engines with the Scania HPI fuel system. Exercise great care when working with or close to return hoses and connections. • Installation close to hot components can cause fire.
More information on fire risk is found in the document Risk of fire and damage in connection with hot components.
Gas vehicles VIKTIGT! It is not permissible to move gas tanks.
More information on gas tanks is found in the document Working on gas vehicles.
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Moving fuel tanks General notes on moving fuel tanks
Temporary corrosion protection The temporary corrosion protection is only used on vehicles with the following chassis serial numbers: Vehicle production period Production site Södertälje Zwolle
Chassis serial number 2013-12-11 - 2014-03-01 2 094 485 - 2 096 918 5 343 303 - 5 358 195
The change does not apply to Angers or São Bernardo do Campo. VIKTIGT! The fuel tanks are treated for transport with a transparent, temporary corrosion protection on visible surfaces. Areas under tank strapping are not treated. In connection with moving the fuel tanks, wash with warm water or high pressure washer, otherwise there is a risk of the tanks gliding. In certain cases, vehicle cleaning agents can be used to remove the corrosion protection more effectively. The fuel pipes must satisfy the requirements of the DIN 73378 standard.
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Moving fuel tanks General notes on moving fuel tanks
Modification and conversion conditions Obs! • A new fuel tank volume requires adjustment of parameters using SDP3 (Scania Diagnos & Programmer 3). Please contact a Scania workshop for assistance. • Replace with original Scania fuel tanks.
High-level fuel tank VIKTIGT! • Positioning the fuel tank higher than the cylinders on vehicles with the Scania HPI fuel system may create problems when starting the engine and carry the risk of damage to the engine. • Fit a shut-off cock in the line for vehicles with the Scania HPI and XPI fuel systems so as not to accidentally empty the tank when changing filter. Follow the recommendations further on in this document.
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Moving fuel tanks Removing and fitting the fuel pick-up unit
Removing and fitting the fuel pick-up unit
1a
1b
The fuel pick-up unit looks different depending on the vehicle’s production period. The different fuel pick-up units are described according to the production period below.
Production period 1 Vehicle production period Production site Södertälje Zwolle Angers São Bernardo do Campo
Chassis serial number 2014-04-11 2 097 744 5 351 210 9 185 429 3 855 196 -
7, 9 and 13 litre engines have a fuel pick-up unit with 2 pipe unions (1a). 16 litre engines have a fuel pick-up unit with 3 pipe unions (1b).
Work description 1. Unscrew all 2 or 3 pipe unions from the fuel pick-up unit and leave the pipes rest-
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ing in the pipe unions. 2. Move the fuel tank. 3. Screw the pipe unions back onto the fuel pick-up unit.
Fuel pick-up units 1a and 1b for production period 1.
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Moving fuel tanks Removing and fitting the fuel pick-up unit
Production period 2 Vehicle production period Production site Södertälje Zwolle Angers São Bernardo do Campo
2
Chassis serial number 2005-05-30 - 2014-04-10 2 009 305 2 097 743 5 126 029 5 351 209 9 100 953 9 185 428 3 570 706 3 855 195
Work description 1. Unscrew all the 4 pipe unions from the fuel pick-up unit and leave the pipes rest-
ing in the pipe unions. 2. Move the fuel tank. 3. Screw the pipe unions back onto the fuel pick-up unit.
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Obs! The fuel pick-up unit for production period 2 has been discontinued from Scania’s range.
Fuel pick-up unit for production period 2.
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Moving fuel tanks Removing and fitting the fuel pick-up unit
Production period 3 Vehicle production period Production site
Chassis serial number - 2005-05-29 - 2 009 304 - 5 126 028 - 9 100 952 - 3 570 705
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Södertälje Zwolle Angers São Bernardo do Campo
3
Fuel pick-up unit for production period 3.
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Moving fuel tanks Removing and fitting the fuel pick-up unit
VIKTIGT!
3
Do not pull the fuel pipes away from the fuel pick-up unit. This may damage the locking clips. It is not permitted to join the fuel pipes. Joining means a risk of leakage. If the pipes are too short, then new, longer pipes must be fitted. 2
Work description 1. Detach the hose clips and carefully pull the pipes out of the unions. 2. Remove the pipe unions with a special tool so as not to damage the locking clips. 3. Move the fuel tank. 4. Push the pipe unions back so they snap into the locking clips. 5. Screw on the pipes.
Designation 1 Locking clip 2 Pipe union 3 Special tool
Part number 1 493 962 1 456 042 99 524
1
309 043
The parts are available from Scania dealers.
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Moving fuel tanks Scania XPI and high-level fuel tanks
Scania XPI and high-level fuel tanks General information The following applies to high-level fuel tanks: • • • •
The tank must not be raised more than 1.2 m. The fuel lines and tank pick-up unit must be original. The bend radii must not be too narrow. The counter pressure in the return pipe must not exceed 350 mbar.
Dimensions and minimum radii when bending
d1 (mm) d2 (mm) 6 ±0.1 4 ±0.2 8 ±0.1 6 ±0.2 12 ±0.15 9 ±0.3 16 ±0.15 12 ±0.3
S (mm) 0.9 0.9 1.35 1.8
Rmin (mm) Part number 30 816 153 40 815 151 60 813 869 95 816 145
S
Dimension 6x1 8x1 12x1.5 16x2
d1 d2
When bending fuel pipes there are limits for the minimum radius Rmin according to the table:
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R min
Dimensions and minimum radii when bending.
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Moving fuel tanks Scania HPI and high-level fuel tanks
Scania HPI and high-level fuel tanks Starting problems The combination of a high-level fuel tank and the Scania HPI fuel system may cause the following problems: • Engine difficult to start. • Engine makes a noise. • Engine gives off white smoke.
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A common symptom is that the engine knocks and gives off white smoke for 10 to 20 seconds after starting up. The injectors are not always closed when the engine is shut off because the degree of closure depends on the position of the crankshaft. Fuel left in the return pipes runs back into the cylinders and causes problems when the engine is started.
High-level fuel tank.
Technical information on Scania engines can be found in documents under Product data. The type of engine and fuel injection system for a specific vehicle is stated in the vehicle’s individual chassis specification (ICS) under Drawings (requires login)
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Moving fuel tanks Scania HPI and high-level fuel tanks
Fuel draining system Engine problems can be resolved with the aid of a fuel draining system. By draining off all fuel after shutting off the engine, the pressure in the pipes disappears and no fuel can run back into the cylinders. VIKTIGT!
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Using only check valves or magnetic shut-off valves is not an acceptable solution. The return fuel contains combustion gases that make it difficult for the check valves to close tight. The fully closed check valve may create overpressure in the system and so cause the same problem.
Use and operation
Fuel draining system.
The draining system comprises a draining tank and a draining pump. The draining pump is controlled by relays. In normal operation, the return fuel will pass through the draining tank and go on to the main tank. Start the draining pump one minute after shutting off the engine after the vehicle has been stopped for the day or for a longer standstill period. Obs! Do not start the draining pump until the engine has been shut down.
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Moving fuel tanks Scania HPI and high-level fuel tanks
Production and installation of the draining system
2
Scania recommends that the draining system should be installed by a Scania workshop. If not, the installation must be approved by a Scania workshop.
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1. Produce a draining tank holding approx. 2.5 litres. See illustration.
100
2. Weld on the nuts for the insert connections and the banjo connector. Use
M16x1.5 for the insert connections and M12x1.5 for the banjo connector, for example. – The insert connections to connect the fuel lines to the fuel tank should be located 30 mm from the underside of the tank. – The insert connections to connect the return pipes from the engine should be located 30 mm from the top of the tank.
1
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3 1. Insert connections for pipes to the fuel tank 2. Insert connections for return pipes from the engine 3. Banjo connector
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Moving fuel tanks Scania HPI and high-level fuel tanks 3. Locate the draining tank (3) at the same height as the lowest point in the return
pipe, roughly level with the chassis frame. The draining tank must be positioned lower than the point at which the return pipe is connected to the engine. 4. Locate the draining pump (4) lower than the draining tank in order for it to work. 5. Connect the return pipe from the engine (6) to the top front of the draining tank (facing the engine). 6. Connect a pipe from the draining tank to its own connection point on the fuel tank (5). 7. Connect a pipe from the draining tank to the draining pump. 8. Connect a pipe from the draining pump to its own connection point on the fuel tank. VIKTIGT!
5
6
3
4
As an alternative to manual handling, a time-controlled relay can be connected to control the activation of the pump.
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Do not modify the fuel tank’s air valve as this may impair the function of the air valve.
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Moving fuel tanks Scania HPI and high-level fuel tanks
RB
RX
RU
RA
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Scania HPI fuel system has 4 connections. The fuel flows from 2 connections on the main tank (RA and RU) to the engine. When the engine is running, the return fuel goes through the 3rd connection (RB) to the main tank. The 4th connection RX) on the fuel pick-up unit is used for the connection of the return hose from the draining pump.
Pickup for HPI fuel system.
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Moving fuel tanks Scania HPI and high-level fuel tanks
Electrical connection Obs! Do not allow the power supply to the pump to pass through the time-based relay.
More information on fuse holder positions is found in the document Central electric unit. 4 1 +24 V
The connection shown is an example.
+24 V
Part information and connection positions 1 2 3 4
Central electric unit fuse 30 Central electric unit fuse 48 Time-based relay Power relay
30
8A
48
8A t
2
Battery voltage +24 V Alternator voltage
3
Sized according to the current consumption of the pump
C494
C494
C494
5 Draining pump
5
C494
More parts information can be found under the next heading.
C494
C487 5
5
M 343 961
C487
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Moving fuel tanks Scania HPI and high-level fuel tanks
Parts for the conversion Draining pump Designation Fuel pump 24 V, from Boscha Banjo union Seal Banjo union Seal Plastic pipe with an inner diameter of 7.5 mmc
Qty 1 1 2 1 2 -
Part number 9 580 234 353 862 1 373 792 302 747 1 373 791 -
Connections between the draining tank and the draining pump Designation Qty Part number Banjo union 1 302 747 Banjo screw 1 812 389 Seal 2 1 373 791
Electrical equipment Designation Time-controlled relayb Electrical cable
Qty 1 -
Part number 456 973 -
Connections between the draining tank and the engine or the fuel tank Designation Qty Part number Insert connection 4 2 081 828
a. Part from Bosch that cannot be purchased from Scania dealers b. Equivalent relays may also be used c. Fuel pipe between the draining pump and the draining tank
The parts are available from Scania dealers.
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